Rover 800 Series 820 825 827 1986-1999 Service Manual

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Type: Car

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Sku: 57921

Tags: 1986 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 800 Series 820 825 827 Car Cars CASE Rover

Product variants

Description

The Rover 800 Series, produced from 1986 to 1999, represents a significant chapter in Rover's history, positioned within the executive car segment. Designed by David Bache, this model is recognized for its distinctive wedge-shaped profile and aerodynamic styling, a departure from previous Rover aesthetics. Available in variants such as the 820, 825, and 827, it offered a blend of luxury, performance, and refinement, often competing with established German and European luxury sedans. The series utilized both Rover's inline-four engines and Honda-derived V6 powertrains, paired with manual and automatic transmissions, including advanced electronic control for automatic gearboxes on higher trims. Its interior prioritized comfort and quality, featuring advanced amenities for its time, and it was offered in both saloon and hatchback body styles, with premium trims like Vanden Plas and Sterling. This comprehensive Workshop Service Manual provides essential information for the maintenance and repair of the Rover 800 Series, covering models from 1986 through 1999. The manual details procedures for all major systems, including engine diagnosis and overhaul, fuel and ignition systems, cooling, exhaust, transmission, drivetrain, suspension, steering, brakes, and the electrical system. It also covers body and chassis work, HVAC, and interior components. Within its 265 pages, owners and technicians will find detailed guidance on scheduled maintenance, repair procedures, disassembly and assembly, adjustments, and troubleshooting. Critical technical data, specifications, and known issues are also included, ensuring a thorough understanding for effective upkeep and repair of these vehicles.

🏷️ Basic Information

Identification

Make:

Rover

Model:

800 Series

Model Variants:

820, 825, 827

Generation:

First Generation (XW)

Codes

Chassis Code:

👋 Introduction

Market Position

Segment:

Executive car segment, offering a blend of luxury, performance, and sophisticated styling for its era.

Competitive Analysis

Competitors:

Competed against models such as the Ford Granada/Scorpio, Vauxhall Carlton/Senator, Peugeot 605, Citroën XM, and German luxury sedans like the BMW 5 Series and Mercedes-Benz E-Class.

Key Features

Styling:

Designed by David Bache, known for its distinctive wedge-shaped profile and aerodynamic lines, a departure from previous Rover designs.

Powertrain:

Featured Honda-derived V6 engines (PG1 and PG2 transmissions) and Rover's own inline-four engines, offering refined performance.

Luxury:

Prioritized comfort and refinement with a focus on interior quality, advanced features for the time, and a smooth ride.

📋 Manual Details

Coverage Areas

Applicable Years:

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

Page Count

Total Pages:

Manual Type

Type:

Workshop Service Manual / Repair Manual

Language

Language:

English

Format

File Format:

📖 Manual Coverage

Systems Covered

Engine:

Comprehensive engine diagnosis, removal, installation, overhaul, and tuning for all specified variants.

Fuel System:

Fuel injection systems (Bosch, Lucas), fuel pumps, injectors, fuel lines, and emissions control.

Ignition System:

Distributorless ignition systems, coil packs, sensors, and electronic control modules.

Cooling System:

Radiator, water pump, thermostat, fan operation, coolant specifications, and pressure testing.

Exhaust System:

Exhaust manifolds, catalytic converters, mufflers, and emission control components.

Transmission:

Manual and automatic transmission diagnosis, removal, installation, overhaul, fluid specifications, and shift control.

Drivetrain:

Front-wheel drive system, driveshafts, CV joints, and differential.

Suspension:

Front and rear suspension components, shock absorbers, springs, bushings, alignment procedures, and specifications.

Steering:

Power steering system, steering rack, pump, fluid specifications, and troubleshooting.

Brakes:

Front and rear disc brakes, ABS (Anti-lock Braking System), brake fluid specifications, bleeding procedures, and component replacement.

Electrical System:

Wiring diagrams, battery, alternator, starter motor, lighting, fuses, relays, and electrical component testing.

Body And Chassis:

Body panel removal and installation, door mechanisms, glass replacement, rust prevention, and structural components.

HVAC:

Heating, ventilation, and air conditioning (HVAC) system diagnosis, components, refrigerant handling, and service.

Interior:

Seat removal and installation, dashboard disassembly, trim panel replacement, and interior component repair.

Diagnostics:

Comprehensive troubleshooting guides, diagnostic trouble codes (DTCs), and testing procedures for all systems.

Procedures Included

Maintenance:

Scheduled maintenance, oil changes, filter replacements, fluid checks, tune-ups, and preventative maintenance.

Repair:

Detailed step-by-step repair instructions for all major components and systems.

Disassembly Assembly:

Complete procedures for removing, disassembling, inspecting, and reassembling vehicle components.

Adjustments:

Precise adjustment procedures for various systems, including engine timing, brake adjustments, and alignment.

Troubleshooting:

Systematic diagnostic approaches to identify and resolve common and complex vehicle problems.

Technical Data:

Includes critical service data, specifications, tightening torques, wear limits, and diagnostic parameters.

Technical Depth

Depth:

Comprehensive, covering everything from basic DIY maintenance to in-depth engine and transmission overhauls.

📊 Manual Specifications

File Format

Readability:

High-resolution PDF, ensuring clarity of text and diagrams. Adobe Reader required.

Print Quality

Printable:

Yes, all pages are fully printable for convenient workshop use.

Binding Type

Digital Format:

Instant Download PDF, no physical product or shipping required.

Paper Type

Digital Quality:

Digitally rendered, providing clear illustrations and detailed text.

⚙️ Engine Specifications

Primary Engine

Engine 820 I:

2.0L (1994cc) Rover M-Series I4, 85 kW (114 hp) @ 5500 rpm, 174 Nm (128 lb-ft) @ 3500 rpm

Engine 820 Sli/Si:

2.0L (1994cc) Rover T-Series I4, 100 kW (134 hp) @ 5750 rpm, 186 Nm (137 lb-ft) @ 3750 rpm (later models)

Engine 825:

2.5L (2498cc) Honda C25A V6, 110 kW (148 hp) @ 6000 rpm, 207 Nm (153 lb-ft) @ 4500 rpm

Engine 827:

2.7L (2675cc) Honda C27A V6, 124 kW (166 hp) @ 6000 rpm, 224 Nm (165 lb-ft) @ 4500 rpm

Performance

Top Speed 827 Vanden Plas:

Approx. 210 km/h (130 mph)

Fuel System

Injection Type:

Electronic Fuel Injection (EFI)

Fuel Type:

Unleaded Petrol (Octane rating specification detailed in manual)

🔧 Transmission

Standard

820 Models:

5-speed Manual Transmission (PG1)

825/827 Models:

4-speed Automatic Transmission (PG2)

Optional

820 Models:

4-speed Automatic Transmission (H54)

Features

Automatic Transmission Control:

Electronic control with 'Sport' and 'Economy' modes on some variants.

📐 Dimensions

Exterior

Length:

Approx. 4845 mm (190.7 in)

Width:

Approx. 1780 mm (70.1 in)

Height:

Approx. 1370 mm (53.9 in)

Weights

Curb Weight:

Varies by model, typically 1450-1550 kg (3197-3417 lbs)

Gross Vehicle Weight:

Specifications available in manual

🛡️ Safety Features

Ratings

Euro Ncap Rating:

Not available for this era of vehicle through standardized NCAP testing.

Active Features

Anti-lock Braking System available on higher trims and optional on many models.

Traction Control:

Optional on some V6 models.

Passive Features

Airbags:

Driver's airbag standard on later models, passenger airbag optional.

Seatbelts:

Three-point inertia reel seatbelts with pre-tensioners on front seats.

💡 Technology Features

Infotainment

Audio System:

Factory fitted radio/cassette players, often with premium speaker systems on higher trims. Cassette players are prone to mechanical failure.

Climate Control:

Manual climate control or automatic climate control systems on higher-spec models, offering a degree of cabin temperature regulation.

Driver Assistance

Cruise Control:

Available as an option or standard on many higher-trim models, providing convenience on long journeys.

Connectivity

Connectivity Features:

Limited by era; primarily focused on in-car entertainment and basic electrical convenience features. No modern Bluetooth or USB connectivity.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 12,000 miles or 12 months, whichever comes first (check specific engine/oil type in manual).

Timing Belt Replacement:

For T-Series engines, every 60,000 miles or 4 years. For Honda V6 engines, timing chain is used (no belt replacement).

Fluid Specifications

Engine Oil Type:

Refer to manual for specific viscosity (e.g., 10W-40, 15W-50) and API service classification based on engine and climate. Likely API SG or SH for later models.

Coolant Type:

Ethylene glycol-based antifreeze, typically a 50/50 mix with distilled water. Specify 'long-life' or OAT coolant if recommended for the specific year.

Brake Fluid Type:

DOT 3 or DOT 4, depending on model year and ABS system requirements. Manual specifies exact type.

Transmission Fluid Automatic:

Dexron III or equivalent specified by the manufacturer for the specific automatic transmission (e.g., H54, PG2).

Transmission Fluid Manual:

API GL-4 or GL-5 gear oil of specified viscosity (e.g., 75W-90).

Known Issues

Rust:

Susceptible to rust, particularly around wheel arches, sills, and subframes. Thorough inspection recommended.

Electrical Gremlins:

Common for older vehicles, but the 800 series can suffer from minor electrical issues due to complex wiring and age. Check fuses, relays, and ground points.

Suspension Wear:

Bushings and ball joints can wear over time, leading to handling issues and knocking noises. Front suspension top mounts are also a common wear item.

Engine Management Sensors:

Various sensors (e.g., Crankshaft Position Sensor, Lambda sensor) can fail, affecting engine performance and economy.

HVAC Blower Motor Resistor:

Common failure point, leading to loss of blower fan speed control. Replacement is a relatively straightforward repair.

📚 Vehicle History

Brand Heritage

Rover Legacy:

The Rover 800 Series was a significant model for Rover, representing a move towards more premium and modern vehicle design, sharing its platform and many components with the Honda Legend.

Model Evolution

Facelift 1991:

The 800 Series received a significant facelift in 1991, with revised styling (often referred to as the 'facelift' or 'R17' generation), improved interior, and new engine options, including the T-Series engine.

Variations:

Offered in various body styles including a 4-door saloon and a 5-door hatchback (often called the 'Fastback'). High-specification 'Vanden Plas' and 'Sterling' trims were also available.

Production

Production Period:

1986 to 1999