Rover 800 Series 820 1986-1999 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Rover Model: 800 Series Model Variant: 820 Production Years Covered: 1986, 1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999 Codes Platform Code: R8 👋 Introduction Market Position Segment: Executive Car / Large Family Car Competitors: Ford Scorpio, Vauxhall Carlton/Vauxhall Senator, BMW 5 Series (E28/E34), Mercedes-Benz W124 E-Class, Audi 100/A6 (C3/C4). Key Features Design: Designed by David Bache and Roy Axe, the Rover 800 Series featured a distinctive 'Lady Penelope' styled exterior, influenced by the concepts of Italian designer Pininfarina. Powertrain: Utilized the 'R' series V6 engine (co-developed with Honda) and later the T-series 4-cylinder engines. Platform Sharing: Shared its platform with the Honda Legend. Manual Value Proposition: An indispensable resource for maintaining the longevity and optimal performance of the Rover 800 Series 820, providing cost savings through self-sufficiency in repairs and maintenance. 📋 Manual Details Coverage Areas Primary Coverage: Comprehensive service, repair, and maintenance for the Rover 800 Series 820. Specific Systems: Engine Mechanical System, Engine Electrical System, Emission Control System, Fuel System, Suspension System, Clutch System, Manual Transaxle System, Automatic Transaxle System, Driveshaft and Axle, Steering System, Brake System, Body Interior and Exterior, Body Electrical System, Restraint System. Page Count Estimated Page Count: High (Typically 800-1500+ pages for a complete workshop manual covering multiple years and engine options). Manual Type Type: Workshop Service Repair Manual / Factory Service Manual Language Language: English Format Format: PDF File Delivery: Instant Download Software Requirements: Adobe PDF Reader, WinZip Compatibility: All Versions of Windows & Mac 📖 Manual Coverage Systems Covered Engine Mechanical: Detailed information on engine assembly, disassembly, cylinder head, piston and connecting rod, crankshaft and main bearing, oil pump, timing system, engine block, and cooling system. Engine Electrical: Comprehensive coverage of ignition system, charging system, starting system, engine control unit (ECU) diagnostics, sensors, and actuators. Emission Control: Diagnosis and repair of emissions-related components, including catalytic converters, oxygen sensors, EVAP system, and EGR system. Fuel System: Service and repair of fuel pump, fuel injectors, fuel pressure regulator, fuel tank, and fuel lines. Suspension: Maintenance and repair of front and rear suspension components, shock absorbers, struts, springs, control arms, and wheel alignment specifications. Clutch Transmission Manual: Detailed procedures for clutch inspection, replacement, and manual gearbox service, including gear shifting mechanisms. Clutch Transmission Automatic: Service and repair of automatic transmission components, torque converter, valve body, and transmission fluid service. Driveshaft Axle: Maintenance and repair of driveshafts, CV joints, constant velocity axles, and wheel bearings. Steering System: Service and repair of power steering system, steering rack, steering column, and steering linkage. Brake System: Comprehensive coverage of brake pads, rotors, calipers, brake fluid, ABS system diagnosis, and hydraulic lines. Body Interior Exterior: Repair and maintenance of body panels, doors, windows, glass, interior trim, seats, and body sealing. Body Electrical: Troubleshooting and repair of lighting systems, power windows, door locks, central locking, audio systems, HVAC controls, and dashboard instruments. Restraint System: Information on airbags, seatbelt mechanisms, and related safety components. Procedures Included Maintenance: Regular maintenance schedules, oil changes, filter replacements, fluid level checks, spark plug replacement, belt inspection and replacement. Troubleshooting: Diagnostic procedures for common and uncommon problems, symptom-based troubleshooting guides, electrical system fault finding. Repair: Step-by-step repair instructions for all major vehicle systems, including engine rebuilds, transmission overhauls, brake replacements, and bodywork repairs. Diagnostics: Guidance on using diagnostic tools, interpreting fault codes, and performing system checks. Wiring Schematics: Detailed wiring diagrams for all electrical systems, allowing for precise diagnosis and repair of electrical faults. Technical Depth Depth: Comprehensive, covering everything from basic fluid checks and filter changes to complete engine and transmission overhauls, including detailed component-level repair. Target Audience: Suitable for both experienced professional mechanics and DIY enthusiasts. 📊 Manual Specifications File Format File Type: PDF Searchable: Yes (Typically, PDF manuals are searchable by keyword). Print Quality Printability: Fully Printable Image Resolution: High-resolution illustrations, diagrams, and photos for clarity. Binding Type Binding: Digital (PDF) - Not Applicable (Printable Pages) Paper Type Paper Type: Digital (PDF) - Not Applicable (Printable Pages) ⚙️ Engine Specifications Primary Engine Engine Family: Rover R-Series V6 Engine Code Examples: M16 (4-cylinder - early models), T16 (4-cylinder - later models), KV6 (V6 - later models, though less common in 820 variants). Displacement 820 4Cyl: 2.0 Liters (1994 cc) Displacement 820 V6: 2.0 Liters (1994 cc) Performance Horsepower 820 4Cyl Tsi: ~130-140 bhp Torque 820 4Cyl Tsi: ~170-180 Nm Horsepower 820 V6 Si: ~150-170 bhp Torque 820 V6 Si: ~180-200 Nm Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) - Bosch L-Jetronic or similar systems depending on year and engine. Fuel Type: Unleaded Petrol (Octane rating as per manual recommendations, typically 95 RON). 🔧 Transmission Standard Type: 5-speed Manual Transaxle Optional Type: 4-speed Automatic Transaxle (e.g., GM Turbo-Hydramatic 440-T4 or Rover's own variants). Features Drive Layout: Front-Wheel Drive (FWD) 📐 Dimensions Exterior Body Styles:...

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Tags: 1986 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 800 Series 820 Car Cars Rover

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Description

🏷️ Basic Information

Identification

Make:

Rover

Model:

800 Series

Model Variant:

Production Years Covered:

1986, 1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999

Codes

Platform Code:

👋 Introduction

Market Position

Segment:

Executive Car / Large Family Car

Competitors:

Ford Scorpio, Vauxhall Carlton/Vauxhall Senator, BMW 5 Series (E28/E34), Mercedes-Benz W124 E-Class, Audi 100/A6 (C3/C4).

Key Features

Design:

Designed by David Bache and Roy Axe, the Rover 800 Series featured a distinctive 'Lady Penelope' styled exterior, influenced by the concepts of Italian designer Pininfarina.

Powertrain:

Utilized the 'R' series V6 engine (co-developed with Honda) and later the T-series 4-cylinder engines.

Platform Sharing:

Shared its platform with the Honda Legend.

Manual Value Proposition:

An indispensable resource for maintaining the longevity and optimal performance of the Rover 800 Series 820, providing cost savings through self-sufficiency in repairs and maintenance.

📋 Manual Details

Coverage Areas

Primary Coverage:

Comprehensive service, repair, and maintenance for the Rover 800 Series 820.

Specific Systems:

Engine Mechanical System, Engine Electrical System, Emission Control System, Fuel System, Suspension System, Clutch System, Manual Transaxle System, Automatic Transaxle System, Driveshaft and Axle, Steering System, Brake System, Body Interior and Exterior, Body Electrical System, Restraint System.

Page Count

Estimated Page Count:

High (Typically 800-1500+ pages for a complete workshop manual covering multiple years and engine options).

Manual Type

Type:

Workshop Service Repair Manual / Factory Service Manual

Language

Language:

English

Format

Format:

File Delivery:

Instant Download

Software Requirements:

Adobe PDF Reader, WinZip

Compatibility:

All Versions of Windows & Mac

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Detailed information on engine assembly, disassembly, cylinder head, piston and connecting rod, crankshaft and main bearing, oil pump, timing system, engine block, and cooling system.

Engine Electrical:

Comprehensive coverage of ignition system, charging system, starting system, engine control unit (ECU) diagnostics, sensors, and actuators.

Emission Control:

Diagnosis and repair of emissions-related components, including catalytic converters, oxygen sensors, EVAP system, and EGR system.

Fuel System:

Service and repair of fuel pump, fuel injectors, fuel pressure regulator, fuel tank, and fuel lines.

Suspension:

Maintenance and repair of front and rear suspension components, shock absorbers, struts, springs, control arms, and wheel alignment specifications.

Clutch Transmission Manual:

Detailed procedures for clutch inspection, replacement, and manual gearbox service, including gear shifting mechanisms.

Clutch Transmission Automatic:

Service and repair of automatic transmission components, torque converter, valve body, and transmission fluid service.

Driveshaft Axle:

Maintenance and repair of driveshafts, CV joints, constant velocity axles, and wheel bearings.

Steering System:

Service and repair of power steering system, steering rack, steering column, and steering linkage.

Brake System:

Comprehensive coverage of brake pads, rotors, calipers, brake fluid, ABS system diagnosis, and hydraulic lines.

Body Interior Exterior:

Repair and maintenance of body panels, doors, windows, glass, interior trim, seats, and body sealing.

Body Electrical:

Troubleshooting and repair of lighting systems, power windows, door locks, central locking, audio systems, HVAC controls, and dashboard instruments.

Restraint System:

Information on airbags, seatbelt mechanisms, and related safety components.

Procedures Included

Maintenance:

Regular maintenance schedules, oil changes, filter replacements, fluid level checks, spark plug replacement, belt inspection and replacement.

Troubleshooting:

Diagnostic procedures for common and uncommon problems, symptom-based troubleshooting guides, electrical system fault finding.

Repair:

Step-by-step repair instructions for all major vehicle systems, including engine rebuilds, transmission overhauls, brake replacements, and bodywork repairs.

Diagnostics:

Guidance on using diagnostic tools, interpreting fault codes, and performing system checks.

Wiring Schematics:

Detailed wiring diagrams for all electrical systems, allowing for precise diagnosis and repair of electrical faults.

Technical Depth

Depth:

Comprehensive, covering everything from basic fluid checks and filter changes to complete engine and transmission overhauls, including detailed component-level repair.

Target Audience:

Suitable for both experienced professional mechanics and DIY enthusiasts.

📊 Manual Specifications

File Format

File Type:

Searchable:

Yes (Typically, PDF manuals are searchable by keyword).

Print Quality

Printability:

Fully Printable

Image Resolution:

High-resolution illustrations, diagrams, and photos for clarity.

Binding Type

Binding:

Digital (PDF) - Not Applicable (Printable Pages)

Paper Type

Paper Type:

Digital (PDF) - Not Applicable (Printable Pages)

⚙️ Engine Specifications

Primary Engine

Engine Family:

Rover R-Series V6

Engine Code Examples:

M16 (4-cylinder - early models), T16 (4-cylinder - later models), KV6 (V6 - later models, though less common in 820 variants).

Displacement 820 4Cyl:

2.0 Liters (1994 cc)

Displacement 820 V6:

2.0 Liters (1994 cc)

Performance

Horsepower 820 4Cyl Tsi:

~130-140 bhp

Torque 820 4Cyl Tsi:

~170-180 Nm

Horsepower 820 V6 Si:

~150-170 bhp

Torque 820 V6 Si:

~180-200 Nm

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI) - Bosch L-Jetronic or similar systems depending on year and engine.

Fuel Type:

Unleaded Petrol (Octane rating as per manual recommendations, typically 95 RON).

🔧 Transmission

Standard

Type:

5-speed Manual Transaxle

Optional

Type:

4-speed Automatic Transaxle (e.g., GM Turbo-Hydramatic 440-T4 or Rover's own variants).

Features

Drive Layout:

Front-Wheel Drive (FWD)

📐 Dimensions

Exterior

Body Styles:

4-door Saloon, 5-door Hatchback (often referred to as the 'Fastback').

Length Saloon:

Approx. 4,830 mm (190.2 in)

Wheelbase:

Approx. 2,740 mm (107.9 in)

Weights

Kerb Weight Approx 820:

~1400-1550 kg

🛡️ Safety Features

Ratings

Euro Ncap Era:

Euro NCAP testing was not standardized or widely implemented in the early part of this vehicle's production run. Later models might have undergone limited testing, but comprehensive ratings are unlikely.

Active Features

Available on higher trim levels and later models.

Traction Control:

Rarely fitted, typically not a standard feature.

Passive Features

Airbags:

Driver's airbag became standard in later years; passenger airbag optional or standard on top trims.

Seatbelts:

Front and rear seatbelts, pre-tensioners on front belts in later models.

💡 Technology Features

Infotainment

Audio System:

Factory fitted cassette players with RDS, often with amplifier options. Upgrades common.

Climate Control:

Manual or automatic climate control systems were available, depending on trim level. The manual covers HVAC system diagnosis.

Driver Assistance

Cruise Control:

Optional on many models, particularly higher trims.

Connectivity

Remote Central Locking:

Available on later models, often linked to alarm systems.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 6,000-10,000 miles or 12 months, depending on driving conditions and oil type used. Consult manual for specific recommendations.

Air Filter Replacement:

Every 12,000-18,000 miles or as needed based on inspection.

Spark Plug Replacement:

Typically every 24,000-36,000 miles for standard plugs, or higher for platinum/iridium plugs. Check manual for specific engine type.

Timing Belt Replacement:

Critical for R-Series and T-Series engines. Typically every 50,000-60,000 miles or 5 years. Failure can cause catastrophic engine damage. Consult manual for exact interval and procedure.

Fluid Specifications

Engine Oil:

API SG/SH or higher, viscosity typically 10W-40 or 15W-40. Consult manual for precise specification and capacity (approx. 4.5-5.5 liters).

Coolant:

Ethylene Glycol based antifreeze, mixed 50/50 with distilled water. Capacity approx. 6-7 liters. Use a quality OAT or HOAT coolant if available.

Brake Fluid:

DOT 3 or DOT 4, depending on system specification. Replace every 2 years or as per manual.

Transmission Fluid Manual:

GL-4 or GL-5 hypoid gear oil, SAE 75W-90 or 80W-90. Capacity approx. 2.0-2.5 liters.

Transmission Fluid Automatic:

Dexron II or equivalent automatic transmission fluid (ATF). Capacity approx. 3.5-4.5 liters for fluid change, more for complete overhaul.

Known Issues

Head Gasket Failure:

A known issue, particularly with the R-Series V6 engine, requiring coolant leaks and potential overheating. The manual will detail diagnostic and repair procedures.

Electrical Gremlins:

Common in older vehicles, the manual's extensive wiring diagrams and troubleshooting sections are vital for diagnosing issues with central locking, alarms, and dashboard displays.

Rust And Corrosion:

Potential for rust on sills, wheel arches, and boot floor, especially in the UK climate. The manual covers bodywork repair and rust prevention.

Suspension Wear:

Components like ball joints, bushes, and top mounts can wear over time, affecting handling and ride quality. The manual provides replacement and alignment procedures.

📚 Vehicle History

Brand Heritage

Rover Legacy:

The Rover 800 Series was positioned as the flagship model for Rover, aiming to compete with premium European sedans and showcase the brand's technological advancements and luxury.

Model Evolution

Mk1 Rover 800:

Launched in 1986, based on the Honda Legend platform. Initially offered with 2.0L and 2.7L V6 (Honda C27A) engines. Known for its distinctive styling.

Mk2 Rover 800 Facelift:

Introduced in 1991 with significant styling revisions (facelift), improved aerodynamics, updated interior, and the introduction of the Rover T-series 2.0L 16v engine and the KV6 engine.

Rover 800 820 Variants:

The '820' designation primarily refers to the 2.0-liter engine variants, including the 820i (single-point injection, 8-valve), 820 Si (multi-point injection, 16-valve), and 820 Turbo (in later years).

Production

Manufacturing Plant:

Solihull, West Midlands, United Kingdom.

Production End Year:

🏆 Awards & Recognition

Recognitions

Industry Accolades:

The Rover 800 Series was generally well-received for its comfort, refinement, and styling at launch, often praised for its European feel and competitive pricing against German rivals.