IMPORTANT SAFETY AND SETUP NOTICE

This installation involves the crankshaft pulley, rotating engine components and the primary engine-speed signal used by the ECU. It is intended for qualified mechanics and experienced installers.

DO NOT START THE ENGINE until the trigger wheel and sensor have been installed and mechanically verified, and an experienced Haltech specialist has configured the trigger system, confirmed correct VR sensor polarity, verified a stable engine-speed signal while cranking and checked base ignition timing with a timing light.

Incorrect trigger-wheel positioning, excessive runout, incorrect sensor clearance, reversed VR polarity or unverified ignition timing may cause a no-start condition, unstable timing or serious engine damage.

Fastener sizes, pulley arrangements and torque specifications can vary between Rover V8 engines and front-cover configurations. Always consult the correct workshop manual for the specific engine and vehicle. Where this guide conflicts with the applicable workshop manual, stop and contact Regal Rover Classics before proceeding.

Kit Contents

Confirm that the following parts are present before beginning:

• 36-1 steel crank trigger wheel
• Variable-reluctance (VR) crank sensor
• Adjustable crank-sensor mounting bracket
• Trigger-wheel spacer
• Threaded retaining ring
• Trigger-wheel mounting bolts and supplied hardware

The customer installs these components onto the engine and crank pulley. The trigger wheel is not drilled, dowelled or welded to the crank pulley.

Required Video Before Installation

Before beginning the installation, watch Nigel’s MegaSquirt V8 crank-trigger fitting video in full. It demonstrates how to transfer the sensor-centreline reference and identify tooth 5 from the missing-tooth gap:

https://www.youtube.com/watch?v=0GHldV2aKg4

Do not proceed with marking, removing or assembling the crank pulley until you understand the tooth-counting method shown in the video. The video explains the alignment method, while this Regal Rover Classics guide takes precedence wherever the supplied RRC hardware or installation details differ.

Preparation

• Park the vehicle securely, select Park or Neutral and apply the parking brake.
• Disconnect the vehicle battery.
• Remove the cooling fan, auxiliary belts and any other components required to safely access and remove the crankshaft pulley.
• Use suitable personal protective equipment.
• Keep hands, tools and wiring clear of rotating components.
• Confirm that you have the correct workshop manual for the engine and front-cover configuration.

Establish Cylinder 1 TDC

The trigger-wheel position must be established with cylinder 1 at Top Dead Centre (TDC) on its compression stroke.

• Rotate the engine by hand in its normal direction of rotation.
• Bring cylinder 1 to TDC on the compression stroke.
• Confirm the compression stroke by checking that both cylinder 1 valves are closed.
• Align the crank-pulley TDC mark with the timing-cover pointer.
• If the accuracy of the existing timing marks is uncertain, establish true TDC using an appropriate mechanical method before continuing.

Figure 1. Crank-pulley TDC mark aligned with the timing-cover pointer. Confirm cylinder 1 is on its compression stroke.

Temporarily Position the Sensor

Using the existing timing-cover mounting holes, temporarily install the RRC sensor bracket and VR sensor.

• The bracket uses existing engine mounting holes. Bracket fasteners are not supplied.
• Do not permanently tighten the bracket at this stage.
• Position the sensor so its centreline is perpendicular to the trigger-wheel teeth.
• Ensure the bracket is rigid and does not contact the pulley, belts or any other rotating component.

Figure 2. Temporary bracket and VR sensor position used to establish the sensor centreline.

Mark the Sensor Centreline

With cylinder 1 still exactly at TDC, mark the loose trigger wheel directly in line with the centre of the VR sensor.

• Use a fine permanent marker or scribe to make a clear reference mark.
• Make the mark at the exact centreline of the sensor, not at either edge of the sensor body.
• Do not move the crankshaft while making or checking this reference mark.

Figure 3. Mark the trigger wheel directly opposite the centre of the VR sensor while the crank remains at TDC.

Remove the Crank Pulley

The mark made in the previous section records the VR sensor centreline while cylinder 1 is at TDC. It is only a reference mark. The trigger wheel cannot be fitted with the crank pulley installed on the engine.

• Before removing anything, confirm the sensor-centreline mark is clear and permanent.
• Remove the temporarily fitted VR sensor and bracket if required for access.
• Remove the auxiliary belts, cooling fan and surrounding components required to access the crank pulley.
• Remove the crankshaft pulley fastener and withdraw the crank pulley in accordance with the correct workshop manual.
• Do not remove, drill or alter the factory locating dowel fitted to the crank pulley.
• Protect the TDC sensor-centreline mark throughout removal and bench assembly.

Figure 4. This is the VR sensor-centreline reference mark made while the crank pulley was still installed and cylinder 1 was at TDC. It does not show final tooth-5 alignment.

Prepare the Crank Pulley on the Bench

• Place the crank pulley face-down on a clean, protected workbench, with the grooved/front face supported so it cannot be damaged.
• Remove the original bolts from the rear of the crank pulley.
• Remove the original rear dust shield. The dust shield is not reused because the RRC trigger-wheel assembly occupies this position.
• Clean the pulley mating surfaces and bolt locations. Remove dirt, rust, oil and old threadlocker without damaging the pulley or the factory locating dowel.
• Check that the supplied spacer, trigger wheel, threaded retaining ring and mounting bolts are clean and undamaged.

Fit and Align the Trigger Wheel

Install the RRC trigger-wheel assembly on the bench using the supplied spacer, 36-1 trigger wheel, mounting bolts and threaded retaining ring.

• Position the supplied spacer and trigger wheel in place of the removed rear dust shield.
• Fit the supplied bolts through the assembly and engage them into the supplied threaded retaining ring. Do not fully tighten them yet.
• Use the sensor-centreline mark transferred from the on-engine TDC setup to establish the wheel position.

TOOTH-5 ALIGNMENT

The missing-tooth gap is the starting reference. VIEWING THE ENGINE FROM THE FRONT, move clockwise from the missing-tooth gap. The first complete tooth immediately after the gap is TOOTH 1. Continue counting each complete tooth clockwise: TOOTH 2, TOOTH 3, TOOTH 4 and TOOTH 5. Do not count the missing-tooth gap as a tooth.

Clearly mark TOOTH 5 before positioning the wheel. Then rotate the loose trigger wheel until the marked fifth tooth aligns exactly with the sensor-centreline reference mark.

Because the pulley is face-down and you are looking at it from the rear during bench assembly, the apparent direction is reversed. Confirm the finished position using the front-view clockwise rule. Do not count the missing-tooth gap as a tooth.

• Once the position is confirmed, apply a small amount of medium-strength threadlocker to the supplied trigger-wheel bolt threads.
• Tighten the bolts progressively and evenly in a criss-cross pattern.
• Confirm the trigger wheel remains centred and tooth 5 remains aligned with the reference mark as the bolts are tightened.
• Do not drill, dowel or weld the trigger wheel to the crank pulley.

Refit the Crank Pulley

• Ensure the crankshaft nose, pulley bore and mating surfaces are clean and undamaged.
• Refit the completed crank-pulley and trigger-wheel assembly in accordance with the correct workshop manual.
• Ensure the factory locating dowel engages correctly.
• Tighten the crankshaft pulley fastener and any existing engine fasteners to the manufacturer’s specification for the specific engine and front-cover configuration.

Do not use a universal torque figure. Rover V8 pulley and front-cover arrangements vary.

Set the VR Sensor Air Gap

• Adjust the bracket so the VR sensor is centred on and perpendicular to the trigger-wheel teeth.
• Set the air gap between the sensor tip and the highest point of a trigger-wheel tooth to 0.5–1.0 mm.
• Measure the gap with a suitable non-magnetic feeler gauge.
• Rotate the engine by hand and check the gap at several points around the trigger wheel.
• Tighten the existing bracket fasteners to the workshop-manual specification for the engine and front cover.
• Recheck the air gap after tightening because bracket movement can alter the clearance.

Figure 5. Final VR sensor alignment. The sensor must be rigid, perpendicular to the teeth and set to a 0.5–1.0 mm air gap.

Check Trigger-Wheel Runout

Measure trigger-wheel runout with a dial indicator while rotating the engine slowly by hand.

• Maximum recommended runout: 0.25 mm.
• If runout exceeds 0.25 mm, stop and correct the wheel centring, spacer seating, retaining-ring position or contamination between mating surfaces.
• Do not attempt to compensate for excessive runout by increasing the sensor air gap.

Mechanical Verification

Before reconnecting the battery or cranking the engine:

• Rotate the crankshaft by hand through at least two complete revolutions.
• Confirm there is no contact between the trigger wheel, VR sensor, bracket, pulley, belts or surrounding components.
• Confirm tooth 5 still aligns with the sensor centreline when cylinder 1 returns to TDC on its compression stroke.
• Recheck the sensor air gap around the full trigger wheel.
• Confirm all fasteners are secure and all wiring is clear of heat, sharp edges and rotating components.

Haltech Setup Before Starting

The physical position of the trigger wheel is only the mechanical starting point. The ECU must still be correctly configured and verified by an experienced Haltech specialist before the engine is allowed to start.

Before startup, the Haltech specialist must:

• Configure the crank trigger as a 36-1 pattern.
• Configure the applicable trigger edge and filtering settings.
• Confirm correct VR sensor wiring and polarity.
• Confirm a stable engine-speed and trigger signal while cranking.
• Disable the injectors in Haltech NSP before cranking, then lock the ignition timing at a known value for the timing-light check. Keep the injectors disabled throughout trigger and base-timing verification.
• Use a timing light to compare commanded timing with actual crankshaft timing.
• Adjust the trigger angle or offset within Haltech NSP until commanded and measured timing agree.
• After timing and trigger synchronisation have been verified, restore normal ignition timing control. Re-enable the injectors in NSP only when the remaining pre-start checks, including fuel pressure and oil pressure, are complete and the installation is ready for the first start.

Do not enter a universal 60° base-timing value or assume the mechanical tooth position completes the ECU setup. Final trigger settings and timing verification are the responsibility of the Haltech specialist.

Final Checklist

• Cylinder 1 TDC and compression stroke positively confirmed.
• Tooth 5 aligned with the VR sensor centreline, counting clockwise when viewed from the front.
• Trigger wheel secured with the supplied spacer, bolts and threaded retaining ring.
• Medium-strength threadlocker applied to the supplied trigger-wheel bolts.
• Factory crank-pulley locating dowel correctly engaged.
• Trigger-wheel runout does not exceed 0.25 mm.
• VR sensor air gap is 0.5–1.0 mm around the full wheel.
• Engine rotates freely through at least two complete crankshaft revolutions.
• Sensor wiring is protected from heat, abrasion and rotating components.
• Haltech trigger configuration, VR polarity, cranking signal and base timing verified before startup.

Maintenance

• Recheck accessible trigger-wheel and sensor-bracket fasteners after the first 500 km.
• Periodically inspect the VR sensor air gap, bracket rigidity and sensor wiring.
• Investigate any new trigger errors, unstable RPM signal or timing movement before further operation.

Support

Email: info@regalroverclassics.com