Manual Rover 820 (1997)

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Rover 820 (1997) - page 1

1380 Rover 800 Series Remake 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) © Hay ...
Rover 820 (1997) - page 2

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 – pr ecaution Page 0•10 Conversion Fac ...
Rover 820 (1997) - page 3

REP AIRS & 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 injecti ...
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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, culm ...
Rover 820 (1997) - page 5

Safety First! 0•5 1380 Rover 800 Series Remake W orking on your car can be danger ous. This page shows just some of the potential risks and hazards, with the aim of cr eating a safety-conscious attitude. General hazar ds Scalding • Don’t r emove the radiator or expansion tank cap while the engine is hot. • Engine oil, automatic transmission ...
Rover 820 (1997) - page 6

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 yea ...
Rover 820 (1997) - page 7

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 ...
Rover 820 (1997) - page 8

0•8 Roadside Repairs 1380 Rover 800 Series Remake T owing 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 ke ...
Rover 820 (1997) - page 9

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 i ...
Rover 820 (1997) - page 10

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 fr om, especially if the engine bay is very dirty already . Leaking oil or fluid can also be ...
Rover 820 (1997) - page 11

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 V olume (capacity) Cubic inches (cu in; in 3 ) x 16.387 = Cubic centimetres (cc; cm 3 ) x 0.061 = Cubic inches (cu in ...
Rover 820 (1997) - page 12

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 . . . . . . . . . . ...
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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 ...
Rover 820 (1997) - page 14

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 ...
Rover 820 (1997) - page 15

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 vehicl ...
Rover 820 (1997) - page 16

Maintenance and servicing 1•5 1 Vehicle identification plate 2 Screen washer reservoir filler 3 Power steering fluid reservoir filler 4 Cooling system expansion tank filler 5 Front shock absorber top mounting 6 Brake and clutch fluid reservoir filler 7 Brake master cylinder 8 Vacuum servo unit 9 Fuel filter 10 Power steering pump drivebelt (early ...
Rover 820 (1997) - page 17

1•6 Maintenance and servicing 1380 Rover 800 Series Remake 1 Vehicle identification plate 2 Screen washer reservoir filler 3 Power steering fluid reservoir filler 4 Cooling system expansion tank filler 5 Front shock absorber top mounting 6 Brake and clutch fluid reservoir filler 7 Brake master cylinder 8 Vacuum servo unit 9 Fuel filter 10 Ignitio ...
Rover 820 (1997) - page 18

Maintenance and servicing 1•7 1 1380 Rover 800 Series Remake 1 Engine undertray 2 Front towing eye 3 Longitudinal support member 4 Clutch slave cylinder 5 Reversing light switch 6 Front tie-bar 7 Transmission drain plug 8 Inner constant velocity joint 9 Transmission filler plug 10 Front anti-roll bar 11 Gearchange rod 12 Steady rod 13 Fuel pipes ...
Rover 820 (1997) - page 19

3 Fluid level checks 1 General 1 Fluids are an essential part of the lubrication, cooling, braking and other systems. Because these fluids gradually become depleted and/or contaminated during normal operation of the vehicle, they must be periodically replenished. See “Lubricants, fluids and capacities” at the beginning of this Chapter before ad ...
Rover 820 (1997) - page 20

up, use only the correct grade and type of oil, as given in the “Lubricants, fluids and capacities” Section of this Chapter; use a funnel if necessary to prevent spills. After adding the oil, refit the filler cap hand-tight. Start the engine, and allow it to idle while the oil is redistributed around the engine - while you are waiting, look car ...
Rover 820 (1997) - page 21

Be sure to use only the specified hydraulic fluid (see “Lubricants, fluids and capacities” at the start of this Chapter) since mixing different types of fluid can cause damage to the system. Warning: Brake hydraulic fluid can harm your eyes and damage painted surfaces, so use extreme caution when handling and pouring it. Wash off spills immedia ...
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embedded in the tread, before they penetrate the tyre to cause deflation. If removal of a nail reveals that the tyre has been punctured, refit the nail, so that its point of penetration is marked. Then immediately change the wheel, and have the tyre repaired by a tyre dealer. Do not drive on a tyre in such a condition. If in any doubt as to the pos ...
Rover 820 (1997) - page 23

the engine is still at normal operating temperature, just after a run; warm oil and sludge will flow out more easily. Park the vehicle on firm, level ground, apply the handbrake, then select 1st or reverse gear (manual transmission) or the “P” position (automatics). Open the bonnet and remove the engine oil filler cap from the valve cover, then ...
Rover 820 (1997) - page 24

fluid. If the vehicle is regularly parked in the same place, close inspection of the ground underneath it will soon show any leaks; ignore the puddle of water which will be left if the air conditioning system is in use. As soon as a leak is detected, its source must be traced and rectified. Where oil has been leaking for some time, it is usually ne ...
Rover 820 (1997) - page 25

wrench to tighten the new plugs to the specified torque (see illustration) . 3 To remove the spark plugs, first open the bonnet; the plugs are easily reached at the top of the engine or on the front and rear facing sides. Note how the spark plug (HT) leads are routed and secured by clips, and on some engines, how they’re positioned along the chan ...
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the firing order, which is essential for proper engine operation. Gain access to the leads and disconnect them as described above for the spark plug check and renewal. 20 Check inside the boot for corrosion, which will look like a white crusty powder. Clean this off as much as possible; if it is excessive, or if cleaning leaves the metal connector ...
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cover or rubber protector, make sure that it’s not torn or damaged. It should completely cover the terminal. Look for any corroded or loose connections, cracks in the case or cover, or loose hold-down clamps. Check the entire length of each lead for cracks and frayed conductors. 6 If corrosion, which looks like white, fluffy deposits is evident, ...
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Power steering pump drivebelt (early “M” series engines) 8 Refer to Chapter 4, Part A or B, and remove the air cleaner components as necessary, for access. 9 Undo the retaining screw and remove the cover over the camshaft pulley (see illustration) . 10 Undo the bolts securing the coolant bypass pipe to the cylinder head and to the main coolant ...
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24 When the tension is correct, tighten the idler pulley retaining nut to the specified torque and lower the car to the ground. Alternator/power steering pump/air conditioning compressor drivebelt (“T” series engines) 25 “T” series engines are fitted with an automatic drivebelt tensioner incorporating a wear indicator to show when the belt ...
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moderate finger pressure. If adjustment is required, proceed as follows. 35 Slacken the bolt in the centre of the tensioner jockey wheel, then turn the adjusting bolt, behind the adjuster, to obtain the correct belt tension (see illustration) . When the adjustment is correct, tighten the jockey wheel bolt. Renewal - 4-cylinder engines 36 Open the b ...
Rover 820 (1997) - page 31

from this while the system is in operation, to the extent that quite a large puddle can be left under the vehicle when it is parked. 2 It’s a good idea to operate the system for about 30 minutes at least once a month, particularly during the winter. Long term non- use can cause hardening, and subsequent failure, of the seals. 3 Because of the com ...
Rover 820 (1997) - page 32

assembly should be maintained, not only to avoid excessive tyre wear, but also to avoid wear in the steering and suspension components. Wheel imbalance is normally signified by vibration through the vehicle’s bodyshell, although in many cases it is particularly noticeable through the steering wheel. Conversely, it should be noted that wear or dam ...
Rover 820 (1997) - page 33

concerned about the condition of the pads, then remove them from the calipers for further inspection (refer to Chapter 9). 7 Check the remaining brake caliper(s) in the same way. 8 If any one of the brake pads has worn down to, or below, the specified limit, all four pads at that end of the car must be renewed as a set (ie all the front pads or all ...
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at the front left-hand side of the engine. Note the condition and colour of the fluid on the dipstick. 5 Wipe the fluid from the dipstick with a clean rag, and re-insert it into the filler tube until the cap seats. 6 Pull the dipstick out again, and note the fluid level. The level should be between the “MIN” and “MAX” marks, on the side of ...
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5 If oil leakage is noted, disconnect the various hoses and pipes, and check that all are clear and unblocked. Remove the air cleaner assembly cover, and check that the hose is clear and undamaged. Always ensure that the air cleaner filter element is clean as this is a vital part of the system. If it is not due for renewal but appears dirty, it may ...
Rover 820 (1997) - page 36

36 Brake fluid renewal 3 The procedure is similar to that for the bleeding of the hydraulic system as described in Chapter 9, except that the brake fluid reservoir should be emptied by syphoning, and allowance should be made for the old fluid to be removed from the circuit when bleeding a section of the circuit. 37 Manual transmission oil renewal 1 ...
Rover 820 (1997) - page 37

expansion tank until coolant, free from air bubbles, flows from the bleed screw. Tighten the bleed screw and continue filling until the coolant level reaches the expansion tank “MAX” level line. 17 Start the engine, run it for approximately two minutes, then switch off. 18 Slowly unscrew the pressure cap one complete turn, wait until all the pr ...
Rover 820 (1997) - page 38

1380 Rover 800 Series Remake 2A General Engine type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Four-cylinder, in-line, double-overhead camshafts Engine codes: “M” series engines: Normally aspirated engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M16 (20 HD) Turbocharged engi ...
Rover 820 (1997) - page 39

Torque wrench settings Nm lbf ft Camshaft cover bolts: “M” series engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 7 “T” series engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 6 Camshaft sprocket bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...
Rover 820 (1997) - page 40

1 General information How to use this Chapter 1 This Part of Chapter 2 is devoted to repair procedures possible while the engine is still installed in the car, and includes only the Specifications relevant to those procedures. Similar information concerning the V6 engines will be found in Part B of this Chapter. Since these procedures are based on ...
Rover 820 (1997) - page 41

3 Disable the ignition system by disconnecting the LT wiring connectors from the ignition coil. Refer to Chapter 5 for further information. 4 Fit a compression tester to the No 1 cylinder spark plug hole - the type of tester which screws into the plug thread is to be preferred. 5 Arrange for an assistant to hold the accelerator pedal fully depresse ...
Rover 820 (1997) - page 42

Single-point fuel injection engines Removal 1 Disconnect the battery negative (earth) lead (refer to Chapter 5, Section 1). 2 Refer to Chapter 4A, and remove the air cleaner air box. 3 Relieve the fuel system pressure as described in Chapter 4A, Section 5. 4 Release the hose clips and disconnect the two fuel hoses from the fuel pipes (see illustrat ...
Rover 820 (1997) - page 43

29 Slacken the nine nuts and bolts securing the manifold to the cylinder head. 30 Remove all the bolts, followed by the two nuts, then withdraw the manifold off the studs and remove it from the engine. Recover the manifold gasket. 31 Clean the manifold and cylinder head mating faces, and obtain a new gasket if the sealing lips of the original are d ...
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Early “M” series engines Removal 1 Disconnect the battery negative (earth) lead (refer to Chapter 5, Section 1). 2 Slacken the right-hand front wheel nuts, jack up the front of the car and support it on axle stands. Remove the roadwheel. 3 Undo the three bolts and remove the access panel under the wheelarch. 4 Refer to Chapter 1 and remove the ...
Rover 820 (1997) - page 45

14 Using an Allen key, undo the timing belt tensioner retaining bolt, and remove the tensioner (see illustration) . 15 Slip the belt off the sprockets, and remove it from the engine. 16 If the timing belt is to be re-used, mark its running direction with an arrow in chalk, and store it on its edge while it is off the engine. 17 Check the belt for a ...
Rover 820 (1997) - page 46

the crankshaft one turn clockwise, then one turn anti-clockwise. It must be emphasised that this is only an approximate setting, and the tension should be checked by a dealer, using the Rover tension gauge, at the earliest opportunity. 52 The remainder of refitting is a reversal of removal. 8 Timing belt (“T” series) - removal, refitting and ad ...
Rover 820 (1997) - page 47

9 Timing belt tensioner and sprockets - removal, inspection and refitting 4 Tensioner Removal 1 Remove the timing belt as described in Sections 7, or 8, according to engine type. 2 On the “M” series engine, the tensioner will have been removed together with the timing belt; proceed to paragraph 6. 3 On the “T” series engine, slacken the ten ...
Rover 820 (1997) - page 48

distributor adaptor plate from the cylinder head (see illustration) . 11 Punch or drill two small holes opposite each other in the seal. Screw a self-tapping screw into each, and pull on the screws with pliers to extract the seal. 12 Clean the seal location in the cylinder head; polish off any burrs or raised edges, which may have caused the seal t ...
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Inspection 17 Clean and inspect the various components removed for signs of excessive wear. 18 Examine the camshaft bearing journals and lobes for damage or wear. If evident, a new camshaft must be fitted or one that has been renovated by a company specialising in exchange components. 19 The camshaft bearing bore diameters in the cylinder head shou ...
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10 Undo the bolt securing the stay bar to the inlet manifold, below the heater hose. 11 Slacken the clips and disconnect the heater bypass hose at the thermostat housing. 12 Slacken the clip and disconnect the heater hose at the other end of the bypass pipe. 13 Undo the bolts securing the bypass pipe to the exhaust manifold, cylinder head and main ...
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removal but refer to the relevant Sections and Chapters for adjustment details as necessary. Multi-point fuel injection engines Removal 34 Carry out the operations described in Paragraphs 1 to 8. 35 On turbocharged engines remove the exhaust manifold as described in the relevant part of Chapter 4. 36 Slacken the clip and disconnect the heater hose ...
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tightened to the specified torque (see illustration) . 15 Apply a bead of RTV sealant to the joint between Nos 1 and 5 main bearing caps and the edge of the crankcase (see illustration) . Apply gasket sealant to the sump and crankcase mating faces, then place a new gasket in position. 16 Refit the sump, and tighten the retaining bolts progressively ...
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2 To remove the pressure relief valve components, extract the split pin and withdraw the plug cap, spring and relief valve plunger (see illustration) . 3 Using a screwdriver, prise out the crankshaft front oil seal from the oil pump housing. Inspection 4 Inspect the condition of the inner and outer rotors for visual signs of scoring or wear ridges. ...
Rover 820 (1997) - page 54

the old ring then splitting it with a chisel. The new ring must then be heated so that it expands slightly, and allowed to cool when in position on the flywheel. As it cools, it contracts to a smaller diameter than the flywheel so as to provide a tight interference fit. The temperatures involved in this operation are critical to avoid damaging the ...
Rover 820 (1997) - page 55

pipes slightly to gain access to the right-hand mounting. 22 Undo the mounting through-bolt, and recover the special nut. Note that the forked end of the nut plate locates over a stud on the body bracket. 23 Undo the two bolts and remove the mounting and snubber plates from the bracket on the engine. 24 Renew the mounting if it shows any sign of da ...
Rover 820 (1997) - page 56

1380 Rover 800 Series Remake 2B General Engine type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V6, single overhead camshaft per bank Engine code: 2.5 litre engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C25A 2.7 litre engines . . . . . . . . . . . . . . ...
Rover 820 (1997) - page 57

Lubrication Engine oil type/specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Chapter 1 Engine oil capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Chapter 1 Torque wrench settings Nm lbf ft Cylinder head bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...
Rover 820 (1997) - page 58

each cylinder head, and is retained in position by a housing bolted to the cylinder head upper face. The camshafts are supported by bearing journals machined directly into the head and housings. Drive to the camshafts is by an internally-toothed composite rubber timing belt, from a sprocket on the front end of the crankshaft. The belt also drives t ...
Rover 820 (1997) - page 59

5 Remove the access cover under the right- hand wheelarch. 6 Using a socket and bar on the crankshaft pulley bolt, rotate the crankshaft pulley, in the normal direction of rotation, until a series of very small notches on the pulley inner rim come into view. The first three notches are the ignition timing marks and can be ignored. The next notch (u ...
Rover 820 (1997) - page 60

one and a half turns. Tighten the locknut securely (see illustration) . 5 Repeat paragraphs 3 and 4 for No 2 cylinder exhaust valves on the rear cylinder head, and No 4 cylinder exhaust valves on the front cylinder head. 6 Rotate the crankshaft through one complete revolution and realign the timing marks. 7 Repeat paragraphs 3 and 4 for No 5 and No ...
Rover 820 (1997) - page 61

and move the harness clear, then withdraw the rear cover from the engine. 5 Undo the four bolts securing the front cover to the cylinder head (see illustration) . 6 Undo the dipstick tube bolt and remove the front cover from the engine. Refitting 7 Refitting is a reversal of removal, but ensure that the lip on the cover lower edge engages behind th ...
Rover 820 (1997) - page 62

illustrations) . Similarly, there is a notch on the front of the crankshaft sprocket which should align with an arrow cast into the oil pump housing (see illustration) . Refitting and adjustment 10 Feed the timing belt around the sprockets, starting with the crankshaft sprocket, then, keeping it taught, feed it over the front camshaft sprocket, wat ...
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worn and are not a loose fit in the camshaft or sprocket holes. Refitting 10 Refitting is a reversal of removal. Ensure that the sprockets are fitted to their correct camshafts and tighten the retaining bolts to the specified torque. Crankshaft sprocket Removal 11 Remove the timing belt as described in Section 12. 12 Slide the sprocket off the fron ...
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specialising in exchange components. If the camshaft appears sound, measure the journal diameters using a micrometer (see illustration) . 19 The camshaft bearing bore diameters in the cylinder head should be measured and checked against the tolerances specified. A gauge will be required for this but if not available, check for excessive movement be ...
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(b) Prime the tappet oil feeds in the cylinder head with oil (see illustration) . (c) Apply RTV sealant to the ends of the camshaft carrier before refitting (see illustration) . (d) Use new gaskets on all joints and tighten the retaining nuts and bolts to the specified torque where given. Tighten the oil gallery bolts in the sequence shown (see ill ...
Rover 820 (1997) - page 66

2 Jack up the front of the car and support it on axle stands. 3 Remove the right-hand front road wheel and the access panel under the wheelarch. 4 Place a jack with interposed block of wood under the sump and just take the weight of the engine. 5 Undo the two right-hand engine mounting retaining bolts. 6 Lower the jack slightly to provide access to ...
Rover 820 (1997) - page 67

transmission removed as described in Chapter 7, remove the clutch assembly (manual transmission) as described in Chap- ter 6. 2 Undo the eight flywheel/driveplate retaining bolts. To prevent the flywheel turning, lock the ring gear teeth using a small strip of angle iron engaged in the teeth and against, or screwed into, a transmission-to-engine re ...
Rover 820 (1997) - page 68

1380 Rover 800 Series Remake 2C 4-cylinder engines Cylinder head Valve seat angle (inlet and exhaust) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45º Valve seat width (inlet and exhaust) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 to 2.0 mm Valves Inlet Exhaust Valve stem diameter . . . . . . . . . . . . . . . . . . . . ...
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Cylinder block Cylinder bore diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.456 to 84.469 mm Maximum cylinder bore taper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm Maximum cylinder bore ovality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 Maximum gasket ...
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thousands of miles of reliable service. Conversely, a neglected engine may require an overhaul very early in its life. Excessive oil consumption is an indication that piston rings, valve seals and/or valve guides are in need of attention. Make sure that oil leaks aren’t responsible before deciding that the rings and/or guides are worn. Perform a ...
Rover 820 (1997) - page 71

8 Disconnect the remaining vacuum hose at the inlet manifold. 9 Undo the bolt securing the engine rear tie- bar support bracket to the inlet manifold (see illustration) . 10 Undo the two through-bolts securing the engine rear tie-bar to the engine and body brackets, and recover the special forked nut (see illustration) . Note that the forked end of ...
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22 Disconnect the HT and LT leads at the ignition coil. 23 Disconnect the single cable at the starter solenoid. 24 Undo the bolt and disconnect the earth lead on the side of the transmission, then slide up the rubber boot and disconnect the reversing light switch wires (see illustration) . 25 On automatic transmission models, extract the spring cli ...
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using a flat bar or large screwdriver, lever between the driveshaft inner constant velocity joint and the differential housing to release the joint. 39 Move the driveshaft clear, then repeat these operations on the left-hand driveshaft. 40 Attach a hoist to the engine using rope slings, or chains attached to brackets secured to the cylinder head. A ...
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5 Engine/transmission (V6 engine) - removal, separation and refitting 3 Note: The engine can be removed from the car only as a complete unit with the transmission; the two are then separated for overhaul. The engine/transmission are removed upwards and out from the top of engine compartment. Removal 1 Extract the retaining clips and release the sup ...
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31 Undo the three expansion tank retaining bolts and move the expansion tank to one side. 32 Jack up the front of the car and support it on axle stands. Remove the front roadwheels. 33 Undo the bolts and remove the access panel under the right-hand wheelarch and the undertray from beneath the wheelarch. 34 Undo the flange bolts and separate the exh ...
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(a) Alternator and mounting brackets. (b) Power steering pump and air conditioning compressor. (c) Distributor, HT leads and spark plugs. (d) Thermostat and housing. (e) Fuel injection system components. (f) Inlet and exhaust manifolds and turbocharger. (g) Oil filter and housing. (h) Engine mountings. (i) Flywheel/driveplate. (j) Water pump. (k) A ...
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arm spacer springs and the rocker arms, and place them in their appropriate compartments of the marked box that has all the hydraulic tappets and slippers removed previously. Alternatively use labelled plastic bags. 6 Undo the eight bolts securing the guide plates and lift the guide plates off their locating dowels. 7 To remove the valves, compress ...
Rover 820 (1997) - page 78

several points, using a micrometer (see illustration) . Any significant difference in the readings obtained indicates wear of the valve stem. Should any of these conditions be apparent, the valve(s) must be renewed. 13 If the valves are in satisfactory condition, they should be ground (lapped) into their respective seats, to ensure a smooth gas-tig ...
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12 Piston/connecting rod assemblies (V6 engine) - removal 3 The procedure is the same as described in the previous Section for 4-cylinder engines, but turn the crankshaft as necessary until each pair of pistons are at the bottom of their stroke and their connecting rod caps are accessible. On later engines it will be necessary to remove the oil baf ...
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2 If any of the castings are extremely dirty, all should be steam-cleaned. 3 After the castings are returned from steam- cleaning, clean all oil holes and oil galleries one more time. Flush all internal passages with warm water until the water runs clear, then dry thoroughly, and apply a light film of oil to all machined surfaces, to prevent rustin ...
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15 If any of the cylinder bores are badly scuffed or scored, or if they are excessively- worn, out-of-round or tapered, the usual course of action would be to have the cylinder block/crankcase rebored, and to fit new, oversized, pistons on reassembly. See a dealer or engine reconditioning specialist for advice. 16 If the bores are in reasonably goo ...
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connecting rod is clear by probing with a piece of wire. Temporarily remove the big-end bearing caps and the old bearing shells, wipe clean the rod and cap bearing recesses, and inspect them for nicks, gouges and scratches. After checking the rods, replace the old shells, slip the caps into place, and tighten the bolts finger-tight. 15 To refit the ...
Rover 820 (1997) - page 83

through filters or the crankcase ventilation system. It may get into the oil, and from there into the bearings. Metal chips from machining operations and normal engine wear are often present. Abrasives are sometimes left in engine components after reconditioning, especially when parts are not thoroughly cleaned using the proper cleaning methods. Wh ...
Rover 820 (1997) - page 84

the piston. Position the gaps of the two oil control rails and the expander at 90º to each other. 4-cylinder “T” series engines - set the compression ring gaps at 120º to each other and away from the inlet valve cut- out side of the piston. Position the gaps of the two oil control rails at 120º to each other and the gap of the expander at 12 ...
Rover 820 (1997) - page 85

Final refitting 14 Carefully lift the crankshaft out of the engine. Clean the bearing surfaces of the shells in the block, then apply a thin, uniform layer of clean molybdenum disulphide-based grease, engine assembly lubricant, or clean engine oil to each surface (see illustration) . Coat the thrustwasher surfaces as well. 15 Lubricate the cranksha ...
Rover 820 (1997) - page 86

8 Tap the top edge of the ring compressor to make sure it’s contacting the block around its entire circumference. 9 Gently tap on the top of the piston with the end of a wooden hammer handle (see illustration) , while guiding the connecting rod’s big-end onto the crankpin. The piston rings may try to pop out of the ring compressor just before e ...
Rover 820 (1997) - page 87

1380 Rover 800 Series Remake 3 Coolant Mixture type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Chapter 1 Cooling system capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Chapter 1 Expansion tank cap System pressure . . . . . . . . . . . . . . . . . . . . . . . . ...
Rover 820 (1997) - page 88

1 General information Engine cooling system The cooling system is of the pressurized, pump-assisted thermosyphon type. The system consists of the radiator, water pump, thermostat, electric cooling fan, expansion tank and associated hoses (see illustrations) . On “M” series 4-cylinder engines, and V6 engines, the impeller type water pump is moun ...
Rover 820 (1997) - page 89

Warning: DO NOT attempt to remove the expansion tank filler cap, or to disturb any part of the cooling system, while it or the engine is hot, as there is a very great risk of scalding. If the expansion tank filler cap must be removed before the engine and radiator have fully cooled down (even though this is not recommended) the pressure in the cool ...
Rover 820 (1997) - page 90

outlet elbow (see illustrations) . Remove the gasket. 4 Withdraw the thermostat from its seat in the housing (see illustration) . 5 To remove the housing, disconnect the coolant temperature sensor wiring multiplug(s). A single sensor is fitted to early engines; two are fitted to later engines. 6 Slacken the retaining clips, and disconnect the heate ...
Rover 820 (1997) - page 91

21 Undo the three bolts and remove the thermostat housing and gasket. 22 Withdraw the thermostat from its seat in the housing. Testing 23 Refer to the procedures described above for 4-cylinder engines. Refitting 24 Refitting is a reversal of removal. Ensure that the housing mating surfaces are clean and use a new gasket. 5 Electric cooling fan asse ...
Rover 820 (1997) - page 92

fitting, and withdraw the switch and seal from the radiator (see illustration) . Refitting 3 Refitting is a reversal of removal, but renew the seal if the old one has deteriorated. Top up the cooling system as described in Chapter 1. Coolant temperature sensors Removal 4 The coolant temperature sensors contain an element, the resistance of which al ...
Rover 820 (1997) - page 93

Radiator and intercooler - turbocharged engines Removal 13 Remove the right-hand headlight lens unit as described in Chapter 12, Section 7. 14 Remove the air cleaner components, as necessary for access to the radiator, as described in the relevant Part of Chapter 4. 15 Drain the cooling system as described in Chapter 1. Leave the bottom radiator ho ...
Rover 820 (1997) - page 94

4 If not already done, undo the centre retaining bolt and remove the timing belt tensioner. 5 Slacken the clip and detach the water inlet hose from the rear of the pump. 6 Undo the bolt securing the support strut to the rear of the pump housing (see illustration) . 7 Undo the four bolts securing the right-hand engine mounting bracket to the water p ...
Rover 820 (1997) - page 95

10 Water pump (V6 engines) - removal and refitting 4 Note: Due to the layout of the V6 engine and the limited space available in the engine compartment, access to most components is extremely limited and may present unforseen difficulties. Read through all the relevant procedures and familiarize yourself with what’s involved before proceeding. No ...
Rover 820 (1997) - page 96

Refitting 9 Refitting is a reversal of removal. Heater blower motor Removal 10 Remove the blower motor and housing assembly from the car as described previously. 11 Extract the clips securing the two halves of the housing assembly, and lift off the upper half. 12 Remove the separator plate. 13 Undo the nut and remove the fan from the motor. 14 Disc ...
Rover 820 (1997) - page 97

12 Heater/air conditioning controls - removal and refitting 1 Heater control unit and cables Removal 1 Remove the cowl around the instrument panel as described in Chapter 12, Section 9. 2 Remove the trim panel under the facia on the driver’s side. 3 Extract the outer cable retaining clips, and slip the cable ends off the heater levers. 4 Withdraw ...
Rover 820 (1997) - page 98

has different fittings requiring different tools, so that there is no chance of the two types of refrigerant becoming mixed accidentally. (e) If for any reason the system must be disconnected, entrust this task to your Rover dealer or a refrigeration engineer. (f) It is essential that the system be professionally discharged prior to using any form ...
Rover 820 (1997) - page 99

31 Working under the car, place a jack and block of wood under the engine to support it, then unscrew the eight bolts that secure the engine longitudinal support member by approximately 15 mm - it should not be necessary to remove the bolts. Have an assistant lever the support member down to give increased clearance, which will allow the compressor ...
Rover 820 (1997) - page 100

1380 Rover 800 Series Remake 4A General System type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Indirect single-point injection with microprocessor control ECU-controlled idle speed: Manual transmission models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700 to 800 rpm Automatic trans ...
Rover 820 (1997) - page 101

1 General information and precautions The fuel system used on Rover 820e and Se models consists of a centrally-mounted fuel tank, electric fuel pump and single-point fuel injection (SPi) system, together with its related electrical and mechanical components. A more detailed description of the SPi system is contained in Section 10. The exhaust syste ...
Rover 820 (1997) - page 102

the body and trunking, disconnect the hot air intake tube, and release the trunking from the connecting duct at the front of the car. Remove the air cleaner body and trunking. 6 If the cold air side intake is to be removed, refer to Chapter 5, and remove the battery. 7 Undo the bolt securing the side intake to the body, and remove the intake and du ...
Rover 820 (1997) - page 103

5 Once the system pressure has been completely relieved, tighten the banjo bolt and dispose of the rags safely. 6 Fuel pump - removal and refitting 1 Warning: Refer to the precautions contained in Section 1 before proceeding. Removal 1 Disconnect the battery negative (earth) lead (refer to Chapter 5, Section 1). 2 Release the fuel system pressure a ...
Rover 820 (1997) - page 104

consult one of the motoring organisations (or a similar authority) for advice on the petrols available and their suitability for your vehicle. 1 The fuel recommended by Rover is given in the Specifications at the beginning of this Chapter, followed by the equivalent petrol currently on sale in the UK. 2 RON and MON are different testing standards.; ...
Rover 820 (1997) - page 105

during warm-up conditions, is fitted to the underside of the inlet manifold. The heater is of the positive temperature coefficient (PTC) type, in which the current consumption of the heating element is high while it heats up, but is greatly reduced at operating temperature. The unit is controlled by a temperature sensor, screwed into the coolant ja ...
Rover 820 (1997) - page 106

16 Check the lost motion gap by inserting a feeler gauge of the specified size between the forked end of the throttle lever and the peg on the linkage. If the gap requires adjustment, slacken the accelerator cable locknuts and reposition the outer cable until the correct setting is achieved (see illustrations) . Tighten the locknuts when the gap is ...
Rover 820 (1997) - page 107

17 Disconnect the injector wiring multiplug. 18 Undo the four screws securing the injector housing to the throttle body, and lift off the housing (see illustration) . The housing may be initially tight, due to the two locating dowels. Recover the gasket from the throttle body. 19 This is the limit of dismantling that can be undertaken on the inject ...
Rover 820 (1997) - page 108

Resonator unit Removal 51 Apply the handbrake, jack up the front of the car and support it on axle stands. 52 Undo the two screws and one bolt securing the access panel to the underside of the front wheelarch on the left-hand side. 53 Disengage the access panel from the front spoiler, and remove it from under the car. 54 Undo the two bolts and with ...
Rover 820 (1997) - page 109

4 To remove the rear section, undo the three nuts securing the rear section to the intermediate section at the flange joint, and separate the joint. Recover the flange gasket. Disengage the rubber mountings at the side and rear, and remove the section from under the car. 5 To remove the intermediate section, undo the nuts securing the intermediate ...
Rover 820 (1997) - page 110

1380 Rover 800 Series Remake 4B General System type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Indirect multi-point injection with microprocessor control ECU-controlled idle speed: Manual transmission models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 850 to 950 rpm Automatic transm ...
Rover 820 (1997) - page 111

1 General information and precautions The fuel system used on earlier Rover 820i, Si, SLi and Turbo models consists of a centrally-mounted fuel tank, electric fuel pump and indirect multi-point fuel injection (MPi) system, together with its related electrical and mechanical components. A more detailed description of the MPi system is contained in S ...
Rover 820 (1997) - page 112

3 Accelerator cable - removal, refitting and adjustment 4 Removal 1 Open the throttle fully by hand, and slip the inner cable end out of the slot on the throttle lever (see illustration) . 2 Slacken the outer cable locknuts, and fully unscrew the outer locknut, nearest to the cable end. 3 Remove the washer and rubber bush, then withdraw the cable f ...
Rover 820 (1997) - page 113

Fuel ECU: The fuel ECU is a microprocessor, which controls the entire operation of the fuel system. Contained in the ECU memory is a program which controls the fuel supply to the injectors, and their opening duration. The program enters sub-routines to alter these parameters, according to inputs from the other components of the system. In addition ...
Rover 820 (1997) - page 114

13 With the CO content correctly adjusted, switch off the engine and connect a tachometer according to the manufacturer’s instructions. 14 Before adjusting the base idle speed, the stepper motor must be cycled to its fully- extended position, using the following procedure: (a) Switch on the ignition. (b) Disconnect the stepper motor wiring multip ...
Rover 820 (1997) - page 115

10 Using a 32 mm spanner, unscrew the stepper motor from the throttle housing. Refitting 11 Refitting is a reversal of removal. Throttle potentiometer Removal 12 Disconnect the throttle potentiometer wiring harness multiplug. 13 Using a dab of paint, mark the position of the potentiometer in relation to the throttle housing, so that if the original ...
Rover 820 (1997) - page 116

plenum chamber to the inlet manifold (see illustration) . 41 Lift the plenum chamber off the manifold, and recover the four locating sleeves and O- ring seals. 42 Clean the manifold and plenum chamber mating faces, and renew the O-ring seals if they show any sign of deterioration. Refitting 43 Refitting is a reversal of removal. Fit the locating sl ...
Rover 820 (1997) - page 117

The gas flows through a specially-shaped housing (the turbine housing) and in so doing, spins the turbine wheel. The turbine wheel is attached to a shaft, at the end of which is another vaned wheel known as the compressor wheel. The compressor wheel spins in its own housing, and compresses the inlet air on the way to the inlet manifold. 3 Boost pre ...
Rover 820 (1997) - page 118

1380 Rover 800 Series Remake 4C General System type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Modular Engine Management System (MEMS) with indirect multi-point injection ECU-controlled idle speed: Normally-aspirated engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 825 to 925 r ...
Rover 820 (1997) - page 119

Torque wrench settings Nm lbf ft Fuel filter banjo union bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 28 Fuel pressure regulator retaining bolts . . . . . . . . . . . . . . . . . . . . . . . . . . 10 7 Brake servo hose banjo union bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 37 Plenum chamber to ...
Rover 820 (1997) - page 120

11 Keeping the cable in this position, screw the square nut along the threaded portion of the outer cable until it just touches the support bracket. 12 Without moving the square nut, clip it into its slot in the support bracket. Models from VIN 152206 13 Switch the ignition on, wait five seconds then switch it off again. This will move the stepper ...
Rover 820 (1997) - page 121

controls an over-run fuel cut-off function. On later versions of the system, the manifold absolute pressure sensor is used to perform the functions of the pedal switch. The ECU, in determining optimum ignition timing, receives information from the crankshaft sensor (engine speed and crankshaft position), manifold absolute pressure sensor (engine lo ...
Rover 820 (1997) - page 122

Refitting 27 Refitting is a reversal of removal, but use a new O-ring seal. Plenum chamber Removal 28 Disconnect the battery negative (earth) lead (refer to Chapter 5, Section 1). 29 Slacken the hose clip and detach the air intake trunking from the throttle housing. 30 Undo the four nuts securing the throttle housing to the plenum chamber, ease the ...
Rover 820 (1997) - page 123

69 Undo the retaining bolt and remove the sensor from the housing on the end of the cylinder head. Refitting 70 Refitting is a reversal of removal. 13 Turbocharger - description and precautions Refer to Part B, Section 13. 14 Turbocharger - removal and refitting 1 Removal 1 Disconnect the battery negative (earth) lead (refer to Chapter 5, Section 1 ...
Rover 820 (1997) - page 124

1380 Rover 800 Series Remake 4D General System type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Programmed fuel injection system with sequential injection Idle speed: 2.5 litre engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 720 to 820 rpm 2.7 litre engines ...
Rover 820 (1997) - page 125

1 General information and precautions The fuel system used on V6 engine Rover models consists of a centrally-mounted fuel tank, electric fuel pump and Honda PGM-Fi programmed fuel injection system A more detailed description of the system is contained in Section 10. The exhaust system consists of a front, intermediate and rear section, suspended fr ...
Rover 820 (1997) - page 126

11 Release the air cleaner assembly from the air duct, disengage the locating pegs and lift the assembly out of the engine compartment. Refitting 12 Refitting is a reversal of removal. Air duct Removal 13 Remove the battery as described in Chapter 5. 14 Remove the air intake trunking and the air cleaner assembly as described previously. 15 Undo the ...
Rover 820 (1997) - page 127

8 Fuel tank - removal, inspection and refitting Refer to Part A, Section 8. 9 Unleaded petrol - general information and usage Note: The information given in this Chapter is correct at the time of writing, and applies only to petrols currently available in the UK. If updated information is thought to be required, check with a Rover dealer. If travel ...
Rover 820 (1997) - page 128

modify these basic values to “fine-tune” the injector opening times to suit precise operating conditions. Information on crankshaft speed and position, coolant temperature, intake air temperature, ambient air temperature, manifold pressure, atmospheric pressure and vehicle speed is supplied to the ECU by the sensors, to enable initial injection ...
Rover 820 (1997) - page 129

14 Locate the adjuster and hook out the tamperproof cap over the adjusting screw, if fitted. 15 Refer to the engine tuning procedure information contained above before starting. 16 Switch off all electrical accessories, and ensure that they remain switched off throughout the adjustment procedure. 17 If, during the adjustment procedure, the cooling ...
Rover 820 (1997) - page 130

16 Slacken the outer cable locknuts, then withdraw the outer cable from the support bracket. 17 On automatic transmission models, release the kickdown cable inner cable end from the throttle lever. 18 Undo the two screws securing the kickdown cable support bracket to the throttle body and move the bracket and cable to one side. 19 Disconnect the wi ...
Rover 820 (1997) - page 131

51 Disconnect the cruise control vacuum hose at the T-piece connector, release the hose from the support clips and move it clear. 52 Undo the two banjo union bolts securing the fuel pipes to the front fuel rail. Release the pipes and collect the copper washers. Cover the open unions after disconnection then move the pipes away. 53 Undo the bolts se ...
Rover 820 (1997) - page 132

Refitting 76 Refitting is a reversal of removal but use a new sealing O-ring. Electronic control unit Removal 77 Disconnect the battery negative (earth) lead (refer to Chapter 5, Section 1). 78 Remove the driver’s seat as described in Chapter 11. 79 Undo the four bolts securing the ECU to the floor. Lift off the ECU cover and collect the spacers ...
Rover 820 (1997) - page 133

vehicle speed sensor, the clutch and brake pedal switches and the shift control switch on the transmission. When the system is engaged, the ECU sends signals to the cruise control actuator which regulates the accelerator pedal position by means of a stepper motor and connecting cable. Once the driver has initiated the system, the road speed will be ...
Rover 820 (1997) - page 134

1380 Rover 800 Series Remake 4E Torque wrench settings Nm lbf ft Oxygen sensor: 4-cylinder engines with sensor in front pipe . . . . . . . . . . . . . . . . . . . . 20 15 4-cylinder engines with sensor in manifold . . . . . . . . . . . . . . . . . . . . 55 41 V6 engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...
Rover 820 (1997) - page 135

the exhaust system. On all models where a catalytic converter is fitted, the system is of the closed-loop type, in which an oxygen sensor in the exhaust system provides the fuel injection/ignition system ECU with constant feedback on the oxygen content of the exhaust gasses. This enables the ECU to adjust the mixture by altering injector opening ti ...
Rover 820 (1997) - page 136

thermostatic valve and release the upper hose from its support clip (see illustration) . 19 Unscrew the thermostatic valve from the coolant passage and remove it from the engine. 20 Refitting is a reversal of removal, but apply a thread sealant to the valve threads prior to refitting. Constant vacuum control valve (V6 engines) - renewal 21 The cons ...
Rover 820 (1997) - page 137

48 Undo the two air suction pipe retaining bolts 49 Undo the two bolts securing the fuel pipe retaining clips adjacent to the air suction valve. 50 Relieve the fuel system pressure as described in Part D, Section 5. 51 Undo the two banjo union bolts securing the fuel pipes to the front fuel rail. Release the pipes and collect the copper washers. Co ...
Rover 820 (1997) - page 138

1380 Rover 800 Series Remake 5 Battery Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lead-acid, maintenance-free Rating - Cold cranking/Reserve capacity . . . . . . . . . . . . . . . . . . . . . . . . 480 A/90 RC, 570 A/110 RC, 520 A/120 RC Ignition coil 4-cylinder engines: Primary resi ...
Rover 820 (1997) - page 139

Alternator Type: 4-cylinder engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lucas/Magneti-Marelli A127, A133 or A1271 V6 engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nippondenso CGK 46 Brush length (nominal): New . .20.0 mm Minimum . . . . . . . . . . . . . ...
Rover 820 (1997) - page 140

connected by its own wires to a spare battery; the vehicle’s own battery is then disconnected from the electrical system, leaving the “memory-saver” to pass sufficient current to maintain audio unit security codes and ECU memory values, and also to run permanently-live circuits such as the clock, all the while isolating the battery in the eve ...
Rover 820 (1997) - page 141

monitor manifold pressure, coolant temperature, intake air temperature, atmospheric pressure and engine speed and pass signals to the fuel system ECU. According to the signals received, the ECU controls the operation of the solenoid valves to provide the appropriate vacuum necessary to create the required ignition advance. On 2.7 litre engines igni ...
Rover 820 (1997) - page 142

the cap. Clean and check the cap as described in Chapter 1. 2 If the cap is to be renewed, record the position of the HT leads in relation to the cap, then pull them off. Transfer the leads to a new cap, refitting them in the same position. 3 To remove the rotor arm, withdraw the plastic shield (where fitted), then undo the retaining grub screw usi ...
Rover 820 (1997) - page 143

terminals (see illustration) . The primary winding resistance should be as given in the Specifications at the beginning of this Chapter. If the resistance is not as specified, the coil should be renewed. 4 On V6 engines, disconnect the wiring multiplug(s) and the distributor HT lead at the coil and connect an ohmmeter across the multiplug terminals ...
Rover 820 (1997) - page 144

4 Undo the three screws and lift off the control box upper cover. 5 Release the wiring multiplugs from the mounting brackets on the front of the control box and disconnect them (see illustration) . Note their connections for refitting. 6 Remove the control box lower cover from the valve plate assembly. 7 Undo the two screws securing the ignition ti ...
Rover 820 (1997) - page 145

marks. The centre notch of the three (usually coloured red) represents 15º BTDC. The remaining two notches represent a timing tolerance of ± 2º (see illustration 10.4). 21 If the engine is being adjusted to run on unleaded fuel, it will be necessary to make an additional notch on the pulley (the existing notches are only applicable when adjustin ...
Rover 820 (1997) - page 146

Refitting 4 Refitting is a reversal of removal, but ensure that the sensor and cylinder block mating faces are clean. 13 Crankshaft sensor - removal and refitting 1 Removal 1 The crankshaft sensor, fitted to 4-cylinder engines is attached to the transmission adaptor plate on the rear facing side of the engine. 2 Jack up the front of the car and sup ...
Rover 820 (1997) - page 147

(a) Check the tension and condition of the alternator (auxiliary) drivebelt - renew it if it is worn or deteriorated (see Chapter 1). (b) Ensure the alternator mounting bolts and nuts are tight. (c) Inspect the alternator wiring harness and the electrical connections at the alternator; they must be in good condition, and tight. (d) Check the releva ...
Rover 820 (1997) - page 148

3 Tip the assembly upwards at the edge, and withdraw it from its location. Disconnect the wiring terminal and remove the regulator and brushbox from the alternator (see illustrations) . 4 Measure the brush length and renew the brushbox and regulator assembly if the brushes are worn below the figure given in the Specifications (see illustration) . 5 ...
Rover 820 (1997) - page 149

8 If the starter motor still does not operate, remove it (see Section 21). The brushes and commutator may be checked (Section 22), but if the fault persists, the motor should be renewed, or taken to an auto-electrician for testing and repair. 9 If the starter motor cranks the engine at an abnormally-slow speed, first make sure that the battery is c ...
Rover 820 (1997) - page 150

9 Prior to refitting the brushes, check the condition of the commutator face on which they run. Wipe the commutator with a solvent- moistened cloth. If the commutator is dirty, it may be cleaned with fine glass paper, then wiped with the cloth. 10 Fit the new brushes using a reversal of the removal procedure. When refitting the brush holder assembl ...
Rover 820 (1997) - page 151

1380 Rover 800 Series Remake 9 General System type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diagonally-split, dual-circuit hydraulic with pressure-reducing valve in rear hydraulic circuit and cable operated handbrake. Anti-lock braking system (ABS) available as standard or optional equipment on lat ...
Rover 820 (1997) - page 152

Handbrake Handbrake linkage lever-to-stop pin clearance . . . . . . . . . . . . . . . . . . . 0.5 to 2.0 mm Torque wrench settings Nm lbf ft Caliper guide pin bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 24 Front caliper carrier bracket to steering knuckle . . . . . . . . . . . . . . . . . . 75 55 Rear calipe ...
Rover 820 (1997) - page 153

7 Unscrew the master cylinder reservoir cap, and top up the reservoir to the “MAX” level line. Do not invert the cap or hydraulic fluid may short out the cap contacts causing the warning light on the instrument panel to flash. Refit the cap loosely, and remember to maintain the fluid level at least above the “MIN” level line throughout the ...
Rover 820 (1997) - page 154

guide pin bolt while holding the guide pin with a second spanner (see illustrations) . 3 Pivot the caliper body upwards and tie it up, using a length of string, under the wheelarch (see illustration) . 4 Lift out the two brake pads together with their shims then, where fitted, remove the upper and lower anti-rattle shims from the caliper carrier br ...
Rover 820 (1997) - page 155

screw. Submerge the free end of the tube in a jar containing a small quantity of brake fluid. 10 Open the bleed screw approximately half a turn, then push the piston back into its bore, as far as it will go, using a G-clamp, or pieces of wood, as levers. When the piston has fully retracted, close the bleed screw, remove the tube and refit the dust ...
Rover 820 (1997) - page 156

6 Front brake disc - inspection, removal and refitting 2 Note: Before starting work, refer to the warning at the beginning of Section 3 concerning the dangers of asbestos dust. Inspection 1 Apply the handbrake, remove the front wheel trim and slacken the wheel nuts. Jack up the front of the car and support it on axle stands. Remove the front roadwh ...
Rover 820 (1997) - page 157

with compressed air and do not inhale any of it. DO NOT use petroleum-based solvents to clean brake parts. Use brake cleaner or methylated spirit only. DO NOT allow any brake fluid, oil or grease to contact the brake pads or disc. Also refer to the warning at the start of Section 2 concerning the dangers of hydraulic fluid. Note: New caliper guide ...
Rover 820 (1997) - page 158

Removal 1 Chock the front wheels, remove the wheel trim and slacken the rear wheel nuts. Jack up the rear of the car and support it on axle stands. Remove the rear roadwheel and ensure that the handbrake is released. 2 Undo the three bolts securing the handbrake linkage cover, and remove the cover from the side of the caliper. 3 On the left-hand ca ...
Rover 820 (1997) - page 159

3 Undo the retaining bolt and release the flexible brake hose support clip from the suspension strut (see illustration) . 4 Withdraw the carrier bracket, complete with caliper and brake pads, from the disc and hub carrier. Tie the caliper assembly from a convenient place under the wheelarch to avoid straining the brake hose (see illustration) . 5 T ...
Rover 820 (1997) - page 160

9•10 Braking system 12.0a Exploded view of the early type master cylinder - non-ABS models 1 Reservoir 2 Stop-pin 3 Reservoir seals 4 Cylinder body 5 Piston retaining circlip 6 Washer 7 O-ring seal 8 Primary piston seal housing 9 Primary piston seal 10 Primary piston washer 11 Primary piston assembly 12 Secondary piston front seal 13 Secondary pi ...
Rover 820 (1997) - page 161

are not available separately. If the master cylinder is in a serviceable condition, and is to be re-used, a new primary piston assembly is included in the repair kit. 11 With the master cylinder dismantled, clean all the components in methylated spirit, or clean hydraulic fluid, and dry with a lint-free cloth. 12 Carefully examine the cylinder bore ...
Rover 820 (1997) - page 162

before condemning the valve to ensure that the brake assemblies themselves, or adverse road conditions, are not causing this condition. In the event of a valve internal failure, brake fluid will be seen seeping from the vent plug on the front of the valve which is covered by a plastic strap. Repair or overhaul of the valve is not possible, and the ...
Rover 820 (1997) - page 163

2 Disconnect the return spring from the brake pedal and pedal bracket (see illustration) . 3 Extract the retaining spring clip and withdraw the clevis pin securing the brake servo pushrod to the pedal. 4 Undo the nut, remove the washer and withdraw the brake pedal pivot bolt from the pedal bracket. Remove the pedal from the car. 5 Prise out the two ...
Rover 820 (1997) - page 164

necessary (see illustration) . Turning the adjuster clockwise will decrease the clearance, and turning it anti-clockwise will increase it. 8 Operate the handbrake two or three times, and recheck the clearance once more. Make a final adjustment if required, then refit the trim cover to the lever, or refit the centre console, as applicable. 9 Refit t ...
Rover 820 (1997) - page 165

side of the lever, and remove the adjuster and spacing washer from the front cable. 9 Release the front cable and gaiter from the handbrake lever assembly, then remove the cable from the gaiter. Refitting 10 Refitting is a reversal of removal. Adjust the handbrake as described in Section 17 before lowering the car to the ground. 20 Handbrake cable ...
Rover 820 (1997) - page 166

22 Vacuum servo unit - general information and testing 1 General information 1 A vacuum servo unit is located between the brake pedal and master cylinder, to provide assistance to the driver when the brake pedal is depressed. This reduces the effort required by the driver to operate the brakes under all braking conditions. 2 The unit operates by va ...
Rover 820 (1997) - page 167

Pressure build-up phase: The solenoid inlet valves are open, and hydraulic pressure from the master cylinder is applied directly to the brake calipers. Constant pressure phase: The solenoid inlet and exhaust valves are closed, and hydraulic pressure at the calipers is maintained at a constant level, even though master cylinder pressure may increase ...
Rover 820 (1997) - page 168

26 Slacken the modulator mounting nuts and remove the unit from its location. Do not attempt to dismantle the modulator, as it is a sealed unit, and no repairs are possible. 27 Refitting is a reversal of removal. Bleed the hydraulic system as described in Sec- tion 2 on completion. Later system 28 Disconnect the battery negative (earth) lead (refer ...
Rover 820 (1997) - page 169

Braking system 9•19 9 1380 Rover 800 Series Remake 1 Electronic control unit cover 2 Left-hand side trim panel 3 Cable connector 4 Rear wheelarch plastic liner 5 Luggage compartment floor grommet 6 Sensor wiring 7 Inner wheelarch grommet 8 Cover bolts 9 Cable cover and guide 10 Cable retaining clip 11 Cable tie 12 Support bracket bolt 13 Cable ha ...
Rover 820 (1997) - page 170

1380 Rover 800 Series Remake 10 Front suspension Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Independent, by unequal length upper and lower suspension arms, with coil springs, telescopic shock absorbers and anti-roll bar Hub bearing endfloat . . . . . . . . . . . . . . . . . . . . . . ...
Rover 820 (1997) - page 171

Tyres Tyre size: 4-cylinder engine models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195/70 VR 14, 195/65 VR 15, 205/55 VR 16 or 215/45 ZR 17 (115/70 R 15 space saver) V6 engine models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195/65 VR 15, 205/60 VR 15 or 205/55 VR 16 (115/70 R 15 spac ...
Rover 820 (1997) - page 172

1 General information The independent front suspension is by unequal length upper and lower suspension arms, and utilizes coil springs and telescopic shock absorbers (see illustration) . Each spring and shock absorber assembly is attached to the body turret at its upper end by a rubber- cushioned mounting, and to the lower suspension arm by a forge ...
Rover 820 (1997) - page 173

2 Front steering knuckle assembly - removal and refitting 3 Note: A new driveshaft retaining nut will be required for refitting. Removal 1 While the car is standing on its wheels. firmly apply the handbrake and put the transmission in gear (PARK on automatic models). 2 Remove the wheel trim, and using a small punch, knock up the staking that secure ...
Rover 820 (1997) - page 174

peened into place. Take the car directly to a suitably-equipped garage, and have them fit and tighten the new nut for you. (c) On cars equipped with ABS brakes, refit the wheel speed sensor as described in Chapter 9. 3 Front hub bearing - renewal 3 1 Remove the steering knuckle from the car as described in the previous Section. 2 Support the steeri ...
Rover 820 (1997) - page 175

3 Support the steering knuckle in a wide- opening vice or on a press bed, and using tubes as mandrels and distance pieces, press the balljoint out of the knuckle. The manufacturer’s special tools being used for this purpose are shown, to give an idea of the arrangement, but lengths of tubular steel work equally well (see illustration) . Refitting ...
Rover 820 (1997) - page 176

be made out of a large nut, with one end suitably shaped by cutting or filing so that two projections are left, which will engage with the collar slots (see illustration) . 6 Engage the home-made tool with the threaded collar slots, then screw two 10 mm nuts onto the threaded end of the spindle, and lock them together. Hold these locknuts to preven ...
Rover 820 (1997) - page 177

2 Undo the nut securing the steering knuckle balljoint to the lower suspension arm (see illustration) . Release the balljoint using a separator tool or two-legged puller. 3 Undo the nut and remove the through-bolt securing the shock absorber forked member to the arm. 4 Undo the bolt securing the anti-roll bar connecting link to the arm. 5 Undo the ...
Rover 820 (1997) - page 178

4 Undo the two bolts securing the tie-bar to the lower suspension arm, and remove the bar from under the car. 5 Withdraw the spacer, inner mounting bush and washer. 6 Renew the mounting bushes if they show any sign of deformation or swelling of the rubber. Refitting 7 Fit the washer, inner bush and spacer, then locate the tie-bar in position. 8 Sec ...
Rover 820 (1997) - page 179

5 Undo the four screws and remove the disc shield. 6 Extract the bearing retaining circlip, then support the hub carrier face-down on blocks or on a press bed. Using a tube or mandrel in contact with the edge of the outer bearing, drive or press the bearing out (see illustrations) . 7 Fit the new bearing in the same way, ensuring that it is pressed ...
Rover 820 (1997) - page 180

3 Lower the jack slowly and carefully to release the tension on the coil spring. 4 When all the tension is released, withdraw the spring from its location, and recover the upper and lower spring seats. Note the fitted position of the lower seat in the transverse link as it is removed. 5 Examine the spring carefully for signs of distortion or damage ...
Rover 820 (1997) - page 181

members, and remove the bar from under the car (see illustration) . 4 If required, the connecting links can be removed after undoing the retaining nut on each side. 5 Check the condition of the connecting link bushes and the anti-roll bar mounting bushes, and renew any that show signs of deterioration. The mounting bushes are slit along their lengt ...
Rover 820 (1997) - page 182

two airbag module retaining screws from the rear of the steering wheel (see illustration) . 18 Lift the airbag module off the steering wheel, disconnect the multiplug from the rear of the module and remove the module from the vehicle. Warning: Position the airbag unit in a safe place, with the mechanism facing downwards as a precaution against acci ...
Rover 820 (1997) - page 183

steering column, and move the column to its lowest position (see illustration) . 4 Undo the single upper screw and the three lower screws, and remove the upper and lower steering column shrouds. 5 Undo the two nuts and remove the washers from the steering column upper mounting. 6 Undo the two bolts and remove the mounting strap from the column lowe ...
Rover 820 (1997) - page 184

20 Refit the column mountings, and tighten the nuts and bolts to the specified torque. 21 Tighten the universal joint clamp bolt. 22 Refit the cover plate and gasket, followed by the universal joint cover. 23 Refit the steering column shrouds and the trim panels. 24 Refit the rotary coupler (where applicable) and steering wheel as described in Sect ...
Rover 820 (1997) - page 185

7 Insert the balljoint into the steering knuckle arm and refit the retaining nut. Tighten the nut to the specified torque, then tighten it further, slightly, to align the next split pin hole. Secure the nut with a new split pin. 8 Tighten the track rod retaining locknut securely, refit the roadwheel and lower the car to the ground. Tighten the whee ...
Rover 820 (1997) - page 186

25 Power steering gear - bleeding 1 1 Remove the filler cap on the power steering fluid reservoir, and fill the reservoir with the specified fluid until the level is up to the MAX mark on the cap dipstick. 2 Disconnect the HT lead from the centre of the ignition coil. 3 Crank the engine on the starter motor for five seconds to prime the power steer ...
Rover 820 (1997) - page 187

19 On models with air conditioning, remove the heat shield (where fitted) from the rear of the pump. 20 Position a suitable container beneath the engine, below the power steering pump. 21 Wipe clean the area around the pipe and hose unions at the rear of the pump. 22 Unscrew the union nut and slacken the hose clip, then disconnect the high pressure ...
Rover 820 (1997) - page 188

Refitting 34 Refitting is a reversal of removal, bearing in mind the following points: (a) Tighten all nuts, bolts and unions to the specified torque. (b) Use a new O-ring on the high pressure pipe connector. (c) Refit and tension the drivebelt as described in Chapter 1. (c) Bleed the power steering gear as described in Section 25. 27 Power steerin ...
Rover 820 (1997) - page 189

edges of the roadwheels. The other method is to use a scuff plate, in which the roadwheel is rolled across a movable plate which records any deviation, or scuff, of the tyre relative to the straight-ahead position, as it moves across the plate. Relatively inexpensive equipment of both types is available from accessory outlets to enable these checks ...
Rover 820 (1997) - page 190

1380 Rover 800 Series Remake 11 Torque wrench settings Nm lbf ft Bonnet hinge bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 7 Boot lid hinge bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 7 Door hinge-to-body bolts . . . . . . . . . . . . . . . . . . . . . . . ...
Rover 820 (1997) - page 191

1 General information 1 The bodyshell and underframe is of all-steel welded construction, and is of computer- originated design. The assembly and welding of the main body unit is completed entirely by computer-controlled robots, and the finished unit is checked for dimensional accuracy using computer and laser technology. In accordance with current ...
Rover 820 (1997) - page 192

Repairs of minor scratches in bodywork If the scratch is very superficial, and does not penetrate to the metal of the bodywork, repair is very simple. Lightly rub the area of the scratch with a paintwork renovator, or a very fine cutting paste, to remove loose paint from the scratch, and to clear the surrounding bodywork of wax polish. Rinse the ar ...
Rover 820 (1997) - page 193

The repair area is now ready for final spraying. Paint spraying must be carried out in a warm, dry, windless and dust-free atmosphere. This condition can be created artificially if you have access to a large indoor working area, but if you are forced to work in the open, you will have to pick your day very carefully. If you are working indoors, dou ...
Rover 820 (1997) - page 194

7 Using a small screwdriver, prise out the clips securing the support struts to the pegs on the bonnet (see illustration) . Release both struts from their pegs. 8 Undo the retaining bolts and carefully lift away the bonnet. Refitting 9 Refitting is a reversal of removal; adjust the bonnet on the hinges to its original position, then check the align ...
Rover 820 (1997) - page 195

and remove the centre lens and reflector assembly (see illustration) . 3 Extract the retaining circlip from the private lock lever, and withdraw the link rod. 4 Drill out the three retaining rivets, and remove the private lock from the boot lid (see illustration) . Refitting 5 Refitting is a reversal of removal. 1992 model year onwards Removal 6 Re ...
Rover 820 (1997) - page 196

13 Fuel filler flap release cable - removal and refitting 1 Removal 1 Open the fuel filler flap, then remove the boot lid/tailgate and fuel filler flap release control, as described in Section 11. 2 Undo the screws securing the rear sill tread plate, lift off the tread plate and move aside the carpet around the sill. 3 Remove the rear seat as descr ...
Rover 820 (1997) - page 197

release cable outer sheath from the lock bracket and disconnect the inner cable from the lock lever Refitting 8 Refitting is a reversal of removal. 17 Tailgate private lock - removal and refitting 1 Pre-1992 model year Removal 1 Open the tailgate, release the screw studs and remove the tailgate inner trim panel. 2 Remove the number plate from the t ...
Rover 820 (1997) - page 198

5 Open the bonnet and undo the seven bolts securing the grille panel. 6 Remove the grille from the bonnet and recover the rubber surround. Refitting 7 Refitting is a reversal of removal. 20 Windscreen, rear window and tailgate glass - removal and refitting 5 The primary window glass on the Rover 800 Series is flush-glazed, and secured to the body s ...
Rover 820 (1997) - page 199

6 Ease back the padded trim at the bottom of the panel, or lift off the plastic cap, to expose the retaining screw, then undo the screw (see illustrations) . 7 Pull out the blanking plug on the rear side of the panel, and undo the recessed screw behind (see illustrations) . 8 Undo the screw at the upper front corner of the panel (see illustration) ...
Rover 820 (1997) - page 200

upwards and withdraw it from the door (see illustration) . 15 Disconnect the switch panel wiring multiplug from the rear of the panel and remove the panel. Refitting 16 Refitting is a reversal of removal. 22 Front door - removal, refitting and adjustment 1 Removal 1 Remove the front door inner trim panel as described in Section 21. 2 Release the ma ...
Rover 820 (1997) - page 201

4 Undo the three screws securing the lock assembly to the door. 5 Lower the lock assembly, and release the interior handle control rod and locking button rod from the lock levers. 6 Disconnect the central locking motor wiring multiplug, and manipulate the lock assembly from the door. Refitting 7 Refitting is a reversal of removal. Coupe models Remo ...
Rover 820 (1997) - page 202

1992 model year onwards Removal 7 Remove the front door inner trim panel as described in Section 21. 8 Undo the four screws securing the handle to the door panel. 9 Slide the handle forward and withdraw it from the door. 10 Disconnect the disconnect the interior handle control rod or cable and remove the handle. Refitting 11 Refitting is a reversal ...
Rover 820 (1997) - page 203

and wiring, connect the window lift motor to the battery and close the window fully. 18 With the window closed, check that the front edge of the glass and the cheater panel are flush, forming a smooth curve (see illustration 27.13). If this is not the case, it will be necessary to obtain additional metal spacers and position these behind the top or ...
Rover 820 (1997) - page 204

6 At the top rear corner of the cassette assembly, note the fitted position of the outer cable retainer in the support bracket. Turn the retainer through 90º to release it from the bracket. 7 Bend the guide tab away from the lower rear pulley and slip the cable off both rear pulleys. 8 Release the outer cable from the clip. 9 Detach the cable ends ...
Rover 820 (1997) - page 205

8 Release the door lock control rod from the plastic guide on the inner face of the door. 9 Move the door lock aside, and undo the bolts securing the exterior handle to the door. 10 Withdraw the exterior handle, release the collar and remove the control rod from the exterior handle lever. 11 Remove the exterior handle from the door. Refitting 12 Re ...
Rover 820 (1997) - page 206

bumper moulding, and release the moulding from the side retaining clips. 8 Withdraw the moulding from the bumper. 9 Where fitted, release the washer pipe clips and studs, and disconnect the wiring multiplug. 10 On later models, prise out the two radiator baffle retaining studs. 11 Undo the bolt securing the dim-dip resistor bracket (where fitted). ...
Rover 820 (1997) - page 207

43 Rear seats - removal and refitting 1 Saloon models Removal - bench type seat (pre-1992 model year) 1 Push the seat base rearwards, and at the same time lift it up to release the two retainers. Remove the seat base from the car. 2 Undo the four bolts at the base of the seat squab. 3 Release the two seat belts from the retainers. 4 Slide the squab ...
Rover 820 (1997) - page 208

front edge of the panel. Repeat this procedure with the remaining three screws, two at the bottom and one at the upper rear of the panel. 16 Using a flat tool or your fingers, release the six studs securing the lower trim panel to the body by prising the panel out, or sharply pulling it out, in the vicinity of each stud. Lift away the panel. 17 Lif ...
Rover 820 (1997) - page 209

plate is fitted just forward of the handbrake lever, release the panel or cover plate, disconnect the wiring multiplugs (where applicable) and manipulate the panel or cover plate over the handbrake lever. 11 Apply the handbrake as hard as possible, then lift the rear of the console over the handbrake lever (see illustrations) . Slide the forward en ...
Rover 820 (1997) - page 210

9 Undo the two screws at the base of the oddments tray below the clock (see illustration) . 10 Withdraw the clock and oddments tray housing from the lower facia, and disconnect the clock wiring multiplug. 11 Undo the two upper screws securing the lower facia, and withdraw the lower facia from its location (see illustrations) . 12 Disconnect the wir ...
Rover 820 (1997) - page 211

cassette player and the clock as described in Chapter 12. 25 Release the two turnbuckles and remove the lower trim panel under the facia on the passenger’s side. 26 Undo the two, or four bolts, as applicable below the glovebox and remove the glovebox from the facia. 27 Pull off the weatherstrip from the front body pillars around the facia and foo ...
Rover 820 (1997) - page 212

1380 Rover 800 Series Remake 12 Bulbs Wattage Headlight dipped beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60/55 Headlight main beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Sidelights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...
Rover 820 (1997) - page 213

1 General information and precautions General information The electrical system is of 12-volt negative earth type. Power for the lights and all electrical accessories is supplied by a lead/acid battery which is charged by the alternator. This Chapter covers repair and service procedures for the various electrical components and systems not associat ...
Rover 820 (1997) - page 214

connection being tested. The resistance reading should be zero; if not, check the connection as follows. 22 If an earth connection is thought to be faulty, dismantle the connection, and clean both the bodyshell and the wire terminal (or the component earth connection mating surface) back to bare metal. Be careful to remove all traces of dirt and co ...
Rover 820 (1997) - page 215

10 To gain access to the wiring loom fusible links, lift off the protective cover on the right- hand side of the fuse and relay box (see illustration) . A blown fusible link indicates a serious wiring or system fault, which must be diagnosed before renewing the link. Luggage compartment fusebox 11 On later models an additional fusebox is located in ...
Rover 820 (1997) - page 216

airbag supplementary restraint system, remove the rotary coupler as described in Chapter 10. 14 Slacken the retaining screw in the front centre of the switch assembly. 15 Disconnect the four wiring multiplugs at the rear, then withdraw the switch assembly from the steering column. 16 Undo the two screws securing the individual switch to the main as ...
Rover 820 (1997) - page 217

31 Pull off the knobs on the heater controls. 32 Undo the three screws securing the cowl to the facia above the instrument panel. 33 Undo the two screws below the vent panel on the driver’s side and the two screws below the heater/air conditioning control panel. 34 Release the clips at the top, at each end, ease the cowl away from the facia sligh ...
Rover 820 (1997) - page 218

17 Turn the bulbholder anti-clockwise to remove it from the light unit, then remove the push-fit bulb from the holder. 18 Fit a new bulb, refit the bulbholder, and push the light unit into position in the wing. Front fog light bulb 19 Undo the two upper screws and remove the light unit surround. 20 Disconnect the wiring multiplug and remove the lig ...
Rover 820 (1997) - page 219

45 Push and turn the bulb anti-clockwise to remove it from the holder. 46 Fit the new bulb, lens and retaining screws. 6 Bulbs (interior lights) - renewal 1 Interior courtesy light 1 Carefully prise the lens from the light body using a thin blade (see illustration) . 2 Remove the festoon-type bulb from the contacts. 3 Fit the new bulb and push the ...
Rover 820 (1997) - page 220

8 Undo the four nuts securing the light cluster to the rear wing, and withdraw the unit from the car (see illustrations) . 9 Refitting is a reversal of removal. Boot lid/tailgate light cluster 10 Remove the bulbholder from the light unit as described in Section 5. 11 Undo the nuts securing the light cluster to the boot lid/tailgate and withdraw the ...
Rover 820 (1997) - page 221

4 Pull off the knobs on the heater controls. 5 Undo the three screws securing the cowl to the facia above the instrument panel (see illustration) . 6 Undo the two screws below the vent panel on the driver’s side and the two screws below the heater/air conditioning control panel (see illustration) . 7 Release the clips at the top, at each end, eas ...
Rover 820 (1997) - page 222

illumination and warning light bulbs are renewed complete with their holders. 3 If a faulty bulb is not accessible, undo the five screws securing the ECU to the rear of the panel, and carefully lift the ECU upwards (see illustration) . Take care not to strain the ribbon connectors. The remaining bulbs are now accessible. 4 Refit the bulbholders by ...
Rover 820 (1997) - page 223

37 Refitting is a reversal of removal. Later models 38 Remove the instrument panel from the car as described in Section 9. Panel illumination and warning light bulbs 39 The bulbholders are secured to the front rear of the instrument panel by a bayonet fitting, and are removed by turning the holders anti-clockwise (see illustration) . Note that the ...
Rover 820 (1997) - page 224

13 Disconnect the wiring connector from the rear of the illumination bulb. If the bulb is to be renewed, simply pull it from its location and fit a new bulb. 14 Disconnect the wiring multiplugs from the clock and side switches. 15 Undo the four nuts and remove the wood finishers from the panel. Carefully ease the finishers from the panel which are ...
Rover 820 (1997) - page 225

and on the extreme edges, then remove the finisher from the car (see illustrations) . 5 Using pointed-nose pliers, release the rubber sealing strip retaining clips (see illustrations) . Be prepared for some of these clips to break during removal. 6 Lift off the centre grille and the left-hand plenum moulding (see illustrations) . 7 Working through ...
Rover 820 (1997) - page 226

17 Tailgate wiper motor and linkage - removal and refitting 1 Removal 1 Disconnect the battery negative (earth) lead (refer to Chapter 5, Section 1). 2 Remove the wiper arm as described in Section 15. 3 Release the plastic clip screws and remove the trim panel from inside the tailgate. 4 Undo the large retaining nut from the wiper motor spindle. 5 ...
Rover 820 (1997) - page 227

disconnect the wiring multiplug from the side of the unit. 3 Undo the four nuts and remove the unit from its location. Refitting 4 Refitting is a reversal of removal. 21 Speakers - removal and refitting 1 Rear speaker - Saloon and Coupe models Removal 1 From inside the luggage compartment, disconnect the two leads and undo the four retaining nuts ( ...
Rover 820 (1997) - page 228

two leads at the amplifier unit (see illustration) . 4 Disconnect the two amplifier leads at the connections to the rear screen demisting element. 5 Disconnect the aerial co-axial lead at the amplifier. 6 Undo the two screws and remove the amplifier from under the parcel shelf. Refitting 7 Refitting is a reversal of removal. Fastback models Removal ...
Rover 820 (1997) - page 229

Warning: Procedures for removal and refitting of the driver’s side airbag module and rotary coupler are given in Chapter 10, Sections 18 and 19 respectively. Those procedures are provided solely to allow removal and refitting of the steering wheel and associated components as part of a normal repair operation. Do not attempt to carry out any othe ...
Rover 820 (1997) - page 230

Wiring diagrams 12•19 12 1380 Rover 800 Series Remake P O R Q L J K 48 30 NK NU 32 31 UN NG 49 33 PN P 50 PN B M B B N N N N B NP N NP WR N WR Y U V W S T X H G 25 26 NS NW 57 23 47 24 27 28 51 29 NS NY NO NR 1 N I N N N P 34 PU PB 35 M N 37 UG 38 UK UW 36 39 NW NS 46 BG GY GY 16 BR BW RS B 2 GY 44 45 US U GY N NW NW Battery Starter motor/ soleno ...
Rover 820 (1997) - page 231

12•20 Wiring diagrams M Windscreen wiper motor Windscreen wiper delay unit Headlight wash motor B 1 27 37 UG SR B 1 Windscreen washer motor B M 1 LGB M 6 B 18 16 14 2 15 3 8 23 22 9 10 21 26 24 11 13 Electric mirror switch Four door window lift control unit 6 5 19 1 4 OU Y 77 GY RH rear window lift switch B B 2 B M U R Passenger's door windo ...
Rover 820 (1997) - page 232

Wiring diagrams 12•21 12 1380 Rover 800 Series Remake P 34 33 Horns PU Heater relay Recirc. light Fresh air light Fresh air solenoid M Heater motor Circuit breaker B B A C D E F G HJ KL M 2 1 3 4 5 6 7 8 B A C D E F G HJ KL M 2 1 3 4 5 6 7 8 Diagram 3: Main wiring diagram (typical) continued - single-point fuel injection models H29044/A 1 Battery ...
Rover 820 (1997) - page 233

12•22 Wiring diagrams 60 PY 3 P 5 LGW Radio/ cassette 3 B Speakers Speakers Filter BW BS Y YB Filter G GB BP BU B A C D E F G HJ KL M 2 1 3 4 5 6 7 8 B A C D E F G HJ KL M 2 1 3 4 5 6 7 8 Diagram 4: Main wiring diagram (typical) continued - single-point fuel injection models H29045 11 No charge warning light 54 NY NR LGY OP 4 spare warning lights ...
Rover 820 (1997) - page 234

Wiring diagrams 12•23 12 1380 Rover 800 Series Remake Connection details No. Diagram/grid ref. 1 5/M5,8/H1 2 5/H2,7/G6,8/E4,8/M8 3 5/H2,7/H6,8/C6,8/L1,10/C1 4 5/H2,8/A4,10/K1 5 5/H5,8/G4,8/L1,10/C1 6 5/F2,6/B6 7 5/H1 8 5/H1,6/A1 9 5/H2,6/F1 10 5/H4,10/L8 11 5/H4,5/H6,5/M2 12 5/H4,7/M4 13 5/H4,6/G4,7/J2,7/J6,8/C6, 8/H4,8/K7,10/K8 14 5/H4,8/B1,8/C2 ...
Rover 820 (1997) - page 235

12•24 Wiring diagrams M Windscreen wiper motor Windscreen wiper delay unit Windscreen washer motor B M 1 LGB 6 B 18 16 14 2 15 3 8 23 22 9 10 21 26 24 11 13 Electric mirror switch Four door window lift control unit 6 5 19 1 4 OU Y 80 GY RH rear window lift switch B B 2 B M U R Passenger's door window lift control unit 9 SR 17 Window lift mot ...
Rover 820 (1997) - page 236

Wiring diagrams 12•25 12 1380 Rover 800 Series Remake P Horns PU Heater relay Recirc. light Fresh air light Fresh air solenoid M Heater motor Circuit breaker B B A C D E F G HJ KL M 2 1 3 4 5 6 7 8 B A C D E F G HJ KL M 2 1 3 4 5 6 7 8 Diagram 7: Main wiring diagram (typical) continued - multi-point fuel injection models H29048/A 1 Battery 2 Igni ...
Rover 820 (1997) - page 237

14 PY 3 P 5 LGW 3 B Speakers Speakers Filter BW BS Y YB Filter G GB BP BU B A C D E F G HJ KL M 2 1 3 4 5 6 7 8 B A C D E F G HJ KL M 2 1 3 4 5 6 7 8 H29049/A 13 No charge warning light 52 NY NR LGY 53 OR 4 spare warning lights Y/R 67 ABS warning light O GO U WN 60 Oil press. warning light 6 55 WB Tachometer Voltmeter B Panel illumination R B RB LG ...
Rover 820 (1997) - page 238

Wiring diagrams 12•27 12 1380 Rover 800 Series Remake B A C D E F G HJ KL M 2 1 3 4 5 6 7 8 B A C D E F G HJ KL M 2 1 3 4 5 6 7 8 Diagram 9: Typical air conditioning system (including engine cooling fan) Mode motor/ rheostat Mode motor/ rheostat Amplifier M A B F D E M G H F I E 18 G G BR Y YR YW GR YS K B 3 B C H B D G E F A J B G H F I E D A G ...
Rover 820 (1997) - page 239

12•28 Wiring diagrams } Multi-point models } Single-point models B A C D E F G HJ KL M 2 1 3 4 5 6 7 8 B A C D E F G HJ KL M 2 1 3 4 5 6 7 8 Diagram 10: Supplementary circuits H29051/A 75 3 P 5 LGW RH rear speaker BW BS Y YB Filter - speakers G GB BW BS RH front tweeter RH front speaker BS BW BP BU N NB G GB W WB G GB RB R Y YB Filter - speakers ...
Rover 820 (1997) - page 240

MOT T est Checks REF•1 This is a guide to getting your vehicle through the MOT test. Obviously it will not be possible to examine the vehicle to the same standard as the pr ofessional MOT tester . However , working through the following checks will enable you to identify any problem areas before submitting the vehicle for the test. Where a testab ...
Rover 820 (1997) - page 241

REF•2 MOT T est Checks Seat belts and seats Note: The following checks ar e applicable to all seat belts, front and rear . M Examine the webbing of all the belts (including rear belts if fitted) for cuts, serious fraying or deterioration. Fasten and unfasten each belt to check the buckles. If applicable, check the retracting mechanism. Check the ...
Rover 820 (1997) - page 242

MOT T est Checks REF•3 Exhaust system M Start the engine. With your assistant holding a rag over the tailpipe, check the entire system for leaks. Repair or renew leaking sections. Jack up the front and rear of the vehicle, and securely support it on axle stands. Position the stands clear of the suspension assemblies. Ensure that the wheels are cl ...
Rover 820 (1997) - page 243

REF•4 MOT T est Checks M Examine the handbrake mechanism, checking for frayed or broken cables, excessive corrosion, or wear or insecurity of the linkage. Check that the mechanism works on each relevant wheel, and r eleases fully , without binding. M It is not possible to test brake efficiency without special equipment, but a road test can be car ...
Rover 820 (1997) - page 244

General Repair Pr ocedures REF•5 Whenever servicing, repair or overhaul work is carried out on the car or its components, observe the following procedur es and instructions. This will assist in carrying out the operation efficiently and to a pr ofessional standard of workmanship. Joint mating faces and gaskets When separating components at their ...
Rover 820 (1997) - page 245

Introduction A selection of good tools is a fundamental requirement for anyone contemplating the maintenance and repair of a motor vehicle. For the owner who does not possess any, their purchase will prove a considerable expense, offsetting some of the savings made by doing-it-yourself. However, provided that the tools purchased meet the relevant n ...
Rover 820 (1997) - page 246

T ools and W orking Facilities REF•7 Spline key set Valve spring compressor Piston ring compressor Compression testing gauge Clutch plate alignment set Brake shoe steady spring cup removal tool Piston ring removal/installation tool Cylinder bore hone Three-legged hub and bearing puller Micrometer set Vernier calipers Dial test indicator and magne ...
Rover 820 (1997) - page 247

REF•8 T ools and W orking Facilities M Impact screwdriver M Micrometer and/or vernier calipers (see illustrations) M Dial gauge (see illustration) M Universal electrical multi-meter M Cylinder compression gauge (see illustration) M Clutch plate alignment set (see illustration) M Brake shoe steady spring cup removal tool (see illustration) M Bush ...
Rover 820 (1997) - page 248

Buying Spar e Parts & V ehicle Identification Numbers REF•9 Buying spare parts Spare parts are available from many sources, including maker’s appointed garages, accessory shops, and motor factors. To be sure of obtaining the correct parts, it will sometimes be necessary to quote the vehicle identification number. If possible, it can also be ...
Rover 820 (1997) - page 249

REF•10 Fault Finding Engine m m Engine fails to rotate when attempting to start m m Engine rotates but will not start m m Engine difficult to start when cold m m Engine difficult to start when hot m m Starter motor noisy or excessively-rough in engagement m m Engine starts but stops immediately m m Engine idles erratically m m Engine misfires at ...
Rover 820 (1997) - page 250

Fault Finding REF•11 The vehicle owner who does his or her own maintenance according to the recommended service schedules should not have to use this section of the manual very often. Modern component reliability is such that, provided those items subject to wear or deterioration are inspected or renewed at the specified intervals, sudden failure ...
Rover 820 (1997) - page 251

REF•12 Fault Finding Engine (continued) Engine misfires at idle speed m m Worn, faulty or incorrectly-gapped spark plugs (Chapter 1). m m Faulty spark plug HT leads (Chapter 1). m m Incorrect ignition timing (Chapter 5). m m Engine management system fault (Chapters 1 and 4). m m Vacuum leak at the inlet manifold or associated hoses (Chap- ters 1, ...
Rover 820 (1997) - page 252

Fault Finding REF•13 Cooling system Overheating m m Insufficient coolant in system (Chapter 1). m m Thermostat faulty (Chapter 3). m m Radiator core blocked or grille restricted (Chapter 3). m m Radiator electric cooling fan(s) or coolant temperature sensor faulty (Chapter 3). m m Engine management system fault (Chapters 1 and 4). m m Pressure ca ...
Rover 820 (1997) - page 253

REF•14 Fault Finding Manual transmission Noisy in neutral with engine running m m Mainshaft bearings worn (noise apparent with clutch pedal released, but not when depressed) (Chapter 7, Part A).* m m Clutch release bearing worn (noise apparent with clutch pedal depressed, possibly less when released) (Chapter 6). Noisy in one particular gear m m ...
Rover 820 (1997) - page 254

Fault Finding REF•15 Braking system Note: Before assuming that a brake problem exists, make sure that the tyres are in good condition and correctly inflated, that the front wheel alignment is correct, and that the vehicle is not loaded with weight in an unequal manner. Apart from checking the condition of all pipe and hose connections, any faults ...
Rover 820 (1997) - page 255

REF•16 Fault Finding Suspension and steering systems Excessive play in steering m m Worn steering column universal joint(s) (Chapter 10). m m Worn steering track rod end balljoints (Chapter 10). m m Worn rack-and-pinion steering gear (Chapter 10). m m Worn steering or suspension joints, bushes or components (Chapter 10). Lack of power assistance ...
Rover 820 (1997) - page 256

Fault Finding REF•17 Wiper blades sweep over too large or too small an area of the glass m m Wiper arms incorrectly-positioned on spindles (Chapter 1). m m Excessive wear of wiper linkage (Chapter 1). m m Wiper motor or linkage mountings loose or insecure (Chapter 12). Wiper blades fail to clean the glass effectively m m Wiper blade rubbers worn ...
Rover 820 (1997) - page 257

REF•18 Glossary of T echnical T erms A ABS (Anti-lock brake system) A system, usually electronically contr olled, that senses incipient wheel lockup during braking and relieves hydraulic pr essure at wheels that ar e about to skid. Air bag An inflatable bag hidden in the steering wheel (driver’ s side) or the dash or glovebox (passenger side). ...
Rover 820 (1997) - page 258

Glossary of T echnical T erms REF•19 Camshaft A rotating shaft on which a series of cam lobes operate the valve mechanisms. The camshaft may be driven by gears, by sprockets and chain or by spr ockets and a belt. Canister A container in an evaporative emission control system; contains activated charcoal granules to trap vapours fr om the fuel sys ...
Rover 820 (1997) - page 259

REF•20 Glossary of T echnical T erms E EGR valve A valve used to introduce exhaust gases into the intake air stream. Electronic contr ol unit (ECU) A computer which controls (for instance) ignition and fuel injection systems, or an anti-lock braking system. For more information r efer to the Haynes Automotive Electrical and Electronic Systems Man ...
Rover 820 (1997) - page 260

Glossary of T echnical T erms REF•21 J Jump start Starting the engine of a vehicle with a discharged or weak battery by attaching jump leads from the weak battery to a charged or helper battery . L Load Sensing Proportioning V alve (LSPV) A brake hydraulic system control valve that works like a proportioning valve, but also takes into considerati ...
Rover 820 (1997) - page 261

REF•22 Glossary of T echnical T erms automatic transmission, a switch that prevents starting if the vehicle is not in Neutral or Park. Strut See MacPherson strut. T T appet A cylindrical component which transmits motion from the cam to the valve stem, either directly or via a pushr od and rocker arm. Also called a cam follower . Thermostat A heat ...
Rover 820 (1997) - page 262

Index REF•23 Note : References throughout this index relate to Chapter•page number A Accelerator cable - 1•13, 4A•3, 4B•3, 4C•2, 4D•3 Accelerator pedal - 4A•3, 4B•3, 4C•3, 4C•4, 4D•3 Acknowledgements - 0•4 Aerial amplifier - 12 • 16 Air bags - 0•5 Air cleaner - 1•15, 4A•2, 4B•2, 4C•2, 4D•2 Air conditioning - ...
Rover 820 (1997) - page 263

REF•24 Index Electronic control unit (ECU) - 4A•7, 4A•8, 4B•7, 4C•5, 4D•9, 4D•10, 5•8, 7B•9, 9•17, 12 • 11 Electronic idle control valve - 4D•7 Emissions control equipment - 1•26, 4E•2 Engine compartment - 1•19, 12 • 7 Engine electrical systems - 5•1 et seq Engine fault - REF • 11 Engine oil - 1•3, 1•8, 1•1 ...
Rover 820 (1997) - page 264

Index REF•25 Open-circuit - 12 • 2 Over-voltage protection relay - 9•17 Overcooling - REF • 13 Overheating - REF • 13 Oxygen sensor - 4E•3 P Pads - 9•3, 9•6 Paint - 1•22 Pedals - 4A•3, 4B•3, 4C•3, 4C•4, 4D•3, 6•6, 9•12 Pinking - REF • 12 Piston rings - 2C•16 Pistons - 2C•11, 2C•12, 2C•14, 2C•18 Plastic co ...
Rover 820 (1997) - page 265

REF•28 Almost ever y car you’ve ever loved, loathed or desired is gathered under one roof at the Haynes Motor Museum. Over 300 immaculately presented cars and motorbikes represent ever y aspect of our motoring heritage, from elegant reminders of bygone days, such as the superb Model J Duesenberg to curiosities like the bug-eyed BMW Isetta. Ther ...

Manufacturer Rover Category Car

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All of them are important, but the most important information from the point of view of use of the device are in the user manual Rover 820 (1997).

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A manual, also referred to as a user manual, or simply "instructions" is a technical document designed to assist in the use Rover 820 (1997) by users. Manuals are usually written by a technical writer, but in a language understandable to all users of Rover 820 (1997).

A complete Rover manual, should contain several basic components. Some of them are less important, such as: cover / title page or copyright page. However, the remaining part should provide us with information that is important from the point of view of the user.

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Manual Rover 820 (1997)

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