🏷️ Basic Information

Make:

Rover / MG

Model:

45 / ZS

Body Style:

Hatchback, Saloon (Sedan), Estate (Wagon)

Generation Codes:

Commonly known as the "R8" generation facelift, based on the Rover 400 series.

Chassis Codes:

RJ (45 Hatchback/Saloon), RT (45 Estate), ZS (MG)

👋 Introduction

Target Audience:

DIY enthusiasts, independent repair shops, and authorized service technicians.

Value Proposition:

Provides dealership-level repair information at a fraction of the cost, enabling significant savings on maintenance and repairs.

Authenticity:

Vehicle-specific, not generic information; represents the exact manual used by authorized technicians.

Ease Of Use:

Clear, concise text with abundant illustrations and diagrams for easy comprehension.

📋 Manual Details

Applicable Years:

1999, 2000, 2001, 2002, 2003, 2004, 2005

Estimated Page Count:

Over 1000 pages (estimated based on comprehensive coverage).

Type:

Service Repair Workshop Manual

Language:

English

Format:

PDF

📖 Manual Coverage

Engine Mechanical:

Full coverage of engine disassembly, assembly, repair, and diagnostics for all variants.

Engine Electrical:

Detailed wiring diagrams, ignition system, starting and charging systems, sensors, ECUs.

Emission Control:

Exhaust systems, catalytic converters, emissions control components and diagnostics.

Fuel System:

Fuel injection systems, fuel pumps, injectors, fuel lines, evaporative emission control.

Clutch System:

Hydraulic clutch operation, clutch disc replacement, pressure plate, release bearing.

Manual Transaxle:

Gearbox removal, disassembly, repair, and reassembly, including gear ratios and specifications.

Automatic Transaxle:

ATF specifications, torque converter, transmission control unit, solenoid operation, diagnostic procedures.

Driveshaft Axle:

Front and rear driveshafts, CV joints, wheel bearings, axle seals.

Suspension System:

Front and rear suspension components, shock absorbers, springs, bushings, alignment specifications.

Steering System:

Power steering system, steering rack, column, tie rod ends, alignment.

Brake System:

Hydraulic brake system, ABS, brake pad and disc replacement, caliper overhaul, bleeding procedures.

Body Interior Exterior:

Body panel removal/installation, door mechanisms, interior trim, seat removal, glass replacement.

Body Electrical:

Lighting systems, power windows, central locking, mirrors, wiper/washer systems, instrument cluster.

HVAC:

Air conditioning system diagnosis and repair, heater core, blower motor, climate control operation.

Restraint System:

Airbag system components, seatbelt operation, SRS module diagnostics.

Maintenance:

Scheduled maintenance, oil changes, filter replacements, fluid checks, tune-ups.

Troubleshooting:

Diagnostic flowcharts, common fault finding, symptom-based troubleshooting.

Repair:

Step-by-step repair procedures for all major components and systems.

Installation:

Procedures for installing replacement parts and accessories.

Depth:

Comprehensive: Covers basic maintenance to complete engine and transmission rebuilds.

Visual Aids:

Includes detailed diagrams, illustrations, and exploded views.

Wiring Schematics:

Complete and detailed wiring schematics for all electrical systems.

📊 Manual Specifications

File Type:

PDF

Searchability:

Searchable text within the PDF document.

Printability:

Fully printable, allowing users to print specific pages or sections.

Binding:

Digital (PDF) - no physical binding.

Paper Recommendation:

Recommended to print on standard A4 or Letter paper for garage use.

⚙️ Engine Specifications

Rover Engines:

K-Series (1.4L, 1.6L, 1.8L petrol), L-Series (2.0L diesel).

Mg Engines:

K-Series (1.8L VVC petrol - common in ZS 180), KV6 (2.5L petrol - less common in ZS).

K Series 1 8L Vvc:

Approx. 145-160 hp (depending on specific tune).

Kv6 2 5L:

Approx. 175-190 hp.

Injection Type:

Multi-point fuel injection (MPI) for petrol engines.

🔧 Transmission

Manual Gearbox:

PG1 5-speed manual transaxle.

Automatic Gearbox:

4-speed automatic transaxle (e.g., JATCO).

Clutch Type:

Hydraulically operated dry single-plate clutch.

📐 Dimensions

Wheelbase:

Approximately 2600 mm (260 cm).

Curb Weight Range:

1200-1400 kg (depending on engine and body style).

🛡️ Safety Features

Euro Ncap:

No specific rating for the 1999-2005 models is readily available, but generally considered average for its era. The MG ZS often had sportier chassis tuning.

ABS:

Available on higher trims and as an option.

Airbags:

Driver and front passenger airbags standard on most models; side airbags optional on some.

💡 Technology Features

Audio System:

Factory fitted radio/cassette or CD player with basic speaker systems.

Cruise Control:

Optional on some models, typically higher trim levels.

Windows:

Manual or electric windows depending on trim level.

🔧 Maintenance

Oil Change Interval:

Typically 9,000 - 12,000 miles or 12 months, whichever comes first.

Timing Belt Replacement:

K-Series engines: Recommended every 60,000 - 80,000 miles or 5 years. Critical to follow.

Engine Oil Type Kseries:

API SG/SH/SJ, ACEA A2/A3. Viscosity: 10W/40 or 10W/30 (depending on climate).

Coolant Type:

Ethylene glycol-based antifreeze/coolant. Typically a pink/orange or blue silicate-free formulation.

Atf Type Automatic:

Specific DEXRON III or equivalent for JATCO automatic transmissions.

K Series Head Gasket:

The K-Series engine is known for potential head gasket failures, especially if coolant levels are not maintained or if overheating occurs. The manual will detail inspection and replacement procedures.

Suspension Wear:

Bushings and ball joints can wear over time, leading to knocking noises and alignment issues.

📚 Vehicle History

Rover Legacy:

Continuation of the Rover Group's tradition of producing accessible family cars.

Mg Sportiness:

MG ZS offered a sportier interpretation of the Rover 45 platform with enhanced suspension and engine options.

Platform Basis:

Based on the Rover R8 platform, which itself had roots in the Honda Civic.

Manufacturing Location:

Longbridge, Birmingham, United Kingdom.

🏆 Awards & Recognition

Industry Position:

Competed in the compact family car segment against rivals like the Ford Focus, Vauxhall Astra, and Volkswagen Golf.