1 General information and
precautions
The fuel system used on earlier Rover 820i,
Si, SLi and Turbo models consists of a
centrally-mounted fuel tank, electric fuel
pump and indirect multi-point fuel injection
(MPi) system, together with its related
electrical and mechanical components. A
more detailed description of the MPi system is
contained in Section 10.
The exhaust system consists of a front,
intermediate and rear section, suspended
from the underbody on rubber mountings, and
bolted to a cast iron manifold at the front. A
ball-and-socket universal joint is incorporated
in the front section, to allow for engine and
exhaust system movement.
Precautions
Warning: Many of the
procedures in this Chapter
require the removal of fuel lines
and connections, which may
result in some fuel spillage. Petrol is
extremely flammable, so take extra
precautions when you work on any part of
the fuel system. Don’t smoke, or allow
open flames or bare light bulbs, near the
work area. Don’t work in a garage where a
natural gas-type appliance (such as a
water heater or clothes dryer) with a pilot
light is present. If you spill any fuel on your
skin, rinse it off immediately with soap and
water. When you perform any kind of work
on the fuel system, wear safety glasses,
and have a Class B type fire extinguisher
on hand. Before carrying out any operation
on the fuel system, refer also to the
precautions given in “Safety first!” at the
beginning of this manual, and follow them
implicitly. Petrol is a highly-dangerous and
volatile liquid, and the precautions
necessary when handling it cannot be
overstressed.
Reference must also be made to Chapter 5,
Section 1 for precautionary notes concerning
the ignition system and battery disconnection,
and to any further safety-related text
contained within the appropriate Section,
before working on the vehicle.
Certain adjustment points in the fuel system
are protected by tamperproof caps, plugs or
seals. In some territories, it is an offence to
drive a vehicle with broken or missing
tamperproof seals. Before disturbing a
tamperproof seal, first check that no local or
national laws will be broken by doing so, and
fit a new tamperproof seal after adjustment is
complete, where required by law. Do not
break tamperproof seals on any vehicle whilst
it is still under warranty.
When working on fuel system components,
scrupulous cleanliness must be observed and
care must be taken not to introduce any
foreign matter into the fuel lines or
components.
2 Air cleaner assembly -
removal and refitting
1
Note: Air cleaner element renewal is
described in Chapter 1.
Removal
Normally-aspirated engines
1 Slacken the hose clip and disconnect the
air trunking at the throttle housing (see
illustration).
2 Disconnect the airflow meter wiring
connector, and release the cable from the
support clip.
3 Undo the two air cleaner body and airflow
meter support bracket bolts, and the two
bolts securing the forward air trunking to its
support bracket (see illustration).
4 Withdraw the air cleaner body, complete
with airflow meter and forward air trunking,
release the trunking from the connecting duct
at the front of the car, and remove the
assembly from the engine compartment.
5 If the cold air side intake is to be removed,
refer to Chapter 5 and remove the battery.
6 Undo the bolt securing the side intake to
the body, and remove the intake and duct.
Turbocharged engines
7 Remove the battery as described in
Chapter 5, then undo the bolts and lift out the
battery tray.
8 Undo the wastegate control solenoid valve
retaining screw and move the valve aside.
9 Disconnect the airflow meter wiring
multiplug.
10 Undo the three mounting bracket
retaining bolts.
11 Release the two clips securing the heat
shield to the heater pipe and remove the heat
shield.
12 Slacken the clip securing the air intake
hose to the turbocharger and release the
hose. Remove the breather hose from the
intake hose.
13 Disconnect the wiring multiplug from the
wastegate control solenoid valve.
14 Release the air cleaner assembly from the
intake duct and carefully lift out the air
cleaner, airflow meter and mounting bracket.
15 The remaining intake ducts can now be
removed as required.
Refitting
16 Refitting is a reversal of removal, but
ensure that all the ducts and trunking are fully
engaged before tightening the various
retaining bolts.
Torque wrench settings Nm lbf ft
Fuel filter banjo union bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 37
Brake servo hose banjo union bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 37
Fuel pump banjo union bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 16
Fuel tank drain plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 37
Fuel tank strap locknuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 13
Exhaust front pipe to manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 22
Exhaust section flange nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 22
Exhaust heat shield retaining bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 18
4B•2 Fuel and exhaust systems - Lucas multi-point injection engines
2.3 Forward air trunking to support
bracket bolt
2.1 Disconnect the air trunking at the
throttle housing
1380 Rover 800 Series Remake
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