Rover 800 Series 820 825 827 1986-1999 Workshop Service Repair Manual
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🏷️ Basic Information Identification Make: Rover Model: 800 Series Model Variants: 820, 825, 827 Production Years: 1986-1999 👋 Introduction Market Position Segment: Executive Car Target Audience: Executive car buyers seeking comfort, refinement, and performance. Competitive Analysis Competitors: Jaguar XJ, BMW 5 Series, Mercedes-Benz E-Class, Ford Scorpio Key Features Design Platform: Honda Legend platform (XL/XJ series) Unique Selling Points: Combination of British design and Japanese engineering reliability (initially) 📋 Manual Details Coverage Areas Vehicle Coverage: Rover 800 Series (820, 825, 827) from 1986 to 1999 Page Count Estimated Page Count: Hundreds of pages (as per description) Manual Type Type: Workshop Service Repair Manual Language Language: English Format Delivery Method: Instant Download File Format: PDF 📖 Manual Coverage Systems Covered Engine: Diagnosis, repair, overhaul, performance tuning Transmission: Service, repair, overhaul, fluid specifications Electrical System: Wiring diagrams, troubleshooting, component testing Brakes: Maintenance, repair, bleeding procedures, component replacement Suspension: Inspection, repair, component replacement Steering: Diagnosis, repair, fluid specifications Fuel System: Diagnosis, repair, fuel pump, injectors Cooling System: Maintenance, repair, coolant specifications Exhaust System: Inspection, repair, catalytic converter information Bodywork: Panel repair, door mechanisms, glass replacement HVAC: Refrigerant, component diagnosis, repair Chassis: Front and rear suspension, steering, wheels, tires Climate Control: Air conditioning system diagnosis and repair, heater matrix Procedures Included Maintenance: Periodic maintenance charts, fluid changes, filter replacements Repair: Step-by-step repair instructions for all major systems Troubleshooting: Diagnostic information and fault finding procedures Overhaul: Detailed engine and transmission overhaul procedures Diagnostics: Component testing and diagnostic fault codes (if applicable to the era) Safety Systems Inspection: Checks for seat belts, airbag system (where applicable) Exterior And Interior Trim Repair: Guidance on removing and refitting trim pieces, door panels, dashboard components. Technical Depth Depth: Comprehensive, suitable for professional technicians and DIY mechanics Diagnostic Procedures: Detailed fault finding trees and diagnostic flowcharts for common issues. Rebuild Procedures: Complete engine rebuild specifications, transmission overhaul, and differential repair instructions. 📊 Manual Specifications File Format Print Quality: Full Printable Zoom Functionality: Zoom IN/OUT Searchable Text: Likely searchable due to PDF format, enhancing user experience. Binding Type Binding: N/A (Digital PDF Download) Paper Type Paper Type: N/A (Digital PDF Download) Requirements Software Requirements: Adobe PDF Reader, WinRAR Compatibility: All Versions of Windows & Mac ⚙️ Engine Specifications Primary Engine 820 Engine Type: Rover KV6 (early models may have had other Rover 4-cylinder engines, but the 800 series is predominantly known for the V6. The mention of 820 might refer to earlier 4-cylinder variants or a specific market designation. For comprehensive coverage, the manual should address both.) 825 Engine Type: Rover KV6 V6 827 Engine Type: Honda C27A 2.7L V6 820 Engine Notes: Early 820 models might have utilized Rover's M-Series 4-cylinder engines (e.g., 2.0L). The manual's comprehensive nature should cover these variations. Performance 820 Power Output (Estimate): Approx. 136-177 hp (depending on engine variant) 825 Power Output: Approx. 177 hp 827 Power Output: Approx. 170 hp Fuel System Injection System: Multi-point Fuel Injection (MPI) Fuel Type: Unleaded Petrol (Premium) 🔧 Transmission Standard Manual Availability: Yes (typically 5-speed on 4-cylinder models, less common on V6) Optional Automatic Availability: Yes (typically 4-speed automatic on V6 models) Features Transmission Type V6: Jatco 4-speed automatic 📐 Dimensions Exterior Body Styles: 4-door Saloon (Sedan), 5-door Hatchback Wheelbase: Approximately 2700 mm (106.3 in) Length: Approximately 4750 mm (187 in) Width: Approximately 1770 mm (70 in) Height: Approximately 1390 mm (55 in) Weights Curb Weight Range: Approx. 1400-1550 kg (3086-3417 lbs) 🛡️ Safety Features Ratings Crash Test Results: Not extensively documented in modern standards, but designed to European safety standards of its era. Active Features ABS: Optional on early models, standard on later versions Passive Features Airbags: Driver airbag standard on later models, optional on early ones. Passenger airbag available on later models. Seatbelts: Pre-tensioned front seatbelts 💡 Technology Features Infotainment Audio System: Factory fitted radio cassette players, often with premium speaker options. Later models may have CD compatibility. Driver Assistance Cruise Control: Available as an option on higher trims. Connectivity Connectivity Features: Limited by era, primarily focused on basic vehicle functions. 🔧 Maintenance Service Intervals Oil Change Interval: Typically 6,000-10,000 miles or 12 months, depending on driving conditions (refer to manual for specific interval). Timing Belt Replacement: For KV6 engines, timing belt replacement is crucial, typically around 60,000-70,000 miles or 5-7 years. (Manual will specify). Fluid Specifications Engine Oil Type: 10W/40 or 15W/40 semi-synthetic or fully synthetic (refer to manual for precise specification based on engine and climate). Coolant Type: Ethylene glycol based antifreeze (e.g., Rover Long Life Coolant or equivalent). Transmission Fluid Automatic: Dexron III or equivalent (specific type for Jatco transmission). Brake Fluid Type: DOT 4 Power Steering Fluid: ATF (Automatic Transmission Fluid) or specific power steering fluid as per manual. Known Issues Kv6 Engine Head Gaskets: Prone to head gasket failure, especially on earlier KV6 engines. The manual will detail inspection and repair. Electrical...
Step-by-step repair instructions for all major systems
Troubleshooting:
Diagnostic information and fault finding procedures
Overhaul:
Detailed engine and transmission overhaul procedures
Diagnostics:
Component testing and diagnostic fault codes (if applicable to the era)
Safety Systems Inspection:
Checks for seat belts, airbag system (where applicable)
Exterior And Interior Trim Repair:
Guidance on removing and refitting trim pieces, door panels, dashboard components.
Technical Depth
Depth:
Comprehensive, suitable for professional technicians and DIY mechanics
Diagnostic Procedures:
Detailed fault finding trees and diagnostic flowcharts for common issues.
Rebuild Procedures:
Complete engine rebuild specifications, transmission overhaul, and differential repair instructions.
📊 Manual Specifications
File Format
Print Quality:
Full Printable
Zoom Functionality:
Zoom IN/OUT
Searchable Text:
Likely searchable due to PDF format, enhancing user experience.
Binding Type
Binding:
N/A (Digital PDF Download)
Paper Type
Paper Type:
N/A (Digital PDF Download)
Requirements
Software Requirements:
Adobe PDF Reader, WinRAR
Compatibility:
All Versions of Windows & Mac
⚙️ Engine Specifications
Primary Engine
820 Engine Type:
Rover KV6 (early models may have had other Rover 4-cylinder engines, but the 800 series is predominantly known for the V6. The mention of 820 might refer to earlier 4-cylinder variants or a specific market designation. For comprehensive coverage, the manual should address both.)
825 Engine Type:
Rover KV6 V6
827 Engine Type:
Honda C27A 2.7L V6
820 Engine Notes:
Early 820 models might have utilized Rover's M-Series 4-cylinder engines (e.g., 2.0L). The manual's comprehensive nature should cover these variations.
Performance
820 Power Output (Estimate):
Approx. 136-177 hp (depending on engine variant)
825 Power Output:
Approx. 177 hp
827 Power Output:
Approx. 170 hp
Fuel System
Injection System:
Multi-point Fuel Injection (MPI)
Fuel Type:
Unleaded Petrol (Premium)
🔧 Transmission
Standard
Manual Availability:
Yes (typically 5-speed on 4-cylinder models, less common on V6)
Optional
Automatic Availability:
Yes (typically 4-speed automatic on V6 models)
Features
Transmission Type V6:
Jatco 4-speed automatic
📐 Dimensions
Exterior
Body Styles:
4-door Saloon (Sedan), 5-door Hatchback
Wheelbase:
Approximately 2700 mm (106.3 in)
Length:
Approximately 4750 mm (187 in)
Width:
Approximately 1770 mm (70 in)
Height:
Approximately 1390 mm (55 in)
Weights
Curb Weight Range:
Approx. 1400-1550 kg (3086-3417 lbs)
🛡️ Safety Features
Ratings
Crash Test Results:
Not extensively documented in modern standards, but designed to European safety standards of its era.
Active Features
ABS:
Optional on early models, standard on later versions
Passive Features
Airbags:
Driver airbag standard on later models, optional on early ones. Passenger airbag available on later models.
Seatbelts:
Pre-tensioned front seatbelts
💡 Technology Features
Infotainment
Audio System:
Factory fitted radio cassette players, often with premium speaker options. Later models may have CD compatibility.
Driver Assistance
Cruise Control:
Available as an option on higher trims.
Connectivity
Connectivity Features:
Limited by era, primarily focused on basic vehicle functions.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically 6,000-10,000 miles or 12 months, depending on driving conditions (refer to manual for specific interval).
Timing Belt Replacement:
For KV6 engines, timing belt replacement is crucial, typically around 60,000-70,000 miles or 5-7 years. (Manual will specify).
Fluid Specifications
Engine Oil Type:
10W/40 or 15W/40 semi-synthetic or fully synthetic (refer to manual for precise specification based on engine and climate).
Coolant Type:
Ethylene glycol based antifreeze (e.g., Rover Long Life Coolant or equivalent).
Transmission Fluid Automatic:
Dexron III or equivalent (specific type for Jatco transmission).
Brake Fluid Type:
DOT 4
Power Steering Fluid:
ATF (Automatic Transmission Fluid) or specific power steering fluid as per manual.
Known Issues
Kv6 Engine Head Gaskets:
Prone to head gasket failure, especially on earlier KV6 engines. The manual will detail inspection and repair.
Electrical Gremlins:
Can suffer from intermittent electrical faults, often related to aging wiring and connections.
Rust:
Common issue on older Rovers, particularly around wheel arches, sills, and boot lid.
Suspension Wear:
Components like ball joints and bushings can wear over time, leading to knocking noises.
📚 Vehicle History
Brand Heritage
Rover Legacy:
Rover was a British automotive marque with a long history of producing luxury and executive vehicles.
Model Evolution
First Generation:
R8/R80 (1986-1994), based on Honda Legend, featuring distinctive styling.
Second Generation:
R40 (1994-1999), redesigned exterior and interior, continued use of Rover KV6 engines, but shared less with Honda.
Production
Manufacturing Location:
Cowley, England
Ownership Changes Impact:
The 800 series experienced the decline of British Leyland and the subsequent ownership by British Aerospace and then BMW, impacting development and market perception.
🏆 Awards & Recognition
Recognitions
Industry Accolades:
While specific awards are not widely highlighted, the 800 series was considered a strong contender in the executive car segment of its time, praised for its ride comfort and refined styling.
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