Manuale d’uso / di manutenzione del prodotto 820 (1997) del fabbricante Rover
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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 speci.
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 chang.
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 gen.
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.
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.
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 . . . . . . . . . . . . . . . .
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.
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.
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.
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 .
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.
1380 Rover 800 Series Remake 1 Engine Direction of crankshaft rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clockwise (seen from right-hand side of vehicle) Oil filter: 4-cylinder engines . . . . . . . . . . . . . . . . . . . .
Ignition system Firing order: 4-cylinder engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3-4-2 (No 1 cylinder at timing belt end) V6 engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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,.
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.
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 to.
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 fil.
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 Tr.
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.
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.
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.
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.
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).
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.
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.
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.
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.
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) .
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 (.
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.
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.
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.
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.
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.
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.
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.
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.
1380 Rover 800 Series Remake 2A General Engine type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Four-cylinder, in-line, double-overhead camshafts Engine codes: “M” series engines: Normally aspirated engines .
Torque wrench settings Nm lbf ft Camshaft cover bolts: “M” series engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 7 “T” series engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
1380 Rover 800 Series Remake 2B General Engine type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V6, single overhead camshaft per bank Engine code: 2.5 litre engines . . . . . . . . . . . . . . . . . . .
Lubrication Engine oil type/specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Chapter 1 Engine oil capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Chapter 1 Torque wrench settings Nm lbf ft Cylinder head bolts .
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.
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.
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.
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) .
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) .
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.
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.
(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.
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.
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.
1380 Rover 800 Series Remake 2C 4-cylinder engines Cylinder head Valve seat angle (inlet and exhaust) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45º Valve seat width (inlet and exhaust) . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder block Cylinder bore diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.456 to 84.469 mm Maximum cylinder bore taper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm Maximum cylinder bore ovality .
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.
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) .
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) .
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.
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.
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.
(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.
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.
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.
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.
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.
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.
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.
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.
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.
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) .
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.
1380 Rover 800 Series Remake 3 Coolant Mixture type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Chapter 1 Cooling system capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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) .
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.
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.
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.
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.
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.
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) .
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.
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 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.
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.
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.
1380 Rover 800 Series Remake 4A General System type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Indirect single-point injection with microprocessor control ECU-controlled idle speed: Manual transmission models .
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.
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.
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).
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.
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.
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) .
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.
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.
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.
1380 Rover 800 Series Remake 4B General System type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Indirect multi-point injection with microprocessor control ECU-controlled idle speed: Manual transmission models .
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.
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.
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.
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.
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.
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.
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.
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 .
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 .
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.
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.
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.
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.
1380 Rover 800 Series Remake 4D General System type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Programmed fuel injection system with sequential injection Idle speed: 2.5 litre engines . . . . . . . . . .
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.
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.
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.
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,.
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.
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.
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.
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.
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.
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 . . . . . . . . . . . . . . . . . . .
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.
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.
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.
1380 Rover 800 Series Remake 5 Battery Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lead-acid, maintenance-free Rating - Cold cranking/Reserve capacity . . . . . . . . . . . . . . . . . .
Alternator Type: 4-cylinder engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lucas/Magneti-Marelli A127, A133 or A1271 V6 engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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 .
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.
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.
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 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.
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.
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.
(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.
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) .
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 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.
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.
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 .
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.
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) .
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.
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.
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.
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 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) .
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 .
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.
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.
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.
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.
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.
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.
Pressure build-up phase: The solenoid inlet valves are open, and hydraulic pressure from the master cylinder is applied directly to the brake calipers.
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.
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 .
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 .
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 . . . . . . . . . . . . . . . . . . . . .
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) .
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).
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.
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) .
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.
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 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.
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) .
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
1380 Rover 800 Series Remake 11 Torque wrench settings Nm lbf ft Bonnet hinge bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 7 Boot lid hinge bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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.
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.
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.
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.
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) .
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.
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.
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.
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) .
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.
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.
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.
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.
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 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.
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.
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.
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.
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) .
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) .
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.
1380 Rover 800 Series Remake 12 Bulbs Wattage Headlight dipped beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60/55 Headlight main beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Sidelights .
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.
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.
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.
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.
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.
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.
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) .
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.
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) .
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.
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) .
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.
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) .
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.
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.
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.
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.
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 N.
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 1.
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 .
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:.
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 .
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 l.
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 .
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.
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.
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 .
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.
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.
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.
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.
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.
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.
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 Pist.
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 compr.
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.
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.
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.
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).
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).
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).
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.
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).
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).
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).
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.
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.
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 .
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.
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, .
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.
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.
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.
Un punto importante, dopo l’acquisto del dispositivo (o anche prima di acquisto) è quello di leggere il manuale. Dobbiamo farlo per diversi motivi semplici:
Se non hai ancora comprato il Rover 820 (1997) è un buon momento per familiarizzare con i dati di base del prodotto. Prime consultare le pagine iniziali del manuale d’uso, che si trova al di sopra. Dovresti trovare lì i dati tecnici più importanti del Rover 820 (1997) - in questo modo è possibile verificare se l’apparecchio soddisfa le tue esigenze. Esplorando le pagine segenti del manuali d’uso Rover 820 (1997) imparerai tutte le caratteristiche del prodotto e le informazioni sul suo funzionamento. Le informazioni sul Rover 820 (1997) ti aiuteranno sicuramente a prendere una decisione relativa all’acquisto.
In una situazione in cui hai già il Rover 820 (1997), ma non hai ancora letto il manuale d’uso, dovresti farlo per le ragioni sopra descritte. Saprai quindi se hai correttamente usato le funzioni disponibili, e se hai commesso errori che possono ridurre la durata di vita del Rover 820 (1997).
Tuttavia, uno dei ruoli più importanti per l’utente svolti dal manuale d’uso è quello di aiutare a risolvere i problemi con il Rover 820 (1997). Quasi sempre, ci troverai Troubleshooting, cioè i guasti più frequenti e malfunzionamenti del dispositivo Rover 820 (1997) insieme con le istruzioni su come risolverli. Anche se non si riesci a risolvere il problema, il manuale d’uso ti mostrerà il percorso di ulteriori procedimenti – il contatto con il centro servizio clienti o il servizio più vicino.
