33412935 mini cooper service manual 2002 2006 complete index (1)
TRANSCRIPT
INDEX 1
WARNING
Your common sense, good judgement, and general alertness are crucial to safe and successful service work. Before attempting any work on your MINI, be sure to read 001 General Warnings and Cautions and the copyright page at the front of the manual. Review these warnings and cautions each time you prepare to work on your MINI. Please also read any warnings and cautions that accompany the procedures in the manual.
A
Acronyms, commonly used 600-3
ABS (antilock brake system)see Brakes
A/Cblower 640-13
resistor / final stage 640-15compressor 640-20, Appendix (13-38)condenser 640-23control panel 640-7description (IHKS, IHKA) 640-3evaporator 640-28evaporator temperature sensor 640-9
expansion valve 640-25interior temperature sensor 640-8pressure sensor 640-27receiver / drier 640-24servo motors 640-12solar sensor 640-10ventilation microfilter 020-26vents 640-12see also Heating
Accelerator pedal position sensor (PWG)
130-7, 130-12, Appendix (13-41)
Accessory beltsee Drive belt
Activated charcoal canister160-3removing and installing 160-15
Air conditioningsee A/Csee also Heating
Air distribution control servo motorsee A/C, servo motors
Air filterhousing, removing / installing
Cooper 130-29Cooper S 130-30JCW 020-16
replacing 020-15
Airbag system (SRS)400-3control module (MRS) 721-6deactivation 721-5driver airbag 721-7head protection airbag 721-8operation 721-4passenger airbag 721-8side-impact crash sensor 721-7triggered 721-5
Alarm see Anti-theft alarm
Alignmentsee Wheel alignment
Alternator (generator)charging system
checking 121-13, Appendix (13-46)quick check 121-12troubleshooting 121-3, 121-12
Cooper 121-15Cooper S 121-16
Amplifiersee Sound system, DSP amplifier
Antenna650-5see also EWS (electronic immobilization)
Anti-theft alarm (DWA)component replacement 515-15siren 515-18tilt sensor 515-16ultrasound module 515-16see also General Module (BC1)
Antifreeze (engine coolant)see Maintenancesee also Cooling system
Antilock brake system (ABS)see Brakes
ASCsee Brakes
ATF (automatic transmission fluid)see Automatic transmission fluidsee also Cooling system
Automatic headlight leveling (LWR)see Headlights, vertical aim control
Automatic seat belt tensionersee Seat belt
Automatic transmissioncontrol module
agitronic 240-19, Appendix (24-12)CVT 240-11 Appendix (24-3)electrical pinouts Appendix (24-17)
CVT switch 240-9drive axle seals
agitronic 240-16CVT 240-10
fluid service 240-2identification 200-3, inhibitor switch Appendix (24-16)oil temperature sensor Appendix (13-122)
removal / installation agitronic 240-22CVT 240-20
serviceagitronic 240-16CVT 240-9
see also Back-up light switchsee also Gearshift
Axle jointsee Drive axle
B
Back-up light switchautomatic transmission
Agitronic (Aisin) 240-16CVT 240-9
manual transmission 230-5
Batterybox (Cooper) 121-10capacity 121-5charger Appendix (01-19)checking, cleaning 020-16current draw Appendix (01-31)electrolyte specific gravity 121-7maintenance 121-6removing / installing
Cooper 121-9Cooper S 121-11
safety terminal replacement 121-11testing 121-7
hydrometer test 121-7load voltage test 121-8open-circuit voltage test 121-8
troubleshooting 121-3
Bearing, wheelsee Front suspension see also Rear suspension
Beltsee Maintenance, drive belt
Blade, wipersee Wipers and washers
Blowersee A/C
2 INDEX
Bodydimensions 400-2gaps, convertible 541-13interior features 400-5safety and security 400-3
Body control modulesee General Module (BC1)
Body side skirtsee Exterior trim
Bonnetsee Engine hood
Brake fluidbleeding 020-18, 340-11
Brake fluid hydraulic pressure sensor340-8
Brake light switch612-6
BrakesABS / ASC / DSC 300-5ABS 340-4
component replacement 340-32ASC 340-6ASC / DSC switch 340-8bleeding brakes 340-11brake booster 340-23brake pads, calipers and rotors 340-13
description 300-4DSC 340-7electronic brake & stability 300-6light switch
see Switchesmaster cylinder 340-21parking brake 340-28troubleshooting 340-9see also Brake light switchsee also Switches, fascia switch module
Bulbssee Lights
Bumperfront
carrier 510-7cover 510-5
rear carrier 510-11cover 510-11
Bus CAN-bus 600-7, Appendix (61-10)Diagnosis Appendix (61-17)D-bus 600-9, Appendix (61-15)K-bus 600-8, Appendix (61-6)system 600-6
C
Camber320-22
Camshaft116-6
Camshaft position sensorsee DME (digital motor electronics)
Camshaft timing chain117-16housing cover
Cooper 117-7Cooper S 117-12
Caster320-22
Catalytic converterand oxygen sensor 020-31, 180-6monitoring OBD-4, Appendix (OBD-13)
Cautions 001-2
CD changersee Sound system
Center brake lightremoving 630-9
Center consolefront 250-3, 513-3rear 513-4
Central locking control 515-3switch
see Switches, fascia switch module
see also General module (BC1)
Chainsee Camshaft timing chain
Charcoal canister, activated160-3removing and installing 160-15
Charging systemsee Alternator (generator)
Clocksee Instruments
Clutchfluid
bleeding and flushing 210-3see also Maintenance
hydraulics 210-3mechanical 210-7release bearing 210-12switch 612-6
Codes, faultOBD-7
Coilsee Ignition system
Coil springsee Front suspension, struts / springssee also Rear suspension, shock absorbers / springs
Component locationstable ECL-3
Compression test113-3, Appendix (01-37)
Compressorsee A/Csee Super charger
Condensersee A/C
Constant velocity (CV) jointsee Drive axle
Continuously variable transmission (CVT)
see Automatic transmission, CVT
Control armsee Front suspensionsee also Rear suspension, suspension arms
Convertible topadjustments 541-14components 541-9electronic components 541-11emergency operation 541-4hydraulic fluid 541-6hydraulic system 541-10roll over bar 541-10operation 541-2sensors and switches 541-9
Coolant (antifreeze)020-19see also Cooling system
Coolant pumpsee Cooling system
Cooling systemantifreeze 020-19automatic transmission (CVT) fluid cooler 170-13
checking 020-19coolant pump
Cooper 170-9Cooper S 170-10
cooling fan (electric) 170-8draining and filling 170-7engine oil cooler (Cooper S) 170-11expansion tank 170-15
INDEX 3
WARNING
Your common sense, good judgement, and general alertness are crucial to safe and successful service work. Before attempting any work on your MINI, be sure to read 001 General Warnings and Cautions and the copyright page at the front of the manual. Review these warnings and cautions each time you prepare to work on your MINI. Please also read any warnings and cautions that accompany the procedures in the manual.
Cooling system (cont.)inspection 170-5overview 170-2radiator 170-14service 020-19thermostat 170-8, Appendix (OBD-16)troubleshooting 170-5
Crankshaft sealfront 119-6rear 119-7
Crankshaft position sensorsee DME (digital motor electronics)
Crash sensorsee Airbag system (SRS), side-impact crash sensor
Cruise control130-11clutch switch 130-18, 612-6
CV jointsee Maintenancesee also Drive axle
CVT see Automatic transmission, CVT
Cylinder head100-6diagnostic testing 113-3leak test 116-14removing / installing
Cooper 113-11Cooper S 113-28
valvessee Valvetrain
D
Dashboard513-7
Deck lidsee Rear hatch
DLC (data link connector)130-25, OBD-3, Appendix (13-99, OBD-3)
DME (digital motor electronics)adaptation Appendix (01-39)camshaft position sensor 120-11, Appendix (13-48)
crankshaft position sensor 120-10, Appendix (13-52)
description (EMS2000) 130-4inputs 130-11intake air temp sensor (IAT) Appendix (13-84)
main relay 130-44, Appendix (13-94)oxygen sensor
function 130-9, 130-17removing / installing 180-5testing Appendix (13-100)OBD II monitor Appendix (OBD-12)
outputs 130-20principles of operation 130-6sensors
MAP sensor (Cooper S) 130-41, Appendix (113-18)
T-MAP sensor (Cooper) 130-41, Appendix (113-16)
T-MAP sensor (Cooper S) 130-42troubleshooting 130-26
DMTL (detection module tank leak)see Evaporative control system
Drive belt, engine accessory020-20
Dome lightsee Lights, interior
Doordoor check 411-2hinge adjustment 411-3removing / installing 411-2panel 411-4window
see Door window
Door glasssee Door window
Door lockhandle
inside 515-9outside 515-8
latch 516-6striker 515-8
Door windowdrop down feature 512-3
adjusting 512-5glass 512-4initializing 512-4motor / regulator 512-7switches 612-7see also General Module (BC1)
Drive axleCV joint 310-7
outer 310-26CV joint boot 310-28description 300-2, 310-7removing / installing 310-23seal
see Manual transmissionsee also Automatic transmission (CVT)
Drive beltsee Maintenance, engine accessory belt
Driveability troubleshootingmain grounds 100-12system voltage 100-11
Driveaway protectionsee EWS (electronic immobilization)
DSCsee Dynamic stability control
DTC (diagnostic trouble code)Code lookup Appendix (13-5)OBD-7, Appendix (03-17)
DVOM (digital-volt ohm meter)Appendix (01-21)
DWAsee Anti-theft alarm
Dynamic stability control (DSC)300-5DSC motion sensor 340-36DSC steering angle sensor 340-37
E
ECM see Engine control module (ECM)
ECT see Engine coolant temperature (ECT) sensor
EDR see Throttle control, electronic (EDR)
EHPS (electrohydraulic power steering)
see Steering
Electric cooling fan see Cooling system, cooling fan
Electrical switchessee Switches
4 INDEX
Electrical systemacronyms 600-3bus system 600-6component location table ECL-3component photos ECL-21engine 121-2troubleshooting 600-9wire color codes ELE-6wiring diagrams ELE-11
Electrical wiring diagramsELE-11
Electronic immobilizationsee EWS (electronic immobilization)
Emergencies020-10convertible top closing 541-4fuel door release ECL-32rear hatch lock release 515-10sunroof closing 540-2
Emergency brakesee Brakes, parking brake
Emergency flashersee Switches, hazard warning
EMS2000see DME (digital engine electronics)
Enginecompression test 113-3crankshaft seals 119-6cylinder leak-down test 113-6diagnostic testing 113-3driveability troubleshooting 100-11engine management 130-4ground connections 100-12, ECL-18identifying features 100-3on-board diagnostics OBD-2removal / installation
Cooper 110-4Cooper S 110-16
specifications 100-2see also Cooling systemsee also Crankshaft sealsee also DME (digital motor electronics)
see also Engine control module (ECM)
see also Engine coolant temperature (ECT) sensor
see also Exhaust systemsee also Fuel injectionsee also Ignition systemsee also Maintenancesee also Throttle housing, electronic (EDR)
Engine control module (ECM)accessing 130-44description 130-5, Appendix (13-66)grounds Appendix (13-68)pin assignments 130-45, Appendix (13-125)
power supply Appendix (13-69)
Engine coolant temperature (ECT) sensor
description Appendix (13-71)replacing
Cooper 130-42Cooper S 130-45
Engine cooling fansee Cooling system, cooling fan (electric)
Engine hoodaligning 310-5grill 410-7latch
adjusting 410-6removing / installing 410-7
raising to service position 410-3removing / installing 410-4scoop trim (Cooper S) 410-8
Engine troubleshooting100-12
Evaporative control systemdescription 160-3EVAP monitor Appendix (OBD-9)EVAP purging Appendix (13-77)leak detection unit (LDP / DMTL)160-15, Appendix (13-109)
leak test Appendix (13-75)see also Activated charcoal canisterpurge solenoid Appendix (13-77)
Evaporatorsee A/C
Exhaust manifoldsee Exhaust system
Exhaust systemback pressure Appendix (01-32)diagrams 180-6exhaust manifold 180-3oxygen sensors 180-5removing / installing 180-2see also Maintenance
Expansion tanksee Cooling system
Expansion valvesee A/C
Exterior lightssee Lightssee also Headlight
Exterior trimMINI emblem 510-12outside mirror 510-3side skirt 510-12
EWS (electronic immobilization)400-4, 515-15aligning with DME Appendix (65-12)control module 515-15electrical plan Appendix (65-17)ring antenna 515-16starting sequence Appendix (65-7)signal testing Appendix (13-79)
F
Fansee Cooling system
Fault codesOBD-7storage 120-4, 130-2, OBD-2
Fenderfront 410-2
Filterssee Maintenance
Final stagesee A/C, blower resistor / final stage
Firing ordersee Ignition system
Flat tire monitor 020-10intializing Appendix (36-10)warning light Appendix (36-8)wheel speed sensors Appendix (36-9)
see also Tire pressure warning
Fluids and lubricantssee Maintenance
Flywheel210-10
Foglightsee Lights
Front oil sealsee Crankshaft seal
Front suspensioncontrol arm 310-17description 300-2, 310-4ride height 300-6stabilizer bar 310-20struts / springs 310-8subframe 230-9, 310-15
attachment points 310-16wheel bearing 310-21see also Drive axlesee also Headlight, vertical aim controlsee also Maintenance
INDEX 5
WARNING
Your common sense, good judgement, and general alertness are crucial to safe and successful service work. Before attempting any work on your MINI, be sure to read 001 General Warnings and Cautions and the copyright page at the front of the manual. Review these warnings and cautions each time you prepare to work on your MINI. Please also read any warnings and cautions that accompany the procedures in the manual.
Headlightaim 630-3assembly 630-6halogen bulb 630-4vertical aim control
module (LWR) 630-4level sensor, front 310-9, 310-17level sensor, rear 330-13
xenon bulb 630-5control module 630-8
see also Switchessee also Wipers and washers
Heating description 640-4heater core 640-16heater core temperature sensor 640-9heating and A/C housing 640-17
Hoodsee Engine hood
I
Identification plates and labels020-8
Idle speed Appendix (13-61)
Ignition coil Appendix (13-86)
Ignition switch interlockshift interlock cable (CVT) 320-8
Ignition lock cylinder320-6, 612-4
Ignition switchsee Switches
Ignition systemcoil assembly 120-9, Appendix (13-86)
disabling 120-8firing order 120-8knock sensor 130-16
checking Appendix (13-91)replacing 120-12
oscilloscope diagrams 120-5spark plugs 020-28wire 120-9
IHKA640-3
IHKS 640-3
Inhibitor switchAppendix (24-16)
Fuel dooremergency release ECL-32
Fuel filter020-26location 160-7
Fuel injectionsee DME (digital motor electronics)see also Fuel injectorsee also Fuel pressure
Fuel injectorfuel rail and injectors 130-27, Appendix (13-81)
OBD monitoring Appendix (13-123, OBD-15)
Fuel level senderleft side 160-7right side 160-9see also Fuel pump
Fuel pressurepressure test
Cooper 160-5, Appendix (16-5)Cooper S 160-6, Appendix (16-5)
electrical circuit Appendix (16-18, 16-22)
volume test Appendix (16-8)see also Fuel pump
Fuel pump160-3inertia switch Appendix (16-17)removing / installing 160-7
Fuel railfuel rail and injectors 130-27
Fuel tankdraining 160-10filler pipe 160-14removing / installing 160-11see also Evaporative control system
Fuse locations ECL-13
FZV (keyless entry)515-3
G
Gas tanksee Fuel tank
Gearshiftautomatic transmission 250-7
shift interlock cable (CVT) 320-8shiftlock cable 250-12
dust boot 250-3knob 250-2manual transmission 250-5
Gearshift cable(s)automatic transmission (CVT) 250-10manual transmission 250-7
General Module (BC1)anti-theft alarm (DWA) control 515-4door lock control 515-3functions 400-6heating and A/C control 640-5lights control 630-2location 515-5window control 512-2wiper control 611-2
Generatorsee Alternator (generator)
Glove compartment513-6
Grillsee Engine hood
Groundslocations ECL-18main engine 100-12
H
Halogen headlightsee Headlight
Hand brakesee Brakes, parking brake
Handle, doorsee Door lock
Hatchsee Rear hatch
Hazard warning switch612-2
6 INDEX
Injectorsee Fuel injector
Input shaft sealsee Manual transmission, seals
Inspection see Maintenance
Instrumentscarrier 620-3clock 620-4cluster 620-2(IKE) self test Appendix (01-41)
Intake manifoldCooper 113-8Cooper S 113-24
Intercooler113-22
Interior lightssee Lights
Interior trim513-17
Interior ventilation microfilter020-26
J
Jack stands020-10
Jump starting020-12
K
Keyless entry (FZV)see FZV (keyless entry)
Keys400-4, 515-3programming Appendix (65-16)service Appendix (65-13)
Knock sensorsee Ignition system
L
Leak detection, fuel tanksee Evaporative control system
Leather upholsterysee Maintenance
LDP (leak detection pump)see Evaporative control system
Level sendersee Fuel level sender
License plate lightsee Lights
Lifting the car020-8
Lightsback-up light 630-9bulb applications 630-2center brake light 630-9foglight 630-10front turn signal 630-11interior lights 630-15license plate light 630-12side marker light 630-12taillight 630-12see also Headlight
Lockssee Central lockingsee also Door locksee also Rear hatch
Lubrication systemdipstick 020-24, 100-6oil pan 119-8oil pressure
checking 119-4warning system, testing 119-5warning switch 119-10
oil pressure relief valve 119-11oil pump 119-10see also Cooling system, engine oil cooler
M
Maintenanceair filter 020-15alignment 020-33, 320-21antifreeze (engine coolant) 020-19battery 020-16belts, engine accessory 020-20body and interior 020-33brake service 020-18catalytic converter 020-31clutch fluid 210-3cooling system, checking 020-19CV joint boot, inspecting 020-31engine accessory drive belt 020-20engine compartment 020-14engine oil 020-23exhaust system, inspecting 020-32fuel filter 020-26fuel tank and fuel lines 020-26idle speed 020-32interior care 020-33leather upholstery and trim 020-34
maintenance tables 020-37microfilter 020-26oil service 020-23oxygen sensors 020-31parking brake 020-19power steering fluid 020-27seat belts 020-34service indicator 020-36spark plugs 020-28special cleaning 020-34suspension 020-32transmission service 020-29tires 020-32washing 020-34waxing 020-35windshield wiper blade 020-35, 611-4
Main relaysee DME (digital motor electronics)
Malfunction indicator lamp (MIL) Appendix (OBD-6)
Manifold, exhaustsee Exhaust system
Manifold, intakesee Intake manifold
Manual transmission200-2fluid 020-29, 230-4identification 200-2removal / installation 230-8seals
drive axle seal 230-6input shaft seal 230-8
see also Back-up light switchsee also Gearshift
MAP (manifold absolute pressure) sensor
see DME (digital motor electronics), sensors
Master cylindersee Brakessee also Clutch, hydraulics
MFEsee Modular front end (MFE)
Microfiltersee A/C, ventilation microfiltersee also Maintenance
MIL (Malfunction indicator lamp)Appendix (OBD-6)
MINI emblemsee Exterior trim
Mirrorsee Exterior trim
INDEX 7
WARNING
Your common sense, good judgement, and general alertness are crucial to safe and successful service work. Before attempting any work on your MINI, be sure to read 001 General Warnings and Cautions and the copyright page at the front of the manual. Review these warnings and cautions each time you prepare to work on your MINI. Please also read any warnings and cautions that accompany the procedures in the manual.
On-board diagnosticsMode 6 Appendix (OBD-17)OBD-2, Appendix (OBD-7)
Outside door handlesee Door lock
Outside mirror switchsee Switches
Oxygen sensorssee DME (digital motor electronics)
P
P-codesOBD-7, Appendix (OBD-5)see also DTC (diagnostic trouble code)
Parasitic drawAppendix (01-31)
Park distance control510-11
Parking brakesee Brakessee also Maintenance
Park neutral switchsee inhibitor switch
Parts020-5
Pedal cluster switchessee Switches
Power steeringsee Steering
Power supply (battery charger)Appendix (01-19)
Power steering fluidsee Maintenancesee also Steering
Power window switchsee Switches, window
Purge solenoidsee Evaporative control system
PWGsee Accelerator pedal position sensor (PWG)
R
Radiatorsee Cooling system
Radiator cooling fansee Cooling system, cooling fan (electric)
Radiator grillsee Exterior trim
Radiosee Sound systemsee also Antenna
Raising vehicle020-8
Rear hatchaligning 412-3emergency release 515-10handle 412-6lock 515-10removing / installing 412-2strut 412-2trim
lower trim 412-4seal 412-6side trim 412-5upper 412-6
Rear main sealsee Crankshaft seal
Rear spoilerremoving (Cooper S) 412-7
Rear suspensioncomponents 330-3description 300-3, 330-2ride height 300-6shock absorbers / springs 330-4stabilizer bar 330-13
link 330-15subframe 330-8trailing arm 330-10
bushing 330-12upper control arm 330-13wheel bearing 330-16see also Maintenancesee also Headlight, vertical aim control
Receiver / driersee A/C
Recirculation control servo motorsee A/C, servo motors
Relay panelsECL-16
Reversing light switchsee Back-up light switch
Ride height300-6
Ring antennasee EWS (electronic immobilization)
MisfireOBD-5, Appendix (OBD-7)
Mode 6see On-board diagostics
Modular front end (MFE)loosening 510-8removing 510-10
MRS (multiple restraint system)see Airbag system (SRS)
N
Navigation systemcarrier 620-3computer 650-8
Neutral safety switchsee Automatic transmission, CVT switch
O
OBD II (on-board diagnostics)130-2, OBD-2OBD II monitors Appendix (OBD-7)plug 130-25, OBD-3
Oil change020-24
Oil pansee Lubrication system
Oil pressuresee Lubrication system
Oil pumpsee Lubrication system
Oil service020-23
8 INDEX
Rocker arm 116-5see also Valvetrain
Roll bar541-10
Rotorsee Brakes
Run flat indicatorsee flat tire monitor
S
Scan tools OBD-3, Appendix (01-18)
Scan tool datadata values (PIDs) Appendix (13-130)
Seatfront 520-4rear 520-6see also Seat belt
Seat beltautomatic tensioner 400-3, 720-4front 720-4rear 720-8troubleshooting 720-2see also Maintenance
Service indicatorsee Maintenance
Shift cablesee Gearshift cable(s)
Shift interlocksee Gearshift
Shift linkagesee Gearshift
Shift locksee Gearshift
Shock absorbersee Rear suspension
Side marker lightsee Lights
Side skirtsee Exterior trim
Sirensee Anti-theft alarm
Slave cylindersee Clutch, hydraulic
Solenoid121-20
Sound systemantenna 650-5CD changer 650-3DSP amplifier, locating 650-3Radio 650-3Speakers 650-4
Spare parts kit020-13
Spark plugssee Maintenance
Speakerssee Sound system
Spoiler, rear (Cooper S)412-7
Springssee Front suspension, struts / springssee also Rear suspension, shock absorbers / springs
SRS (supplemental restraint system)see Airbag system (SRS)
Stabilizer barsee Front suspensionsee also Rear suspension
Starterremoving / installing 121-19solenoid 121-20troubleshooting 121-3, 121-18
Steering column 320-6
covers 320-7cooling fan 320-16, Appendix (32-18)components 320-13description 300-3, 320-3, Appendix (32-4)
fluidbleeding and filling 320-13see also Maintenance, power steering fluid
lower steering shaft 320-10power steering pump 320-14, Appendix (32-7)
rack 320-16rack boot 320-19wheel 320-3tie rod 320-19
Steering column switchessee Switches
Steering columnsee Steering
Steering wheel switchessee Switches
Stop light switchsee Brake light switch
Strutsee Front suspension
Subframesee Front suspensionsee also Rear suspension
Sunroofinitializing 540-2adjusting 540-3components 540-4emergency closing 540-2glass panel 540-5
gasket 540-6motor 540-6switch 540-5trim 540-6
Supercharger130-34, Appendix (13-113)pulley 130-36
Suspensionsee Front suspensionsee also Rear suspension
SwitchesASC / DSC
see fascia switch module (below)central locking
see fascia switch module (below)fascia switch module 612-6hazard warning 612-2headlight 612-3ignition
switch 612-5outside mirror 612-7pedal cluster switches 612-6seat heater 612-7steering column switches 612-4steering wheel switches 612-3sunroof 540-5tire pressure warning (RWD) 612-8turn signal / headlight dimmer 612-5window
see fascia switch module (above)wiper / washer 612-5see also Back-up light switch
T
Tailgatesee Rear hatch
Taillightssee Lights
Temperature control servo motorsee A/C, servo motors
Tensioner, engine accessory beltremoving and installing 130-36
Thermostatsee Cooling system
INDEX 9
WARNING
Your common sense, good judgement, and general alertness are crucial to safe and successful service work. Before attempting any work on your MINI, be sure to read 001 General Warnings and Cautions and the copyright page at the front of the manual. Review these warnings and cautions each time you prepare to work on your MINI. Please also read any warnings and cautions that accompany the procedures in the manual.
Throttle housing, electronic (EDR)actuator Appendix (13-56)Cooper 130-32Cooper S 130-33throttle posiiton Appendix (13-62)
Throw-out bearingsee Clutch, mechanical
Tie rodsee Steering
Tightening fasteners020-4
Tilt sensorsee Anti-theft alarm
Timing chainsee Camshaft timing chain
Tire, changing020-10
Tire pressure warning switch 612-8see also Flat tire monitor
Tires300-4see also Flat tire monitorsee also Maintenancesee also Tire pressure warning
T-MAP (temperature and manifold absolute pressure) sensor
see DME (digital motor electronics), sensors
Toe320-21
Tools020-6see also Special tools section at beginning of each repair group
Towing010-12
Traction controlsee Brakes, ABS / ASC / DSC
Transmissionsee Automatic transmissionsee also Manual transmission
Transmission fluid 200-4see Maintenancesee also Automatic transmissionsee also Manual transmission
Transmission fluid coolersee Cooling system
Transmission input shaft oil sealsee Manual transmission, seals
Transmission lubricant200-4see also Automatic transmissionsee also Manual transmission
Transmission output shaft oil sealsee Manual transmission, drive axle seal
see also Automatic transmission, drive axle seal
Transmission servicesee Manual transmission, seals
Trim, interiorsee Interior trimsee also Doors, panelsee also Rear hatch, trimsee also Steering, steering column covers
see also Sunroof, trim
Turn signal see Switchessee also Lights
U
Ultrasound modulesee Anti-theft alarm
V
Vacuum boostersee Brakes, brake booster
Valves (engine)see Valvetrain
Valvetraincamshaft 116-6description 100-8rocker arms and shafts 116-5valve
guides 116-16removing / installing 116-14seats 116-17springs 116-17stem oil seals 116-15
Vehicle identification number (VIN)002-1, 020-8
Ventilation microfiltersee A/Csee also Maintenance
Vertical aim controlsee Headlight, vertical aim control
Vibration damper, crankshaftCooper 117-5Cooper S 117-10
Voltage testssee Electrical system, troubleshooting
W
Warnings 001-1
Warnings, cautions and notes020-3, Appendix (01-04)
Washerssee Wipers and washers
Washingsee Maintenance
Water pumpsee Cooling system, coolant pump
Waxingsee Maintenance
Wheel, steeringsee Steering
Wheel alignment320-21ride height 300-6
Wheel bearingsee Front suspensionsee also Rear suspension
Wheels300-4
Wheel speed sensorsAppendix (36-9)
Window see Door window
Wipers and washersblade 020-35, 611-4front wiper
arm 611-5blade 611-5motor and linkage 611-76
rear window wiperarm 611-6blade 611-5motor 611-7
relays 611-4switch 611-3, 612-5washer system 611-8
headlight washer 611-10front washer nozzle 611-8pump 611-9rear washer nozzle 611-8reservoir 611-9
Wiring diagramsELE-11
Working under vehicle safely020-9
X
Xenon headlightsee Headlight
established 1950Automotive Reference™
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MINI CooperService Manual: 2002-2006MINI Cooper, MINI Cooper S, convertible
Price: $139.95Bentley Stock Number: BM06Publication Date: 2010.08.20ISBN: 978-0-8376-1639-1Hardcover, 8 3/8 in. x 11 in.Case quantity: 11424 pages, 2208 photos, illustrations and diagramsIncludes: 336 page MINI Cooper DTC-based diagnostic manual AND 16 page color MINI Familiarization section
The MINI Cooper Service Manual: 2002-2006 is a comprehensive source of service information and specifications for MINI Cooper models from 2002 to 2006. Whether you’re a professional or a do-it-yourself MINI owner, this manual will help you understand, care for and repair your car.
Features:
• Procedures for everything from basic oil change service to interpreting the malfunction indicator light (MIL). This manual tells you what to do and how and when to do it.
• Engine and cylinder head service, including camshaft timing chain setup and adjustment.
• Information for specific driveability problems, including explanation of the engine management system and OBD II diagnostic trouble codes (DTCs).
• Theory of operation and repair information for the EMS2000 engine management system.
• Supercharger and intercooler information, including component removal and replacement (Cooper S).
• Drivetrain maintenance, including troubleshooting, adjustment and repair of clutch, gearshift linkage and drive axles.
• Manual and automatic transmission removal, installation, seal replacement and external service.
• System description and repair information for Antilock Brakes (ABS), Automatic Stability Control (ASC) and Dynamic Stability Control (DSC).
• Heating and air conditioning repair (IHKS / IHKA), including component replacement.
• Body adjustments and repairs, including sunroof and convertible.• Wiring schematics and extensive electrical component section
specifying relay, control module and ground locations with detailed illustrations and photos.
• Includes bonus Diagnosis Without Guesswork manual. Written for the professional technician as well as the MINI enthusiast, this advanced DTC-based diagnostic troubleshooting manual is your comprehensive source of engine management and on-board system diagnosis.
Models & engines covered:
Cooper: 1.6 liter normally aspirated engineCooper S: 1.6 liter supercharged engine
Transmissions covered:
Cooper: Manual 5-speed transmission (Midlands, Getrag) Automatic continuously variable transmission (CVT)Cooper S: Manual 6-speed transmission (Getrag) Automatic with Agitronic (Aisin)
Measuring camshaft axial play.116 Cylinder Head and Valvetrain
Locate difficult-to-find fuses.610 Electrical Component Locations
BentleyPublishers.com
Updated EditionNow includes MINI Diagnostic Trouble Code Manual
Includes complete text of the MINI Cooper - Diagnosis Without Guesswork: 200-2006 diagnostic trouble code manual
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