Rover 820, 825, 827. Repair Manual - part 14

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 Lift off the plastic caps and undo the two
bolts securing the seat belt lower anchorage
bar to the body. Release the bar and slide out
the seat belt.
18 Release the seat belt from the guide in the
door pillar.
19 Undo the bolts at the base of the inertia
reel, and remove the seat belt components.
20 Undo the bolt securing the seat belt stalk
to the seat, and remove the stalk.

Refitting

21 Refitting is a reversal of removal.

Rear seat belts

Removal

22 Remove the rear seat base and squab as
described in Section 43.
23 Undo the bolts at the seat belt lower
anchorages.
24 Remove the belt guide from the rear
parcel shelf.
25 Remove the trim cap over the top
anchorage (early models), undo the retaining
bolt and recover the spacer and fibre washer.
26 From within the luggage compartment,
undo the bolt at the base of the inertia reel,

and remove the seat belt assembly from the
luggage compartment. On later Saloon
models it will be necessary to remove the rear
parcel shelf for access to the inertia reel.
27 Undo the retaining bolts and remove the
individual static belts as required.

Refitting

28 Refitting is a reversal of removal.

46 Sunroof - 

general information

A mechanically or electrically operated steel

sunroof is available as standard or optional
equipment according to model.

The sunroof is maintenance-free, but any

adjustment or removal and refitting of the
component parts should be entrusted to a
dealer, due to the complexity of the unit and
the need to remove much of the interior trim
and headlining to gain access. The latter
operation is involved, and requires care and
specialist knowledge to avoid damage.

47 Centre console -

removal and refitting

1

Removal

1 On manual transmission models, unscrew
the gear lever knob and remove the gear lever
boot.

2 On automatic transmission models, undo
the retaining screw and lift off the selector
lever. Carefully prise up the selector lever
quadrant, disconnect the wiring multiplugs
and remove the quadrant.
3 Prise up the coin trays or switch panels on
each side of the handbrake lever (see
illustration). Remove the coin trays, or
disconnect the multiplugs and remove the
switch panels.
4 Insert a screwdriver under the rear end of
the cover trim over the handbrake lever. Prise
up the cover rear end, then withdraw the
cover from the handbrake lever (see
illustration).
5 Lift back the edges of the carpet under the
coin holder or switch panel locations, and
undo the two console retaining bolts under
the carpet (see illustration).
6 Remove the rear ashtray, followed by the
ashtray insert (where fitted). Disconnect the
ashtray wiring multiplugs and remove the
ashtray (see illustration).
7 Undo the two screws securing the rear of
the console, in the ashtray aperture (see
illustration).
8 Where applicable, prise off the plastic caps
and undo the two screws at the extreme
forward sides of the console, beneath the
facia.
9 On models with a high console, open the
cassette holder lid, and undo the two screws
at the base of the cassette racks (see
illustration).
10 Where a switch panel or removable cover

Bodywork and fittings  11•19

47.5  Console left-hand retaining bolt

(arrowed)

47.4  Prise up the handbrake lever cover

trim

47.3  Prise up the coin trays

47.9  Undo the two screws at the base of

the cassette rack

47.7  . . . and undo the two rear screws

47.6  Remove the rear ashtray and 

insert . . .

11

1380 Rover 800 Series Remake

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 end of the console out from under the
facia and remove the console from the car. On
some models, there is barely sufficient
clearance to allow the console to clear the
handbrake under normal conditions, and if it
proves impossible to do this, refer to Chapter
9 and slacken the handbrake adjuster to allow
the lever to be pulled up further.

Refitting

12 Refitting is a reversal of removal. Adjust

the handbrake as described in Chapter 9, if
the adjuster position was disturbed.

48 Facia - 

removal and refitting

4

Pre-1992 model year

Removal

1 Remove the instrument panel and the radio
cassette player as described in Chapter 12.
2 Release the turnbuckles and remove the
trim panel under the facia on the driver’s side.
Remove the additional panel over the clutch,
brake and accelerator pedals (see
illustration).
3 Release the heater outer cable retaining

clips on the lower right-hand side of the
heater, and slip the inner cable ends off the
lever studs (see illustration).
4 Pull off the control knobs on the heater
control switches (see illustration).
5 Undo the two nuts and two bolts securing
the steering column clamp and mounting
bracket under the facia. Remove the clamp
and lower the column.
6 Release the retaining button and withdraw
the triangular-shaped trim panels at the base
of the lower facia (see illustration).
7 Undo the retaining screw now exposed on
each side, securing the lower facia side
braces to the support bracket (see
illustration).
8 Using a screwdriver, release the radio
mounting plate side retainers and remove the
mounting plate (see illustrations).

11•20 Bodywork and fittings

48.8b  . . . and remove the mounting plate

48.8a  Release the radio mounting plate

retainers (arrowed) . . .

48.7  Undo the side brace retaining screws

(arrowed)

48.6  Withdraw the trim panel at the base

of the lower facia

48.4  Pull off the heater knobs

48.3  Release the heater cables at the

heater (arrowed)

48.2  Remove the trim panel under the

facia

47.11b  . . . and lift the console over the

handbrake lever

47.11a  Apply the handbrake fully . . .

1380 Rover 800 Series Remake

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 wiring multiplug at the rear
and remove the lower facia from the car.
13 Undo the screw at each end of the cross-
brace under the facia on the driver’s side (see
illustration).
14 Undo the bolt at each lower end of the
facia (see illustration).
15 Undo the two bolts on the front support
plate at the base of the facia (see
illustration).

16 Lift up the cover plate on the facia top, at
the centre below the windscreen, and undo
the bolt below the plate (see illustration).
17 Prise out the trim caps at each side of the
facia, adjacent to the door apertures and
undo the bolt behind (see illustrations).
18 With the help of an assistant, lift the facia
from its location and withdraw it slightly
forward.
19 Disconnect the wiring multiplug at the
inertia switch, and at the fusebox, and
disconnect the two main loom multiplugs.
20 With all the wiring disconnected, remove
the facia from the car.

Refitting

21 Refitting is a reversal of removal. When
connecting the heater cables, adjust the
position of the outer cables in their retaining

clips so as to give full travel of the heater
levers, consistent with full travel of the control
levers.

1992 model year onwards

Warning: On vehicles fitted with
a passenger’s side air bag, seek
the advice of a Rover dealer
concerning safety implications
before proceeding.

Removal

22 Where fitted, have the passenger side air-
bag module removed by a Rover dealer, or
seek his advise concerning the feasibility of
the following operations before proceeding.
23 Remove the steering wheel and steering
column as described in Chapter 10.
24 Remove the instrument panel, the radio

Bodywork and fittings  11•21

48.11b  . . . and remove the lower facia

48.11a  Undo the lower facia upper 

screws . . .

48.9  Undo the screws in the oddments

tray

48.17b  . . . and undo the bolts in the door

apertures

48.17a  Prise out the trim caps . . .

48.16  Lift up the centre cover plate and

undo the bolt below the plate

48.15  Undo the front support plate bolts

(arrowed)

48.14  Undo the bolt at the facia lower end

48.13  Undo the cross-brace screws

11

1380 Rover 800 Series Remake

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 footwell.
28 Undo the two screws each side and single
retaining stud on the left-hand side, and
remove the two footwell trim panels.
29 Remove the radio cassette player
mounting housing.
30 Remove the fusebox cover under the facia
on the driver’s side if not already done.
31 From within the clock aperture, undo the
ashtray securing screw, disconnect the wiring
connectors and remove the ashtray.
32 Release the retaining button and withdraw

the triangular-shaped trim panels at the base
of the lower facia.
33 Undo the four upper screws and two inner
screws securing the lower facia to the upper
facia. Remove the lower facia.
34 Prise out the trim caps at each side of the
facia, adjacent to the door apertures and
undo the bolt behind.
35 Undo the two bolts on the front support
plate at the base of the facia.
36 Lift up the cover plate or light sensor
panel on the facia top, at the centre below the
windscreen, and undo the bolt behind.
37 Undo the two bolts securing the facia
mounting brackets to the body.
38 Where fitted, undo the additional securing
bolt behind the glovebox aperture.
39 Disconnect the wiring multiplugs at the
fusebox, noting their locations.
40 Disconnect the two main wiring harness
multiplugs.

41 Where fitted, disconnect the two air
conditioning wiring harness multiplugs.
42 Detach the relay from the facia rail above
the pedals on the driver’s side.
43 Disconnect any remaining wiring
multiplugs, noting their locations.
44 Where applicable, release the heater outer
cable retaining clips on the lower right-hand
side of the heater, and slip the inner cable
ends off the lever studs.
45 With all the wiring disconnected, remove
the facia from the car.

Refitting

46 Refitting is a reversal of removal. When
connecting the heater cables, adjust the
position of the outer cables in their retaining
clips so as to give full travel of the heater
levers, consistent with full travel of the control
levers.

11•22 Bodywork and fittings

1380 Rover 800 Series Remake

1380 Rover 800 Series Remake

12

Bulbs

Wattage

Headlight dipped beam  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

60/55

Headlight main beam  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

55

Sidelights  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

Direction indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21

Side repeater lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

Front fog light  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

55

Stop/tail lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21/5

Reversing lights  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21

Rear fog light  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21

Number plate light  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

Engine compartment light  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

Interior courtesy lights  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 or 10

Map reading and courtesy light  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

Footwell and glovebox lights  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 or 5

Vanity mirror light  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

Luggage compartment light  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10

Instrument panel illumination and warning lights  . . . . . . . . . . . . . . . . . .

1.2

Ignition warning light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2

Switch illumination bulbs  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.36

Heater control illumination bulbs  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.36 and 1.2

Chapter 12 Body electrical system

Airbag supplementary restraint system - general information  . . . . . 26
Aerial amplifier - removal and refitting  . . . . . . . . . . . . . . . . . . . . . . . 22
Anti-theft system - general information . . . . . . . . . . . . . . . . . . . . . . . 24
Anti-theft system components - removal and refitting  . . . . . . . . . . . 25
Battery - removal and refitting . . . . . . . . . . . . . . . . . . . . .See Chapter 5
Battery check, maintenance and charging  . . . . . . . . . . .See Chapter 1
Bulbs (exterior lights) - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

Bulbs (interior lights) - renewal  . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

Central control unit - description, removal and refitting  . . . . . . . . . . 11
Clock - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Compact disc player - removal and refitting . . . . . . . . . . . . . . . . . . . 20
Electrical fault finding - general information  . . . . . . . . . . . . . . . . . . .

2

Electrical system check  . . . . . . . . . . . . . . . . . . . . . . . . . .See Chapter 1
Exterior light units - removal and refitting  . . . . . . . . . . . . . . . . . . . . .

7

Fuses and relays - general information  . . . . . . . . . . . . . . . . . . . . . . .

3

General information and precautions  . . . . . . . . . . . . . . . . . . . . . . . .

1

Headlight beam alignment - checking and adjustment  . . . . . . . . . .

8

Horn - removal and refitting  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Instrument panel - removal and refitting  . . . . . . . . . . . . . . . . . . . . . .

9

Instrument panel components - removal and refitting  . . . . . . . . . . . 10
Power amplifier - removal and refitting  . . . . . . . . . . . . . . . . . . . . . . . 23
Radio/cassette player - removal and refitting  . . . . . . . . . . . . . . . . . . 19
Speakers - removal and refitting  . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Switches - removal and refitting  . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

Tailgate wiper motor and linkage - removal and refitting  . . . . . . . . . 17
Trip computer - removal and refitting  . . . . . . . . . . . . . . . . . . . . . . . . 13
Windscreen/tailgate and headlight washer system and 

wiper blade check  . . . . . . . . . . . . . . . . . . . . . . . . . . . .See Chapter 1

Windscreen/tailgate/headlight washer system components - 

removal and refitting  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Windscreen wiper motor and linkage - removal and refitting  . . . . . . 16
Wiper arms - removal and refitting  . . . . . . . . . . . . . . . . . . . . . . . . . . 15

12•1

Specifications

Contents

Easy, suitable for
novice with little
experience

Fairly easy, suitable
for beginner with
some experience

Fairly difficult,
suitable for competent
DIY mechanic

Difficult, suitable for
experienced  DIY
mechanic

Very difficult,
suitable for expert DIY
or  professional

Degrees of difficulty

5

4

3

2

1

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 associated with
the engine. Information on the battery, ignition
system, alternator, and starter motor can be
found in Chapter 5.

Precautions

Warning: Before carrying out
any work on the electrical
system, read through the
precautions given in “Safety

first!” at the beginning of this manual and
in Chapter 5.

Caution: Prior to working on any
component in the electrical system, the
battery negative lead should first be
disconnected, to prevent the possibility of
electrical short-circuits and/or fires.
Disconnection of the battery will, however,
erase the audio unit anti-theft security
code and also erase the memories of many
of the electrical system electronic control
units. Refer to Chapter 5, Section 1 for
additional information on the effects of
battery disconnection.

2

Electrical fault finding -
general information

2

Note: Refer to the precautions given in
“Safety first!” and in Section 1 of this Chapter
before starting work. The following tests relate
to testing of the main electrical circuits, and
should not be used to test delicate electronic
circuits (such as engine management systems,
anti-lock braking systems, etc), particularly
where an electronic control module is used.
Also refer to the precautions given in Chap-
ter 5, Section 1.

General

1 A typical electrical circuit consists of an
electrical component, any switches, relays,
motors, fuses, fusible links or circuit breakers
related to that component, and the wiring and
connectors which link the component to both
the battery and the chassis. To help to
pinpoint a problem in an electrical circuit,
wiring diagrams are included at the end of this
manual.
2 Before attempting to diagnose an electrical
fault, first study the appropriate wiring diagram,
to obtain a complete understanding of the

components included in the particular circuit
concerned. The possible sources of a fault can
be narrowed down by noting if other
components related to the circuit are operating
properly. If several components or circuits fail
at one time, the problem is likely to be related
to a shared fuse or earth connection.
3 Electrical problems usually stem from
simple causes, such as loose or corroded
connections, a faulty earth connection, a
blown fuse, a melted fusible link, or a faulty
relay. Visually inspect the condition of all
fuses, wires and connections in a problem
circuit before testing the components. Use
the wiring diagrams to determine which
terminal connections will need to be checked
in order to pinpoint the trouble-spot.
4 The basic tools required for electrical fault-
finding include a circuit tester or voltmeter (a
12-volt bulb with a set of test leads can also
be used for certain tests); an ohmmeter (to
measure resistance and check for continuity);
a battery and set of test leads; and a jumper
wire, preferably with a circuit breaker or fuse
incorporated, which can be used to bypass
suspect wires or electrical components.
Before attempting to locate a problem with
test instruments, use the wiring diagram to
determine where to make the connections.
5 To find the source of an intermittent wiring
fault (usually due to a poor or dirty
connection, or damaged wiring insulation), a
“wiggle” test can be performed on the wiring.
This involves wiggling the wiring by hand to
see if the fault occurs as the wiring is moved.
It should be possible to narrow down the
source of the fault to a particular section of
wiring. This method of testing can be used in
conjunction with any of the tests described in
the following sub-Sections.
6 Apart from problems due to poor
connections, two basic types of fault can
occur in an electrical circuit - open-circuit, or
short-circuit.
7 Open-circuit faults are caused by a break
somewhere in the circuit, which prevents
current from flowing. An open-circuit fault will
prevent a component from working.
8 Short-circuit faults are caused by a “short”
somewhere in the circuit, which allows the
current flowing in the circuit to “escape” along
an alternative route, usually to earth. Short-
circuit faults are normally caused by a
breakdown in wiring insulation, which allows a
feed wire to touch either another wire, or an
earthed component such as the bodyshell. A
short-circuit fault will normally cause the
relevant circuit fuse to blow.

Finding an open-circuit

9 To check for an open-circuit, connect one
lead of a circuit tester or the negative lead of a
voltmeter either to the battery negative
terminal or to a known good earth.
10 Connect the other lead to a connector in
the circuit being tested, preferably nearest to
the battery or fuse. At this point, battery
voltage should be present, unless the lead

from the battery or the fuse itself is faulty
(bearing in mind that some circuits are live
only when the ignition switch is moved to a
particular position).
11 Switch on the circuit, then connect the
tester lead to the connector nearest the circuit
switch on the component side.
12 If voltage is present (indicated either by
the tester bulb lighting or a voltmeter reading,
as applicable), this means that the section of
the circuit between the relevant connector
and the switch is problem-free.
13 Continue to check the remainder of the
circuit in the same fashion.
14 When a point is reached at which no
voltage is present, the problem must lie
between that point and the previous test point
with voltage. Most problems can be traced to
a broken, corroded or loose connection.

Finding a short-circuit

15 To check for a short-circuit, first
disconnect the load(s) from the circuit (loads
are the components which draw current from
a circuit, such as bulbs, motors, heating
elements, etc).
16 Remove the relevant fuse from the circuit,
and connect a circuit tester or voltmeter to the
fuse connections.
17 Switch on the circuit, bearing in mind that
some circuits are live only when the ignition
switch is moved to a particular position.
18 If voltage is present (indicated either by
the test bulb lighting or a voltmeter reading,
as applicable), this means that there is a
short-circuit.
19 If no voltage is present during this test,
but the fuse still blows with the load(s)
reconnected, this indicates an internal fault in
the load(s).

Finding an earth fault

20 The battery negative terminal is connected
to “earth” - the metal of the engine/
transmission unit and the vehicle body - and
many systems are wired so that they only
receive a positive feed, the current returning via
the metal of the car body. This means that the
component mounting and the body form part
of that circuit. Loose or corroded mountings
can therefore cause a range of electrical faults,
ranging from total failure of a circuit, to a
puzzling partial failure. In particular, lights may
shine dimly (especially when another circuit
sharing the same earth point is in operation),
motors (eg wiper motors or the radiator cooling
fan motor) may run slowly, and the operation of
one circuit may have an apparently-unrelated
effect on another. Note that on many vehicles,
earth straps are used between certain
components, such as the engine/transmission
and the body, usually where there is no metal-
to-metal contact between components, due to
flexible rubber mountings, etc.
21 To check whether a component is
properly earthed, disconnect the battery (refer
to Chapter 5, Section 1) and connect one lead
of an ohmmeter to a known good earth point.
Connect the other lead to the wire or earth

12•2 Body electrical system

1380 Rover 800 Series Remake

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 corrosion, then use a knife to
trim away any paint, so that a clean metal-to-
metal joint is made. On reassembly, tighten the
joint fasteners securely; if a wire terminal is being
refitted, use serrated washers between the
terminal and the bodyshell, to ensure a clean
and secure connection. When the connection is
remade, prevent the onset of corrosion in the
future by applying a coat of petroleum jelly or
silicone-based grease, or by spraying on (at
regular intervals) a proprietary ignition sealer.

3

Fuses and relays - 
general information

1

Note: It is important to note that the ignition
switch and the appropriate electrical circuit must
always be switched off before any of the fuses (or
relays) are removed and renewed. In the event of
the fuse/relay unit having to be removed. When
disconnecting the battery, reference should be
made to Chapter 5, Section 1.

General

1 Two or three fuseboxes are used on Rover
800 models. One is located inside the car

under the facia on the driver’s side with an
auxiliary fusebox alongside it, another is
located on the left-hand side of the engine
compartment and, on later models, a third is
located in the luggage compartment on the
left-hand side. The main vehicle system relays
are located on a relay panel behind the interior
fusebox, and also in the engine compartment
fuse and relay box. Additional relays are
located in various locations according to
model and equipment fitted.

Interior fusebox

2 To gain access to the fuses, release the
turnbuckles at the base of the trim panel
beneath the steering column, and lift away the
panel. The fuse locations, current rating and
circuits protected are shown on a label
attached to the inside of the panel. Each fuse
is also colour-coded, and has its rating
stamped on it (see illustrations).
3 To remove a fuse from its location, withdraw
the removal tool from the fusebox, push the
tool over the fuse to be removed and pull out
the fuse (see illustrations). Refit the fuse by
pressing it firmly into position. Spare fuses are
located in a vertical row on the right-hand side
of the fusebox, or in marked vacant spaces.
4 Always renew the fuse with one of an
identical rating. Never renew a fuse more than
once without finding the source of the trouble.
5 To gain access to the relays behind the
fusebox, undo the two fusebox retaining
bolts, one at each end, and ease the unit
away from its location. For greater access,
mark the various wiring multiplugs to avoid

confusion when refitting, then disconnect
them and remove the fusebox completely.
6 The relays can be removed by simply
pulling them from their respective locations. If
a system controlled by a relay becomes
inoperative, and the relay is suspect, operate
the system and if the relay is functioning it
should be possible to hear it click as it is
energised. If this is the case, the fault lies with
the components of the system. If the relay is
not being energised, then the relay is either
not receiving a main supply voltage, a
switching voltage, or the relay itself is faulty.

Engine compartment fuse and
relay box

7 The engine compartment fuse and relay
box contains additional fuses, some vehicle
system relays, and the main wiring loom
fusible links.
8 To gain access, press the upper edge of the
retaining catch on the fuse and relay box
cover, lift the cover at the front and disengage
the rear tags (see illustration). A symbol
identifying the function of each fuse is marked
on the cover.
9 The fuses and relays can be renewed in the
same way as for the interior fusebox
described previously. The fuse removal tool,
together with the spare fuses, is located at the
front of the box. On certain models, additional
fuses and relays are located on the outside
edge of the box, with the fuses under a
protective cover. Lift off the cover to renew
each individual fuse (see illustration).

Body electrical system  12•3

3.3a  Use the fuse removal tool 

(arrowed) . . .

3.2b  . . . noting the fuse identification on

the rear of the panel

3.2a  Lift away the trim panel for access to

the fusebox . . .

3.9  Additional fuse located under a cover

on the outside of the fuse and relay box

3.8  Removing the engine compartment

fuse and relay box cover

3.3b  . . . to withdraw the fuses from their

locations

12

1380 Rover 800 Series Remake

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 the luggage compartment either
behind the left-hand rear light cluster or
behind the left-hand side interior trim panel
(see illustration).
12 To gain access to the rear fusebox, either
remove the protective cover at the rear of the
light cluster, or release the trim panel on the
side of the luggage compartment. Fuse

renewal is the same as described previously
for the other fuseboxes.

4

Switches - 
removal and refitting

1

Note: Disconnect the battery negative (earth)
lead before removing any switch and
reconnect the lead after refitting the switch
(refer to Chapter 5, Section 1).

Ignition switch/steering column
lock

1 The ignition switch is an integral part of the
steering column lock, and reference should be
made to Chapter 10.

Steering column switches

Pre-1992 model year

2 Remove the steering wheel as described in
Chapter 10.
3 Undo the three lower screws and the single
upper screw, and remove the upper and lower
steering column shrouds (see illustrations).
4 Release the fibre optic lead from the
bulbholder by carefully prising up the plastic
tag (see illustration).
5 Depress the retainers at the top and bottom
of the switch, then pull the switch out of the
steering column boss (see illustrations).
6 Disconnect the wiring multiplug and
remove the switch from the car.
7 The switch on the other side of the column
is removed in the same way.
8 Refitting is a reversal of removal.

1992 model year onwards

9 Remove the steering wheel as described in
Chapter 10.
10 Undo the three lower screws, and remove
the upper and lower steering column shrouds
(see illustration).
11 Release the turnbuckles and lower the
fusebox cover at the base of the steering
column.
12 On models without cruise control or
airbag supplementary restraint system,
remove the slip ring from the centre of the
switch assembly.
13 On models with cruise control, and/or

12•4 Body electrical system

4.5b  . . . and remove the switch

4.5a  Depress the top and bottom switch

retainers . . .

4.4  Release the fibre optic lead from the

bulbholder

4.3c  . . . then lift off the steering column

shrouds

4.3b  . . . and single upper screw . . .

4.3a  Undo the three lower screws . . .

3.11  Luggage compartment fusebox

(arrowed) located behind the left-hand side

interior trim panel

3.10  Lift off the protective cover for

access to the fusible links

1380 Rover 800 Series Remake

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 assembly.
17 Disconnect the wiring multiplug at the rear
and withdraw the switch from the main
assembly. Use a thin flat blade to release the
switch from its location as it is withdrawn.
18 The switch on the other side of the
column is removed in the same way.
19 Refitting is a reversal of removal. Refer to
Chapter 10 when refitting the rotary coupler
and steering wheel.

Centre console switches

20 Carefully prise up the coin holder or
switch panel as applicable from the side of
the centre console.

21 If individual switches are fitted, disconnect
the wiring multiplug, depress the lugs on the
side of the switch and withdraw the switch from
the coin holder panel (see illustration).
22 If a multi-switch pack is fitted, disconnect
the wiring multiplug and remove the switch
panel complete.
23 Refitting is a reversal of removal.

Door switches

24 Remove the front or rear door inner trim
panel as described in Chapter 11.

25 Release the switch pack assemblies from
the rear of the trim panel and withdraw them.
Note that the individual switches in the switch
packs cannot be removed separately. If any are
faulty, or if renewal of a switch is necessary, the
complete switch pack must be obtained.
26 Refitting is a reversal of removal.

Courtesy light door pillar
switches

27 Undo the retaining screw and withdraw the
switch from the door pillar (see illustration).
28 Disconnect the wiring and remove the
switch. Tie the wiring to the door striker plate
while the switch is removed to prevent the
wires dropping into the pillar.
29 Refitting is a reversal of removal.

Instrument cowl switch units

30 Carefully prise out the rear of the cover
plate at the extreme left-hand side of the cowl
and push the plate forward to release the front
clips  (see illustration). Undo the screw
behind the plate, now exposed.

Body electrical system  12•5

4.21  Centre console switch removal

4.10  Steering column switch details on later models

4.30  Exploded view of the instrument cowl switch units

4.27  Courtesy light door pillar switch

location

12

1380 Rover 800 Series Remake

2 Shroud retaining screws

and lower shroud

3 Switch assembly centre

retaining screw

4 Wiring multiplugs
5 Switch assembly
6 Individual switch retaining

screws

7 Wiring multiplug
8 Column switch

1 Cover plate
2 Retaining screw
3 Heater control knobs
4 Retaining screw locations
5 Switch panel multiplugs and

bulbholders

6 Heater/air conditioning 

control multiplugs 
and bulbholders

7 Vent panel retaining 

screws

8 Vent panel
9 Switch unit 

retaining screws

10 Switch unit
11 Heater/air conditioning 

control unit retaining screws

12 Heater/air conditioning 

control unit

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 slightly,
and disconnect the switch panel and heater
control/air conditioning wiring multiplugs.
35 Remove the cowl from the car.
36 Undo the four screws and remove the
driver’s vent panel.
37 Undo the three screws and remove the
switch unit.
38 Undo the four screws and remove the
heater and air conditioning control unit.
39 Refitting is a reversal of removal.

Lower facia switches

40 Refer to Section 12 for removal of the
switches on the clock console.

5

Bulbs (exterior lights) -
renewal

1

Note: Ensure that all exterior lights are
switched off before disconnecting the wiring
connectors to any exterior light bulbs.

Headlight dipped beam bulb

Note: On 1992 model year onwards vehicles,

remove the headlight lens unit first, as
described in Section 7, for access to the bulb.
1 From within the engine compartment,
disconnect the wiring multiplug at the rear of
the headlight bulb, then pull off the rubber
cover (see illustration).
2 Release the wire retaining clip and
withdraw the bulb from its location in the
headlight lens unit (see illustration). Take
care not to touch the bulb glass with your
fingers; if touched. clean the bulb with
methylated spirit.
3 Fit the bulb, ensuring that the lugs in the
bulb engage with the slots in the lens unit.
4 Refit the retaining clip, rubber cover and
wiring plug. Ensure that the tab marked TOP
on the cover is uppermost.

Sidelight bulb

Note: On 1992 model year onwards vehicles,
remove the headlight lens unit first, as
described in Section 7, for access to the bulb.
5 From within the engine compartment,
disconnect the wiring multiplug at the rear of
the headlight bulb, then pull off the rubber
cover.
6 Withdraw the sidelight bulbholder from the
headlight lens unit and remove the bulb from
the holder (see illustration).
7 Fit a new bulb to the holder and fit the
holder to the lens unit.
8 Refit the rubber cover and headlight wiring
plug. Ensure that the tab marked TOP on the
cover is uppermost.

Headlight main beam bulb

Note: On 1992 model year onwards vehicles,
remove the headlight lens unit first, as
described in Section 7, for access to the bulb.
9 Withdraw the plastic cover, release the wire
clip and withdraw the bulb from the headlight
lens unit (see illustration). Take care not to
touch the bulb glass with your fingers; if
touched, clean the bulb with methylated spirit.
10 Disconnect the wiring connectors and
remove the bulb.
11 Connect the wiring to the new bulb and
place the bulb in the light unit, ensuring that
the flange cut-out locates in the housing
ridge.
12 Refit the wire clip and the plastic cover.

Front direction indicator bulb

13 From within the engine compartment,
unhook the retaining spring and withdraw the
lens unit and seal from the wing (see
illustration).
14 Press and turn the bulbholder anti-
clockwise to remove it from the lens unit;
remove the bulb from the holder in the same
way (see illustration).
15 Refit the bulb and holder, locate the lens
unit in position and secure with the retaining
spring.

Direction indicator side repeater
bulb

16 Press the light unit to the right, free the
left-hand retainer and withdraw the unit from
the front wing.

12•6 Body electrical system

5.14  Withdraw the lens assembly and

remove the bulbholder

5.13  Unhook the direction indicator lens

retaining spring

5.9  Withdraw the main beam bulb from the

headlight unit

5.6  Withdraw the sidelight bulbholder from

the headlight unit

5.2  Release the wire clip and withdraw the

bulb from the headlight unit

5.1  Disconnect the headlight dipped beam

bulb multiplug

1380 Rover 800 Series Remake

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 light unit from the front bumper
assembly
21 Release the rubber cover at the base of
the light unit and disconnect the wiring at the
connector.
22 Release the retaining spring clip and
withdraw the bulb and holder.
23 Fit a new bulb then refit the components.

Rear light cluster bulbs

Rear wing light cluster

24 From within the luggage compartment,
release the trim covering (where fitted) for
access to the light cluster.
25 On early models, press the retainer on the
access panel and remove the panel (see
illustration).
26 Lift the top retainer on the bulb panel,
press the two bottom retainers and withdraw
the panel (see illustration). On the later type
bulb panel, press the top and bottom
retainers together and remove the panel (see
illustration).
27 Remove the bulbs as required by

depressing and turning anti-clockwise (see
illustration).
28 Fit the new bulb(s), push the bulb panel
into position and refit the access panel and/or
trim panel.

Boot lid/tailgate light cluster

29 On Saloon and Coupe models, unscrew
the plastic fasteners to release the boot lid
trim lining. On Fastback models, remove the
plastic cover.
30 Squeeze the plastic lever and withdraw
the bulbholder.
31 Remove the bulbs as required by
depressing and turning anti-clockwise.
32 Fit the new bulb(s), push the bulbholder
into position and refit the lining or cover.

Number plate light bulb

Saloon models - pre-1992 model year

33 Open the boot lid, turn the bulbholder
anti-clockwise and withdraw the bulb and
holder (see illustration).
34 Remove the push-fit bulb from the holder.
35 Fit the new bulb and refit the bulbholder.

Fastback models - pre-1992 model
year

36 Open the tailgate, release the plastic
retaining screws and remove the inner trim.
37 Turn the bulbholder anti-clockwise and
withdraw the bulb and holder (see
illustration).

38 Remove the push-fit bulb from the holder.
39 Fit the new bulb and refit the bulbholder
and trim.

All models - 1992 model year onwards

40 Undo the two screws and withdraw the
number plate light unit from its location (see
illustration).
41 Squeeze the two plastic tags together and
release the bulbholder from the light unit (see
illustration).
42 Remove the festoon bulb from the holder.
43 Fit the new bulb and refit the bulbholder
and light unit.

Engine compartment light bulb

44 Open the bonnet, undo the two retaining
screws and remove the light lens.

Body electrical system  12•7

5.26b  On the alternative bulb panel, press
the top and bottom retainers together and

remove the panel

5.27  Rear light cluster bulb renewal

5.26a  Lift the top retainer on the bulb

panel, press the two bottom retainers and

withdraw the panel

5.25  Press the retainer on the access

panel and remove the panel

5.40  On later models, undo the number plate

light unit retaining screws (arrowed) . . .

5.37  Number plate light bulbholder on

early Fastback models

5.33  Number plate light bulbholder on

early Saloon

12

1380 Rover 800 Series Remake

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 lens into
place.

Map reading and courtesy light

4 To renew the courtesy light bulb, carefully
prise the light lens from its housing using a
small screwdriver.
5 Remove the festoon-type bulb from the
contacts.
6 Fit the new bulb and push the lens into place.
7 To renew the map reading light bulb, remove
the courtesy light lens as just described, and
undo the two light unit retaining screws.
8 Withdraw the light unit and remove the
push-fit or bayonet-fit bulb.
9 Fit the new bulb and refit the light unit.

Vanity mirror light

10 Move the light switch to the down
position.
11 Carefully prise off the mirror surround from
the light unit taking care that the mirror does
not drop out as the surround is removed.
12 Lift the mirror out and remove the festoon
bulb(s) from the holder(s).
13 Fit the new bulb(s), locate the mirror in
position and refit the surround. Ensure that
the switch mechanism is aligned as the
surround is fitted.

Footwell and glovebox lights

14 From within the glovebox or under the
footwell as applicable, carefully prise the light
from its location using a small screwdriver.
15 Release the festoon-type bulb from its
contacts.
16 Fit the new bulb and push the light back
into position.

Luggage compartment light

17 Using a small screwdriver, carefully prise
the right-hand end of the light from its location
under the rear parcel shelf on Saloon models,
or on the rear side panels on Fastback models.
18 Withdraw the light unit, turn the bulb anti-
clockwise and remove it from the light unit.
19 Fit the new bulb and push the light back
into position.

Instrument panel illumination
and warning lights

20 Refer to Section 10.

Switch illumination

Facia switches and heater/air
conditioner control switches

21 Remove the instrument cowl as described
in Section 9.
22 With the wiring multiplugs disconnected,
remove the relevant bulb, which is a push-fit
in the multiplug holder.
23 Fit a new bulb, then refit the instrument
cowl as described in Section 9.

Hazard warning switch

24 Lift off the switch lens on the steering
column upper shroud, and remove the push-
fit bulb.
25 Fit a new bulb, and press the lens into place.

Steering column switches (early
models)

26 Undo the three lower screws and the
single upper screw, and remove the upper
and lower steering column shrouds.
27 Withdraw the bulbholder from the rear of

the fibre optic diffuser unit then remove the
bulb from the holder (see illustration).
28 Fit a new bulb, push the bulbholder into
place and refit the steering column shrouds.

7

Exterior light units - 
removal and refitting

1

Note: Ensure that all exterior lights are
switched off before disconnecting the wiring
connectors to any exterior light bulbs.

Headlight lens unit

1 On pre-1992 model year vehicles, remove
the radiator grille as described in Chapter 11.
2 Remove the front direction indicator light
assembly as described in Section 5.
3 Disconnect the wiring multiplug at the rear
of the headlight dipped beam bulb, and
separate the main beam wiring at the
connector 

(see illustration).

4 Undo the two bolts securing the headlight
lens unit to the front body panel. On later
models, undo the additional screw on the side
of the unit accessible through the direction
indicator light aperture.
5 Release the unit from the lower lugs and
remove it from the car (see illustration).
6 Refitting is a reversal of removal.

Rear light cluster assembly

Rear wing light cluster

7 Remove the bulb panel from the light unit
as described in Section 5.

12•8 Body electrical system

7.5  Release the lens unit from the lower

lugs

7.3  Separate the headlight main beam

wiring at the connector

6.27  Withdraw the bulbholder from the

fibre optic diffuser unit

6.1  Prise off the courtesy light lens

5.41  . . . squeeze the two plastic tags

together and release the bulbholder from

the light unit

1380 Rover 800 Series Remake

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 unit
from the car.
12 Refitting is a reversal of removal.

Number plate light unit

Pre-1992 model year

13 On Fastback models, remove the trim
panel on the inside of the tailgate.
14 Undo the six retaining screws and remove
the rear lens reflector and number plate
assembly (see illustration).
15 Undo the two screws securing each
number plate light unit and withdraw the
unit(s) (see illustration).
16 Turn the bulbholder anti-clockwise to
remove the bulb, then remove the light unit
from the car.,
17 Refitting is a reversal of removal.

1992 model year onwards

18 Refer to Section 5.

8

Headlight beam alignment -
checking and adjustment

3

1 Accurate adjustment of the headlight beam
is only possible using optical beam 
setting equipment and this work should
therefore be carried out by a Rover 
dealer or service station with the necessary
facilities.

2 Temporary adjustment can be made 
when the headlight unit has been 
removed and refitted, or to compensate for
normal adjustment whenever a heavy 
load is being carried. Turn the adjustment
screws at the rear of the headlight 
unit to make the adjustment (see 
illustration).

3 Before making any adjustments to the
headlight settings, it is important that the tyre
pressures are correct and that the vehicle is
standing on level ground. Bounce the front of
the vehicle a few times to settle the
suspension. Ideally somebody of normal size
should sit in the driver’s seat during the
adjustment and the vehicle should have a full
tank of fuel.

4 Whenever temporary adjustments are
made, the settings must be reset as 
soon as possible once the vehicle is in normal
use.

9

Instrument panel - 
removal and refitting

1

Removal

1 Disconnect the battery negative (earth) lead
(refer to Chapter 5, Section 1).
2 Undo the three lower screws and the single
upper screw, or three lower screws only on
later models, and remove the upper and lower
steering column shrouds.
3 Carefully prise out the rear of the cover
plate at the extreme left-hand side of the cowl
and push the plate forward to release the front
clips. Undo the screw behind the plate, now
exposed (see illustrations).

Body electrical system  12•9

7.14  Remove the rear lens reflector and

number plate assembly

7.8b  Removing the rear light cluster

assembly

7.8a  Rear light cluster side retaining nuts

(arrowed)

9.3b  . . . and undo the screw behind

9.3a  Prise out the instrument cowl cover

plate . . .

8.2  Headlight beam horizontal adjustment

screw (1) and vertical adjustment screw (2)

7.15  Undo the two screws securing each

number plate light unit

12

1380 Rover 800 Series Remake

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,
ease the cowl away from the facia slightly,
and disconnect the switch panel and heater
control/air conditioning wiring multiplugs.
8 Remove the cowl from the car.
9 Lower the steering column as far as it will
go by means of the rake adjuster.
10 Undo the two screws at each end of the
instrument panel (see illustration).
11 Ease the panel away from the facia, then
disconnect the wiring multiplugs and the earth
lead Lucar connector from the rear of the
panel.
12 Remove the instrument panel from the
car.

Refitting

13 Refitting is a reversal of removal.

10 Instrument panel

components - 
removal and refitting

1

Early models

1 Remove the instrument panel from the car
as described in Section 9.

Panel illumination and warning light
bulbs

2 The bulbholders are secured to the rear of
the instrument panel by a bayonet fitting, and
are removed by turning the holders anti-
clockwise (see illustrations). Note that the

12•10 Body electrical system

10.2b  Instrument panel warning light bulb

renewal

10.2a  Exploded view of the instrument panel fitted to early models

1 Panel front illumination

bulbs

2 Low oil pressure warning

light bulb

3 Ignition warning light bulb
4 High engine temperature

warning light bulb

5 Low fuel warning light bulb
6 Panel rear illumination bulb
7 R/H direction indicator

warning light bulb

8 Spare bulb
9 Brake warning light bulb

10 Spare bulb
11 ABS warning light bulb
12 Spare bulb
13 Spare bulb
14 Spare bulb
15 Sidelight warning light 

bulb

16 Main beam warning light

bulb

17 Trailer direction indicator

warning light bulb

18 L/H direction indicator

warning light bulb

19 Secondary printed circuit
20 Main printed circuit
21 ECU cover
22 ECU
23 Instrument panel body
24 Front illumination prism
25 Gauge illumination prism
26 Side housing
27 Warning light colour strips
28 Faceplate
29 Earth strap
30 Screw
31 Cowl and faceplate

9.10  Instrument panel right-hand side

retaining screws

9.6  . . . and the two screws each side at

the bottom

9.5  Undo the three cowl screws (arrowed)

above the instrument panel . . .

1380 Rover 800 Series Remake

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 turning clockwise
to lock. Where applicable, lay the ECU in
position and secure with the five screws.

Instrument panel window and
faceplate

5 Carefully release the eight clips, four at the
top and four at the bottom, securing the
window to the instrument panel body (see
illustration).
6 Withdraw the window and remove the
faceplate.
7 Refitting is a reversal of removal.

Electronic control unit (ECU)

8 Disconnect the two ribbon connector
multiplugs and the centre wiring multiplug
from the top of the ECU.
9 Undo the five screws and withdraw the
ECU from the rear of the instrument panel.
10 Refitting is a reversal of removal.

Secondary printed circuit

11 Remove the ECU as described previously.
12 Undo the two voltmeter retaining nuts.
13 Remove the bulbholders as applicable.
14 Undo the five printed circuit retaining
screws.
15 Release the five retaining studs.
16 Ease the printed circuit off the two
locating pins, and remove it from the rear of
the panel.
17 Refitting is a reversal of removal.

Main printed circuit

18 Remove the instrument panel window and
faceplate, the ECU and the secondary printed
circuit as described previously
19 Withdraw the warning light colour strips
from the front of the panel.
20 Pull off the trip reset button.
21 Disconnect the ribbon connector from the
tachometer by carefully levering off the metal
retainer with a small screwdriver. Remove the
metal retainer from the ribbon.
22 Remove the bulbholders.

23 Undo the nuts from the gauge studs.
24 Release the two printed circuit retaining
studs.
25 Ease the printed circuit off the locating
pins, and remove it from the rear of the panel.
26 Refitting is a reversal of removal.

Speedometer

27 Remove the instrument panel window and
faceplate, and the ECU as described
previously.

28 Undo the three speedometer retaining
screws, release the wiring harness and
remove the speedometer from the instrument
panel.
29 Refitting is a reversal of removal.

Tachometer

30 Remove the instrument panel window and
faceplate, and the ECU as described previously.
31 Undo the two tachometer retaining
screws.
32 Disconnect the ribbon connector from the
tachometer by carefully levering off the metal
retainer with a small screwdriver. Remove the
metal retainer from the ribbon.
33 Remove the tachometer from the
instrument panel.
34 Refitting is a reversal of removal.

Voltmeter, oil pressure, coolant
temperature and fuel gauges

35 Remove the instrument panel window and
faceplate, and the ECU as described
previously.
36 Undo the two retaining nuts and remove
the relevant gauge as applicable.

Body electrical system  12•11

10.5  Instrument panel window upper

retaining clips (arrowed)

10.3  Instrument panel ECU retaining

screws (arrowed)

10.39  Exploded view of the instrument panel fitted to later models

12

1380 Rover 800 Series Remake

1 Panel rear illumination bulbs
2 Fuel system check warning light

bulb (where fitted)

3 Ignition warning light bulb
4 Cruise control warning light bulb

(where fitted)

5 Direction indicator warning light

bulb

6 Main beam warning light bulb
7 Trailer direction indicator

warning light bulb

8 Low oil pressure warning 

light bulb

9 Sidelight warning light

bulb

10 Hazard warning light 

bulb

11 Brake warning light bulb
12 Low fuel warning light bulb
13 Transmission S4 switch warning

light bulb (where fitted)

14 Catalyst overheat warning light

bulb (where fitted)

15 ABS warning light bulb (where

fitted)

16 Printed circuit
17 Circuit board
18 Circuit board cover
19 Instrument panel housing
20 Tachometer
21 Temperature gauge
22 Speedometer
23 Fuel gauge
24 Illumination bulb circuit board
25 Panel illumination covers
26 Faceplate
27 Cowl and window
28 Panel front illumination bulbs
29 Trip reset button

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
illumination and warning light bulbs are
renewed complete with their holders.
40 If a faulty bulb is not accessible, undo the
three screws securing the circuit board and its
cover to the rear of the panel. Remove the
cover and carefully lift the circuit board
upwards. Take care not to strain the ribbon
connectors. The remaining bulbs are now
accessible.
41 Refit the bulbholders by turning clockwise
to lock. Where applicable, lay the circuit board
in position and secure with the cover and
retaining screws.

Instrument panel window and
faceplate

42 Carefully release the eight clips, four at
the top and four at the bottom, securing the
window to the instrument panel body.
43 Undo the four screws, two at each end of
the instrument panel.
44 Withdraw the window and release the
additional bulbholder at the rear.
45 Pull off the trip reset button and remove
the faceplate.
46 Refitting is a reversal of removal.

Circuit board

47 Disconnect the ribbon connector
multiplug from the circuit board.
48 Undo the three screws and withdraw the
cover and circuit board from the rear of the
instrument panel.
49 Refitting is a reversal of removal.

Tachometer

50 Remove the instrument panel window and
faceplate, and the circuit board as described
previously.
51 Undo the three tachometer retaining
screws and withdraw the tachometer from the
instrument panel.
52 Refitting is a reversal of removal.

Speedometer

53 Remove the instrument panel window and
faceplate, and the circuit board as described
previously.
54 Undo the four small screws, and three
large screws at the rear of the speedometer
and withdraw it from the instrument panel.
55 Refitting is a reversal of removal.

Coolant temperature and fuel gauges

56 Remove the instrument panel window and
faceplate and, if the temperature gauge is
being removed, the circuit board, as
described previously.

57 Undo the three gauge retaining screws
and remove the relevant gauge from the
instrument panel.
58 Refitting is a reversal of removal.

Printed circuit

59 Remove all the components from the
instrument panel as described previously.
60 Release the printed circuit from the thirty
retaining pins and remove it carefully from the
instrument panel.
61 Refitting is a reversal of removal.

11 Central control unit -

description, removal and
refitting

1

Description

1 Later models are equipped with a central
control unit (CCU) located under the facia
behind the fusebox (see illustration). The
function of the unit is to replace the various
control units located behind the relay tower
on earlier models, and to reduce the
complexity of the wiring harness previously
required.
2 The CCU incorporates a diagnostic feature
for connection to a Rover dedicated test
appliance.

Removal

3 Disconnect the battery negative (earth) lead
(refer to Chapter 5, Section 1).
4 Detach the access panel or fusebox cover
below the steering column.
5 Undo the retaining nut then withdraw the
unit from the mounting pin.
6 Disconnect the wiring multiplugs at the rear
of the unit and remove the unit from the car.

Refitting

7 Refitting is a reversal of removal.

12 Clock - 

removal and refitting

1

Digital clock - early models

Removal

1 Disconnect the battery negative (earth) lead
(refer to Chapter 5, Section 1).
2 Undo the two screws at the base of the
oddment tray opening.
3 Withdraw the oddment tray and disconnect
the clock wiring multiplug.
4 Remove the oddment tray. Undo the two
clock retaining screws and remove the clock.

Refitting

5 Refitting is a reversal of removal.

Digital clock - later models

Removal

6 Disconnect the battery negative (earth) lead
(refer to Chapter 5, Section 1).
7 Carefully prise the clock assembly from the
lower facia. The unit is retained by moulded
clips which compress as the unit is
withdrawn.
8 Disconnect the multiplug and remove the
clock from the lower facia.
9 To renew the illumination bulb, turn the
bulbholder anti-clockwise to remove.

Refitting

10 Refitting is a reversal of removal.

Analogue clock

Removal

11 Disconnect the battery negative (earth)
lead (refer to Chapter 5, Section 1).
12 Carefully prise the clock assembly from
the lower facia. The unit is retained by
moulded clips on each side which compress
as the unit is withdrawn.

12•12 Body electrical system

11.1  Central control unit attachments and connections

1 Unit retaining nut
2 Central control unit (front

face)

3 Wiring multiplugs
4 Central control unit

(underside)

5 Multifunction unit bracket

screws

6 Multifunction unit
7 Audible signal unit

1380 Rover 800 Series Remake