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Rover 100 1980-1990 Workshop Repair Service Manual

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🏷️ Basic Information Identification Make: Rover Model: 100 Series Common Name: Rover Metro (post-1990 facelift and badging) Chassis Code: XX (for the 100 Series, though often referred to by its...
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Rover 100 1980-1990 Workshop Repair Service Manual
🏷️ Basic Information
Identification
Make:
Rover
Model:
100 Series
Common Name:
Rover Metro (post-1990 facelift and badging)
Chassis Code:
XX (for the 100 Series, though often referred to by its Metro designation)
Generation
Generation Code:
XA/XB/XC (Metro generation that the 100 Series is derived from)
Codes
Platform:
BMC ADO22 (original Mini platform derivation)
👋 Introduction
Market Position
Segment:
Supermini/Compact Car
Target Audience:
DIY mechanics, independent repair shops, classic car enthusiasts.
Competitive Analysis
Key Competitors:
Ford Fiesta, Fiat Uno, Peugeot 205, Volkswagen Polo, Vauxhall Nova/Corsa.
Key Features
Design Heritage:
Evolved from the Leyland/Austin Mini Metro, retaining its compact dimensions and innovative Hydragas suspension.
Brand Evolution:
Represents Rover's attempt to update and re-badge the Metro to maintain its appeal in a competitive market.
📋 Manual Details
Coverage Areas
Years Covered:
1980, 1981, 1982, 1983, 1984, 1985, 1986, 1987, 1988, 1989, 1990
Page Count
Estimated Page Count:
500-800 (typical for comprehensive workshop manuals of this era)
Manual Type
Manual Type:
Workshop Repair and Service Manual
Language
Language:
English
Format
Format:
PDF Download
Manual Specifications
File Format:
PDF
Print Quality:
High-resolution scans for clear text and diagrams, suitable for printing.
Binding Type:
Not Applicable (Digital Format)
Paper Type:
Not Applicable (Digital Format)
Searchability:
Likely text-searchable if converted from OCR'd documents, enhancing usability.
📖 Manual Coverage
Systems Covered
Engine:
Detailed coverage of engine mechanicals, cooling, lubrication, fuel delivery (carburetor and early injection systems), ignition, and exhaust.
Transmission:
Manual and automatic transmission overhaul, clutch operation, and drive axle components.
Suspension:
Hydragas suspension system (front and rear), damper units, suspension arms, and related components.
Steering:
Steering rack, column, and linkage components; power steering system (if equipped).
Brakes:
Hydraulic system, master cylinder, wheel cylinders, calipers, brake discs, drums, and parking brake.
Electrical:
Wiring diagrams, lighting, ignition system, charging system, starter motor, instrumentation, and ancillary electrical components.
Bodywork:
Body panel removal and installation, door mechanisms, glass, trim, and underbody protection.
HVAC:
Heating system operation and components.
Procedures Included
Maintenance:
Regular servicing, oil changes, filter replacements, spark plug adjustments, fluid checks, and lubrication points.
Troubleshooting:
Diagnostic flowcharts and common fault finding for all major systems.
Repair:
Step-by-step instructions for component removal, overhaul, and reassembly.
Diagnostics:
Guidance on identifying issues using symptom-based approaches and basic test equipment.
Engine Overhaul:
Detailed instructions for engine disassembly, inspection, and rebuilding.
Transmission Rebuild:
Comprehensive guidance for manual and automatic gearbox repairs.
Brake Service:
Pad/shoe replacement, caliper/cylinder overhaul, bleeding procedures.
Technical Depth
Depth Level:
Comprehensive; covers from basic scheduled maintenance to complete engine and transmission rebuilds, electrical system diagnostics, and bodywork repairs.
Diagnostic Tools Required:
Basic hand tools, torque wrench, multimeter, feeler gauges, compression tester, timing light.
⚙️ Engine Specifications
Primary Engine
Engine Code:
A-Series (Various displacements)
Displacement Common:
1.0 L (998 cc) and 1.3 L (1275 cc)
Configuration:
Inline-4, transverse, front-wheel drive
Performance
Horsepower 1.0L:
Approx. 45-50 bhp
Horsepower 1.3L:
Approx. 60-65 bhp (standard), up to 70-90 bhp (performance variants like MG)
Torque 1.3L:
Approx. 70-80 lb-ft (standard)
Fuel System
Fuel Delivery Common:
Single Zenith Stromberg or SU carburetors, later models may have basic Lucas fuel injection (MPI).
Fuel Type:
Unleaded Petrol (95 RON)
Ignition System:
Distributor-based ignition, breaker points or electronic ignition (Lucas).
🔧 Transmission
Standard
Type:
4-speed manual transaxle
Optional
Type:
3-speed automatic transaxle (BorgWarner 35/37 derived)
Features
Clutch Type:
Dry single-plate diaphragm spring clutch
Manual Gear Ratios:
Varies by model, typically around 3.1:1 for 1st gear.
Fluid Specifications
Manual Transmission Fluid:
API GL-4 SAE 90 or SAE 80W-90 gear oil (Check manual for specific viscosity)
Automatic Transmission Fluid:
Dexron II (or equivalent)
📐 Dimensions
Exterior
Length:
Approx. 3400 mm (133.9 inches)
Width:
Approx. 1590 mm (62.6 inches)
Height:
Approx. 1370 mm (53.9 inches)
Wheelbase:
Approx. 2090 mm (82.3 inches)
Weights
Kerb Weight:
Approx. 750-850 kg (1653-1874 lbs)
Gross Vehicle Weight:
Approx. 1100-1200 kg (2425-2646 lbs)
🛡️ Safety Features
Ratings
Crash Test Era:
Limited official NCAP or equivalent testing for this era; relies on contemporary safety standards.
Active Features
Brakes:
Disc front, drum rear; optional front ventilated discs on higher trims/performance models.
Parking Brake:
Rear drum brake mechanism, cable operated.
Passive Features
Seatbelts:
Inertia-reel front seatbelts, lap belts for rear passengers.
Body Structure:
Integral construction with controlled crumple zones (typical for late 70s/early 80s design principles).
Steering Column:
Collapsible steering column to mitigate driver injury.
💡 Technology Features
Infotainment
Radio:
Basic AM/FM radio/cassette player, often a dealer-fit option or aftermarket unit.
Speakers:
Typically 2 or 4 speakers.
Driver Assistance
ABS:
Not typically fitted as standard; could be a rare option on later higher-spec models.
Power Steering:
Optional on some models, particularly 1.3L variants.
Connectivity
Connectivity Features:
None in the modern sense; basic electrical connections for lights and ignition.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 6,000 miles or 6 months, whichever comes first.
Air Filter Replacement:
Every 12,000 miles or 12 months.
Spark Plug Replacement:
Every 12,000-18,000 miles, depending on type.
Coolant Change Interval:
Every 24,000 miles or 24 months (using correct anti-freeze/inhibitor).
Fluid Specifications
Engine Oil Specification:
API SF/CD SAE 20W-50 or 10W-40 (refer to manual for ambient temperature suitability).
Engine Oil Capacity:
Approx. 3.5 - 4.0 litres (with filter, 1.3L engine)
Coolant Specification:
Ethylene glycol based antifreeze with corrosion inhibitors. Typically a 50/50 mix with distilled water.
Brake Fluid Specification:
DOT 3 or DOT 4.
Known Issues
Suspension:
Hydragas suspension spheres can lose pressure or leak; require specialist charging/maintenance. Potential for wear in suspension arms and bushes.
Engine Cooling:
Overheating can occur if cooling system maintenance is neglected; water pump leaks are also common.
Electrical:
Corrosion in wiring looms, especially earth points; issues with ignition switches, alternators, and wiper motors.
Rust:
Prone to corrosion in wheel arches, sills, boot floor, and around window seals.
Carburettor:
Zenith Stromberg carburetors can become temperamental and require regular tuning or rebuilding.
📚 Vehicle History
Brand Heritage
Manufacturer Legacy:
Rover, a marque with a long history in British automotive manufacturing, known for executive cars and innovative engineering (e.g., the original Mini, Range Rover).
Model Evolution
Predecessor:
Austin/Morris/Rover Metro (launched 1980)
Transformation:
The Rover 100 Series was a significant facelift and re-branding of the Austin/Morris Metro, launched in 1990. It aimed to modernize the car's image and improve its perceived quality and refinement.
Production
Production Period Metro:
1980-1998
Production Period Rover 100:
1990-1997
Manufacturing Location:
Longbridge, Birmingham, UK (primarily)
🏆 Awards & Recognition
Recognitions
Automotive Press:
While the original Metro received mixed reviews, the Rover 100 aimed for a more premium feel within its segment, though it was still considered dated by some contemporary reviews compared to newer rivals.
Market Perception:
The Rover 100 was an important model for Rover's small car strategy, retaining a loyal customer base and a significant presence in the UK market.
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