Torque wrench settings Nm lbf ft
Fuel filter banjo union bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 28
Fuel pressure regulator retaining bolts . . . . . . . . . . . . . . . . . . . . . . . . . . 10 7
Brake servo hose banjo union bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 37
Plenum chamber to inlet manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 7
Fuel rail to inlet manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 7
Fuel pump banjo union bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 16
Fuel tank drain plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 37
Fuel tank strap locknuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 16
Fuel temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 11
Turbocharger to exhaust manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 22
Turbocharger exhaust elbow bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 18
Turbocharger to exhaust front pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 7
Exhaust front pipe to manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 22
Exhaust section flange nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 22
Exhaust heat shield retaining bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 18
4C•2 Fuel and exhaust systems - MEMS multi-point injection engines
1380 Rover 800 Series Remake
1 General information and
precautions
The fuel system used on later Rover 820i,
Si, SLi and Vitesse models consists of a
centrally-mounted fuel tank, electric fuel
pump and indirect multi-point fuel injection,
as part of the Modular Engine Management
System (MEMS). A more detailed description
of the 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
catalytic converter is fitted between the front
and intermediate sections and a flexible joint is
also 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 Remove the battery as described in
Chapter 5.
2 Slacken the hose clip and disconnect the
air intake hose between the throttle housing
and air cleaner at the air cleaner end.
3 Undo the two bolts securing the air cleaner
assembly to the mounting bracket.
4 Disengage the peg at the base of the air
cleaner, release the unit from the intake ducts
and remove it from the engine compartment.
5 The remaining intake ducts can now be
removed as required.
Turbocharged engines
6 Slacken the clip and release the air intake
hose on the side of the air cleaner body.
7 Slacken the clip and release the boost
control solenoid valve hose from its
connection next to the air intake hose.
8 Undo the two bolts on the side of the air
cleaner body and remove the unit from the
engine compartment.
9 The remaining intake ducts can now be
removed as required.
Refitting
10 Refitting is a reversal of removal, but
ensure that all the ducts and trunking are fully
engaged before tightening the various
retaining bolts.
3 Accelerator cable - removal,
refitting and adjustment
2
Removal
1 Open the throttle fully by hand, and slip the
inner cable end out of the slot on the throttle
lever.
2 Unclip the square nut and release the cable
from the support bracket.
3 Release the cable from the support clip in
the engine compartment.
4 From inside the car, release the turnbuckles
and lift out the trim panel over the clutch,
brake and accelerator pedals.
5 Prise the retaining clip from the top of the
accelerator pedal, and disconnect the inner
cable.
6 Release the cable from the engine
compartment bulkhead by turning the retainer
through 90º and withdraw the cable from the
car.
Refitting and adjustment
Models up to VIN 152206
7 Refit the cable at the pedal end using a
reversal of removal.
8 At the throttle housing end, screw the
square adjusting nut fully onto the threaded
portion of the outer cable.
9 Connect the inner cable to the throttle lever,
and locate the outer cable in the slot in the
support bracket.
10 Hold the throttle closed then pull the outer
cable away from the throttle lever until all
slack and lost motion are taken up.
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