Rover 800 Series 820 825 827 1986-1999 Factory Service Repair Manual
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🏷️ Basic Information Identification Make: Rover Model: 800 Series Model Variants: 820, 825, 827 Production Years Covered: 1986-1999 Codes Vin Decoder Information: Manual likely contains VIN decoding guidelines specific to the Rover 800 Series. 👋 Introduction Market Position Segment: Executive car segment. Target Audience: Owners and independent workshops servicing Rover 800 Series vehicles. Competitive Analysis Competitors: Competed against vehicles like the Ford Scorpio, BMW 5 Series (E34), Mercedes-Benz E-Class (W124), and Volvo 480/850. Key Features Design Influence: Based on the platform shared with the Honda Legend. Luxury Appointments: Known for its comfortable ride, spacious interior, and premium features for its era. Badge Engineering: Early models shared significant components and technology with Honda. 📋 Manual Details Coverage Areas Primary Coverage: Full factory service and repair for Rover 800 Series models 820, 825, and 827. Secondary Coverage: Maintenance schedules, troubleshooting, wiring diagrams, specifications. Page Count Estimated Page Count: Comprehensive; exact count not specified, but typical for a full factory service manual covering multiple years and variants would be 1000+ pages. Manual Type Type: Factory Service Repair Manual (FSM) Scope: Diagnostic, repair, maintenance, overhaul, and troubleshooting. Language Language: English Format Digital Format: PDF 📖 Manual Coverage Systems Covered Engine: All engine variants including 2.0L (M16/T-series), 2.5L (KV6), and 2.7L (Honda V6). Transmission: Manual and automatic transmissions, including repair, overhaul, and fluid specifications. Drivetrain: Front-wheel drive system, driveshafts, CV joints, differentials. Suspension: Front and rear suspension systems, including struts, springs, control arms, bushings. Steering: Power steering system, steering rack, pump, linkages. Brakes: Hydraulic brake system, ABS (if equipped), disc and drum components, hydraulic lines, fluid specifications. Electrical System: Battery, charging system, starting system, lighting, ignition system, fuse box diagrams. Fuel System: Fuel pump, injectors, fuel lines, fuel filter, tank, emissions control systems. Cooling System: Radiator, thermostat, water pump, coolant specifications, hoses. Exhaust System: Exhaust manifolds, catalytic converters, mufflers, pipes. Body And Chassis: Body panel removal and installation, interior trim, doors, windows, seals, structural components. HVAC: Heating, ventilation, and air conditioning system diagnosis and repair. Comfort And Convenience: Power windows, locks, mirrors, seats, sunroofs, interior lighting. Procedures Included Routine Maintenance: Oil changes, filter replacements, fluid checks and top-ups, spark plug replacement, belt inspections. Troubleshooting: Diagnostic procedures for common and uncommon faults, symptom-based troubleshooting guides. Repair Overhaul: Step-by-step instructions for component removal, repair, reassembly, and installation for all major systems. Diagnostics: On-board diagnostics (OBD) procedures, fault code retrieval and interpretation (if applicable to later models in the range). Wiring Diagrams: Detailed electrical wiring schematics for all vehicle systems. Technical Specifications: Torque specifications, clearances, fluid capacities, and other critical measurements. Special Tools: Identification and usage of any specialized tools required for specific repairs. Technical Depth Depth: Extremely high. Covers everything from basic fluid changes to complete engine and transmission rebuilds. Detail Level: Comprehensive, including exploded views, diagrams, step-by-step instructions, and troubleshooting flowcharts. 📊 Manual Specifications File Format Format: PDF (Portable Document Format) Searchability: Likely text-searchable within the PDF for efficient information retrieval. Print Quality Printability: Designed to be printable for users who prefer a physical copy. Binding Type Binding: N/A (Digital Format) Paper Type Paper: N/A (Digital Format) Software Requirements Reader: Adobe Acrobat Reader or compatible PDF viewer. Decompression: WinZip or compatible file archiver (if delivered as a compressed archive). Compatibility Operating Systems: Windows and macOS. ⚙️ Engine Specifications Primary Engine 820 Engine: Rover T-series 2.0L (1994cc) 16-valve DOHC I4, often turbocharged (e.g., 820ti). 825 Engine: Rover KV6 2.5L (2497cc) 24-valve SOHC V6. 827 Engine: Honda C27A 2.7L (2675cc) 24-valve SOHC V6. Performance 820 Performance Range: Approx. 100-136 hp (naturally aspirated), up to 197 hp (turbocharged). 825 Performance: Approx. 177 hp. 827 Performance: Approx. 170 hp. Fuel System Fuel Injection: Multi-point fuel injection (MPI) across all models. Fuel Type: Unleaded gasoline (petrol). 🔧 Transmission Standard 820 Transmission: 5-speed manual. Optional 820 Transmission Auto: 4-speed automatic (e.g., PG1). 825 827 Transmission: 4-speed automatic (e.g., Honda/Rover R40/45). Features Type: Front-wheel drive. 📐 Dimensions Exterior Body Styles: Saloon (sedan) and Coupe. Length: Approximately 4750-4850 mm (187-191 inches) depending on body style and year. Width: Approximately 1750-1780 mm (69-70 inches). Height: Approximately 1390-1420 mm (55-56 inches). Weights Curb Weight: Approx. 1350-1550 kg (2976-3417 lbs) depending on engine and specification. 🛡️ Safety Features Ratings Crash Test Results: Euro NCAP ratings not available for early models; later models would have had updated safety features and potentially improved ratings, but specific data may be scarce. Active Features ABS: Available on higher trims and later models, often as an option. Passive Features Airbags: Driver airbag standard on later models; passenger airbag optional/standard on high trims later in production. Seatbelts: Front seatbelt pre-tensioners and height adjustment. 💡 Technology Features Infotainment Audio System: Factory fitted radio/cassette player with multiple speaker options, upgraded systems available on higher trims. Cruise Control: Available as an option or standard on higher trims. Driver Assistance ABS: As mentioned in safety, often optional...
Approx. 100-136 hp (naturally aspirated), up to 197 hp (turbocharged).
825 Performance:
Approx. 177 hp.
827 Performance:
Approx. 170 hp.
Fuel System
Fuel Injection:
Multi-point fuel injection (MPI) across all models.
Fuel Type:
Unleaded gasoline (petrol).
🔧 Transmission
Standard
820 Transmission:
5-speed manual.
Optional
820 Transmission Auto:
4-speed automatic (e.g., PG1).
825 827 Transmission:
4-speed automatic (e.g., Honda/Rover R40/45).
Features
Type:
Front-wheel drive.
📐 Dimensions
Exterior
Body Styles:
Saloon (sedan) and Coupe.
Length:
Approximately 4750-4850 mm (187-191 inches) depending on body style and year.
Width:
Approximately 1750-1780 mm (69-70 inches).
Height:
Approximately 1390-1420 mm (55-56 inches).
Weights
Curb Weight:
Approx. 1350-1550 kg (2976-3417 lbs) depending on engine and specification.
🛡️ Safety Features
Ratings
Crash Test Results:
Euro NCAP ratings not available for early models; later models would have had updated safety features and potentially improved ratings, but specific data may be scarce.
Active Features
ABS:
Available on higher trims and later models, often as an option.
Passive Features
Airbags:
Driver airbag standard on later models; passenger airbag optional/standard on high trims later in production.
Seatbelts:
Front seatbelt pre-tensioners and height adjustment.
💡 Technology Features
Infotainment
Audio System:
Factory fitted radio/cassette player with multiple speaker options, upgraded systems available on higher trims.
Cruise Control:
Available as an option or standard on higher trims.
Driver Assistance
ABS:
As mentioned in safety, often optional or standard on higher trims.
Connectivity
Early Features:
Limited connectivity by modern standards; focus on power accessories and comfort features.
🔧 Maintenance
Service Intervals
Oil Change:
Typically every 10,000 miles or 12 months (check manual for specific intervals by engine and oil type).
Timing Belt:
For T-series engines, timing belt replacement recommended every 60,000 miles or 4-5 years. KV6 and Honda engines use timing chains or different belt intervals. Consult manual for exact intervals.
Fluid Specifications
Engine Oil:
API SG or higher; viscosity typically 10W/40 or 5W/30 synthetic, depending on climate and engine. Consult manual for specific grades.
Coolant:
Ethylene glycol-based antifreeze. Typically a 50/50 mix with distilled water. Specific type (e.g., OAT, HOAT) depends on the model year and original fill.
Brake Fluid:
DOT 3 or DOT 4 hydraulic fluid.
Transmission Fluid Auto:
Dexron II/III or equivalent for automatic transmissions (check manual for specific type and capacity).
Known Issues
Head Gasket:
The Rover T-series and KV6 engines are known for potential head gasket failures, especially if overheated or poorly maintained.
Electronics:
Older electronics and wiring can be prone to issues due to age and environmental factors.
Suspension Wear:
Wear in suspension bushings and mounts can lead to knocking noises and degraded handling.
📚 Vehicle History
Brand Heritage
Rover Legacy:
Successor to the Rover SD1, representing Rover's move into the executive saloon market with European styling and technology.
Model Evolution
Project K Platforms:
Part of Rover's 'R' project, heavily influenced by Honda partnership, sharing the platform with the second-generation Honda Legend.
Primarily produced in the United Kingdom (Cowley plant).
Production End:
Production ceased in 1999, succeeded by the Rover 75.
🏆 Awards & Recognition
Recognitions
Industry Reviews:
Received positive reviews for comfort, ride quality, and value in its segment at launch, though later facing increased competition and reliability concerns.