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

Remove

Make
Rover
Model
Coupé, Cabriolet & Tourer 200/400 Coupé, Cabriolet & Tourer Workshop Manual
Section
Repairs › Remove
Manifold and exhaustRemove

Service Repair No. Front pipe – 30.10.09
Service Repair No. Flange gasket – 30.10.26

Diagram of exhaust manifold with numbered components 1 through 5
  1. Working in the sequence illustrated, fit and tighten exhaust manifold nuts and bolts to 45 Nm.
  2. Position engine front mounting bracket, fit nut and bolts and tighten to 83 Nm.
  3. Lower and remove trolley jack
  4. Position battery tray to body, fit bolts and tighten to 9 Nm.
  5. Secure harness clips to battery tray.
  6. Connect coolant rail hose to water pump and tighten clip.
  7. Align coolant rail to cylinder head, fit bolt and tighten to 25 Nm.
  8. Connect coolant rail hose to thermostat housing and tighten clip.
  9. Connect 2 coolant hoses to turbocharger and tighten clips.
  10. Fit turbocharger hose heat shield.
  11. Align dipstick tube to heat shield and coolant rail, fit bolts and tighten to 9 Nm.
  12. Air conditioning models only: Align air conditioning pipe bracket to coolant rail, fit and tighten bolt to 9 Nm.
  13. Connect oxygen sensor multiplug.
  14. Remove plugs from connections. Connect oil feed hose to turbocharger and tighten union.
  15. Connect vacuum hoses to turbocharger and secure with clips.
  16. Connect intake hose to turbocharger and tighten clip.
  17. Connect breather hose to turbocharger intake hose and secure with clip.
  18. Clean mating faces of oil drain pipe and turbocharger, fit new gasket to oil drain pipe.
  19. Fit oil drain pipe to turbocharger and tighten bolts to 8 Nm.
  20. Fit exhaust front pipe.
  21. Air conditioning models only: Fit alternator, see ELECTRICAL – Repairs.
  22. Fit intercooler, see MODULAR ENGINE MANAGEMENT SYSTEM – MPi – Repairs.
  23. Refill cooling system, see MAINTENANCE.

Remove

  1. Disconnect battery earth lead.
  2. Raise vehicle on a ramp.
Diagram showing flange joint with callout numbers 3
  1. Remove 4 nuts from flange joint.
  2. Remove and discard gasket from flange.
Diagram showing front pipe connection to catalytic converter with callout numbers 5, 6, 7
  1. Remove 3 nuts, securing front pipe to catalytic converter.
  2. Disconnect rubber mounting from front pipe.
  3. Remove front pipe from vehicle.
  4. Remove and discard gasket, front pipe to catalytic converter.

Refit

  1. Clean all mating faces.
  2. Position a new flange gasket and fit front pipe to manifold, tighten nuts to 50 Nm.
  3. Position a new gasket and fit front pipe to catalytic converter; fit nuts and tighten to 34 Nm.
  4. Connect rubber mounting to front pipe.
  5. Lower ramp.
  6. Connect battery earth lead.

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

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