MINI Cooper 2002 – 2006 Service Repair Manual

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.


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