33412935 mini cooper service manual 2002 2006 complete index (1)

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


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


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


cooling fan (electric) 170-8draining and filling 170-7engine oil cooler (Cooper S) 170-11expansion tank 170-15

INDEX 3

WARNING


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


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


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


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


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


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


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™

Bentley Publishers, 1734 Massachusetts Avenue, Cambridge, MA 02138-1804 USATel: 617-547-4170 • Toll Free: 800-423-4595 • Fax: 617-876-9235http://www.bentleypublishers.com/contact-sales

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

bentley_bm06_new.product.announcement.pdf

33412935 mini cooper service manual 2002 2006 complete index (1)

Documents