Rover 45 & MG ZS 1999-2005 Workshop Service Repair Manual
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🏷️ Basic Information
Identification
Make:
MG
Model:
ZS
Year:
1999-2005
Codes
Rover Platform:
R30 (derived from Honda Civic EJ/EK platform)
👋 Introduction
Market Position
Segment:
Compact family car / Sports saloon (MG ZS)
Competitive Analysis
Key Competitors:
Ford Focus, Volkswagen Golf, Vauxhall Astra, Peugeot 306/307, Renault Megane
Key Features
Manual Value Proposition:
Provides official factory-level repair and maintenance information for DIY enthusiasts and professional mechanics.
Visual Aid Quality:
Includes hundreds of photos, illustrations, and detailed drawings.
📋 Manual Details
Coverage Areas
Geographic Coverage:
Primarily Europe and UK markets
Model Variants:
All styles and configurations of Rover 45 and MG ZS
Page Count
Estimated Page Count:
Hundreds of pages (specific number not provided, but implies comprehensive)
Manual Type
Type:
Workshop Service Repair Manual
Language
Language:
English
Format
Delivery Format:
Digital Download (PDF)
📖 Manual Coverage
Systems Covered
Powertrain:
Engine, transmission, fuel system, exhaust system
Chassis:
Suspension, steering, brakes, wheels, tires
Electrical:
Wiring diagrams, lighting, ignition, starting, charging, accessories, diagnostics
Body:
Bodywork, interior trim, doors, windows, seats, safety features
Procedures Included
Maintenance:
Routine checks, fluid changes, filter replacements, scheduled servicing
Repair:
Step-by-step repair instructions for all major components and systems
Troubleshooting:
Diagnostic procedures for identifying and resolving common faults and problems
Technical Depth
Depth:
Comprehensive from basic maintenance to complete disassembly and rebuild
Detail Level:
Detailed substeps, notes, cautions, and warnings
📊 Manual Specifications
File Format
Format:
PDF
Print Quality
Printability:
Printable without restrictions
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper:
N/A (Digital Download)
Software Requirements
Reader:
Adobe PDF Reader
⚙️ Engine Specifications
Primary Engine
Rover 45 Engine Options:
1.4L K-series (KV6), 1.6L K-series (KV6), 1.8L K-series (KV6), 2.0L L-series (diesel)
Mg Zs Engine Options:
1.6L K-series, 1.8L K-series, 2.5L KV6
Performance
K Series 1.8L Power:
Approx. 117 bhp (VVC option offered higher output)
Mg Zs 2.5L Kv6 Power:
Approx. 175 bhp
Fuel System
K Series Fuel Injection:
Multi-point fuel injection (MPI)
L Series Diesel Fuel System:
Direct injection, potentially with turbocharging
🔧 Transmission
Standard
Rover 45 Transmission:
5-speed manual
Optional
Rover 45 Automatic:
4-speed automatic (e.g., JATCO)
Mg Zs Transmission:
5-speed manual, 5-speed manual (for VVC models)
Features
Performance Manual Gearing:
Close-ratio gearing available on performance variants.
📐 Dimensions
Exterior
Body Styles:
4-door saloon, 5-door hatchback
Wheelbase:
Approx. 2550 mm
Weights
Curb Weight Range:
Approx. 1150 kg - 1350 kg depending on engine and specification
🛡️ Safety Features
Ratings
Euro Ncap Rating:
3 stars (for related models, specific rating for this generation may vary)
Active Features
Braking System:
ABS, EBD (Electronic Brakeforce Distribution)
Passive Features
Airbags:
Driver and front passenger airbags (side airbags optional on some models)
Seatbelts:
Pre-tensioning seatbelts with force limiters
💡 Technology Features
Infotainment
Audio System:
Factory fitted radio/cassette or CD player, often with steering wheel controls on higher trims.
Driver Assistance
Cruise Control:
Optional on higher specification models.
Connectivity
Early Bluetooth:
Limited to aftermarket or very late model options.
🔧 Maintenance
Service Intervals
Oil Change Interval Petrol:
Typically 9,000 - 12,000 miles or 12 months, whichever comes first.
Cambelt Replacement Kseries:
Crucial: 60,000 miles or 4 years (failure of K-series cambelt can cause severe engine damage).
Fluid Specifications
Engine Oil Spec:
API SG/SH/SJ or ACEA A2-96/A3-96, viscosity 10W/40 or 5W/40 (refer to manual for precise grade based on temperature).
Coolant Spec:
Ethylene glycol-based antifreeze, mixed 50/50 with distilled water (e.g., Rover Anti-Freeze)
Brake Fluid Spec:
DOT 4
Known Issues
K Series Hgf:
Head Gasket Failure (HGF) is a well-documented and critical issue on K-series engines, requiring skilled repair.
Cooling System:
Perished hoses, failing water pumps, and thermostat issues are common.
Electronics:
Lucas 10AS alarm system can be problematic; Body Control Module (BCM) issues.
📚 Vehicle History
Brand Heritage
Rover Legacy:
Continued the legacy of Rover's compact executive cars, building on the Rover 400/45 series.
Model Evolution
Rover 45 Origin:
Facelift and rebranding of the Rover 400 (RD) series.
Mg Zs Development:
Sporting derivative of the Rover 45, offering enhanced performance and styling.
Production
Production Period:
1999 - 2005
Manufacturing Plant:
Longbridge, Birmingham, UK
🏆 Awards & Recognition
Recognitions
Mg Zs Reputation:
The MG ZS was generally well-received for its handling and sporty feel, often praised in contemporary reviews.
Rover 45 Positioning:
Positioned as a comfortable and refined compact executive car.