Rover seria 800 Haynes [ENG], ⊆ ⊇ WRZUTA [ccc]
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Rover 820, 825
&
827
Service and Repair Manual
J. S. Mead
Models covered
Rover 820, 825, 827 and Sterling models with 4-cylinder and V6 petrol engines,
including special/limited editions
1994 cc, 2494 cc & 2675 cc
Does not cover 8-valve carburettor (petrol) engine or Diesel-engined models
(1380-304-11AA3)
© Haynes Publishing 1997
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1 2 3
Printed by
J H Haynes & Co. Ltd, Sparkford, Nr Yeovil,
Somerset BA22 7JJ
Haynes Publishing
Sparkford, Nr Yeovil, Somerset BA22 7JJ, England
Haynes North America, Inc
861 Lawrence Drive, Newbury Park, California 91320, USA
Editions Haynes S.A.
147/149, rue Saint Honoré, 75001 Paris, France
Haynes Publishing Nordiska AB
Box 1504, 751 45 Uppsala, Sweden
A book in the
Haynes Service and Repair Manual Series
All rights reserved. No part of this book may be reproduced or transmitted
in any form or by any means, electronic or mechanical, including
photocopying, recording or by any information storage or retrieval system,
without permission in writing from the copyright holder.
ISBN
1 85960 273 8
British Library Cataloguing in Publication Data
A catalogue record for this book is available from the British Library.
1380 Rover 800 Series Remake
Contents
LIVING WITH YOUR ROVER
Introduction
Page
0•4
Safety First!
Page
0•5
General dimensions and weights
Page
0•6
Roadside Repairs
Jacking, towing and wheel changing
Page
0•7
Jump starting
Page
0•9
Identifying leaks
Page
0•10
Radio/cassette unit anti-theft system – precaution
Page
0•10
Conversion Factors
Page
0•11
ROUTINE MAINTENANCE
Routine maintenance and servicing
Routine maintenance
Page
1•1
Servicing Specifications
Page
1•2
Lubricants, fluids and capacities
Page
1•3
Maintenance schedule
Page
1•4
Maintenance procedures
Page
1•8
Weekly checks
Page
1•8
Every 6000 or six months
Page
1•11
Every 12 000 miles or 12 months
Page
1•13
Every 24 000 miles or 2 years
Page
1•23
Every 48 000 miles
Page
1•26
Every 60 000 miles or 5 years
Page
1•26
1380 Rover 800 Series Remake
Contents
REPAIRS & OVERHAUL
Engine and Associated Systems
4-cylinder engine – in-car engine repair procedures
Page
2A•1
V6 engine – in-car engine repair procedures
Page
2B•1
Engine removal and general engine overhaul procedures
Page
2C•1
Cooling, heating and air conditioning systems
Page
3•1
Fuel and exhaust systems – Single-point injection engines
Page
4A•1
Fuel and exhaust systems – Lucas multi-point injection engines
Page
4B•1
Fuel and exhaust systems – MEMS multi-point injection engines
Page
4C•1
Fuel and exhaust systems – Honda PGM-Fi injection engines
Page
4D•1
Fuel and exhaust systems – Emissions control systems
Page
4E•1
Engine electrical systems
Page
5•1
Transmission
Clutch
Page
6•1
Manual transmission
Page
7A•1
Automatic transmission
Page
7B•1
Driveshafts
Page
8•1
Brakes
Braking system
Page
9•1
Suspension and Steering
Suspension and steering systems
Page
10•1
Body Equipment
Bodywork and fittings
Page
11•1
Body electrical systems
Page
12•1
Wiring Diagrams
Page
12•19
REFERENCE
MOT Test Checks
Page
REF•1
General Repair Procedures
Page
REF•5
Tools and Working Facilities
Page
REF•6
Buying Spare Parts and Vehicle Identification Numbers
Page
REF•9
Fault Finding
Page
REF•10
Glossary of Technical Terms
Page
REF•18
Index
Page
REF•23
0•4
Introduction
Introduction to the Rover 800 Series
Designed in conjunction with the Honda
Motor Company of Japan, the Rover 800
series was launched in the UK in July 1986 as
a replacement for the ageing Rover SD1.
Initially available in four-door Saloon guise, a
Fastback version was added to the range in
mid-1988. Minor styling revisions were
applied to various models in the intervening
years, culminating in a major facelift to all
models for the 1992 model year. This saw the
introduction of the “second generation” Rover
800 series with significant styling and
engineering revisions, together with the
launch of the Coupe model later in the same
year.
Three different engines are used in the
Rover models covered by this manual.
820 models are powered by a 2.0 litre,
4-cylinder, sixteen valve engine with single-
point or multi-point fuel injection. The early
version of this power unit is based on the
proven O-series engine used previously in the
Montego and earlier Austin Rover vehicles,
but with an all new cylinder head and valve
train. For the 1992 model year the T-series
version was announced which shared many of
the O-series components but with significant
revisions in many areas. Both these engines
are available in normally aspirated or
turbocharged versions.
825, 827 and Sterling models are powered
by a 2.5 or 2.7 litre V6 twenty four valve
engine with programmed fuel injection. Both
versions of this engine are virtually identical
apart from an increase in cylinder bore
diameter to provide the larger capacity of the
2.7 litre unit.
On all models, the engine is mounted
transversely at the front of the car and drives
the front wheels through a five-speed manual,
or four speed automatic transmission.
Suspension is independent at the front by
double wishbones and coil springs, and at the
rear by transverse links and coil springs.
Power-assisted steering is standard on all
models.
A comprehensive range of electrical and
interior features are offered as standard
equipment, including electric front windows,
central locking and stereo radio cassette
player. Anti-lock braking, air conditioning,
headlight wash, electric rear windows, driver
and passenger airbags and many other
features and accessories are also available as
optional or standard equipment according to
model.
Acknowledgements
Thanks are due to Champion Spark Plug,
who supplied the illustrations showing spark
plug conditions. Thanks are also due to
Sykes-Pickavant Limited, who provided some
of the workshop tools, and to all those people
at Sparkford who helped in the production of
this manual.
We take great pride in the accuracy of
information given in this manual, but
vehicle manufacturers make alterations
and design changes during the production
run of a particular vehicle of which they do
not inform us. No liability can be accepted
by the authors or publishers for loss,
damage or injury caused by any errors in,
or omissions from, the information given.
Project vehicles
The main project vehicle used in the
preparation of this manual, and appearing in
many of the photographic sequences was a
1986 Rover 820 Se Saloon. Additional work
was carried out and photographed on a 1988
Rover 820 Si Fastback and a 1992 Rover
Sterling.
Rover 820i Saloon
Rover 800 Coupe
1380 Rover 800 Series Remake
Safety First!
0•5
Working on your car can be dangerous.
This page shows just some of the potential
risks and hazards, with the aim of creating a
safety-conscious attitude.
General hazards
Scalding
• Don’t remove the radiator or expansion
tank cap while the engine is hot.
• Engine oil, automatic transmission fluid or
power steering fluid may also be dangerously
hot if the engine has recently been running.
Burning
• Beware of burns from the exhaust system
and from any part of the engine. Brake discs
and drums can also be extremely hot
immediately after use.
Crushing
• When working under or near
a raised vehicle,
always
supplement the
jack with axle
stands, or use
drive-on
ramps.
Never
venture
under a car which
is only supported by a jack.
• Take care if loosening or tightening high-
torque nuts when the vehicle is on stands.
Initial loosening and final tightening should
be done with the wheels on the ground.
Fire
• Fuel is highly flammable; fuel vapour is
explosive.
• Don’t let fuel spill onto a hot engine.
• Do not smoke or allow naked lights
(including pilot lights) anywhere near a
vehicle being worked on. Also beware of
creating sparks
(electrically or by use of tools).
• Fuel vapour is heavier than air, so don’t
work on the fuel system with the vehicle over
an inspection pit.
• Another cause of fire is an electrical
overload or short-circuit. Take care when
repairing or modifying the vehicle wiring.
• Keep a fire extinguisher handy, of a type
suitable for use on fuel and electrical fires.
Electric shock
• Ignition HT
voltage can be
dangerous,
especially to
people with heart
problems or a
pacemaker. Don’t
work on or near the
ignition system with
the engine running or
the ignition switched on.
• Mains voltage is also dangerous. Make
sure that any mains-operated equipment is
correctly earthed. Mains power points should
be protected by a residual current device
(RCD) circuit breaker.
Fume or gas intoxication
• Exhaust fumes are
poisonous; they often
contain carbon
monoxide, which is
rapidly fatal if inhaled.
Never run the
engine in a
confined space
such as a garage
with the doors shut.
• Fuel vapour is also
poisonous, as are the vapours from some
cleaning solvents and paint thinners.
Poisonous or irritant substances
• Avoid skin contact with battery acid and
with any fuel, fluid or lubricant, especially
antifreeze, brake hydraulic fluid and Diesel
fuel. Don’t syphon them by mouth. If such a
substance is swallowed or gets into the eyes,
seek medical advice.
• Prolonged contact with used engine oil can
cause skin cancer. Wear gloves or use a
barrier cream if necessary. Change out of oil-
soaked clothes and do not keep oily rags in
your pocket.
• Air conditioning refrigerant forms a
poisonous gas if exposed to a naked flame
(including a cigarette). It can also cause skin
burns on contact.
Asbestos
• Asbestos dust can cause cancer if inhaled
or swallowed. Asbestos may be found in
gaskets and in brake and clutch linings.
When dealing with such components it is
safest to assume that they contain asbestos.
Special hazards
Hydrofluoric acid
• This extremely corrosive acid is formed
when certain types of synthetic rubber, found
in some O-rings, oil seals, fuel hoses etc, are
exposed to temperatures above 400
0
C. The
rubber changes into a charred or sticky
substance containing the acid.
Once formed,
the acid remains dangerous for years. If it
gets onto the skin, it may be necessary to
amputate the limb concerned.
• When dealing with a vehicle which has
suffered a fire, or with components salvaged
from such a vehicle, wear protective gloves
and discard them after use.
The battery
• Batteries contain sulphuric acid, which
attacks clothing, eyes and skin. Take care
when topping-up or carrying the battery.
• The hydrogen gas given off by the battery
is highly explosive. Never cause a spark or
allow a naked light nearby. Be careful when
connecting and disconnecting battery
chargers or jump leads.
Air bags
• Air bags can cause injury if they go off
accidentally. Take care when removing the
steering wheel and/or facia. Special storage
instructions may apply.
Diesel injection equipment
• Diesel injection pumps supply fuel at very
high pressure. Take care when working on
the fuel injectors and fuel pipes.
Warning: Never expose the hands,
face or any other part of the body
to injector spray; the fuel can
penetrate the skin with potentially fatal
results.
Remember...
DO
• Do use eye protection when using power
tools, and when working under the vehicle.
• Do wear gloves or use barrier cream to
protect your hands when necessary.
• Do get someone to check periodically
that all is well when working alone on the
vehicle.
• Do keep loose clothing and long hair well
out of the way of moving mechanical parts.
• Do remove rings, wristwatch etc, before
working on the vehicle – especially the
electrical system.
• Do ensure that any lifting or jacking
equipment has a safe working load rating
adequate for the job.
A few tips
DON’T
• Don’t attempt to lift a heavy component
which may be beyond your capability – get
assistance.
• Don’t rush to finish a job, or take
unverified short cuts.
• Don’t use ill-fitting tools which may slip
and cause injury.
• Don’t leave tools or parts lying around
where someone can trip over them. Mop
up oil and fuel spills at once.
• Don’t allow children or pets to play in or
near a vehicle being worked on.
1380 Rover 800 Series Remake
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