Kia Cooper Mini 1998, Mini User Manual
Workshop Manual
Werkplaatshandboek
Manuel D’Atelier
Werkstatthandbuch
Manuale D’Officina
Manual De Taller
Manual de Oficina
AMENDMENT INSTRUCTION SHEET
MINI WORKSHOP MANUAL
Publication Number RCL 0193ENG - 2nd Edition
Amendment Number: XN-001/97ENG Date: 12/96
To ensure that this manual is kept up to date and that a record of amendments to this manual is available, an
Amendment Instruction Sheet will be issued with each set of revised pages.
• The Title page of the Manual is re-issued, and the Part No. has been raised to the next edition. Except for the
Contents pages, all revised and new pages have the issue date at the foot of each page, together with an
indication of whether the pages are revised or new.
• This Amendment Instruction Sheet must be inserted at the front of the manual to indicate that the amendment
has been incorporated. Do not discard previous Amendment Instruction sheets.
• Your manual is only complete to this issue providing all prior Amendments are included.
• The filing instructions give section and page numbers affected. Additional pages or complete new sections may
be issued, insert the pages as instructed.
FILING INSTRUCTIONS
Section Discard Existing
Introduction Title Page Title Page Introduction of new sections. Part number
Information Contents Page Contents Page Corrections to existing information and
Engine Contents Page Contents Page Corrections to existing information and
Emission Control Description and
Engine Management
System - MEMS
Fuel Delivery System Contents Page Contents Page Corrections to existing information and
Pages
General data,1 General data,1
Torque wrench
settings, 1&3
Repairs, 33-37 Repairs, 33-41
operation, 1
Repairs, 1 Repairs,1
Contents Page Contents Page Corrections to existing information.
Description and
operation, 1-11
- Adjustments
Repairs, 1 Repairs,1
Insert New Pages Reason for Amendment
raised to next edition.
addition of new torque figures.
Torque wrench
settings, 1-5
addition of new repair procedures.
Description and
operation, 1
Description and
operation, 1-11
Corrections to existing information.
introduction of Adjustments section.
Cooling System Repairs, 3 Repairs,3 Corrections to existing information.
Manifold & Exhaust
Systems
Clutch Contents page Contents Page Corrections to existing information and
Description and
operation, 3
Adjustments, 1 Adjustments, 1
Repairs, 1-7 Repairs,1-11
Description and
operation, 3
Corrections to existing information.
addition of new repair procedures.
Continued.....
Section Discard Existing
Pages
Insert New Pages Reason for Amendment
Manual Gearbox Contents page Contents Page Corrections to existing information and
Adjustments, 1 Adjustments, 1
- Repairs, 1-5
Drive shafts - Contents Page NewSection
- Repairs, 1-5
Steering Contents page Contents Page Corrections to existing information and
- Adjustments, 1
Repairs, 1 Repairs, 1-11
Suspension - Contents Page New Section.
- Adjustments, 1
- Repairs, 1&3
Brakes Contents Page Contents Page Corrections to existing information and
Adjustments, 1 Adjustments, 1
Repairs, 1&3 Repairs, 1-17
Restraint Systems Description and
operation, 3
Repairs, 3&5 Repairs, 3&5
Body Contents Page Contents Page Corrections to existing information and
Exterior fittings,
1&3
Interior trim
components, 1
Screens, 1 Screens, 1
- Seats and seat
Description and
operation, 3
Exterior fittings,
1-7
Interior trim
components, 1-7
belts, 1&3
addition of new repair procedures.
addition of new repair procedures.
addition of new repair procedures.
Corrections to existing information.
addition of new repair procedures.
Heating & Ventilation - Contents Page New Section.
- Repairs, 1-7
Wipers & Washers Contents Page Contents page Addition of new repair procedures
Repairs, 1 Repairs, 1-7
Electrical Contents Page Contents Page Corrections to existing information and
Description and
operation, 1
Adjustments, 1 Adjustments, 1
Repairs, 1-19 Repairs, 1-27
Instruments Repairs, 7 Repairs, 7 Corrections to existing information.
Description and
operation, 1
addition of new repair procedures.
AMENDMENT INSTRUCTION SHEET
MINI WORKSHOP MANUAL
Publication Number RCL0193ENG (3rd Edition)
Amendment Number: XN003.98ENG Date: 11/98
To ensure that this manual is kept up to date and that a record of amendments to this manual is available, an
Amendment Instruction Sheet will be issued with each set of revised pages.
• The Title page of the Manual is re-issued, and the Part No. has been raised to the next edition. Except for the
Contents pages, all revised and new pages have the issue date at the foot of each page, together with an
indication of whether the pages are revised or new.
• This Amendment Instruction Sheet must be inserted at the front of the manual to indicate that the amendment
has been incorporated. Do not discard previous Amendment Instruction sheets.
• Your manual is only complete to this issue providing all prior Amendments are included.
• The filing instructions give section and page numbers affected. Additional pages or complete new sections may
be issued, insert the pages as instructed.
FILING INSTRUCTIONS
Section Discard Existing
Pages
TITLE PAGE Title page Title page Part number raised to 4th Edition and year
INSTRUMENTS Contents page Contents page Additional jobs added
INSTRUMENTS Page 9 Pages 9 and 11 Speedometer cable upper and lower added
Insert New Pages Reason for Amendment
of copyright amended.
AMENDMENT INSTRUCTION SHEET
MINI WORKSHOP MANUAL
Publication Number RCL0193ENG (4th Edition)
Amendment Number: XN002.99ENG Date: 06/99
To ensure that this manual is kept up to date and that a record of amendments to this manual is available, an
Amendment Instruction Sheet will be issued with each set of revised pages.
• The Title page of the Manual is re-issued, and the Part No. has been raised to the next edition. Except for the
Contents pages, all revised and new pages have the issue date at the foot of each page, together with an
indication of whether the pages are revised or new.
• This Amendment Instruction Sheet must be inserted at the front of the manual to indicate that the amendment
has been incorporated. Do not discard previous Amendment Instruction sheets.
• Your manual is only complete to this issue providing all prior Amendments are included.
• The filing instructions give section and page numbers affected. Additional pages or complete new sections may
be issued, insert the pages as instructed.
FILING INSTRUCTIONS
Section Discard Existing
Pages
TITLE PAGE Title Page Title Page Part number raised to 5th Edition.
ELECTRICAL Contents page Contents page Contents changed.
Adjustments pages
1&2
Repairs pages 1 &2Repairs pages 1 &2Auxiliary Drive Belt - Remove and Refit -
Repairs page 27 Repairs pages 27
Insert New Pages Reason for Amendment
Adjustments pages
1&2
&28
Auxiliary Drive Belt - Check and Adjust Caution regarding drive belt adjusting bolt
added.
Cautions regarding drive belt adjusting bolt
added.
CD Player - Remove and Refit - New
operation issued herewith.
WORKSHOP
INTRODUCTION
GENERAL INFORMATION
INFORMATION
ENGINE
EMISSION CONTROL
ENGINE MANAGEMENT SYSTEM
FUEL DELIVERY SYSTEM
COOLING SYSTEM
MANUAL
This manual covers changes to Mini models
manufactured from VIN SAXXNNAZEBD 134455
and should be used in conjunction with the following
manuals.
AKM 7169 Mini Repair Manual
RCL 0194 Mini Electrical Circuit Diagrams
MANIFOLD & EXHAUST SYSTEMS
CLUTCH
MANUAL GEARBOX
DRIVE SHAFTS
STEERING
SUSPENSION
BRAKES
Publication Part No. RCL 0193ENG (5th Edition)
Published by Rover Technical Communication
1998 Rover Group Limited
RESTRAINT SYSTEMS
BODY
HEATING & VENTILATION
WIPERS & WASHERS
ELECTRICAL
INSTRUMENTS
INTRODUCTION
CONTENTS
INTRODUCTION
INTRODUCTION 1......................................................................................................
REPAIRS AND REPLACEMENTS 2...........................................................................
SPECIFICATION 2......................................................................................................
ABBREVIATIONS AND SYMBOLS 3..........................................................................
Page
INTRODUCTION
INTRODUCTION
How to use this Manual
To assist in the use of this Manual the section title is
given at the top and the relevant sub-section is given
at the bottom each page.
Each major section starts with a contents page,
listing the information contained in the relevant
sub-sections. To assist filing of revised information
each sub-section is numbered from page 1.
The individual items comprising repair operations
are to be followed in the sequence in which they
appear. Items numbers in the illustration are referred
to in the text.
Adjustment and repair operations include reference
to Service tool numbers and the associated
illustration depicts the tool. Where usage is not
obvious the tool is shown in use. Adjustment and
repair operations also include reference to wear
limits, relevant data, torque figures, and specialist
information and useful assembly details. Each
adjustment or repair operation is given its Repair
Operation Time number. WARNINGS, CAUTIONS
and NOTES have the following meanings:
References
References to the LH or RH side given in this
Manual are made when viewing the vehicle from the
rear. With the engine and gearbox assembly
removed, the crankshaft pulley end of the engine is
referred to as the front.
Operations covered in this Manual do not include
reference to testing the vehicle after repair. It is
essential that work is inspected and tested after
completion and if necessary a road test of the
vehicle is carried out particularly where safety
related items are concerned.
Dimensions
The dimensions quoted are to design engineering
specification with Service limits where applicable.
WARNING: Procedures which must be
followed precisely to avoid the possibility
of injury.
CAUTION: Calls attention to procedures
which must be followed to avoid damage
to components.
NOTE: Gives helpful information.
INTRODUCTION 1
INTRODUCTION
REPAIRS AND REPLACEMENTS
When replacement parts are required it is essential
that only Rover recommended parts are used.
Attention is particularly drawn to the following points
concerning repairs and the fitting of replacement
parts and accessories.
Safety features and corrosion prevention treatments
embodied in the car may be impaired if other than
Rover recommended parts are fitted. In certain
territories, legislation prohibits the fitting of parts not
to the manufacturer’s specification. Torque wrench
setting figures given in this Manual must be used.
Locking devices, where specified, must be fitted. If
the efficiency of a locking device is impaired during
removal it must be renewed.
Owners purchasing accessories while travelling
abroad should ensure that the accessory and its
fitted location on the car conform to legal
requirements.
The Terms of the vehicle Warranty may be
invalidated by the fitting of other than Rover
recommended parts.
SPECIFICATION
Rover are constantly seeking to improve the
specification, design and production of their vehicles
and alterations take place accordingly. While every
effort has been made to ensure the accuracy of this
Manual, it should not be regarded as an infallible
guide to current specifications of any particular
vehicle.
This Manual does not constitute an offer for sale of
any particular vehicle. Rover Dealers are not agents
of Rover and have no authority to bind the
manufacturer by any expressed or implied
undertaking or representation.
All Rover recommended parts have the full backing
of the vehicle Warranty.
Rover Dealers are obliged to supply only Rover
recommended parts.
2
INTRODUCTION
ABBREVIATIONS AND SYMBOLS
INTRODUCTION
After Bottom Dead Centre ABDC
After Top Dead Centre ATDC
Air conditioning A/C
Air fuel ratio AFR
Alternating current ac
Amperes A
Anti-lock brake system ABS
Automatic temperature control ATC
Before Bottom Dead Centre BBDC
Before Top Dead Centre BTDC
Bottom Dead Centre BDC
British Standards BS
Camshaft Position CMP
Carbon monoxide CO
Celcius (Centigrade) C
Centimetre cm
Chlorofluorocarbons CFC’s
Cubic centimetres cm
Crankshaft position CKP
Degree (angle) deg. or °
Degree (temperature) deg. or °
Dial test indicator DTI
Diameter dia.
Direct current dc
Electronic Control Unit ECU
Exhaust gas recirculation EGR
Engine Control Module ECM
Engine coolant temperature ECT
Fuel Injection Pump FIP
Manifold absolute pressure MAP
Mass air flow MAF
Maximum max.
Mercury Hg
Metre m
Metric unit of horse power PS
Miles per hour mph
Millimetre mm
Minimum min
Minus (of tolerance) Minute (angle) ’
Model Year MY
Multi-point injection MPi
Negative (electrical) (-)
Newton metre Nm
Number No.
3
Outside diameter o.dia.
Percentage %
Plus or minus ±
Plus (tolerance) +
Positive (electrical) +
Positive crankcase ventilation PCV
Radius r
Ratio :
Reference ref
Revolutions per minute rev/min
Right-hand RH
Right-hand drive RHD
Rover Engineering Standards RES
Gramme (mass) g
High compression hc
High Tension h.t.
Hour h
Idle Air Control Valve IACV
Inertia Fuel Shut-off IFS
Intake air temperature IAT
Internal diameter i.dia.
International Organisation for
ISO
Standardization
Kilometre km
Kilogramme kg
Left-hand LH
Left-hand drive LHD
Light emitting diode LED
Litre l
Low Compression lc
Second (angle) "
Single overhead camshaft SOHC
Specific gravity sp.gr
Square centimetres cm
Standard std.
Supplementary Restraint System SRS
Synchronizer/synchromesh synchro
Thousand k
Top dead centre TDC
Throttle position TP
United Kingdom UK
United States US
Variable induction system VIS
Vehicle identification number VIN
Volt V
Watt W
2
INTRODUCTION 3
GENERAL INFORMATION
CONTENTS
VEHICLE IDENTIFICATION NUMBER
VEHICLE IDENTIFICATION NUMBER 1....................................................................
IDENTIFICATION NUMBER LOCATIONS 1...............................................................
GENERAL PRECAUTIONS AND FITTING INSTRUCTIONS
GENERAL PRECAUTIONS AND FITTING INSTRUCTIONS 1..................................
Dangerous substances 1.............................................................................................
Engine oils 1................................................................................................................
Health Protection Precautions 1..................................................................................
Environmental Protection Precautions 1......................................................................
SAFETY INSTRUCTIONS 2........................................................................................
FUEL HANDLING PRECAUTIONS
FUEL HANDLING PRECAUTIONS 1..........................................................................
ELECTRICAL PRECAUTIONS
ELECTRICAL PRECAUTIONS 1.................................................................................
Page
GENERAL INFORMATION
VEHICLE IDENTIFICATION NUMBER
Location
The Vehicle Identification Number (VIN) plate is
attached to the RH inner wing valance.
The VIN is also etched into the lower LH corners of
the windscreen and rear window.
Paint and Trim colour codes
3-letter codes identifying the original Paint and Trim
colours are stamped on the VIN plate.
Paint
Example: H A M
H= Basic colour
A= Mark identifier
M= Colour/Shade name
Trim
Example: L P R
L= Basic colour
P= Mark identifier
R= Colour/Shade name
Vehicle identification number
Example: SAXXNNAZEBD134455
S= Geographic area
A= Country
X= Manufacturer
XN= Marque/Model
N= Class
A= Body
Z= Engine
E= Transmission and Steering
B= Model change
D= Assembly plant
6 figures= Serial number
IDENTIFICATION NUMBER LOCATIONS
Engine number
Stamped on the front face of the cylinder block
adjacent to the alternator.
Gearbox number
Shown on a label attached to the upper face of the
final drive housing.
Body number
The body number is stamped on a plate fixed to the
bonnet locking platform.
VEHICLE IDENTIFICATION NUMBER 1
GENERAL INFORMATION
GENERAL PRECAUTIONS AND FITTING INSTRUCTIONS
Ignition system safety precautions
WARNING: Before commencing work on
an ignition system, all high tension
terminals, adapters and diagnostic
equipment for testing should be inspected to
ensure that they are adequately insulated and
shielded to prevent accidental personal contacts
and minimise the risk of shock. Wearers of
surgically implanted pacemaker devices should
not be in close proximity to ignition circuits or
diagnostic equipment.
Dangerous substances
WARNING: Many liquids and other
substances used in motor vehicles are
poisonous and should under no
circumstances be consumed and should, as far
as possible, be kept from contact with the skin.
These substances among others include acid,
anti- freeze, asbestos, brake fluid, fuel,
windscreen washer additives, lubricants,
refrigerant and various adhesives.
Always read carefully the instructions printed on
labels or stamped on components and obey
them implicitly. Such instructions are included
for reasons of your health and personal safety.
Never disregard them.
Used engine oils: Prolonged exposure to used
engine oils can cause serious skin disorders,
avoid excessive skin contact and always adhere
to the following recommendations:
Engine oils
Prolonged and repeated contact with mineral oil will
result in the removal of natural fats from the skin,
leading to dryness, irritation and dermatitis. In
addition, used engine oil contains potentially harmful
contaminants which may cause skin cancer.
Adequate means of skin protection and washing
facilities must be provided.
Health Protection Precautions
• Avoid prolonged and repeated contact with oils,
particularly used engine oils.
• Wear protective clothing, including impervious
gloves where practicable.
• Do not put oily rags in pockets.
• Avoid contaminating clothes, particularly
underpants, with oil.
• Overalls must be cleaned regularly. Discard
heavily soiled clothing and oil impregnated
footwear.
• First aid treatment should be obtained
immediately for open cuts and wounds.
• Use barrier creams, applying before each work
period, to help the removal of oil from the skin.
• Wash with soap and water to ensure all oil is
removed (skin cleansers and nail brushes will
help). Preparations containing lanolin replace the
natural skin oils which have been removed.
• Do not use petrol, kerosene, diesel fuel, gas oil,
thinners or solvents for cleaning skin.
• If skin disorders develop, obtain medical advice
without delay.
• Where practicable, degrease components prior
to handling.
• Where there is a risk of eye contact, eye
protection should be worn, for example, chemical
goggles or face shields; in addition an eye wash
facility should be provided.
Environmental Protection Precautions
It is illegal to pour used oil on to the ground, down
sewers or drains, or into water courses.
Burning of used engine oil in small space heaters or
boilers can be recommended only for units of
approved design. The heating system must meet the
regulatory standards of HMIP for small burners of
less than 0.4 MV. If in doubt check with the
appropriate local authority and/or manufacturer of
approved appliance.
Dispose of used oil and used filters through
authorised waste disposal contractors to licensed
waste disposal sites, or to the waste oil reclamation
trade. If in doubt, contact the Local Authority for
advice on disposal facilities.
GENERAL PRECAUTIONS AND FITTING INSTRUCTIONS 1
GENERAL INFORMATION
SAFETY INSTRUCTIONS
Jacking
The recommended jacking points are given in
LIFTING AND TOWING, always ensure that any
lifting apparatus has adequate load and safety
capacity for the weight to be lifted. Ensure the
vehicle is standing on level ground prior to lifting or
jacking. Apply the handbrake and chock the wheels.
Never rely on a jack as the sole means of support
when working beneath the vehicle. Use additional
safety supports beneath the vehicle.
Do not leave tools, lifting equipment, spilt oil, etc.
around or on the work bench area.
Precautions against damage
Always fit wing and seat covers before commencing
work. Avoid spilling brake fluid or battery acid on
paintwork. Wash off with water immediately if this
occurs.
Disconnect the battery earth lead before starting
work, see ELECTRICAL PRECAUTIONS.
Always use the recommended service tool or a
satisfactory equivalent where specified.
Protect exposed bearing and sealing surfaces and
screw threads from damage.
Brake shoes and pads
WARNING: Always fit the correct grade
and specification of brake linings and
renew brake pads and brake shoes in axle
sets only.
Brake hydraulics
WARNING: It is imperative that the correct
brake fittings are used and that threads of
components are compatible.
Always use two spanners when slackening or
tightening brake pipe or hose connections. Ensure
that hoses run in a natural curve and are not kinked
or twisted. Fit brake pipes securely in their retaining
clips and ensure that the pipe run cannot contact a
potential chafing point.
Containers used for hydraulic fluid must be kept
absolutely clean. Do not store hydraulic fluid in an
unsealed container, it will absorb water and in this
condition would be dangerous to use. Do not allow
hydraulic fluid to be contaminated with mineral oil, or
use a container which has previously contained
mineral oil. Do not re-use fluid from the system.
Always use clean brake fluid or a recommended
alternative to clean hydraulic components. Fit a
blanking cap to an hydraulic union and a plug to its
socket after removal to prevent the ingress of dirt.
Absolute cleanliness must be observed with
hydraulic components.
Engine coolant caps and plugs
Extreme care is necessary when removing engine
coolant caps and plugs when the engine is hot and
especially if it is overheated. To avoid the possibility
of scalding allow the engine to cool before
attempting coolant cap or plug removal.
Cleaning components
Always use the recommended cleaning agent or
equivalent.
Do not use degreasing equipment for components
containing items which could be damaged by the
use of this process. Whenever possible clean
components and the area surrounding them before
removal. Always observe scrupulous cleanliness
when cleaning dismantled components.
2
GENERAL PRECAUTIONS AND FITTING INSTRUCTIONS
GENERAL INFORMATION
Joints and joint faces
Fit joints dry unless otherwise specified in this
Manual.
If gaskets and/or jointing compound is
recommended for use; remove all traces of old
jointing material prior to reassembly. Do not use a
tool which will damage the joint faces and smooth
out any scratches or burrs on the joint faces using
an oil stone. Do not allow dirt or jointing material to
enter any tapped holes.
Prior to reassembly, blow through any pipes,
channels or crevices with compressed air.
Screw threads
Both UNF and metric threads to ISO standards are
used.
Damaged nuts, bolts and screws must always be
discarded.
Cleaning up damaged threads with a die or tap
impairs the strength and closeness of fit of the
threads and is not recommended.
Bolt identification
An ISO metric bolt or screw made of steel and larger
than 6 mm in diameter can be identified by either of
the symbols ISO M or M embossed or indented on
top of the head.
In addition to marks to identify the manufacturer, the
head is also marked with symbols to indicate the
strength grade, e.g. 8.8; 10.9; 12.9; 14.9. As an
alternative, some bolts and screws have the M and
strength grade symbol on the flats of the hexagon.
Castellated nuts must not be slackened back to
accept a split-pin, except in those recommended
cases when this forms part of an adjustment.
Do not allow oil or grease to enter blind threaded
holes. The hydraulic action on screwing in the bolt or
stud could split the housing.
Always tighten a nut or bolt to the recommended
torque figure. Damaged or corroded threads can
affect the torque reading.
To check or re-tighten a bolt or screw to a specified
torque figure, first slacken a quarter of a turn, then
retighten to the correct torque figure.
GENERAL PRECAUTIONS AND FITTING INSTRUCTIONS 3
GENERAL INFORMATION
Nut identification
A nut with an ISO metric thread is marked on one
face or on one of the flats of the hexagon with the
strength grade symbol 8, 12, or 14. Some nuts with
a strength grade 4, 5 or 6 are also marked and some
have the metric symbol M on the flat opposite the
strength grade marking.
A clock face system is used as an alternative
method of indicating the strength grade. The
external chambers or a face of the nut is marked in a
position relative to the appropriate hour mark on a
clock face to indicate the strength grade.
A dot is used to locate the 12 o’clock position and a
dash to indicate the strength grade. If the grade is
above 12, two dots identify the 12 o’clock position.
Locking devices
Always release locking tabs and fit new locking
washers, do not re-use locking tabs. Always use a
backing spanner when slackening or tightening
brake and fuel pipe unions.
Fitting a split pin
Always fit new split-pins of the correct size for the
hole in the bolt or stud. Do not slacken back nut to
enter split-pin.
Always fit new roll pins of an interference fit in the
hole.
Always fit new circlips of the correct size for the
groove.
Self-locking nuts
Self-locking nuts, i.e. nylon insert or metal stiff nuts
can be re-used providing resistance can be felt
when the locking portion of the nut passes over the
thread of the bolt or stud.
4
GENERAL PRECAUTIONS AND FITTING INSTRUCTIONS
GENERAL INFORMATION
Self-locking bolts and screws
Self-locking bolts and screws, i.e. nylon patched or
trilobular thread can be re-used providing resistance
can be felt when the locking portion enters the
female thread.
Nylon patched bolts and screws have a locking
agent pre-applied to the threads. They are identified
by the presence of a coloured section of thread
which extends for up to 180° around the thread.
Trilobular i.e. Powerlok bolts have a special thread
form which creates a slight interference in the
tapped hole or threads of the nut into which it is
screwed.
DO NOT re-use self-locking fasteners in critical
locations eg engine bearings flywheel. Always use
the correct replacement self-locking nut, bolt or
screw.
DO NOT fit non self-locking fasteners in applications
where a self-locking nut, bolt or screw is specified.
Encapsulated bolts and screws
Encapsulated bolts and screws have a
micro-encapsulated locking agent pre-applied to the
thread. They are identified by the presence of a
coloured section of thread which extends completely
around the thread - 360°. The locking agent is
released and activated by the assembly process and
is then chemically cured to provide the locking
action.
Unless a specific repair procedure states otherwise,
encapsulated bolts may be re-used providing the
threads are undamaged and the following procedure
is adopted.
Remove loose adhesive from the bolt and housing
threads, ensure threads are clean and free of oil and
grease. Apply an approved adhesive.
Fit a new encapsulated bolt, or if not available a bolt
of equivalent specification treated with an approved
adhesive.
GENERAL PRECAUTIONS AND FITTING INSTRUCTIONS 5
GENERAL INFORMATION
Oil seals
Always renew oil seals which have been removed
from their working location either as an individual
component or as part of an assembly.
Ensure the surface on which the new seal is to run is
free of burrs or scratches. Renew the component if
the original sealing surface cannot be completely
restored.
Protect the seal from any surface which it has to
pass when being fitted. Use a protective sleeve or
tape to cover the relevant surface.
Lubricate the sealing lips with a recommended
lubricant before use to prevent damage in initial use.
On dual lipped seals, smear the area between the
lips with grease.
Use the recommended service tool to fit an oil seal.
If the correct service tool is not available, use a
suitable tube approximately 0.4 mm smaller than the
outside diameter of the seal.
Body repairs
Any damage found, that would affect the corrosion
resistance of the vehicle during the Warranty period
must be rectified by an authorised Rover Dealer to
the standards, and by the methods, detailed in the
Body Repair Manual.
Replacement body panels
Body panels are supplied coated in cathodic
electrocoat primer.
Synthetic rubber
Many ’O’ rings, seals, hoses, flexible pipes and other
similar items which appear to be natural rubber, are
in fact, made of synthetic materials called
Fluoroelastomers. Under normal operating
conditions this material is safe and does not present
a health hazard. However, if the material is
damaged by fire or excessive heating, it can break
down and produce highly corrosive Hydrofluoric acid
which can cause serious burns on contact with skin.
If skin contact does occur:
Press or drift the seal in to the depth of its housing,
with the sealing lip facing the lubricant to be retained
if the housing is shouldered, or flush with the face of
the housing where no shoulder is provided.
Service tools and garage equipment
Special service tools have been developed to
facilitate removal, dismantling and assembly of
mechanical components in a cost effective and
practical manner without causing damage. Some
operations in this Manual cannot be carried out
without the aid of the relevant service tools.
TestBook
TestBook is a computerised workshop tool which
provides your dealership with instant access to the
very latest Technical Information from ROVER,
allowing for accurate and effective fault diagnosis
and repair of all Rover Vehicles.
Where specific garage equipment is required for
diagnosis and repair, reference should be made to
the Service Tools and Equipment Programme where
details of the equipment recommended by Rover
Service may be found.
• Remove any contaminated clothing immediately.
• Irrigate effected area with a copious amount of
cold water or limewater for 15 to 60 minutes.
• Obtain medical assistance immediately
Should the material be in a burnt or over-heated
condition handle only with seamless industrial
gloves. Decontaminate and dispose of loves
immediately after use.
6
GENERAL PRECAUTIONS AND FITTING INSTRUCTIONS
GENERAL INFORMATION
FUEL HANDLING PRECAUTIONS
General
The following information provides basic precautions
which must be observed if petrol (gasoline) is to be
handled safely. It also outlines other areas of risk
which must not be ignored. This information is
issued for basic guidance only, and if in doubt
appropriate enquiries should be made of your local
Fire Officer.
Petrol - Gasoline
Petrol/gasoline vapour is highly flammable and in
confined spaces is also explosive and toxic.
When petrol/gasoline evaporates it produces 150
times its own volume in vapour which when diluted
with air becomes a readily ignitable mixture. The
vapour is heavier than air and will always fall to the
lowest level. It can readily be distributed throughout
a workshop by air currents; consequently, even a
small spillage of petrol/ gasoline is potentially very
dangerous.
Always have a fire extinguisher containing FOAM,
CO2, GAS or POWDER close at hand when
handling or draining fuel or when dismantling fuel
systems and in other areas where fuel containers
are stored.
Always disconnect the vehicle battery before
carrying out dismantling or draining work on a fuel
system.
Fuel tank drainage
WARNING: Petrol/gasoline must not be
extracted or drained from any vehicle
whilst it is standing over a pit.
Draining or extraction of petrol/gasoline from a
vehicle fuel tank must be carried out in a well
ventilated area.
The receptacle used to contain the
petrol/gasoline must be more than adequate for
the full amount of fuel to be extracted or drained.
The receptacle should be clearly marked with its
contents, and placed in a safe storage area
which meets the requirements of local authority
regulations.
CAUTION: When petrol/gasoline has been
extracted or drained from a fuel tank the
precautions governing naked lights and
ignition sources should be maintained.
Fuel tank removal
When the fuel line is secured to the fuel tank outlet
by a spring steel clip, the clip must be released
before the fuel line is disconnected or the fuel tank is
removed. This procedure will avoid the possibility of
residual petrol fumes in the fuel tank being ignited
when the clip is released.
As an added precaution fuel tanks should have a
’PETROL (GASOLINE) VAPOUR’ warning label
attached to them as soon as they are removed from
the vehicle.
Whenever petrol/gasoline is being handled, drained
or stored or when fuel systems are being
dismantled, all forms of ignition must be
extinguished or removed; any leadlamps must be
flameproof and kept clear of spillage.
WARNING: No one should be permitted to
repair components associated with
petrol/gasoline without first having
specialist training.
FUEL HANDLING PRECAUTIONS 1
GENERAL INFORMATION
Fuel tank repairs
Under no circumstances should a repair to any fuel
tank involving heat treatment be carried out without
first rendering the tank SAFE, by using one of the
following methods:
a. STEAMING: With the filler cap and tank unit
removed, empty the tank. Steam the tank for at least
two hours with low pressure steam. Position the tank
so that condensation can drain away freely, ensuring
that any sediment and sludge not volatized by the
steam is washed out during the steaming process.
b. BOILING: With the filler cap and tank unit
removed, empty the tank. Immerse the tank
completely in boiling water containing an effective
alkaline degreasing agent or a detergent, with the
water filling and also surrounding the tank for at least
two hours.
After steaming or boiling, a signed and dated label to
this effect should be attached to the tank.
Body and chassis repairs
When a body or chassis repairs involve the use of
heat, all fuel pipes which run in the vicinity of the
repair area must be removed, and the tank outlet
plugged, BEFORE HEAT IS APPLIED. If the repair
is in the vicinity of the fuel tank, the tank must be
removed.
Plastic fuel pipes are particularly susceptible to heat,
even at relatively low temperature, and can be
melted by heat conducted from some distance away.
Fuel lines or tanks must not be removed whilst the
vehicle is over an inspection pit.
2
FUEL HANDLING PRECAUTIONS
GENERAL INFORMATION
ELECTRICAL PRECAUTIONS
General
The following guidelines are intended to ensure the
safety of the operator whilst preventing damage to
the electrical and electronic components fitted to the
vehicle. Where necessary specific precautions are
detailed in the relevant sections of this Manual which
should be referred to prior to commencing repair
operations.
Equipment - Prior to commencing any test
procedure on the vehicle ensure that the relevant
test equipment is working correctly and any harness
or connectors are in good condition, this particularly
applies to mains lead and plugs.
WARNING: Before commencing work on
an ignition system all high tension
terminals, adapters and diagnostic
equipment for testing should be inspected to
ensure that they are adequately insulated and
shielded to prevent accidental personal contacts
and minimise the risk of shock. Wearers of
surgically implanted pacemaker devices should
not be in close proximity to ignition circuits or
diagnostic equipment.
Polarity - Never reverse connect the vehicle battery
and always observe the correct polarity when
connecting test equipment.
High Voltage Circuits - Whenever disconnecting live
ht circuits always use insulated pliers and never
allow the open end of the ht lead to come into
contact with other components particularly ECU’s.
Exercise caution when measuring the voltage on the
coil terminals while the engine is running, high
voltage spikes can occur on these terminals.
Having confirmed a component to be faulty switch
off the ignition and disconnect the battery. Remove
the component and support the disconnected
harness. When replacing the component keep oily
hands away from electrical connection areas and
push connectors home until any locking tabs fully
engage.
Battery disconnection
Before disconnecting the battery, switch off all
electrical equipment. If the radio is to be serviced,
ensure the security code has been deactivated.
CAUTION: To prevent damage to electrical
components ALWAYS disconnect the
battery when working on the vehicle
electrical system. The earth lead must be
disconnected first and reconnected last.
Always ensure that battery leads are routed
correctly and are not close to any potential
chafing points.
Battery charging
Recharge the battery out of the vehicle and keep the
top well ventilated. While being charged or
discharged, and for approximately fifteen minutes
afterwards, batteries emit hydrogen gas. This gas is
inflammable.
Always ensure any battery charging area is well
ventilated and that every precautions is taken to
avoid naked flames and sparks.
Connectors and Harness - The engine compartment
of a vehicle is a particularly hostile environment for
electrical components and connectors. Always
ensure these items are dry and oil free before
disconnecting and connecting test equipment. Never
force connectors apart either by using tools or by
pulling on the wiring harness. Always ensure locking
tabs are disengaged before removal and not
orientation to enable correct reconnection. Ensure
that any protective covers and substances are
replaced if disturbed.
ELECTRICAL PRECAUTIONS 1
GENERAL INFORMATION
Disciplines
Switch off ignition prior to making any connection or
disconnection in the system as electrical surge
caused by disconnecting ’live’ connections can
damage electronic components.
Ensure hands and work surfaces are clean and free
of grease, swarf, etc. as grease collects dirt which
can cause tracking or high-resistance contacts.
When handling printed circuit boards, treat them as
you would a disc - hold by the edges only; note that
some electronic components are susceptible to body
static.
Connectors should never be subjected to forced
removal or refit, especially inter-board connectors,
damaged contacts will cause short- circuit and
open-circuit conditions.
Prior to commencing test, and periodically during
test, touch a good earth, i.e. cigar lighter socket, to
discharge body static as some electronic
components are vulnerable to static electricity.
Grease for electrical connectors
All under bonnet and under body connectors are
protected against corrosion by the application of a
special grease on production. Should connectors be
disturbed in service or repaired or replaced, a
grease of this type, available in 150 gm tubes under
Part No. BAU 5811, should again be applied.
NOTE: The use of other greases must be
avoided as they can migrate into relays,
switches etc. contaminating the contacts
and leading to intermittent operation or failure.
2
ELECTRICAL PRECAUTIONS
INFORMATION
CONTENTS
LIFTING AND TOWING
JACKING, SUPPORTING AND TOWING 1................................................................
WORKSHOP JACK 2..................................................................................................
WHEEL-FREE LIFT 2..................................................................................................
TOWING 2...................................................................................................................
GENERAL DATA
ENGINE 1....................................................................................................................
FUEL SYSTEM 1.........................................................................................................
COOLING SYSTEM 1..................................................................................................
CLUTCH 2...................................................................................................................
MANUAL GEARBOX 2................................................................................................
AUTOMATIC GEARBOX 2..........................................................................................
FINAL DRIVE 2............................................................................................................
WHEELS 3...................................................................................................................
TYRE SIZE 3...............................................................................................................
TYRE PRESSURES 3.................................................................................................
ELECTRICAL 3............................................................................................................
DIMENSIONS 4...........................................................................................................
WEIGHTS 4.................................................................................................................
Page
ENGINE TUNING DATA
Model: SPi with manual gearbox 1..............................................................................
Model: SPi with automatic gearbox 2...........................................................................
Model: MPi 3................................................................................................................
TORQUE WRENCH SETTINGS
GENERAL 1.................................................................................................................
ENGINE 1....................................................................................................................
EMISSION CONTROL 2..............................................................................................
ENGINE MANAGEMENT SYSTEM 2..........................................................................
FUEL SYSTEM 2.........................................................................................................
COOLING 2.................................................................................................................
MANIFOLD AND EXHAUST 3.....................................................................................
CLUTCH 3...................................................................................................................
MANUAL GEARBOX 3................................................................................................
STEERING 3...............................................................................................................
SUSPENSION 4..........................................................................................................
BRAKES 4...................................................................................................................
RESTRAINT SYSTEMS 4...........................................................................................
BODY 5........................................................................................................................
HEATING AND VENTILATION 5.................................................................................
WIPERS AND WASHERS 5........................................................................................
ELECTRICAL 5............................................................................................................
INSTRUMENTS 5........................................................................................................
CAPACITIES, FLUIDS AND LUBRICANTS
CAPACITIES 1.............................................................................................................
FLUIDS 1.....................................................................................................................
LUBRICATION 2..........................................................................................................
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