🏷️ Basic Information

Make:

Rover / MG

Model:

45 / ZS

Production Years Covered:

1999-2005

Generation Codes:

RJ (Rover 45), ZS (MG ZS)

Chassis Codes:

Often referred to by its platform derivation from the Honda Civic (EG/EJ generation) but as the RDX platform for the UK market.

👋 Introduction

Segment:

Compact family car / performance compact (MG ZS variant)

Competitors:

Ford Focus, Vauxhall Astra, Volkswagen Golf, Peugeot 306/307, Renault Mégane.

Distinguishing Factors:

The Rover 45 and MG ZS offered a blend of comfort and practicality (Rover 45) or sporty driving dynamics and aggressive styling (MG ZS). Based on the Rover KV6 engine in higher trims, providing a unique powertrain for the class.

📋 Manual Details

Systems Covered:

Engine mechanical, engine control systems, emission control systems, cooling system, fuel system, intake system, exhaust system, clutch system, manual transaxle system, automatic transaxle system, drive shaft, propeller shaft, differential case, front axle, rear axle, steering system, suspension system (front and rear), brake system (front and rear), parking brake, ABS, ESP, SRS (airbag), interior trim, exterior body panels, doors, windows, sunroof, HVAC system, electrical systems (lighting, instruments, power accessories, infotainment), wiring diagrams, troubleshooting, maintenance.

Total Pages:

> 390 pages

Type:

Owners Workshop Manual / Service and Repair Manual

Language:

English

File Format:

PDF

📖 Manual Coverage

Engine Mechanical:

Complete disassembly, inspection, repair, and reassembly of engine components including cylinder head, cylinder block, pistons, connecting rods, crankshaft, camshafts, valves, timing belt/chain, oil pump, etc. Specifics for various engine variants (K-Series, KV6, etc.).

Engine Control System:

Detailed diagnostics, testing, and repair of ECU, sensors (crankshaft position, camshaft position, MAP, TPS, O2, etc.), actuators (injectors, ignition coils), and fuel delivery systems.

Transmission:

Covers both manual and automatic transmissions, including clutch system (master and slave cylinders, clutch plate), gear selection, torque converter, valve body, and transmission fluid specifications.

Brake System:

Inspection, repair, and maintenance of front and rear disc brakes, brake pads, rotors, calipers, brake lines, master cylinder, brake booster, ABS system components, and brake fluid type and bleeding procedures.

Electrical System:

Comprehensive coverage including wiring diagrams for all major systems, charging system (alternator, battery), starting system (starter motor, starter switch), lighting systems, ignition system, instrumentation, power windows, central locking, audio systems, and airbag system.

Maintenance:

Routine maintenance tasks such as oil changes, filter replacements, spark plug replacement, coolant checks and flushes, brake fluid changes, and lubrication schedules.

Repair:

Step-by-step instructions for a wide range of repairs, from minor adjustments to major component overhauls, including engine rebuilds, transmission repairs, suspension overhauls, brake system servicing, and electrical diagnostics.

Troubleshooting:

Detailed troubleshooting guides with symptoms, possible causes, and diagnostic steps for common issues across all vehicle systems.

Depth:

Detailed enough for both DIY enthusiasts and professional mechanics. Includes technical specifications, torque values, diagnostic procedures, and complete disassembly/reassembly instructions.

📊 Manual Specifications

Searchable Bookmarked:

Yes (Searchable and Bookmarked for efficient navigation)

Printable:

Yes (All pages are printable)

Binding:

Digital (PDF)

Paper Type:

N/A (Digital)

Device Compatibility:

iPad-ready, PC (Windows), Mac, Linux

Drm Free:

Yes (DRM-free, without any restriction)

⚙️ Engine Specifications

Rover 45 K Series:

Rover K-Series engines: 1.4L (1396cc), 1.6L (1588cc), 1.8L (1796cc) - 4 cylinders. Offering varied power outputs suitable for daily driving.

Mg Zs K Series Vvc:

MG ZS featured tuned K-Series engines, including the 1.8L VVC (Variable Valve Control) producing around 160 PS, providing a significant performance uplift.

Rover Kv6 Engine:

Available in some Rover 45 models and higher-spec MG ZS variants: 2.5L (2497cc) V6 engine, offering smoother power delivery and increased performance.

Typical Horsepower Range:

82 PS (1.4L) to 175 PS (2.5L V6) depending on engine and tune.

Injection Type:

Multi-point fuel injection (MPI) for most variants.

🔧 Transmission

Manual Options:

5-speed manual transaxle.

Automatic Options:

4-speed automatic transaxle (e.g., JATCO transmission in some models).

Clutch Type:

Hydraulically operated single dry plate clutch.

📐 Dimensions

Body Styles:

4-door Sedan, 5-door Hatchback, 5-door Estate (Tourer).

Curb Weight Range:

Approx. 1200 kg - 1450 kg depending on body style and engine.

🛡️ Safety Features

Euro Ncap:

Euro NCAP ratings varied, with later models incorporating more safety features. Original R80 platform (pre-99) had lower scores, but improvements were made. Expect around 3-4 stars for later models in this period.

ABS:

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

Airbags:

Driver and passenger front airbags standard. Side airbags available on higher trims or as options.

💡 Technology Features

Audio System:

Standard radio/cassette or CD player with optional upgraded sound systems. Manual covers installation and troubleshooting.

ABS Esp:

ABS was increasingly common. ESP (Electronic Stability Program) was less common on this generation but may have been an option on higher-spec models.

Remote Central Locking:

Remote central locking and alarm systems were available, with manual covering their operation and troubleshooting.

🔧 Maintenance

Oil Change Interval:

Typically every 10,000 miles or 12 months, whichever comes first, depending on driving conditions.

Timing Belt Replacement:

Crucial for K-Series engines. Recommended replacement every 60,000-70,000 miles or 5-7 years. Failure can cause catastrophic engine damage. KV6 engines use a timing belt system requiring similar attention.

Engine Oil:

API SJ or higher, ACEA A3/B3. Viscosity typically 5W-30 or 10W-40, depending on climate. Consult manual for specific engine requirements.

Coolant:

Ethylene glycol-based antifreeze/coolant with corrosion inhibitors. Typically a 50/50 mix with distilled water. Rover's original recommendation was Rover/Texaco X/S coolant (often silicate-free).

Brake Fluid:

DOT 4.

Transmission Fluid Manual:

API GL-4, SAE 75W-90 or 80W-90 gear oil.

Transmission Fluid Automatic:

ATF (Automatic Transmission Fluid) - specific type depends on the gearbox manufacturer (e.g., Dexron II/III or equivalent).

Head Gasket K Series:

The K-Series engine is known for potential head gasket failures, particularly on earlier models. This manual would provide detailed procedures for diagnosis and replacement.

Cooling System Leaks:

Corrosion in the coolant system and potential leaks from hoses, radiator, or water pump are common and addressed in the manual.

Electrical Gremlins:

As with many cars of this era, minor electrical issues can occur, which the comprehensive wiring diagrams in this manual are invaluable for troubleshooting.

📚 Vehicle History

Rover Legacy:

Successor to the Rover 400 series, continuing Rover's tradition of building solid, comfortable family cars, albeit with a more modern design and platform sharing with Honda.

Rover 45 Vs Mg Zs:

The Rover 45 was the mainstream model, while the MG ZS was the performance-oriented variant, featuring a stiffer suspension, sportier styling, and more powerful engine options.

Manufacturing Location:

Longbridge, Birmingham, United Kingdom.

🏆 Awards & Recognition

Market Reception:

While not typically winning major awards, the Rover 45/MG ZS were seen as competent and value-oriented offerings in their segment, with the MG ZS being particularly praised for its engaging driving experience.