🏷️ Basic Information Identification Make: Rover / MG Model: MG ZR 160 / Rover 25 Product Name: Rover MG ZR 160 Rover 25 Service Repair Workshop Manual PDF Product Description: Complete Factory Service Repair Workshop Manual for Rover MG ZR 160 and Rover 25. Available for instant download. Codes Engine Codes Implied: K16 (likely 1.8L VVC for 160 model) 👋 Introduction Market Position Market Position Rover 25: The Rover 25 was positioned as a compact family hatchback, offering practicality and comfort in the competitive supermini segment. It succeeded the Rover 200 series. Market Position Mg Zr 160: The MG ZR 160 was the performance-oriented variant of the Rover 25, targeting a younger demographic seeking a sporty driving experience with a distinctive aesthetic. It competed with other hot hatchbacks of its era. Competitive Analysis Competitors Rover 25: Ford Fiesta, Vauxhall Corsa, Volkswagen Polo, Peugeot 206, Renault Clio. Competitors Mg Zr 160: Ford Fiesta ST, Vauxhall Corsa GSi/VXR, Peugeot 206 GTi, Renault Clio Sport (RS). Key Features Key Features Manual: Factory-level detail, hundreds of pages, detailed photos & diagrams, step-by-step instructions, exploded diagrams, comprehensive coverage. 📋 Manual Details Coverage Areas Manual Scope: All repairs, servicing, and troubleshooting procedures. Body Repair: Includes procedures for dent repair, panel replacement, welding, and corrosion prevention. Page Count Page Count Estimate: Hundreds of pages (specific count not provided, but described as very detailed). Manual Type Manual Type: Factory Service Repair Workshop Manual Language Language: English (implied by product description and professional terminology) Format Format: PDF (Digital Download) Searchability: PDF format typically allows for text searching of keywords within the manual. 📖 Manual Coverage Systems Covered Engine Systems: Engine mechanical, cooling system, fuel system, ignition system, exhaust system, lubrication system, engine management (ECU), emissions control. Transmission Systems: Manual transmission (gearbox, clutch, linkage), automatic transmission (if applicable), drive shafts, differential. Chassis Systems: Suspension (front and rear), steering system, braking system (including ABS if equipped), wheels and tires. Electrical Systems: Battery, charging system, starting system, lighting system, instrument cluster, wiring diagrams, fuses and relays, body electricals (windows, locks, mirrors), audio system, climate control. Body And Trim: Body panels, doors, hinges, latches, interior trim, seating, glass, sunroof (if equipped), exterior trim, bumpers. Engine Management Diagnostics: Detailed information on engine control unit (ECU) functions, sensor testing, and diagnostic trouble codes (DTCs) if applicable for the era. Climate Control System: Operation and repair of heating, ventilation, and air conditioning (HVAC) systems. Procedures Included Maintenance Procedures: Scheduled maintenance, oil changes, filter replacements, fluid checks and top-ups, spark plug replacement, belt replacement, brake pad replacement. Repair Procedures: Engine overhaul, transmission rebuild, clutch replacement, brake caliper overhaul, suspension component replacement, starter motor replacement, alternator replacement, bodywork repair. Troubleshooting Procedures: Diagnostic procedures for common faults, fault code interpretation (if applicable), step-by-step troubleshooting guides for various systems. Diagnostic Procedures: Component testing, fault finding charts, wiring diagrams for electrical system diagnostics. Performance Tuning Guidance: While primarily a repair manual, it will contain specifications for stock performance that can serve as a baseline for tuning. The VVC system on the 160 model will have specific maintenance and operational details. Technical Depth Technical Depth: Comprehensive, from basic maintenance to in-depth engine and transmission rebuilds, including detailed diagnostics and component testing. Component Rebuilds: Detailed procedures for rebuilding major components like engines, transmissions, brake calipers, and steering racks. Wiring Diagrams: Comprehensive, color-coded wiring diagrams for all electrical circuits, aiding in diagnosis and repair. 📊 Manual Specifications File Format File Format: PDF Print Quality Print Quality: Printable (single pages or entire manual), high-resolution images and diagrams. Binding Type Binding Type: N/A (Digital download, no physical binding) Paper Type Paper Type: N/A (Digital download, no physical paper) Compatibility Device Compatibility: Compatible with all Windows and MAC computers, tablets, and smartphones. Licensing Usage License: Lifetime usage, no expiry dates, no renewal fees. ⚙️ Engine Specifications Primary Engine Engine Type Mg Zr 160: Naturally Aspirated Inline-4, 16-valve, DOHC (likely K-Series VVC) Performance Displacement Mg Zr 160: 1.8 Liters (1796 cc) Horsepower Mg Zr 160: Approx. 160 PS (158 bhp / 118 kW) @ 7000 rpm (VVC variant) Torque Mg Zr 160: Approx. 175 Nm (129 lb-ft) @ 4750 rpm (VVC variant) Variable Valve Control: MG ZR 160 features the Variable Valve Control (VVC) system for enhanced power and torque delivery across the rev range. Fuel System Fuel Delivery System: Multi-point Fuel Injection (MPI) Engine Management Engine Management System: ECU controlled ignition and fuel injection. 🔧 Transmission Standard Standard Transmission Type: 5-speed Manual Transmission Optional Optional Transmission Type: 4-speed Automatic Transmission (available on some Rover 25 variants, potentially some ZR models) Features Clutch Type: Hydraulically operated single dry plate clutch. 📐 Dimensions Exterior Body Styles: 3-door hatchback, 5-door hatchback Weights Curb Weight Mg Zr 160 Approx: Around 1150 kg (2535 lbs) 🛡️ Safety Features Ratings Euro Ncap Rating Rover 25: 3 stars (for original Rover 25, facelift models...