Rover 200 Rover 25 Series 1999-2005 Service Repair Workshop Manual Download Pdf
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🏷️ Basic Information Identification Make: Rover Model: 200 / 25 Series Years Covered: 1999-2005 Codes Platform Codes: R8 (Rover 200 Series - early part of range), Coventry (Rover 25 Series) 👋 Introduction Market Position Target Audience: Rover 200/25 owners, independent garages, DIY mechanics Competitive Analysis Value Proposition: Comprehensive, factory-level repair information at a fraction of the cost of official manufacturer manuals, lifetime access Key Features Visual Aid: Hundreds of detailed photos and diagrams Instruction Style: Step-by-step instructions Content Quality: Professional grade, as used by mechanics 📋 Manual Details Coverage Areas Primary Coverage: Mechanical, Electrical, Bodywork, Troubleshooting, Diagnostics, Maintenance, Repair Secondary Coverage: Vehicle specifications, wiring diagrams, torque settings, special tools Page Count Estimated Pages: Hundreds (specific count not provided, but implied to be comprehensive) Manual Type Type: Factory Service Repair Workshop Manual Language Language: English Format Format: PDF (Downloadable) 📖 Manual Coverage Systems Covered Powertrain: Engine mechanical, engine management, fuel system, cooling system, exhaust system, transmission (manual and automatic), clutch, drivetrain Chassis: Suspension (front and rear), steering system, brakes (front and rear, ABS), wheels and tires Electrical: Battery, charging system, ignition system, lighting, instruments, warning indicators, engine control module (ECM) wiring, body control module (BCM) wiring, infotainment wiring, power windows, central locking, security systems Body: Body construction, exterior panels, interior trim, seats, doors, windows, glass, bumpers, paint and corrosion protection Procedures Included Maintenance: Scheduled maintenance checks, oil and filter changes, fluid level checks and top-ups, spark plug replacement, air filter replacement, brake fluid changes, coolant changes Repair: Engine rebuilds, transmission overhaul, brake caliper replacement, suspension component replacement, steering rack repair, electrical component diagnosis and replacement, body panel repair and replacement Troubleshooting: Diagnostic flowcharts for common symptoms (e.g., engine not starting, poor performance, brake issues, electrical faults) Technical Depth Depth: Comprehensive, suitable for professional mechanics and advanced DIY enthusiasts Detail Level: Step-by-step instructions, detailed photos, exploded diagrams, torque specifications, wiring schematics 📊 Manual Specifications File Format Compatibility: Windows and MAC compatible Licensing: Lifetime usage, no expiry date, no renewal fees Print Quality Printability: Printable (single pages or entire manual) Binding Type Binding: N/A (Digital download) Paper Type Paper Type: N/A (Digital download) Access Access: Instant download Device Compatibility: Computer, tablet, smartphone Installation: No installation required, viewable with standard PDF reader ⚙️ Engine Specifications Primary Engine Engine Codes: K-Series (e.g., K14, K16, KV6), L-Series Diesel Engine Variant 1 4L Displacement 1 4: 1396 cc (1.4 Litre) Power 1 4: Approx. 75-105 PS (depending on exact tune and model variant) Torque 1 4: Approx. 115-130 Nm (depending on exact tune and model variant) Engine Variant 1 6L Displacement 1 6: 1589 cc (1.6 Litre) Power 1 6: Approx. 82-110 PS (depending on exact tune and model variant) Torque 1 6: Approx. 130-145 Nm (depending on exact tune and model variant) Engine Variant 2 0L Vvc Displacement 2 0 Vvc: 1994 cc (2.0 Litre VVC) Power 2 0 Vvc: Approx. 145-160 PS Torque 2 0 Vvc: Approx. 180-195 Nm Engine Variant Diesel Displacement Diesel: 1905 cc (2.0 Litre L-Series Diesel) Power Diesel: Approx. 75-82 PS Torque Diesel: Approx. 135-145 Nm Fuel System Fuel Injection: Multi-point fuel injection (MPI) for petrol engines Diesel Fuel System: Direct injection (rotary pump or common rail depending on exact L-Series variant) Performance Fuel Type: Unleaded Petrol (95 RON recommended), Diesel 🔧 Transmission Standard Transmission Manual Gearbox: 5-speed manual (PG1 gearbox family for most petrol variants) Optional Transmission Automatic Gearbox: 4-speed automatic (often JATCO or equivalent) Features Clutch Type: Hydraulically operated dry single plate clutch 📐 Dimensions Exterior Body Styles: 3-door hatchback, 5-door hatchback, 4-door saloon (Rover 200), 5-door hatchback (Rover 25) Length: Varies by body style, approx. 3900-4300 mm Width: Approx. 1600-1700 mm Height: Approx. 1350-1400 mm Weights Kerb Weight: Approx. 1050-1250 kg (depending on engine and equipment) 🛡️ Safety Features Ratings Euro Ncap: Mixed, generally received poor to average ratings for its era. Consult specific NCAP reports for precise scores. Active Features ABS: Optional on many models, standard on higher trims/later models Passive Features Airbags: Driver airbag standard, passenger airbag optional/standard on higher trims Seatbelts: Pyrotechnic pre-tensioners for front seatbelts 💡 Technology Features Infotainment Radio System: Factory fitted radio/cassette or CD player with AM/FM tuner. Optional CD changer. Speaker System: Basic 4-speaker system, with optional additional speakers Driver Assistance Parking Sensors: Optional on later models Connectivity Auxiliary Input: Rarely fitted as standard, often an aftermarket addition or via an adapter. 🔧 Maintenance Service Intervals Oil Change Interval: Typically 10,000 miles or 12 months, whichever comes first (check specific year/engine) Timing Belt Interval: Critical for K-Series engines. Typically 60,000 miles or 4-5 years. Failure can lead to catastrophic engine damage. Fluid Specifications Engine Oil Type: API SG/SH or ACEA A2-96. Viscosity: 5W-30, 10W-40, 15W-50 depending on climate. Consult manual for exact specification. Coolant Type: Ethylene glycol based, long-life coolant. Typically a 50/50 mix with distilled water. Rover specific coolant often...
Suspension (front and rear), steering system, brakes (front and rear, ABS), wheels and tires
Electrical:
Battery, charging system, ignition system, lighting, instruments, warning indicators, engine control module (ECM) wiring, body control module (BCM) wiring, infotainment wiring, power windows, central locking, security systems
Body:
Body construction, exterior panels, interior trim, seats, doors, windows, glass, bumpers, paint and corrosion protection
Procedures Included
Maintenance:
Scheduled maintenance checks, oil and filter changes, fluid level checks and top-ups, spark plug replacement, air filter replacement, brake fluid changes, coolant changes
Repair:
Engine rebuilds, transmission overhaul, brake caliper replacement, suspension component replacement, steering rack repair, electrical component diagnosis and replacement, body panel repair and replacement
Troubleshooting:
Diagnostic flowcharts for common symptoms (e.g., engine not starting, poor performance, brake issues, electrical faults)
Technical Depth
Depth:
Comprehensive, suitable for professional mechanics and advanced DIY enthusiasts
Approx. 1050-1250 kg (depending on engine and equipment)
🛡️ Safety Features
Ratings
Euro Ncap:
Mixed, generally received poor to average ratings for its era. Consult specific NCAP reports for precise scores.
Active Features
ABS:
Optional on many models, standard on higher trims/later models
Passive Features
Airbags:
Driver airbag standard, passenger airbag optional/standard on higher trims
Seatbelts:
Pyrotechnic pre-tensioners for front seatbelts
💡 Technology Features
Infotainment
Radio System:
Factory fitted radio/cassette or CD player with AM/FM tuner. Optional CD changer.
Speaker System:
Basic 4-speaker system, with optional additional speakers
Driver Assistance
Parking Sensors:
Optional on later models
Connectivity
Auxiliary Input:
Rarely fitted as standard, often an aftermarket addition or via an adapter.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically 10,000 miles or 12 months, whichever comes first (check specific year/engine)
Timing Belt Interval:
Critical for K-Series engines. Typically 60,000 miles or 4-5 years. Failure can lead to catastrophic engine damage.
Fluid Specifications
Engine Oil Type:
API SG/SH or ACEA A2-96. Viscosity: 5W-30, 10W-40, 15W-50 depending on climate. Consult manual for exact specification.
Coolant Type:
Ethylene glycol based, long-life coolant. Typically a 50/50 mix with distilled water. Rover specific coolant often recommended.
Brake Fluid Type:
DOT 4
Transmission Fluid Manual:
GL-4 75W/90 or 80W/90 gear oil
Transmission Fluid Automatic:
Dexron III (or equivalent specified by manufacturer)
Known Issues
K Series Hgf:
Head Gasket Failure (HGF) is a well-documented and common issue, especially on earlier K-Series engines. Early detection and repair are crucial.
Cooling System Faults:
Perished hoses, faulty thermostats, and coolant leaks can contribute to HGF. The 'flow restrictor' on some K-series engines can also cause issues.
Electrical Gremlins:
Various minor electrical faults can occur, often related to poor earth connections or aging wiring looms.
📚 Vehicle History
Brand Heritage
Manufacturer:
Rover Group (originally British Leyland)
Model Evolution
Rover 200 Series Origin:
Successor to the Austin Maestro/Montego era, based on the Honda Civic/Logo platform sharing (early R8 generation). Later facelifted into the Rover 25.
Rover 25 Series Launch:
Launched in 1999 as a significant facelift of the Rover 200 Series, featuring updated styling, interior, and some mechanical revisions. Positioned as a compact family car.
Production
Production Period:
1999-2005 (for the Rover 25 Series, with the Rover 200 Series overlapping from 1995-1999)
Manufacturing Location:
Longbridge, Birmingham, UK
🏆 Awards & Recognition
Recognitions
Market Perception:
Considered a solid if unexciting compact car of its era. Known for its comfortable ride and handling, particularly the chassis derived from Honda. The brand faced financial difficulties during its production run.
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