Rover 45 & MG ZS 1999-2005 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: MG Model: ZS Year: 1999-2005 Codes Rover Platform: R30 (derived from Honda Civic EJ/EK platform) 👋 Introduction Market Position Segment: Compact family car / Sports...

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Type: Car

Vendor:

Sku: 198497

Tags: 1999 2000 2001 2002 2003 2004 2005 45 Car Cars MG MG ZS Rover ZS

Product variants

Description

🏷️ Basic Information

Identification

Make:

Model:

Year:

1999-2005

Codes

Rover Platform:

R30 (derived from Honda Civic EJ/EK platform)

👋 Introduction

Market Position

Segment:

Compact family car / Sports saloon (MG ZS)

Competitive Analysis

Key Competitors:

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

Key Features

Manual Value Proposition:

Provides official factory-level repair and maintenance information for DIY enthusiasts and professional mechanics.

Visual Aid Quality:

Includes hundreds of photos, illustrations, and detailed drawings.

📋 Manual Details

Coverage Areas

Geographic Coverage:

Primarily Europe and UK markets

Model Variants:

All styles and configurations of Rover 45 and MG ZS

Page Count

Estimated Page Count:

Hundreds of pages (specific number not provided, but implies comprehensive)

Manual Type

Type:

Workshop Service Repair Manual

Language

Language:

English

Format

Delivery Format:

Digital Download (PDF)

📖 Manual Coverage

Systems Covered

Powertrain:

Engine, transmission, fuel system, exhaust system

Chassis:

Suspension, steering, brakes, wheels, tires

Electrical:

Wiring diagrams, lighting, ignition, starting, charging, accessories, diagnostics

Body:

Bodywork, interior trim, doors, windows, seats, safety features

Procedures Included

Maintenance:

Routine checks, fluid changes, filter replacements, scheduled servicing

Repair:

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

Troubleshooting:

Diagnostic procedures for identifying and resolving common faults and problems

Technical Depth

Depth:

Comprehensive from basic maintenance to complete disassembly and rebuild

Detail Level:

Detailed substeps, notes, cautions, and warnings

📊 Manual Specifications

File Format

Format:

Print Quality

Printability:

Printable without restrictions

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper:

N/A (Digital Download)

Software Requirements

Reader:

Adobe PDF Reader

⚙️ Engine Specifications

Primary Engine

Rover 45 Engine Options:

1.4L K-series (KV6), 1.6L K-series (KV6), 1.8L K-series (KV6), 2.0L L-series (diesel)

Mg Zs Engine Options:

1.6L K-series, 1.8L K-series, 2.5L KV6

Performance

K Series 1.8L Power:

Approx. 117 bhp (VVC option offered higher output)

Mg Zs 2.5L Kv6 Power:

Approx. 175 bhp

Fuel System

K Series Fuel Injection:

Multi-point fuel injection (MPI)

L Series Diesel Fuel System:

Direct injection, potentially with turbocharging

🔧 Transmission

Standard

Rover 45 Transmission:

5-speed manual

Optional

Rover 45 Automatic:

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

Mg Zs Transmission:

5-speed manual, 5-speed manual (for VVC models)

Features

Performance Manual Gearing:

Close-ratio gearing available on performance variants.

📐 Dimensions

Exterior

Body Styles:

4-door saloon, 5-door hatchback

Wheelbase:

Approx. 2550 mm

Weights

Curb Weight Range:

Approx. 1150 kg - 1350 kg depending on engine and specification

🛡️ Safety Features

Ratings

Euro Ncap Rating:

3 stars (for related models, specific rating for this generation may vary)

Active Features

Braking System:

ABS, EBD (Electronic Brakeforce Distribution)

Passive Features

Airbags:

Driver and front passenger airbags (side airbags optional on some models)

Seatbelts:

Pre-tensioning seatbelts with force limiters

💡 Technology Features

Infotainment

Audio System:

Factory fitted radio/cassette or CD player, often with steering wheel controls on higher trims.

Driver Assistance

Cruise Control:

Optional on higher specification models.

Connectivity

Early Bluetooth:

Limited to aftermarket or very late model options.

🔧 Maintenance

Service Intervals

Oil Change Interval Petrol:

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

Cambelt Replacement Kseries:

Crucial: 60,000 miles or 4 years (failure of K-series cambelt can cause severe engine damage).

Fluid Specifications

Engine Oil Spec:

API SG/SH/SJ or ACEA A2-96/A3-96, viscosity 10W/40 or 5W/40 (refer to manual for precise grade based on temperature).

Coolant Spec:

Ethylene glycol-based antifreeze, mixed 50/50 with distilled water (e.g., Rover Anti-Freeze)

Brake Fluid Spec:

DOT 4

Known Issues

K Series Hgf:

Head Gasket Failure (HGF) is a well-documented and critical issue on K-series engines, requiring skilled repair.

Cooling System:

Perished hoses, failing water pumps, and thermostat issues are common.

Electronics:

Lucas 10AS alarm system can be problematic; Body Control Module (BCM) issues.

📚 Vehicle History

Brand Heritage

Rover Legacy:

Continued the legacy of Rover's compact executive cars, building on the Rover 400/45 series.

Model Evolution

Rover 45 Origin:

Facelift and rebranding of the Rover 400 (RD) series.

Mg Zs Development:

Sporting derivative of the Rover 45, offering enhanced performance and styling.

Production

Production Period:

1999 - 2005

Manufacturing Plant:

Longbridge, Birmingham, UK

🏆 Awards & Recognition

Recognitions

Mg Zs Reputation:

The MG ZS was generally well-received for its handling and sporty feel, often praised in contemporary reviews.

Rover 45 Positioning:

Positioned as a comfortable and refined compact executive car.