29 Slacken the nine nuts and bolts securing
the manifold to the cylinder head.
30 Remove all the bolts, followed by the two
nuts, then withdraw the manifold off the studs
and remove it from the engine. Recover the
manifold gasket.
31 Clean the manifold and cylinder head
mating faces, and obtain a new gasket if the
sealing lips of the original are damaged.
Refitting
32 Refitting is a reversal of removal; tighten
the manifold nuts and bolts in the sequence
shown, to the specified torque (see
illustration 5.24).
6 Exhaust manifold -
removal and refitting
1
Note: Never work on or near a hot exhaust
system and in particular, the catalytic
converter (where fitted).
Single-point fuel injection
engines
Removal
1 Disconnect the battery negative (earth) lead
(refer to Chapter 5, Section 1).
2 Refer to Chapter 4A, Section 2, and remove
the necessary air cleaner components to
provide access to the front and side of the
engine.
3 Drain the cooling system as described in
Chapter 1.
4 Remove the dipstick from the dipstick tube.
5 Remove the distributor cap and place it to
one side.
6 Apply the handbrake, jack up the front of
the car and support it on axle stands.
7 Undo the four bolts securing the exhaust
front pipe flange to the manifold. Separate the
flange and recover the gasket.
8 Undo the bolts on both sides securing the
two halves of the manifold stove together, and
remove the outer half (see illustrations).
9 Undo the bolt securing the heater bypass
pipe to the cylinder head and to the main
coolant pipe support bracket (see
illustrations).
10 Slacken the clip securing the bypass pipe
connecting hose to the thermostat housing.
11 Undo the five nuts and bolts securing the
manifold to the cylinder head, noting that the
upper nut also secures the bypass pipe
bracket (see illustration).
12 Release the connecting hose from the
thermostat housing, and withdraw the bypass
pipe from the manifold stud.
13 Remove the manifold from the cylinder
head, followed by the inner half of the stove
and the manifold gasket.
14 Clean the manifold and cylinder head
mating faces, and obtain a new gasket if the
original is damaged.
Refitting
15 Refitting is a reversal of removal; tighten
the manifold nuts and bolts starting with the
upper two, then the lower centre, then the two
outer, to the specified torque. Make sure that
the inner half of the stove is in position before
fitting the manifold.
Multi-point fuel injection
engines
Normally-aspirated engines
16 Refer to the procedures described above
for single-point fuel injection engines, but
ignore the instructions to remove the manifold
stove, which is not fitted to models with multi-
point fuel injection.
Turbocharged engines
17 Refer to Chapter 4B or 4C as applicable
and remove the turbocharger.
18 Refer to the procedures described above
for single-point fuel injection engines, but
ignore the instructions to remove the manifold
stove, which is not fitted to models with multi-
point fuel injection.
7 Timing belt (“M” series) -
removal, refitting and
adjustment
4
Note: Accurate adjustment of the timing belt
entails the use of a tension checking gauge
which is a Rover special tool. An approximate
setting can be achieved using the method
described in this Section, but the tension
should be checked by a Rover dealer on
completion.
Note: On early “M” series engines the
crankshaft pulley and timing belt sprocket are
a one-piece assembly secured by a single
centre bolt. On later “M” series engines (with a
front mounted power steering pump), the
pulley and sprocket are two separate
components secured by the centre retaining
bolt and four additional bolts. As this
difference significantly affects the timing belt
procedures, identify the type being worked on
before proceeding.
2A•6 4-cylinder engine – in-car engine repair procedures
6.11 Undo the manifold nuts and bolts,
noting that the upper nut also secures the
bypass pipe bracket
6.9b . . . and to the main coolant pipe
bracket (arrowed)
6.9a Undo the bolt securing the bypass
pipe to the cylinder head (arrowed) . . .
6.8b . . . and remove the stove outer half6.8a Undo the bolts securing the two
halves of the manifold stove . . .
1380 Rover 800 Series Remake
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