🏷️ Basic Information

Make:

Rover

Model:

25

Model Variant:

MG ZR

Trim Level:

160

Applicable Years:

Specific production years for Rover 25 / MG ZR 160 (typically early 2000s to mid-2000s, exact range to be confirmed by manual content)

Engine Code:

Rover K Series

👋 Introduction

Market Position:

The Rover 25 and MG ZR were positioned as compact sports hatchbacks, offering a blend of practicality and performance, particularly the MG ZR variant which was performance-tuned.

Competitive Analysis:

Competed against other mainstream and performance-oriented compact hatchbacks of its era, such as the Ford Focus, Vauxhall Astra, Volkswagen Golf, and performance variants from other manufacturers.

Key Features:

Sporty styling (especially MG ZR), engaging driving dynamics, robust Rover K Series engine, practical hatchback body style.

Manual Value Proposition:

Provides essential, in-depth technical information for owners and technicians to maintain, diagnose, and repair the Rover 25 and MG ZR 160. Its comprehensive nature, including overhaul manuals and system descriptions, makes it invaluable for enthusiasts and professional mechanics.

Manual Target Audience:

Professional MG Rover technicians, independent repair shops, and experienced DIY enthusiasts who require detailed and accurate technical data.

📋 Manual Details

Coverage Areas:

Comprehensive coverage for Rover 25 and MG ZR 160 models, including mechanical systems, electrical systems, bodywork, and specific overhaul procedures.

Page Count:

Estimated extensive page count (specific number not provided, but described as 'very FULL comprehensive'). Likely several hundred pages based on scope.

Manual Type:

Factory Workshop Service Repair Manual

Language:

English (implied by target audience 'MG ROVER technicians worldwide')

Format:

PDF

📖 Manual Coverage

Systems Covered:

Engine (1.8L Rover K Series), Transmission Overhaul, Drivetrain, Suspension, Steering, Brakes, Fuel System, Ignition System, Cooling System, Lubrication System, Exhaust System, Electrical Systems (including ECUs, wiring diagrams), Body & Chassis, HVAC, Interior Trim, Pre-Delivery Inspection.

Electrical Systems Detail:

Comprehensive electrical diagrams, wiring harnesses, fuse box layouts, component locations, and diagnostic procedures for all electrical systems, including lighting, power windows, central locking, instrument cluster, and engine management.

Bodywork And Chassis Repair:

Includes procedures for body panel replacement, structural repairs, corrosion protection, and interior trim removal/installation.

Procedures Included:

Routine maintenance, scheduled servicing, troubleshooting, diagnostics, component removal and installation, major repair procedures, component overhaul (engine, gearbox), electrical fault finding, body repair, safety system checks, pre-delivery inspection protocols.

Troubleshooting Procedures:

Detailed fault-finding charts and diagnostic trees for common and uncommon issues, categorized by symptom and system.

Suspension And Steering Alignment:

Detailed specifications for wheel alignment (caster, camber, toe), suspension component replacement, and steering system adjustments.

Technical Depth:

Deep technical depth, designed for professional technicians. Covers everything from basic adjustments to complete engine and gearbox rebuilds. Includes detailed diagnostic flowcharts and specifications.

Engine Rebuild Procedures:

In-depth instructions for complete engine rebuilds, including cylinder head removal and inspection, piston and connecting rod installation, crankshaft installation, bearing clearances, and valve train setup.

Diagnostics And Troubleshooting Depth:

Advanced diagnostic techniques for identifying intermittent faults, electrical issues, and mechanical problems using specialized tools and procedures outlined in the manual.

📊 Manual Specifications

File Format:

PDF (Portable Document Format)

Searchability:

Likely searchable text within the PDF, allowing for quick access to specific topics.

Print Quality:

As a factory manual PDF, it should support high-quality printing for workshop use, including diagrams and illustrations.

File Size Estimation:

Likely a substantial file size due to the comprehensive nature and inclusion of diagrams and illustrations, potentially ranging from 100MB to 500MB+.

Binding Type:

N/A (Digital Format)

Paper Type:

N/A (Digital Format)

⚙️ Engine Specifications

Engine Type:

Rover K Series Inline-4

Displacement:

1.8 Liters (1796 cc)

Engine Configuration:

DOHC (Double Overhead Camshaft), 16 Valves

Horsepower Mg Zr 160:

Approximately 160 PS (158 bhp; 118 kW) - specific output may vary slightly by model year.

Torque Mg Zr 160:

Approximately 165 Nm (122 lb-ft) - specific output may vary slightly by model year.

Fuel Injection:

Multi-point Fuel Injection (MPI) - specific details on ECU and injection strategy will be in the manual.

Cooling Type:

Liquid-cooled, pressurized system.

ECU Type:

Likely Lucas/Rover ECU, specific part numbers and details in manual.

Engine Diagnostics:

Information on OBD-II (On-Board Diagnostics) compliance, common diagnostic trouble codes (DTCs), and procedures for reading and clearing codes using diagnostic tools.

🔧 Transmission

Transmission Type:

Manual Transmission (likely 5-speed Getrag or similar Rover-derived unit for the 160 model).

Transmission Type Optional:

Automatic transmission may have been available on some Rover 25 variants, but likely not standard on the MG ZR 160.

Gearbox Overhaul:

Includes a dedicated Gearbox Overhaul Manual, indicating detailed procedures for gearbox repair and rebuilding.

Gearbox Oil Type:

Specific manual gearbox oil specification (e.g., API GL4 or GL5, viscosity grade) will be detailed in the manual.

📐 Dimensions

Body Style:

Hatchback (3-door and 5-door variants exist for Rover 25, MG ZR primarily 3-door)

Kerb Weight:

Approximately 1150-1250 kg for MG ZR 160 variants (exact figure varies by specification).

🛡️ Safety Features

Euroncap Rating:

MG ZR typically achieved a 3-star Euro NCAP rating. Specific details and breakdown of tests will be in the manual.

Active Features:

Anti-lock Braking System (ABS) - standard on many 160 models, Electronic Brakeforce Distribution (EBD) - if equipped.

Passive Features:

Driver and passenger front airbags, side airbags (optional on some models), seatbelt pre-tensioners, reinforced safety cell.

💡 Technology Features

Infotainment System:

Basic infotainment systems common for the era, typically including an FM/AM radio with CD player. Advanced features like satellite navigation were less common or optional.

Driver Assistance:

Limited driver assistance features by modern standards, primarily ABS if optioned. No electronic stability control (ESC) or advanced driver aids.

Connectivity:

Basic connectivity via an auxiliary input for audio devices might be present on later models or as an aftermarket addition.

🔧 Maintenance

Service Intervals:

Typically 12,000 miles or 12 months for routine servicing. Timing belt replacement is critical for the K Series engine, with intervals usually around 60,000 miles or 5 years. Manual will provide precise intervals and intervals for other components.

Engine Oil Type:

Specific oil viscosity (e.g., 5W-30 or 10W-40) and API/ACEA specifications for the K Series engine will be detailed. Common recommendation is semi-synthetic or fully synthetic.

Coolant Type:

Specific coolant type (e.g., OAT - Organic Acid Technology, or HOAT - Hybrid OAT) and concentration for Rover K Series engines will be specified. Typically a pink or orange coloured coolant.

Brake Fluid Type:

DOT 4 brake fluid is typically used.

Known Issues:

Head gasket failure on the K Series engine is a well-documented issue, particularly on earlier iterations. The manual will likely cover inspection and repair procedures related to this. Other potential issues include cooling system leaks, minor electrical gremlins, and wear on suspension components due to sporty driving.

Oil Filter Part Number:

Specific part numbers for oil filters, air filters, and cabin filters will be listed in the manual.

Timing Belt Replacement Procedures:

Detailed step-by-step instructions for timing belt replacement, including critical alignment procedures and torque specifications for pulleys and tensioners.

Front Brake Type:

Ventilated discs (e.g., 282mm diameter on MG ZR 160).

Rear Brake Type:

Solid discs (e.g., 260mm diameter on MG ZR 160).

Tire Size Standard Mg Zr 160:

Typically 195/55R16 or 205/45R17, depending on factory specification and alloy wheel size.

Wheel Bolt Pattern:

Commonly 4x100mm or 5x100mm (exact specification to be confirmed by manual, likely 4x100mm for earlier models).

📚 Vehicle History

Brand Heritage:

Rover has a long and storied history in British automotive manufacturing, known for producing a range of vehicles from executive saloons to compact hatchbacks. MG is a performance sub-brand focused on sporty variants.

Model Evolution:

The Rover 25 (internal codename R25) was launched in 1999 as a replacement for the Rover 200 series. The MG ZR was introduced in 2001 as the performance variant of the Rover 25, distinguished by its more aggressive styling, uprated suspension, and the more powerful 1.8 K Series engine.

Production Period:

Rover 25: 1999-2005. MG ZR: 2001-2005. Production ceased due to the financial collapse of MG Rover Group.

🏆 Awards & Recognition

Recognitions:

The MG ZR, in particular, received positive reviews for its driving dynamics and value for money in the hot hatch segment of its time. Specific awards are not widely publicized for this model line.