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Rover 100 1980-1990 Workshop Repair Service Manual

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This manual covers the Rover 100 Series, also commonly known as the Rover Metro, produced from 1980 through 1990. Evolving from the original Austin/Morris Metro, this compact supermini represents Rover's effort to modernize and refine a well-established platform, derived from the original Mini's underpinnings. It features a transverse, front-wheel-drive configuration powered by the A-Series engine, available in 1.0L and 1.3L displacements, and utilizes the distinctive Hydragas suspension system. Designed for urban mobility and everyday commuting, the Rover 100 Series aimed to offer a balance of practicality and a more refined driving experience within its segment, competing with models like the Ford Fiesta and Peugeot 205. This comprehensive workshop repair and service manual provides detailed guidance for owners, mechanics, and technicians. It covers essential maintenance procedures, including routine servicing, fluid checks, and component replacements, along with in-depth troubleshooting and repair instructions for all major vehicle systems. Sections dedicated to the engine, transmission, suspension (including the Hydragas system), brakes, steering, and electrical components offer step-by-step procedures for diagnostics, overhaul, and reassembly. Additionally, the manual includes technical specifications, wiring diagrams, and information on bodywork, ensuring thorough support for maintaining and restoring the Rover 100 Series. 🏷️ 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...
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Rover 100 1980-1990 Workshop Repair Service ManualRover 100 1980-1990 Workshop Repair Service ManualRover 100 1980-1990 Workshop Repair Service ManualRover 100 1980-1990 Workshop Repair Service Manual
This manual covers the Rover 100 Series, also commonly known as the Rover Metro, produced from 1980 through 1990. Evolving from the original Austin/Morris Metro, this compact supermini represents Rover's effort to modernize and refine a well-established platform, derived from the original Mini's underpinnings. It features a transverse, front-wheel-drive configuration powered by the A-Series engine, available in 1.0L and 1.3L displacements, and utilizes the distinctive Hydragas suspension system. Designed for urban mobility and everyday commuting, the Rover 100 Series aimed to offer a balance of practicality and a more refined driving experience within its segment, competing with models like the Ford Fiesta and Peugeot 205. This comprehensive workshop repair and service manual provides detailed guidance for owners, mechanics, and technicians. It covers essential maintenance procedures, including routine servicing, fluid checks, and component replacements, along with in-depth troubleshooting and repair instructions for all major vehicle systems. Sections dedicated to the engine, transmission, suspension (including the Hydragas system), brakes, steering, and electrical components offer step-by-step procedures for diagnostics, overhaul, and reassembly. Additionally, the manual includes technical specifications, wiring diagrams, and information on bodywork, ensuring thorough support for maintaining and restoring the Rover 100 Series.
🏷️ 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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