Rover 800 Series 820 825 827 1986-1999 Service Repair Shop Manual
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🏷️ Basic Information Identification Make: Rover Model: 800 Series Sub Models Covered: 820, 825, 827 Production Years Covered: 1986-1999 👋 Introduction Market Position Vehicle Segment: Executive Car / Luxury Car Target Audience For Manual: Rover 800 Series owners looking to perform their own maintenance and repairs, saving on dealership costs. Competitive Analysis Competitors Vehicle Class: Jaguar XJ-S, BMW 5 Series, Mercedes-Benz E-Class, Audi 100/A6 Key Features Of Manual Ease Of Use: Easy to follow step-by-step instructions, clear pictures, and wiring diagrams. Cost Savings: Enables owners to perform repairs themselves, potentially saving thousands on labor costs. Accessibility: Instant download, accessible on multiple devices. 📋 Manual Details Coverage Areas Primary Coverage: Service, Repair, Maintenance Additional Coverage: Routine Maintenance, Troubleshooting, Wiring Diagrams Page Count Estimated Page Count: Extensive (specific number not provided, but described as 'full professional quality in depth') Manual Type Type: Service Repair Shop Manual Language Language: English Format Format: PDF Download Compatibility Operating Systems: Windows, macOS, Linux, Tablets, Smartphones 📖 Manual Coverage Systems Covered Powertrain: Engine (all variants), Transmission (automatic and manual), Drivetrain, Cooling System, Fuel System, Exhaust System Chassis: Suspension (front and rear), Steering System, Brakes (hydraulic, ABS if applicable), Wheels and Tires Electrical: Ignition System, Charging System, Starting System, Lighting, Instrumentation, Body Electrical (power windows, locks, mirrors), Audio System, HVAC Controls, ECU/ECM Diagnostics Body: Body Panels, Doors, Hood, Trunk, Bumpers, Glass, Interior Trim, Seating Procedures Included Maintenance: Oil and Filter Change, Air Filter Replacement, Spark Plug Replacement, Coolant Flush, Brake Fluid Flush, Power Steering Fluid Change, Transmission Fluid Change, Wiper Blade Replacement, Bulb Replacement, Battery Maintenance Repair: Engine Overhaul, Cylinder Head Gasket Replacement, Timing Belt/Chain Replacement, Alternator Replacement, Starter Motor Replacement, Brake Pad/Disc Replacement, Wheel Bearing Replacement, Radiator Replacement, Fuel Pump Replacement, Ignition Coil Replacement, Sensor Replacement (MAP, TPS, O2, etc.), Suspension Component Replacement (shocks, struts, control arms), Exhaust System Repair, Electrical Component Repair, Door Mechanism Repair, Window Regulator Replacement Diagnostics: Troubleshooting common issues, Reading diagnostic trouble codes (DTCs), Electrical circuit testing, Fuel system pressure testing, Compression testing Technical Depth Depth: Comprehensive, from basic maintenance to complex repairs and diagnostics. Includes step-by-step instructions and illustrative diagrams. Detail Level: Professional quality, in-depth coverage suitable for DIY enthusiasts and independent mechanics. 📊 Manual Specifications File Format Type: PDF Searchability: Likely searchable text-based PDF (standard for professional manuals) Print Quality Printability: Printable pages for convenient workshop use Binding Type Type: N/A (Digital Download) Paper Type Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Codes And Variants: Rover KV6, Honda PG series (e.g., PG-1 for manual transmission variants), Rover M series (early models) Engine Displacement 820: 2.0 Liters (1994cc) Engine Displacement 825: 2.5 Liters (2498cc - typically Rover KV6) Engine Displacement 827: 2.7 Liters (2675cc - Honda C27A V6) Performance Horsepower 820: Varies by sub-model and year, typically 115-140 bhp Horsepower 825: Varies by KV6 variant, typically 170-185 bhp Horsepower 827: Approximately 177 bhp Fuel System Injection Type: Electronic Fuel Injection (EFI) Fuel Type: Unleaded Petrol (Gasoline) 🔧 Transmission Standard Transmission Types: Manual and Automatic transmissions were available across the range. Optional Specific Automatic Transmissions: Often sourced from ZF or Honda depending on engine and year. Features Manual Gearbox Codes: Rover PG-1 (often paired with 4-cylinder engines) Fluid Specifications Automatic Transmission Fluid: Specific ATF type depends on the transmission manufacturer (e.g., Dexron-III for some ZF units, Honda ATF for Honda units). Manuals will specify exact types. Manual Transmission Fluid: Specific GL-4 or GL-5 gear oil, viscosity dependent on ambient temperature (e.g., 75W-90). Manuals will specify. 📐 Dimensions Exterior Body Styles: 4-door Saloon, 5-door Hatchback (sometimes referred to as R800 Hatch or fastback) Wheelbase: Approximately 2745 mm (108.1 inches) for most variants. Weights Curb Weight: Varies significantly by model and engine, typically ranging from 1350 kg to 1550 kg. 🛡️ Safety Features Ratings Crash Test Information: No official Euro NCAP ratings for early models. Later models would have undergone testing according to contemporary standards. Manual provides safety system diagnostics. Active Features Braking System: Discs front, drums or discs rear. Anti-lock Braking System (ABS) was optional or standard on higher trims/later models. Passive Features Restraints: Seat belts, driver and passenger airbags (optional or standard depending on year and trim). 💡 Technology Features Infotainment Audio System: Factory fitted radios and CD players, often with cassette players in earlier models. Speaker systems varied by trim level. Driver Assistance Cruise Control: Available on higher trim levels and later models. Connectivity Features: Limited by era; primarily focused on basic vehicle functions and comfort features. No modern connectivity like Bluetooth or USB as standard. 🔧 Maintenance Service Intervals Oil Change: Typically every 6,000-10,000 miles or 12 months, whichever comes first (refer to manual for exact specifications). Timing Belt: Crucial for KV6 and some other engines; typically replaced every 60,000-80,000 miles or 5-7 years. Consult the manual for specific engine and interval. Spark Plugs: Intervals vary by plug...
Troubleshooting common issues, Reading diagnostic trouble codes (DTCs), Electrical circuit testing, Fuel system pressure testing, Compression testing
Technical Depth
Depth:
Comprehensive, from basic maintenance to complex repairs and diagnostics. Includes step-by-step instructions and illustrative diagrams.
Detail Level:
Professional quality, in-depth coverage suitable for DIY enthusiasts and independent mechanics.
📊 Manual Specifications
File Format
Type:
PDF
Searchability:
Likely searchable text-based PDF (standard for professional manuals)
Print Quality
Printability:
Printable pages for convenient workshop use
Binding Type
Type:
N/A (Digital Download)
Paper Type
Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Codes And Variants:
Rover KV6, Honda PG series (e.g., PG-1 for manual transmission variants), Rover M series (early models)
Engine Displacement 820:
2.0 Liters (1994cc)
Engine Displacement 825:
2.5 Liters (2498cc - typically Rover KV6)
Engine Displacement 827:
2.7 Liters (2675cc - Honda C27A V6)
Performance
Horsepower 820:
Varies by sub-model and year, typically 115-140 bhp
Horsepower 825:
Varies by KV6 variant, typically 170-185 bhp
Horsepower 827:
Approximately 177 bhp
Fuel System
Injection Type:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded Petrol (Gasoline)
🔧 Transmission
Standard
Transmission Types:
Manual and Automatic transmissions were available across the range.
Optional
Specific Automatic Transmissions:
Often sourced from ZF or Honda depending on engine and year.
Features
Manual Gearbox Codes:
Rover PG-1 (often paired with 4-cylinder engines)
Fluid Specifications
Automatic Transmission Fluid:
Specific ATF type depends on the transmission manufacturer (e.g., Dexron-III for some ZF units, Honda ATF for Honda units). Manuals will specify exact types.
Manual Transmission Fluid:
Specific GL-4 or GL-5 gear oil, viscosity dependent on ambient temperature (e.g., 75W-90). Manuals will specify.
📐 Dimensions
Exterior
Body Styles:
4-door Saloon, 5-door Hatchback (sometimes referred to as R800 Hatch or fastback)
Wheelbase:
Approximately 2745 mm (108.1 inches) for most variants.
Weights
Curb Weight:
Varies significantly by model and engine, typically ranging from 1350 kg to 1550 kg.
🛡️ Safety Features
Ratings
Crash Test Information:
No official Euro NCAP ratings for early models. Later models would have undergone testing according to contemporary standards. Manual provides safety system diagnostics.
Active Features
Braking System:
Discs front, drums or discs rear. Anti-lock Braking System (ABS) was optional or standard on higher trims/later models.
Passive Features
Restraints:
Seat belts, driver and passenger airbags (optional or standard depending on year and trim).
💡 Technology Features
Infotainment
Audio System:
Factory fitted radios and CD players, often with cassette players in earlier models. Speaker systems varied by trim level.
Driver Assistance
Cruise Control:
Available on higher trim levels and later models.
Connectivity
Features:
Limited by era; primarily focused on basic vehicle functions and comfort features. No modern connectivity like Bluetooth or USB as standard.
🔧 Maintenance
Service Intervals
Oil Change:
Typically every 6,000-10,000 miles or 12 months, whichever comes first (refer to manual for exact specifications).
Timing Belt:
Crucial for KV6 and some other engines; typically replaced every 60,000-80,000 miles or 5-7 years. Consult the manual for specific engine and interval.
Spark Plugs:
Intervals vary by plug type (e.g., copper, platinum, iridium), usually between 30,000 and 100,000 miles.
Fluid Specifications
Engine Oil:
Specific viscosity (e.g., 10W-40, 5W-30) and API/ACEA specification dependent on engine type. Manual will detail exact requirements.
Coolant:
Ethylene glycol-based antifreeze, typically a 50/50 mix with distilled water. Specific color/type may vary. Manual will specify.
Known Issues
Common Problems:
Head gasket failures (especially on early KV6 engines), suspension wear, electrical gremlins, rust in sills and arches, aging rubber components (hoses, mounts).
Diagnostic Points:
The manual's troubleshooting section will be invaluable for diagnosing these common issues.
📚 Vehicle History
Brand Heritage
Rover History:
Rover, a historic British marque, was known for its executive and luxury vehicles. The 800 Series was a significant model for the brand's revival.
Model Evolution
Generations:
The Rover 800 Series was based on the extensive joint venture project with Honda, resulting in the Honda Legend. It underwent facelifts and updates throughout its production run.
Production
Manufacturing Locations:
Cowley, Oxfordshire, United Kingdom
Notable Variants:
SD (Standard Door) andimbledon variants, high-performance models like the Vitesse.
🏆 Awards & Recognition
Recognitions
Industry Acclaim:
The Rover 800 Series was well-received in its segment for its comfort, refinement, and strong performance from the V6 engines, particularly the Honda-derived units. Specific awards are not extensively documented but it was considered a competitive offering in the luxury executive class of its time.