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Hints and Tips: Rover engines
Diesel L-series
Rover 600 - after fully filling with oil, engine revs invoulantory upon startup
Cause:
Oil fill procedure was incorrectly followed which meant oil entering the crankcase breathing system. If oil is poured into the engine too quickly it is a possibility that some oil will enter the breathing system. Then when the engine is started the oil in the system may cause the car to rev briefly beyond normal range. Ensure that oil is pour into the engine at a reasonable rate.
Rover 220, 420, 620 Diesel L series engines - Oil leak from engine oil cooler hose
Oil leak from oil cooler hose as crimped joint cutting into hose.
Action:
Replace hoses with improved parts(should be covered under warranty).
Rover 220, 420, 620. Rover 25, Rover 45, L series diesel engines.
Problem:
While carrying out certain repairs on the car, oil contamination around the camshaft and fuel injection pump 
drive gears may lead you to think that the oil seals have gone.
Cause:
Likely that the oil has originated from the drive gears themselves. Oil is from natural bleed and excess oil 
left behind from the gear manufacturing process.
Action:
Inspect closely to ensure that the oil seals have not been leaking. Clean the oil away with suitable 
solvent(excluding timing belts!!)
Rover 218/418 turbo diesel(DUX engine).
Problem:
Oil leaking from between the oil pump drive pinion and the crankshaft.
Cause:
This problem is with the pinion key way in relation to the crank shoulder.
Action:
Investigate the oil leak by removing the auxiliary drive belt pulley. If oil is found to be leaking from the crank 
then a modified pinion with a spacer should be fitted.
Rover 218/418 DUX engine
Affects all normally aspirated diesel engines.
Problem:
Five thicknesses of head gasket are now available for fitting
Cause:
These new gaskets improve emissions.
Rover metro diesel
Problem:
Oil or coolant may be leaking from cylinder head to block joint.
Cause:
Fluid deposits around where the engine is assembled. When engine temperature increases surplus fluid 
can bleed from screw heads and deposit itself along the head joint.
Action:
Clean off excess fluid.
T-Series engine
Models
820-T16, 220/420, 620 Turbo
Problem:
Excessive oil consumption/pinking - valve stem finish. Likely to occur on low mileage vehicles. Pinking 
likely to occur while car is warming up and at low speed acceleration.
Cause:
The finish is poor on the inlet valve stem. This means there will be wear on the valve stem lip.
Action:
Replace inlet valves with new part. Replace the inlet valve stem seals with new seals.
If the engine has been suffering from pinking decoke the combustion chamber and piston crown before 
rebuild. If the car has been misfiring, remove all valves, replace inlet valves. Also remove the exhaust 
valves and clean stems of carbon. Clean all exhaust valve guides. Replace all valve seals.
Excessive oil consumption - incorrect valve stem seal.
Range:
820, 220/420 - T16 versions
Problems:
If you have replaced the seals of replaced the cylinder head the oil seals for the valve stems do not fit 
correctly. Old and new type seals are not interchangeable.
Action:
Ensure new correct seals are used when replacing.
Oil leaks from rear of engine - incorrect diagnosis.
Oil leaks from the rear of the engine can be mis-diagnosed and incorrectly repaired.
Range:
T - series engines : 220, 420, 620 turbo, 820 
Action:
If engine oil has not been changed since new then an ultra violet light can be used to confirm an engine 
oil leak. Engine oil has dye added at factory (gear box oil has no dye added).
1, Does oil appear between back plate and sump or back plate and gearbox?
    Back plate and sump:
Start investigating from top of engine. Check cam cover seals, rear cam seals, and cylinder head gasket. 
Replace if any seem suspect. If all are ok then check the sump and sump gasket interface.
2. Oil leak visible between back plate and gearbox.
Look for external gearbox leaks i.e. drive shaft seals, speedo cable/transducer, casing joints. If all are 
fine then the gearbox may need removing so you can check the input seal.
Loss of power/misfire during warm-up period.
Soon after start the car, it develops a misfire. After a while, when the car has warmed, the misfire is no 
longer apparent and is fine until the next cold start. This mainly affects cars that are only used for short 
journeys.
Models:
T series engines : 220/420, New 420, 620 turbo, 820
Cause:
Carbon deposits on the exhaust valves mean they stick open and cause loss of compression. Cause 
can be short journeys that don't allow the engine to warm, and engine never reaching higher RPM.
Action:
Replace the valves with newer 'carbon break' valves(part number LGH101000). These are fitted to vehicles 
after '96. 
K-series engine.
Loss of power/misfire - valve sticking
Range:
111,114, New 214/216/200 Vi, New 414/416, metro 1.1/1.4 XW 214/414
Problem:
Loss of power and misfire is likely to occur while the engine is warming up but can also occur when it's 
warm and while the engine is at various RPM. Likely to occur on cars that have done more the 5000 miles.
Cause:
Journeys that don't allow the car to warm up to optimum operating temperature and shorter journeys that 
never allow the car to reach high RPM are a prime cause. The valve stems particularly the exhaust ones 
become clogged with carbon deposits. 
Action:
New carbon break valves should be fitted to replace the old. These new valve stems have a slight narrowing 
to allow the small amount of carbon deposit which occur naturally to form without fouling.
Idle speed remains high - throttle pin
Range:
214, Metro
Problem:
Engine speed remains high when car comes to a halt and fails to return to normal.
Cause:
Lack of lubrication in the rubber dust boot means the throttle control pin sticks.
Action:
Apply a tiny amount of rubber grease to inner lip of seal while the rubber dust boot is removed. Make sure 
the pin is clean and free from corrosion.
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LIST OF COMMON FAILURES

Doubting your own analysis work? Take a look at our rogues gallery of common failures

Fault codes for Bosch and Simtec Mpi main engine ECU

ALFA  ROMEO
156 Tiptronic gearbox actuator problems *Failure on early type Motronic ECUs due to on board amplifier failure

AUDI

Audi A4 throttle body failing
Audi A4 & A6 96-01 ABS Pumps commonly failing
Audi Quattro ABS Pump - 0 265 220 408

Audi TT dashboard failing
Bosch 0281 diesel ECU prone to causing lack of turbo boost
Audi Zexel aircon compressor failing

Detailed list of Audi faults

Audi idle speed problems

Audi strange vibrations and noises

Audi A4 fault codes

*2.6 and 2.8 litre cars with twin cat system, passenger side cat failing (probably due to thermal shocking from puddles)

BMW

Light control module on new shape 3 Series failing leaving only 1 headlight
BMW Diesel EDC pump problems
Faults on BMW engine management
Faults on BMW ABS systems
Faults on BMW wiring harnesses
Faults on BMW sensors
Faults on BMW electrical systems auxiliary equipment
Faults on BMW starter motors Faults on BMW alternators *Distributorless systems are suffering failed coil packs. This burns out drive components on the ECU. It is essential to replace offending coil pack before replacing ECU! *Failure on early Bosch ABS Controllers
*Failure on Teves type ABS pump/modulator/Controller, 93 on
*Failure on early type Motronic ECUs due to on board amplifier failure

CITROEN

Citroen Saxo electronic power steering failing
Citroen Saxo 1.1 96-03 SPi throttle body failing
Citroen ZX 1.1 96-97 SPi throttle body failing
Citroen Berlingo 1.1 96-02 SPi throttle body failing
Citroen Saxo ECU's failing - IAW8P80, IAW8P81 Common rail diesel technology - new problems
Sagem SL96 ecu - coil pack failing leading to damage to ecu. Citroen Common Rail HDi in tank fuel pumps failing Citroen Airflow meters prone to throttle potentiometer problems. *Xantia ABS ECU failure. This may be caused by over voltage. ABS light comes on and stays on. Citroen Synergy Bendix Anti Lock Braking (ABS) system is now a part of BBA-reman's remanufactured range Citroen Xsara ABS ECU fault codes Citroen Saxo ABS ECU fault codes Xantia 1.8 Cat failure Marelli IAW8P series of ECUs causing erratic tickover and stalling. BBA always supply latest generation software to rectify problems

FORD

Ford Probe 4 Cylinder Distributor Failing - T6T57871
Ford Probe 6 Cylinder Distributor Failing - T0T57071
Ford Probe distributors failing...BBA now supply new and reman
Ford Scorpio 95 ABS system failing due to faulty controller
Mondeo Bendix Mecatronic ABS system
Bosch 0281 diesel ECU prone to causing lack of turbo boost

Detailed hints and tips for Fords

Information on Ford ABS systems

Ford Probe air mass meters
Ford Galaxy suffering air con compressor failures
*Early Granada 88 on ABS Pump/Modulator problems
*Later Scorpio ABS Controllers 95 on
*Many EEC IV generation ECUs suffering driveability problems . BBA always supply latest generation software to rectify problems
*Ford Probe suffers from immobiliser problems, taking out ignition module on distributor. Occasionally leads to ECU failure.
*Any Ford Cat prior to 95 (possibly just due to shear volume of Fords & poor servicing)

FIAT

Punto/Brava/Bravo power steering suffering motor problems             
Fiat Seicento Citymatic Clutch Actuator failing
Fiat Punto 1996 onwards ECU failing
Fiat Ulysees Bendix Anti Lock Braking (ABS) system is now a part of BBA-reman's remanufactured range Fiat Marea ABS have a Lucas ABS system and are beginning to fail.

HONDA

Honda Civic 1.5 distributor TD40U
Honda Civic 1.6 distributor TD42U
Honda Accord distributor TD31U
Honda Accord distributor TD58U
Honda Concerto distributor TD02U
Honda Accord/Civic/Legend distributors failing...BBA now supply
Honda Accord/Concerto/Legend/Prelude ABS pumps/Modulators
Honda Diesel EDC pump problem

*Common 4 wheel steer ECU failures
Honda Civic ABS ECU fault codes

Honda ALB2 ABS computer fault codes

Honda ALB2 ABS pump, testing & bleeding


HYUNDA

Mitsubishi type idle control valves failing
*Early type KEFICO ECU failures on S coupes
*Lantra 1.8 Cats breaking up

ISUZU

Isuzu diesel ECUs

JAGUAR

Jaguar XK8 and XJ8 ABS + ETCS failing
Jaguar XK8 Throttle Bodies failing
Jaguar XJ6 ABS Controller
*Early Bosch type separate controller "0 265" type failing
*Early Teves type separate controller failing
*Early ECUs prone to rusting on pins

LANDROVER

Air suspension modulator for Classic and Vogue SE
Range Rover booster block problem
Range Rover 4.6 HSE ABS pumps failing
Range Rover ABS pump problems
Land Rover Discovery BeCM failing Land Rover Freelander SRS controller problems Freelander L series diesel ECU problems after jump starting WABCO ABS system failure as fitted on Discovery and FreeLander LandRover ABS ECU fault codes *Common ECU and Air Flow Meter problems resulting erratic tickover and poor starting *ABS Pumps and Booster Blocks.Often caused by a pump relay sticking on, eventually wrecking pump and making brakes almost impossible to use. *Twin down pipe Cats on all 3.5 and 3.9 Models *BECM body control and auxiliary controller. Can cause incorrect operation of Suspension, Lights, Wipers etc

MAZDA

Mazda 626 2.5l 6 cylinder distributors failing
Mazda Sumitomo ABS system as fitted to Mazdas since 1987

MERCEDES

Mercedes A Class electric hydraulic power steering failing
Mercedes A Class combined air mass meter and ECU
Merecedes A Class air flow meters failing
Mercedes 111 16v engine throttle body failing
Mercedes C and E Class ABS pump failing
Mercedes C/E/S Class, CLK/SLK throttle bodies failing
Mercedes CL and SL class soft top convertible roof controllers failing

Mercedes 280/300/350 ECU
Mercedes 300/AMG 300 ECU
Mercedes CLK 320, SL 280, SL 320 ECU
Mercedes VDO ecu systems being damaged by harness overheating

Mercedes Seimens and Bosch ignition modules failing

Mercedes E Class ABS ECU fault codes

*Common Ignition ECU failures
*C Class & E Class Cats rattling from 93 on

MITSUBISHI

Mitsubishi SpaceWagon distributors failing...BBA now supply
Mitsubishi Gdi throttle actuator

Mitsubishi Shogun 3.0 litre V6 ECU failing
Mitsubishi GTO ECU failing
Common ECU failures resulting no spark or fuel
Mitsubishi type idle control valves failing

Mitsubishi FTO ECU controlled alternators failing

Mitsubishi Carisma ABS ECU fault codes

Mitsubishi V6 petrol engine throttle position sensor failing
Mitsubishi GDI engines injector drivers failing
*Distributors failing on all models

NISSAN

Nissan Micra throttle bodies are a now a big request at BBA.
Nissan Micra Bosch type throttle bodies fitted to newer Micra's failing.
Nissan Micra distributors failing...BBA now supply reman units
Nissan Sunny / Primera throttle bodies commonly failing
Nissan Airflow meters prone to throttle potentiometer problems. Nissan Almera and Primera ABS ECU fault codes *Micra and Primera ECUs
* Maxima V6 ECU failing due to water ingress. Heater matrix above ECU must be replaced!

PEUGEOT

Peugeot 307 electric hydraulic power steering failing
Peugeot 106 1.1 96- SPi throttle body failing
Peugeot 306 1.1 96-97 SPi throttle body failing
Peugeot Partner 1.1 SPi throttle body failing
Peugeot 106 and 206 ECU's failing - IAW8P80, IAW8P81 Common rail diesel technology - new problems Sagem SL96 ecu - coil pack failing leading to damage to ecu. Peugeot Common Rail HDi in tank fuel pumps failing Peugeot Airflow meters prone to throttle potentiometer problems
Peugeot 405/406/806 Bendix Anti Lock Braking(ABS) system is now a part of BBA-reman's remanufactured range Detailed list on Peugeot faults Peugeot 106, 306, 406, 605 ABS ECU fault codes Peugeot 106 electronic power steering failing *Marelli IAW8P series of ECUs causing erratic tickover and stalling. BBA always supply latest generation software to rectify problems *106 Cat failure due to rusting *406 Cat breakup

PORSCHE

*Common Ignition ECU failures

RANGE ROVER

Air suspension modulator for Classic and Vogue SE
Range Rover booster block problem
Range Rover 4.6 HSE ABS pumps failing
Range Rover ABS pump problems
Land Rover Discovery BeCM failing Land Rover Freelander SRS controller problems Freelander L series diesel ECU problems after jump starting WABCO ABS system failure as fitted on Discovery and FreeLander LandRover ABS ECU fault codes *Common ECU and Air Flow Meter problems resulting erratic tickover and poor starting *ABS Pumps and Booster Blocks.Often caused by a pump relay sticking on, eventually wrecking pump and making brakes almost impossible to use. *Twin down pipe Cats on all 3.5 and 3.9 Models *BECM body control and auxiliary controller. Can cause incorrect operation of Suspension, Lights, Wipers etc

RENAULT

Renault Clio electric hydraulic power steering failing.
Renault Megane (new shape) electronic power steering pump failing
Renault Megane Bosch 5.5 ABS vulnerable to water.
Renault Kangoo van air flow meter failing
*Espace ECUs *Auto Gearbox Controllers on Clios and 21's *Laguna Cats

ROVER

Rover 600 distributors failing - TD58U
Rover 600 distributors failing - TD31U
Rover 216 distributors failing - TD02U
Body Control module failing on Rover Mini/100/200/400/25/45/MGF Rover 200 / 400 / 600 diesel ECU prone to failure after jump starting Rover 600 ABS Pumps/Modulators 90 on Rover Diesel EDC pump problems Rover 600 and 800 ABS ECU fault codes Rover engine problems Rover engine management problems Rover distributors failing. BBA supply new and reman. *All Motorola MEMMS units *Cats on Rover 214s, all models, breaking up

SAAB

Tiptronic gearbox actuators on 900 blowing fuses
*Bosch LH Jetronic fuel injection ECU 
*9000 ABS/TRACS Control Computer failure

SEAT

Seat Ibiza electric hydraulic power steering failing
Seat Ibiza 1.4 throttle body failing
Seat Ibiza and Cordoba ABS ECU fault codes
*Cats on 1.4 Ibiza

SKODA

Skoda Felicia 1.3 throttle body failing

SUZUKI

Mitsubishi type idle control valves failing
*ECUs on Vitaras and Swifts
*Cats on Vitaras

TOYOTA

Toyota Avensis power steering failing
*Cats on Previas. Flexi connection rattling.

VAUXHALL(GM)

Corsa power steering pump failure
Astra power steering pump failure
Vauxhall Zafira Electric Power Steering Pump failure
Vauxhall Corsa Throttle Bodies
Vauxhall Astra, Corsa air flow meters failing
Vauxhall Astra 1.7 td Isuzu engine ECU failing
Vauxhall Astra 1.6 8v 1999 onwards ECU problems Omega and Vectra ABS units prone to faults
Vauxhall fault codes for GM Multec SPi *Bosch MOTRONIC ECU common failure *ABS Pump Modulators/Controllers Cavaliers & Calibras Vauxhall Vectra Kelsey Hayes Pumps/Controllers/Modulators a very common failure *Omega and Vectra Cats, 8v and 16v, rusting at join of twin downpipes

VW

VW Polo electric hydraulic power steering failing
VW Polo 1.4 throttle body failing
VW Golf/Passat/Scirocco Teves IV ABS pump failing due to open circuit solenoid and leaking fluid
VW Lupo/Polo/Golf/Bora/Passat throttle body failing
Teves 20 ABS units fitted on a range of VW's failing
Bosch 0281 diesel ECU prone to causing lack of turbo boost

VW Zexel aircon compressor failing

VW Sharran suffering air con compressor failures
Detailed list of Volkswagen faults
Volkswagen idle speed problems

Passat 96-01 ABS pumps commonly failing
*Digifant II ECU, typically in winter. Can be weak battery or engine earth strap removed without disconnecting battery.
*Gti Cats, Especially Passat and Golf 1.8 and 2.0 litre
*1.4 Polo Cats

VOLVO

Volvo 850 93-95 Teves IV ABS pump failing due to open circuit solenoid and leaking fluid
Volvo 850 '95 onwards, Teves 20 ABS unit failures
Volvo 99- Marrelli electronic throttle system

*Common ECU failures on early type "0 280" early type fuel injection ECUs
*Early type ABS Controller Volvo 440/460 91 on

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