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Rover 800 Series 820 825 827 1986-1999 Repair Service Manual

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🏷️ Basic Information Identification Make: Rover Model: 800 Series Model Variants: 820, 825, 827 Generation Generation Code: R17 Codes Chassis Codes: XW 👋 Introduction Market Position Positioning: The Rover 800 Series was positioned as a luxury executive car, aiming to compete with established German and Japanese brands. It offered a blend of British styling, comfort, and modern technology for its era. Competitive Analysis Competitors: Primary competitors included the BMW 5 Series, Mercedes-Benz E-Class, Audi 100/A6, Jaguar XJ, and high-end Japanese models like the Toyota Camry and Nissan Maxima. Key Features Platform Sharing: Shared its platform with the Honda Legend, benefiting from Japanese engineering and reliability. Design Philosophy: Characterized by its distinctive 'Blade' styling, influenced by Rover's previous designs and the Honda Legend. Manual Benefit Value Proposition: Enables owners and technicians to perform accurate and professional maintenance and repairs, saving money and extending vehicle life. 📋 Manual Details Coverage Areas Model Years Covered: 1986, 1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999 Page Count Estimated Page Count: Comprehensive (exact number not specified, but extensive coverage implied) Manual Type Manual Type: Workshop Service Manual Language Language: English Format Digital Format: PDF 📖 Manual Coverage Systems Covered Engine Service: Full repair and overhaul of engine assemblies. Fuel System: Comprehensive coverage of fuel delivery, injection, and management systems. Ignition System: Detailed procedures for ignition timing, components, and diagnostics. Lubrication System: Information on oil circulation, lubrication points, and maintenance. Cooling System: Repair and maintenance of radiators, water pumps, thermostats, and fans. Exhaust System: Procedures for exhaust manifold, catalytic converter, and muffler service. Electrical System: Extensive coverage of wiring diagrams, components, and diagnostics. Transmission Service: Repair and overhaul for both manual and automatic transmissions. Drivetrain Service: Coverage of drive shafts, CV joints, and differential components. Suspension System: Maintenance and repair of struts, shock absorbers, control arms, and bushings. Steering System: Procedures for power steering pump, rack and pinion, and steering column service. Brake System: Detailed instructions for disc and drum brakes, ABS systems, and hydraulic components. Body And Chassis: Information on body panels, doors, glass, and structural repairs. HVAC System: Coverage of air conditioning and heating system maintenance and repair. Interior Trim: Procedures for seat removal, dashboard components, and interior paneling. Procedures Included Routine Maintenance: Complete guide to scheduled servicing, oil changes, filter replacements, etc. Troubleshooting Diagnostics: Diagnostic procedures and fault finding for various systems. Component Removal Installation: Step-by-step instructions for removing and installing all major components. Engine Rebuild: Detailed overhaul procedures for engine internals. Transmission Overhaul: In-depth procedures for complete transmission rebuilds. Electrical Diagnostics: Schematics, testing procedures, and wiring harness repair. Brake Bleeding: Specific instructions for brake system bleeding, including ABS systems. Torque Specifications: Essential torque values for critical fasteners. Special Tool Identification: Identification and usage of specific Rover special tools. Technical Depth Depth: Comprehensive, covering routine maintenance to major overhauls and diagnostics, suitable for professional technicians and experienced DIY enthusiasts. 📊 Manual Specifications File Format File Format: PDF Print Quality Printability: Printable Binding Type Binding: N/A (Digital PDF) Paper Type Paper Type: N/A (Digital PDF) Delivery Method Delivery: Fast and Free Electronic Delivery via Email ⚙️ Engine Specifications Primary Engine Engine 820 Variant: Rover KV6 or Honda 2.0L (various configurations: 2.0L SOHC, DOHC, Turbocharged) Engine 825 Variant: Rover V6 (2.5L, typically SOHC) Engine 827 Variant: Honda C32A V6 (2.7L, DOHC) Performance Horsepower Range: Approximately 130-170 hp for 4-cylinder, 160-190 hp for V6 variants (specifics vary by engine and year). Torque Range: Approximately 170-240 Nm (specifics vary by engine and year). Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) across most variants. Recommended Fuel: Unleaded gasoline (Octane rating typically 95 RON or higher for V6, may vary for specific engines). Engine Management ECU Type: Various ECUs depending on engine and year, including Lucas, Denso, or Rover specific systems. 🔧 Transmission Standard Standard Transmission Type: Manual transmission (e.g., 5-speed) often standard on lower engine variants. Optional Optional Transmission Type: Automatic transmission (e.g., 4-speed automatic, often sourced from Honda or ZF) available on most models. Features Transmission Fluid Type: Specific Automatic Transmission Fluid (ATF) required, e.g., Dexron II/III or equivalent, and manual gearbox oil (e.g., API GL-4). 📐 Dimensions Exterior Body Styles: 4-door Saloon (Sedan), 5-door Hatchback (often referred to as the 'Fastback'). Wheelbase: Approximately 2770 mm (109.1 inches). Length: Approximately 4760-4850 mm (187.4-190.9 inches). Width: Approximately 1770-1790 mm (69.7-70.5 inches). Height: Approximately 1380-1420 mm (54.3-55.9 inches). Weights Curb Weight Range: Approximately 1400-1600 kg (3086-3527 lbs), depending on engine and specification. 🛡️ Safety Features Ratings Crash Test Data: While specific NCAP ratings for all years/models might not be readily available from the era, the chassis was designed with European safety standards in mind. Later models saw improvements in passive safety. Active Features ABS Availability: Anti-lock Braking System (ABS) was an optional or standard feature on higher trims and later models. Traction Control:...
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Rover 800 Series 820 825 827 1986-1999 Repair Service Manual
🏷️ Basic Information
Identification
Make:
Rover
Model:
800 Series
Model Variants:
820, 825, 827
Generation
Generation Code:
R17
Codes
Chassis Codes:
XW
👋 Introduction
Market Position
Positioning:
The Rover 800 Series was positioned as a luxury executive car, aiming to compete with established German and Japanese brands. It offered a blend of British styling, comfort, and modern technology for its era.
Competitive Analysis
Competitors:
Primary competitors included the BMW 5 Series, Mercedes-Benz E-Class, Audi 100/A6, Jaguar XJ, and high-end Japanese models like the Toyota Camry and Nissan Maxima.
Key Features
Platform Sharing:
Shared its platform with the Honda Legend, benefiting from Japanese engineering and reliability.
Design Philosophy:
Characterized by its distinctive 'Blade' styling, influenced by Rover's previous designs and the Honda Legend.
Manual Benefit
Value Proposition:
Enables owners and technicians to perform accurate and professional maintenance and repairs, saving money and extending vehicle life.
📋 Manual Details
Coverage Areas
Model Years Covered:
1986, 1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999
Page Count
Estimated Page Count:
Comprehensive (exact number not specified, but extensive coverage implied)
Manual Type
Manual Type:
Workshop Service Manual
Language
Language:
English
Format
Digital Format:
PDF
📖 Manual Coverage
Systems Covered
Engine Service:
Full repair and overhaul of engine assemblies.
Fuel System:
Comprehensive coverage of fuel delivery, injection, and management systems.
Ignition System:
Detailed procedures for ignition timing, components, and diagnostics.
Lubrication System:
Information on oil circulation, lubrication points, and maintenance.
Cooling System:
Repair and maintenance of radiators, water pumps, thermostats, and fans.
Exhaust System:
Procedures for exhaust manifold, catalytic converter, and muffler service.
Electrical System:
Extensive coverage of wiring diagrams, components, and diagnostics.
Transmission Service:
Repair and overhaul for both manual and automatic transmissions.
Drivetrain Service:
Coverage of drive shafts, CV joints, and differential components.
Suspension System:
Maintenance and repair of struts, shock absorbers, control arms, and bushings.
Steering System:
Procedures for power steering pump, rack and pinion, and steering column service.
Brake System:
Detailed instructions for disc and drum brakes, ABS systems, and hydraulic components.
Body And Chassis:
Information on body panels, doors, glass, and structural repairs.
HVAC System:
Coverage of air conditioning and heating system maintenance and repair.
Interior Trim:
Procedures for seat removal, dashboard components, and interior paneling.
Procedures Included
Routine Maintenance:
Complete guide to scheduled servicing, oil changes, filter replacements, etc.
Troubleshooting Diagnostics:
Diagnostic procedures and fault finding for various systems.
Component Removal Installation:
Step-by-step instructions for removing and installing all major components.
Engine Rebuild:
Detailed overhaul procedures for engine internals.
Transmission Overhaul:
In-depth procedures for complete transmission rebuilds.
Electrical Diagnostics:
Schematics, testing procedures, and wiring harness repair.
Brake Bleeding:
Specific instructions for brake system bleeding, including ABS systems.
Torque Specifications:
Essential torque values for critical fasteners.
Special Tool Identification:
Identification and usage of specific Rover special tools.
Technical Depth
Depth:
Comprehensive, covering routine maintenance to major overhauls and diagnostics, suitable for professional technicians and experienced DIY enthusiasts.
📊 Manual Specifications
File Format
File Format:
PDF
Print Quality
Printability:
Printable
Binding Type
Binding:
N/A (Digital PDF)
Paper Type
Paper Type:
N/A (Digital PDF)
Delivery Method
Delivery:
Fast and Free Electronic Delivery via Email
⚙️ Engine Specifications
Primary Engine
Engine 820 Variant:
Rover KV6 or Honda 2.0L (various configurations: 2.0L SOHC, DOHC, Turbocharged)
Engine 825 Variant:
Rover V6 (2.5L, typically SOHC)
Engine 827 Variant:
Honda C32A V6 (2.7L, DOHC)
Performance
Horsepower Range:
Approximately 130-170 hp for 4-cylinder, 160-190 hp for V6 variants (specifics vary by engine and year).
Torque Range:
Approximately 170-240 Nm (specifics vary by engine and year).
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI) across most variants.
Recommended Fuel:
Unleaded gasoline (Octane rating typically 95 RON or higher for V6, may vary for specific engines).
Engine Management
ECU Type:
Various ECUs depending on engine and year, including Lucas, Denso, or Rover specific systems.
🔧 Transmission
Standard
Standard Transmission Type:
Manual transmission (e.g., 5-speed) often standard on lower engine variants.
Optional
Optional Transmission Type:
Automatic transmission (e.g., 4-speed automatic, often sourced from Honda or ZF) available on most models.
Features
Transmission Fluid Type:
Specific Automatic Transmission Fluid (ATF) required, e.g., Dexron II/III or equivalent, and manual gearbox oil (e.g., API GL-4).
📐 Dimensions
Exterior
Body Styles:
4-door Saloon (Sedan), 5-door Hatchback (often referred to as the 'Fastback').
Wheelbase:
Approximately 2770 mm (109.1 inches).
Length:
Approximately 4760-4850 mm (187.4-190.9 inches).
Width:
Approximately 1770-1790 mm (69.7-70.5 inches).
Height:
Approximately 1380-1420 mm (54.3-55.9 inches).
Weights
Curb Weight Range:
Approximately 1400-1600 kg (3086-3527 lbs), depending on engine and specification.
🛡️ Safety Features
Ratings
Crash Test Data:
While specific NCAP ratings for all years/models might not be readily available from the era, the chassis was designed with European safety standards in mind. Later models saw improvements in passive safety.
Active Features
ABS Availability:
Anti-lock Braking System (ABS) was an optional or standard feature on higher trims and later models.
Traction Control:
Traction Control System (TCS) was available on some higher-specification models, particularly those with V6 engines.
Passive Features
Airbags:
Driver airbag became standard on later models; passenger airbags were less common or optional.
Seatbelts:
Pre-tensioned seatbelts were introduced on later models.
Rollover Protection:
Reinforced A and B pillars for improved structural integrity.
💡 Technology Features
Infotainment
Audio System:
Factory fitted radio/cassette players, often with CD changer compatibility on higher trims. Later models may feature upgraded audio systems.
Climate Control:
Manual or automatic climate control systems were available depending on trim level.
Driver Assistance
Cruise Control:
Cruise control was a common option on higher-specification models.
Connectivity
Central Locking Remote:
Remote central locking was introduced on later models.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 6,000 - 10,000 miles (10,000 - 15,000 km) or 12 months, whichever comes first, depending on engine and oil type.
Timing Belt Replacement:
For engine variants using a timing belt (e.g., some O-series, KV6), replacement is typically recommended every 60,000 - 90,000 miles (96,000 - 144,000 km) or 5-7 years.
Fluid Specifications
Engine Oil Specification:
API SG/SH or higher, SAE 10W-40 or 10W-30 recommended for most conditions. Consult manual for specific engine requirements.
Coolant Specification:
Ethylene glycol-based antifreeze/coolant, mixed 50/50 with distilled water. Specific Rover coolant or equivalent.
Brake Fluid Specification:
DOT 3 or DOT 4 brake fluid.
Known Issues
Common Issues General:
Rusting (wheel arches, sills), electrical gremlins (especially in earlier models), cooling system leaks (hose failures, radiator issues), suspension component wear (bushes, ball joints), and head gasket issues on some KV6 engines.
Common Issues Engine:
Perceived fragility of some Rover engines compared to Honda units. Issues with idle control valves and throttle bodies on electronic injection systems.
Common Issues Electrical:
Faulty window regulators, central locking issues, and dashboard warning light malfunctions are reported.
📚 Vehicle History
Brand Heritage
Rover Legacy:
The Rover 800 Series represented a significant step for Rover, aiming to move upmarket and recapture the prestige associated with the brand. It was a successor to the Austin Montego and Morris Ital.
Model Evolution
First Generation R17:
Launched in 1986, based on the platform co-developed with Honda. Initial models featured Rover's own 2.0L O-series engine and the Honda 2.7L V6.
Facelift R17 Facelift 1991:
Significant facelift in 1991 (often referred to as the '800') introduced redesigned exterior styling, improved interior, and revised powertrains including the new Rover KV6 engine, replacing the older O-series and Honda V6 in many applications.
Facelift R17 Facelift 1996:
Further update in 1996 with minor styling tweaks and powertrain refinements.
Production
Production Period:
1986-1999.
Manufacturing Location:
Cowley, Oxford, United Kingdom.
🏆 Awards & Recognition
Recognitions
Awards:
The Rover 800 Series was generally well-received for its comfortable ride, quiet cabin, and luxury appointments, though it faced stiff competition. Specific awards are not widely publicized for this model in a manner comparable to modern vehicles.
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