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TR 7TRB

ROVER 3500I I I. ~ ( 6 . ~ ~ ~ ~TRIUMPH FUEL INJECTION~ oJ!~ . 2 l ~ ~NORTH AMERICAN SPECIFICATION - 1980 MODEL YEAR

EMISSION AND EVAPORATIVE LOSS CONTROL EQUIPMENTANDMAINTENANCE INFORMATION

.JAGUAR ROVER TRIUMPH INC6OOWlLLOWTREE ROAD. lEONIANEWJERSEY07605Publication Part No. AKM 8072/80 U.S.A.

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THIS HANDBDDK IS TD BE USED IN CONJUNCTiONWITH THE DRIVERS/OWNERS HANDBOOK FORCOMPLETE VEHICLE OPERATION.

INTRODUCTIONVehIcles manufactured to the North American specification satIsfy the requirements of the vanous Federal. California State andother Regulations.This publication describes the function of the emission and evaporative loss control systems. together with instructions for themaintenance required to keep the vehicle in good running orderThe Manufacturers reserve the right to vary their specifications WIth or Without nollce, and al such times and In such manner asthey think fit. Major as well as mmor changes may be involved in accordance With the Manufacturer's policy of constant productImprovement

The replacement or repair of the emission control devicesand systems may be performed by any automotive repairestablishment or individual using any automotive part whichhas been certified by the part manufacturer.

2

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EMISSION AND EVAPORATIVE LOSS CONTROL SYSTEMS

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Fig. 2 Rover 3500 Fuel Instructions3

FuelCAUTION: It is essential that unleaded fuels are used inthese vehicles otherwise serious damage can be caused tothe catalytic converter and the oxygen sensor(s) f it ted in theexhaust system,Emission Control Systems - ServicingThe importance of servicing at the correCllntervals cannot beover-stressed, as improvements in design and manufacturingtechniques count for nothing i f the servicing standards arenot upheld.Routine servicing. carried out at the mileage intervals quotedin the 'Maintenance Summary', helps to prevent deteriorationof the systemsIt is recommended that all servicing. particularly of theemission and evaporative loss control systems, be carried outby ski lled and competent personnel.After any attention to these systems, or after a change to theengine settings, it is essential that the exhaust emissionlevels are checked using proper equipment.

EMISSION AND EVAPORATIVE LOSSCONTROL SYSTEMSAl l Rover-Triumph models entering the North Amer icanmarkets incorporate ef ficient emission control systems,These systems enable the vehicles to conform with allcurrent Regulations governing the emission of hydrocarbons,carbon monoxide. n it ric oxide and the emission of fuel, byevaporation, from the fuel delivery system.

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EMISSION AN D EVAPORATIVE LOSS CONTROL SYSTEMS

4

Fig. 3 Main electronic fuel injection system compommu

Electronic Fuel InjectionIn convenltonal carburener luel system engines. fuel mixeswith the aIr stream entering the engine combustIOnchambers by means of fixed and/or vanable Jets In thecarburetter(sJ Despite advances In desIgn. the carburetter ISno t a total ly efficient means 01 dispensing fuel lo r all themany and varIed engine operating conditions. parllcularlywhen stringent e::o:haust emiSSion levels must be met For thisreason an electrOniC fuel Injection system IS f it ted to thesemodels and carburetters are nOt used.An electrOniC fuel Injection system comprises. as the namesuggests. 01 two parts:-A fuel injection system and an electronic control for the fuelinjection system.

Key to Fig. 3(AI Fuel Injector(8) Fuel pressure regulator(e ) Extra AIr Valve(D) Fuel pump(E) Ai r F low MeterIF) Electronic control Unit

Should it be necessary to remove or exchange an injector, ane w sealing ring must be fined.

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EMISSION AND EVAPORATIVE LOSS CONTROL SYSTEMSFuel Injection System ComponentsFuel is drawn from a tank al the rear of the vehicle andpressurised to approximately 2,5 kgf/cm2 (36 Ibl /in2 ) by anelectric fuel pump located b e n e a ~ h the car floor. The fuelpump will only operate when the ign it ion and/or the startermotor circui ts are energised, From this pump fuel passesthrough fuel filters located in the engine compartment (Rover3500) or beneath the car f loor (TR models} to a pressureregulator , the spr ing chamber of which is connected to theengine intake manifold. As a result, the difference betweenthe intake manifold pressure and the fuel pressure is heldconstant, excess fuel being returned to the fuel tank via ananti-surge potA fuel rai l l inks the pressure regulator with the fuel injectors,one injector being f it ted in to each inlet manifold spur. Theinjectors may be either open ' or 'closed and are solenoidoperated, The injector solenoids are energised through arelay actuated by the ignit ion circuit and are pulsed to openby the electronic control unit (LeU.) completing the circuitto 'ground:' When 'open'the injectors spray fuel into the Inletmanifold to be drawn into the engine cylinders at the nextinduction stroke of the working cycle.Therefore there needs to be no fixed relationship between theinjector timing and the engine ign it ion or valve t iming.The injectors are programmed to open' in banks of four. inunison, twice per engine operating cycle (two revolut ions).On eight cyl inder engines the two banks of four injectorsoperate alternately, The time that the injectors are open'governs the amount of fuel supplied to the engine and thisopen' t ime is computed by the electronic control unit fromthe input it receives f rom var ious sensors

Fig,4 TR7 Fuel injection system components

Key to Fig, 4(1) Cold start injector(2) Injectors(3) Fuel rail(4) Cold start injector - fuel feed pipe(5) Fuel pressure regulator(6) Return line to fuel tank(7) Pipe to plenum chamber(8) Thermo time switch 5

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Fig. 5 TR8 Fuel injection system (:omponents

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(1) Fuel feed Plpe from tank(3) Fuel rail(6) Manifold depreSSion to pressure regulator Pipe(8) Injectors(9) Cold start in jector fuel feed pipS(10) Cold star l Injector6

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Fig. 6 Rover 3600 Fuel injection system componenta

(1) Fuel feed pipe from tank(2) Fuel fllter/s)(3) Fuel rail(4) Pressure regulator(5) Fuel inlet to pressure regulator

(6) Manifold depression to pressure regulator pipe(7) Excess fuel return to tank f rom pressure regulator(8) Injectors(9) Cold start injector fuel feed pipe(10) Cold start injector7

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Electric Fuel Pump OperationThe fuel pump IS energIsed, .ndependant of the electrOniCcontrol Unit, from an output terminal on the combined relayThe combined relay IS the co mp onent t ha t prOVIdes aninterface between the main vehIcle electrical harness andthose ,tems that are spec,f,cally related to the electrOniC fuelinjectIOn system. An inertia SWItch .s Included In the CirCUit toIsolate the fuel p um p and prevent II from operattng In theevent o f an Impact type accident The CIrCUit is also routedthrough the electrOniC control system Air Flow Meter where asimple contact SWitch ensures tha t the fuel pump cannotoperate when no air IS flOWing mto the e ng in e i,e the engineis no! running. ThiS contact SWitch IS by-passed when thestarter motor CirCUit IS energisedOnce the engine IS runnmg a ClrCUlt f rom the Ignl\ lon SWitchpasses through a relay ,aground,via the electroniC control Uniton TAl models When energised th.s relay permIts a CIrCUItto be made to the AIr Flow Meter contact SWItch ProvIdingthe contact switch IS closed a CirCUit IS completed through asecond relay, again to ground. When energised thiS secondrelay completes the CirCUIt to operate the fuel pumpUnder engme start ing conditions the Air Flow Meter contactswi tch wo uld no rma lly Isolate the fuel pump as no air ISf lowing through the engine. To o ve rcome thiS an Input IStaken direct from the starter m otor CirCUit to energise thesecond relay and thus permit the fuel pump to operate duringthe engine starting operation

8 Fig. 8 Circuit principles of fuel pump operation

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EMISSION AND EVAPORATIVE LOSS CONTROL SYSTEMSCold Starting Fuel Injection System ComponentsTo assist cold start ing, a separate cold start injector sprays afine jet of fuel against the air stream entering the plenumchamber before fuel is added to il by the main inJeclors. Thecold start injector is energised from the engine starter motorci rcuit and has In series with it a thermot ime switch Thisswitch is dual activated by the engine coolant temperature(heat) and a heater coi l around a bi-metal str ip (time), the coilbeing again energised from the starter motor CIrCUit. Thepurpose of the thermotime switch is to ensure that the coldstart Injector wil l not be energised when the engine is atnormal operating temperature or should the starter motor beused for prolonged periods when the engine is below normaloperating termperature. Thus the switch prevents extra fuelbeing supplied to the engine when it is not reqUired. Theswitch will Isolate the cold start injector after approximately 8to 12 seconds at -20C (_4F) decreasing this lime as theengine approaches its normal operating temperature,Although the cold start injector and thermot lme sWitchoperate independantly of the electronic control unit, an Inputto the E.C U. is taken from the starter motor CIrCUlI. This inputcauses the E.C.U to slightly lengthen the time that the maininjectors are open thus allOWing more fuel to be supplied tothe engine whenever the starter motor IS operated, This takesplace irrespective of the mlormation supplied to the E.C.U bythe other sensors or any operation 01 the cold start InjectorMaintenance of Fuel Injection System ComponentsApart from attention to the fuel filters alter 80.000 km(50 000 milesL the, remaining components of the fuelinjection system reqUire no routme maintenance.

2157Fig. 9 Cold starting injector

2158Fig. 11 Thermotime switch

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2174

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111 EJII!OT I "RSWITCH

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EMISSION AND EVAPORATIVE LOSS CONTROL SYSTEMSElectronic Control of the Fuel Injection SystemAt the heart of the electronic control system is the ElectronicControl Unit (E.C.U.) which is a box approximately 23 x 18 x5 ems (9 x 7 x 2 Inches) located beneath a plate on the Irontpassenger footwell (Rover 3500) or under the glove box (TRmodels), The E.C.U. receives input signals from varioussensors and computes from these an output signal to the fuelinjector solenoid circuits. When activated the solenoids'open' the injectors to spray fuel into the engine inletmanifold, the injectors remaining 'open' for between 1.5 and10 milliseconds depending on engine running conditions.The electronic control unit is sealed, it requires nomaintenance and should not be opened or tampered with.Engine SpeedOne of the f irst inputs required by the EG.U. is that of enginespeed and this input is very simply obtained by taking atapping from the ignition coil low tension circu it output(negative terminal) , Thus the ign it ion low tenSion circuitpulses are passed to the E.C,U. to be computed into anengine speed input.Ai r Flow MeterIn addit ion to fuel. the most important input to the engine isair and the ratio of air to fuel affects both the performance ofthe engine and the emission levels of the exhaust gases,Electronically controlled fuel injection systems can 'measure'the air used by the engine In one of two ways. by air pressureor by air flow. The air flow alternative IS used on thesemodels.

12 Fig. 13 Electronic control unitContinued

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EMISSION AND EVAPORATIVE LOSS CONTROL SYSTEMSTo measure the air flow Into the engine an Air Flow Meter isfitted In the engine compartment between the air cleaner anda plenum chamber above the engine. The plenum chamberacts as a collecting bOil: for the mgolng air and helps tosmooth out any rapId fluctuations in air flow that might upsetthe Air Flow Meter signals.The AIr Flow Meter Iiself IS basical ly a short tube In whichthere is a pivoted measUring flap that IS moved by air flowingpast It Into the engine To reduce excessive f luttering of thisflap, such as would be caused by sudden changes or pulsesin the air f low. a compensating f lap IS fllted as part of thesame casting as the measur ing Ilap_ The position of themeasunng flap IS controlled by the a lf drawn into the engmeand the act ion of a co il return spr ing The mass of air drawnInto the engine at any t ime IS Indlcatrve of the engine loadand a SIgnal. proport ional to the flap posi ti on. is passed tothe EC.UHowever. the air mass IS related to air denSItYwhich In turn ISdependant upon aIr temperature Therefore an AIrTemperature Sensor IS Incorporated Into the Air Flow Meterand this sends a separate elect rica l Signal to the EC UDue to the act ion of the COil return spring. the Air Flow Metermeasuring flap IS almost closed when the engine IS Idlingand an Idle aIr by-pass channel IS provIded to assIst theengine to breathe at this low speed Air passing through theby-pass channel IS not registered by the Air Flow Metermeasuring flap

"."Fig.14 Air f low m.t ....

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14

Fig. 15 Contact type throttle switch

Fig. 16 Potentiometer type throttle switch2163

Throttle SwitchesThrottle switches form 'part of the electronic control fo r thefuel injection system and provide the E.C.U. with informationon throttle operating conditions, Two types of switches canbe used dependant upon the type of information required bythe E.C.U. to perform its funct ion.A contact type switch is fit ted to TA? models and is locatedon the thrott le body in the engine compartment. The sWitchcontacts close when the accelerator pedal is fully depressed.s ignall ing to the EC.U. to lengthen the time that the maininjectors are 'open', thus supplying extra fuel for theacceleration required.A potentiometer type switch is f itted to TRB and Rover 3500models on the engine plenum chamber In Ime With thethrottle input spindle, This switch is a simple electr ica lpotentiometer (variable resistance) whose electrical signal tothe ECU depends upon the posit ion of the throttle spindleand hence the accelerator pedal. The E.C.U will detectchanges in throttle position by the voltage output f rom thepotentiometer. Using this together With information from theother sensors it will adjust the fuel Input accordingly. eitherfor degrees of acceleration and deceleration or for constantengine speed, When a very sudden acceleration IS Signalledto the E,C.U. by the throttle potentiometer. all Injectors arepulsed to operate once simultaneously to ensure adequateengine response.

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Coolant Temperature SensorThis sensor is localed al the to p of the engme (TRl) orbetween the cylinder heads (TRS and Rover 3500) andprovides coolant temperature mformat lon to the ECU. Thisinformation causes the ECU. to lengthen the time that themain injec tors are 'open' redUCing this lime as the enginewarms up and cutting it off when normal engine operatingtemperture is reached. In pract ice the sensor functions bymodifying an output voltage from the E.CU through an'earth' return Circuit.Extra Air ValveThis valve is mounted above a water passage near the Inletmanifold and registers the same temperature as the engmecoolant. Its purpose is to provide the addit ional air requiredto maintam a sat is factory engine Idle speed unti l the enginereaches normal operating temperature. This air IS taken froma point before the throttl e butterfly (but after the Air FlowMeter. so that the air is registered by the E.CU,) and returned10 the plenum chamber after the throt tle butterf ly.To allow air to pass through the Extra Air Valve. and thus by-pass the throttle butterfly. an open ing in a rota tab le meta ldisc is a ligned wi th the inlet and outlet tubes on the valveThe posit ion of this disc is controlled by a bi-metal striPwhich deflects according 10 the temperature It experiencesAs the bi-metal str ip heats up it rotates the metal diSC until itsopening no longer l ines up with the air valve tubes and theextra air source is reduced and finally terminated as normalengine operating temperature is reached. The bi-metal stripis heated from two sources. the coolant temperature and aheater coi l around the strip. The heater colliS energised fromthe fuel injection system combined relay while the engine ISrunning,

2164Fig. 17 Coolant temper tu te sensor

Fig. 18 Extra air valve15

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16

Fig. 1S1 OJlY9'lO Sensor

The Oxygen sensorls) require replacement at the intervalsstated in the maintenance summary, and a reminder lampon the fascia will i l luminate at this mileage interval. Pleasesee your Dealer, or quali fied service out le t, as soon asconvenient after the reminder lamp illuminates.

Overrun ValveThis second air f low control device bleeds air into the engineinlet manifold, via the piunum chamber, when the manifolddepression is hIgh and thus maintains combustlOn dUringengine overrun.

The valve operates independantty of the electronIC controlsystem and on TAJ models IS mcorporated In the throttlebutterfly connectmg the constant depresslOn region betweenthe throttle and the Ai r Flow Meter measuring flap On vemodels It IS a separate valve on the sIde of the thrOllle body

Oxygen SensorA smgle sensor IS fi tted to TAJ models and two sensors arefitted to TAe and Rover 3500 vehicles They are located Inthe exhaust system near to the catalyst(s) and. like thecatalyst(sl. reqUire only UNLEADED fuello be used to preventdamage to them. These sensors monitor the composition ofexhaust gases leaving the engineThe Internal workmg surfaces of the sensors are coated wllha thin p la tinum layer which IS permeable to gas A speCialceramiC layer protects the electrodes agamst corrOSion andthiS become conductIVe to olCyQen a toms at about 600C11112F) If the concentration of oxygen mSlde the sensor(from the exhaust gasesl differs from that outside the sensor(atmosphere) a voltage IS developed between the twosurfaces that changes when the outer electrode has catalytiCactivIty ThiS voltage IS passed to the ECU which comparesIt against a reference voltage for Ideal combusti on andadjusts the main injector 'open' lime accordingly to permitmore or less fuel to be used by the engme More fuel wil l useup the excess oxygen m the exhaust gas. less fuel Will allowmore oxygen, and so the ideal oxygen content IS supplied topermit the catalyst to operate at ItS best effiCiency

Conunued

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FIg. 23 SchematiC wmng dIagram of electronic fuel injection system components{note that alternative cable colours C1re shown according [0 model hlmentl

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Fig. 24 TR8 E.G.R. synem

Fig. 26 Rover 3500 e.G.R. system,.,

The remaming emission and evaporauve loss control systemcomponents described in this section Bre no t directconnec ted With the fuel injec tion system or liS e lec troncontrol devicesExhaust Ga s Recirculation (E.G.R.) System (TAB anRover 3500 only)Sy s te m D e sc r ip t io nTo reduce the Nitrous Oxide (NOx) content in the exhaust. thpeak combustion temperatures Bre lowered by recirculatingcontrolled quantity of the exhaust gases through thcombustion process.The E,G.A. valve is mounted on the exhaust manlfold.control signal , taken from a thrallie edge tapping, gives nrecircu la tion at idle or fu ll load, but does allow an amount oreCIrculation. dependent on the vacuum signal andmetermg profile on the valve under par t-load condi lionsExhaust gas flows from the valve to the Inlet plenum chambevia a lagged pipe

Key to Fig. 24 and Key to Fig; 25(1) E.G.A. valve(2) Exhaust manifold(3) E.G.A. pipe (asbestos lagged)(4) Throttte edge vacuum to E.G.A. valve(5) Plenum chamber

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Function ChecksWarm the engine to normal runnmg temperature. Ensure thatthe Idle speed returns to normal Blip the throttle and observethe valve. which should open and close as the engine speedchanges.If the valve is nOI operatmg. remove the E.G. A. valve andcheck the valve operation usmg a vacuum test gauge. Fit anew EG R valve if It 1$ found to be defective.

Crankcase BreathingTo ensure that piston 'blow by' gases do not escape from thecrankcase to the atmosphere, a depression 1$ maintained Inthe crankcase under all operatmg conditions. This IS achIevedby connect ing the crankcase breathing hOUSing 10 a POIi'llbetween the air meter flap and the throttle plate ie . aconstant depression region,On Rover 3500 and TRS models air is drawn into the righthand rock.er cover via an air f il ter and restnctor and drawn offf rom the engine on the left hand rock.er cover. A flame trap isfitted In the draw off housing.

Evaporative Loss Control SystemThe funct ion of this control system IS to prevent fuelhydrocarbon vapours from entenng the atmosphere. This ISachllwed by providing no external fuel tank. breathing systemand as an alternative venting the tank through two adsorptioncanisters located In the engine compartment.To prevent the canisters flooding due to thermal expanSion ofany fuel in the tank. the tank f il ler neck IS entered well downInto the tank, and a pipe let into the tank at maximum fuellevel vents into the f il ler neck to allow for fuel expansion. AliqUid vapour separator IS Incorporated into the fuel tank ventPipe to reduce the quantity of vapour passed to the canisters.Any fuel vapour IS purged from the canisters once the engineIS running by means of a connection to a constant depreSSionregion between the air meter flaps and the throttle butterf ly.WARNING: The use of compressed air to clean anadsorption canister or clear a blockage in th e evaporativesystem is very dangerous. An explosive gas present in apart ly saturated canister may be ignited by the heatgenerated when compressed ai r passes through thecanister.

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1. fuel lank2. Fuel f,lle, pipe3. VapOl.Jr separiUOl4 Vapour feed line5 Fuel return line6 Fuel feed lone

8

7. Fuel pump8. Fuel f l i l e r . ~9. Charcoal canoster10. Injectors11. fuel pressure regulator12. Purge line13. Crankcase purge line

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22Fig. 26 TR7 Crankc.se br th ing l ind evepor.tive loss control systems


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1. Fuel tarok2. Fuel f i l le r p ip e3. Vapour separator4, Vapour feed line5. Fuel return hne6. Fuel feed line

7, Fuel pump8. Fuel filters9. Charcoal canisters10. Injectors11. Fuel pressure regulator12. Purge line

Fig. 27 TR8 Crankcase breathing a n d e v ap o ra ti v e loss c o nt r ol s y st em s2170

23

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A Purge poont from Chiorcnal e - I e < 10o;onst.,,\ ~ ~ s " ' " reg"", !hI dlol.....trOC:lor fittedS All onle, 10 eng.ne cr..kuse 0 040

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CATALYTIC DEVICESThe fol lowing precautions apply to catalyt ic devices:-(1) In order to maintain the efficiency of the emissioncontrol system it is essent ial to use UNLEADEDgasoline only; this fuel also minimises spark plug

fouling thereby sustaining engine performance.(2) DO NOT tamper with the eng ine settings. they havebeen established to ensure that the vehicle will comply

with stringent exhaust emission regulations. Incorrectengine set tings could cause unusual ly high catalyt icconverter temperatures and thus result in damage tothe converter and vehicle. If adjustment to the settingsis considered necessary, this should be performed by aRover Triumph Dealer or other qualified facility,(3) A correctly tuned engine optimises exhaust emiSSions,performance and fuel economy and it is recommended

that the vehicle is maintained as out lined under theMAINTENANCE SUMMARY of this handbook.(4) DO NOT cont inue to operate the vehicle if any engine

malfunction is evident, malfunctions should be rectifiedimmediately. For instance, misfire, loss of engineper fo rmance or eng ine run-on may lead to unusuallyhigh catalytic converter temperatures and may result indamage to the converter and car.

(5) NEVER leave the vehicle unattended with the enginerunning.(6) The use of a catalyt ic converter increases exhaustsystem tempera tures, (part icular ly under engine

malfunction!. therefore do not operate or park thevehicle in areas where combustible materials such asdry grass or leaves may come into contact with theexhaust system(7) The vehic le is designed for normal road use. Below areexamples of abuse which could damage the catalyticconverter and and may lead to a dangerouscondition due to excessively high catalytic convertertemperatures.(a) Competition use(b) Off roadway use(c) Excessive engine revolutions(d) Overloading the vehicle(e) Excessive towing loads(f) Switching off the engine and coast ing In gear

(8) DO NOT run the engine with either a spark p lug leaddisconnected or a spark plug removed. DO NOT useany device that requires an insert into a spark plug holein order to generate air pressure. (e.g. tyre pump, paintspray attachment. etc.). as this could result in catalyticconverter damage.(9 ) DO NOT push or tow the vehicle to start it. thiS coulddamage the catalyt ic converter I t IS recommended thaI

jumper leads are used.(10) Heavy impact on the converter casing must be avoidedas i t contains ceramic material which is easily damaged.


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MaintenanceMaintenance of the emission and evaporative loss controlsystems is limited to the routine checks listed in theMaintenance Summary and renewing the Oxygen Sensor(s)at the intervals stated. These vehicles have a dashboardmounted service interval warning lamp which illuminatesat the required oxygen sensor renewal mileage. Shouldthi s warning lamp i l luminate, the sensor(s) should bechanged and the lamp actuating mechanism reset by yourDealer or service outlet using a special service tool key.

26

Checking the Electronic Fuel Injection Control SystemApart from the obvious functional checks possible as a resu01 reading the foregoing component and systemdescriptions, the detai led checking of the electronic controsystem for malfunction requires training and the use ospecial test equipment. It is therefore recommended thathese checks are entrusted to your Dealer or to any servicoutlet that has the special ised knowledge and tesequipment.

MAINTENANCE SUMMARY

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MAINTENANCE SUMMARYNORTH AMERICAN SPECIFICATION - 1980 MODEL YEARThe fol lowing items should be checked by the dr;\I8r weekly or before a long journey:-

Engine 011 levelBrake f luid levelAutomatic transmiSSion flUid levelRadiator coolant levelBattery electrolyte level

All washer reservoir water levelsAll lyres for pressure and condillonAll l ights for operationAll wipers and washers for operation

MAINTENANCE INTERVALSse e SEPARATE CHART seTS FOR 1980 CARBURETTED MODELS

S _ i e - DISTANCEc _ MILEAGE X 1000l e t t e r IN ANY EVENT. THE PERIOD BETWEEN S E R V i C eS S H OU L D NOT EXCEED TWELVE MONTHS.A , 1.' 22.5 37.6 57.5 72.5 87.5C " 45 .. 950 JO .,E .. 100

SpecifIed otherwlse.-Should the vehicle be used for a high proport ion of short Journeys or be operated rn severe condilions. it may requiremore frequent servlcmg or particular allenilOn to specIfic Items Your Dealer will be pleased to adVise you re'lardrngparticular selVlce reqUirements under these conditions See items marked "C".

Additional maintenance mformallon IS gIVen at the end of the Mamtenance Summary on the fol lowing pages27

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MAINTENANCE SUMMARY Opera tions indicated . r . applicable u p to 50,000 miles only .

Operations indicated Ir . applicable from 50,000 mil. . onward. only.c Oper ations i nd ieat ed . r . to be constdared M V ' ~ M1f.iee only.

28

OPERATING DESCRIPTIONLUBRICATION & FLUIDSRenew engine oil ..................................Renew engine oit filter ............................Check/top-up brake fluid reservoir .Checkltop,up clutch fluid reservoir...................Check/top-up automatic transmission fluid..............Renew automatic transmission oil and filter .Check/top-up battery electrolyte ....................Check/top-up cooling system ........................Check/top-up gearbox oil .Check!topup rear axle/final drive unit oil. .lubricate distributor (Not TR 7) .lubricate accelerator control linkage and pedal pivot,check operation .Check/top-up power steering reservoir fluid .lubricate all locks, hinges and door-check mechanisms(not steering Jock) .lubricate steering rack and pinion (TR7fTR8} .ENGINECheck for oil leaks _ . Check/adjust all driving belts . Check/adjust all driving belts, renew as necessary .Check cooling and heater system for leaks and hoses forsecurity and condition. . .Renew air cleaner element. . .

SERVICEABCDEx x x x xx x x xx x x x xx x x x xx x x x xxx x x x xx x x x xx x x x xx x x x xxx xx x x x

x x x x xx x

x x x x xc c c xx x xc c c cx

MAINTENANCE SUMMARY

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OPERATING DESCRIPTIONENGINERenew crankcase breather filter (TRB/Rover 3500) .

"'Clean crankcase breather flame trap .Check crankcase breathing and evaporative 1055control systems . . . . . . . . . . . . . . . . . . .Check hoses/pipes and restrictors for blockage securityand condition .Check/adjust torque of cylinder head nuts & bolts (TR7).

IGNITION Renew spark plugs .Clean/adjust spark plugs, renew as necessary ."Check ignition wiring (including electric fuel pump wiring)fo r security. fraying and chafiny .

"Check ignition wiTing (including electric fuel pump wiring)for security, fraying and chafing ."Check/adjust ignition timing using electronic equipment"Check security of distributor vacuum unit line, andoperation of vacuum unit. . .

SERVICEABC DExx

xx xx

xx x,x xx x xx x

FUEL AND EXHAUST SYSTEMSCheck fuel system for leaks, pipes and unions for chafingand corrosion _. . . . . . . . . . . . . . . . . x x x x xCheck exhaust system for leaks and security. . . . . . . . . . x x x x xCheck condition of fuel filler cap seal. . . . . . . . . . . . . . c c..Renew fuel filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . x.... Renew fuel filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . x xRenew oxygen sensor(s) and reset service interval counter. . . x"Check/adjust idle speed _. . . . . ......... . . x....Check/adjust idle speed.. . . . . . . . . . . . . . . . . . . . . x x 29

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OPERATING DESCRIPTIONTRANSMISSION. BRAKES, STEERING & SUSPENSIONCheck fo r oil leaks .Check condition and security of steering unit, jointsand gaiters : - .Inspect brake pads/linings for wear, discs drums for condition,adjust as necessary .Check brake servo hoses for security and condition .Check/adjust front wheel alignment .Check visually brake and clutch hydraulic hoses/pipes andunions fo r cracks, chafing. leaks and corrosion .Check tightness of propeller shah coupling bolts .Check/adjust front hub bearing end float .

WHEELS AND TIRESCheck tires for tread depth and visually for external cuts infabric, exposure if ply or cord structure, lumps, bulges oruneven wear .Check that tires comply with manufacturer's specifications . .Check/adjust tire pressures, including spare wheel. .Check tightness or road wheel fastenings .ELECTRICALCheck/adjust operation of all washers and topup reservoirs . .Check function of original equipment. lamps, horns. wipersand aU warning indicators .Check wiper blades and arms. renew if necessary .Check/adjust headlamp alignment .Clean and grease battery connections .

30

SERVICEABC 0 Ex x x x x

x x xx x xx x x x xx

x x x xx x xx x x

x x x xx x x xx x x xx x x x x

x x x x xx x x x xx x x xx x x xx x x

MAINTENANCE SUMMARY

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OPERATING DESCRIPTIONBODYCheck condition, security and operation of seats and seatbelts. . . . . . . . . . . . . . . . . . . . . . .Check operation of all passenger door, hood, trunk, reardoor and steering column locks. . . . . .Check operation of window controls .

GENERALRoad/roller test. Check brake operation and function of allinstrumentation .Report additional work required. . .

SERVICEABC DEx x x x xx x x x xx x x x x

x x x x xx x x x x* Operations indicated are applicable up to 50,000 miles only.Operations indicated are applicable from 50,000 miles onwards only.c Operations indicated are to be considered severe service only.

Additional Preventative MaintenanceIn addi tion to the recommended periodical inspection ofbrake components it is adVisable as the car ages, and as aprecaut ion against the ef fects of wear and deterioration. tomake a more searching inspection and renew parts asnecessary.It is recommended that:-(1) Disc brake pads. drum brake linings. hoses and pipesshould be examined at Intervals no greater than thoselaid down in the Maintenance Summary_

(2) Brake Iluid should be changed complete ly every 18months or 37.500 km (22 500 miles) whichever is thesooner.(3) All f lu id seals in the hydraulic system. all f lexible hoses.the brake servo filter and load sensing valve (wherefilted). should be renewed every 3 years or 62,500 km

(37,500 miles) whichever is the sooner, At the sametime the working surfaces of the piston and bores In themaster cyl inders and other slave cyl inders should beexamined and new parts f ined where necessary.Continued

3'

MAINTENANCE AND ADJUSTMENTS

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(4) eare mus t be laken always 10 observe the followmgpOlnts:-

lal At all lImes use the recommended brake flUId.(b l Never leave flUid In unsealed containers It absorbsmOisture qUickly and can be dangerous II used rn the

brak mg sy stem In thiS condition(e) FlUid dramed from the syst em or used for bleedingshould be discarded(d) The neces si ty for absolute cleanlmess throughout

cannot be over-emphasised

Replacement Brake Pads and ShoesWhen It becomes necessary to renew brake pads and shoes.It IS essential Ihat only genuine components With Ihe correctgrade of lining are used Always fit new pads or shoes ascomplete axle sets. never mdividually or as a Single wheelse t Seflous conseQuences could result from OUI of balancebrakmg d ue to mixing of linmgsReplacement brake pads and shoes are obtainable from yourDealerThe operations tabled In the maintenance summary are listedm the same order on thiS and the follOWing pages. WithsuffiCient detail to enable a person With an average

32

knowledge o f motor vehicle technology to complete them.W here appropr iate. week ly check s not Included In themaintenance ,nterval summary have been Interspersed withthe labled operationsThe replacement or repair of the emission control devicesand systems may be performed by any automotive repairestablishment or individual using any automotive part whichhas been certified by the part manufacturer.However. It IS recommended that only skilled andexperienced personnel attend to I tems relatmg to the engmet une or t he emission and evaporative loss control systemsWhen these Items have received attention. the exhaustemiSSion level should be checked USing proper eQuipment toensure that I t conforms to the standards laId down for thesemodels

Lubricate Al l Grease Points (Except HubslUsmg a recommended grease. lubricate Ihe handbrakemechanical Imkage and cable gUides and. where f it ted. theautomatiC transmiSSion exposed selector ImkageUSing a medium 011. l ub nca te the brake an d cl ut ch pedalPivots takmg care to wipe away all surplus Olt to aVOidstamlng the carpet

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Lubricate Steering Rack and PinionTRJ and TAB onlyUSing a recommended grease. lubricate the sleering rackand pmlon as fol lows>(1) Wipe clean t he p lug and surrounding area.(21 Remove the grease nipple plug, lakmg care not todisturb the larger damper plug(3) Fit a sUitable grease mpple In p lace of the plug(4) Turn the steering wheel to lull fight hand lock(5) Apply a grease gun to the grease nipple and gIVe 5strokes only.

CAUTION: Overg reasmg can cause damage to theprotectIVe gaiters and/or seals(6) Remove the grease nipple and refIt the plug.(7) Wipe away any surplus grease

Check!Top up Engine Oil level(1) Stand the car on level ground.(2) If the engine has been running, allow time for the oil to

drain back into the sump,(3) Withdraw the dipst ick(4) Usmg a non fluffy cloth, wipe the d ipsti ck clean andreplace It(5) Withdraw the dipstick and note the oil leveL Replace

the dipstick(6) Add a recommended grade of oil, as necessary,through the f il ler cap00 NOT OVERFILL

2

A ~ 7 0 0 2Fig, 1 Steering unit lubrication

Fig, 2 TR7 engine oil dipstick end fil ler ClIp3


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\ \ - - ~1722

Fig. 3 V8 engine oil dipstick and filler cap

1693Fig. 4 Engine sump drain plug

34

Renew Engine Oil(1) Stand the car on level ground.(2) If the engme has been runmng, allow time for the 01110dram back into the sump(3) Using the dipstIck, check the sump oil level and place a

suitable contamer beneath the sump drain plug(4) Slowly unscrew the drain plug until the all starts tof low. When the f low lessens remove the plug and dramthe sump.(5) Refit the drain plug(6) Add a recommended grade 01 oil, as necessary,through the f il le r cap.(7) Run the engine, check for oFlleaks and finally top up theoil to the correct level.

DO NOT OVERFILL

MAINTENANCE AND ADJUSTMENT

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(

TR7 and va engine oil f i ltert

/..--- , ir - ' ~ ~~

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Fig. 7 Clutch fluid reservoir

Fig. 8 TR7 Automatic transmission fluid level dipstick36

1669

1673

To avoid din enter ing the system ensure that the reservOir isclean externally before removing the cap. Use only new fluidtaken from a sealed container and fe-seal the container afteruse, Replace the reservoir cap immediatly after f il lingCheck/Top-up Clutch Fluid ReservoirTo prevent dirt entering the system, clean the cap andsurrounding area prior to removing the cap. Top-up the fluiduntil it is level with the tine on the side of the reservOIr.Check!Top-up Automatic Transmission FluidCheck the f luid level as follow$:-(1) Stand the car on level ground and apply the handbrakefirmly. Start the engine from cold and, with thefootbrake f irmly applied. run the engine at Idle speedfor 2 to 3 minutes. passing the se lector lever throughthe complete range of positions to ensure that the

transmission is primed.(2) Select the 'P' (Park) position and apply the handbrake.Leave the engine runn ing at Idle speed.(3) Remove the t ransmiss ion dipst ick and wipe It with aclean. n o n ~ f l u f f y cloth.(4) Replace the dipstick, ensuring that i t is pushed ful ly into

the tube and withdraw it immediately for reading.(5) Check the f lu id level on the side of the dipst ick marked'COLO' and if necessary. add fluid: see 'Lubricat ion

Recommendations'(6 l Repeat ins tructions 1 to 5 until the f luid level is correct .

DO NOT OVERFILL THE TRANSMISSIONContinued


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Where the reverse side of the dipst ick carries marks denoted'HOI', the fluid level check may be carried out with thetransmission at normal operat ing temperature. Theprocedure is as described above except that the vehicle mustbe driven for 25-30 km (15 miles) to warm the transmission.The check is then carried ou t using the 'Hor side of thedipstick.When operating at high ambient temperatures and ondir t roads, periodically inspect and remove dust and muddeposits from the slots and screen on the underside of thetorque converter housing, and from the underside of thetransmission 011 sump these, deposits can adversely affectproper cooling of the unit.

Renew Automatic Transmission Fluid and FilterBorg Warner automatic transmission (TR and Rover 3500)It is recommended that at intervals of 48,000 km (30 000miles) the oi l strainer be replaced using the fol lowingprocedure:-CAUTION: Utmost cleanliness must be maintained at allt imes during this procedure.(1) Drain the transmiss ion by removing the fi ller tube andnut from the boss.(2) Remove the oi l pan.(3) Remove the oi l s trainer and gasket.

(4) Fit a new strainer and gasket. tightening the securingbolts to a torque of 0.23 to 0.35 kgf m (1 7 to 2.5 IbfhI.(5) Clean out the oil pan and refit it using a new gasket.Tighten the securing bolts evenly to a torque of 0,69 to

1.1 kgf m (5 to 8 Ibf in).(6) Relit the liIIer tube and securing nut(7) Add transmission fluid until the level is correct on thetransmission dipstick before running the engine and

topping up the fluid level in accordance with theprocedure detai led under Check /top-up automatict ransmission f lu id in this handbook.

1674Fig. 9 va automatic transmission fluid level dipstick


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1- . , t '

Fig.10 Cooling system header tank

fiQl. 11 O..rbox oi l fi l l .rA."el plug38

2138

Check!Top-up Battery ElectrolyteExamine the level of the electrolyte In t he cel ls and lOP-UPWith distilled water If necessary The electrolyte level shouldjust cover the separators. More f requent checks should bemade dur ing hot weather and If the car 1$ subjected to longJourneys.WARNING: Never us. 8 naked flame when eX81fliningthe battery since the mix tu re of oxygen and hydrogengiven off by the battery i . dangerously explosive.

Check!Top up Cooling SystemThe pressurised cooling system incorporates a header tankwhich provides a single point for coolant filling and levelchecking.The coolant level should be malntamed at 25 mm ( l Inch)below the neck of the header tank (1)If the cooling system has been dramed the procedure forref il ling the syslem IS as follows:( t ) Remove the header tank f il le r cap(2) Set the interior healer controls 10 the maximum heal

position.(3) FIll the system unti l the coolant level is 25 mm 11 Inch)

below the neck of the header tank.(4) Refit the header tank filler cap and run the engme at

approximately 1500 rev/m in until the coolanttemperature rises sufficiently to open Ihe thermostat.(5) SlOP Ihe engine and. observing the warning below

remove the header lank fi ller cap.Continued


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(6) Top up the coolant level as necessary un1l1 I' IS 25mm(, mch) below the header tank fil ler neck(7 ) Aefn the filler cap

WARN ING: When i t is necessary to remove th epressurelfiller cap from 8 ho t engine. exercise great car.by protecting the hands against escaping steam. Slowlyturn the pressure cap anti-clockwise until resistance ofth e safety stop is felt. leave th e cap in this posit ion untilal l pressure is released. Press the cap downwardsagainst the spring to c1e.r th e safety stops. and continueturning until i t can be lifted off.

Fig. 13 Axl. oi l f i l ler/ level plug - TAB

Check/Top-up Manual Gearbox Oi lWith the vehic le standmg on level ground

( l ) Remove the oil level filler plug(2) Top up the oil unt il illS level with the bottom of the f il lerplug threads.(3) Allow surplus 011 to dram away before wiping clean andrefitting the plug.

Check!Topup Rear Axle OilW ith the vehicle standing on level ground(, ) Remove the 011 level f il ler p lug(2) Top up the oil unttl lt IS level with the bonom of the fillerplug threads(3) Allow surplus 011 to dram away before WIping clean andrefitting the plug

1676Fig. 12

1675

Axle od filler/level plug TRB and Rover 3500

39


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5

1691

Lubricate Distributor(1 ) Remove the distr ibutor cap(2) Pull off the rotor(3) Remove the p last ic anlt- fl ash cover.(4) Apply two drops of engine oil 10 the fel t pad to lubricatethe rotor cawer bearing

(5) Inject live drops of engme oil through the apertures tolubricate the centrifugal liming control(6) Apply one drop of engine 011 (0 each of the twoJubncatlOn apertures of the moving plate bearmg(7) Reverse instruction (1 ) to (3)

lubricate Accelerator Control Linkage and Pedal PivotThe accelerator control hnk.age will nOI require adjustmentsduring normal operation. To ensure complete throttle closurea degree of 'iosl mOllon' or slackness IS Incorporated Into theImkage: no a ll empt mus t be made to eliminate thisLubricate al l Locks, Hinges and Door Check Mechanisms(Not steermg lock)Check!Top-up Fluid i n Power S teer ing ReservoirStand the vehIcle on level ground(1) Wipe clean the reservoir cap and .surroundlng areas(2) Remove the reservoir cap_(3) Wipe the dipstick clean and replace It In poSition(4) Withdraw the dipstick again and note the f lUid levelagamst the marks on the dIpstIckI f topping-up is necessary:(5) Add a recommended flUid via the filler cap 10 bong thelevel Just below t he h Igh mark on the dipstick

DO NOT OVERFILL(6) Replace the reservoir cap

I

Fig. 14 Distributor lubrication

Fig. 15 Power steering reservoir1679

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MAlNTENANCE AND ADJUSTM ENTS

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Check for Engine Oil leaksCheck/adjust all Driving BeltsCheck/adjust all Driving Belts, Renew as Necessary(1) Inspect all drive belts.

(2) Renew any belt that is ellher:(a) worn or (b) damaged(3) Check dnving belt te nsi on u si ng the f ol lo wr ng as a

guide:-Alternator driver belt - 13 to 19 mm (t 10 t m).Power steering pump dr ive bel t - 19 to 25 mm (f to1 m).Air conditioning pump drive belt - 19 to 25 mm (f to1 Inl.Measured at the mid point of the l on ge st belt runbetween pulleys,

(4) Should adjustment be necessary:-Slacken, but do not remove. the appropriate Uni tmounting nuts/bolts.Slacken. but do not remove. the Unit Pivot nuts/bolts,Adjust the posit ion of the Unit to achieve correct bel ttension.RfHighlen the pivot and mounting nuts/bolts.

(5) To renew a drive belt. follow the procedure underInstruction (4). noting that other drive belts may have tobe rem ov ed tor access,

41


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Fig. 16 Ai r cleaner element

42

Check Cooling and Heater Systems for leaks and Hosesfo r security and condition.Renew Air Cleaner ElementThe a lf cleaner IS located In the engme compartment forwardof the front suspenSion lurrel, on the r ight hand side for TRmodels and the left hand side for Rover 3500To renew the air c leaner element:-(1) Remove the plpe(s) from the air cleaner case(2) TA - Remove IOUf nuts/bolts securing the a lf cleanercase to the car body

Rover 3500 - Remove the single wmg nut screw f ix ingsecuring the air c leaner case t o lIS mounting bracket

(3) Remove the screws to release the two halves of the ai rcleaner case.Carefully Ilfl al l the top half of the case 10 expose the aircleaner element

(S) Remove and discard the element, noting Its POSition forreflltlng

(6) Clean the Interior of the air cleaner case and 111 a newelemenl

(7) Reverse instructions (1) to (4)


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Check/Adjust Torque of Cylinder Head Nuts/Bolts ~ TAl(1) To avoid d is to rt ion 01 the cyl inder head It is importantthat the retaining nuts and bolts are tightened inalphabetical order, as i llustrated. to the correct torqueof 7.6kgf m (50 ft/lb).(2) When releasing the nuts and bolts. prior to removingthe cyl inder head. the sequence must be reversed.(3) When checking the torque loading of the nuts and bol tsthey should first be slackened off to overcome staticfriction and then fe-lightened to the correct torquefigure 17.

Clean Crankcase Breather Flame Trapva Engines only(1) Detach the hose from the flame trap_(2) Unscrew the flame trap_(3) Clean the f lame trap thoroughly, renew it if satisfactorycleaning is not possible or there are signs ofdeteriorat ion or damage.(4) Refit the flame trap and reconnec t the hose(5) Run the engine until it is at normal operatmg

temperature and, if necessary, adjust the idle speed,Check Crankcase Breathing and Evaporative Loss ControlSystemsC he ck H os es /P ip es an d Restrictors for 8lockage.Security an d Condition

1668

Fig.17 TR7 evlinder head fastenings

43


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Fig. 19 Crankcase breather filter

44

Renew Crankcase Breather Filterva Engines onlyThe breather f il ter is located at the rear of the left hand rockecoverTo renew the f,rter:-(1) Using the f ingers and thumb. prise the f il ler upwards torerease It from the rocker cover(2) D iscard the Idter(31 Fit a new f ilter, presSing It gently onto the rocker cove

until it cl ips Into p lace

Clean/Adjust Spark Plugs. Renew as NecessaryRenew Spark Plugs(,) Remove the leads from the spark plugs .(2) Use a special spark plug spanner when removing orrefitt ing spark plugs.(3) Use a sand/gr it air blast service uni t to clean the plugelectrodes and a stiff wire brush (0 clean the plugthreads.(4) WIpe c lean the ceramic sur face and inspect for cracks

or damage. Renew the plug If necessary.(5) Set the elec trode gap to the recommended clearance.(See General SpecifIcatIon) usmg a special spark pluggauge and settmg tool. movmg the Side electrode only

Continued


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(6) Take great care when f it ting spark plugs not to cross-thread the plug, otherwise costly damage to thecylinder head will result.

(7) Tighten .the plugs just suff icient to ensure a leakproofjOint with the cylinder head.00 NOT OVERTIGHTEN

(8) When f it ti ng the leads to the plugs ensure tha t theshrouds are f irmly seated on the plugs

It is imponant that only the specif ied spark plugs are usedfo r replacements. See General Specification,

Incorrect grades of plug may lead to piston over-heating andengine failure.

Check Security of Distr ibutor Vacuum Line andOperation of Vacuum Uni tCheck Ignition Wir ing ( including e lect ric fuel pumpwiring) fo r secur ity, f raying. chaffing and deterioration

Fig.20 Spark plug ga p sBtting tool

45


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1671

/

Check/Adjust Ignition Timing Using ElectronEquipment(1) Reier to General Specification Tumng Data for corre

settmgs(21 Use recognised proprietary eqUIpment to vertfy Ignll1

I Immg with the engme runmng. connecting thequipment followmg the manufacturers InstructIonsIf adjustment is necessary.(3) Stop the engine and slacken the dlstnbutor clamp bo

Fig. 21 TR7 crankshaft t iming marks

Fig. 22 va crankshllft timing mlll 'b46


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(4) Rotate th e dIstributor body Sl ight ly clockwise [0advance the l iming or anlldockwlse 10 retard thetlmmg

Check Fuel System fo r leaks. Pipes and U nion s fo rc ha fi ng a nd corrosion.C h ec k E xh a us t System fo r leaks lind security.

47

MAl NTENANCE AN D ADJ USTM ENTS

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Fig. 25 TRB and Rover 3500 engine setting screws

..

..

Fig. 24 TR7 Engine setting screws

2137

Check/Adjust Engine Idle SpeedsEnsure that all other factors affecting the correct running othe engine are in good order . e.g. I gnit ion timing. valvetiming, valve tappet clearance and fuel supply systemoperation,I f n e ce s sa r y have th e c or r ec t o p er a ti on o f th e electronic fueinjection control system verified by your Dealer or otheservice outlet using the special equipment required.

(1) Run th e engine until It r eac he s n or ma l operatingtemperature.

(2) Using the air bleed screw (A) on the plenum chamberadjust the engine Idle speed to be within the limitsgiven In the General Specification, Tuning Data(3) USing an approved type exhaust gas analyser. check theexhaust gas CO level.

Adjust as necessar y uSing the air bleed screw (Bl,(4 l Recheck the engine Idle speed. If adjustment ISnecessary. repeat instructions (2} to (4}.

Renew Fuel Filter(s)On TR m odels the fuel fifter(s) are located under the bodyforward of the rear axle.On Rover 3500 m odels the fuel fi lter( s) are located in theengine compartment. rearward of the left hand Ironsuspension turret.A single or twin fi lters may be fi tt ed.

Conrinued48


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(1) Depressunse th e fuel system by disconnecting the fuelpump ground lead and cranking the engine fo r severalseconds Reconnect the fuel pump earth lead.(2) Release t he f ue l p ip es from the filter. c lamping them toprevent spIllage.(3) S lacken off th e filter clamp. bracket fastenings.(4) Withdraw the filter noting Its poSition lo r refitting(5 ) Fit a ne w fitter an d reverse Instructions (2 ) to (4).

Check Condition of Fuel Filler Ca p SealR en ew O xyg en Sensorlsl and Reset S er vi ce I nt er va lCounterThe oxygen sensor is located on the exhaust manifold onTR7 models and one sensor is located on each exhaustpipe forward of the catalyst, on TR 8 and Rover 3500models.To renew the sensor(s):-(1) Disconnect the electrical lead from the sensor.(2) Unscrew the sensor from the exhaust manifold/pipe.tak ing care no t to strain the exhaust system(3) Lubflcate the threads of the ne w sensor and fit It to theexhaust manifold/pipe rlghten the sensor sufficient to

make a g as t Ig ht seal. but do not overtighten.(4) Reconnect the electrical leads to th e senSOL(5) Reset the Servtce Interval Counter uSing lh e special toolnecessary lo r this purpose Fig. 27

1"163

Fig.26 Oxygen s .nso r - TR7

2

Oxygen ..nsor - TRB lind Rover 350049


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1681

50

5Fig. 28 F ront b rake di sc and pads

Check for Oil/Fluid leaksCheck condition and secur ity of Steering Unit, Joints aGaitersInspect Brake Pads fo r wear and Discs fo r condition(1) Jack up the front of the car and support the bodystands,(2) Remove the road wheel.(3) Remove the diSC brake pads, as fol1ows:-

(a) Withdraw the two spnng pins from the brake pretaining pms.(b) Withdraw the brake pad retaining pms.(e) lift out the brake pads complete with any dampishims fitted

CAUTION: Do not depress the brake pedal whilst the paare removed(4) Check the pad condition. If the fnctlon lining has bereduced to 3mm IO.125m) or If there IS not suffiCie

matenal to provide a thickness of 3mm (0 125before the next service interval. the pads shouldrenewed(5) Check the brake dISC fo r excessive scormg and run-o(6) If new brake pads are bemg fitted p ress the calippistons into their respective bores.

(7) Clean the brake pad locatIons in Ihe caliper(8) Fit the brake pads complete With any dampmg shimfitted.(9) Fit the brake pad retaining pins to the cal iper asecure WIth spring pins

(10) Fit the f ront wheel and lower the car off the stand(11) Firmly depress the footbrake several times to correclocate the fnctlOn pads.


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Inspect Brake Linings fo r wear and Drums fo r condition(1) Jack up the rear of the car and support the body onstands(2) Remove the car road wheels.(3) Remove the feaf brak.e drum as fol lows:

(a) Release the handbrake(b) Remove the countersunk screws securing the brake

drum to the hub and withdraw t he brake drum,(4} Check the brake linings for wear. If they are excessivelyworn, damaged. or contaminated by oil or grease thelinings should be replaced. Remove any surplus oil,grease and dust f rom the linings and drum.(5) Replace the brake drum.(6) Fit the feaf road wheels and lower the car,Check/Adjust Footbrake OperationSelf-adjusting brakes are l it ted to the front and rear, Frontadjustment is hydraulically self-compensating to provide forbrake pad wear. In the rear brakes a self-adjustingmechanism incorporated in the brake-shoe handbrakelinkage maintains a fixed brake Imer/drum running clearance,self-adjustment occurs on the application of the handbrake.

{1) With the hand brake off. check the brake pedal forspongy operation and excessive travel(2) If the pedal has spongy operation. bleed the brakes see page 53

1682

1683

Fig.29 Rear brake drum

5

Fig. 30 Handbrake adjustment - TR models51


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..

Fig. 31 Handbrake adjustment - R O Y 8 ~ 3500

52

Check/Adjust Handbrake Operation(1) With the foot clear of the brake pedal. check thehandbrake for excessive travel.(2) If the handbrake travel is excessive. adjust thehandbrake as fol lows:-(3) Jack up the rear of the vehicle and support the axle onstands.(4) Release the handbrake.

TR Models(5) Disconnect the handbrake cables from the rear brakebackplate levers.(6) Apply ing f inger pressure, push the brake operatinglevers inboard to ensure that the operating levers are incontact with the brake-shoe webs.(7) Maintaining the compensator in the vertical posit ion,adjust the cable forks so that the clevis pin can beentered through them and the operating levers withoutstraining the cables. Ensure that the rear wheels do notdrag.(8) Insert and fix the clevis pins.(9) Screw in each fork and adjuster 3+ completerevolut ions and t ighten the locknuts.110) Apply alternately the hand and foot brakes severaltimes.With 251bf effort applied to the handbrake, the travel ofthe lever should be between four and seven inches.

ROVER 3500Ensure that the hydraulic system is free of a ir beforecommencing this procedure.(1) Completely slacken all handbrake cables.

Continued


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(2) Release the handbrake.(3) Press the footbrake hard three l imes(4) USing the fork adjuster take alt the slack out of the lef t

hand rear cable and operat ing lever, maintaining thecompensator at 15% to the lelt 01 vertical(5) Tighten the locknut.(6) Take the slack out of the Inner cable by pulling theadjuster rearwards and t Ighten the locknut In thisposition

(7 ) With 251bs effort applied to the handbrake. the brakesshould be hard on al the third notch WIth no retardational the first notch (if not satisfactory repeat operat ion 6)(8) Tighten both l ocknuts against the tunnel abutmentbracket.

(5) Fully depress the brake pedal and follow WIth threerapid succesSl'Je strokes Allow the pedal to returnRepeat this procedure until f lUid free from aIr bubblesIssues from the wheel cylinder

(6 ) Depress the brake pedal, close the nipple and releasethe pedal.(7) Remove t he b leed tube18) Anach the bleed tube to the opPOsIte front cahper andrepeat instructions (4 ) to (7 )

(9) Anach the bleed lUbe to the smgle nipple on the rearfight hand backplate and repeat mstruClions (4) to (7 )

(10 FIt the pressure failure sWitch to the master cylmder andconnect the wires The P D W A shuttle fined to thiSvehicle IS self-centrmg

Bleeding the Brake SystemDo not a llow the f luid level In the reservOir to fall below halfcapacity. When topping-up during the bleeding process, DONOT USE aerated f luid exhausted from the system, DO NOTbleed the system with the servo In operation (enginerunning),(1) Disconnect the wires to the pressure failure switch andremove the pressure failure SWitch from the underSide

of the master cylinder(2) Release the handbrake(3) Attach the bleed tube to the b leed nIpple of the frontcaliper farthest from the master cylinder. allowmg thef ree end of the bleed tube to hang submerged in brakeflUid In a transparent contamer14l Open t he b leed nipple (90 to 180 degrees)

1685Fig. 32 Bleeding. front bJllke


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541678Fig. 34

Fig. 33 Brake servo fittar:...;.:",;""'---.-----,

Adjusting front wheel alignment - TR models

Check Brake Servo Hoses for SEcurity and conditionRenew Brake Servo Fil ter(1) Rover 3500 models - remove the glovebox.(2) Remove the brake stop light SWitch.(3) Remove the split Pil', plain washer and clevISsecuring the servo rod to the brake pedal(4) Remove the rubber ?oot f rom the push-rod.(5) Withdraw the filter.(6) Reverse instructions (1) to (5) as applicable.

Check/Adjust Front Wheel AlignmentChecking(, ) Locale the car on level ground and posit ion the frowheels in the straight-ahead position

(2) Using wheel alignment equipment , check the frowheels for toe-in. The follOWing requirements shouldmet:-(a) Centralized steering-wheel.{b} Centralized steering-rack,(c) Front wheels paral lel to l ,59mm ( ~ i n , ) toe-in T

or paral lel to 3,1mm (i in) toe-in Rover 3500, kecondition,(d) Ball centres of both t ie-rods equal

Continued


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Adjusting{3) Slacken the outer clips on the rack gaiters,On Rover 3500 the gaiters afe oil filled.(4) Slacken the locknut and the tie-rod outer ball Joints.

(5) Shorten or extend both tie-rods by an equal amount toobtain the required setllng. ensuring that the ballcentres on both t ie-rods are equal.

(6) T ighten the locknuts at the t ie-rod outer ball jOints.(7) Tighten the gaiter clips and, Rover 3500 only. replenishany oil lost

Check Visually Brake and Clutch Hydraul ic Hoses/P ipesand Unions fo r cracks, chafing , l eaks and cor rosion .

\Adjust Front Hub Baarings End FloatJack up the front 01 the car and support the body on standsRemove the road wheel and check the hub bearings for endf loat . I f excessive, adjust as follows(1) Prise off the grease cap. withdraw the split pm andremove the nut retaining cap. where fitted.(2) Whilst spinning the hub t ighten the slotted nut to Sib Itand unscrew the nut one f lat to give 0,05mm to 0,2mm

(G.002m to 0 .008 in) hub end float.CAUTION; This torque f igure must not be exceeded,

(3) Fit a new split pin. replace the nut remaining cap.grease cap and road wheel Repeat operation onopposite hub,Continued

Fig. 35 Adjusting front wheel a l ignment- Rovar 3500

1725Fig. 36 TR Front hub

55

MAINTENANCE AND ADJUSTM ENTS

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Fig. 37 Rover 3500 Front hub

56

At major overhaul peflod or every 24.000 km (15000 mlleor 15 months), fe-pack th e front hubs with grease afollows:(1) Jack up the front of the car and remove the road whee(2) Without disturbmg the hydraulic Pipe unions, unscre

the cal iper secUring bol ts and 11ft t he cal iper from tdisc. tymg It to a convenient point to prevenlll hangmbv the attached hydrau lic pipe Note the numbershims fitled between the cal iper and the verucal Imk(3) Prise off the grease cap. withdraw the split pin an

unscrew the slotted nu l Remove the '0 ' washer apull the hub assembly f rom the stub axle(4) Wash atl grease from the hub and bearings Pack th

hub and bearmgs with grease. working II weH Into trollers and fe-assemble(5) Adjust the end float as described above(6) Re-assemble the brake caliper Unit. reflltlng any shimremoved dUring dismantling(7 ) Refit the road wheel, repeat the above operations withe opposite wheel hub and lower the car

Check Tightness of Propellor Shaft Coupling Bolts,If cor rec t these bol ts Will be tIghtened to a to rque of 4 ,7 km (341bl ttlCheck tyres for t read depth , v isua ll y fo r external cutstyre fabric, exposure of ply or cord structure. lumpbulges or uneven wearCheck that tyres conform to manufacturer's specificatio


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Check/Adjust Tyre Pressures Including Spar. Wheel.Adjust lyre pressures In accordance with therecommendations given belowAdjust the pressures whI ls t the tvres are cold. Ie bef or e aJourney As tyres warm up, thelf pressures Increase A warmtvre bled to the recommended pressure WIll be under-mflatedwhen cold

Should the vehicle be tuned to increase it s maximum speed,or be used fo r racing, consult the respective tyre companyregarding the need fo r tyres of full racing construction.Check tightness of Road Wheel FasteningsIf corre ct the se will be tightened to a torque ofTR Models - 10,3 kgf m (7 5 Ibf hIRover 3500 - 9.1 kgf m (66 lbl hI

Inflation PressuresFront RearTyre Size and Type loading Conditions kgf/cm 2 Ibflln 2 bars kgf/cm 2 Ibf/in2 ba'S

TR7 AutomatIc175/70 SA 13 Radial ply tubeless All 1 6 2 . 17 19 28 20TRl Manual185/70 SA 13 Radial ply tubeless All 1 6 2 ' 1 7 19 28 2 0JRB185/70 HR 13 Radial ply tubeless All 1 6 2 ' 1 7 19 28 2 0Rover 3500) 195/70 HR 14 1 - 4 up (no luggage) 1 8 26 1 6 18 26 18Radial ply tubeless More than 4 up 1 8 26 1 8 20 30 21

57


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Fig. 38 TR Windscreen washer reservoir

~'I,

'.

Check/Adjust Operation of atl Washers and Top-uReservoir(s)Check the level of waler In the t ranslucent windscreewasher container and. If required. replenish the containewith clean soft water. Use windshield washer solvent.During freezmg conditions It IS beneficial to fill the containwith a mixture of water and a proprietary windscreen washadditive This will assist in the dispersal 01 snow and Ice fromthe screen.Do no t add engine anti-freeze solutions to the containeas this will d isco lour the paintwork and damage wipeblades and sealing rubber.Should a screen washer je t b8come obstructed. a strandfine wire not greater than O.7mm (0 0301n) diameter can bused to clear the Jet onficeCheck function of original equipment i.e. lamps. hornswipers and all warning indicators.

Fig. 39 Rover 3500 windscreen washer reservoir58


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Check. jf necessary. renew Wiper BladesExamine each wiper blade in turn for damage WeI the glassbefore operating the wipers and check the wiper bladeoperation for smearing and adequate removal of dirt. Replaceany wiper blade thai is damaged or unsat isfactory InoperationService position of wiper ar ms and blades ~ Wet thewindscreen. Swi tch on ign it io n and wipe rs. Sto p the wiperassembly in a vertical position by switching off the ignition atan appropriate moment an d l if t the w ip er arm an d b lad e fromthe screen,Do not swi tch on the ignition until the arm is returned to itsn orma l p osit io n on the screen. If this is done the pantographarm, TR models. will jam. the motor will stall and theappropriate fuse will "blow' to prevent da mag e to the arm ormotorRenew Driver 's Wiper Blede ~ TR modelsDepress the clip and withdraw the wiper blade from the pivotblock.Renew Passenger's Wiper Blade ~ TR modelsRenew either Wiper Blade - Rover 3500Depress the dip and withdraw the w ip er blade from the a rm.Refit the wiper blades by reversing the removal procedure

1688Fig. 40 TR Driver's side wiper blade removal

Fig.41 Wiper blade removal59


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Fig. 42 TR H..dlllmp beam adjustment1720

= = = ~

o

B

--

Check/Adjust Headlamp AlignmentBeam aiming can besl be accomplished using any "frestanding" equipment such as a Lucas Beamsetter or BeaAlmer This or Similar equipment IS available at moqualified service outlets and It s use will ensure maximuroad illumination With minimum discomfort to other roausersBeam Aiming - II should be pOSSible to adjust the beamwithout removing the headlamp surround. Screw 'POSitions the beam In the hOrIZontal plane. Screw 'B' controb ea m h eigh tC le an a nd Gr.ase Battery ConnectionsEnsure that the battery to p and terminals remain c lean andry Coat the terminals With petroleum Jelly (Vaseline)prevent corrOSion If electrolyte has been sp illed. clean thaffected area WIth a cloth mOIstened WIth ammomaneutralise the aCId and prevent aCId corrosion.Ensure that the battery IS alwayS firmly clamped In pOSItIOb y t he retalnmg assembly When fltllng battery leads do nhammer the terminals to the terminal pOsts Such action mad amag e t he battery.The battery will deteflorate rapidly if le h m a dIschargecondition If t he u ni t is reduced to a lo w state o f cha rg eshoud be r echa rg ed a t the first oppOrtunity.

60Fig. 4 3 Rov.r 3500 Helldlllmp beam adjustment


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Check Condition, Security and Operation of Seats andSeat Belts.Check fastenings. which if correct will be lightened to thefo llowing torque values:-Seat belt to seat sl ide, wheel arch and mounting bracket n in UNF sel screw 4.4k9f m (321bl It)Seat Belt Warnmg Switch to Gearbox Extension - t in UNCswitch 2.0kgf m 1151bf ttlSeat Shdes to Floor - Bmm cap screw 3.Okgl m (221bf ft )Seat Slides to Seal Frame - 6mm cap screw a.9kgf m (7lbfhiCheck seat belts for signs of wear, damage or deterioration.Renew any belt that is suspect or that has been in use whenthe vehicle has been involved In an Impact accident.Referring to the driver's!owner's handbook, check thaI theseat bel t warning system is operating correct ly.Check Operation of Se8t Belt Inertia Reel MechanismTo provide t he use rs with max imum freedom during normaldriving condit ions the seat bel ts are of the inertia reel type.Hard braking or f as t cornering locks the belts immediately.The following road test must be carried ou t only undermaximum safe road conditions, Le. on a dry, straight. trafficf ree road.With the safety harness fitted t o the driver and passenger asdescribed in the drivers/owner's handbook. drive the car at 8km/h (5 m.p.h.l . Ensuring that It IS safe to do so, brakesharply

The safety harness should lock automatically. holding bothdriver and passenger securely In position.It is important when braking that the reactIOns of both driverand passenger are normal, Ie . the body must not be thrownforward in ant icipat ion, thus causing a 'snatching" action ofthe bel t which would operate the locking mechanismSnatch test - Whilst seated. fas ten the seat belt and gnpthe shoulder beh at approximately shoulder level with theopposIte hand. Pull the belt sharply In a downwards direction.the belt should lock.If the belt fails to lock on test. consu lt your Dealer or acompetent service outlet.

Check operation of el l Door, Bonnet an d luggageCompartment locksCheck operation o f W in do w ControlsRoad/Roller test. Check Brake operation and function ofall InstrumentationReport addit ional work required

61

WIRING DIAGRAMSKEY OIAGRAMS 64 TO

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69.

62

m e.n....,(2),1,11. . . . . . . . .131 $'- '_ Mol'"I'" I iud lamp Rea.y(S) lI ,!g.elfl 000< Lock $oIenood(In . . . . ......,MoUlr C1tCUlt 8dlllOnrr,g C""'1II 0001441 AIr ConchtlOn Reliti'(45) KornRela.14e) fJvI Cond!IIonong(471 ThrottJeJatt1481 Wlndac:t-.WIf/W' Pump Molor(49) Homa

(501 W J . . . . - e : - ~ N I . _ S - d l1511 WindK:t-.w,pet Mol '"(52) Low Fuell Wa",. .g Ughl(53) Low Fuel CAant 0elII'I'Unll(54) FuelGauge ra"" l..h1 Sensor(55) IgnttIOn Corl(!le) IgtlltlOn OoslnbIJlDf(571 Low 011 Pressure WI''' ' ' ' ll UghtS.. .tch(58) Hlndbrl1teWaonlng Ught S""teh1591 811kl una Flliur. WI,nlng LoghtS""lchleol He.llCl Aear WlncIowWarn,"lI LI;!>1(61) H"ledA.a,WinclowS""ICh(62) Hilled All,WIndOW Elemenl(63) 11,.dl.mp. Ma,n allm W.,nlnglIght1641 Hlldl.mp. Ml1n 8 . ,m AH(65) H,adlamp!Mlln Be.m LH(66) H,adl.mp. 0.1' Bllm - LH(67) Headlamp. 0.1' Beam LH(68) S.oa Marker lamp - AH(e91 Hon l S .oa lamp RH(701 S.oaMar_lamp LH1711 Front Sd e lamp - LHIn l Reao $Jo:IaIarnp - LH1731 HOO t Fog Lamp II H1741 ReaoFogGulOdlalTl(l-LH1751 Reao Fog Guard ump FtH

(16) Re.SIdelamp-LHIn ) Ae.SIdoIIoiI.rl

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(1021 Brake/SlopWarni"ll L.mpi S....,ch11031 O"ect>on Indic.IOt WernIng light"1041 o.'lIClIOn Indoe:alOtW.r/l,nll Ught,.,(105) A_l Ing ~ p . II H0 ( 6 ) !Wve'&IfIQ LImp LH1101/ 8,.I

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(The key 10 this wiring diagram is given on pages 62 and 63)

64

WIRING DIAGRAMS

SUPPLEMENTARY WIRING DIAGRAM - TR7 - U.S.A. MARKET

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o(The key to 'his witlng diagram IS given on pages 62 and 63)

III 114

oo

oo

-------------,,,

,'IT--H6 rI7 lI I I "' '" '"

225165

WIRING DIAGRAMSMAIN WIRING DIAGRAM - TRB - U.S.A. MARKET

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.,*-.,.,,'"" "'"

..

' ~ - lI ~ ' I ~ : ~ -' '" I ...I lJ - - I '"~ , , ~ ~ S f L -"_._.-

(The key to this wiring diagram is given on pages 62 and 63).I

..

"" ....---"'

..~ "~..---"'

66

WIRING DIAGRAMSSUPPLEMENTARY WIRING DIAGRAM - TR8 - U.S.A. MARKET

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(The key to this wiring diagram IS given on pages 62 and 63 ).. ... ,.. ", ,n,,' ,j 'JL ..f .... - ..~ 11 '" .- - . -- ....". IL ,

if ;.. .. .. ....

..

.. .. .. ,,. ,

~.. .. ..

,. - -- -- -. - -- -- .. '.--,n--- ns s67

WIRING DIAGRAMSMAIN WIRING DIAGRAM - ROVER 3500 - U.S.A. MARKET

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(The key to this wiring diagram is given on pages 62 and 63).~ - y! ~ ~ .. , '""T)--' ,. , ~ i' " a t ~ J .]JIT .,J ,,. I ". --. , . , , "', ,. '"I J . . H ' ~i -. ,. ".-J Iii' " W ~ ~i1f.,. 1.1 T- o 0 ,." ~ ". ............ "," "Ij ,, ~ ,:::: I , ,, ~ "'" I " . 0--0-- 0'rJ ' IIIIII ~ ,. :;.... .l1" ~ " " >" ""'""-" .... , ~ i:: ; ; ! :1'::" c; w " - ~ F ~ iQ, 0----"'- 0 ;; 0 ""0 '" 125l

"

,"

..'."""""..'"'"..,68

WIRING DIAGRAMS

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SUPPLEMENTARY WIRING DIAGRAM - ROVER 3600 - U.S.A. MARKET(The key to this wiring diagram is given on pages 62 and 631.

225369

GENERAL SPECIFICATIONTR7 TR8 end 3500

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ENGINEBore/StrokeCapacityCompression ratioValve TimingValve clearanceIdle SpeedsLUBRICATIONal l pump pressureall ftlter

COOLING SYSTEMCIrculatIonPressureCapThermostatFan

70

Inlet ValveExhaust ValveInlet ValveExhaust valve

4 cylinders in Ime - i ncli ned at 4590,3mm (3.56in)78mm (3.07,")1998cm J (122in J )8.0:1 nominalOpens 16 B.T.DC: Closes 56ABO COpens 56 B.RDC., Closes 16" ATOeO.2mm (0.008m) I EngmeO,5mm 10.018m) Cold750 to 900 rev/min Engine operatingtemperatureWet sump system3.5kgf/cm 2 150Ibf/in:l) nommalFull flow type. ReplaceableelementPressurized 'No Loss' Systemincorporating a separate header lankImpellor Type PumpThermostatically controlled flow1.05kgf/cm2 (1 5lbf/in 2)88C (190F)13 Blades. 356mm (14m) diSwith Viscous Couplmg

Cars fitted with air conditioning areequipped with two thermostaticallycontrolled electrically driven fans.each having 4 blades.

VB88.9mm (3 51n/71. 1mm 12.8in)3528cm3 (215In 3 )8 15 1 nominalOpens 30 8TD C; Closes 75A.BO COpens 68BBD C.. Closes 37A.iD CNot applicable - self adJuslmghydrauhc tappets are fitted.750 to 900 rev/min Engme operatingtemperatureWet sump system2.5kgf/cm l (35Ibflin l ) nominalFull flow type DisposablecartridgePressurized 'No Loss' SystemIncorporatmg a separate header lank.Impellor Type PumpThermostatically controlled flow1.05kgf/cm l (1 5lbflin1)88C 1190F)7 Blades. 406mm (16m) diawith VISCOUS Coupling

TR7

GENERAL SPECIFICATIONTRB and Rover 3500

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FUEL SYSTEMMakeITVPeAir CleanerCrankcase Ventilatton andEvaporatIVe EmISSion Control

IGNITION SYSTEMCOli Tvpe/Pnmary Winding Resistance at20C (68F)Distributor

Rotation viewed on rotorTiming StaticDynamic at IdleSparking Plugs

elECTRICALBallery -Amps capacity at 20 HRDischarge rateAlternatorSlarter MotorBulbs

Tank Forward of Rear Axle, No Reserve TapBasch/AnalogueElectrOniC Fuel InjectionReplaceable paper elementSee pages 21 to 24

6 Volt Coil With ballast resIstorIncorporated Into wIring harnessLucas 15C11.30 to 1 45 ohmsLucas 47DE4ElectroniC POlntless-Pick up air gap 38.00mm (O,Q15in)Anti-clockwise10B.T.D,C,2 A.TD.C.Champion N 12. y, or Umpart GSP 131gap O.64mm (O.025In)

12 volt Negative Earth40Lucas 17 ACA or 20 ACAl ucas 2M 100 pre-engagedSee Chart on page 77

Tank. Forward of Rear Axle, No Reserve Taplucas/DigitalElectroniC Fuelln,ectlonReplaceable paper elementSee pages 21 to 24

6 Volt COIl With ballast resistorIncorporated Into wiring harnesslucas22C12/0,9to 1.1 ohmslucas 35DE8ElectroniC POlntless-Pick up air gap 38,OOmm (O.015in)Cloc!

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MANUAL TRANSMISSIONClutch

Gearbox ratios to 1Overall ratios to 1 3.90Overall ratios 3.45Final drive ratioEngine rev/mm at 10 m.p,hEngine rev/min at 10 k.p,h.

All synchromesh, five speed gearbox216mm(8.5inldiaSingle dry plate diaphragm typeTop 4th 3rd 2nd 151 Rev0.83 1,00 1.40 2,09 3.32 3.433.243.905.46 8.1512.9513382.86 3.454.86 7.21 11.4511.83

3.9: 1 or 3A5: 1481 579 810 12091921299 359 503 7511193

All synchromesh, live speed gearbo241mm (9.5in) diaSingle dry plate diaphragm typeTop 4th 3rd 2nd 1st Rev0.83 1,00 1.40 2,09 3,32 3.42 .56 3.08 4.31 6.44 10,2310.5

3.081TR8 380 457 639 955 1517236 284 397 594 943Rover 3500 360 430 605 900 1435225 270 375 565 895

Maximum recommended road speed inintermediate gears, corresponding toengine speed of 6500 rev/min (TR7) or6000 rev/min (TRS)m.p.h.k,p,h.

Road speed at 1000 engine rev/minin top gear

80.2 53.8 33.8129 865 54.4

20.8 m.p,h. (33.5 km/hl

TRB

Rover 3500

TRBRover 3500

93.8 62.8 39.5151 101.163.699 66 42158 105 67

26.3 m.p.h. (42.4 km!h)27.8 m,p.h. (44.4 km!h)

AUTOMATIC TRANSMISSION

GENERAL SPECIFICATIONTR7 TR8 end Rover 3500Borg Warner type 65 Borg Warner type 65

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TransmiSSion conversion rangeOveral l rat ios to 1Road speed at 1000 engine rev/mm In3rd gear

TransmiSSion shift speedsSelectorShiftRoad speed m.p.h.k.p,h.

3,d 2nd 1s t Re, 3'd 2nd 1st R. .1.00 145 239 209 1.00 145 2_39 2.093.27 4.74 783 685 30B 447 7.36 645200 m.p.h. (32.3 km/hl TAB 21.9 m.p.h (352 km/h)Rover 3500 23.2 rn,.p.h (374 km/h)

Zero light Part Zero ught Partthrottle throttle throttle throttle throttle throttle1 2 0 0 1 2 0 02-1 1-2 2-3 3-2 TRB 2-1 1-2 2-3 3-230-38 8-12 , 2-16 30-40 26-37 9-13 13-17 44 max.48-61 13-19 23-26 48-64 42-59 14-21 21-27 71 max.Rover 3500 16-26 915 14-1927-44 15-25 24-32

KickdownSelectorShiftRoad speed m.p.h.k.p.h

D'-238-4461-71

D2-'65-]1105-114

D'-258-6693-106D'- I

30-3848-61

2'-238-4461-71

22-'30-384861

TABDOD 11-2 2-3 3-2 21

37-46 67-76 56-70 26-375974108-12290-11342-59

D 2 23-1 1-2 21

24-39 37-46 26-3739-63 59-74 42-59

Fmal drIVe ratIo 3.27'

Rover 4().50 73-83 51-64 28- 40 28- 40 4().50 28-403500 68-85 123-14086108 47-68 47-68 68-8847-68

3.08:173

STEERING AND SUSPENSION

GENERAL SPECIFICATIONTR7Rack and Pinion TRBRack and Pinion ROVER 3500Rack and Pinion

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} kerb condition

Steering wheel turns - lock 10 lockTurning circle - between kerbsfront wheel alignmentFront camber

castork.p.i.

Coil springs f ront and rear3,88m 129 feetl1.5mm (0 tonIn) toe In,*" negatIVe 1"3t" 1"11t" 1"

Coil sprmgs front and rear3,88m (29 feet)1.5mm (0 tonIn) Joe Inf" negatIve 1"3io 1"111-"1"

Coil sprmgs front and rear2,104m (34-l-feet)3.1mm (0 10 t In) toe In0 12 1013 tO1

Hydraulic footbrake operates a tandem master cylmder to front and rear brakesIndependently MechanIcal handbrake to rear wheels only

204 x 38mm (8 x l im)303cm 2 (46,9in 2)486cm 2 (754m2)

BRAKESFront brakes- caliper disc

- l in ing area- swep t areaRear brakes- drum - TA7 auto- Immgarea- swep t areaRear brakes- drum - other models- l in ing area- swept area

WHEELS AND TYRESDIMENSIONSLengthWidthHeIght unladenWheelbaseFront trackRear track74

248mm (9 751n) d,a107cm 2 (16.6In2)1184cm2 ( l235m 2 )

229 x 445mm (9390cm2 (60 41n2)638cm2 (98 9m 2)330mm (13m) 5 tJ4173mm(1643In)1681 mm (66 21n)1258mm (49 51n)2160mm (85m)1409mm (55 51n)1404mm (55 31n)

248mm (9 75m) dla154 8cm 2 (24 01n 2 )1274cm2 (197 5m2 )

x l t ln)229 x 445mm (9 x 1tln)390cm2 (604m 2 )638cm2 (989m 2 )330mm (13m) 5tJ4203mm (165 4ml1681mm (66 2m)1258mm (49 5m)2160mm (85In)1409mm (55 51n)1404mm (553m)

258mm (10.125In) d,a154 8cm2 (24,0In2)1370cm2 (2124In2)

229 x 57mm (9 x 2iln)500cm 2 (77.5in2)820 2cm2 (137 ll n 2)355mm (l4In) 6J4698mm (18501n)1768mm (6961n)1382mm (54 41n)2215mm(l10Bln)1500mm (59. l in)1500mm (59 l in)

Tft7WEIGHTS 'approximate'

COUPEManual gearbox Automatic

GENERAL SPECIFICATIONCONVERTIBLE

Manual gearbox Automatic

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Show-oom - minimumUnladen - maximumGross vehicleMaxImum al(le load - I r on t

- r ea rTOWIng capacity - braked tra,ler

1048kg (231 Olbs)1138kg (2509lbs)1340kg f2954lbsl715kg{1576lbsl665kg (l466Ibs)1340kg (2954Ibs)

lQ16kg f224Qlbsi11061

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76

Approximate CllpaciliasComponent Conditions Metric U,SA Imperial Temperature Range Service SA.E. ViscosityHIres pints pints Classification SpecificationEng,ne Engmll, Drain Above 14Q F1l0C) SAE lOW/50, SAE 20W/50and Rehll m '0 " '0 SAE lOW/40, SAE 2DW!4QTAe " 9.3 7.75Rover 3500 ,., 10.2 '5 -5 Q F to 50F (-20 'C AP' SAE 10W!30,SAE 10W!4Q.Extra for 0,1 Filter m 0.5 12 1O to IO'C) SE SAE lOW/50TAe 05 12 1ORover 3500 05 12 1O Below 14'F l - lO'el SAE 5W!20. SAE 5W!30Gearbox Gearbox from Dry Above 30'F (OCI5 speed 1 5 33 2,75Aeal Axle from Dry Below 30 Q FmOe! API-GL4 SAE 75WHypo,dHypoid TR7 Auto 1.3 27 2,25TAl 5 speed 11 " 2.0TAB and Rover 3500 '. 5 33 2TAutomatic With oil TAT " ", 95T,lIrlsmiss,on cooler TR8ar'ld Rover.3500 '0 "9 '" A" ATFtypeGPOW(!' steerIng 15 32 27TR8 and Rover 3500 NLGI2Steenng R a c ~ TRT MultipurposeA" GrBaseHubs and Chassis A" MultipurposeGrease POlOts GreaseB r a ~ e and OOT3 (FMVSS 116) and SAE SpecificationClutch Fluid A" J 1703d MlOimum boiling PPlOt500 Q F (260ClWindscreen Windscreen Washer A o t i - f r e e ~ e Flu,d(Propnetary Brands)WasherAnllfreeze Cooling System TR? " 160 13.4 Permanent type ethylene glycol base w,th suitable onh,bitorTAe 10.9 23.0 192 lor mIxed metal sYstems. 50% solution.Rover 3500 11.0 23.4 195GallonsFuel Tank TAJ andTA8 54.5 14.4 120 91 Octane - Use unleaded Gasol ine onfyAover 3500 659 '" 18.8

BULB CHART

GENERAL SPECIFICATION

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UNIPAAT ROVER/TRIUMPHTR MODELS ROVER 3500 WATIAGE PART NO. PART NO.HeadJamps 50/40 514578

Headlamps I Outer 60/37 5 DRe 1862Inner 50 DRC1861Flasher. stop, reverse lamps Flasher, stop, reverse and rear fog guard lamps 21 GLB 382 264591/502379No. plate Illumination. tail lamps Front side, door open guard. boot lamps 5 GLB 207 10211/57591Warning lights Instrument i llumination. handbrake warning 1 2 GLB 286 DRG 1186/UKC2412Marker lamps 3 GLB 504 518414

Tail lamps 4 GLB 233 570822No_ plate Illumination, interior, map, glovebox 6 GLB 254 311240Hazard warning bulb 15 GLB 280

Front Side lamps Fibre optiC light source 5 GLB 989 50689Underbonnet and brake failure warning light 5 GLB 501 570829Cigar lighter Illumination 22 GLB 643 530054Clock illumination 22 GLB 987 232590

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GENERAL SPECIFICATIONAccelerator Control LinkageAdsorption CanisterAir Cleaner Element

402142

- Coolant Temperature Sensor- Electronic Cont rol Unit- Engine Speed

15121

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Automatic Transmission

BatteryBleeding the Brake SystemBrake F lu id Reservo irBrake Pads and LiningsBrake ServoBreather FilterBulb Chart

CapacitiesCatalytic ConverterClutch Flu id Reservoi rCooling SystemCrankcase BreathingCylinder Head Fastenings

DistributorDriving Bel ts

Electronic Fuel Injection- Ai r Flow Meter-Checking- Cold Starting- Components

78

.36 and 37

38 and 605335.50 and 51544477

762536382143

40 and 4541

122695

- Extra Ai r Valve- Fue l Pump- Lambda (Oxygen) Sensor(s)- Maintenance- Overun Valve- Throttle Switches

Emission Control SystemsEngine Oit- FilterEvaporative Loss Control SystemExhaust Gas Recirculation (E.G.R.I SystemFoot Brake Operation and AdjustmentFront Hub Bearing End FloatFuelGearbox Oi lGearbox Oil

Handbrake Operation and AdjustmentHeadlamp AlignmentIdle SpeedsIgnition- Distributor-T im ing

-Wi r ing

1516 and 499 and 26

114

333521205155

3 and 763970526048

40 and 455 and 46

45

INDEX

Introduction 2 Seats and Seat Belts 61Lubricants 76 Steering Rack and Pinion 33Spark Plugs 44

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Lubrication 32Maintenance Summary 27 Tyre Pressures 57Power Steering 40Propeller Shaft Coupling Bolts 56 Washers and Reservoirs 58Reaf Axle Oil 39 Wheel Alignment 54Repl:;lcement Brake Pads and Shoes 32 Wiper Blades 59Road Wheel Fastenings 57 Wiring Diagrams .62

79

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80 UTtfO IN U.S...... SIMAX, N.Y_. I.M H80

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