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Rover 820, 825 & 827 Service and Repair Manual

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Rover 820, 825 & 827 Service and Repair Manual Rover 820, 825 & 827 Service and Repair Manual J. S. Mead (1380-304-11AA3) 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 ABCDE © Haynes Publishing 1997 FGHIJ Printed by J H Haynes & Co. Ltd, Sparkford, Nr Yeovil, KLMNO PQRST Somerset BA22 7JJ A book in the Haynes Service and Repair Manual Series 1 2 3 Haynes Publishing All rights reserved. No part of this book may be reproduced or transmitted Sparkford, Nr Yeovil, Somerset BA22 7JJ, England in any form or by any means, electronic or mechanical, including Haynes North America, Inc photocopying, recording or by any information storage or retrieval system, 861 Lawrence Drive, Newbury Park, California 91320, USA without permission in writing from the copyright holder. Editions Haynes S.A. ISBN 1 85960 273 8 147/149, rue Saint Honoré, 75001 Paris, France British Library Cataloguing in Publication Data Haynes Publishing Nordiska AB A catalogue record for this book is available from the British Library. Box 1504, 751 45 Uppsala, Sweden 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 are available in normally aspirated or Acknowledgements Motor Company of Japan, the Rover 800 turbocharged versions. Thanks are due to Champion Spark Plug, series was launched in the UK in July 1986 as 825, 827 and Sterling models are powered who supplied the illustrations showing spark a replacement for the ageing Rover SD1. by a 2.5 or 2.7 litre V6 twenty four valve plug conditions. Thanks are also due to Initially available in four-door Saloon guise, a engine with programmed fuel injection. Both Sykes-Pickavant Limited, who provided some Fastback version was added to the range in versions of this engine are virtually identical of the workshop tools, and to all those people mid-1988. Minor styling revisions were apart from an increase in cylinder bore at Sparkford who helped in the production of applied to various models in the intervening diameter to provide the larger capacity of the this manual. years, culminating in a major facelift to all 2.7 litre unit. We take great pride in the accuracy of models for the 1992 model year. This saw the On all models, the engine is mounted information given in this manual, but introduction of the “second generation” Rover transversely at the front of the car and drives vehicle manufacturers make alterations 800 series with significant styling and the front wheels through a five-speed manual, and design changes during the production engineering revisions, together with the or four speed automatic transmission. run of a particular vehicle of which they do launch of the Coupe model later in the same Suspension is independent at the front by not inform us. No liability can be accepted year. double wishbones and coil springs, and at the by the authors or publishers for loss, Three different engines are used in the rear by transverse links and coil springs. damage or injury caused by any errors in, Rover models covered by this manual. Power-assisted steering is standard on all or omissions from, the information given. 820 models are powered by a 2.0 litre, models. 4-cylinder, sixteen valve engine with single- A comprehensive range of electrical and point or multi-point fuel injection. The early interior features are offered as standard version of this power unit is based on the equipment, including electric front windows, Project vehicles proven O-series engine used previously in the central locking and stereo radio cassette The main project vehicle used in the Montego and earlier Austin Rover vehicles, player. Anti-lock braking, air conditioning, preparation of this manual, and appearing in but with an all new cylinder head and valve headlight wash, electric rear windows, driver many of the photographic sequences was a train. For the 1992 model year the T-series and passenger airbags and many other 1986 Rover 820 Se Saloon. Additional work version was announced which shared many of features and accessories are also available as was carried out and photographed on a 1988 the O-series components but with significant optional or standard equipment according to Rover 820 Si Fastback and a 1992 Rover revisions in many areas. Both these engines model. Sterling. Rover 820i Saloon Rover 800 Coupe 1380 Rover 800 Series Remake Safety First! 0•5 Working on your car can be dangerous. • Mains voltage is also dangerous. Make This page shows just some of the potential sure that any mains-operated equipment is Special hazards risks and hazards, with the aim of creating a correctly earthed. Mains power points should Hydrofluoric acid safety-conscious attitude. be protected by a residual current device (RCD) circuit breaker. • This extremely corrosive acid is formed General hazards when certain types of synthetic rubber, found Fume or gas intoxication in some O-rings, oil seals, fuel hoses etc, are 0 Scalding • Exhaust fumes are exposed to temperatures above 400 C. The • Don’t remove the radiator or expansion poisonous; they often rubber changes into a charred or sticky tank cap while the engine is hot. contain carbon substance containing the acid. Once formed, • Engine oil, automatic transmission fluid or monoxide, which is the acid remains dangerous for years. If it power steering fluid may also be dangerously rapidly fatal if inhaled. gets onto the skin, it may be necessary to hot if the engine has recently been running. Never run the amputate the limb concerned. engine in a • When dealing with a vehicle which has Burning confined space suffered a fire, or with components salvaged • Beware of burns from the exhaust system such as a garage from such a vehicle, wear protective gloves and from any part of the engine. Brake discs with the doors shut. and discard them after use. and drums can also be extremely hot • Fuel vapour is also The battery immediately after use. poisonous, as are the vapours from some cleaning solvents and paint thinners. • Batteries contain sulphuric acid, which Crushing attacks clothing, eyes and skin. Take care • When working under or near Poisonous or irritant substances when topping-up or carrying the battery. a raised vehicle, • Avoid skin contact with battery acid and • The hydrogen gas given off by the battery always with any fuel, fluid or lubricant, especially is highly explosive. Never cause a spark or supplement the antifreeze, brake hydraulic fluid and Diesel allow a naked light nearby. Be careful when jack with axle fuel. Don’t syphon them by mouth. If such a connecting and disconnecting battery stands, or use substance is swallowed or gets into the eyes, chargers or jump leads. drive-on seek medical advice. Air bags ramps. • Prolonged contact with used engine oil can Never cause skin cancer. Wear gloves or use a • Air bags can cause injury if they go off venture barrier cream if necessary. Change out of oil- accidentally. Take care when removing the under a car which soaked clothes and do not keep oily rags in steering wheel and/or facia. Special storage is only supported by a jack. your pocket. instructions may apply. • Take care if loosening or tightening high- • Air conditioning refrigerant forms a Diesel injection equipment torque nuts when the vehicle is on stands. poisonous gas if exposed to a naked flame • Diesel injection pumps supply fuel at very Initial loosening and final tightening should (including a cigarette).
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