Rover 800 Series 820 825 827 1986-1999 WSM Service Repair Manual
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🏷️ Basic Information Identification Make: Rover Model: 800 Series Sub Models: 820, 825, 827 Production Years Covered: 1986-1999 👋 Introduction Market Position Vehicle Segment: Executive/Luxury Sedan and Coupe. Competitive Analysis Competitors: Ford Scorpio, Vauxhall Carlton/Omega, BMW 5 Series, Mercedes-Benz E-Class (W124), Audi 100/A6. Key Features Vehicle Platform: Shared platform with Honda Legend (XA Series). Manual Value Proposition: Empowers owners to perform repairs themselves, saving significant costs on labor and dealership visits. Manual Value Proposition Manual Benefit 1: Easy to follow, step-by-step instructions. Manual Benefit 2 Manual Benefit 2: Comprehensive coverage of all service and repair jobs. Manual Benefit 3 Manual Benefit 3: Includes vital wiring diagrams for electrical system diagnosis. Manual Benefit 4 Manual Benefit 4: Enables owners to become more knowledgeable about their vehicle. 📋 Manual Details Coverage Areas Primary Coverage: Service, Repair, Maintenance Page Count Estimated Page Count: Extensive (Specific count not provided, but described as 'full professional quality in depth') Manual Type Type: Workshop Manual (WSM) / Service Repair Manual Language Language: English Format Delivery Method: Instant Download File Format: PDF Requirements Software Requirements: Adobe PDF Reader Compatibility Operating System Compatibility: All Versions of Windows & Mac 📖 Manual Coverage Systems Covered Engine Systems: Engine mechanical, fuel system, ignition system, cooling system, lubrication system, exhaust system, engine management (ECU), emissions control. Transmission Systems: Manual transmission, automatic transmission, clutch, driveline, differentials. Chassis Systems: Suspension (front and rear), steering system, braking system (including ABS if applicable), wheels and tires. Electrical Systems: Wiring diagrams, lighting system, charging system (alternator, battery), starting system, instruments and controls, infotainment system, power accessories, body electrical. Body And Interior: Body repair, exterior trim, interior trim, seating, glass and mirrors, heating and ventilation, air conditioning (HVAC). Procedures Included Maintenance Procedures: Routine maintenance, oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspection and replacement. Repair Procedures: Step-by-step instructions for component removal, installation, adjustment, and repair across all major vehicle systems. Troubleshooting Diagnostics: Diagnostic fault finding, common problems and solutions, diagnostic trouble codes (DTCs) where applicable. Technical Depth Depth: Comprehensive, covering routine maintenance to complex repairs and diagnostics. Visual Aids: Includes pictures and wiring diagrams for ease of understanding and execution of repairs. 📊 Manual Specifications File Format Print Quality: Full Printable (High-resolution for clear reproduction) Page Organization: Printable pages for convenient use in garage/workshop. Binding Type Binding: N/A (Digital download format) Paper Type Paper Type: N/A (Digital download format) ⚙️ Engine Specifications Primary Engine Engine Codes: P-Series (Honda-derived), KV6 (later models, less common for this manual's scope but worth noting overlap). Performance 820 Engine Variant 1: 2.0L (1998cc) OHC 'M' Series inline-four (e.g., M16). 820 Engine Variant 2: 2.0L (1998cc) DOHC 'T' Series inline-four (Turbocharged). 825 Engine Variant: 2.5L (2497cc) Honda J-Series V6 (e.g., J25A). 827 Engine Variant: 2.7L (2675cc) Honda J-Series V6 (e.g., J27A). Horsepower Range: Approximately 130-180 hp (depending on engine and specific variant). Fuel System Fuel Delivery: Multi-point fuel injection (MPI) for all variants. Fuel Type: Unleaded Gasoline. 🔧 Transmission Standard Transmission Type 820: 5-speed Manual (Getrag or Rover). Optional Transmission Type 820 Optional: 4-speed Automatic (ZF or Rover). Transmission Type V6 Optional: 4-speed Automatic (ZF or Rover). Features Driveline: Front-wheel drive (FWD). 📐 Dimensions Exterior Body Styles: 4-door Saloon (Sedan), 5-door Fastback (Hatchback). Length: Approx. 4,740 mm (186.6 in) for Saloon. Wheelbase: Approx. 2,769 mm (109.0 in). Weights Curb Weight Range: Approx. 1,400 - 1,600 kg (3,086 - 3,527 lb) depending on engine and trim. 🛡️ Safety Features Ratings Crash Test Data: Limited widely available public crash data for this specific era. Manual will detail structural integrity and safety system design. Active Features Braking System: Front ventilated discs, rear solid discs. ABS available on higher trims/later models. Passive Features Airbags: Driver airbag standard on later models, passenger airbag optional/standard on top trims. Side airbags not common for the early part of this production run. Seatbelts: Three-point inertia reel seatbelts front and rear. 💡 Technology Features Infotainment Audio System: Factory fitted radios, often with cassette players. CD players became available on higher trims or as optional upgrades. Speaker configurations varied. Climate Control: Manual heating and ventilation, with optional climate control systems on higher-spec models. Driver Assistance Cruise Control: Optional on many variants, particularly those with automatic transmission. ABS: Anti-lock Braking System available on higher trims or as an option from mid-production onwards. Connectivity Connectivity Features: Limited by modern standards; primarily focused on vehicle systems rather than external device integration. Some models may have basic phone preparation wiring. 🔧 Maintenance Service Intervals Oil Change Interval: Typically 6,000 - 9,000 miles (10,000 - 15,000 km) or 12 months, depending on oil specification and driving conditions. Timing Belt Replacement: For 2.0L 'M' Series engines: 60,000 miles (96,000 km) or 4-5 years. For V6 engines: 90,000 miles (144,000 km) or 6 years. Crucial due to non-interference design implications. Fluid Specifications Engine Oil: API SG/SH...
Suspension (front and rear), steering system, braking system (including ABS if applicable), wheels and tires.
Electrical Systems:
Wiring diagrams, lighting system, charging system (alternator, battery), starting system, instruments and controls, infotainment system, power accessories, body electrical.
Body And Interior:
Body repair, exterior trim, interior trim, seating, glass and mirrors, heating and ventilation, air conditioning (HVAC).
Procedures Included
Maintenance Procedures:
Routine maintenance, oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspection and replacement.
Repair Procedures:
Step-by-step instructions for component removal, installation, adjustment, and repair across all major vehicle systems.
Troubleshooting Diagnostics:
Diagnostic fault finding, common problems and solutions, diagnostic trouble codes (DTCs) where applicable.
Technical Depth
Depth:
Comprehensive, covering routine maintenance to complex repairs and diagnostics.
Visual Aids:
Includes pictures and wiring diagrams for ease of understanding and execution of repairs.
📊 Manual Specifications
File Format
Print Quality:
Full Printable (High-resolution for clear reproduction)
Page Organization:
Printable pages for convenient use in garage/workshop.
Binding Type
Binding:
N/A (Digital download format)
Paper Type
Paper Type:
N/A (Digital download format)
⚙️ Engine Specifications
Primary Engine
Engine Codes:
P-Series (Honda-derived), KV6 (later models, less common for this manual's scope but worth noting overlap).
Performance
820 Engine Variant 1:
2.0L (1998cc) OHC 'M' Series inline-four (e.g., M16).
820 Engine Variant 2:
2.0L (1998cc) DOHC 'T' Series inline-four (Turbocharged).
825 Engine Variant:
2.5L (2497cc) Honda J-Series V6 (e.g., J25A).
827 Engine Variant:
2.7L (2675cc) Honda J-Series V6 (e.g., J27A).
Horsepower Range:
Approximately 130-180 hp (depending on engine and specific variant).
Fuel System
Fuel Delivery:
Multi-point fuel injection (MPI) for all variants.
Approx. 1,400 - 1,600 kg (3,086 - 3,527 lb) depending on engine and trim.
🛡️ Safety Features
Ratings
Crash Test Data:
Limited widely available public crash data for this specific era. Manual will detail structural integrity and safety system design.
Active Features
Braking System:
Front ventilated discs, rear solid discs. ABS available on higher trims/later models.
Passive Features
Airbags:
Driver airbag standard on later models, passenger airbag optional/standard on top trims. Side airbags not common for the early part of this production run.
Seatbelts:
Three-point inertia reel seatbelts front and rear.
💡 Technology Features
Infotainment
Audio System:
Factory fitted radios, often with cassette players. CD players became available on higher trims or as optional upgrades. Speaker configurations varied.
Climate Control:
Manual heating and ventilation, with optional climate control systems on higher-spec models.
Driver Assistance
Cruise Control:
Optional on many variants, particularly those with automatic transmission.
ABS:
Anti-lock Braking System available on higher trims or as an option from mid-production onwards.
Connectivity
Connectivity Features:
Limited by modern standards; primarily focused on vehicle systems rather than external device integration. Some models may have basic phone preparation wiring.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically 6,000 - 9,000 miles (10,000 - 15,000 km) or 12 months, depending on oil specification and driving conditions.
Timing Belt Replacement:
For 2.0L 'M' Series engines: 60,000 miles (96,000 km) or 4-5 years. For V6 engines: 90,000 miles (144,000 km) or 6 years. Crucial due to non-interference design implications.
Fluid Specifications
Engine Oil:
API SG/SH or ACEA A2-96. Viscosity typically 10W-40 or 15W-40, check manual for specific engine and climate recommendations. For V6, 5W-30 or 10W-40 often specified.
Coolant:
Ethylene glycol-based antifreeze. Specific mixture ratio and type (e.g., OAT or HOAT for later models if applicable, though likely conventional for earlier ones) detailed in manual.
Brake Fluid:
DOT 3 or DOT 4.
Transmission Fluid Automatic:
Dexron II-E or Dexron III (for ZF transmissions, check specific ZF type). Rover automatic transmissions may have unique fluid requirements.
Known Issues
Rust Corrosion:
Common issue on older British cars; check wheel arches, sills, and boot floor.
Electronics:
Early models can suffer from minor electrical gremlins due to wiring loom quality or age.
V6 Engine Head Gaskets:
The KV6 engine (introduced in later 800s, potentially covered) is known for head gasket issues, but this manual focuses on the Honda V6 which is generally more reliable but still requires proper maintenance.
Suspension Components:
Wear in bushings and ball joints can affect ride and handling over time.
📚 Vehicle History
Brand Heritage
Manufacturer:
Rover Group (British Leyland heritage).
Model Evolution
Generation Codename:
R8 (pre-facelift), R8 Facelift (post-1994).
Key Facelift Changes:
Revised styling (front and rear), updated interior, improved engines, and new features introduced around 1994.
Production
Manufacturing Location:
Cowley, Oxford, United Kingdom.
Production Period:
1986-1999.
🏆 Awards & Recognition
Recognitions
Industry Recognition:
The Rover 800 series was generally well-received for its styling and comfort, particularly the V6 models, offering a strong value proposition against its German rivals when new.
Specific Awards:
No specific major awards stand out prominently for this model in its entirety, but it was considered a significant step forward for Rover in the executive segment.
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