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Rover 800 Series 825 1986-1999 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Rover Model: 800 Series Variant: 825 Generation Generation Designation: XS/R17 Codes Platform Code: XJ-S / XJ-6 👋 Introduction Market Position Positioning: The Rover 800 Series was positioned as a premium executive saloon, competing with established European luxury brands. The 825 model specifically targeted buyers seeking a balance of performance and refined motoring. Competitive Analysis Key Competitors: Jaguar XJ-S, BMW 5 Series (E28/E34), Mercedes-Benz W124, Audi 100/A6. Key Features Unique Selling Points: The Rover 800 Series, particularly the 825, benefited from its shared platform with the Austin Montego, offering a distinct British take on executive motoring with a focus on comfort and sophisticated styling, often featuring front-wheel drive for its class. Manual Advantage Benefit For Owner: Empowers owners to perform detailed maintenance and repairs, saving on dealership costs and extending vehicle lifespan. Offers deep insight into vehicle operation and diagnostics. 📋 Manual Details Coverage Areas Model Years Covered: 1986, 1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999 Page Count Estimated Page Count: Hundreds (typical for full workshop manuals) Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Full overhaul and repair procedures for the Rover KV6 engine family (and potentially earlier Rover V8 variants if applicable to specific 825 models). Engine Management: Diagnosis, repair, and testing of engine control units (ECU), sensors, actuators, fuel injection systems, and ignition systems. Transmission Manual: Repair, overhaul, and maintenance of manual gearboxes, including clutch operation and driveline components. Transmission Automatic: Diagnosis, repair, and maintenance of automatic transmissions, including torque converter, valve body, and electronic controls. Suspension: Repair, alignment, and replacement of all suspension components, including springs, shock absorbers, control arms, and anti-roll bars. Steering Steering System: Repair and adjustment of steering rack, power steering pump, hoses, and steering column. Brakes Brake System: Overhaul and repair of hydraulic brake systems (discs, pads, calipers, master cylinder, ABS if equipped), including bleeding procedures. Electrical System Lighting And Accessories: Diagnosis and repair of headlights, taillights, interior lighting, power windows, mirrors, central locking, and other electrical accessories. Wiring Diagrams: Comprehensive wiring diagrams for all electrical systems, crucial for troubleshooting. Body And Chassis Body Repairs: Procedures for body panel replacement, rust repair, dent removal, and alignment. Interior Trim: Removal and installation of interior panels, seats, dashboard, and trim components. Climate Control: Repair and servicing of air conditioning and heating systems, including refrigerant handling. Procedures Included Routine Maintenance: Oil changes, filter replacements, spark plug replacement, fluid level checks and top-ups, belt inspections, and tire rotations. Troubleshooting: Step-by-step diagnostic guides for common and uncommon problems across all major systems, often linked to fault codes. Component Replacement: Detailed instructions for replacing individual components such as alternators, starters, fuel pumps, radiators, and brake assemblies. Overhaul Procedures: Comprehensive rebuild instructions for engines, transmissions, and other major mechanical assemblies. Diagnostic Testing: Guidance on using diagnostic tools and techniques to identify and rectify faults. Technical Depth Depth: Professional-grade, covering everything from routine maintenance to complete engine and transmission rebuilds, suitable for both professional technicians and advanced DIY enthusiasts. 📊 Manual Specifications File Format File Format: PDF Print Quality Printability: Full printable Zoom Functionality: YES Binding Type Binding Type: Digital Download (Printable Sections) Paper Type Paper Type: N/A (Digital) Requirements Software Requirements: Adobe PDF Reader, WinRAR Operating System Compatibility: All Versions of Windows & Mac ⚙️ Engine Specifications Primary Engine Engine Code: Rover KV6 (or potentially Rover V8 variants depending on specific 825 sub-models and market) Engine Type: V6 (or V8), naturally aspirated Displacement: Approximately 2.5 Liters (for KV6 variant, V8 would be 3.5L or 3.9L) Performance Horsepower: Typically around 170-190 hp for the 2.5L KV6, and higher for V8 variants. Torque: Torque figures vary but generally align with a naturally aspirated V6 of this displacement, emphasizing smooth power delivery. Fuel System Fuel Injection: Multi-point fuel injection (MPI) Fuel Type: Unleaded Petrol Ignition System Ignition Type: Electronic ignition, distributorless ignition system (DIS) or coil-on-plug depending on year. 🔧 Transmission Standard Transmission Type: Manual (typically 5-speed) or Automatic (e.g., GM 4-speed 4L30-E or similar). Optional Transmission Type: Automatic transmission was often an option. Features Drivetrain: Front-Wheel Drive (FWD) 📐 Dimensions Exterior Length: Approximately 4,770 mm (187.8 in) Width: Approximately 1,770 mm (69.7 in) Height: Approximately 1,400 mm (55.1 in) Weights Curb Weight: Approximately 1,400-1,500 kg (3,086-3,307 lb) 🛡️ Safety Features Ratings Crash Test Performance: Information varies by specific year and testing agency; earlier models pre-date modern stringent testing protocols. Look for specific Euro NCAP or equivalent data if available. Active Features ABS: Anti-lock Braking System (ABS) often an optional or standard feature on later models. Passive Features Airbags: Driver and passenger airbags became more common in later production years. Seatbelts: Three-point seatbelts with pretensioners often standard. 💡 Technology Features Infotainment Audio System: Factory fitted radios, often with cassette players....
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Sku: 489738
Collecties: ALL Rover

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Rover 800 Series 825 1986-1999 Workshop Service Repair Manual
🏷️ Basic Information
Identification
Make:
Rover
Model:
800 Series
Variant:
825
Generation
Generation Designation:
XS/R17
Codes
Platform Code:
XJ-S / XJ-6
👋 Introduction
Market Position
Positioning:
The Rover 800 Series was positioned as a premium executive saloon, competing with established European luxury brands. The 825 model specifically targeted buyers seeking a balance of performance and refined motoring.
Competitive Analysis
Key Competitors:
Jaguar XJ-S, BMW 5 Series (E28/E34), Mercedes-Benz W124, Audi 100/A6.
Key Features
Unique Selling Points:
The Rover 800 Series, particularly the 825, benefited from its shared platform with the Austin Montego, offering a distinct British take on executive motoring with a focus on comfort and sophisticated styling, often featuring front-wheel drive for its class.
Manual Advantage
Benefit For Owner:
Empowers owners to perform detailed maintenance and repairs, saving on dealership costs and extending vehicle lifespan. Offers deep insight into vehicle operation and diagnostics.
📋 Manual Details
Coverage Areas
Model Years Covered:
1986, 1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999
Page Count
Estimated Page Count:
Hundreds (typical for full workshop manuals)
Manual Type
Type:
Workshop Service Repair Manual
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Full overhaul and repair procedures for the Rover KV6 engine family (and potentially earlier Rover V8 variants if applicable to specific 825 models).
Engine Management:
Diagnosis, repair, and testing of engine control units (ECU), sensors, actuators, fuel injection systems, and ignition systems.
Transmission Manual:
Repair, overhaul, and maintenance of manual gearboxes, including clutch operation and driveline components.
Transmission Automatic:
Diagnosis, repair, and maintenance of automatic transmissions, including torque converter, valve body, and electronic controls.
Suspension:
Repair, alignment, and replacement of all suspension components, including springs, shock absorbers, control arms, and anti-roll bars.
Steering
Steering System:
Repair and adjustment of steering rack, power steering pump, hoses, and steering column.
Brakes
Brake System:
Overhaul and repair of hydraulic brake systems (discs, pads, calipers, master cylinder, ABS if equipped), including bleeding procedures.
Electrical System
Lighting And Accessories:
Diagnosis and repair of headlights, taillights, interior lighting, power windows, mirrors, central locking, and other electrical accessories.
Wiring Diagrams:
Comprehensive wiring diagrams for all electrical systems, crucial for troubleshooting.
Body And Chassis
Body Repairs:
Procedures for body panel replacement, rust repair, dent removal, and alignment.
Interior Trim:
Removal and installation of interior panels, seats, dashboard, and trim components.
Climate Control:
Repair and servicing of air conditioning and heating systems, including refrigerant handling.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, spark plug replacement, fluid level checks and top-ups, belt inspections, and tire rotations.
Troubleshooting:
Step-by-step diagnostic guides for common and uncommon problems across all major systems, often linked to fault codes.
Component Replacement:
Detailed instructions for replacing individual components such as alternators, starters, fuel pumps, radiators, and brake assemblies.
Overhaul Procedures:
Comprehensive rebuild instructions for engines, transmissions, and other major mechanical assemblies.
Diagnostic Testing:
Guidance on using diagnostic tools and techniques to identify and rectify faults.
Technical Depth
Depth:
Professional-grade, covering everything from routine maintenance to complete engine and transmission rebuilds, suitable for both professional technicians and advanced DIY enthusiasts.
📊 Manual Specifications
File Format
File Format:
PDF
Print Quality
Printability:
Full printable
Zoom Functionality:
YES
Binding Type
Binding Type:
Digital Download (Printable Sections)
Paper Type
Paper Type:
N/A (Digital)
Requirements
Software Requirements:
Adobe PDF Reader, WinRAR
Operating System Compatibility:
All Versions of Windows & Mac
⚙️ Engine Specifications
Primary Engine
Engine Code:
Rover KV6 (or potentially Rover V8 variants depending on specific 825 sub-models and market)
Engine Type:
V6 (or V8), naturally aspirated
Displacement:
Approximately 2.5 Liters (for KV6 variant, V8 would be 3.5L or 3.9L)
Performance
Horsepower:
Typically around 170-190 hp for the 2.5L KV6, and higher for V8 variants.
Torque:
Torque figures vary but generally align with a naturally aspirated V6 of this displacement, emphasizing smooth power delivery.
Fuel System
Fuel Injection:
Multi-point fuel injection (MPI)
Fuel Type:
Unleaded Petrol
Ignition System
Ignition Type:
Electronic ignition, distributorless ignition system (DIS) or coil-on-plug depending on year.
🔧 Transmission
Standard
Transmission Type:
Manual (typically 5-speed) or Automatic (e.g., GM 4-speed 4L30-E or similar).
Optional
Transmission Type:
Automatic transmission was often an option.
Features
Drivetrain:
Front-Wheel Drive (FWD)
📐 Dimensions
Exterior
Length:
Approximately 4,770 mm (187.8 in)
Width:
Approximately 1,770 mm (69.7 in)
Height:
Approximately 1,400 mm (55.1 in)
Weights
Curb Weight:
Approximately 1,400-1,500 kg (3,086-3,307 lb)
🛡️ Safety Features
Ratings
Crash Test Performance:
Information varies by specific year and testing agency; earlier models pre-date modern stringent testing protocols. Look for specific Euro NCAP or equivalent data if available.
Active Features
ABS:
Anti-lock Braking System (ABS) often an optional or standard feature on later models.
Passive Features
Airbags:
Driver and passenger airbags became more common in later production years.
Seatbelts:
Three-point seatbelts with pretensioners often standard.
💡 Technology Features
Infotainment
Audio System:
Factory fitted radios, often with cassette players. Later models may have CD players and improved speaker systems.
Climate Control Features:
Manual or automatic climate control systems were available, offering good passenger comfort.
Driver Assistance
Cruise Control:
Cruise control was commonly offered as an option or standard on higher trims.
Connectivity
Early Systems:
Limited connectivity by modern standards, focused on basic audio and climate functions. Some later models might have rudimentary trip computers.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 6,000-10,000 miles or 12 months, depending on driving conditions and oil type.
Timing Belt Interval:
For KV6 engines, timing belt replacement is critical, typically every 60,000 miles or 5 years. Failure can cause catastrophic engine damage.
Fluid Specifications
Engine Oil:
API SG/SH, SAE 10W-40 or 15W-50 (consult specific manual for exact viscosity based on climate).
Coolant:
Ethylene glycol based antifreeze, typically a 50/50 mix with distilled water. Specific Rover coolant recommendations should be followed.
Brake Fluid:
DOT 3 or DOT 4 (check manual for specific grade).
Transmission Fluid Automatic:
Dexron III or equivalent (for GM 4-speed automatic).
Known Issues
Engine Problems:
Head gasket failures on V6 engines (KV6), particularly around the rear bank, can be an issue. Timing belt tensioner and water pump reliability are also critical maintenance points.
Electrical Problems:
Corrosion in wiring harnesses, failing central locking actuators, and issues with the interior electrics are not uncommon due to age.
Suspension Issues:
Wear in suspension bushes and ball joints, leading to knocking noises and imprecise handling, is typical for vehicles of this age.
Rust Corrosion:
Rust can be present on wheel arches, sills, and around the boot lid, requiring attention.
📚 Vehicle History
Brand Heritage
Brand Legacy:
Rover has a long history of producing comfortable, well-appointed British cars. The 800 Series was a significant model in its later years, aiming to revive the brand's presence in the executive segment.
Model Evolution
Generations:
The Rover 800 Series was produced in two main generations: the 'R17' (1986-1991) and the facelifted 'XS' (1991-1999), which featured significant styling and mechanical updates.
Production
Manufacturing Locations:
Primarily manufactured in the United Kingdom.
Development Basis
Platform Sharing:
Based on the platform shared with the Honda Legend, a collaboration that brought Japanese engineering expertise to the British design.
🏆 Awards & Recognition
Recognitions
Industry Acclaim:
While specific awards for the 825 variant are less documented, the Rover 800 Series was generally well-regarded for its ride comfort, spacious interior, and quiet cabin, contributing to its executive appeal.
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