Rover seria 800 Haynes Sam Naprawiam ENG.pdf

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)

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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

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 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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