Rover 100

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ROVER 100
SERIES
REPAIR MANUAL
SUPPLEMENT
This Repair Manual Supplement covers Rover 100
MPi models manufactured from VIN 110566, and
should be used in conjunction with the following
manual:
RCL 0009ENG ROVER 100 Repair Manual
Publication Part No. RCL 0177ENG
Published by Rover Technical Communication
 ROVER GROUP LlMlTED 1996
lNTRODUCTlON
GENERAL lNFORMATlON
lNFORMATlON
MAlNTENANCE
ENGlNE
ENGlNE MANAGEMENT SYSTEM
- MEMS
FUEL DELlVERY SYSTEM
COOLlNG SYSTEM
MANlFOLD & EXHAUST SYSTEMS
MANUAL GEARBOX
AUTOMATlC GEARBOX
INTRODUCTION
INTRODUCTION 1
INTRODUCTION
How to use this ManuaI
To assist in the use of this Manual the section title is
given at the top and the relevant sub-section is given
at the bottom each page.
Each major section starts with a contents page,
listing the information contained in the relevant
sub-sections. To assist filing of revised information
each sub-section is numbered from page 1.
The individual items comprising repair operations
are to be followed in the sequence in which they
appear. ltems numbers in the illustration are referred
to in the text.
Adjustment and repair operations include reference
to Service tool numbers and the associated
illustration depicts the tool. Where usage is not
obvious the tool is shown in use. Adjustment and
repair operations also include reference to wear
limits, relevant data, torque figures, and specialist
information and useful assembly details. Each
adjustment or repair operation is given its Repair
Operation Time number. WARNlNGS, CAUTlONS
and NOTES have the following meanings:
WARNING: Procedures which must be
foIIowed preciseIy to avoid the possibiIity
of injury.
CAUTION: CaIIs attention to procedures
which must be foIIowed to avoid damage
to components.
NOTE: Gives heIpfuI information.
References
References to the LH or RH side given in this
Manual are made when viewing the vehicle from the
rear. With the engine and gearbox assembly
removed, the crankshaft pulley end of the engine is
referred to as the front.
Operations covered in this Manual do not include
reference to testing the vehicle after repair. lt is
essential that work is inspected and tested after
completion and if necessary a road test of the
vehicle is carried out particularly where safety
related items are concerned.
Dimensions
The dimensions quoted are to design engineering
specification with Service limits where applicable.
INTRODUCTION
2 INTRODUCTION
REPAIRS AND REPLACEMENTS
When replacement parts are required it is essential
that only Rover recommended parts are used.
Attention is particularly drawn to the following points
concerning repairs and the fitting of replacement
parts and accessories.
Safety features and corrosion prevention treatments
embodied in the car may be impaired if other than
Rover recommended parts are fitted. ln certain
territories, legislation prohibits the fitting of parts not
to the manufacturer's specification. Torque wrench
setting figures given in this Manual must be used.
Locking devices, where specified, must be fitted. lf
the efficiency of a locking device is impaired during
removal it must be renewed.
Owners purchasing accessories while travelling
abroad should ensure that the accessory and its
fitted location on the car conform to legal
requirements.
The Terms of the vehicle Warranty may be
invalidated by the fitting of other than Rover
recommended parts.
All Rover recommended parts have the full backing
of the vehicle Warranty.
Rover Dealers are obliged to supply only Rover
recommended parts.
SPECIFICATION
Rover are constantly seeking to improve the
specification, design and production of their vehicles
and alterations take place accordingly. While every
effort has been made to ensure the accuracy of this
Manual, it should not be regarded as an infallible
guide to current specifications of any particular
vehicle.
This Manual does not constitute an offer for sale of
any particular vehicle. Rover Dealers are not agents
of Rover and have no authority to bind the
manufacturer by any expressed or implied
undertaking or representation.
INTRODUCTION
INTRODUCTION 3
ABBREVIATIONS AND SYMBOLS
After Bottom Dead Centre ABDC
After Top Dead Centre ATDC
Air conditioning A/C
Air fuel ratio AFR
Alternating current ac
Amperes A
Anti-lock brake system ABS
Automatic temperature control ATC
Before Bottom Dead Centre BBDC
Before Top Dead Centre BTDC
Bottom Dead Centre BDC
British Standards BS
Carbon monoxide CO
Celcius (Centigrade) C
Centimetre cm
Chlorofluorocarbons CFC's
Cubic centimetres cm
3
Crankshaft position CKP
Degree (angle) deg. or 
Degree (temperature) deg. or 
Dial test indicator DTl
Diameter dia.
Direct current dc
Electronic Control Unit ECU
Exhaust gas recirculation EGR
Electronic air control valve EACV
Engine Control Module ECM
Electronic Diesel Control EDC
Engine coolant temperature ECT
Fuel lnjection Pump FlP
Gramme (mass) g
High compression hc
High Tension h.t.
Hour h
lntake air temperature lAT
lnternal diameter i.dia.
lnternational Organisation for
Standardization
lSO
Kilometre km
Kilogramme kg
Left-hand LH
Left-hand drive LHD
Light emitting diode LED
Litre l
Low Compression lc
Manifold absolute pressure MAP
Mass air flow MAF
Maximum max.
Mercury Hg
Metre m
Metric unit of horse power PS
Miles per hour mph
Millimetre mm
Minimum min
Minus (of tolerance) -
Minute (angle) '
Model Year MY
Multi-function unit MFU
Multi-point injection MPi
Negative (electrical) (-)
Newton metre Nm
Number No.
Outside diameter o.dia.
INTRODUCTION
4 INTRODUCTION
Percentage %
Plus or minus 
Plus (tolerance) +
Positive (electrical) +
Positive crankcase ventilation PCV
Positive temperature coefficient PTC
Power assisted steering PAS
Radius r
Ratio :
Reference ref
Revolutions per minute rev/min
Right-hand RH
Right-hand drive RHD
Rover Engineering Standards RES
Second (angle) "
Single overhead camshaft SOHC
Specific gravity sp.gr
Square centimetres cm
2
Standard std.
Supplementary Restraint System SRS
Synchronizer/synchromesh synchro
Thousand k
Top dead centre TDC
Throttle position TP
United Kingdom UK
United States US
Variable induction system VlS
Vehicle identification number VlN
Volt V
Watt W
INFORMATION
GENERAL DATA 1
ENGINE
Type 8 valve SOHC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder arrangement 4 in line - transverse . . . . . . . . . . . . . . . . . . . . . . . .
Bore 75.00 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stroke
1.1 63.25 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.4 79.80 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Capacity
1.1 1120 cm
3
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.4 1396 cm
3
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Firing order 1 - 3 - 4 - 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rotation Clockwise, viewed from front of engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Copression ratio
1.1 9.7 : 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.4 9.5 : 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VaIve timing - 1.1
lnlet:
Opens 3BTDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Closes 37ABDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust:
Opens 35BBDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Closes 5ATDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve open period 220 . . . . . . . . . . . . . . . . . . . . . . . . . . .
VaIve timing - 1.4
lnlet:
Opens 13BTDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Closes 47ABDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust
Opens 53BBDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Closes 7ATDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve open period 240 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubrication
System type Wet sump, crankshaft driven eccentric rotor pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Relief valve opening pressure 4.1 bar . . . . . . . . . . . . . . . . . .
Pressure at idle 1.7 to 3.5 bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maximum pressure at 6500 rev/min 7.0 bar (below 40C) . . . . . . . . . . . . .
Oil pressure warning light switch opens 0.3 to 0.5 bar . . . . . . . . . .
Oil filter Full flow with disposable canister . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL SYSTEM
Electronic fuel injection data See Engine Tuning Data . . . . . . . . . . . . . . . . . . .
Fuel Pump:
make / type Electric immersible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump maximum pressure at 13.5V 4.1 bar . . . . . . . . . . . . .
Regulated injection pressure range 3.0  0.2 bar . . . . . . . . . . . . .
INFORMATION
2 GENERAL DATA
COOLING SYSTEM
Pressure cap opens 0.9 to 1.0 bar . . . . . . . . . . . . . . . . . . . . . . . . . .
Thermostat starts to open 88   2 C . . . . . . . . . . . . . . . . . . . . .
Thermostat fully open 100  2C . . . . . . . . . . . . . . . . . . . . . . . .
Cooling fan operation: On 88 to 92C . . . . . . . . . . . . . . . . . . . . . . . .
CLUTCH
Type Diaphragm spring, cable operated self adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clutch plate diameter 190 mm . . . . . . . . . . . . . . . . . . . . . . . . .
MANUAL GEARBOX
Gearbox code 5C 35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gear ratios:
Fifth 0.854 : 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fourth 1.104 : 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Third 1.333 : 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Second 1.947 : 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
First 3.417 : 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reverse 3.583 : 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AUTOMATIC GEARBOX
Type Constantly Variable Transmission (CVT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gearbox code VT-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ratios Range 2.47 : 1 to 0.445 : 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FINAL DRIVE
Ratio 3.538 : 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Road speed at 1000 rev/min:
Fifth 32.0 km/h . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.9 mph
Fourth 26.1 km/h . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.2 mph
Third 20.6 km/h . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.8 mph
Second 13.9 km/h . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7 mph
First 8.0 km/h . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.0 mph
INFORMATION
GENERAL DATA 3
WHEELS
WheeI size and type:
All models except GTa 4
1
/
2
J x 13 steel . . . . . . . . . . . . . . . . . . . . . . .
GTa 5
1
/
2
J x 13 alloy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TYRE SIZE
All models 155/65-SR 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TYRE PRESSURES
Pressures (coId):
Loading conditions bar Ibf/in
AII Ioad conditions
Manual gearbox
Front and Rear 2.1 30
Automatic gearbox
Front and Rear 2.3 33
ELECTRICAL
System 12 volt, negative earth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery
Type 007 maintenance free:
Cold crank 280 amps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reserve capacity 50 minutes . . . . . . . . . . . . . . . . . . . . . . . . . . .
Type 063 maintenance free:
Cold crank 360 amps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Type 063S maintenance free:
Cold crank 405 amps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AIternator
Type A115 - 65A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maximum output 65 Amps . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Regulator 21TR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starter motor
Type M79 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power 0.9 kW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INFORMATION
4 GENERAL DATA
DIMENSIONS
Overall length 3.750 m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overall width (including mirrors): 1.775 m . . . . . . . . . . . . . . . .
Overall height (excluding aerial):
Cabriolet 1.380 m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
All other models 1.377 m . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ground clearance * 150 mm . . . . . . . . . . . . . . . . . . . . . . . . . .
Wheelbase 2.269 m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Track:
Front 1.348 m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear 1.297 m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Turning circle (kerb to kerb) 9.87 m . . . . . . . . . . . . . . . . . . . .
* At unladen weight
WEIGHTS
UnIaden (fueI tank fuII, excIuding optionaI
fittings)
1.1 Knightsbridge (3 Door) 830 kg . . . . . . . . . . . . . . . . . . . .
1.1 Knightsbridge (5 Door) 845 kg . . . . . . . . . . . . . . . . . . . .
1.1 Knightsbridge SE (3 Door) 840 kg . . . . . . . . . . . . . . . . . .
1.1 Knightsbridge SE (5 Door) 855 kg . . . . . . . . . . . . . . . . . .
1.1 SLi (3 Door) 845 kg . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.1 SLi (5 Door) 860 kg . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.4 SLi (3 Door) 845 kg . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.4 SLi (5 Door) 860 kg . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.4 GSi (5 Door) 865 kg . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.4 GTa 845 kg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.1 Cabriolet 880 kg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.4 Cabriolet 880 kg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maximum gross vehicle weight 1320 kg . . . . . . . . . . . . . . . . .
Maximum towing weight with braked trailer -
restart on a 12%, 1 in 8 gradient, with one
passenger:*
Knightsbridge models 700 kg . . . . . . . . . . . . . . . . . . . . . . .
1.1 models 800 kg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.4 models 800 kg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Towing hitch downward load 50 kg . . . . . . . . . . . . . . . . . . .
Maximum roof rack load (distributed) 70 kg . . . . . . . . . . . .
* Any additional weight, such as luggage or extra
passengers, should be deducted from the
maximum towing weight.
INFORMATION
ENGINE TUNING DATA 1
ModeI: 1.1 K8 with MPi Year: 1996 on
Engine
Type / Capacity K8/1119 cm
3
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Firing order 1 - 3 - 4 - 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compression ratio 9.75 : 1 . . . . . . . . . . . . . . . . . . . . . . . . . . .
ldle speed, controlled by the ECM * 875  50 rev/min . . . . . . . . . . . . .
Exhaust gas CO content at idle less than 0.5% hot . . . . . . . . . . . . . . . . .
lgnition timing at idle speed | 10  5BTDC (controlled by fuel ECM) . . . . . . . . . . . . . . . . . .
Ignition CoiI
Type F type dry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Part No GCL 201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Primary resistance at 20C 0.63 to 0.77 ohm . . . . . . . . . . . . . . . . . . . .
Spark PIugs
Type GSP 6662 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Plug gap 0.85 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Management System
Type lndirect multi-port fuel injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MEMS ECM MKC 103420 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel pump WFX 100860 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel pressure regulator MKW 100016 . . . . . . . . . . . . . . . . . . . . . .
Fuel pressure 3.0  0.2 bar constant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
lnjectors MJY 10015 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Throttle position sensor MJC 10020 . . . . . . . . . . . . . . . . . . . . . . .
lntake air temperature sensor NNK 10001 . . . . . . . . . . . . . . . . . .
Coolant temperature sensor MEK 100060 . . . . . . . . . . . . . . . . . . .
Oxygen sensor MHK 10006 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel grade 95 RON minimum - UNLEADED fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAUTION: Do not use LEADED fueI as it wiII damage the cataIyst. Serious damage to the engine may
occur if a Iower octane number fueI than that recommended is used.
* No electrical load present
|Crankshaft degrees and rev/min
INFORMATION
2 ENGINE TUNING DATA
ModeI: 1.4 K8 with MPi Year: 1996 on
Engine
Type / Capacity K8/1396 cm
3
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Firing order 1 - 3 - 4 - 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compression ratio 9.9 : 1 . . . . . . . . . . . . . . . . . . . . . . . . . . .
ldle speed, controlled by the ECM * 875  50 rev/min . . . . . . . . . . . . .
Exhaust gas CO content at idle less than 0.5% hot . . . . . . . . . . . . . . . . .
lgnition timing at idle speed | 10  5BTDC (controlled by fuel ECM) . . . . . . . . . . . . . . . . . .
Ignition CoiI
Type F type dry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Part No GCL 201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Primary resistance at 20C 0.63 to 0.77 ohm . . . . . . . . . . . . . . . . . . . .
Spark PIugs
Type GSP 6662 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Plug gap 0.85 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Management System
Type lndirect multi-port fuel injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MEMS ECM:
Manual Transmission MKC 103400 . . . . . . . . . . . . . . . . . . . . . . .
Automatic Transmission MKC 103410 . . . . . . . . . . . . . . . . . . . . .
Fuel pump WFX 100860 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel pressure regulator MKW 100016 . . . . . . . . . . . . . . . . . . . . . .
Fuel pressure 3.0  0.2 bar constant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
lnjectors MJY 10015 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Throttle position sensor MJC 10020 . . . . . . . . . . . . . . . . . . . . . . .
lntake air temperature sensor NNK 10001 . . . . . . . . . . . . . . . . . .
Coolant temperature sensor MEK 100060 . . . . . . . . . . . . . . . . . . .
Oxygen sensor MHK 10006 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel grade 95 RON minimum - UNLEADED fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAUTION: Do not use LEADED fueI as it wiII damage the cataIyst. Serious damage to the engine may
occur if a Iower octane number fueI than that recommended is used.
* No electrical load present
|Crankshaft degrees and rev/min
INFORMATION
TORQUE WRENCH SETTINGS 1
Refer to the appropriate section heading for component torque figures, e.g.
Road wheel nuts - refer to SUSPENSION,
Exhaust front pipe to manifold - refer to MANIFOLD AND EXHAUST
GENERAL
Bolt M6 10 Nm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bolt M8 25 Nm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bolt M10 45 Nm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bolt M12 80 Nm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE
Timing belt cover bolts. 5 Nm . . . . . . . . . . . . . . . . . . . . . . .
Timing belt tensioner pulley backplate screw 10 Nm . . . . . .
Timing belt tensioner pulley Allen screw 45 Nm . . . . . . . . . .
Cylinder head bolts:
1st stage* 20 Nm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2nd stage* a further 180 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3rd stage* a further 180 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Timing belt rear cover bolts 10 Nm . . . . . . . . . . . . . . . . . . . .
Camshaft gear bolt 35 Nm . . . . . . . . . . . . . . . . . . . . . . . . . .
Camshaft cover bolts 10 Nm . . . . . . . . . . . . . . . . . . . . . . . . .
Engine lifting bracket bolt 9 Nm . . . . . . . . . . . . . . . . . . . . .
Engine LH support member bolts 45 Nm . . . . . . . . . . . . . . .
Engine mounting to support member bolts 45 Nm . . . . . . . .
Engine steady bar bracket bolts to engine 85 Nm . . . . . . . . .
Flywheel rear cover plate bolts:
M6 bolts 8 Nm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M10 nut/bolt 38 Nm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flywheel front cover plate bolts 8 Nm . . . . . . . . . . . . . . . . .
Flywheel lower cover plate bolts 8 Nm . . . . . . . . . . . . . . . .
Engine steady bracket bolt to body 45 Nm . . . . . . . . . . . . . .
INFORMATION
2 TORQUE WRENCH SETTINGS
MODULAR ENGINE MANAGEMENT SYSTEM
Fuel feed pipe to fuel rail bolts 5 Nm . . . . . . . . . . . . . . . . . .
ldle air control valve (lACV) Torx screws 8 Nm . . . . . . . . . .
Engine coolant temperature (ECT) sensor 15 Nm . . . . . . . .
Crankshaft position (CKP) sensor 6 Nm . . . . . . . . . . . . . . .
Throttle position (TP) sensor 1.5 Nm . . . . . . . . . . . . . . . . . . .
Air cleaner to battery tray bolts 9 Nm . . . . . . . . . . . . . . . . .
Fuel filter outlet union 28 Nm . . . . . . . . . . . . . . . . . . . . . . . .
Fuel filter inlet union 28 Nm . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel rail feed hose bolts 10 Nm . . . . . . . . . . . . . . . . . . . . . .
Fuel rail to inlet manifold bolts 10 Nm . . . . . . . . . . . . . . . . . .
lntake air temperature (lAT) sensor 7 Nm . . . . . . . . . . . . . .
Oxygen (H02S) sensor 55 Nm . . . . . . . . . . . . . . . . . . . . . . .
Distributor cap screws 3 Nm . . . . . . . . . . . . . . . . . . . . . . . .
Rotor arm screw 8 Nm . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spark plugs 27 Nm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
lgnition coil:
M10 bolts 25 Nm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M6 bolt 9 Nm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Throttle housing bolts 7 Nm . . . . . . . . . . . . . . . . . . . . . . . .
MANIFOLDS AND EXHAUST
Front pipe to manifold nuts 50 Nm . . . . . . . . . . . . . . . . . . . .
lnlet manifold support stay bolt 25 Nm . . . . . . . . . . . . . . . . .
Catalytic converter nuts 45 Nm . . . . . . . . . . . . . . . . . . . . . . .
Exhaust manifold nuts* 45 Nm . . . . . . . . . . . . . . . . . . . . . . .
lnlet manifold to cylinder head nuts/bolts* 25 Nm . . . . . . . . .
lnlet manifold chamber to inlet manifold bolts 25 Nm . . . . . .
* Tighten in sequence
MANUAL GEARBOX
Gearcase bolt 28 Nm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gearbox mounting bracket to gearbox bolts 80 Nm . . . . . . .
Gearbox drain plug 35 Nm . . . . . . . . . . . . . . . . . . . . . . . . . .
Gearbox filler/level plug 35 Nm . . . . . . . . . . . . . . . . . . . . . . .
INFORMATION
TORQUE WRENCH SETTINGS 3
AUTOMATIC GEARBOX
Mounting bracket to gearbox bolts 45 Nm . . . . . . . . . . . . . . .
Gearbox fluid cooler unions 37 Nm . . . . . . . . . . . . . . . . . . . .
FRONT SUSPENSION
Road wheel nuts 70 Nm . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL
Battery tray bolts 9 Nm . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INFORMATION
CAPACITIES, FLUIDS AND LUBRICANTS 1
CAPACITIES
Fuel tank 30.5 litres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine oil refill and filter change 4.5 litres . . . . . . . . . . . . . . . .
Manual gearbox refill 2.0 litres . . . . . . . . . . . . . . . . . . . . . . . . .
Automatic gearbox 4.5 litres . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cooling system refill 4.5 litres . . . . . . . . . . . . . . . . . . . . . . . . .
Windscreen washer reservoir 2.6 litres . . . . . . . . . . . . . . . . . .
FLUIDS
FueI
Octane rating: UNLEADED fuel - 95 RON minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAUTION: CataIyst equipped vehicIes MUST NOT be run on LEADED fueI as damage to the cataIyst
wiII resuIt.
Brake/CIutch FIuid
For topping-up Rover recommend the use of AP
New Premium Super DOT 4 brake fluid or Castrol
Universal DOT 4 brake/clutch fluid.
Anti-freeze soIutions
The overall anti-freeze concentration should not fall,
by volume below 50% to ensure that the
anti-corrosion properties of the coolant are
maintained. Anti-freeze concentrations greater than
60% are not recommended as cooling efficiency will
be impaired.
Use UNIPART SUPERPLUS ANTI-FREEZE AND
SUMMER COOLANT to protect the cooling system.
lf this is not available, use an ethylene glycol based
anti-freeze, containing no methanol with
non-phosphate corrosion inhibitors suitable for use
in mixed metal engines to ensure the protection of
the cooling system against frost and corrosion.
CAUTION: No other 'universaI' anti-freeze
shouId be used with UNIPART
SUPERPLUS ANTI-FREEZE AND SUMMER
COOLANT.
The cooling system should be drained, flushed and
refilled with the correct amount of anti-freeze
solution at three years and every two years
thereafter.
After filling with anti-freeze solution, attach a warning
label to a prominent position on the vehicle stating
the type of anti-freeze contained in the cooling
system to ensure that the correct type is used for
topping-up.
The recommended quantities of anti-freeze for
different degrees of frost protection are:
SoIution Amount of anti-freeze Commences freezing Frozen soIid
50% Litres C F C F
AII modeIs 2.3 - 36 - 33 - 48 - 53
INFORMATION
2 CAPACITIES, FLUIDS AND LUBRICANTS
LUBRICATION
The engine and other lubricating systems are filled
with high-performance lubricants giving prolonged
life.
CAUTION: You shouId aIways use a high
quaIity oiI of the correct viscosity range in
the engine and gearbox during
maintenance and when topping-up. The use of
oiI not to the correct specification can Iead to
high oiI and fueI consumption and uItimateIy to
damaged components.
Oil to the correct specification contains additives
which disperse the corrosive acids formed by
combustion and prevent the formation of sludge
which can block the oil ways. Additional oil additives
should not be used.
Always adhere to the recommended servicing
intervals.
Engine oiI
VlSCOSlTY / TEMPERATURE RANGES
Use oil meeting specification RES.22.OL.G4 or the
requirements of ACEA A2:96, and having a viscosity
band recommended for the temperature range of
your locality. Where oils to these RES and European
specifications are not available, well known brands
of oils meeting APl SG or SG/CD quality should be
used.
ManuaI gearbox
Use the following oils for refill or topping-up:
ESSO Gear oil BV 75W/80W
SHELL SF5288 75W/80W
TOTAL Transmission BV 75W/80W
UNlPART Gear oil BV 75W/80W
The following oils may be used for topping-up only:
BP Hypogear TL 75W/80W
CASTROL EPX 75W/80W
DUCKHAMS Hypoid PT 75W/80W
Gear Iinkage
Use a grease containing 3% Molybdenum
Disulphide.
Automatic gearbox
Use only the following fluid for a complete refill:
ESSO CVT fluid - EZL 799
Top-up only, use any fluid meeting the following
specification:
ATF Dexron ll specification - FN 1975.
GeneraI Greasing
Use Multipurpose Lithium Base Grease N.L.G.l.
consistency No. 2.
MAINTENANCE
MAINTENANCE 1
UNDERBONNET LOCATIONS
1. Windscreen and rear screen washer reservoir
2. Coolant expansion tank
3. Engine oil dipstick
4. Brake fluid reservoir
5. Fuel filter
6. Distributor
7. Charcoal canister
8. Battery
9. Engine compartment fusebox
10. Air cleaner
11. Gearbox fluid dipstick (Automatic)
12. Crankcase ventilation hoses
13. Spark plugs
14. Engine oil filler cap
15. Camshaft timing belt
MAINTENANCE
2 MAINTENANCE
SPARK PLUGS
Service repair no - 18.20.02
Remove
1. Disconnect h.t. leads from spark plugs.
2. Using a 16 mm spark plug socket, remove 4
spark plugs.
Refit
1. Fit terminals to new spark plugs.
2. Set gap of each spark plug to 0.85 mm.
3. Fit spark plugs and tighten to 27 Nm.
4. Connect h.t. leads to spark plugs.
MAINTENANCE
MAINTENANCE 3
AIR CLEANER ELEMENT
Remove
1. Release 4 clips securing 2 halves of air
cleaner.
2. Release top half of air cleaner and position
aside.
3. Remove and discard air cleaner element.
Refit
1. Clean inside of air cleaner casing.
2. Fit new air cleaner element in casing.
3. Position top half of air cleaner casing and
secure clips.
FUEL FILTER
Remove
1. Disconnect battery earth lead.
2. Position absorbent cloth around outlet pipe
union.
3. Loosen union to relieve fuel pressure.
CAUTION: To prevent damage to fueI
system pipes and components, use two
spanners when Ioosening or tightening
unions.
4. Disconnect fuel outlet pipe from fuel filter.
5. Position absorbent cloth around fuel filter inlet
pipe union.
6. Loosen union and allow fuel to seep into cloth.
7. Disconnect fuel inlet pipe from fuel filter.
8. Loosen bolt securing fuel filter to bracket.
9. Remove and discard filter.
Refit
1. Position new filter in bracket with arrow
pointing away from inlet pipe.
2. Clean fuel pipe unions.
3. Connect fuel inlet pipe to fuel filter and tighten
union to 28 Nm.
4. Connect fuel outlet pipe to fuel filter and tighten
union to 28 Nm.
5. Connect battery earth lead.
ENGINE
REPAIRS 1
CAMSHAFT REAR OIL SEAL.
Remove.
2. Release 4 clips securing air cleaner cover.
3. Loosen clip securing air intake hose to throttle
body.
4. Remove air cleaner cover.
5. Remove air cleaner element.
6. Release 2 screws securing distributor cap.
7. Disconnect coil h.t. lead from distributor cap
and move cap aside.
8. Remove flash shield.
9. Remove Allen screw securing rotor arm.
10. Remove rotor arm from camshaft spindle.
11. Screw tool 18G 1299A into camshaft oil seal.
12. Remove oil seal by tightening centre bolt tool
18G 1299A-1.
ENGINE
2 REPAIRS
Refit
1. Clean sealing areas of cylinder head and
camshaft, ensure all traces of rubber are
removed, DO NOT scrape.
2. Lubricate sealing surfaces.
3. Using tool 18G 1587, fit oil seal.
4. Clean rotor arm retaining screw and apply
Loctite 242 to the first 3 threads.
5. Fit rotor arm, and tighten Allen screw to 8 Nm.
6. Fit flash shield.
7. Fit distributor cap and tighten screws to 3 Nm.
8. Connect coil h.t. lead.
9. Fit air cleaner element.
10. Position air cleaner cover, connect air intake
hose, align cover to air cleaner and secure
clips.
11. Tighten clip securing intake hose.
CYLINDER HEAD GASKET
Remove
2. Drain cooling system. See REPAIR MANUAL -
Maintenance.
3. Remove camshaft timing belt upper cover.
4. Remove camshaft cover.
5. Raise front of vehicle.
WARNING: Support on safety stands.
6. Turn steering on to RH lock.
7. Remove 3 centre screws from scrivets,
securing under wing splash shield.
8. Remove 3 scrivets.
9. Remove splash shield.
ENGINE
REPAIRS 3
10. Rotate crankshaft to align camshaft gear timing
marks with top face of cylinder head - 90
BTDC.
11. Loosen tensioner pulley bolt
1
/
2
turn.
12. Loosen tensioner backplate screw
1
/
2
turn.
13. Push tensioner pulley down to fully OFF
position.
14. Tighten backplate screw to 10 Nm.
15. Ease timing belt off camshaft gear.
CAUTION: Ease timing beIt off gears using
fingers onIy. MetaI Ievers may damage the
beIt and gear.
16. Restrain camshaft gear using tool 18G 1521
and remove bolt and washer securing
camshaft gear to camshaft.
17. Remove camshaft gear.
18. Disconnect tensioner spring.
19. Remove timing belt tensioner centre Allen
screw and backplate screw.
20. Remove camshaft timing belt tensioner and
spring.
21. Remove 3 bolts securing camshaft timing belt
rear cover.
ENGINE
4 REPAIRS
22. Loosen clips securing coolant hoses to coolant
outlet elbow.
23. Disconnect coolant hoses from outlet elbow.
24. Disconnect multiplugs from coolant sensors on
outlet elbow.
25. Loosen locknut, release
kickdown cable from abutment bracket and
disconnect inner cable from throttle cam.
26. Release throttle cable adjusting nut from
abutment bracket.
27. Release throttle cable from throttle cam.
28. Disconnect evaporative emission canister
vacuum pipe from inlet manifold.
ENGINE
REPAIRS 5
29. Disconnect ECM vacuum pipe from inlet
manifold.
30. Depress plastic collar on quick release
connector and disconnect brake servo vacuum
hose from inlet manifold.
31. Release clip securing coolant hose to inlet
manifold and disconnect hose.
32. Position absorbent cloth around fuel filter outlet
union.
33. Loosen fuel filter outlet union to relieve fuel
pressure. Re-tighten union to 28 Nm.
system pipes or components, use two
unions.
34. Release clip securing fuel return hose to fuel
rail and disconnect hose.
CAUTION: PIug fueI system hoses and
connections.
35. Release fuel return pipe from 2 clips on
underside of inlet manifold.
ENGINE
6 REPAIRS
36. Remove 2 bolts securing fuel feed pipe to fuel
rail.
37. Remove fuel feed pipe from fuel rail and
discard 'O' ring.
CAUTION: PIug the connections.
38. Release injector harness multiplug from
bracket on throttle body.
39. Disconnect multiplug from injector harness.
40. Disconnect multiplug from lAT sensor.
41. Disconnect multiplug from TP sensor.
42. Disconnect multiplug from lACV.
43. Disconnect coil h.t. lead from distributor.
ENGINE
REPAIRS 7
44. Remove bolt securing inlet manifold to support
bracket.
45. Remove 3 bolts securing both h.t. lead guide
brackets to cylinder head.
46. Remove 2 brackets.
47. Remove 3 nuts securing exhaust front pipe to
manifold.
48. Release front pipe from manifold, remove and
discard gasket.
CAUTION: DO NOT aIIow front pipe to
hang on oxygen sensor Iead.
49. Remove 10 cylinder head bolts in sequence
shown. Remove bolts and store in fitted order.
50. Using assistance, move timing belt back plate
aside and remove cylinder head assembly from
cylinder block.
51. Remove cylinder head gasket from cylinder
block and discard.
ENGINE
8 REPAIRS
52. Remove 2 location dowels from cylinder block.
53. Fit cylinder liner clamps 18G 1736/1 to
cylinder block and secure with cylinder head
bolts.
CAUTION: Do not rotate crankshaft with
cyIinder head removed. PIace cyIinder
head on bIocks of wood to avoid
damaging vaIves.
Refit
1. Remove bolts securing cylinder liner clamps to
cylinder block and remove clamps.
2. Clean joint surfaces of cylinder head and
cylinder block.
3. Check cylinder head face for warpage, across
centre and from corner to corner.
Cylinder head:
Maximum warpage = 0.05 mm.
Clean oil and coolant passages.
lf necessary, de-carbonise piston crowns and
cylinder head.
4. Clean cylinder head bolts with a wire brush.
lnspect cylinder head bolts for signs of
damage.
5. Wash cylinder head bolts and wipe dry. Apply
a light film of oil to bolt threads and underside
of head bolts.
6. Clean location dowels and fit to cylinder block.
7. Fit new cylinder head gasket, dry, to cylinder
block.
8. Using assistance, fit cylinder head onto
cylinder block, carefully locating dowels.
9. Carefully enter cylinder head bolts. DO NOT
DROP. Screw bolts into place by hand.
ENGINE
REPAIRS 9
10. Working in the sequence shown, progressively
tighten the cylinder head bolts using the
following procedure:
i. All bolts to 20 Nm. Use a felt tip pen and
mark position of radial mark on each bolt head.
ii. Turn all bolts through 180.
iii. Turn all bolts through another 180 and
align radial mark.
CAUTION: If boIt is overtightened, back off
90 then reaIign radiaI marks.
11. Clean exhaust front pipe flange and manifold
mating faces.
12. Fit flange gasket, connect front pipe, fit nuts
and tighten to 50 Nm.
13. Fit h.t. lead guide brackets and secure with
bolts.
14. Connect coil h.t. lead to distributor.
15. Fit bolt securing inlet manifold to support
bracket and tighten to 25 Nm.
16. Connect multiplug to lACV.
17. Connect multiplug to TP sensor.
18. Connect multiplug to lAT sensor.
19. Connect injector harness multiplug and secure
on throttle body mounting bracket.
20. Fit new 'O' ring to fuel feed pipe
21. Fit fuel feed pipe to fuel rail and tighten bolts to
5 Nm.
22. Connect fuel return hose to fuel rail and secure
with clip.
23. Secure fuel return pipe to clips on underside of
inlet manifold.
24. Connect coolant hose to inlet manifold secure
with clip.
25. Connect brake servo pipe to inlet manifold.
26. Connect ECM vacuum pipe to inlet manifold.
27. Fit evaporative emission canister vacuum pipe
to inlet manifold and secure with clip.
28. Connect throttle cable to throttle cam.
29. Locate throttle cable adjusting nut in abutment
bracket.
30. Connect kickdown cable to
throttle cam and locate outer cable to abutment
bracket.
31. Connect coolant pipes to outlet elbow on
cylinder head and secure with clips.
32. Connect multiplugs to coolant sensors on
outlet elbow.
33. Fit camshaft timing belt rear cover bolts and
tighten to 10 Nm.
ENGINE
10 REPAIRS
34. Position camshaft timing belt tensioner to
engine and fit centre bolt and backplate screw.
35. Connect camshaft timing belt tensioner spring.
36. Clean camshaft gear.
37. Fit camshaft gear to camshaft.
38. Fit bolt and washer securing camshaft gear to
camshaft. Using tool 18G 1521 restrain
camshaft and tighten bolt to 35 Nm.
39. Check correct alignment of timing marks for
90 BTDC.
40. Fit timing belt over camshaft gear, keeping belt
taut from crankshaft to camshaft gears.
41. Using fingers only, ease timing belt over
tensioner pulley and coolant pump drive gear,
ensuring belt is positioned centrally around
gears and pulley.
42. Loosen tensioner backplate screw.
43. Rotate crankshaft clockwise 2 complete
revolutions and align camshaft timing gear with
top face of cylinder head.
44. Tighten tensioner backplate screw to 10 Nm.
45. Tighten tensioner pulley Allen screw to 45 Nm.
46. Fit camshaft cover gasket.
47. Fit timing belt upper cover.
48. Position splash shield.
49. Fit scrivets and tighten centre screws.
50. Remove stand(s) and lower vehicle.
51. Refill cooling system. See REPAIR MANUAL -
Maintenance.
52. Adjust throttle cable.
53. Adjust throttle and kickdown
cable.
ENGINE
REPAIRS 11
CAMSHAFT COVER GASKET
Remove
2. Release 2 clips and disconnect 2 breather
hoses from camshaft cover.
3. Progressively loosen and remove 12 bolts
securing camshaft cover.
4. Remove camshaft cover.
NOTE: The gasket is re-usabIe and shouId
remain attached to camshaft cover.
5. Check condition of sealing path. lt should be
complete and attached to gasket. Remove
gasket from camshaft cover only if sealing path
is damaged or detached from gasket.
Refit
1. Clean mating surfaces of camshaft cover and
carrier.
2. Clean inside of camshaft cover. lf necessary,
wash oil separator elements in solvent and
blow dry.
CAUTION: If camshaft cover gasket is to
be renewed, fit new gasket to camshaft
cover.
3. Fit camshaft cover to camshaft carrier. Fit bolts
and working in sequence illustrated, tighten
progressively to 10 Nm.
4. Connect breather hoses to cover and secure
with clips.
ENGINE
12 REPAIRS
ENGINE AND GEARBOX ASSEMBLY
Service repair no - 12.37.01/99
Remove
1. Remove bonnet. See REPAIR MANUAL -
Body.
2. Remove air cleaner.
3. Depress 2 retainers and release fuse box from
bracket
4. Disconnect multiplug from purge valve.
5. Disconnect purge hose from inlet manifold.
6. Release clip and disconnect charcoal canister
hose from fuel tank breather pipe.
7. Remove 5 bolts and 1 Torx screw securing
battery tray.
8. Collect fuse box bracket.
9. Remove battery tray and charcoal canister
assembly.
10. Remove 2 nuts securing air cleaner support
bracket and remove bracket.
ENGINE
REPAIRS 13
11. Disconnect multiplug from ECM.
12. Disconnect vacuum hose from ECM.
13. Release main harness multiplug from bracket.
14. Disconnect multiplug.
15. Disconnect 2 multiplugs from relay module.
16. Disconnect multiplug from inertia switch.
17. Release oxygen sensor relay from bracket.
18. Remove bolt securing earth leads to body.
19. Remove fuse box lid.
20. Remove main 30 amp fuse.
21. Depress retainer and slide battery lead
connector from fuse box.
ENGINE
14 REPAIRS
22. Remove clutch cable tension spring 'C' clip
23. Release clutch cable from bulkhead clip.
24. Release clutch cable from release lever and
abutment bracket, position cable aside.
25. Release clip securing speedo cable joint and
separate upper cable from lower cable.
ENGINE
REPAIRS 15
26. Using tool 18G 1592 , disconnect gear change
linkage ball joint from upper selector lever.
Maintenance.
28. Loosen clip and disconnect top hose from
cylinder head.
29. Loosen 2 clips and disconnect 2 hoses from
heater.
30. Loosen clip and disconnect hose from
expansion tank.
ENGINE
16 REPAIRS
31. Release clip and disconnect coolant hose from
inlet manifold.
32. Position cloth to fuel feed union.
33. Use a backing spanner and disconnect fuel
feed union from filter.
34. Release clip and disconnect fuel return hose
from fuel rail.
abutment bracket.
36. Disconnect throttle cable from throttle cam and
move aside
ENGINE
REPAIRS 17
37. Depress plastic collar and disconnect brake
servo hose from inlet manifold.
38. Disconnect 2 multiplugs from washer pumps.
39. Remove 3 screws securing washer reservoir
and move reservoir aside.
41. Remove starter motor. See REPAIR MANUAL
- EIectricaI.
42. Release and disconnect oxygen sensor
multiplug.
43. Remove clip securing oxygen sensor lead to
engine harness.
44. Disconnect exhaust front pipe from manifold.
45. Using tool 18G 1592, disconnect gear change
linkage ball joint from lower selector lever.
ENGINE
18 REPAIRS
46. Loosen bolt securing engine steady bar to
body.
47. Remove 3 bolts securing engine steady bar
bracket to gearbox and pivot steady bar down.
48. Position container under gearbox. Remove
gearbox filler/level and drain plugs, allow oil to
drain. Refit plugs and tighten to 35 Nm.
49. Drain engine oil if required. See REPAIR
MANUAL - Maintenance.
50. Remove both drive shaft and hub assemblies.
See REPAIR MANUAL - ManuaI Gearbox -
DifferentiaI OiI SeaI.
51. Release plug leads from clip.
52. Fit lifting bracket tool 18G 1572/2 and tighten
bolt to 9 Nm.
53. Fit lifting bracket tool 18G 1572/2 to cylinder
head above dipstick tube, and tighten bolt to 9
Nm.
54. Use a hoist and connect adjustable lifting
bracket 18G 1698 to engine.
55. Raise chains to take weight of engine without
exerting load on mountings.
ENGINE
REPAIRS 19
56. Remove through bolt from engine RH
mounting.
57. Remove 2 bolts securing LH mounting bracket
to mounting.
58. Remove 4 bolts securing mounting support
member to sub frame.
59. Remove support member.
60. Raise and tilt power unit with gearbox down
slightly.
CAUTION: Ensure gear seIector Ievers are
pushed against cross-member and
gearbox to avoid damage during Iifting.
61. Manoeuvre power unit across engine
compartment, ensure gear linkage is clear and
lift power unit from vehicle.
ENGINE
20 REPAIRS
Refit
1. Lower power unit into vehicle and set
horizontal.
2. Position LH support member to sub frame, fit
bolts and tighten to 45 Nm.
3. Align mounting bracket to LH mounting, fit bolts
4. Align RH mounting, fit bolt and tighten to 85
Nm.
5. Remove adjustable lifting bracket 18G 1598.
6. Remove lifting brackets tool 18G 1572 from
cylinder head.
7. Secure plug leads to clips.
8. Fit both drive shaft and hub assemblies. See
REPAIR MANUAL - ManuaI Gearbox -
9. Clean gearchange linkage ball joint, and using
tool 18G 1594 connect ball joint.
10. Connect steady bar bracket to gearbox, fit bolts
11. Connect oxygen sensor multiplug and secure
to bracket.
12. Secure oxygen sensor lead to engine harness
with clip.
13. Connect exhaust front pipe to manifold.
14. Fit starter motor. See REPAIR MANUAL -
EIectricaI.
16. Position washer reservoir and tighten screws.
17. Connect washer pump multiplugs.
18. Connect servo pipe to manifold.
19. Connect throttle cable to throttle cam and
adjust cable.
20. Connect fuel return hose and secure clip.
21. Connect fuel feed hose union to filter and using
backing spanner, tighten union to 28 Nm.
22. Connect heater hoses and tighten clips.
23. Connect expansion tank hose to inlet manifold
and secure clip.
24. Connect expansion tank hose and tighten hose
clip.
25. Connect top hose and tighten clip.
26. Clean gearchange upper ball joint, and using
tool 18G 1584 connect ball joint.
27. Connect speedo cable.
28. Connect clutch cable to release lever and
secure in clip.
29. Fit battery feed cable connector to fuse box
and fit 30A fuse and fuse box lid.
30. Secure earth leads to body.
31. Secure oxygen sensor relay to bracket.
connect multiplugs to inertia switch, relay
module, ECM and harness.
32. Secure harness multiplug to bracket.
33. Position air cleaner support bracket and tighten
nuts.
34. Position battery tray and charcoal canister
assembly.
35. Position fuse box bracket, fit bolts securing
battery tray and tighten to 9 Nm.
36. Connect charcoal canister hose and secure
with clip.
37. Connect ECM vacuum hose to inlet manifold.
38. Secure fuse box to bracket.
39. Fit air cleaner.
40. Refill gearbox oil. See REPAIR MANUAL -
Maintenance.
41. Refill engine oil. See REPAIR MANUAL -
Maintenance.
Maintenance.
43. Fit bonnet. See REPAIR MANUAL - Body.
ENGINE
REPAIRS 21
ENGINE AND AUTOMATIC GEARBOX
ASSEMBLY
Remove
Body.
bracket
battery tray.
assembly.
ENGINE
22 REPAIRS
13. Release main harness multiplug from bracket.
14. Disconnect multiplug.
16. Disconnect multiplug from inertia switch.
17. Release oxygen sensor relay from bracket.
18. Remove bolt securing earth leads to body.
19. Remove fuse box lid.
20. Remove main 30 amp fuse.
21. Depress retainer and slide battery lead
connector from fuse box.
ENGINE
REPAIRS 23
Maintenance.
24. Loosen clip and disconnect top hose from
cylinder head.
25. Loosen 2 clips and disconnect 2 hoses from
heater.
26. Loosen clip and disconnect hose from
expansion tank.
ENGINE
24 REPAIRS
inlet manifold.
28. Remove 3 nuts securing expansion tank to
body.
29. Position expansion tank aside.
30. Position cloth to fuel feed union.
31. Use a backing spanner and disconnect fuel
feed union from filter.
from fuel rail.
ENGINE
REPAIRS 25
abutment bracket.
34. Disconnect throttle cable from throttle cam and
move aside.
37. Remove 3 screws securing washer reservoir
and move reservoir aside.
- EIectricaI.
40. Release and disconnect oxygen sensor
multiplug.
41. Remove clip securing oxygen sensor lead to
engine harness.
42. Disconnect exhaust front pipe from manifold.
ENGINE
26 REPAIRS
43. Disconnect inhibitor switch multiplug.
44. Release inhibitor switch harness from clip on
gearbox case.
45. Loosen nut securing selector cable rod to
selector lever.
46. Remove bolt securing engine steady bar to
body.
bracket to gearbox.
48. Release selector cable rod and steady bar.
49. Drain gearbox fluid. See REPAIR MANUAL -
Maintenance.
50. Drain engine oil if required. See REPAIR
See REPAIR MANUAL - Automatic Gearbox
- DifferentiaI OiI SeaI.
52. Disconnect fluid cooler hose connections from
adapters on gearbox.
53. Discard 'O' rings and position hoses aside.
ENGINE
REPAIRS 27
54. Release plug leads from clip.
55. Fit lifting bracket, tool 18G 1572/2 and tighten
bolt to 9 Nm.
56. Fit lifting bracket tool, 18G 1572/2 to cylinder
head above dipstick tube, and tighten bolt to 9
Nm.
57. Use a hoist and connect adjustable lifting
bracket 18G 1698 to engine.
58. Raise chains to take weight of engine without
59. Remove through bolt from engine RH
mounting.
ENGINE
28 REPAIRS
to mounting.
61. Loosen 2 bolts securing mounting to support
member.
member to subframe.
64. Raise power unit and manoeuvre from engine
compartment.
Refit
1. Lower power unit into vehicle.
2. Position LH support member to subframe, fit
3. Align mounting bracket to LH engine mounting,
fit bolts and tighten to 45 Nm.
4. Tighten bolts securing mounting to to support
member to 45 Nm.
5. Align engine RH mounting, fit bolt and tighten
to 85 Nm.
6. Remove adjustable lifting bracket 18G 1598.
7. Remove lifting brackets tool 18G 1572 from
cylinder head.
8. Secure plug leads to clips.
REPAIR MANUAL - Automatic Gearbox -
10. Remove plugs from fluid cooler hoses and
adaptors.
11. Clean unions, lubricate NEW 'O' rings with
clean transmission fluid and fit to unions.
12. Connect unions to gearbox adapters and
tighten unions to 37 Nm.
13. Position steady bar bracket to gearbox, and
connect selector cable.
14. Fit bolts securing steady bar and tighten to 85
Nm.
15. Adjust selector cable. See REPAIR MANUAL -
Automatic Gearbox.
16. Connect inhibitor switch multiplug and secure
lead to clip.
17. Connect exhaust front pipe to manifold.
18. Connect oxygen sensor multiplug and secure
to bracket.
19. Secure lead to engine harness with clip.
EIectricaI.
ENGINE
REPAIRS 29
22. Position washer reservoir and tighten screws.
23. Connect washer pump multiplugs.
24. Connect servo pipe to manifold.
25. Connect throttle cable to throttle cam and
adjust cable.
26. Connect fuel return hose and secure clip.
27. Connect fuel feed hose union to filter and
tighten union.
28. Position expansion tank and tighten nuts.
29. Connect heater hoses and tighten clips.
30. Connect expansion tank hose to inlet manifold
and secure clip.
31. Connect expansion tank hose and tighten hose
clip.
32. Connect top hose and tighten clip.
34. Fit battery feed cable connector to fuse box
and fit 30A fuse and fuse box lid.
35. Secure earth leads to body.
36. Secure oxygen sensor relay to bracket.
connect multiplugs to inertia switch, relay
module, ECM and harness.
37. Secure harness multiplug to bracket.
nuts.
39. Position battery tray and charcoal canister
assembly, position fuse box bracket, fit bolts
with clip.
44. Refill gearbox fluid. See REPAIR MANUAL -
Maintenance.
45. Refill engine oil. See REPAIR MANUAL -
Maintenance.
Maintenance.
CAMSHAFT TIMING BELT UPPER COVER
Remove
2. Remove 3 screws securing washer reservoir to
body and move reservoir aside.
3. Loosen lower bolt securing camshaft timing
belt upper cover to engine.
4. Remove 6 bolts securing camshaft timing belt
upper cover to rear cover.
5. Remove camshaft timing belt upper cover.
ENGINE
30 REPAIRS
Refit
1. Clean camshaft timing belt upper cover.
2. Position timing belt upper cover, ensuring
correct position of rubber seal.
3. Fit bolts securing camshaft timing belt upper
cover to rear cover and tighten to 5 Nm.
4. Tighten bolt securing camshaft timing belt
upper cover to engine to 5 Nm.
5. Align washer reservoir and fit and tighten
screws.
6. Connect multiplugs to washer pumps.
ENGINE MANAGEMENT SYSTEM - MEMS
DESCRIPTION AND OPERATION 1
ENGINE COMPARTMENT COMPONENT
LOCATIONS
1. Fuel pressure regulator
2. Manifold absolute pressure sensor (part of
ECM)
3. ldle air control valve
4. lntake air temperature sensor
5. Throttle position sensor
6. EVAP canister and purge valve
7. Distributor
8. Relay module
9. Engine control module (ECM)
10. Air cleaner
11. Engine coolant temperature sensor
12. Crankshaft position sensor
13. Oxygen sensor
14. lgnition coil
2 DESCRIPTION AND OPERATION
ENGINE MANAGEMENT SYSTEM
The Engine Control Module (ECM) monitors the
conditions required for optimum combustion of fuel
in the cylinder through sensors located at strategic
points around the engine. As a result of these
sensor inputs, the engine control module can adjust
the fuel quantity and timing of the fuel being
delivered to the cylinders.
The main features are as follows:
 A single ECM controls the fuel injection system
and the ignition system. The ECM incorporates
short circuit protection and can store intermittent
faults on certain inputs. TestBook can interrogate
the ECM for these stored faults.
 The ECM is electronically immobilised which
prevents the engine from being started unless it
receives a coded signal from the anti-theft control
unit.
 ln conjunction with the throttle position sensor
the ECM uses the speed/density method of air
flow measurement to calculate fuel delivery. This
method measures the inlet air temperature and
inlet manifold pressure and assumes that the
engine is a calibrated vacuum pump, with its
characteristics stored in the ECM, it can then
determine the correct amount of fuel to be
injected.
 A separate diagnostic connector allows engine
tuning or fault diagnosis to be carried out using
TestBook without disconnecting the ECM
harness multiplug.
 The ECM harness multiplug incorporates
specially plated pins to minimise oxidation and
give improved reliability.
 The ECM controls the operation of the radiator
and air conditioning cooling fans, based on
signals received from the engine coolant
temperature sensor.
 lf certain system inputs fail, the ECM implements
a back-up facility to enable the system to
continue functioning, although at a reduced level
of performance.
IGNITION SYSTEM
The ECM determines the optimum ignition timing
based on the signals from the following sensors:
1. Crankshaft position sensor - Engine speed and
crankshaft position
2. Manifold absolute pressure sensor - Engine
load
3. Engine coolant temperature sensor - Engine
temperature
4. Manifold absolute pressure sensor - Throttle
pedal released
The engine management system uses no centrifugal
or vacuum advance. Timing is controlled by the
ECM which is energised by the main relay, located
within the relay module.
Spark distribution is achieved by means of a rotor
arm and distributor mounted at the No.4 cylinder end
of the inlet camshaft.
BASIC IGNITION TIMING
The speed and position of the engine is detected by
the crankshaft position (CKP) sensor which is bolted
to, and projects through, the engine adaptor plate
adjacent to the flywheel.
The CKP sensor is an inductive sensor consisting of
a bracket mounted body containing a coil and a
permanent magnet which provides a magnetic field.
The CKP sensor is situated so that an air gap exists
between it and the flywheel. Air gap distance is
critical for correct operation.
The flywheel incorporates a reluctor ring which
consists of 32 poles spaced at 10 intervals, with 4
missing poles at 30, 60, 210 and 250. The
missing poles inform the ECM when to operate the
groups of injectors. When the flywheel rotates, as a
pole passes the CKP sensor it disturbs the magnetic
field inducing a voltage pulse in the coil. This pulse
is transmitted to the ECM.
By calculating the number of pulses that occur within
a given time, the ECM can determine the engine
speed. This is a primary input necessary to make
the engine run.
The manifold absolute pressure (MAP) sensor is
located within the ECM. lt detects manifold pressure
via a hose connected to the inlet manifold. The MAP
sensor converts pressure variations into graduated
electrical signals which can be read by the ECM.
lncreases and decreases in the manifold pressure
provide the ECM with an accurate representation of
the load being placed on the engine allowing the
ECM to adjust the quantity of fuel being injected and
the ignition timing to achieve optimum fuelling of the
engine.
IGNITION TIMING COMPENSATION
The engine coolant temperature (ECT) sensor is a
'thermistor' (a temperature dependent resistor), i.e.
the voltage output varies in proportion to
temperature. The ECT sensor is located on top of
the coolant outlet elbow. The ECM constantly
monitors this signal and uses the information to
provide optimum driveability and emissions by
advancing or retarding the ignition timing.
With the throttle pedal released and the engine at
idle, the ECM uses the fast response of the engine
to ignition timing to maintain idle stabilisation.
When loads are placed on or removed from the
engine, the ECM responds to changes in engine
speed and in conjunction with adjusting the idle air
control (lAC) valve, advances or retards the ignition
timing to maintain a specified idle speed. When load
is removed from the engine the lAC valve returns to
its original position and the ignition timing returns to
the idle setting.
NOTE: Due to the sensitivity of this
system the ignition timing wiII be
constantIy changing at idIe speed.
IGNITION COMPONENTS
The coil for the programmed ignition system is
mounted on the back of the engine. The coil has a
lower primary winding resistance (0.63 to 0.77 ohms
at 20C) than a coil in a conventional ignition
system. This allows the full h.t. output to be reached
faster and so makes the coil operation more
consistent throughout the engine speed range.
1. Distributor cap
2. Rotor arm
3. Retaining screw
4. Anti-flash shield
The distributor cap, carrying a central carbon brush
and four h.t. lead pick-ups, is located at the No.4
cylinder end of the inlet camshaft and surrounds the
rotor arm. The rotor arm is secured by a retaining
screw to a 'D' shaped stub shaft, which is press
fitted into a vibration absorbing bush in the camshaft
and is protected from oil contamination by an
anti-flash shield which incorporates an oil drain.
FUEL SYSTEM
The Modular Engine Management System (MEMS)
is controlled by an ECM mounted in the engine
compartment. The ECM is an adaptive unit which
over a period of time learns the load and wear
characteristics of the engine it controls. The ECM
remembers and updates two main engine
requirements when the engine is running at normal
operating temperature:
1. The position of the idle air control (lAC) valve
required to achieve a specified idle speed. This
is then used as a reference for lAC valve
movement to achieve idle speed under all load
conditions.
2. The fuelling change or offset required to
achieve a set oxygen sensor voltage. This
allows the system to provide the correct
fuelling without having to apply excessive
adjustments to the fuelling which can adversely
affect the emissions and driveability.
NOTE: After fitting a different ECM,
TestBook wiII be required to reprogramme
the ECM with the code from the anti-theft
controI unit and to perform a fuII engine tune
procedure.
The ECM inputs and outputs are shown in the
following table:
INPUTS OUTPUTS
Crankshaft position sensor Purge valve
Manifold absolute pressure sensor lgnition coil
Engine coolant temperature sensor lnjectors
lntake air temperature sensor ldle air control valve
Heated oxygen sensor ECM Fuel pump relay
Throttle position sensor Diagnostic connector
Diagnostic input Heated oxygen sensor relay
Battery supply Main relay
Starter signal Cooling fans
Earth supply Air conditioning
Anti-theft control unit
The intake air temperature (lAT) sensor is located in
the side of the inlet manifold. The lAT sensor is of
the negative temperature coefficient (NTC) type,
designed to reduce its resistance with increasing
temperature. The ECM receives a signal
proportional to the temperature of the intake air.
When used in conjunction with the signal from the
manifold absolute pressure sensor the ECM can
calculate the volume of oxygen in the air and adjust
the quantity of fuel being injected to achieve
optimum fuelling of the engine.
The four fuel injectors are fitted between the
pressurised fuel rail and inlet manifold. Each injector
comprises a solenoid operated needle valve and a
specially designed nozzle to ensure good fuel
atomisation.
The injectors are controlled in grouped mode with 2
& 3 being grouped and 1 & 4 being grouped, with
the injectors in each group being operated
alternatively. The ECM determines when to operate
the injectors based on the signal it receives from the
crankshaft position sensor.
The ECM provides an earth signal for the period the
injectors are required to be open, the injector
solenoids are energised and fuel is sprayed into the
inlet manifold onto the back of the inlet valves. The
ECM carefully meters the amount of fuel injected by
adjusting the injector opening period (pulse width).
During cranking, when the engine speed is below
approximately 400 rev/min, the ECM increases the
injector pulse width to aid starting. The amount of
increase depends upon engine coolant temperature.
To prevent flooding, the ECM periodically inhibits the
operation of the injectors.
The throttle housing is located between the inlet
manifold and air intake hose and is sealed to the
manifold by an 'O' ring. The throttle housing
incorporates a throttle disc which is connected to the
throttle pedal via the throttle lever and a cable.
There are two breather pipes connected to the
throttle housing; one either side of the throttle disc.
When the engine is running with the throttle disc
open, both pipes are subject to manifold depression
and draw crankcase fumes into the manifold. When
the throttle disc is closed, only the pipe on the inlet
manifold side of the disc is subject to manifold
depression. This pipe incorporates a restrictor to
prevent engine oil being drawn into the engine by
the substantially greater manifold depression.
Mounted on the throttle housing are the throttle
position sensor and idle air control valve.
The throttle position (TP) sensor is a potentiometer
attached to the throttle housing and is directly
coupled to the throttle disc. The TP sensor is
non-adjustable. Closed throttle is detected by the TP
sensor which initiates idle speed control via the idle
air control valve.
The ECM supplies the TP sensor with a 5 volt
supply and an earth path. The TP sensor returns a
signal proportional to throttle disc position.
Throttle disc movement causes voltage across the
TP sensor to vary. The ECM calculates the rate of
change of the voltage signal in positive
(acceleration) or negative (deceleration) directions.
From this the ECM can determine the required
engine speed, rate of acceleration or rate of
deceleration and apply acceleration enrichment,
deceleration fuel metering or over-run fuel cut-off.
The idle air control (lAC) valve is mounted on the
inlet manifold and controlled by the ECM. The lAC
valve opens a pintle valve situated in an air passage
in the throttle housing, allowing air to bypass the
throttle disc and flow straight into the inlet manifold.
By changing the amount the lAC valve is open the
ECM can control engine idle speed and cold start air
flow requirements by adjusting the flow of air in the
passage.
During cold starting the ECM indexes the lAC valve
open slightly to provide a level of fast idle,
dependent on engine coolant temperature. As the
engine warms, fast idle is gradually decreased until
normal operating temperature is reached.
The position of the lAC valve should be within the
range of 20 to 40 steps when the engine is running.
NOTE: Adjustment of the IAC vaIve ONLY
appIies to the 'Iearnt' position, not the
actuaI position at idIe, so adjustment is
not recommended.
lf the valve is identified as being outside this range it
can be adjusted to within range using TestBook.
This ensures that the lAC valve is at the optimum
position within its range for providing further
movement to compensate for changes in engine
load or temperature in accordance with signals from
the ECM.
NOTE: The position of the throttIe disc is
preset during manufacture and the throttIe
position setting screw MUST NOT be
adjusted.
The relay module is located in the engine
compartment adjacent to the engine control module.
The relay module contains the following relays:
 Main relay - energised when the ignition is
switched on and supplies power to the ECM.
 Fuel pump relay - energised by the ECM for a
short period when the ignition is switched on,
during cranking and while the engine is running.
 Starter relay - energised by the cranking signal
from the ignition switch.
 Heated oxygen sensor relay - energised by the
ECM and supplies current to the heated oxygen
sensor element.
The purge valve is an integral part of the EVAP
canister, and is driven directly from the ECM. When
the purge valve is opened it allows the EVAP
canister to vent into the engine inlet manifold. The
valve is opened by the ECM for varying periods
under specific engine conditions to avoid degrading
engine performance.
The electric fuel pump is located inside the fuel tank
and is energised by the ECM via the fuel pump relay
in the relay module and the fuel cut-off switch.
The fuel pump delivers more fuel than the maximum
load requirement for the engine, pressure is
therefore maintained in the fuel system under all
conditions.
The pressure regulator is a mechanical device
controlled by manifold depression and is mounted
on one end of the fuel rail. The regulator ensures
that fuel rail pressure is maintained at a constant
pressure difference to that in the inlet manifold, as
manifold depression increases the regulated fuel
pressure is reduced in direct proportion.
When pressure exceeds the regulator setting,
excess fuel is returned to the fuel tank swirl pot
which contains the fuel pump pick-up.
The electrical circuit for the fuel pump incorporates
an inertia fuel shut-off (lFS) switch which, in the
event of a sudden deceleration, breaks the circuit to
the fuel pump preventing fuel being delivered to the
engine. The lFS switch is situated in the engine
compartment, fixed to the bonnet switch bracket
which is located on the bulkhead, and must be reset
by pressing the rubber top before the engine can be
restarted.
WARNING: ALWAYS check for fueI Ieaks
and the integrity of fueI system
connections before resetting the switch.
A diagnostic connector, located on a bracket above
the passenger compartment fuse box, allows engine
tuning or fault diagnosis to be carried out using
TestBook without disconnecting the ECM harness
multiplug.
The modular engine management system operates
a closed loop emission system to ensure the most
efficient level of exhaust gas conversion.
A heated oxygen sensor (HO2S) fitted in the
exhaust manifold monitors the exhaust gases. lt
supplies a small voltage proportional to exhaust
oxygen content to the ECM. As the air/fuel mixture
weakens, the exhaust oxygen content increases and
the voltage to the ECM decreases. lf the mixture
becomes richer, the oxygen content decreases and
the voltage to the ECM increases.
From this signal the ECM can determine the air/fuel
mixture being delivered to the engine and can adjust
the duration the injectors are open to maintain the
ratio necessary for efficient gas conversion by the
catalyst.
The HO2S has an integral heating element to
ensure an efficient operating temperature is quickly
reached from cold. The electrical supply to the
heater element is controlled by the ECM via the
HO2S relay in the relay module.
When the throttle pedal is depressed the ECM
receives a rising voltage from the throttle position
sensor and detects a rise in manifold pressure from
the manifold absolute pressure sensor. The ECM
provides additional fuel by increasing the normal
injector pulse width and also provides a small
number of extra additional pulses on rapid throttle
openings.
The ECM implements over-run fuel cut-off when the
engine speed is above 1600 rev/min with engine at
normal operating temperature and the throttle
position sensor in the closed position, i.e. the vehicle
is 'coasting' with the throttle pedal released. The
ECM indexes the idle air control valve open slightly
to increase the air flow through the engine to
maintain a constant manifold depression to keep
emissions low.
Fuel is immediately reinstated if the throttle is
opened. lf the engine speed drops below 1600
rev/min on over-run, fuel is progressively reinstated.
To prevent damage at high engine speeds the ECM
will implement fuel cut-off at engine speeds above
approximately 7000 rev/min; fuel being gradually
reinstated as speed falls.
When the starter switch is turned off, the ECM will
keep the main relay energised for approximately 30
seconds while it drives the idle air control valve to its
power down position, ready for the next engine start.
The ECM monitors the engine coolant temperature
for a minimum of 2 minutes after the starter switch is
turned off.lf the coolant temperature rises above a
certain limit, the ECM switches on the radiator fans.
Once the fans are running the ECM will not power
down until either the coolant temperature falls below
a certain limit or 8 minutes have elapsed since the
starter switch was turned off. lf the coolant
temperature has not risen above the limit after 2
minutes, the ECM will power down.
AIR INTAKE SYSTEM
1. Air cleaner element
2. Throttle disc
3. ldle air control valve
4. lnlet manifold
5. lnjector
6. Purge valve
7. EVAP canister
8. Engine Control Module
9. Fuel trap
lntake air is drawn into the throttle housing through an air filter element. lncorporated in the throttle housing are the
throttle disc and the throttle position sensor.
Air is passed from the throttle housing via the manifold chamber into the inlet manifold where it is mixed with fuel
injected by the injectors before the mixture is drawn into the combustion chamber.
An engine load signal is applied to the manifold absolute pressure sensor from the manifold chamber. This signal is
used to calculate the fuel to be delivered by the injectors.
ADJUSTMENTS 1
THROTTLE CABLE
NOTE: Before adjusting cabIe, ensure that
cabIe is correctIy routed and Iocated. Do
not attempt to adjust throttIe cabIe or
engine idIe speed by means of the throttIe stop
screw.
Adjust
1. Release cable adjusting nut from abutment
bracket.
2. Position outer cable to abutment bracket so
that adjusting nut contacts top of the abutment
bracket.
3. Hold throttle cam in fully closed position,
ensure throttle cam contacts throttle stop
screw.
4. Rotate cable adjusting nut until all slack is
taken out of inner cable. Ensure throttle does
not open.
bracket.
6. Operate throttle pedal and ensure that full
throttle pedal movement is available.
REPAIRS 1
DISTRIBUTOR CAP AND ROTOR ARM
Remove
1. Noting their fitted positions, disconnect 5 h.t.
leads from distributor cap.
2. Loosen 2 screws securing distributor cap to
engine.
3. Remove distributor cap.
4. Rotate engine to gain access to rotor arm
screw.
5. Remove and discard screw securing rotor arm
to camshaft.
6. Remove rotor arm.
7. Remove distributor flash shield.
Refit
1. Clean distributor cap, rotor arm and flash
shield.
2. Examine distributor cap and rotor arm for signs
of damage or tracking; renew if necessary.
3. Fit flash shield.
4. Clean rotor arm screw thread in camshaft with
thread tap.
5. Position rotor arm on camshaft.
6. Fit new patchlock screw to secure rotor arm to
camshaft and tighten to 8 Nm.
7. Fit distributor cap and align holes in cap and
flash shield with those in engine.
8. Fit 2 screws securing distributor cap to engine.
9. Connect h.t. leads to distributor cap.
IGNITION COIL
Remove
3. Disconnect multiplug from ignition coil.
4. Disconnect h.t. lead from ignition coil.
5. Remove 3 bolts securing igntion coil to engine.
6. Remove ignition coil.
Refit
1. Position ignition coil to engine.
2. Fit bolts securing ignition coil to engine, tighten
2 x M10 bolts to 25 Nm and M6 bolt to 9 Nm.
3. Connect h.t. lead to ignition coil.
4. Connect multiplug to ignition coil.
2 REPAIRS
ENGINE CONTROL MODULE (ECM)
Remove
4. Remove screw securing ECM to mounting
bracket.
5. Release and remove ECM.
Refit
1. Fit ECM to mounting bracket and tighten
screw.
2. Connect vacuum hose to ECM.
3. Connect multiplug to ECM.
NOTE: A new ECM wiII need to be
programmed with the code from the
anti-theft security unit using TestBook,
before the engine can be started.
IDLE AIR CONTROL VALVE (IACV)
Remove
3. Remove 2 TX20 Torx screws securing lACV to
inlet manifold.
4. Remove lACV.
5. Remove and discard 'O' ring from lACV.
Refit
1. Clean mating faces of lACV and housing.
2. Lubricate NEW 'O' ring with silicone grease
and fit to lACV.
3. Position lACV to housing, fit screws and
tighten to 8 Nm.
REPAIRS 3
INTAKE AIR TEMPERATURE (IAT) SENSOR
Remove
3. Remove lAT sensor.
Refit
1. Clean threads of lAT sensor.
2. Clean mating faces of lAT sensor and inlet
manifold.
3. Fit lAT sensor to inlet manifold and tighten to 7
Nm.
ENGINE COOLANT TEMPERATURE (ECT)
SENSOR
Remove
2. Disconnect multiplug from ECT sensor.
3. Position container to collect coolant spillage.
4. Remove ECT sensor.
Refit
1. Clean threads of ECT sensor.
2. Apply Loctite 577 to threads of ECT sensor.
3. Fit ECT sensor and tighten to 15 Nm.
4. Connect multiplug to ECT sensor.
6. Top-up coolant. See REPAIR MANUAL -
Maintenance.
4 REPAIRS
CRANKSHAFT POSITION (CKP) SENSOR
Remove
1. Disconnect multiplug from CKP sensor.
2. Remove bolt securing CKP sensor to flywheel
housing.
3. Remove CKP sensor.
Refit
1. Clean CKP sensor and mating face on flywheel
housing.
2. Position CKP sensor, fit bolt and tighten to 6
Nm.
3. Connect multiplug to CKP sensor.
THROTTLE POSITION (TP) SENSOR
Remove
3. Remove and discard 2 TX20 Torx screws and
wave washers securing TP sensor to throttle
housing.
4. Remove TP sensor specification plate.
5. Pull TP sensor from throttle spindle.
CAUTION: Do not twist or appIy Ieverage
to TP sensor.
Refit
1. Clean mating faces of throttle housing and TP
sensor.
2. Fit TP sensor to throttle spindle. Ensure that
during fitting, the machined flat on the throttle
spindle is aligned with the mating portion of the
TP sensor.
REPAIRS 5
CAUTION: The TP sensor can be easiIy
damaged during fitting. When pressing the
sensor onto the throttIe spindIe, use
fingers onIy, and onIy appIy pressure to the area
shown shaded in the iIIustration.
3. Rotate TP sensor in an anti-clockwise direction
to align fixing holes.
CAUTION: Do not rotate sensor in a
cIockwise direction, and ensure that it is
not rotated beyond its internaI stops.
4. Fit TP sensor specification plate.
5. Fit new Torx screws and wave washers, and
tighten to 1.5 Nm.
CAUTION: Do not exceed specified torque
figure.
7. Operate throttle cable cam 2 or 3 times and
ensure that full travel to the throttle open and
the throttle closed positions is available.
ENGINE MANAGEMENT RELAY MODULE
The engine management relay module contains the
following relays:
Main relay
Starter relay
Fuel pump relay
HO2S relay
Remove
1. Release charcoal canister from bracket and
move aside for access.
2. Release relay module from mounting bracket.
4. Remove relay module.
Refit
1. Position relay module and connect 2
multiplugs. Ensure multiplugs are correctly
engaged.
2. Secure relay module to mounting bracket.
3. Secure charcoal canister to bracket.
6 REPAIRS
AIR CLEANER
Remove
1. Remove battery. See REPAIR MANUAL -
EIectricaI.
2. Release clip securing intake hose to throttle
housing.
3. Remove 2 bolts securing air cleaner to battery
tray.
4. Disconnect intake hose from throttle housing.
5. Release and remove air cleaner assembly.
Refit
1. Position and locate air cleaner.
2. Align air cleaner to battery tray.
3. Fit bolts securing air cleaner to battery tray and
tighten to 9 Nm.
4. Connect intake hose to throttle housing and
secure clip.
5. Fit battery. See REPAIR MANUAL -
EIectricaI.
REPAIRS 7
THROTTLE CABLE
Remove
1. Release cable adjusting nut from abutment
bracket.
2. Release inner cable from cam.
3. Rotate collar through 90 and release cable
from bulkhead.
4. Release nylon clip and disconnect throttle
cable from pedal.
5. Remove throttle cable.
Refit
1. Feed cable through bulkhead and connect
inner cable to pedal.
2. Smear rubber grease of both sides of the
rubber seal and secure cable to bulkhead.
4. Connect cable adjusting nut to abutment
bracket.
8 REPAIRS
HEATED OXYGEN (HO2S) SENSOR
Remove
2. Disconnect HO2S multiplug.
3. Release multiplug from bracket on coolant rail.
4. Remove cable tie securing sensor harness to
engine harness and release sensor harness.
5. Using a 22 mm open ended spanner remove
HO2S and collect sealing washer.
6. Discard sealing washer.
Refit
1. Fit NEW sealing washer to HO2S.
2. Fit HO2S and tighten to 55 Nm.
3. Secure multiplug to bracket on coolant rail.
4. Connect HO2S multiplug to harness.
5. Secure sensor harness to engine harness with
cable tie.
REPAIRS 9
THROTTLE HOUSING
Remove
2. Release clip securing air intake hose to throttle
housing.
3. Disconnect air intake hose from throttle
housing.
4. Disconnect lACV hose from throttle housing.
6. Release clip and disconnect breather hose
from throttle housing.
abutment bracket.
8. Disconnect kickdown cable
from throttle cam.
9. Disconnect throttle cable from throttle cam.
10. Remove 4 bolts securing throttle housing to
inlet manifold.
11. Remove throttle housing.
12. Remove and discard 'O' ring from throttle
housing.
Refit
1. Clean mating faces of throttle housing and inlet
manifold.
2. Lubricate new 'O' ring with silicone grease and
fit to throttle housing.
3. Position throttle housing to inlet manifold and
align injector harness multiplug bracket.
4. Fit bolts securing throttle housing to inlet
manifold and tighten to 7 Nm.
bracket.
throttle cam.
8. Connect breather hose to inlet manifold and
secure with clip.
10. Connect hose from lACV to throttle housing.
11. Connect air intake hose to throttle housing and
secure clip.
13. Check throttle cable
adjustment.
14. Check throttle and
kickdown cable adjustments.
10 REPAIRS
ECM FUEL TRAP
Remove
2. Disconnect ECM vacuum hose from fuel trap.
3. Disconnect vacuum hose for inlet manifold.
4. Release and remove fuel trap from mounting
bracket.
Refit
1. Fit fuel trap to mounting bracket.
2. Connect vacuum hoses to fuel trap and inlet
manifold.
FUEL RAIL
Remove
union.
3. Loosen union to relieve fuel pressure, then
re-tighten to 28 Nm.
system pipes or components, use two
unions.
4. Remove inlet manifold chamber.
REPAIRS 11
5. Release clip and remove vacuum hose from
fuel pressure regulator.
from fuel pressure regulator.
7. Position an absorbent cloth around fuel feed
connection.
rail.
9. Release fuel feed pipe from fuel rail and
discard 'O' ring.
10. Remove 4 clips securing injectors to fuel rail.
11. Remove 2 bolts securing fuel rail to inlet
manifold.
12. Release and remove fuel rail from injectors.
13. Remove and discard 'O' ring from each
injector.
14. Fit protective caps to each injector.
12 REPAIRS
Refit
1. Clean injector recesses in fuel rail.
2. Remove protective caps from injectors.
3. Lubricate new 'O' rings with silicone grease
and fit to injectors.
4. Fit fuel rail to injectors and secure with clips.
5. Fit bolts securing fuel rail to inlet manifold and
tighten to 10 Nm.
6. Lubricate new 'O' ring with silicone grease. Fit
'O' ring to fuel feed pipe.
7. Position fuel feed pipe to fuel rail, fit bolts and
tighten to 5 Nm.
8. Connect fuel return hose to fuel pressure
regulator and secure with clip.
9. Fit inlet manifold chamber.
FUEL INJECTORS
Remove
2. Remove fuel rail.
3. Disconnect multiplugs from injectors.
4. Remove injectors from inlet manifold.
5. Remove and discard 'O' rings from injectors.
6. Fit protective caps to injectors.
Refit
1. Clean injectors and recesses in inlet manifold.
2. Remove protective caps from injectors.
3. Lubricate new 'O' rings with silicone grease
and fit to injectors.
4. Fit injectors to inlet manifold.
5. Connect multiplugs to injectors.
6. Fit fuel rail.
FUEL DELIVERY SYSTEM - MEMS
FUEL DELIVERY SYSTEM
1. lnjectors
2. Fuel pressure regulator
3. Fuel return line
4. Non return valve
5. Fuel tank
6. Fuel pump
7. Swirl pot
8. Fuel filter
A recirculating fuel system is used to supply fuel to the injectors at a constant pressure and return excess fuel to the
fuel tank.
Fuel pressure is produced by an electric pump immersed in the fuel tank and operating in a swirl pot to maintain a
constant fuel level around the fuel pick-up.
Pressurised fuel is fed to an in-line filter via a non return valve which prevents fuel returning to the tank when to
pump is not running. Fuel is delivered from the fuel filter to the fuel rail which supplies the injectors. A fuel pressure
regulator mounted on the fuel rail controls the pressure in the fuel rail and returns excess fuel to the swirl pot in fuel
tank. A venturi in the fuel tank causes returning fuel to draw cool fuel into the swirl pot.
COOLING SYSTEM - MEMS
COOLING SYSTEM COMPONENTS
1. Radiator
2. Radiator mounting bushes
3. Radiator mounting brackets
4. Cooling fan
5. Bottom hose
6. Top hose
7. Pipe - bottom hose to thermostat
8. Thermostat housing
9. Thermostat housing 'O' ring
10. Coolant pump 'O' ring
11. Coolant pump
12. Expansion tank
13. Hose - heater feed
14. Hose - heater return
15. Bleed plug
16. Hose - expansion tank to thermostat
17. Hose - expansion tank to coolant pipe
18. Bleed screw
COOLING SYSTEM OPERATION
A = COLD
B = HOT
1. Bottom hose
2. Heater matrix
3. Thermostat
4. Top hose
5. Expansion tank
6. Radiator
7. Coolant pump
The cooling system employed is the bypass type.
When the engine is cold the thermostat closes off coolant feed from the radiator bottom hose. Coolant is drawn via
the heater matrix from the cylinder block, this allows some heat transfer to the radiator via the top hose by
convection while retaining the majority of the heat within the cylinder block.
The siting of the thermostat in the inlet rather than the outlet side of the system provides a reduced warm up time by
circulating a small amount of coolant around a shorter tract, this also prevents temperature build up within the
cylinder head prior to the thermostat opening.
As the temperature increases the thermostat gradually opens, bleeding cool coolant into the cylinder block and
allowing hot coolant to flow to the radiator via the top hose, balancing the flow of hot and cold fluid to maintain
temperature. As the thermostat opens further so the full flow of coolant is drawn through the radiator.
REPAIRS 1
COOLING FAN
Remove
1. Remove air cleaner assembly.
3. Release fan motor multiplug from bracket and
disconnect multiplug.
4. Remove 4 bolts securing fan cowl to radiator.
5. Remove fan and cowl assembly.
Refit
1. Position fan and cowl assembly.
2. Fit and tighten bolts securing cowl.
3. Connect multiplug and secure to bracket.
5. Fit air cleaner assembly.
RADIATOR BLOCK
Remove
1. Remove cooling fan and cowl assembly.
2. Position container below radiator.
3. Loosen top hose clips, disconnect hose from
radiator and remove hose from engine.
4. Loosen bottom and expansion tank hose clips
and disconnect hoses from radiator.
5. Remove 4 bolts securing radiator top mounting
brackets.
6. Remove 2 mounting brackets.
2 REPAIRS
7. Remove 2 bolts securing coolant pipe to
radiator.
8. Release radiator from lower mountings and
remove.
9. Remove clip securing coolant pipe hose to
radiator.
10. Disconnect hose and remove coolant pipe and
hose assembly.
Refit
1. Fit coolant pipe and hose assembly and tighten
hose clip.
2. Fit radiator assembly.
3. Align coolant pipe and tighten bolts.
4. Fit radiator top mounting brackets and fit and
tighten bolts.
5. Fit top hose to engine, connect hose to radiator
and tighten hose clips.
6. Connect bottom and expansion tank hoses to
radiator and tighten hose clips.
7. Fit cooling fan and cowl assembly.
Maintenance.
9. Remove container.
MANIFOLD & EXHAUST SYSTEMS
INLET AND EXHAUST MANIFOLD
1. lnlet manifold chamber
2. Gasket - inlet manifold chamber
3. lnlet manifold
4. Gasket - inlet manifold to cylinder head
5. Gasket - exhaust manifold to cylinder head
6. Exhaust manifold
7. Gasket - exhaust front pipe to manifold
8. Self-locking nut
9. Flanged nut
10. Flanged bolt - inlet manifold to cylinder head
11. Flanged nut
12. Flanged bolt - manifold chamber to manifold
REPAIRS 1
FRONT PIPE TO MANIFOLD GASKET
Remove
2. Remove 3 nuts securing front pipe to manifold.
3. Release front pipe from manifold.
CAUTION: DO NOT Iet the front pipe hang
on oxygen sensor Iead.
4. Remove gasket from manifold flange.
Refit
1. Clean manifold and front pipe flanges.
2. Fit new gasket to manifold flange.
3. Position front pipe to manifold, fit nuts and
tighten to 50 Nm.
INLET MANIFOLD GASKET
Remove
Maintenance.
union. Loosen union to relieve fuel pressure.
Re-tighten union to 28 Nm.
system pipes and components, use two
unions.
2 REPAIRS
4. Remove clip and disconnect air intake hose
8. Remove 4 bolts securing throttle housing to
inlet manifold, collect multiplug bracket and
place throttle housing aside.
9. Remove and discard 'O' ring from throttle
housing.
10. Disconnect hose from lACV and remove hose
from throttle housing
bracket and disconnect multiplug.
REPAIRS 3
from manifold.
14. Release clip and remove breather hose from
camshaft cover.
16. Disconnect ECM vacuum hose from inlet
manifold.
from fuel rail.
18. Release fuel return hose from 2 clips on
underside of inlet manifold.
inlet manifold.
20. Remove bolt securing support stay to inlet
manifold.
rail.
23. Release fuel feed pipe from fuel rail, remove
and discard 'O' ring.
4 REPAIRS
24. Working from the centre outwards,
progressively slacken then remove 6 bolts and
2 nuts securing inlet manifold to cylinder head.
25. Remove inlet manifold, remove and discard
gasket.
Refit
1. Ensure inlet manifold and cylinder head mating
faces are clean.
2. Fit new gasket to inlet manifold.
CAUTION: Gasket must be fitted dry.
3. Fit inlet manifold, fit bolts and nuts and tighten
to 25 Nm in the sequence shown.
4. Fit bolt securing support stay to inlet manifold
5. Connect coolant hose to inlet manifold and
secure with clip.
6. Remove plugs from fuel hoses.
fit to fuel feed pipe.
8. Fit fuel feed pipe to fuel rail, fit bolts and tighten
to 10 Nm.
10. Connect fuel return hose to fuel rail and secure
with clip.
11. Secure fuel return hose to clips on underside of
inlet manifold.
12. Connect ECM vacuum pipe and brake servo
vacuum hose to inlet manifold.
13. Fit breather pipe between inlet manifold and
camshaft cover and secure with clips.
REPAIRS 5
15. Clean mating faces of inlet manifold and
throttle housing.
fit to throttle housing.
17. Position multiplug bracket and throttle housing,
fit bolts and tighten to 7 Nm.
18. Connect multiplug to injector harness and
secure multiplug to bracket.
20. Connect breather hose to throttle housing and
secure with clip.
21. Connect hose to lACV and secure with clip.
22. Connect purge hose to inlet manifold and
secure with clip.
23. Connect air intake hose to air cleaner and
secure with clip.
Maintenance.
EXHAUST MANIFOLD GASKET
Remove
2. Remove 3 nuts securing exhaust front pipe to
manifold.
3. Release front pipe from manifold and discard
gasket.
CAUTION: DO NOT aIIow front pipe to
hang on oxygen sensor Iead.
4. Remove 7 nuts securing exhaust manifold to
cylinder head.
5. Remove exhaust manifold.
6. Remove and discard exhaust manifold gasket.
6 REPAIRS
Refit
1. Clean mating faces of cylinder head and
manifold.
2. Fit new gasket to manifold studs.
3. Position manifold on studs, fit nuts and tighten
in the sequence shown to 45 Nm.
4. Clean exhaust manifold and front pipe flange
mating faces.
5. Fit flange gasket, connect front pipe, fit nuts
INLET MANIFOLD CHAMBER GASKET
Remove
2. Release clip and disconnect air intake hose
REPAIRS 7
6. Disconnect purge hose from manifold
chamber.
7. Loosen locknut, release
kickdown cable from abutment bracket and
disconnect inner cable from throttle cam.
abutment bracket.
9. Disconnect throttle cable from throttle cam.
servo vacuum hose from manifold chamber.
11. Disconnect ECM vacuum hose from manifold
chamber.
12. Disconnect fuel pressure regulator vacuum
hose from manifold chamber.
from manifold chamber.
8 REPAIRS
mounting bracket beneath throttle housing.
15. Release coil h.t. lead from clip beneath throttle
housing.
16. Remove 5 bolts securing manifold chamber to
inlet manifold.
17. Remove inlet manifold chamber.
18. Remove and discard inlet manifold chamber
gasket.
Refit
1. Clean mating surfaces of inlet manifold and
manifold chamber gasket.
2. Position new gasket to inlet manifold.
3. Fit manifold chamber to inlet manifold and
align.
4. Fit bolts securing manifold chamber to inlet
manifold and tighten progressively to 25 Nm.
5. Secure coil h.t. lead and injector harness
multiplug to mounting bracket beneath throttle
housing.
6. Connect breather hose to manifold chamber
and secure with clip.
7. Connect fuel pressure regulator vacuum hose
to manifold chamber.
8. Connect ECM vacuum hose to manifold
chamber.
9. Connect brake servo vacuum hose to manifold
chamber.
bracket.
throttle cam and locate outer cable to abutment
bracket.
13. Connect purge hose to manifold chamber and
secure with clip.
14. Connect breather hose to throttle housing and
secure with clip.
17. Connect air intake hose to throttle housing and
secure with clip.
20. Adjust throttle and kickdown
cable.
MANUAL GEARBOX
REPAIRS 1
GEARBOX ASSEMBLY
Remove
Body.
bracket
battery tray.
assembly.
MANUAL GEARBOX
2 REPAIRS
11. Disconnect 2 reverse switch Lucars.
12. Remove clutch cable tension spring 'C' clip
13. Release clutch cable from bulkhead clip.
14. Release clutch cable from release lever and
abutment bracket. Move cable aside.
MANUAL GEARBOX
REPAIRS 3
linkage ball joint from upper selector lever.
- EIectricaI.
body.
bracket to gearbox.
21. Remove steady bar brack
linkage ball joint from lower selector lever.
23. Position container under gearbox. Remove
gearbox filler/level and drain plugs, and allow
oil to drain. Refit plugs and tighten to 35 Nm.
See REPAIR MANUAL - ManuaI Gearbox -
25. Remove 3 bolts securing flywheel lower cover
plate to engine.
26. Remove cover plate.
27. Remove 3 bolts securing flywheel front cover
plate.
MANUAL GEARBOX
4 REPAIRS
29. Remove 2 bolts securing flywheel rear cover
plate and nut and bolt securing harness
bracket and flywheel rear cover plate.
30. Release harness bracket and remove rear
cover plate.
31. Fit suitable lifting equipment to gearbox lifting
eye.
32. Raise chains to take weight of gearbox without
33. Support engine on a jack.
CAUTION: Use a bIock of wood or hard
rubber pad to protect engine.
34. Release clip securing harness to gearbox
mounting support member.
to mounting.
member to subframe.
38. Remove 2 bolts securing gearbox LH mounting
bracket to gearbox.
39. Remove mounting bracket.
MANUAL GEARBOX
REPAIRS 5
40. Lever power unit forward approximately 25 mm
and insert wooden block, measuring 150 mm x
80 mm, lengthways between engine and
subframe to hold power unit forward.
41. Remove 4 bolts securing gearbox to engine.
42. Release gearbox from engine, raise and
manoeuvre gearbox clear of engine
compartment.
Refit
1. Use gear case bolt to secure small open ended
spanner in position illustrated to prevent clutch
release lever moving.
2. Connect lifting equipment to gearbox.
3. Lower gearbox into engine compartment and
secure on dowels.
4. Fit bolts securing gearbox and tighten to 85
Nm.
5. Remove jack, lever power unit forward and
remove block from between engine and
subframe.
6. Position LH mounting bracket to gearbox, fit
7. Position support member to subframe, fit bolts
8. Adjust height of power unit to align mounting
bracket to LH engine mounting, fit bolts and
tighten to 45 Nm.
9. Remove lifting equipment.
10. Position harness to support member and
secure clip.
REPAIR MANUAL - ManuaI Gearbox -
12. Position flywheel rear cover plate, align
harness bracket, fit 2 small bolts and tighten to
8 Nm.Tighten large nut and bolt to 38 Nm.
13. Position flywheel front cover plate, fit bolts and
tighten to 8 Nm.
14. Position flywheel lower cover plate, fit bolts and
tighten to 8 Nm.
MANUAL GEARBOX
6 REPAIRS
15. Clean ball joint, and using tool 18G 1594
connect gearchange linkage lower ball joint.
16. Position steady bar bracket to gearbox, fit bolts
17. Align steady bar bracket to body, fit bolt and
tighten to 45 Nm.
EIectricaI.
20. Clean ball joint and connect gearchange upper
ball joint using 18G 1584.
22. Loosen bolt and remove small spanner, tighten
bolt to 28 Nm.
23. Connect clutch cable to release lever and
secure in clip.
nuts.
25. Position battery tray and charcoal canister.
26. Position fuse box bracket, fit bolts and tighten
to 9 Nm.
with clip.
28. Connect purge hose to inlet manifold.
29. Connect multiplug to purge valve.
31. Fit air cleaner,
Maintenance.
AUTOMATIC GEARBOX
ADJUSTMENTS 1
THROTTLE AND KICKDOWN CABLE
Adjust
1. Loosen kickdown cable adjusting nut and
locknut.
3. Rotate and hold throttle cam in its fully open
position.
4. With assistance, insert a 1 mm thick feeler
gauge between the kickdown cable adjusting
nut (A) and abutment bracket.
5. Tighten adjusting nut (A) to remove all free
play from kickdown cable. Ensure throttle cam
is still in its fully open position.
6. Remove feeler gauge and tighten kickdown
cable locknut (B).
7. Release throttle cam and check that full
movement of throttle cam is achievable.
AUTOMATIC GEARBOX
REPAIRS 1
KICKDOWN CABLE
Remove
2. Remove air cleaner assembly.
- EIectricaI.
5. Remove fluid pan. See REPAIR MANUAL -
Automatic Gearbox.
6. Loosen downshift cable lock and adjusting
nuts.
7. Release inner cable from throttle cam.
8. Release downshift cable from abutment
bracket.
9. Release inner cable from valve cam inside
gearbox using a piece of stiff wire with a hook
on the end.
AUTOMATIC GEARBOX
2 REPAIRS
10. Release downshift outer cable from
transmission case using 18G 1650.
11. Remove kickdown cable.
Refit
1. Position kickdown cable and secure outer
cable to gearbox case.
2. Connect inner cable to valve cam.
3. Secure cable to abutment bracket and connect
inner cable to throttle cam.
4. Fit fluid pan. See REPAIR MANUAL -
Automatic Gearbox.
EIectricaI.
7. Refill gearbox with fluid. See REPAIR
8. Adjust throttle and kickdown cables.
9. Fit air cleaner.
GEARBOX ASSEMBLY
Remove
Body.
bracket
AUTOMATIC GEARBOX
REPAIRS 3
battery tray.
assembly.
separate upper from lower cable.
12. Loosen kickdown cable locknut and adjusting
nut.
13. Release kickdown inner cable from throttle
cam.
14. Release cable from abutment bracket.
Maintenance.
AUTOMATIC GEARBOX
4 REPAIRS
16. Loosen clip,and disconnect top hose from
cylinder head.
17. Disconnect oxygen sensor multiplug from
engine harness and release from bracket.
19. Release exhaust front pipe from manifold.
- EIectricaI.
21. Disconnect multiplug from inhibitor switch and
release lead from clip.
22. Loosen nut securing selector cable rod to
selector lever.
23. Release selector cable rod from selector lever.
AUTOMATIC GEARBOX
REPAIRS 5
body.
bracket to gearbox.
26. Remove steady bar bracket.
27. Drain gearbox fluid. See REPAIR MANUAL -
Maintenance.
See REPAIR MANUAL - Automatic Gearbox
- DifferentiaI OiI SeaI.
29. Disconnect fluid cooler hoses from adapators
on gearbox.
30. Remove and discard 2 'O' rings.
31. Position hoses aside.
32. Remove 3 bolts securing flywheel lower cover
plate to engine.
34. Remove 3 bolts securing flywheel front cover
plate.
AUTOMATIC GEARBOX
6 REPAIRS
36. Remove 2 bolts securing flywheel rear cover
plate.
37. Remove rear cover plate.
38. Fit suitable lifting equipment to gearbox lifting
eye.
39. Raise chains to take weight of gearbox without
40. Support engine on a jack.
CAUTION: Use a bIock of wood or hard
rubber pad to protect engine.
to mounting.
member to sub frame.
43. Remove support member and mounting
assembly.
AUTOMATIC GEARBOX
REPAIRS 7
44. Remove 4 bolts securing gearbox to engine.
45. Release gearbox from engine, raise and
manoeuvre gearbox clear of engine
compartment.
46. Remove 3 bolts securing mounting bracket to
gearbox.
47. Remove mounting bracket.
Refit
1. Position mounting bracket to gearbox,fit bolts
2. Clean engine and gearbox mating faces.
3. Wipe dowels and dowel holes
4. Connect lifting equipment to gearbox.
5. Lower gearbox into engine compartment and
manoeuvure onto dowels.
CAUTION: Ensure gearbox input shaft is
correctIy engaged in drive pIate.
6. Fit bolts securing gearbox and tighten to 85
Nm.
7. Position support member to subframe, fit bolts
8. Adjust height of power unit to align mounting
bracket to LH engine mounting, fit bolts and
tighten to 45 Nm.
9. Remove lifting equipment.
REPAIR MANUAL - Automatic Gearbox -
11. Position flywheel rear cover plate, fit bolts and
tighten to 8 Nm.
12. Position flywheel front cover plate, fit bolts and
tighten to 8 Nm.
13. Position flywheel lower cover plate, fit bolts and
tighten to 8 Nm.
14. Remove plugs from fluid cooler hose
connections and from adaptors on gearbox.
15. Clean unions, lubricate NEW 'O' rings with
clean gearbox fluid and fit to unions.
16. Connect hoses to gearbox adaptors and
tighten unions to 37 Nm.
17. Position steady bar bracket to gearbox, fit bolts
18. Align steady bar bracket to body, fit bolt and
tighten to 45 Nm.
19. Connect selector cable rod to selector lever.
20. Adjust selector cable. See REPAIR MANUAL -
Automatic Gearbox.
21. Connect inhibitor switch multiplug.
22. Secure inhibitor switch harness to clip on
gearbox
AUTOMATIC GEARBOX
8 REPAIRS
EIectricaI.
24. Fit front pipe to manifold.
nuts.
28. Position battery tray and charcoal canister.
29. Position fuse box bracket, fit bolts and tighten
to 9 Nm.
with clip.
Maintenance.

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