Rover 800 Series 820 1986-1999 WSM Service Manual Repair
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๐ท๏ธ Basic Information Identification Make: Rover Model: 800 Series Model Variant: 820 Codes Production Code: R8 Engine Code Family: M16 / T ๐ Introduction Market Position Segment: Executive car segment Competitive Analysis Competitors: Ford Scorpio, Vauxhall Carlton/Omega, BMW 5 Series (E34), Mercedes-Benz E-Class (W124), Audi 100/A6 (C3/C4) Key Features Unique Selling Points: Front-wheel drive platform (shared with Honda Legend), distinctive styling, powerful engines (for its era), spacious interior ๐ Manual Details Coverage Areas Years Covered: 1986, 1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999 Page Count Estimated Page Count: Varies by specific publication, typically 500-1000+ pages for full WSM Manual Type Type: Workshop Service Manual (WSM) / Repair Manual Language Language: English Format Format: PDF (Downloadable) ๐ Manual Coverage Systems Covered Engine: Full diagnostics, repair, overhaul, tuning, emissions control for M16 and T-Series engines Transmission: Manual and automatic transmission overhaul, clutch, driveshafts, differentials Brakes: Hydraulic system, ABS (where fitted), disc/drum brake overhaul, parking brake Suspension Steering: Front and rear suspension, steering rack, power steering system Electrical: Comprehensive wiring diagrams, ignition system, lighting, charging system, starter motor, ECUs, sensors Body Chassis: Body panel repair, interior trim, glass, doors, locks, heating, ventilation, air conditioning (HVAC) Fuel System: Fuel injection (MPI/SPI), fuel pump, injectors, fuel tank, exhaust system Procedures Included Maintenance: Routine servicing, oil changes, filter replacements, fluid checks, belt adjustments Troubleshooting: Diagnostic charts, fault finding procedures, common problems and solutions Repair Overhaul: Step-by-step instructions for component removal, repair, and reinstallation (e.g., engine rebuild, gearbox overhaul) Installation: Instructions for replacing major components and accessories Specifications Data: Torque values, clearances, diagnostic parameters, component identification Technical Depth Depth: In-depth, professional level covering all aspects from routine maintenance to major overhauls and complex diagnostics ๐ Manual Specifications File Format File Type: PDF Print Quality Printability: Full printable pages, allowing users to print specific sections for workshop use Binding Type Binding: N/A (Digital Download) Paper Type Paper Quality: N/A (Digital Download) Software Requirements Reader Software: Adobe Acrobat Reader or compatible PDF viewer required Compatibility Operating Systems: Compatible with all versions of Windows and macOS Delivery Method Delivery: Instant Digital Download โ๏ธ Engine Specifications Primary Engine Engine Family: Rover M16 (non-turbo) and Rover T-Series (turbocharged) Engine Family Details M16 Description: 2.0-litre (1994cc) 16-valve DOHC inline-four cylinder engine, developed with Honda. T Series Description: 2.0-litre (1994cc) 16-valve DOHC turbocharged inline-four cylinder engine. Performance M16 Power Output: Approx. 130-140 bhp (depending on variant and market) T Series Power Output: Approx. 170-200 bhp (depending on turbocharger and boost pressure) Fuel System Injection Type: Electronic Multi-Point Fuel Injection (MPI) or Single-Point Fuel Injection (SPI) on earlier/lower-spec models Ignition System Ignition Type: Electronic ignition with distributor or distributorless (DIS) depending on year and variant Cooling System Cooling Type: Pressurized liquid cooling system with thermostatically controlled fan ๐ง Transmission Standard Standard Transmission: 5-speed manual gearbox Optional Optional Transmission: 4-speed automatic transmission (e.g., ZF 4HPxx series) Features Drive Layout: Front-wheel drive (FWD) Differential: Open differential integrated into the transaxle ๐ Dimensions Exterior Body Styles: 4-door saloon, 5-door hatchback (R8) Weights Kerb Weight: Approx. 1300-1500 kg (depending on engine and specification) Gross Vehicle Weight: Varies by model and GVW rating ๐ก๏ธ Safety Features Ratings Crash Test Results: Euro NCAP ratings not available for this generation; contemporary safety standards were lower. Manual will cover structural integrity and occupant protection systems of its time. Active Features ABS: Anti-lock Braking System (ABS) available as an option on higher trims and later models Passive Features Airbags: Driver airbag standard on later models, passenger airbag optional or standard on top trims. Early models may not have airbags. Seatbelts: Three-point inertia reel seatbelts with pre-tensioners on front seats (depending on year) ๐ก Technology Features Infotainment Audio System: Factory fitted cassette players, CD players (on later models), often with amplifier systems. Upgrade options are common. Driver Assistance Cruise Control: Available as an option on many models Connectivity Remote Locking: Central door locking, remote keyless entry on later models Climate Control HVAC System: Manual air conditioning, climate control systems on higher specifications. ๐ง Maintenance Service Intervals Oil Change Interval: Typically 6,000-10,000 miles or 12 months (refer to manual for specific grade and intervals) Spark Plug Replacement: Varies by plug type (standard, platinum, iridium); consult manual for specific intervals. Timing Belt Replacement: For M16 and T-Series engines, typically 60,000 miles or 4-5 years. Critical to follow manufacturer's recommendation to avoid catastrophic engine damage. Fluid Specifications Engine Oil Specification: API SG/SH or ACEA A2-96; SAE 10W/40 or 15W/50 (refer to manual for exact viscosity based on ambient temperature) Coolant Specification: Ethylene glycol based antifreeze; typically 50% concentration with distilled water. Specific OAT or HOAT coolant may be recommended for later models. Check manual for compatibility. Automatic Transmission Fluid: Dexron II or III (check manual for specific ZF gearbox requirements) Brake Fluid Specification: DOT 3 or DOT 4 Known Issues Common Problems:...
Approx. 1300-1500 kg (depending on engine and specification)
Gross Vehicle Weight:
Varies by model and GVW rating
๐ก๏ธ Safety Features
Ratings
Crash Test Results:
Euro NCAP ratings not available for this generation; contemporary safety standards were lower. Manual will cover structural integrity and occupant protection systems of its time.
Active Features
ABS:
Anti-lock Braking System (ABS) available as an option on higher trims and later models
Passive Features
Airbags:
Driver airbag standard on later models, passenger airbag optional or standard on top trims. Early models may not have airbags.
Seatbelts:
Three-point inertia reel seatbelts with pre-tensioners on front seats (depending on year)
๐ก Technology Features
Infotainment
Audio System:
Factory fitted cassette players, CD players (on later models), often with amplifier systems. Upgrade options are common.
Driver Assistance
Cruise Control:
Available as an option on many models
Connectivity
Remote Locking:
Central door locking, remote keyless entry on later models
Climate Control
HVAC System:
Manual air conditioning, climate control systems on higher specifications.
๐ง Maintenance
Service Intervals
Oil Change Interval:
Typically 6,000-10,000 miles or 12 months (refer to manual for specific grade and intervals)
Spark Plug Replacement:
Varies by plug type (standard, platinum, iridium); consult manual for specific intervals.
Timing Belt Replacement:
For M16 and T-Series engines, typically 60,000 miles or 4-5 years. Critical to follow manufacturer's recommendation to avoid catastrophic engine damage.
Fluid Specifications
Engine Oil Specification:
API SG/SH or ACEA A2-96; SAE 10W/40 or 15W/50 (refer to manual for exact viscosity based on ambient temperature)
Coolant Specification:
Ethylene glycol based antifreeze; typically 50% concentration with distilled water. Specific OAT or HOAT coolant may be recommended for later models. Check manual for compatibility.
Automatic Transmission Fluid:
Dexron II or III (check manual for specific ZF gearbox requirements)
Brake Fluid Specification:
DOT 3 or DOT 4
Known Issues
Common Problems:
Head gasket failure (especially on early non-turbo models), electrical gremlins, rust in common areas (wheel arches, sills, rear screen surround), suspension wear, minor trim degradation
Turbo Specific Issues:
Turbocharger wear, intercooler leaks, boost control issues on T-Series models
๐ Vehicle History
Brand Heritage
Rover Legacy:
Rover was a British automotive marque with a long history, known for producing reliable and comfortable cars. The 800 Series was intended to be a more modern and executive offering.
Model Evolution
Generations:
The Rover 800 Series, codenamed R8, was produced from 1986 to 1999. It underwent a significant facelift (often referred to as the '800 Series Facelift' or 'Phoenix Project') in 1991, which updated styling and engineering.
Production
Manufacturing Location:
Cowley, Oxford, United Kingdom
Production Period:
1986 - 1999
๐ Awards & Recognition
Recognitions
Industry Awards:
While specific awards for the 800 Series 820 are not widely publicized, it was part of Rover's push into a more premium market segment during its production run.