Rover 800 Series 820 825 827 1986-1999 Service Manual PDF Download

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Basic Information Identification Make: Rover Model: 800 Series Model Variants: 820, 825, 827 Generation: First Generation (XW) Codes Chassis Code: XW Introduction Market Position Segment: Executive car segment, offering a...

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Description

Basic Information
Identification
Make:	Rover
Model:	800 Series
Model Variants:	820, 825, 827
Generation:	First Generation (XW)
Codes
Chassis Code:	XW

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:	265
Manual Type
Type:	Workshop Service Manual / Repair Manual
Language
Language:	English
Format
File Format:	PDF

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
ABS:	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