Mini REPAIR MANUAL -- HOW TO FIX YOUR CAR OR TRUCK

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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!

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Get Full Access 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!
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Using the Automotix DIY repair procedures will save you hundreds and even thousands of dollars! In addition, it will save you hours of touring the city searching for Mini mechanics you can trust. The Automotix DIY solution is particularly affordable. A full access to the entire DIY repair procedures and diagrams for your Mini vehicle will cost less than a single gallon of gas. Here are some of the DIY repair tips and procedures you will find here:

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 -> System Service -> 745 -> Brake System Bleed -> Component Replacement -> Control Module -> Front Speed Sensor -> Hydraulic Unit -> M3, 325 & 330 -> M5, 525, 530, 540, 740 & 750 -> Rear Speed Sensor -> X5 -> Z3 -> Z8
Vehicle: 2003 Mini Cooper S 1.6 L4 GAS

Brake System Bleed

Refer to "Hydraulic Brake Systems," for procedures.

Component Replacement

Hydraulic Unit
M3, 325 & 330
  • Remove end firewall and seal.
  • Disconnect vacuum lines and electrical connector.
  • Remove master cylinder as outlined in "Hydraulic Brake Systems" section.
  • Mark brake lines for installation alignment.
  • Disconnect brake lines.
  • Disconnect connector.
  • Remove brake lines with rubber grommet from body and press toward engine. Do not bend brake lines.
  • Remove mounting bolts and hydraulic unit.
  • Reverse procedure to install. Bleed brake system as outlined in "Hydraulic Brake Systems" section.
...

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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 -> Component Locations ->
Vehicle: 2004 Mini Cooper S 1.6 L4 GAS

The fuel filter is located on the righthand s...

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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
Vehicle: 2002 Mini Cooper S 1.6 L4 GAS

  • Raise and support vehicle, then tire and wheel assemblies.
  • Remove axle shaft nut.
  • Drain transaxle oil into suitable container.
  • Remove mounting bolts and support brake caliper aside. Do not stretch brake lines.
  • Remove nut and disconnect steering tie rod end from knuckle using knuckle puller tool No. 32 3 090, or equivalent.
  • Remove ABS sensor.
  • Remove nut and disconnect lower cont...

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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+.

Relearn Procedures -> TPMS Sensor Location
Vehicle: 2005 Mini Cooper 1.6 L4 GAS

TPMS Sensor Location

Place the ignition switch in the On position, then press button with flat...

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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: 2005 Mini Cooper S 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+

Coolant Hose, Replace -> Lower -> Upper
Vehicle: 2009 Mini Cooper 1.6 L4 GAS

Lower

  • Drain coolant into a suitable container.
  • Reposition clamp on radiator outlet and remove hose.
  • Reposition clamp on coolant pipe and remove hose.
  • Remove hose from vehicle.
  • Reverse procedure ...

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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: 2006 Mini Cooper 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+.

Body Components Diagram for 2005 Mini Cooper  1.6 L4 GASBody Components Diagram for 2005 Mini Cooper 1.6 L4 GAS

Components on diagram:
  • Connector X10201
  • Connector X10202
  • Fuse Holder II
  • Instrument Panel Components Diagram for 2008 Mini Cooper Clubman 1.6 L4 GASInstrument Panel Components Diagram for 2008 Mini Cooper Clubman 1.6 L4 GAS

    Components on diagram:
  • Passenger Airbag Deactivation Switch
  • Adapter 612350
  • Adapter 612360
  • Adapter 616030
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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.

    2003 Mini Cooper S 1.6 L4 GAS Wiring Diagram2003 Mini Cooper S 1.6 L4 GAS Wiring Diagram

    Components on diagram:
  • Gear Position Switch
  • Electronic Immobilizer Control Unit
  • Digital Motor Electronics Unit
  • 2008 Mini Cooper  1.6 L4 GAS Wiring Diagram2008 Mini Cooper 1.6 L4 GAS Wiring Diagram

    Components on diagram:
  • Radio
  • Roof Antenna
  • Antenna Diversity
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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+.

    Document: COOPER S WITH JCW KIT - DME PROGRAMMING PROCEDURE
    Vehicle: 2005 Mini Cooper S 1.6 L4 GAS

    Auto Systems:
  • Electronic Devices, Computers, PROMS, Sensors
  • Document: VEHICLE MEMORY - REVISED
    Vehicle: 2002 Mini Cooper 1.6 L4 GAS

    Auto Systems:
  • Electronic Devices, Computers, PROMS, Sensors
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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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