🏷️ Basic Information Identification Make: Rover MG Model: MG ZR Model Variant: ZR 160 Related Model: Rover 25 Codes Chassis Code Common: RG Engine Code Primary: K4 👋 Introduction Market Position Positioning: Performance-oriented hatchback derived from the Rover 25, targeting enthusiasts and those seeking a sportier alternative. Competitive Analysis Competitors: Ford Focus ST, Vauxhall Astra GSI, Peugeot 206 GTi, Renault Clio RS. Key Features Highlight: Sporty styling, enhanced chassis and suspension, powerful engine options, driver-focused interior. Manual Value Proposition Benefit: Enables cost savings through DIY maintenance and repairs, empowers owners with technical knowledge. 📋 Manual Details Coverage Areas Primary Coverage: Complete Service and Repair Procedures (A-Z) Model Coverage: All Models, Engines, Trim, and Transmission Types Page Count Estimated Page Count: Comprehensive (Exact count not specified, but implies full factory manual scope) Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: Digital Downloadable (PDF) 📖 Manual Coverage Systems Covered Powertrain: Engine, Fuel System, Ignition System, Exhaust System, Cooling System, Lubrication System Transmission Drivetrain: Manual and Automatic Transmissions, Clutch, Driveshafts, Differential Chassis Suspension Steering: Front Suspension, Rear Suspension, Steering System, Wheel Alignment Braking System: Front and Rear Brakes (Disc/Drum as applicable), ABS (if equipped), Brake Lines, Master Cylinder Electrical System: Battery, Charging System, Starting System, Lighting, Instrumentation, Wiring Diagrams, ECU, Sensors Body Interior Exterior: Body Panels, Doors, Windows, Seats, HVAC System, Body Control Modules Procedures Included Routine Maintenance: Oil Changes, Filter Replacements, Fluid Checks and Top-ups, Spark Plug Replacement, Belt Inspections Diagnostics Troubleshooting: Systematic Fault Finding for all major systems, DTC interpretation (OBD-II where applicable) Major Repairs: Engine Overhauls, Transmission Rebuilds, Suspension Component Replacement, Brake System Overhauls Component Replacement: Alternator, Starter Motor, Radiator, Water Pump, Fuel Pump, Brake Calipers, Shocks/Struts Body Repair: Panel Alignment, Dent Repair Procedures, Glass Replacement Technical Depth Depth: Comprehensive (from basic maintenance to complete rebuilds and diagnostics) Instruction Style: Step-by-step instructions with accompanying pictures 📊 Manual Specifications File Format Format: PDF (Portable Document Format) Compatibility: All PC & MAC Computers, Tablets, Mobile Phones Required Software: Adobe Reader (free download) Print Quality Printability: Printable (single page, chapter, or entire manual) Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: Naturally Aspirated Inline-4 (Rover K-Series) Displacement Cc: 1796cc Engine Code Variant: KV6 for some variants, but ZR 160 primarily uses K4 (2.0L variants exist) Performance Horsepower Ps: 160 PS (approx. 158 bhp) Torque Nm: 174 Nm (approx. 128 lb-ft) Fuel System Fuel Delivery: Multi-Point Fuel Injection (MPI) Fuel Type: Unleaded Petrol (RON 95 recommended, RON 98 for optimal performance) 🔧 Transmission Standard Transmission Type: 5-Speed Manual (PG1) Optional Transmission Type: 4-Speed Automatic (Optional on some Rover 25 variants, less common on ZR 160) Features Clutch Type: Hydraulic Dry Single Plate Clutch 📐 Dimensions Exterior Body Style: 3-Door or 5-Door Hatchback Length Mm: 3990 mm Width Mm: 1700 mm Height Mm: 1385 mm Weights Kerb Weight Kg: Approx. 1100-1150 kg (depending on specification) Gross Vehicle Weight Kg: Approx. 1575 kg 🛡️ Safety Features Ratings Euro Ncap Rating: 3 Stars (for the Rover 25 upon which it's based, prior to significant updates) Active Features ABS: Optional ABS system available on certain trims/models. Traction Control: Traction Control System (TCS) was an optional extra. Passive Features Airbags: Driver and Passenger Airbags standard on most models, side airbags optional. Seatbelts: Pre-tensioned Seatbelts 💡 Technology Features Infotainment Head Unit: Original equipment typically included a cassette player or CD player with basic radio functionality. Aftermarket upgrades are common. Speaker System: Standard 4-speaker or 6-speaker system depending on trim level. Driver Assistance Cruise Control: Optional on higher trim levels. Connectivity Auxiliary Input: Not standard on early models; often added via aftermarket solutions or specific trim packs. 🔧 Maintenance Service Intervals Oil Change Interval Km: 15,000 km or 12 months, whichever comes first. Spark Plug Replacement Km: 60,000 km (for Iridium/Platinum plugs) or 30,000 km (for standard plugs). Timing Belt Replacement Km: 105,000 km or 7 years (critical for K-Series engines). Fluid Specifications Engine Oil Type: API SJ/SL, ACEA A3/B3, SAE 10W/40 or 10W/50 (check manual for specific climate recommendations). Coolant Type: OAT (Organic Acid Technology) Antifreeze/Coolant, typically blue or pink. Brake Fluid Type: DOT 4 Transmission Fluid Type Manual: API GL-4 SAE 75W/90 Known Issues Head Gasket Failure: The K-Series engine is known for potential head gasket failures, particularly earlier models. The manual will detail specific inspection and repair procedures. Thermostat Failure: Thermostat housing can be a weak point, leading to coolant leaks and overheating. Manual will provide replacement steps. Rear Axle Bushes: Wear in rear axle suspension bushes can lead to handling issues and premature tyre wear. Manual covers replacement. 📚 Vehicle History Brand Heritage Heritage: MG (Morris Garages) has a long history of producing sporty versions of standard British cars. Model Evolution Predecessor: MG MGF and Rover 200 series. Development: Developed...