Rover 820, 825, 827. Repair Instruction - part 1

1380 Rover 800 Series Remake

Rover 820, 825

&

827

Service and Repair Instruction

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)

A book in the Haynes Service and Repair Instruction 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.

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

ABCDE
FGHIJ
KLMNO
PQRST

1 2 3

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

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

Instruction 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

Contents

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 instruction. 
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 instruction,
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 instruction.

We take great pride in the accuracy of

information given in this instruction, 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 instruction, 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.

0•4

Introduction

1380 Rover 800 Series Remake

Introduction to the Rover 800 Series

Rover 820i Saloon

Rover 800 Coupe

Safety First!

0•5

1380 Rover 800 Series Remake

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.

0•6

General dimensions and weights

1380 Rover 800 Series Remake

Dimensions

Overall length:

Pre-1992 model year  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4694.0 mm

1992 model year onwards  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4882.0 mm

Overall width - including mirrors:

Pre-1992 model year  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1946.0 mm

1992 model year onwards:

Saloon and Fastback models  . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1965.0 mm

Coupe models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1900.0 mm

Overall height (unladen):

Pre-1992 model year  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1398.0 mm

1992 model year onwards:

Saloon and Fastback models  . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1363.0 mm

Coupe models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1400.0 mm

Wheelbase  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2760.0 mm

Front track  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1490.0 mm

Rear track  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1450.0 mm

Ground clearance  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

145.0 mm

Weights

Kerb weight*:

820 Saloon models  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1305 to 1405 kg

820 Fastback models  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1335 to 1435 kg

820 Coupe models  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1420 kg

825 and Sterling Saloon models . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1360 to 1400 kg

827 and Sterling Saloon models . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1400 to 1470 kg

827 and Sterling Fastback models  . . . . . . . . . . . . . . . . . . . . . . . . . . .

1410 to 1510 kg

827 Coupe models  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1450 kg

Maximum roof rack load:

Saloon and Fastback models  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

70 kg

Coupe models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

50 kg

Maximum towing weight:

820 models with instruction transmission:

Braked trailer (all models except Turbo)  . . . . . . . . . . . . . . . . . . . . .

1550 kg

Braked trailer (Turbo models)  . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1025 kg

Unbraked trailer  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

500 kg

820 models with automatic transmission:

Braked trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1025 kg

Unbraked trailer  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

500 kg

825, 827 and Sterling models:

Braked trailer**  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1550 kg

Unbraked trailer  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

500 kg

Maximum towing hitch downward load  . . . . . . . . . . . . . . . . . . . . . . . . .

70 kg

*Depending on model and specification - refer to Rover dealer for exact recommendations.
**On automatic transmission models, an auxiliary fluid cooler must be fitted if the towing weight is to exceed 1000 kg.

Roadside Repairs

0•7

1380 Rover 800 Series Remake

Jacking, towing and wheel changing

Jacking

The jack supplied with the vehicle tool kit

should only be used for changing the
roadwheels - see “Wheel changing” later in
this Section. When carrying out any other kind
of work, raise the vehicle using a hydraulic (or
“trolley”) jack, and always supplement the
jack with axle stands positioned under the
vehicle jacking points (see illustration).

When using a hydraulic jack or axle stands,

always position the jack head or axle stand

head under one of the relevant jacking points.

To raise the front of the vehicle, position the

jack head under the front towing eye which is
welded to the longitudinal support member
running under the engine. Do not position the
jack under the longitudinal member itself, or
under the sump or any of the steering or
suspension components.

To raise the rear of the vehicle, position the

jack head under the rear towing eye which is
welded to the reinforcement panel under the
spare wheel carrier.

If the side of the vehicle is to be raised,

position the jack head under the reinforced
areas at the front or rear of the side sills.

The jack supplied with the vehicle also

locates in the reinforced areas of the side sills.
Ensure that the jack head is correctly engaged
before attempting to raise the vehicle.

Never work under, around or near a raised

vehicle unless it is adequately supported in at
least two places.

Jacking points and axle stand locations

1 Front towing eye - used for raising the front of the car
2 Reinforced sill area - used for raising the side of the car, or

supporting on axle stands

3 Front chassis member - used for supporting the car on axle 

stands

4 Rear chassis member - used for supporting the car on axle stands

5 Reinforced sill area - used for raising the side of the car, or

supporting on axle stands

6 Rear towing eye - used for raising the rear of the car
7 Square tubular chassis sections - Not suitable for jacking or

supporting

8 Suspension components - Not suitable for jacking or supporting

0•8

Roadside Repairs

1380 Rover 800 Series Remake

Towing

Towing eyes are fitted to the front and rear

of the vehicle for attachment of a tow rope.
The front towing eye is situated under the
centre of the front bumper and the rear towing
eye is located under the centre of the rear
bumper behind a detachable trim plate.

Always turn the ignition key to position II to

ensure that the steering is unlocked and that
the various switches (indicators and lights) are
functional. It should also be noted that the
brake servo and power-assisted steering will
not be operating with the engine switched off
and therefore an allowance will need to be
made for reduced braking efficiency and
increased steering effort.

Before being towed, release the handbrake

and place the gear lever in neutral. Do not tow
at a speed greater than 30 mph. On no
account may the car be towed with the front
wheels on the ground if the transmission is
faulty, if the transmission oil or fluid is low or if
the towing distance is greater than 30 miles.

Wheel changing

To change a roadwheel, first remove the

spare wheel and jack which are located under
the luggage compartment floor (see
illustration). Firmly apply the handbrake and
engage first gear on instruction transmission
models or PARK on automatic transmission
models. Place chocks at the front and rear of
the wheel diagonally opposite the one to be
changed.

Remove the wheel trim and slacken the

wheel nuts with the tools provided in the tool
kit. Position the jack head in the reinforced
jacking point, at the base of the sill nearest to
the wheel to be changed. Raise the jack to just
take the weight of the car. If the tyre is flat,
position the base of the jack so that it is flat on
the ground. If the tyre is not flat, position the
jack so that the base elbow is resting on the
ground and the base is just clear (see
illustration). Raise the vehicle until the wheel
is just clear of the ground, then remove the
wheel nuts and the wheel. Fit the spare wheel
and screw on the wheel nuts. Lower the jack
until the tyre is just touching the ground, and
tighten the wheel nuts moderately tight. Now
lower the jack fully and tighten the wheel nuts
securely in a diagonal sequence. Refit the
wheel trim, then remove the jack and stow it
together with the wheel and tools in the
luggage compartment. Remember to check
the tightness of the wheel nuts using a torque
wrench at the earliest opportunity.

Spare wheel and tool locations

1 Tool kit
2 Floor panel

3 Spare wheel clamp
4 Spare wheel

Using the vehicle tool kit jack

1 Jack base positioned flat on the ground (deflated tyre)
2 Jack positioned with base elbow on the ground, and base just clear (inflated tyre)

Roadside Repairs

0•9

1380 Rover 800 Series Remake

When jump-starting a car using a
booster battery, observe the following
precautions:

4

Before connecting the booster
battery, make sure that the ignition is
switched off.

4

Ensure that all electrical equipment
(lights, heater, wipers, etc) is
switched off.

4

Make sure that the booster battery is
the same voltage as the discharged
one in the vehicle.

4

If the battery is being jump-started
from the battery in another vehicle,
the two vehcles MUST NOT TOUCH
each other.

4

Make sure that the transmission is in
neutral (or PARK, in the case of
automatic transmission).

Jump starting will get you out
of trouble, but you must correct
whatever made the battery go
flat in the first place. There are 

three possibilities:

1

The battery has been drained by
repeated attempts to start, or by

leaving the lights on.

2

The charging system is not working
properly (alternator drivebelt slack

or broken, alternator wiring fault or
alternator itself faulty).

3

The battery itself is at fault
(electrolyte low, or battery worn out).

Connect one end of the red jump lead to
the positive (+) terminal of the flat
battery

Connect the other end of the red lead to
the positive (+) terminal of the booster
battery.

Connect one end of the black jump lead
to the negative (-) terminal of the
booster battery

Connect the other end of the black
jump lead to a bolt or bracket on the
engine block, well away from the
battery, on the vehicle to be started.

1

2

3

4

Make sure that the jump leads will not
come into contact with the fan, drive-
belts or other moving parts of the
engine.

5

Start the engine using the booster
battery, then with the engine running at
idle speed, disconnect the jump leads in
the reverse order of connection.

6

Jump starting

Jump starting

0•10

Roadside Repairs

1380 Rover 800 Series Remake

Puddles on the garage floor or drive, or

obvious wetness under the bonnet or 
underneath the car, suggest a leak that needs
investigating. It can sometimes be difficult to
decide where the leak is coming from,
especially if the engine bay is very dirty
already. Leaking oil or fluid can also be blown
rearwards by the passage of air under the car,
giving a false impression of where the
problem lies.

Warning: Most automotive oils
and fluids are poisonous. Wash
them off skin, and change out of
contaminated clothing, without
delay.

Identifying leaks

The smell of a fluid leaking
from the car may provide a
clue to what’s leaking. Some
fluids are distinctively

coloured. It may help to clean the car
carefully and to park it over some clean
paper overnight as an aid to locating the
source of the leak.

Remember that some leaks may only
occur while the engine is running.

Sump oil

Gearbox oil

Brake fluid

Power steering fluid

Oil from filter

Antifreeze

Engine oil may leak from the drain plug...

...or from the base of the oil filter.

Leaking antifreeze often leaves a crystalline
deposit like this.

Gearbox oil can leak from the seals at the
inboard ends of the driveshafts.

A leak occurring at a wheel is almost
certainly brake fluid.

Power steering fluid may leak from the pipe
connectors on the steering rack.

Radio/cassette unit anti-theft system - precaution

The radio/cassette unit fitted as standard

equipment by Rover is equipped with a built-
in security code, to deter thieves. If the power
source to the unit is cut, the anti-theft system
will activate. Even if the power source is
immediately reconnected, the radio/cassette
unit will not function until the correct security

code has been entered. Therefore, if you do
not know the correct security code 
for the radio/cassette unit do not
disconnect either of the battery terminals, or
remove the radio/cassette unit from the
vehicle. 

To enter the correct security code, follow

the instructions provided with the
radio/cassette player handbook.

If an incorrect code is entered, the unit will

become locked, and cannot be operated.

If this happens, or if the security code is lost

or forgotten, seek the advice of your Rover
dealer.

Conversion Factors

0•11

1380 Rover 800 Series Remake

Length (distance)

Inches (in)

x 25.4

= Millimetres (mm)

x 0.0394 = Inches (in)

Feet (ft)

x 0.305

= Metres (m)

x 3.281 = Feet (ft)

Miles

x 1.609

= Kilometres (km)

x 0.621 = Miles

Volume (capacity)

Cubic inches (cu in; in

3

)

x 16.387 = Cubic centimetres (cc; cm

3

)

x 0.061 = Cubic inches (cu in; in

3

)

Imperial pints (Imp pt)

x 0.568 = Litres (l)

x 1.76

= Imperial pints (Imp pt)

Imperial quarts (Imp qt)

x 1.137 = Litres (l)

x 0.88

= Imperial quarts (Imp qt)

Imperial quarts (Imp qt)

x 1.201 = US quarts (US qt)

x 0.833 = Imperial quarts (Imp qt)

US quarts (US qt)

x 0.946 = Litres (l)

x 1.057 = US quarts (US qt)

Imperial gallons (Imp gal)

x 4.546 = Litres (l)

x 0.22

= Imperial gallons (Imp gal)

Imperial gallons (Imp gal)

x 1.201 = US gallons (US gal)

x 0.833 = Imperial gallons (Imp gal)

US gallons (US gal)

x 3.785 = Litres (l)

x 0.264 = US gallons (US gal)

Mass (weight)

Ounces (oz)

x 28.35 = Grams (g)

x 0.035 = Ounces (oz)

Pounds (lb)

x 0.454 = Kilograms (kg)

x 2.205 = Pounds (lb)

Force

Ounces-force (ozf; oz)

x 0.278 = Newtons (N)

x 3.6

= Ounces-force (ozf; oz)

Pounds-force (lbf; lb)

x 4.448 = Newtons (N)

x 0.225 = Pounds-force (lbf; lb)

Newtons (N)

x 0.1

= Kilograms-force (kgf; kg)

x 9.81

= Newtons (N)

Pressure

Pounds-force per square inch

x 0.070 = Kilograms-force per square

x 14.223 = Pounds-force per square inch

(psi; lbf/in

2

; lb/in

2

)

centimetre (kgf/cm

2

; kg/cm

2

)

(psi; lbf/in

2

; lb/in

2

)

Pounds-force per square inch

x 0.068 = Atmospheres (atm)

x 14.696 = Pounds-force per square inch

(psi; lbf/in

2

; lb/in

2

)

(psi; lbf/in

2

; lb/in

2

)

Pounds-force per square inch

x 0.069 = Bars

x 14.5

= Pounds-force per square inch

(psi; lbf/in

2

; lb/in

2

)

(psi; lbf/in

2

; lb/in

2

)

Pounds-force per square inch

x 6.895 = Kilopascals (kPa)

x 0.145 = Pounds-force per square inch

(psi; lbf/in

2

; lb/in

2

)

(psi; lbf/in

2

; lb/in

2

)

Kilopascals (kPa)

x 0.01

= Kilograms-force per square

x 98.1

= Kilopascals (kPa)

centimetre (kgf/cm

2

; kg/cm

2

)

Millibar (mbar)

x 100

= Pascals (Pa)

x 0.01

= Millibar (mbar)

Millibar (mbar)

x 0.0145 = Pounds-force per square inch

x 68.947 = Millibar (mbar)

(psi; lbf/in

2

; lb/in

2

)

Millibar (mbar)

x 0.75

= Millimetres of mercury (mmHg)

x 1.333 = Millibar (mbar)

Millibar (mbar)

x 0.401 = Inches of water (inH

2

O)

x 2.491 = Millibar (mbar)

Millimetres of mercury (mmHg)

x 0.535 = Inches of water (inH

2

O)

x 1.868 = Millimetres of mercury (mmHg)

Inches of water (inH

2

O)

x 0.036 = Pounds-force per square inch

x 27.68 = Inches of water (inH

2

O)

(psi; lbf/in

2

; lb/in

2

)

Torque (moment of force)

Pounds-force inches

x 1.152 = Kilograms-force centimetre

x 0.868 = Pounds-force inches

(lbf in; lb in)

(kgf cm; kg cm)

(lbf in; lb in)

Pounds-force inches

x 0.113 = Newton metres (Nm)

x 8.85

= Pounds-force inches

(lbf in; lb in)

(lbf in; lb in)

Pounds-force inches

x 0.083 = Pounds-force feet (lbf ft; lb ft)

x 12

= Pounds-force inches

(lbf in; lb in)

(lbf in; lb in)

Pounds-force feet (lbf ft; lb ft)

x 0.138 = Kilograms-force metres

x 7.233 = Pounds-force feet (lbf ft; lb ft)

(kgf m; kg m)

Pounds-force feet (lbf ft; lb ft)

x 1.356 = Newton metres (Nm)

x 0.738 = Pounds-force feet (lbf ft; lb ft)

Newton metres (Nm)

x 0.102 = Kilograms-force metres

x 9.804 = Newton metres (Nm)

(kgf m; kg m)

Power

Horsepower (hp)

x 745.7 = Watts (W)

x 0.0013 = Horsepower (hp)

Velocity (speed)

Miles per hour (miles/hr; mph)

x 1.609 = Kilometres per hour (km/hr; kph) x 0.621 = Miles per hour (miles/hr; mph)

Fuel consumption*

Miles per gallon (mpg)

x 0.354 = Kilometres per litre (km/l)

x 2.825 = Miles per gallon (mpg)

Temperature

Degrees Fahrenheit = (°C x 1.8) + 32

Degrees Celsius (Degrees Centigrade; °C) = (°F - 32) x 0.56

* It is common practice to convert from miles per gallon (mpg) to litres/100 kilometres (l/100km), where mpg x l/100 km = 282

1380 Rover 800 Series Remake

1

Engine

Direction of crankshaft rotation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Clockwise (seen from right-hand side of vehicle)

Oil filter:

4-cylinder engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Champion B101

V6 engines:

paper type  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Champion X119

cannister type  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Champion E102

Cooling system

Coolant protection at 33% antifreeze/water mixture ratio:

Slush point  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

-19ºC (-2ºF)

Solidifying point  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

-36ºC (-33ºF)

Coolant protection at 50% antifreeze/water mixture ratio:

Slush point  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

-36ºC (-33ºF)

Solidifying point  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

-48ºC (-54ºF)

Fuel system

Air filter element:

“M” series 4-cylinder engines  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Champion W114

“T” series 4-cylinder engines  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Champion type not available

V6 engines  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Champion W601

Fuel filter:

4-cylinder engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Champion L208

V6 engines  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Champion L207

Chapter 1
Routine maintenance and servicing

Accelerator cable and linkage check and lubrication  . . . . . . . . . . . . 10
Air cleaner element renewal  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Air conditioning system check  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Automatic transmission fluid level check  . . . . . . . . . . . . . . . . . . . . . 31
Automatic transmission fluid renewal  . . . . . . . . . . . . . . . . . . . . . . . . 35
Auxiliary drivebelts check and renewal  . . . . . . . . . . . . . . . . . . . . . . . 16
Battery check, maintenance and charging  . . . . . . . . . . . . . . . . . . . . 14
Bodywork, paint and exterior trim check  . . . . . . . . . . . . . . . . . . . . . 28
Brake check  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Brake fluid renewal  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Braking system hydraulic fluid seal check and renewal  . . . . . . . . . . 40
Clutch operation and hydraulic hose condition check  . . . . . . . . . . . 25
Coolant renewal  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Cooling system check  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9

Door, boot, tailgate and bonnet check and lubrication . . . . . . . . . . . 27
Driveshaft rubber gaiter and CV joint check  . . . . . . . . . . . . . . . . . . . 22
Electrical system check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Emissions control equipment check  . . . . . . . . . . . . . . . . . . . . . . . . . 41
Engine base idle speed and CO content check  . . . . . . . . . . . . . . . . 19
Engine compartment wiring check  . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Engine oil and filter change  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7

Exhaust system check  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Fluid level checks  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

Fuel filter renewal  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Introduction  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

Manual transmission oil level check  . . . . . . . . . . . . . . . . . . . . . . . . . 20
Manual transmission oil renewal  . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Positive Crankcase Ventilation (PCV) system check . . . . . . . . . . . . . 33
Power steering fluid level check  . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

Road test  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Roadwheel nut tightness check  . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Routine maintenance  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2

Seat belt check  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Spark plug renewal  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Steering, suspension and roadwheel check  . . . . . . . . . . . . . . . . . . . 21
Timing belt condition and tension check  . . . . . . . . . . . . . . . . . . . . . 32
Timing belt renewal  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Tyre and tyre pressure checks  . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

Underbody and fuel/brake line check  . . . . . . . . . . . . . . . . . . . . . . . . 24
Underbonnet check for fluid leaks and hose condition  . . . . . . . . . .

8

Windscreen/tailgate and headlight washer system and wiper 

blade check  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

1•1

Specifications

Contents

Easy, suitable for
novice with little
experience

Fairly easy, suitable
for beginner with
some experience

Fairly difficult,
suitable for competent
DIY mechanic

Difficult, suitable for
experienced  DIY
mechanic

Very difficult,
suitable for expert DIY
or  professional

Degrees of difficulty

5

4

3

2

1

Ignition system

Firing order:

4-cylinder engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-3-4-2 (No 1 cylinder at timing belt end)

V6 engines  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-4-2-5-3-6 (No 1 cylinder at timing belt end on rear bank)

Spark plugs:

Type: *

4-cylinder normally aspirated engines  . . . . . . . . . . . . . . . . . . . . . .

Champion RC9YCC

4-cylinder turbocharged engines up to 1992 model year . . . . . . . .

Champion RC7YCC

4-cylinder turbocharged engines 1992 model year onwards  . . . . .

Champion RC9YCC

V6 engines  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Champion RC9YCC4

Electrode gap: *

4-cylinder engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.8 mm

V6 engines  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.0 mm

Spark plug (HT) leads:

Type:

4-cylinder engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Champion LS-05 boxed set

V6 engines  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Champion boxed set not available

Maximum resistance per lead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30 000 ohms

* Information on spark plug types and electrode gaps is as recommended by Champion Spark Plug. 
Where alternative types are used, refer to their manufacturer’s recommendations

Braking system

Front brake pad thickness (including backing but excluding shims):

New . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17.4 mm

Minimum  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.2 mm

Rear brake pad thickness (including backing):

New . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14.5 mm

Minimum  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.2 mm

Tyres

Tyre pressures (cold):

Front

Rear

195/70 VR 14 tyres  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.8 bar (26 psi)

1.8 bar (26 psi)

195/65 VR 15 tyres  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.0 bar (28 psi)

2.0 bar (28 psi)

205/55 VR or ZR 16 tyres  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2 bar (32 psi)

2.2 bar (32 psi)

205/60 VR 15 tyres  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.0 bar (28 psi)

2.0 bar (28 psi)

215/45 ZR 17 tyres  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3 bar (34 psi)

1.9 bar (28 psi)

115/70 R 15 (space saver spare tyre)  . . . . . . . . . . . . . . . . . . . . . . . . .

4.1 bar (60 psi)

4.1 bar (60 psi)

Note: For sustained high speeds above 100 mph (160 km/h), increased pressures are necessary. 
Consult the driver’s handbook supplied with the vehicle.

Wiper blades

Windscreen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Champion X-5103

Tailgate/rear window  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Champion X-5103

Torque wrench settings

Nm

lbf ft

Power steering pump bolts:

4-cylinder engines - rear-mounted pump . . . . . . . . . . . . . . . . . . . . . .

25

18

4-cylinder engines - front-mounted pump:

Early version (4 mounting bolts)  . . . . . . . . . . . . . . . . . . . . . . . . . . .

10

7

Later version (5 mounting bolts)  . . . . . . . . . . . . . . . . . . . . . . . . . . .

25

18

V6 engines:

Mounting bolt  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

39

29

Adjusting nut  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22

16

Power steering pump drivebelt tensioner wheel retaining 
nut  (4-cylinder engines - rear mounted pump)  . . . . . . . . . . . . . . . . . . .

45

33

Alternator pivot and mounting bolts (4-cylinder engines) . . . . . . . . . . . .

25

18

Alternator adjustment bracket bolts (4-cylinder engines  . . . . . . . . . . . .

12

9

Alternator side pivot bolt (V6 engines)  . . . . . . . . . . . . . . . . . . . . . . . . . .

45

33

Alternator lower mounting nut (V6 engines)  . . . . . . . . . . . . . . . . . . . . . .

24

17

Engine oil drain plug  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

45

33

Manual transmission filler/level and drain plugs . . . . . . . . . . . . . . . . . . .

45

33

Automatic transmission drain plugs:

4-cylinder engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15

11

V6 engines  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

40

30

Spark plugs:

4-cylinder engines up to 1991  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18

13

4-cylinder engines from 1991 onward  . . . . . . . . . . . . . . . . . . . . . . . .

25

18

V6 engines  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18

13

Roadwheel nuts  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

110

81

1•2

Specifications

1380 Rover 800 Series Remake

Lubricants and fluids

Component or system

Lubricant type/specification

1  Engine

Multigrade engine oil to specification API SG/CD or better,
viscosity range 5W/50 to 10W/40

2  Cooling system

Soft water, and antifreeze (ethylene glycol-based, suitable
for use in mixed-metal cooling systems)

3  Manual transmission

Multigrade engine oil to specification API SG/CD or better,
viscosity 10W/40 

4  Automatic transmission

Dexron IID type ATF

5  Power steering fluid reservoir

Dexron IID type ATF

6  Brake and clutch fluid reservoir

Hydraulic fluid to FMVSS 116 DOT 4

General greasing

Multipurpose lithium based grease

Capacities

Engine oil (including filter)  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.5 litres

Cooling system:

4-cylinder engines:

“M” series engines  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.0 litres

“T” series engines  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.0 litres

V6 engines:

2.5 litre engines  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.0 litres

2.7 litre engines  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.6 litres

Manual transmission (drain and refill)  . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3 litres

Automatic transmission (drain and refill):

4-cylinder engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.0 litres

V6 engines  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2 litres

Power steering reservoir  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.5 litres

Fuel tank  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

68 litres

Lubricants, fluids and capacities

1•3

1

1380 Rover 800 Series Remake

Rover 800 Series maintenance schedule

1•4

Maintenance and servicing

1380 Rover 800 Series Remake

The manufacturer’s recommended maintenance schedule for

these vehicles is as described below - note that the schedule starts
from the vehicle’s date of registration. These are the minimum
maintenance intervals recommended by the factory for vehicles
driven daily, but subjected only to “normal” use. If you wish to keep
your car in peak condition at all times, you may wish to perform some
of these procedures even more often. Because frequent maintenance
enhances the efficiency, performance and resale value of your car,
we encourage you to do so. If your usage is not “normal”, shorter
intervals are also recommended - the most important examples of

these are noted in the schedule. These shorter intervals apply
particularly if you drive in dusty areas, tow a caravan or trailer, sit
with the engine idling or drive at low speeds for extended periods (ie,
in heavy traffic), or drive for short distances (less than four miles) in
below-freezing temperatures.

Although the manufacturer’s intervals have been extended to one

main service at 12 000 mile (12 monthly) intervals for 1994 models
onward, the earlier schedule which also includes a lubrication service
at 6000 mile (6 monthly) intervals, is the schedule shown in this
Chapter.

Weekly checks

m

m

Check the engine oil level, and top-up if necessary
(Section 3).

m

m

Check the brake fluid level, and top-up if necessary
(Section 3). If repeated topping-up is required, check the
system for leaks or damage at the earliest possible
opportunity (Section 24).

m

m

Check the windscreen/tailgate and headlight washer fluid
level, and top-up if necessary (Section 3).

m

m

Check the tyre pressures, including the spare (Section 4).

m

m

Visually check the tyres for excessive tread wear, or
damage (Section 4).

m

m

Check the operation of all (exterior and interior) lights and
the horn, wipers and windscreen/tailgate washer system
(Sections 6 and 13).

m

m

Renew any blown bulbs (Chapter 12), and clean the
lenses of all exterior lights.

m

m

Check the coolant level, and top-up if necessary (Sec-
tion 3).

m

m

Check the battery electrolyte level, where applicable
(Section 3).

m

m

Check the power steering fluid level, and top-up if
necessary (Section 5).

m

m

Check the aim of the windscreen/tailgate/headlight
washer jets, correcting them if required (Section 6).

m

m

Check the condition of the wiper blades, renewing them if
worn or no longer effective (Section 6).

m

m

Visually check all reservoirs, hoses and pipes for leakage
(Section 8).

m

m

Check the operation of the air conditioning system (where
applicable) (Section 18).

Every 12 000 miles (20 000 km) or 
12 months, whichever occurs first

m

m

Check the cooling system (Section 9).

m

m

Check the operation of the accelerator cable and linkage
(Section 10).

m

m

Renew the spark plugs (models without emission control
equipment) (Section 11).

m

m

Renew the air cleaner filter element (models without
emission control equipment) (Section 12).

m

m

Check the electrical system (Section 13).

m

m

Check the battery (Section 14).

m

m

Check the seat belts (Section 15).

m

m

Check the auxiliary drivebelt(s) (Section 16).

m

m

Check the condition of all engine compartment wiring
(Section 17).

m

m

Check the condition of all air conditioning system
components (where applicable) (Section 18).

m

m

Check the engine idle speed and mixture (where
applicable) (Section 19).

m

m

Check the manual transmission oil level (Section 20).

m

m

Check the steering, suspension and roadwheels (Sec-
tion 21).

m

m

Check the driveshaft rubber gaiters and CV joints (Sec-
tion 22).

m

m

Check the exhaust system (Section 23).

m

m

Check the underbody, and all fuel/brake lines (Sec-
tion 24).

m

m

Check the clutch operation and hydraulic hose condition
(Section 25).

m

m

Check the brake system (Section 26).

m

m

Check the doors and bonnet, and lubricate their hinges
and locks (Section 27).

m

m

Check the condition of the bodywork and all exterior trim
(Section 28).

m

m

Check the security of all roadwheel nuts (Section 29).

m

m

Road test (Section 30).

m

m

Check the level of the automatic transmission fluid after
road test (Section 31).

Every 6000 miles (10 000 km) or 
6 months, whichever occurs first

m

m

Change the engine oil and filter (Section 7).

m

m

Check under the bonnet for fluid leaks and hose condition
(Section 8).