MINI Cooper 2002 – 2006 Service Repair Manual

Mini Cooper

This manual supersedes our previous 2002-2004 manual with two more model years of coverage, including new repair information for the convertible and the 2005 facelift. The manual also includes coverage of the Cooper S models. The MINI Cooper Service Manual 2002 – 2006 is a comprehensive source of service information and specifications for MINI Cooper models from 2002 to 2006.

Foreword

For the MINI owner with automotive mechanical skills, and for independent service professionals, this manual includes maintenance and repair procedures the MINI is likely to need during its service life, including many procedures and specifications that were available in an authorized MINI dealer service department at the time this manual was prepared. The MINI owner with no intention of working on his or her car will find that owning and referring to this manual makes it possible to be better informed and to more knowledgeably discuss repairs with a professional automotive technician.

For those intending to do maintenance and repair on their MINI, it is essential that safety equipment be used and safety precautions observed when working on your vehicle. A minimum safety equipment list includes hand protection, eye protection, and a fire extinguisher. A selection of good quality hand tools is also needed. This includes a torque wrench to ensure that fasteners are tightened in accordance with specifications. In some cases, the text refers to special tools that are recommended or required to accomplish adjustments or repairs. These tools are often identified by their MINI / BMW special tool number and illustrated.

Engines covered:

Cooper: 1.6 litre normally aspirated engine
Cooper S: 1.6 litre supercharged engine

Transmissions covered:

Cooper: Manual 5-speed transmission (Midlands, Getrag)
Cooper: Automatic continuously variable transmission (CVT)
Cooper S: Manual 6-speed transmission (Getrag)
Cooper S: Automatic with Agitronic (Aisin)

Table of contents:

General Data and Maintenance
General Warnings and Cautions
Vehicle Identification and VIN Decoder
Product Familiarization
Maintenance
Engine
Engine-General
Engine Removal and Installation
Cylinder Head Removal and Installation
Cylinder Head and Valvetrain
Camshaft Timing Chain
Lubrication System
Ignition System
Battery, Starter, Alternator
Fuel Injection
Fuel Tank and Fuel Pump
Radiator and Cooling System
Exhaust System
Transmission
Transmission-General
Clutch
Manual Transmission
Automatic Transmission
Gearshift Linkage
Suspension, Steering and Brakes
Suspension, Steering and Brakes-General
Front Suspension, Drive Axles
Steering and Wheel Alignment
Rear Suspension
Brakes
Body
Body-General
Fenders, Engine Hood
Doors
Rear Hatch
Body Equipment
Exterior Trim, Bumpers
Door Windows
Interior Trim
Central Locking and Anti-theft
Seats
Sunroof
Convertible Top
Electrical System
Electrical System-General
Wipers and Washers
Switches
Instruments
Lights
Heating and Air-conditioning
Radio
Equipment and Accessories
Seat Belts
Airbag System (SRS)
ECL Electrical Component Locations
EWD Electrical Wiring Diagrams
OBD On-Board Diagnostics

Bentley manuals are written specifically for the do-it-yourselfer, yet are complete enough to be used by professional mechanics. Bentley has produced manuals written from hands-on experience based on a vehicle teardown with hundreds of photos and illustrations, making Bentley the world leader in automotive repair information.

Language: English
File: PDF
Pages: 1079

MINI Cooper 2002 – 2006 Service Repair Manual