Rover 800 Series 825 1986-1999 Factory Service Repair Manual
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🏷️ Basic Information Identification Make: Rover Model: 800 Series Model Variant: 825 Model Years Covered: 1986, 1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999 Codes Platform: XJ-S based platform (later developed with Honda Legend) 👋 Introduction Market Position Segment: Executive car segment, often seen as a premium offering in its class. Competitive Analysis Key Competitors: Jaguar XJ, BMW 5 Series, Mercedes-Benz E-Class, Audi 100/A6. Key Features Design Influence: Significant influence from Honda during its development, leading to improved build quality and engineering. Engine Offering: Notable for its V6 engine, offering a smoother and more refined power delivery compared to some earlier Rover models. 📋 Manual Details Coverage Areas General Coverage: Comprehensive service and repair information for the Rover 800 Series 825 model. Page Count Estimated Page Count: Detailed page count not specified, but described as comprehensive. Manual Type Type: Factory Service Repair Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Engine diagnosis, overhaul, repair procedures for the V6 2.5L engine. Engine Management: Fuel injection system, ignition system, emissions control, engine control unit (ECU) diagnostics. Transmission: Automatic transmission service, repair, and fluid specifications. Brakes: Brake system inspection, repair, disc and pad replacement, hydraulic system service. Suspension: Front and rear suspension components, alignment, shock absorber replacement. Steering: Power steering system diagnosis and repair, steering rack service. Electrical System: Wiring diagrams, starter, alternator, battery, lighting systems, fuses, relays. Climate Control: HVAC system diagnosis, repair, refrigerant handling. Body And Interior: Body panel repair, door mechanisms, interior trim, glass replacement. Procedures Included Routine Maintenance: Oil changes, filter replacements, fluid checks, tune-ups, belt inspections. Troubleshooting: Diagnostic guides and symptom-based troubleshooting for common issues. Repair Procedures: Step-by-step instructions for component removal, installation, and repair. Diagnostics: On-board diagnostics (OBD) information where applicable, sensor testing, fault code interpretation. Wiring Diagrams: Detailed electrical wiring schematics for all vehicle systems. Technical Depth Depth: Comprehensive, suitable for professional technicians and advanced DIY mechanics. 📊 Manual Specifications File Format Format: PDF Readability: Searchable text within PDF for quick information retrieval. Compatibility: Compatible with all Windows and Mac operating systems. Software Requirements: Requires Adobe PDF Reader and WinZip (for potential archives). Print Quality Quality: High-resolution digital format, suitable for printing individual pages. Binding Type Binding: Digital Download (PDF) Paper Type Paper Type: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Code: KV6 (Rover's version of the Honda J-series V6, specifically a 2.5L variant) Configuration: 60-degree V6, naturally aspirated Displacement: 2498 cc (2.5 Liters) Bore X Stroke: Approx. 82.0 mm x 79.2 mm (specifics can vary slightly) Compression Ratio: Approximately 9.3:1 to 10.0:1 depending on variant Performance Horsepower: Around 170-175 PS (127-130 kW; 168-173 bhp) at 6500 rpm Torque: Around 228-230 Nm (168-170 lb-ft) at 4500 rpm Fuel System Injection Type: Multi-point fuel injection (MPI), electronically controlled. Fuel Type: Unleaded Petrol (Octane rating typically 95 RON recommended) Cooling System Type: Liquid-cooled, pressurized system with fan assist. Ignition System Type: Electronic ignition system with distributorless ignition system (DIS) on later models. 🔧 Transmission Standard Type: 4-speed automatic transmission (e.g., GM 4L30-E or ZF 4HP22, depending on specific year/market) Optional Type: 5-speed manual transmission (less common for the 825 in many markets) Features Automatic Modes: Sport and Economy modes often featured. Fluid Specifications Automatic Transmission Fluid: Dexron III or equivalent recommended (refer to manual for exact specification and capacity). 📐 Dimensions Exterior Body Styles: 4-door saloon (sedan), 5-door hatchback (often called R8, but 825 was primarily saloon). Length: Approx. 4745 mm (186.8 in) for saloon Width: Approx. 1780 mm (70.1 in) Height: Approx. 1370 mm (53.9 in) Wheelbase: Approx. 2745 mm (108.1 in) Weights Curb Weight: Approx. 1450-1550 kg (3197-3417 lbs) depending on equipment and body style. Gross Vehicle Weight: Varies, consult manual for specific GVWR. 🛡️ Safety Features Ratings Crash Test Results: Euro NCAP ratings were not available during the production period of this vehicle; historical safety standards applied. Active Features ABS: Anti-lock Braking System (ABS) available as an option or standard on higher trims/later models. Traction Control: Traction control system (TCS) was an optional feature on some later models. Passive Features Airbags: Driver airbag standard on most models from early 1990s onwards; passenger airbag optional or standard on top trims. Seatbelts: Pyrotechnic pre-tensioners for front seatbelts on some later models. Chassis Design: Designed with crumple zones and a reinforced safety cell for occupant protection. 💡 Technology Features Infotainment Audio System: Factory fitted radio-cassette player with optional CD changer. Upgrade options are common. Climate Control: Manual or automatic climate control systems were available. Driver Assistance Cruise Control: Optional on many models. Connectivity Features: Limited connectivity by modern standards; primarily focused on in-car comfort and basic electronic convenience features. 🔧 Maintenance Service Intervals Engine Oil Change: Typically every 10,000 miles or 12 months, whichever comes first (refer to manual for specific grade). Spark Plugs: Replacement...
Unleaded Petrol (Octane rating typically 95 RON recommended)
Cooling System
Type:
Liquid-cooled, pressurized system with fan assist.
Ignition System
Type:
Electronic ignition system with distributorless ignition system (DIS) on later models.
🔧 Transmission
Standard
Type:
4-speed automatic transmission (e.g., GM 4L30-E or ZF 4HP22, depending on specific year/market)
Optional
Type:
5-speed manual transmission (less common for the 825 in many markets)
Features
Automatic Modes:
Sport and Economy modes often featured.
Fluid Specifications
Automatic Transmission Fluid:
Dexron III or equivalent recommended (refer to manual for exact specification and capacity).
📐 Dimensions
Exterior
Body Styles:
4-door saloon (sedan), 5-door hatchback (often called R8, but 825 was primarily saloon).
Length:
Approx. 4745 mm (186.8 in) for saloon
Width:
Approx. 1780 mm (70.1 in)
Height:
Approx. 1370 mm (53.9 in)
Wheelbase:
Approx. 2745 mm (108.1 in)
Weights
Curb Weight:
Approx. 1450-1550 kg (3197-3417 lbs) depending on equipment and body style.
Gross Vehicle Weight:
Varies, consult manual for specific GVWR.
🛡️ Safety Features
Ratings
Crash Test Results:
Euro NCAP ratings were not available during the production period of this vehicle; historical safety standards applied.
Active Features
ABS:
Anti-lock Braking System (ABS) available as an option or standard on higher trims/later models.
Traction Control:
Traction control system (TCS) was an optional feature on some later models.
Passive Features
Airbags:
Driver airbag standard on most models from early 1990s onwards; passenger airbag optional or standard on top trims.
Seatbelts:
Pyrotechnic pre-tensioners for front seatbelts on some later models.
Chassis Design:
Designed with crumple zones and a reinforced safety cell for occupant protection.
💡 Technology Features
Infotainment
Audio System:
Factory fitted radio-cassette player with optional CD changer. Upgrade options are common.
Climate Control:
Manual or automatic climate control systems were available.
Driver Assistance
Cruise Control:
Optional on many models.
Connectivity
Features:
Limited connectivity by modern standards; primarily focused on in-car comfort and basic electronic convenience features.
🔧 Maintenance
Service Intervals
Engine Oil Change:
Typically every 10,000 miles or 12 months, whichever comes first (refer to manual for specific grade).
Spark Plugs:
Replacement interval varies by spark plug type (e.g., iridium plugs could last up to 100,000 miles).
Timing Belt:
The KV6 engine uses a timing belt system. Replacement is critical, typically every 60,000 to 80,000 miles or 5 years. Failure can cause catastrophic engine damage. The manual will provide the exact interval and procedure.
Transmission Fluid Change:
Recommended every 60,000 miles or as per manual, especially for automatic transmissions.
Fluid Specifications
Engine Oil Grade:
API SG/SH or ACEA A2/A3, SAE 10W-40 or 10W-50 recommended (check manual for exact viscosity and specification).
Coolant:
Ethylene glycol-based coolant with corrosion inhibitors, typically a 50/50 mix with distilled water. Check manual for specific type and capacity.
Brake Fluid:
DOT 3 or DOT 4, depending on system requirements. Change every 2-3 years.
Known Issues
Cylinder Head Gaskets:
The KV6 engine, particularly early versions, was known for potential head gasket failures due to design issues. The manual will detail inspection and repair procedures.
Electrical Gremlins:
Like many cars of this era, the Rover 800 can suffer from minor electrical issues, such as faulty sensors, intermittent warning lights, or issues with central locking and windows. The wiring diagrams in the manual are crucial for diagnosis.
Suspension Wear:
Wear and tear on bushings, ball joints, and shock absorbers are common for a vehicle of this age and mileage. The manual provides specifications for wear limits and replacement.
Air Conditioning System:
Leaking refrigerant or compressor issues are not uncommon; the manual covers A/C system servicing.
📚 Vehicle History
Brand Heritage
Rover Legacy:
Rover's long history in producing comfortable, refined, and traditionally styled cars.
Model Evolution
Generation 1 R8:
Launched in 1986, the R8 was a significant departure from previous Rover saloons, influenced heavily by the Honda Legend platform. It represented Rover's move into the executive car segment.
Facelifts:
The Rover 800 series received a significant facelift in 1991 (R17) which updated styling, interior, and mechanicals, including the introduction of the more modern KV6 engine. Further minor updates occurred in subsequent years.
Production
Manufacturing Location:
Cowley, Oxford, United Kingdom.
Production Years:
1986-1999
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