Mini Cooper 2002 - 2006 Service Repair Workshop Manual [PDF]

Zitiervorschau

MINI Cooper

Service Manual 2002, 2003, 2004, 2005, 2006 Cooper, Cooper S, including convertible with Diagnostic Trouble Code Manual

B BentleyPublishers .com

020-1

020 Maintenance

General

020-2

How to use this manual 020-2 Warnings, Cautions and Notes 020-3

Basic Service Information 020-3 Diagnostic trouble codes (DTCs), accessing .. 020-3 Tightening fasteners 020-4 Parts 020-5 To o l s 020-6

Identification Plates and Labels 020-8 Ve h i c l e I d e n t i fi c a t i o n N u m b e r ( V I N ) 0 2 0 - 8 Date of manufacture 020-8 Engine and transmission codes 020-8

Raising

Vehicle

020-8

Lifting vehicle 020-8 Raising vehicle safely using vehicle jack 020-9 Working safely under vehicle 020-9

Emergencies

020-10

Flat tire monitor Changing a tire Jump starting Indicator and warning lights To w i n g Spare parts kit

020-10 020-10 020-12 020-12 020-12 020-13

Engine Compartment Components .. 020-14 Engine covers, removing and installing 020-14

Air

Filter

Service

020-15

A i r fi l t e r , r e p l a c i n g ( C o o p e r ) 0 2 0 - 1 5 A i r fi l t e r , r e p l a c i n g ( C o o p e r S ) 0 2 0 - 1 5 A i r fi l t e r , a s s e m b l y ( J C W ) 0 2 0 - 1 6

Battery Brake

Service Service

020-16 020-18

Brake fl u i d , replacing 020-18 B r a k e p a d / r o t o r w e a r, c h e c k i n g 0 2 0 - 1 8 Brake system, inspecting 020-18 Parking brake, checking 020-19

Cooling System, Checking 020-19 Engine Accessory Belt Service 020-20

Fuel

System

Interior Ventilation Microfilter, Replacing Power Steering Fluid Service, Checking

Oil

Service

020-23

Engine oil, checking level 020-24 E n g i n e o i l a n d fi l t e r , c h a n g i n g 0 2 0 - 2 4

020-26

020-26 020-27

Spark Plugs, Replacing 020-28 Transmission Service 020-29 Transmission service, automatic (CVT) 020-29 Transmission service, automatic (Agitronic).. 020-29 Transmission service, manual 020-30

Other Mechanical Maintenance 020-31 Catalytic converter and oxygen sensors .... 020-31 Clutch fl u i d , checking 020-31 Drive axle joint (CV joint) boots, inspecting 020-31 Exhaust system, inspecting 020-32 Idle speed 020-32 Suspension, inspecting 020-32 Ti r e s , c h e c k i n g i n fl a t i o n p r e s s u r e 0 2 0 - 3 2 Tires, rotating 020-32 Wheels, aligning 020-33

Body and Interior Maintenance 020-33 Body and hinges, lubricating 020-33 Exterior washing 020-33 Interior care 020-33 Leather upholstery and trim 020-34 Polishing 020-34 Seat belts 020-34 Special cleaning 020-34 Washing chassis 020-34 Waxing 020-35 Windshield wiper blade maintenance 020-35

Service

Intervals

020-36

Service interval display (SIA) 020-36 SIA, resetting 020-36 Inspection I, Inspection II 020-36 Maintenance tables 020-37

Accessory belt, replacing (Cooper) 020-21 Accessory belt, replacing (Cooper S) 020-22

Engine

Service

Fuel fi l t e r 020-26 Fuel tank and lines, inspecting 020-26

TABLES

a. b. c.

Oil Inspection Inspection

service I service II service

020-37 020-38 020-40

©2006 BentleyPublishers.com—All Rights Reserved

ELE-1

General

ele-2

Special tools ELE-3 Circuit and terminal descriptions ELE-3 Electrical schematic symbols ELE-5 Sample wiring schematic ELE-6 Electrical wiring diagram component i d e n t i fi e r ELE-7

Electrical wiring diagrams ABS/ASC E L E - 11 ABS / DSC ELE-16 Airbag system ELE-19 Air-conditioning ELE-181 Automatic transmission (Aisin) ELE-28 Automatic transmission (CVT) ELE-37 Battery ELE-48 Brake light switch ELE-53 Bus system (K-bus / CAN-bus) ELE-56 Central locking ELE-70 Charging system ELE-78 Clutch switch ELE-53 Convertible top ELE-81 Electrochromic rear view mirror ELE-91

Electronic immobilizer (EWS) ELE-93 Engine cooling ELE-97 Engine management ELE-100 Exterior lights ELE-130 General Module (Body Computer) ELE-152 Heated seats ELE-179 Heating and Air-conditioning ELE-181 Horns ELE-194 Instruments ELE-196 Interior lights / illumination ELE-223 Mirrors ELE-231 Multifunction (MFL) steering wheel ELE-234 Navigation system ELE-240 On-board computer ELE-242 Park distance control ELE-243 Power steering ELE-247 Power windows ELE-248 Radio / CD changer ELE-252 Rear window defogger ELE-261 Starter ELE-265 Sunroof ELE-266 Wiper / washers ELE-267

Electrical Component Locations .see Repair Group ECL

Relay and fuse positions, component and ground locations

NOTE— • Common MINI acronyms are explained in 600 Electrical System—General. • Airbags systems, formerly known by the acronym SRS (sup plemental restraint system), are currently referred to by the BMW acronym MRS (multiple restraint system). • Every attempt has been made in this repair manual to stan dardize component names. However, in some cases, the same component may appear with different names. Regard less of the component name, the alphanumeric component designation used on the wiring diagrams is consistent throughout.

1 ©2006 BentleyPublishers.com—All Rights Reserved

Electrical Wiring Diagrams ELE-41 Automatic transmission (CVT) Transmission speed sensor (pagel of 1)

87

F04 15A

X8687 A6000 Digital motor electronics control unit

« X6000

1.0 RT/WS

0.5 SW

I

I

Y8516

>

1

0.5 BR

Jt}'

31 i 4

2

0.5 RT

0.5 BR

0.5 BR

X01191

X01191

X01191

0.5 RT

0.5 RT

0.5 RT

101199

ing light

MC06ele22401

C S f c ■■ ! '£ 2006 BentleyPublishers.com-AII Rights Reserved

Electrical Wiring Diagrams ELE-183 Heating and A/C Power supply (from March 2003 to Sept. 2005)

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r

,

"J

'l

i

5A

i

F29 I I 1

r 1 1 1

""

K4 1 1 1

1

i

A47 Fuse holder I

r

i

1 1 1

1 1 1

I

i

2 ' X10207

4

-'

4

S241 Switch panel

' X1879

X10201

,

4.0 RT/GN 2

f

X146

4.0 RT

■

X10659 F"

X01114

0.5 GR/RT 14

0.35 WS/RT/GE 15

X1527

———▶ 0.5 VI/BL/GE 9

r 1 1 1

0.75 RT 3

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,??■&£ ;. 'r'v'"< ;\ ' ©2006 BentleyPublishers.com—All Rights Reserved

Electrical Wiring Diagrams ELE-241 Navigation system (from March 2002) (page 2 of 2)

A47

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! I