🏷️ Basic Information Identification Make: Rover / MG Model: MG ZR / Rover 25 Trim Level: 160 Covered Models: MG ZR, Rover 25 Generation Mg Zr Generation: First Generation (2001-2005) Rover 25 Generation: Post-facelift (2000-2005) 👋 Introduction Market Position Vehicle Segment: Compact / Supermini Brand Strategy: MG focused on sportier variants of Rover platforms, offering a more engaging driving experience. Competitive Analysis Key Competitors: Ford Focus, Vauxhall Astra, Volkswagen Golf, Peugeot 206 Key Features Mg Zr Focus: Sporty styling, revised suspension tuning, performance-oriented engines (especially the 160 variant). Manual Value Proposition: Provides comprehensive technical data essential for maintaining and repairing the specific models and engines covered, offering significant cost savings over professional servicing. 📋 Manual Details Coverage Areas Manual Type: Workshop Service Repair + Owner's Manual Language: English Format: PDF (delivered as ZIP archive) Page Count: Over 1100 pages Compatibility: All Windows versions, All Mac versions (requires Adobe Acrobat Reader) 📖 Manual Coverage Systems Covered Powertrain: Engine, Fuel Delivery, Cooling, Exhaust, Clutch, Manual Transmission, Automatic Transmission, Driveshaft Chassis: Steering, Front Suspension, Rear Suspension, Brake System Body & Electrical: Restraint System, Doors, Exterior Fitting, Interior Trim, Screens, Seats & Seat Belts, Sunroofs, Body & Accessories, Heating & Ventilation, Air Conditioning, Wiper & Washer System, Electrical System, Instruments Procedures Included Maintenance: Scheduled maintenance, fluid changes, lubrication, filter replacement Repair: Component disassembly, inspection, repair, and reassembly for all major vehicle systems Diagnostics: Troubleshooting guides, fault finding procedures, diagnostic trouble codes (DTCs) interpretation for engine management system Technical Depth Level Of Detail: Comprehensive, step-by-step instructions with detailed illustrations and diagrams Target Audience: Do-it-yourself enthusiasts and experienced professional mechanics 📊 Manual Specifications File Format Digital Format: PDF File Size: 32 MB Archival Format: ZIP Print Quality Printability: Printable on demand, allowing users to print specific pages Illustrations: Detailed illustrations, diagrams, and pictures Binding Type Binding Type: N/A (Digital Format) Paper Type Paper Type: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Code 1: K Series Engine Configuration 1: 1.8L (1796cc) Inline-4 Engine Type 1: DOHC (Double Overhead Camshaft), 16 Valve Performance 160 Variant: MG ZR 160 typically produced around 160 PS (118 kW; 158 hp) and 174 Nm (128 lb-ft) of torque. (Specific figures may vary slightly by model year.) Secondary Engine Engine Code 2: L Series Engine Configuration 2: 2.0L (1994cc) Inline-4 Engine Type 2: SOHC (Single Overhead Camshaft), Turbocharged, Intercooled Diesel Fuel System Fuel Injection K Series: Multi-point fuel injection (MPI) Fuel Type K Series: Unleaded Petrol (Gasoline) Fuel Type L Series: Diesel 🔧 Transmission Standard Manual Transmission Option: R65 and PG1 manual transmissions Optional Automatic Transmission Option: EM-CVT (Electronic Continuously Variable Transmission) Features Transmission Coverage: Detailed repair and maintenance procedures for both manual and automatic transmissions. 📐 Dimensions Exterior Body Styles: Typically 3-door and 5-door hatchback Wheelbase: Approximately 2520 mm (99.2 in) Length: Approximately 3970 mm (156.3 in) Width: Approximately 1680 mm (66.1 in) Height: Approximately 1380 mm (54.3 in) Weights Curb Weight: Varies by engine and specification, typically around 1100-1250 kg (2425-2755 lbs) Gross Vehicle Weight: Refer to vehicle's compliance plate (specific figures vary) 🛡️ Safety Features Ratings Euro Ncap Rating: MG ZR achieved a 3-star Euro NCAP rating for adult occupant protection (version tested may vary). Active Features Braking System: Front ventilated discs, rear solid discs (upgrade to larger discs on performance models like 160). ABS typically optional or standard on higher trims. Traction Control: Typically not standard on all models, may be present on higher trims or optional. Passive Features Airbags: Driver and front passenger airbags standard, side airbags optional on some models. Seat Belts: Pre-tensioning front seatbelts. 💡 Technology Features Infotainment Audio System: Typically aftermarket or factory fitted radio/cassette or CD players. Manual will cover basic wiring and removal/installation. Driver Assistance ABS: Anti-lock Braking System (ABS) was optional or standard depending on trim and model year. The manual details its operation and components. Connectivity Connectivity Features: Limited by era; typically basic power accessories. No modern Bluetooth or smartphone integration from the factory. 🔧 Maintenance Service Intervals Oil Change Interval: Typically every 10,000 miles or 12 months, whichever comes first. (Refer to manual for specific K Series/L Series recommendations). Timing Belt Replacement: K Series engines are belt-driven. Replacement is crucial, typically at 60,000-80,000 miles or 5-7 years. Failure can cause severe engine damage. L Series (diesel) is chain-driven or belt-driven depending on exact variant and maintenance needs. Fluid Specifications Engine Oil K Series: Refer to manual, typically 5W-30 or 10W-40, API SJ/SL or ACEA A3/B3 rated. K Series engines can be sensitive to oil choice and level. Coolant Type: Ethylene glycol based, OAT (Organic Acid Technology) type, typically pink or orange. Capacity around 6.0-7.0 liters. Brake Fluid: DOT 4 Transmission Oil Manual: GL-4 rated gear oil, typically 75W-90 or 80W-90. Capacity varies for R65/PG1. Known Issues K Series Head Gasket: The K Series engine is notoriously known for...