Rover 800 Series 825 1986-1999 Full Service Repair Manual
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🏷️ Basic Information Identification Make: Rover Model: 800 Series Model Variant: 825 Production Years Covered: 1986-1999 Codes Platform Code: XJ-60 (RWD Platform) 👋 Introduction Market Position Positioning: Executive/Luxury Sedan, targeting a premium segment in its era. Competitive Analysis Competitors: Competed against other executive sedans of the era such as the BMW 5 Series, Mercedes-Benz E-Class, Audi 100/A6, and higher-trim models from Ford, Peugeot, and Volvo. Key Features Platform Sharing: Shared its platform with the Austin-Morris Rover SD1, later evolved into the Rover 800 series, designed in collaboration with Honda (based on the Honda Legend platform). Design Philosophy: A blend of British luxury and engineering with Japanese reliability and technology, a significant departure from previous Rover models. 📋 Manual Details Coverage Areas Primary Coverage: Full Service Repair, Maintenance, Diagnostics, Overhaul Secondary Coverage: Electrical Schematics, Troubleshooting, Bodywork, Accessories Page Count Estimated Page Count: Varies (typically 500-1000+ pages for comprehensive manuals of this era) Manual Type Type: Full Service and Repair Manual Language Language: English Format Digital Format: PDF Print Capability: Full Printable Delivery Delivery Method: Instant Download Requirements Software Requirements: Adobe PDF Reader, WinRAR (for potential archives) Compatibility: All Versions of Windows & Mac OS 📖 Manual Coverage Systems Covered Powertrain: Engine, Fuel System, Ignition System, Exhaust System, Cooling System, Lubrication System Drivetrain: Transmission (Automatic & Manual), Clutch, Driveshafts, Differential Chassis: Suspension (Front & Rear), Steering System, Braking System (ABS if equipped) Electrical: Wiring Diagrams, Ignition System, Charging System, Lighting, Instruments, ECUs, Body Control Modules Body And Interior: Body Panels, Doors, Windows, Seats, HVAC, Trim Air Conditioning And Heating: HVAC system diagnosis, refrigerant handling (with appropriate safety warnings), blower motor, heater core, and AC compressor service. Procedures Included Maintenance: Routine Service, Fluid Changes, Filter Replacements, Belt Inspections/Replacements Diagnostics: Troubleshooting Guides, Fault Code Interpretation (OBD-I/Proprietary), Component Testing Repair: Engine Rebuild, Transmission Overhaul, Suspension Component Replacement, Brake System Repair, Electrical Component Replacement Technical Details: Torque Specifications, Clearances, Timing Procedures, Electrical Component Testing Voltages/Resistances Bodywork And Paint: Body panel alignment, rust repair procedures, glass replacement, sealing. Interior Trim: Removal and installation of door panels, dashboard components, seat covers, and headliner. Technical Depth Depth: Comprehensive - Covers basic maintenance to complete engine and transmission rebuilds, including detailed electrical diagnostics and wiring schematics. Diagnostic Tools: Details on using specific diagnostic tools or methods for the era, including reading fault codes and signal analysis. 📊 Manual Specifications File Format Format: PDF Searchability: Likely text-searchable if digitally created, but image-based PDFs may not be. Print Quality Printability: High (all pages printable) Binding Type Digital Binding: N/A (Digital Download) Paper Type Digital Paper Equivalent: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Code Family: Rover KV6 (later models), Honda J-series (PGM-FI engines) Engine Displacement 825: 2.5 Liters (typically for the '825' designation) Engine Type 825: V6 (Naturally Aspirated) Performance Horsepower 825 Approx: 170-190 hp (depending on specific engine variant and emissions controls) Torque 825 Approx: 180-200 lb-ft (depending on specific engine variant) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI / PGM-FI) Fuel Type: Unleaded Gasoline Technical Details Valve Train: DOHC (Double Overhead Camshafts) Engine Code Examples Example Engine Codes: PG1 (Manual Transmission), PG2/PG3 (Automatic Transmission), M16/T-Series (4-cyl, less common on 825), KV6 (later V6 models). 🔧 Transmission Standard Transmission Type Standard: Automatic Transmission Optional Transmission Type Optional: Manual Transmission (less common on 825 models, more prevalent on 4-cylinder variants) Features Automatic Gear Count: 4-Speed Automatic (e.g., ZF 4HP22) Manual Gear Count: 5-Speed Manual Fluid Specifications Automatic Transmission Fluid: Dexron II or equivalent (consult manual for exact specification) Manual Transmission Fluid: GL-4 Gear Oil (specific viscosity to be confirmed in manual) 📐 Dimensions Exterior Body Styles: 4-door Sedan, 5-door Fastback (often referred to as the 'Fastback' or 'Hatchback' variant) Weights Curb Weight Approx: 1400-1600 kg (depending on body style and specification) Gross Vehicle Weight Rating Gvwr Approx: 1900-2100 kg 🛡️ Safety Features Ratings Crash Test History: Limited comprehensive independent crash test data available from official bodies for this specific era and model. Early models predated standardized modern crash testing protocols. Active Features Braking System: Front: Ventilated Discs, Rear: Solid Discs (ABS optional/standard on higher trims). Steering: Power Assisted Rack and Pinion Passive Features Airbags: Driver-side airbag became standard on later models; passenger airbags were optional or introduced later. Seatbelts: Pre-tensioner seatbelts for front occupants on later models. 💡 Technology Features Infotainment Audio System: Factory fitted radios and cassette players, often with premium speaker systems. CD changers may have been optional. Climate Control: Manual or Automatic Climate Control (ECC - Electronic Climate Control) depending on trim level. Driver Assistance Cruise Control: Standard on higher trim levels or optional. Anti Lock Braking System ABS: Optional on earlier models, standard on many later versions. Connectivity Pre Broadband Era Features: Primarily analog systems; no modern infotainment or connectivity features like Bluetooth or USB. 🔧 Maintenance Service Intervals Oil Change Interval: Typically 6,000 -...
Executive/Luxury Sedan, targeting a premium segment in its era.
Competitive Analysis
Competitors:
Competed against other executive sedans of the era such as the BMW 5 Series, Mercedes-Benz E-Class, Audi 100/A6, and higher-trim models from Ford, Peugeot, and Volvo.
Key Features
Platform Sharing:
Shared its platform with the Austin-Morris Rover SD1, later evolved into the Rover 800 series, designed in collaboration with Honda (based on the Honda Legend platform).
Design Philosophy:
A blend of British luxury and engineering with Japanese reliability and technology, a significant departure from previous Rover models.
📋 Manual Details
Coverage Areas
Primary Coverage:
Full Service Repair, Maintenance, Diagnostics, Overhaul
Body panel alignment, rust repair procedures, glass replacement, sealing.
Interior Trim:
Removal and installation of door panels, dashboard components, seat covers, and headliner.
Technical Depth
Depth:
Comprehensive - Covers basic maintenance to complete engine and transmission rebuilds, including detailed electrical diagnostics and wiring schematics.
Diagnostic Tools:
Details on using specific diagnostic tools or methods for the era, including reading fault codes and signal analysis.
📊 Manual Specifications
File Format
Format:
PDF
Searchability:
Likely text-searchable if digitally created, but image-based PDFs may not be.
170-190 hp (depending on specific engine variant and emissions controls)
Torque 825 Approx:
180-200 lb-ft (depending on specific engine variant)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI / PGM-FI)
Fuel Type:
Unleaded Gasoline
Technical Details
Valve Train:
DOHC (Double Overhead Camshafts)
Engine Code Examples
Example Engine Codes:
PG1 (Manual Transmission), PG2/PG3 (Automatic Transmission), M16/T-Series (4-cyl, less common on 825), KV6 (later V6 models).
🔧 Transmission
Standard
Transmission Type Standard:
Automatic Transmission
Optional
Transmission Type Optional:
Manual Transmission (less common on 825 models, more prevalent on 4-cylinder variants)
Features
Automatic Gear Count:
4-Speed Automatic (e.g., ZF 4HP22)
Manual Gear Count:
5-Speed Manual
Fluid Specifications
Automatic Transmission Fluid:
Dexron II or equivalent (consult manual for exact specification)
Manual Transmission Fluid:
GL-4 Gear Oil (specific viscosity to be confirmed in manual)
📐 Dimensions
Exterior
Body Styles:
4-door Sedan, 5-door Fastback (often referred to as the 'Fastback' or 'Hatchback' variant)
Weights
Curb Weight Approx:
1400-1600 kg (depending on body style and specification)
Gross Vehicle Weight Rating Gvwr Approx:
1900-2100 kg
🛡️ Safety Features
Ratings
Crash Test History:
Limited comprehensive independent crash test data available from official bodies for this specific era and model. Early models predated standardized modern crash testing protocols.
Driver-side airbag became standard on later models; passenger airbags were optional or introduced later.
Seatbelts:
Pre-tensioner seatbelts for front occupants on later models.
💡 Technology Features
Infotainment
Audio System:
Factory fitted radios and cassette players, often with premium speaker systems. CD changers may have been optional.
Climate Control:
Manual or Automatic Climate Control (ECC - Electronic Climate Control) depending on trim level.
Driver Assistance
Cruise Control:
Standard on higher trim levels or optional.
Anti Lock Braking System ABS:
Optional on earlier models, standard on many later versions.
Connectivity
Pre Broadband Era Features:
Primarily analog systems; no modern infotainment or connectivity features like Bluetooth or USB.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically 6,000 - 10,000 miles or 12 months (refer to manual for exact interval based on driving conditions).
Timing Belt Replacement:
Recommended replacement every 60,000 miles or 5 years for interference engines (especially KV6).
Transmission Fluid Change:
Recommended every 30,000 - 50,000 miles or as per manual recommendations.
Fluid Specifications
Engine Oil Type:
10W-40 or 5W-40 Synthetic/Semi-Synthetic (API SG/SH or ACEA A2/A3, consult manual for specific viscosity and API rating).
Coolant Type:
Ethylene Glycol based antifreeze (typically a 50/50 mix with distilled water). Consult manual for specific type (e.g., HOAT or OAT).
Brake Fluid Type:
DOT 3 or DOT 4 (consult manual for specific recommendation)
Power Steering Fluid:
ATF (Automatic Transmission Fluid) compatible with Dexron II or equivalent.
Known Issues
Electrical Faults:
Common issues include intermittent dashboard lights, faulty window regulators, starter motor issues, and corroded wiring connectors, especially in humid environments.
Engine Problems:
KV6 engines can be prone to head gasket failures and coolant leaks due to design. Timing belt tensioners and water pump failures are also critical maintenance items. Early Honda engines are generally more reliable.
Suspension Wear:
Wear in suspension bushes, ball joints, and shock absorbers is common with age and mileage.
Exhaust System Corrosion:
Corrosion of exhaust components, particularly the catalytic converter and rear silencer, due to age and road salt.
📚 Vehicle History
Brand Heritage
Rover Legacy:
Rover was a British automotive marque with a long history known for producing robust, often luxurious, and comfortable vehicles. The 800 Series aimed to revive Rover's position in the executive car market.
Model Evolution
Series Development:
The Rover 800 Series (developed under project codes 'R17' and later '800') was a significant undertaking, representing a collaboration with Honda. It replaced the Rover SD1 and was based on the Honda Legend platform, bringing enhanced build quality and reliability.
Facelifts And Updates:
The 800 series received significant updates, including the introduction of the KV6 engine, improved styling (often referred to as the 'facelift' or 'Brooklands' styling), and technology enhancements over its production run.
Production
Manufacturing Location:
Cowley, Oxford, United Kingdom
Production Period:
1986 - 1999
🏆 Awards & Recognition
Recognitions
Historical Awards:
While specific awards for the 825 are not prominently recalled, the Rover 800 Series as a whole was considered a step forward for Rover, aiming for automotive excellence and market appeal in the premium segment.
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