🏷️ Basic Information

Make:

Rover

Model:

45

Model Variant:

MG ZS

Platform Code:

R8 (PG1)

👋 Introduction

Target Audience:

DIY mechanics, home enthusiasts, professional technicians

Value Proposition:

Provides factory-level repair information for a fraction of the cost of dealer service. Comprehensive coverage ensures all maintenance and repair needs are met.

Accuracy:

Based on original factory documentation, ensuring accuracy and reliability

Visuals:

Includes hundreds of detailed photos and diagrams, including exploded views

Accessibility:

Instant PDF download for immediate use on multiple devices

📋 Manual Details

Model Years Covered:

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

Estimated Page Count:

Hundreds (Exact count not specified, but described as extensive)

Type:

Full Service & Repair Workshop Manual

Language:

English

Format:

PDF Download

📖 Manual Coverage

Powertrain:

Engine overhaul, fuel system, ignition system, exhaust system, cooling system, lubrication system

Transmission:

Manual and automatic transmission repair, clutch service, drive axles

Chassis:

Suspension systems (front and rear), steering system, braking system (including ABS), wheels and tires

Electrical:

Full electrical system diagrams, wiring schematics, lighting, starting and charging system, instruments and controls, body electrical components

Bodywork:

Body panel repair, doors, windows, interior trim, body seals, structural components

Maintenance:

Routine servicing, oil changes, filter replacements, tune-ups, fluid level checks

Repair:

Step-by-step repair instructions for all major components and systems

Troubleshooting:

Diagnostic procedures, fault finding, common problems and solutions

Diagnostics:

OBD-II system diagnosis, sensor testing, actuator testing

Depth:

Comprehensive (covers basic maintenance to full engine rebuilds and advanced diagnostics)

📊 Manual Specifications

File Type:

PDF

Searchable:

Likely (typical for factory PDF manuals)

Printable:

Yes (single pages or entire manual)

Binding:

N/A (Digital Download)

Paper Quality:

N/A (Digital Download)

Licensing Terms:

Lifetime use, no expiry, no renewal fees

Operating Systems:

Windows and MAC compatible

⚙️ Engine Specifications

Engine Codes:

K-Series (e.g., K4, K6, K8, KV6 - specific engines depend on R45/ZS variant)

Displacement Options:

1.4L, 1.6L, 1.8L (4-cylinder); 2.0L (V6 for some MG ZS models)

Horsepower Range:

Approx. 95-115 hp (4-cylinder), 150-170 hp (V6)

Torque Range:

Approx. 125-145 Nm (4-cylinder), 180-200 Nm (V6)

Fuel Delivery:

Multi-point Fuel Injection (MPI) or Sequential Electronic Fuel Injection (SEFI)

Ignition Type:

Distributorless Ignition System (DIS) or Coil-on-Plug (COP) depending on engine variant

Cooling Type:

Pressurized liquid cooling system with electric fan

🔧 Transmission

Standard Transmission:

5-speed manual (PG1 gearbox family)

Optional Transmission:

4-speed automatic (e.g., JATCO 4F27E or similar)

Clutch Type:

Hydraulic actuated single dry plate clutch

Gear Ratios:

Specific ratios detailed for each engine/transmission combination within the manual.

📐 Dimensions

Body Styles:

4-door Saloon (Sedan), 5-door Hatchback

Curb Weight Range:

Approx. 1200-1400 kg, depending on engine and specification

🛡️ Safety Features

Euro Ncap Rating:

3 stars (for Rover 45/MG ZS)

ABS:

Anti-lock Braking System (ABS) optional or standard on higher trims

Airbags:

Driver and passenger airbags standard, side airbags optional

Seatbelts:

Pre-tensioned seatbelts with load limiters

💡 Technology Features

Audio System:

Factory fitted radio/cassette or CD player with optional amplifier and speaker upgrades. Manual covers speaker replacement and head unit integration.

Cruise Control:

Optional on higher trim levels. Manual will include installation and troubleshooting for cruise control systems.

Remote Central Locking:

Standard on most models, with key fob operation. Manual covers key fob programming and receiver diagnosis.

🔧 Maintenance

Oil Change Interval:

Typically 9,000-12,000 miles or 12 months, whichever comes first (refer to manual for specific engine)

Timing Belt Replacement:

Essential for 4-cylinder K-series engines. Interval varies, often around 60,000 miles or 5 years. The KV6 engine uses a timing belt system as well, requiring regular inspection and replacement.

Engine Oil Specification:

e.g., 5W-30 or 10W-40 API SL/SM, ACEA A3/B3 (refer to manual for exact specification based on engine and climate)

Coolant Specification:

Ethylene glycol-based antifreeze (e.g., Rover Longlife Coolant or equivalent OAT/HOAT)

Transmission Fluid Manual:

API GL-4 75W/80 or 75W/90 gear oil (e.g., Rover TEXACO MTF 94 or equivalent)

Transmission Fluid Automatic:

ATF Dexron II or III specification (refer to manual for exact type)

Head Gasket:

A well-known issue with the K-series engines, particularly earlier versions, is head gasket failure. The manual will detail inspection and replacement procedures for the updated gasket and sealant (often referred to as 'Payne's grey' sealant).

Cooling System:

Potential for coolant leaks due to aging hoses, water pump failure, or radiator issues. The KV6 engine is particularly sensitive to cooling system maintenance.

Electronic Issues:

Various minor electrical gremlins can occur, such as faulty window regulators, central locking issues, or instrument cluster problems. The manual's electrical diagrams are crucial for diagnosing these.

📚 Vehicle History

Brand Context:

The Rover 45 and MG ZS are descendants of the British Leyland/Rover Group 'R8' platform, which also underpinned the Rover 200/400 series and Honda Concerto.

Predecessor:

Rover 400 series (RT platform)

Successor:

MG ZS was effectively succeeded by the MG TF as the primary performance offering in its segment after MG Rover's collapse. The Rover 45 was replaced by the conceptually similar MG 550/Roewe 550 in China.

Production Period:

1999-2005

Manufacturing Location:

Longbridge, Birmingham, UK

🏆 Awards & Recognition

Industry Standing:

The MG ZS, in particular, was praised for its handling and sporty character, often competing well against rivals in its class for driving dynamics.