Workshop Manuals Factory service & repair Rover
Rover 200/400 Coupé, Cabriolet & Tourer Workshop Manual13 · Manifold and exhaust
13 · Engine

Refit

Make
Rover
Model
Coupé, Cabriolet & Tourer 200/400 Coupé, Cabriolet & Tourer Workshop Manual
Section
Repairs › Refit
Manifold and exhaustRefit
  1. Disconnect breather hose from inlet manifold.
  2. Depress plastic collar to release quick fit connector and disconnect brake servo hose from inlet manifold.
  3. Disconnect ECU vacuum pipe from inlet manifold.
Diagram showing breather hose, brake servo hose, and ECU vacuum pipe connections on the inlet manifold
  1. Release clip, disconnect fuel return hose from fuel rail.

CAUTION: Plug the connections.

  1. Slacken clip, disconnect expansion tank hose from inlet manifold.
  2. Release fuel return hose from clips.
Diagram showing fuel return hose, injector harness multiplug, and air temperature sensor multiplug connections
  1. Release injector harness multiplug from bracket, disconnect multiplug.
  2. Disconnect multiplug from air temperature sensor.
Diagram showing bolts securing fuel feed pipe and release of fuel feed pipe from fuel rail
  1. Remove 2 bolts securing fuel feed pipe to fuel rail.
  2. Release fuel feed pipe from fuel rail, remove and discard 'O' ring.

CAUTION: Plug the connections.

  1. Working from the centre outwards, progressively slacken then remove 3 nuts and 4 bolts securing inlet manifold to cylinder head.
Diagram showing removed inlet manifold with gasket surface visible
  1. Remove inlet manifold, remove and discard gasket.

Refit

  1. Ensure mating surfaces are clean and that metal inserts are fitted in inlet manifold stud and bolt holes.
  2. Fit new gasket, position inlet manifold to studs.

CAUTION: Gasket must be fitted dry.

Diagram showing tightening sequence for inlet manifold bolts and nuts, numbered 1 through 6
  1. Fit bolts and nuts and tighten in sequence shown to 25 Nm.
  2. Connect expansion tank hose to inlet manifold, tighten clip.
  3. Lubricate a new 'O' ring with silicone grease and position to fuel feed pipe.
  4. Position fuel feed pipe to fuel rail, fit bolts and tighten to 10 Nm.
  5. Connect multiplug to air temperature sensor.
  6. Connect multiplug to injector harness, secure multiplug to bracket.
  7. Connect fuel return hose to fuel rail, tighten clip.
  8. Secure fuel return hose in clips.
  9. Connect ECU vacuum pipe and brake servo vacuum hoses to inlet manifold.
  10. Connect breather pipe to inlet manifold.
  11. Connect multiplug to stepper motor.
  12. Clean inlet manifold and throttle housing mating surfaces.
  13. Lubricate a new 'O' ring with silicone grease and fit to throttle housing.
  14. Position throttle housing to inlet manifold, fit bolts and tighten to 4 Nm.
  15. Secure throttle cable in clip.
  16. Connect multiplug to throttle potentiometer.
  17. Connect breather hose to throttle housing, tighten clip.
  18. Connect hose to stepper motor, secure clip.
  19. Connect purge hose to inlet manifold, tighten clip.

Parts & tools for this job For Rover Coupé, Cabriolet & Tourer

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