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Mini CAR/TRUCK REPAIR PROCEDURES AND DIAGRAMS - WHAT Mini REPAIR SHOPS DON'T WANT YOU TO KNOW
Learn how to repair a car or truck, install or remove parts, wire an engine, reset warning lights, replace fuel filter, fix auto body and more. Get Automotix DIY!Select Model
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Automotix DIY provides automotive consumers and do it yourselfers; the most comprehensive repair information about Mini car and truck
repair procedures including Mini engine diagrams, wiring diagrams, repair work estimating measures, technical service bulletins, auto body work
guidance, starter & alternator replacement procedures, serpentine belt replacement procedures, radiator & hose replacement procedures, tune-up &
drivability specifications, quick lube illustrations, preventive maintenance guide, engine light reset instructions, parts removal and install
procedures, fuel filter replacement directions, component location diagrams, air filter locations & replacement instructions, a/c system
specifications, and general auto service procedures. You don't have to be a car mechanic or technician to know how to fix your Mini
automobile. Try the Automotix DIY solution today!
BRAKE SERVICE PROCEDURES FOR Mini AUTOMOBILES
Includes anti-lock brakes, disc, drum, power and hydraulic brake services diagnostics and procedures for domestic and imported Mini cars and light trucks from 1990+.
Anti-lock Brakes -> Description
Vehicle: 2002 Mini Cooper S 1.6 L4 GAS
The Anti-Lock Brake System (ABS) consists of a control unit, hydraulic unit, speed sensors and wiring harness, Fig. . Each speed sensor has a gear wheel which runs past the permanently magnetized edge of the speed sensor installed in the wheel hub. The rotary motion of the wheels is recorded by inductive sensors and an electric signal is sent to the electronic control unit.
The electronic control unit is located in a compartment on the right side of the engine compartment. This control unit inputs acceleration, deceleration and slip factors from the electronic speed sensors, which ar...
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FUEL FILTER REPLACEMENT PROCEDURES FOR Mini AUTOMOBILES
Fuel filter replacement procedures with corresponding images for most domestic and imported Mini cars and light trucks sold in the U.S. for 1980+.
Mini -> Fuel Filter Replacement -> -> Fuel System Pressure Relief -> Removal & Installation
Vehicle: 2004 Mini Cooper 1.6 L4 GAS
Fuel System Pressure Relief
Do not smoke or allow an open flame of any type when working on or near any fuel system related components. The highly flammable vapor mixtures may ignite, resulting in serious personal injury.
After the battery has been disconnected and reconnected, some abnormal driveability symptoms may occur. The vehicle may need to be driven while it relearns its adaptive strategy.
- Remove engine cover, then the pressure test fitting cap.
- Connect a suitable pressure gauge to pressure test fitting on fuel rail.
- Place fuel pressure gauge hose into suitable container.
- Relie...
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DRIVELINE, U-JOINT & CV AXLES REPLACEMENT PROCEDURES FOR Mini AUTOMOBILES
Includes CV axle, universal joint, and driveline replacement, for domestic and imported Mini cars and light trucks from 1990+.
CV AXLE SHAFT, Replace -> Left -> Right
Vehicle: 2007 Mini Cooper S 1.6 L4 GAS
Left
- Raise and support vehicle.
- Remove wheel and tire assembly.
- With an assistant applying brakes, remove and discard axle shaft collar nut.
- Drain oil from transaxle.
- Remove caliper bolts.
- Remove caliper and hang aside, ensuring that brake hose is not under tension.
- Remove steering tie rod end from knuckle using separator tool No. 323090 or equivalent. Discard locknut.
- Remove ABS sensor from knuckle.
- Remove outer lower control arm nut.
- Remove lower control arm from knuckle using separator tool No. 321190 or equivalent. Discard nut.
- Release inner axle shaft from gearbox.
- Remove and di...
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TIRE PRESSURE MONITORING SYSTEM PROCEDURES FOR Mini AUTOMOBILES
Description, component locations, reset procedures, relearn procedures, diagnosis and testing, wiring diagrams, component replacement, and identification of vehicles equipped and not equipped with tire pressure monitoring system for most domestic and imported Mini cars and light trucks sold in the U.S. from mid 1990's+.
Diagnosis & Testing -> Accessing Diagnostic Trouble Codes -> Clearing Diagnostic Trouble Codes -> Diagnostic Trouble Code Identification
Vehicle: 2004 Mini Cooper 1.6 L4 GAS
Accessing Diagnostic Trouble Codes
Connect a suitable scan tool the DLC (Data Link Connector). Follow the scan tool manufacturers instructions.
Diagnostic Trouble Code Identificati...
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STARTER & ALTERNATOR REPLACEMENT PROCEDURES FOR Mini AUTOMOBILES
Includes starter and alternator replacement procedures for domestic and imported Mini cars and light trucks from 1990+.
Starter, Replace
Vehicle: 2008 Mini Cooper 1.6 L4 GAS
- Disconnect battery ground cable.
- Loosen clamp and detach air intake hose.
- Unlock intake duct and detach from intake filter housing.
- Remove intake filter housing.
- Remove fuel tank vent valve, if equipped.
- Raise vehicle on suitable lift.
- Remove righthand wheel nuts.
- Remove bolts from vacuum tank and set to one side, if equipped.
- Discon...
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CABIN AIR FILTER LOCATIONS & REPLACEMENT PROCEDURES FOR Mini AUTOMOBILES
Cabin air filter locations and replacement procedures with corresponding images for most domestic and imported Mini cars and light trucks sold in the U.S. as equipped to the current model year.
Cabin Air Filter Service -> Mini -> Cooper -> 2002-06 Coupe & 2005-08 Convertible -> 2007-09 Coupe & 2009 Convertible
Vehicle: 2007 Mini Cooper 1.6 L4 GAS
2002-06 Coupe & 2005-08 Convertible
The Mini is equipped with a service interval indicator.
- Remove the four cabin air filter cover retaining screws. The cabin air filter cover is located at the lower righthand side of the instrument panel below the storage bin, Fig. .
- Disengage the cabin air filter cover retainers, then remove the cover, Fig. .
- Pull the cabin air filter downward to remove.
- Install the new cabin air filter element into the filter housing, Fig. . Ensure the filter element is properly located in the guides.
- Install the cabin air filter cover. Ensure the retainers are engaged, the...
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MAINTENANCE LAMP RESET PROCEDURES FOR Mini AUTOMOBILES
Maintenance lamp reset procedures with corresponding images for most domestic and imported Mini cars and light trucks sold in the U.S. from 1990+.
Mini -> Tire Pressure Monitoring System (TPMS) Warning Indicator ->
Vehicle: 2006 Mini Cooper 1.6 L4 GAS
- On models less iDrive, proceed as follows:
- The Tire Pressure Warning Lamp will illuminate when low tire pressure has been detected.
- After all tires have been inflated to the proper pressure, place the ignition switch in the on position, then press button with flat tire logo on center console to reset lamp for at least 4 seconds. The system will th...
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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR Mini AUTOMOBILES
Includes radiator, cooling and heater hose replacement procedures for domestic and imported Mini cars and light trucks from 1990+
Radiator, Replace
Vehicle: 2003 Mini Cooper 1.6 L4 GAS
Danger of scalding. Open pressure cap on fill tower, only after engine has cooled down.
- Turn off ignition.
- Drain coolant into a suitable container.
- Remove front carrier.
- Remove oil cooler if equipped (ECVT only).
- Remove upper radiator hose.
- Remove condenser retaining bolts and lift conde...
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SERPENTINE BELT SERVICE PROCEDURES FOR Mini AUTOMOBILES
Serpentine belt replacement procedures with corresponding images for most domestic and imported Mini cars and light trucks sold in the U.S. from 1990+.
Serpentine Drive Belt, Replace
Vehicle: 2008 Mini Cooper S 1.6 L4 GAS
If drive belt is to be reused: Mark direction of travel and reinstall drive belt in same direction of travel.
- Remove tank venting valve.
- Remove underpan.
- Relie...
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COMPONENT LOCATION DIAGRAMS FOR Mini AUTOMOBILES
Component location diagrams for most Mini cars and light trucks sold in the U.S. from 1990+.
 Door Components Diagram for 2005 Mini Cooper S 1.6 L4 GASComponents on diagram: |
 Engine Compartment Components Diagram for 2004 Mini Cooper 1.6 L4 GASComponents on diagram: |
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WIRING DIAGRAMS FOR Mini AUTOMOBILES
OEM drawn wiring diagrams for most Mini cars and light trucks sold in the U.S.
 2008 Mini Cooper S 1.6 L4 GAS Wiring DiagramComponents on diagram: |
 2008 Mini Cooper Clubman 1.6 L4 GAS Wiring DiagramComponents on diagram: |
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TECHNICAL SERVICE BULLETINS FOR Mini AUTOMOBILES
OEM TSB listings for most Mini cars and light trucks sold in the U.S. from 1985+.
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Document: BRAKE LIGHTS ON WITH IGNITION OFF Vehicle: 2002 Mini Cooper 1.6 L4 GAS Symptoms: |
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Document: TRANSMISSION NOISE DIAGNOSIS - 5-SPEED GETRAG Vehicle: 2005 Mini Cooper 1.6 L4 GAS Symptoms: |
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COMPONENT/PARTS SPECIFICATIONS FOR Mini AUTOMOBILES
BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most Mini cars and light trucks sold in the U.S. and Canada from 1970+.
- Brake caliper mounting bolt torque
- Brake drum runout, machining, & discard specs
- Minimum brake lining thickness.
- Brake rotor runout, parallelism, machining, discard, & finish specs
A/C SYSTEM SPECIFICATIONS: Air conditioning refrigerant capacity and type as well as lubricant capacity for most Mini cars and light trucks sold in the U.S. and Canada from 1980+.
- Refrigerant capacity & type, compressor oil viscosity, total system oil capacity & compressor clutch gap
COOLING SYSTEM BLEED: Cooling system bleeder valve identification, bleeder type and bleed procedures for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1986+.
PREVENTIVE MAINTENANCE: Preventive maintenance recommendations and required services for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1980+. Includes severe and routine service schedules
QUICK-LUBE and ILLUSTRATIONS: Fluid recommendations, capacities, drain plug torques, tire data, and severe service recommended preventive maintenance schedules. Information covers most Mini cars and light trucks sold in the U.S. and Canada from 1980+. Engine and chassis service images.
- Automatic transmission/transaxles capacities, lubricant recommendations
- Differential/final drive capacities, lube recommendations, grades, & viscosities
- Final drive fill & drain plug torques
- Number of lubrication fittings & plugs
- Power steering, brake, & clutch fluid recommendations
- Manual transmission/transaxle capacities, lube recommendations, grades, & viscosities
- Number of lubrication fittings & plugs
- Power steering, brake, & clutch fluid recommendations
- Engine oil capacities, API grade recommendations, SAE viscosity recommendations, drain plug torque
- Severe service maintenance & interval recommendations
- Tire sizes, wheel nut/bolt torque, pressures & rim sizes
- Transfer case capacities, lube recommendations, grades, & viscosities
TUNE-UP & DRIVEABILITY SPECIFICATIONS: Most tune-up specifications for most Mini cars and light trucks sold in the U.S. and Canada from 1980+
- Airflow sensor electrical specifications
- Tensioning specifications for systems with automatic tensioners
- Barometric pressure sensor specs
- Battery group number and cranking performance
- Crankshaft & camshaft position sensor resistance
- Engine compression pressures
- Coolant temperature sensor specs
- Computer advance.
- Diesel fuel temperature sensor resistance.
- Distributor advance specifications
- Ignition pickup coil resistance
- Exhaust gas recirculation temperature sensor resistance
- Engine fastener torque values
- Firing order diagrams
- Fuel system pressures
- Generator (alternator) specs
- Intake air temperature sensor specs
- Ignition coil specifications
- Fuel injector resistance
- Engine idle speeds
- Knock sensor resistance
- Manifold absolute pressure sensor specs
- Mixture control solenoid resistance
- Voltage regulator specs
- Spark plug applications & gaps
- Starter motor electrical specs.
- Tensioning specifications for systems without automatic tensioners
- Throttle body temperature sensor resistance
- Ignition timing in degrees at rpm
- Transmission oil temperature sensor resistance
- Throttle position sensor specs
- Vacuum sensor valve specs
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