🏷️ Basic Information Identification Make: Rover Model: 25 Model Variant: MG ZR Trim Level: 160 Applicable Years: Specific production years for Rover 25 / MG ZR 160 (typically early 2000s to mid-2000s, exact range to be confirmed by manual content) Codes Engine Code: Rover K Series 👋 Introduction Market Position Market Position: The Rover 25 and MG ZR were positioned as compact sports hatchbacks, offering a blend of practicality and performance, particularly the MG ZR variant which was performance-tuned. Competitive Analysis Competitive Analysis: Competed against other mainstream and performance-oriented compact hatchbacks of its era, such as the Ford Focus, Vauxhall Astra, Volkswagen Golf, and performance variants from other manufacturers. Key Features Key Features: Sporty styling (especially MG ZR), engaging driving dynamics, robust Rover K Series engine, practical hatchback body style. Manual Value Proposition Manual Value Proposition: Provides essential, in-depth technical information for owners and technicians to maintain, diagnose, and repair the Rover 25 and MG ZR 160. Its comprehensive nature, including overhaul manuals and system descriptions, makes it invaluable for enthusiasts and professional mechanics. Manual Target Audience Manual Target Audience: Professional MG Rover technicians, independent repair shops, and experienced DIY enthusiasts who require detailed and accurate technical data. 📋 Manual Details Coverage Areas Coverage Areas: Comprehensive coverage for Rover 25 and MG ZR 160 models, including mechanical systems, electrical systems, bodywork, and specific overhaul procedures. Page Count Page Count: Estimated extensive page count (specific number not provided, but described as 'very FULL comprehensive'). Likely several hundred pages based on scope. Manual Type Manual Type: Factory Workshop Service Repair Manual Language Language: English (implied by target audience 'MG ROVER technicians worldwide') Format Format: PDF 📖 Manual Coverage Systems Covered Systems Covered: Engine (1.8L Rover K Series), Transmission Overhaul, Drivetrain, Suspension, Steering, Brakes, Fuel System, Ignition System, Cooling System, Lubrication System, Exhaust System, Electrical Systems (including ECUs, wiring diagrams), Body & Chassis, HVAC, Interior Trim, Pre-Delivery Inspection. Electrical Systems Detail: Comprehensive electrical diagrams, wiring harnesses, fuse box layouts, component locations, and diagnostic procedures for all electrical systems, including lighting, power windows, central locking, instrument cluster, and engine management. Bodywork And Chassis Repair: Includes procedures for body panel replacement, structural repairs, corrosion protection, and interior trim removal/installation. Procedures Included Procedures Included: Routine maintenance, scheduled servicing, troubleshooting, diagnostics, component removal and installation, major repair procedures, component overhaul (engine, gearbox), electrical fault finding, body repair, safety system checks, pre-delivery inspection protocols. Troubleshooting Procedures: Detailed fault-finding charts and diagnostic trees for common and uncommon issues, categorized by symptom and system. Suspension And Steering Alignment: Detailed specifications for wheel alignment (caster, camber, toe), suspension component replacement, and steering system adjustments. Technical Depth Technical Depth: Deep technical depth, designed for professional technicians. Covers everything from basic adjustments to complete engine and gearbox rebuilds. Includes detailed diagnostic flowcharts and specifications. Engine Rebuild Procedures: In-depth instructions for complete engine rebuilds, including cylinder head removal and inspection, piston and connecting rod installation, crankshaft installation, bearing clearances, and valve train setup. Diagnostics And Troubleshooting Depth: Advanced diagnostic techniques for identifying intermittent faults, electrical issues, and mechanical problems using specialized tools and procedures outlined in the manual. 📊 Manual Specifications File Format File Format: PDF (Portable Document Format) Searchability: Likely searchable text within the PDF, allowing for quick access to specific topics. Print Quality: As a factory manual PDF, it should support high-quality printing for workshop use, including diagrams and illustrations. File Size Estimation: Likely a substantial file size due to the comprehensive nature and inclusion of diagrams and illustrations, potentially ranging from 100MB to 500MB+. Binding Type Binding Type: N/A (Digital Format) Paper Type Paper Type: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Type: Rover K Series Inline-4 Displacement: 1.8 Liters (1796 cc) Engine Configuration: DOHC (Double Overhead Camshaft), 16 Valves Performance Horsepower Mg Zr 160: Approximately 160 PS (158 bhp; 118 kW) - specific output may vary slightly by model year. Torque Mg Zr 160: Approximately 165 Nm (122 lb-ft) - specific output may vary slightly by model year. Fuel System Fuel Injection: Multi-point Fuel Injection (MPI) - specific details on ECU and injection strategy will be in the manual. Cooling System Cooling Type: Liquid-cooled, pressurized system. Engine Management ECU Type: Likely Lucas/Rover ECU, specific part numbers and details in manual. Engine Diagnostics: Information on OBD-II (On-Board Diagnostics) compliance, common diagnostic trouble codes (DTCs), and procedures for reading and clearing codes using diagnostic tools. 🔧 Transmission Standard Transmission Type: Manual Transmission (likely 5-speed Getrag or similar Rover-derived unit for the 160 model). Optional Transmission Type Optional: Automatic transmission may have been available on some Rover 25 variants, but likely not standard on the MG ZR 160. Features Gearbox Overhaul: Includes a dedicated Gearbox Overhaul Manual, indicating detailed procedures for gearbox repair and rebuilding. Fluid Specifications Gearbox Oil Type: Specific manual gearbox oil specification (e.g., API GL4 or GL5, viscosity...