Rover 800 Series 825 1986-1999 Repair Service Manual
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🏷️ Basic Information Identification Make: Rover Model: 800 Series Model Variant: 825 Product Name: Rover 800 Series 825 1986-1999 Repair Service Manual Generation Model Generation: XJ-S based platform (initially), later RWD platform. Codes Platform Code: RWD Platform (SD1 derived) 👋 Introduction Market Position Market Segment: Executive/Luxury Sedan Competitive Analysis Competitors: Jaguar XJ, BMW 5 Series, Mercedes-Benz E-Class, Audi 100/A6 Key Features Design Influence: Initial design influenced by Italian styling house Italdesign Giugiaro and Rover's own design team, later facelifts incorporated more contemporary styling cues. Powertrain Options: Primarily featured Rover's K-Series V6 and later Honda J-series V6 engines. 📋 Manual Details Coverage Areas Applicable Years: 1986, 1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999 Trim Levels Covered: All 825 variants Page Count Page Count: Not specified, but implied to be comprehensive. Manual Type Manual Type: Repair Service Manual Intended Audience: Professional Technicians & DIY Mechanics with basic electrical/mechanical knowledge. Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Complete engine repair, diagnostics, and overhaul for the 825 model. Transmission: Manual and automatic transmission service, repair, and adjustment. Drivetrain: Front-wheel drive components, driveshafts, CV joints, differential. Suspension: Front and rear suspension systems, shock absorbers, springs, bushings, alignment. Steering: Power steering system, steering rack, column, linkage. Brakes: Hydraulic system, disc and drum brakes, ABS (if equipped), parking brake. Electrical: Wiring diagrams, battery, alternator, starter, lighting, ignition, sensors, ECUs. Fuel System: Fuel injection, fuel pump, injectors, fuel lines, emissions controls. Cooling System: Radiator, water pump, thermostat, hoses, fan, heater core. Exhaust System: Manifold, catalytic converter, mufflers, pipes. Body And Frame: Body panel repair, structural components, doors, glass, interior trim. HVAC: Heating, ventilation, and air conditioning system service and repair. Body Electronics: Power windows, locks, mirrors, central locking, alarms. Procedures Included Maintenance: Routine maintenance tasks, fluid changes, filter replacements, inspections. Troubleshooting: Diagnostic procedures for common and uncommon faults, symptom-based guides. Disassembly Assembly: Step-by-step instructions for component removal and installation. Repair: Detailed repair procedures for all major vehicle systems. Cleaning: Component cleaning and preparation for reassembly. Reinstalling: Correct procedures for reinstalling repaired or replaced components. Specifications Data: Torque values, clearances, fluid capacities, electrical resistance. Technical Depth Depth: Comprehensive, covering major overhauls, diagnostics, and routine maintenance. Illustrations: Includes illustrations, diagrams, and pictures to aid understanding. 📊 Manual Specifications File Format File Format: PDF Print Quality Printable: Full Printable Zoom Functionality: Zoom IN/OUT enabled Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) Delivery Delivery Method: Instant Download Requirements Software Requirements: Adobe PDF Reader & WinZip Compatibility Operating Systems: All Versions of Windows & Mac ⚙️ Engine Specifications Primary Engine Engine Type: V6 (Rover K-Series/Honda J-Series) Displacement 825: 2.5 Liters (approx. 2500cc) Performance Horsepower Typical 825: 160-190 hp (depending on year and specific engine variant) Torque Typical 825: 180-220 lb-ft (depending on year and specific engine variant) Fuel System Fuel Delivery: Multi-point Fuel Injection (MPI) Engine Management: Electronic Fuel Injection (EFI) / Engine Control Unit (ECU) Technical Details Bore X Stroke: Refer to manual for specific engine codes (e.g., K25 - 82mm x 79.2mm for some 2.5L variants). Compression Ratio: Refer to manual for specific engine codes. Valvetrain: DOHC (Double Overhead Camshaft) with 4 valves per cylinder. 🔧 Transmission Standard Transmission Type Standard: Often paired with a 4-speed automatic transmission. Optional Transmission Type Optional: Some models offered a 5-speed manual transmission. Features Automatic Transmission Features: Electronically controlled automatic gearbox with 'Sport' and 'Economy' modes on later models. 📐 Dimensions Exterior Body Styles: 4-door Sedan, 5-door Fastback (often referred to as the 'Hatchback' or 'Brooklands' model). Wheelbase: Approximately 2740 mm (107.9 in) Length: Approximately 4770 mm (187.8 in) for Sedan, 4800 mm (189.0 in) for Fastback. Weights Curb Weight: Approximately 1500-1600 kg (3300-3527 lbs) 🛡️ Safety Features Ratings Crash Test History: Limited formal crash test data publicly available for this era and model, but designed to meet prevailing safety standards of its time. Active Features ABS: Anti-lock Braking System (ABS) available on higher trims and later models. Traction Control: Traction control systems were introduced on later models. Passive Features Airbags: Driver airbag became standard on later models; passenger airbag optional/standard on top trims. Seatbelts: Pyrotechnic seatbelt pre-tensioners on front seats on later models. 💡 Technology Features Infotainment Audio System: Factory fitted Clarion or Philips audio systems with cassette player and AM/FM radio; later models offered CD players. Climate Control: Manual or automatic climate control systems, including air conditioning. Driver Assistance Cruise Control: Cruise control was an optional or standard feature on higher trims. Connectivity Onboard Diagnostics: OBD-I or early OBD-II compliant systems depending on the year and market. 🔧 Maintenance Service Intervals Oil Change Interval: Typically every 7,500-10,000 miles or 12 months, whichever comes first (refer to manual for specific grades and intervals). Timing Belt Replacement: Refer to manual for specific engine variant (K-Series V6...
Rover 800 Series 825 1986-1999 Repair Service Manual
Generation
Model Generation:
XJ-S based platform (initially), later RWD platform.
Codes
Platform Code:
RWD Platform (SD1 derived)
👋 Introduction
Market Position
Market Segment:
Executive/Luxury Sedan
Competitive Analysis
Competitors:
Jaguar XJ, BMW 5 Series, Mercedes-Benz E-Class, Audi 100/A6
Key Features
Design Influence:
Initial design influenced by Italian styling house Italdesign Giugiaro and Rover's own design team, later facelifts incorporated more contemporary styling cues.
Powertrain Options:
Primarily featured Rover's K-Series V6 and later Honda J-series V6 engines.
Comprehensive, covering major overhauls, diagnostics, and routine maintenance.
Illustrations:
Includes illustrations, diagrams, and pictures to aid understanding.
📊 Manual Specifications
File Format
File Format:
PDF
Print Quality
Printable:
Full Printable
Zoom Functionality:
Zoom IN/OUT enabled
Binding Type
Binding Type:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
Delivery
Delivery Method:
Instant Download
Requirements
Software Requirements:
Adobe PDF Reader & WinZip
Compatibility
Operating Systems:
All Versions of Windows & Mac
⚙️ Engine Specifications
Primary Engine
Engine Type:
V6 (Rover K-Series/Honda J-Series)
Displacement 825:
2.5 Liters (approx. 2500cc)
Performance
Horsepower Typical 825:
160-190 hp (depending on year and specific engine variant)
Torque Typical 825:
180-220 lb-ft (depending on year and specific engine variant)
Fuel System
Fuel Delivery:
Multi-point Fuel Injection (MPI)
Engine Management:
Electronic Fuel Injection (EFI) / Engine Control Unit (ECU)
Technical Details
Bore X Stroke:
Refer to manual for specific engine codes (e.g., K25 - 82mm x 79.2mm for some 2.5L variants).
Compression Ratio:
Refer to manual for specific engine codes.
Valvetrain:
DOHC (Double Overhead Camshaft) with 4 valves per cylinder.
🔧 Transmission
Standard
Transmission Type Standard:
Often paired with a 4-speed automatic transmission.
Optional
Transmission Type Optional:
Some models offered a 5-speed manual transmission.
Features
Automatic Transmission Features:
Electronically controlled automatic gearbox with 'Sport' and 'Economy' modes on later models.
📐 Dimensions
Exterior
Body Styles:
4-door Sedan, 5-door Fastback (often referred to as the 'Hatchback' or 'Brooklands' model).
Wheelbase:
Approximately 2740 mm (107.9 in)
Length:
Approximately 4770 mm (187.8 in) for Sedan, 4800 mm (189.0 in) for Fastback.
Weights
Curb Weight:
Approximately 1500-1600 kg (3300-3527 lbs)
🛡️ Safety Features
Ratings
Crash Test History:
Limited formal crash test data publicly available for this era and model, but designed to meet prevailing safety standards of its time.
Active Features
ABS:
Anti-lock Braking System (ABS) available on higher trims and later models.
Traction Control:
Traction control systems were introduced on later models.
Passive Features
Airbags:
Driver airbag became standard on later models; passenger airbag optional/standard on top trims.
Seatbelts:
Pyrotechnic seatbelt pre-tensioners on front seats on later models.
💡 Technology Features
Infotainment
Audio System:
Factory fitted Clarion or Philips audio systems with cassette player and AM/FM radio; later models offered CD players.
Climate Control:
Manual or automatic climate control systems, including air conditioning.
Driver Assistance
Cruise Control:
Cruise control was an optional or standard feature on higher trims.
Connectivity
Onboard Diagnostics:
OBD-I or early OBD-II compliant systems depending on the year and market.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 7,500-10,000 miles or 12 months, whichever comes first (refer to manual for specific grades and intervals).
Timing Belt Replacement:
Refer to manual for specific engine variant (K-Series V6 often used a timing belt, J-series used a timing chain).
Fluid Specifications
Engine Oil Specification:
API SG/SH or ACEA A2, SAE 10W-40 or 10W-50 (refer to manual for precise grade).
Coolant Specification:
Ethylene glycol based antifreeze, typically a 50/50 mix with distilled water.
Transmission Fluid Automatic:
Dexron II or III (refer to manual for specific type and capacity).
Brake Fluid Specification:
DOT 3 or DOT 4 (refer to manual).
Known Issues
Common Problems:
Head gasket issues (particularly on K-series engines), electrical gremlins, rust around wheel arches and sills, suspension wear.
Preventative Maintenance:
Regular checks of coolant levels, vigilant attention to engine temperature, and rustproofing are recommended.
📚 Vehicle History
Brand Heritage
Brand Focus:
Rover historically focused on producing comfortable, refined, and capable saloon cars with a strong emphasis on British craftsmanship.
Model Evolution
Launch Year:
1986
Facelifts:
Received significant facelifts in 1992 (MkII) and 1995 (MkIII), updating styling, interior, and mechanicals.
Engine Partnerships:
Development involved collaboration with Honda, leading to the use of Honda-derived J-series V6 engines in later versions.
Production
Production Period:
1986 - 1999
Manufacturing Location:
Solihull, West Midlands, United Kingdom
🏆 Awards & Recognition
Recognitions
General Reputation:
The Rover 800 series was generally well-regarded for its comfortable ride, refined interior, and strong performance, positioning it as a capable executive car.