ROVER 45 MG ZS Factory Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Rover Model: 45 / MG ZS Brand Association: MG Vehicle Generation Era: Late 1990s - Early 2000s Platform Basis: Rover 400 Series (RT) / Honda...

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Type: Car

Vendor:

Sku: 203041

Tags: 45 Car Cars MG MG ZS Rover ZS

Product variants

Description

🏷️ Basic Information

Identification

Make:

Rover

Model:

45 / MG ZS

Brand Association:

Vehicle Generation Era:

Late 1990s - Early 2000s

Platform Basis:

Rover 400 Series (RT) / Honda Civic (EG/EJ)

Codes

Internal Project Codes:

R30 (Rover 45 development), MG ZS development

👋 Introduction

Market Position

Target Audience:

DIY Mechanics, Independent Garages, Rover/MG Enthusiasts

Competitive Analysis

Value Proposition:

OEM-level information, significant cost saving over dealer servicing

Key Features

Completeness:

Extremely comprehensive, covering all aspects of vehicle repair and maintenance

Ease Of Use:

No software installation required, single searchable PDF file

Longevity Of Use:

Useful for the entire ownership period of the vehicle

📋 Manual Details

Coverage Areas

Manual Scope:

Comprehensive Workshop Service and Repair

Page Count

Total Pages:

> 3500

Manual Type

Manual Category:

Factory Workshop Service Repair Manual (OEM Equivalent)

Language

Primary Language:

English

Format

Digital Format:

Software Requirements

Installation Needed:

Usability

Navigation Features:

Bookmarks

Printing Capability:

Printable

📖 Manual Coverage

Systems Covered

Powertrain:

Engine (K Series, L Series, KV6), Transmission (Manual & Automatic)

Chassis:

Suspension, Steering, Brakes, Wheels & Tires

Electrical:

Full Electrical Library, Wiring Diagrams, ECUs

Bodywork:

Body Shell, Exterior Trim, Interior Trim, HVAC

Procedures Included

Maintenance:

Scheduled Maintenance, Fluid Checks/Changes, Filter Replacements

Repair:

Step-by-Step Repair Procedures for all major systems

Overhaul:

Full Overhaul Manual sections included

Diagnostics:

Troubleshooting Guides, T4 Diagnostic System information

Installation:

Accessory Fitting Instructions

Technical Depth

Coverage Level:

Complete: From routine maintenance to full engine/transmission rebuilds

Diagnostic Support:

Includes procedures and reference for the T4 diagnostic system

Electrical Diagrams Detail:

Detailed electrical circuit diagrams for all vehicle systems

📊 Manual Specifications

File Format

Document Type:

Single PDF file

Print Quality

Print Readability:

High (suitable for printing)

Binding Type

Physical Format Consideration:

N/A (Digital Format)

Paper Type

Physical Format Consideration:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine Series 1:

K Series

Engine Series 2:

L Series (Diesel)

Engine Series 3:

KV6 (Rover 6-cylinder)

K Series Variants

Common Displacements:

1.4L (1396cc), 1.6L (1588cc), 1.8L (1796cc)

Engine Design:

Inline-4 Cylinder, DOHC, 16 Valves (typically)

L Series Variants

Common Displacement:

2.0L (1994cc)

Engine Design:

Inline-4 Cylinder, SOHC, Diesel (Turbocharged variants common)

Kv6 Variants

Common Displacement:

2.5L (2497cc)

Engine Design:

V6 Cylinder, DOHC, 24 Valves

Performance

K Series Power Range:

~100-120 hp (depending on displacement and tune)

L Series Power Range:

~90-110 hp (for turbocharged variants)

Kv6 Power Range:

~175-190 hp (for the 2.5L)

Fuel System

K Series Fuel Delivery:

Multi-point Fuel Injection (MPI)

L Series Fuel Delivery:

Direct Injection (Diesel)

Kv6 Fuel Delivery:

Multi-point Fuel Injection (MPI)

🔧 Transmission

Standard

Manual Transmission Options:

5-speed manual (e.g., PG1 gearbox)

Optional

Automatic Transmission Options:

4-speed automatic (e.g., JATCO unit common on some variants)

Features

Clutch Type:

Hydraulically Actuated Single Dry Plate

Fluid Specifications

Manual Gearbox Oil:

Refer to manual for specific GL-4 or GL-5 grades and viscosity (e.g., SAE 75W-90)

Automatic Transmission Fluid:

Refer to manual for specific ATF type (e.g., Dexron III or equivalent)

📐 Dimensions

Exterior

Body Styles:

4-door Sedan, 5-door Hatchback

Wheelbase Approx:

2600 mm (102.4 in)

Overall Length Approx:

4350-4380 mm (171.3-172.4 in)

Weights

Kerb Weight Range:

~1200-1350 kg (depending on engine and specification)

🛡️ Safety Features

Ratings

Euro Ncap Rating:

Not explicitly rated under modern comprehensive standards, but derived from earlier platforms.

Active Features

Braking System:

Front Ventilated Discs, Rear Solid Discs (ABS optional/standard on higher trims)

Passive Features

Airbags:

Driver and Passenger Airbags (standard on most models), Side Airbags (optional)

Seatbelts:

Pre-tensioning front seatbelts

💡 Technology Features

Infotainment

Audio System:

Factory fitted radio/cassette or CD player with speaker systems. Manual covers basic operation and replacement.

Driver Assistance

Available as an option or standard on higher trims. Manual details its operation and fault finding.

Connectivity

Wiring Harnesses:

Extensive wiring diagrams provided for all electrical systems, facilitating diagnosis of intermittent faults or aftermarket installations.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically 10,000 miles or 12 months (whichever comes first), refer to manual for specific engine.

Timing Belt Replacement:

Critical for K Series engines. Intervals vary, often 60,000-90,000 miles or 5-7 years. Refer to manual for precise interval and specific K Series variant.

Fluid Specifications

Engine Oil Specification:

Refer to manual for specific grade (e.g., 5W-30, 10W-40) and API/ACEA ratings, depending on engine type (K, L, KV6) and climate.

Coolant Specification:

Ethylene Glycol based, OAT or HOAT type (often pink or orange hue). Refer to manual for exact specification (e.g., Rover Longlife Coolant).

Brake Fluid Specification:

DOT 3 or DOT 4 (refer to manual for exact type).

Known Issues

K Series Head Gasket:

Notorious for head gasket failure, especially earlier models. The manual provides procedures for diagnosis and replacement.

Cooling System Reliability:

Potential for radiator, hose, and water pump leaks. The manual details inspection and replacement.

L Series Diesel Specifics:

Potential for injector issues or turbocharger problems, covered in diagnostic sections.

📚 Vehicle History

Brand Heritage

Rover Legacy:

Continuation of Rover's mid-size saloon and hatchback tradition, aiming for a premium feel.

Model Evolution

Rover 45 Development:

Facelift and re-skin of the Rover 400 Series (RT), launched in 1999.

Mg Zs Development:

Performance-oriented variant of the Rover 45, developed by MG Rover Group.

Production

Production Period:

Rover 45: 1999-2005; MG ZS: 2001-2005

Manufacturing Location:

Longbridge, Birmingham, UK

🏆 Awards & Recognition

Recognitions

Industry Accolades:

While specific awards are not readily cited for these models, they were positioned as contenders in the compact executive and sporting saloon segments of their era.

Ratings

Reliability Ratings:

As with many cars from this period, reliability can be variable. The manual is crucial for maintaining these vehicles.

Certifications

Manual Certification:

OEM (Original Equipment Manufacturer) quality documentation