Repair manual
MINI Cooper S I Repair Manual
Step-by-step repair and maintenance instructions for the MINI Cooper S I (2000–2006): removal, installation, adjustment, diagnostics and parameter checks with illustrations.
- Basic Electricity
- Electromotive Force
- Theory of Electron Flow
- Conventional Theory of Electron Flow
- Voltage
- Ampere
- Ohms
- Circuits
- Series Circuit
- Parallel Circuit
- Series-Parallel Circuit
- Short Circuit
- Ohm's Law
- Ohm's Law - Series Circuits
- Ohm's Law Parallel Circuit - 2 Branches
- Ohm's Law Parallel Circuit - more than 2 Branches
- Ohm's Law in Series-Parallel circuit
- Worksheet
- Magnetic Theory
- Fundamentals of Magnetism
- Electromagnetic Induction
- Generator
- Alternator
- Ignition Coil
- DC Voltage
- AC Voltage
- Conductors, Insulators and Semi-Conductors
- Conductors
- Insulators
- Semi-Conductors
- Semi-Conductor Doping
- N-Type Material
- P-Type Material
- Junctions
- Transistors
- Relays
- Solenoids
- Stepper Motors
- Common Circuit Designations
- Review Questions
- 51 00 ... Removing and installing/replacing bonnet stripes
- 51 00 ... Safety instructions for working on cars with airbag systems
- 51 00 ... Service position of engine hood
- 51 11 050 Removing and installing/replacing carrier for front bumper trim
- 51 11 130 Removing and installing/replacing straightening attachment for front bumper
- 51 11 150 Removing and installing/replacing side trim (without side-marker lamp) of front bumper
- 51 11 152 Removing and installing/replacing lower spoiler of front bumper
- 51 11 156 Removing and installing front bumper trim
- 51 11 157 Replacing front bumper trim
- 51 11 179 Removing and installing/replacing upper grille of bumper trim
- 51 11 180 Removing and installing/replacing grille of bumper trim
- 51 11 507 Adjusting front bumper laterally
- 51 12 050 Removing and installing/replacing carrier for rear bumper trim
- 51 12 070 Removing and installing/replacing center spoiler on rear bumper trim
- 51 12 072 Removing and installing/replacing side spoiler on rear bumper trim
- 51 12 156 Removing and installing rear bumper trim
- 51 12 157 Replacing rear bumper trim
- 51 13 000 Removing and installing/replacing front grill center section
- 51 13 077 Removing and installing/replacing grille for air inlet/heating
- 51 13 100 Removing and installing/replacing trim on hood/bonnet/wheel arch on left or right
- 51 13 102 Removing and installing/replacing side cowl panel cover strip
- 51 13 105 Removing and installing/replacing rear wheel arch trim
- 51 13 301 Removing and installing/replacing finisher - roof panel - side
- 51 13 402 Removing and installing/replacing strip handle (rear lid)
- 51 13 403 Replacing strip handle (rear lid)
- 51 14 002 Removing and installing/replacing front MINI emblem
- 51 14 012 Removing and installing / replacing rear MINI emblem
- 51 14 110 Removing and installing/replacing rear model designation
- 51 16 000 Removing and installing/replacing mirror on left or right front door
- 51 16 026 Replacing mirror glass
- 51 16 040 Removing and installing/replacing housing on left or right door mirror
- 51 16 060 Removing and installing or replacing interior rear-view mirror.
- 51 16 080 Removing and installing or replacing sunvisor and left or right counter support
- 51 16 156 Removing and installing/replacing ashtray insert
- 51 16 196 Removing and installing / replacing cover for center armrest
- 51 16 198 Removing/installing or replacing trim between front center console and instrument panel
- 51 16 200 Removing and installing front center console
- 51 16 201 Replacing front center console
- 51 16 202 Removing and installing/replacing front cup holder
- 51 16 206 Removing and installing / replacing center armrest
- 51 16 210 Removing and installing / replacing finisher for preselector lever
- 51 16 216 Removing and installing rear center console
- 51 16 216 Removing and installing rear storage compartment (with center armrest)
- 51 16 217 Replacing rear center console
- 51 16 217 Replacing rear storage compartment (with center armrest)
- 51 16 218 Removing and installing / replacing rear storage compartment holder
- 51 16 341 Removing and installing/replacing lock cylinder for glovebox
- 51 16 360 Removing and installing right glovebox
- 51 16 390 Removing and installing/replacing instrument panel trim storage tray (passenger side)
- 51 16 392 Removing and installing/replacing storage compartment in instrument panel trim (driver's side)
- 51 16 450 Removing and installing or replacing rear grab handle
- 51 21 003 Replacing front left or right door detent (lock striker)
- 51 21 004 Adjusting front left or right door detent
- 51 21 090 Removing and installing/replacing door lock in left or right front door
- 51 21 140 Removing and installing/replacing complete lock cylinder in left or right front door
- 51 21 150 Blocking, if necessary initializing, car key in immobilizer control module
- 51 21 170 Removing and installing/replacing outside handle on left or right front door
- 51 21 225 Removing and installing/replacing inside handle on left or right front door
- 51 21 235 Removing and installing/replacing cable for inside door opener on left or right front door
- 51 21 280 Removing and installing/replacing door arrester on left or right front door
- 51 21 300 Removing and installing/replacing window cavity cover strip on outer side of front door
- 51 21 330 Removing and installing/replacing window cavity inner strip on outer side of front door
- 51 21 370 Removing and installing/replacing cover on lower edge of left or right front door
- 51 23 004 Adjusting engine hood/bonnet lock
- 51 23 100 Removing and installing/replacing right engine hood/bonnet lock
- 51 23 110 Removing and installing/replacing left engine hood/bonnet lock
- 51 23 200 Removing and installing/replacing lever with bracket for hood/bonnet fastener
- 51 23 211 Removing and installing/replacing cable for front engine hood locks (with storage compartment)
- 51 23 212 Removing and installing/replacing cable for front engine hood locks (with glovebox)
- 51 23 265 Removing and installing/replacing left or right gas pressure support fro engine hood/bonnet
- 51 24 004 Adjusting rear lid lock
- 51 24 040 Removing and installing/replacing rear lid lock and striker
- 51 24 065 Removing and installing/replacing Bowden cable for manual rear lid unlocking
- 51 24 100 Removing and installing/replacing rear lid lock (lower section)
- 51 24 130 Removing and installing/replacing striker for rear lid lock
- 51 24 300 Removing and installing / replacing left or right gas pressure prop from trunk lid (Tailgate)
- 51 31 ... Instructions on gluing windscreen
- 51 31 ... Removing windscreen with "Roll Out 2000"
- 51 31 000 Removing and installing/replacing windscreen
- 51 31 015 Repairing damage to windscreens caused by pitting (stone chips) (clear and tinted laminated safety glass)
- 51 31 021 Removing and installing/replacing rubber frame for windscreen (top)
- 51 31 043 Removing and installing/replacing bottom ornamental strip for windscreen, left or right
- 51 31 045 Removing and installing/replacing trim on A-pillar, left or right
- 51 31 200 Removing and installing/replacing rear window
- 51 31 283 Removing and Installing/Replacing - Tailgate upper finisher
- 51 31 284 Removing and installing/replacing - tailgate lower finisher
- 51 32 154 Adjusting left or right front door window
- 51 32 170 Removing and installing or replacing front left or right door window
- 51 33 000 Removing and installing (replacing) power window unit in left or right front door
- 51 36 040 Removing and installing / replacing strip on rear side window at bottom left or right
- 51 36 060 Removing and installing/replacing finisher - rear quarter glass - front
- 51 36 062 Removing and installing / replacing finisher - rear quarter glass - rear
- 51 36 070 Removing and installing/replacing left or right rear side window
- 51 41 000 Removing and installing front left or right door trim panel
- 51 41 001 Replacing front left or right door trim panel
- 51 41 008 Removing and installing/replacing front door water deflector
- 51 41 018 Replacing speaker trim on front left or right door trim panel
- 51 41 060 Removing and installing/replacing armrest on left or right front door (from 09/2002)
- 51 41 060 Removing and installing/replacing armrest on left or right front door (up to 09/2002)
- 51 43 002 Removing and installing rear left or right side trim panel
- 51 43 005 Replacing rear left or right side trim panel
- 51 43 040 Removing and installing/replacing storage compartment in rear left or right side trim panel
- 51 43 050 Removing and installing/replacing grill for speaker (in rear side trim panel)
- 51 43 148 Removing and installing or replacing trim on left or right door pillar (top)
- 51 43 201 Removing and installing or replacing trim for front left or right roof ('A' post)
- 51 43 251 Removing and installing/replacing trim for rear left or right roof pillar (C-pillar)
- 51 44 001 Removing and installing/replacing headliner (without slide/tilt sunroof)
- 51 44 011 Removing and installing/replacing headliner (with slide/tilt sunroof)
- 51 44 152 Removing and installing/replacing sunroof finisher - front
- 51 44 156 Removing and installing/replacing sunroof finisher - rear
- 51 45 030 Removing and installing instrument panel trim (with carrier and heater)
- 51 45 033 Removing and installing instrument panel trim (with carrier and air conditioner)
- 51 45 050 Removing and installing instrument panel top section trim (up to 04/07)
- 51 45 050 Removing and installing instrument panel upper section trim (from 07/04)
- 51 45 051 Replacing instrument panel top section trim (up to 04/07)
- 51 45 055 Removing and installing/replacing airbag cover on passenger side (up to 07/04)
- 51 45 060 Removing and installing/replacing decorative trim for instrument panel (middle)
- 51 45 066 Removing and installing decorative trim for instrument panel (driver's side)
- 51 45 068 Removing and installing decorative trim for instrument panel (passenger side)
- 51 46 003 Removing and installing/replacing trim for oddments tray (rear parcel shelf)
- 51 46 050 Removing and installing/replacing top trim on tail panel
- 51 47 000 Removing and installing/replacing front left or right entrance cover strip (inside)
- 51 47 101 Removing and installing/replacing luggage compartment floor trim panel
- 51 47 450 Removing and installing/replacing complete carpet
- 51 47 490 Removing and installing/replacing front underbody protection (engine)
- 51 48 001 Removing and installing/replacing engine hood/bonnet sound insulation
- 51 49 003 Removing and installing/replacing trim for rear window frame on left or right
- 51 49 005 Removing and installing/replacing trim for lower trunk lid (tailgate)
- 51 49 006 Removing and installing/replacing trim for upper trunk lid (tailgate)
- 51 71 040 Removing and installing/replacing front left or right wheel arch liner
- 51 71 041 Removing and installing/replacing rear left or right wheel arch liner
- 51 71 145 Removing and installing/replacing seal on front door aperture
- 51 71 360 Removing and installing/replacing seal on tailgate aperture
- 51 71 447 Removing and installing/replacing trim for cover on left or right frame side member
- MINI Body
- Body Safety
- The Body Shell
- MINI Convertible
- Cross Members
- Roof
- Front Apron Panel
- Front Side Panel
- Hood
- Hood Latch
- Tailgate
- Tailgate Latch and Striker
- Tailgate Trim Upper and Side
- Tailgate Trim Lower
- Doors
- Door Mounting
- Door Striker
- Door Latch
- Front Bumper
- Front Bumper Adjustment
- Front Bumper Trim
- Rear Bumper
- Rear Bumper Trim - (MINI COOPER S ONLY)
- Park Distance Control (PDC) Sensors (x4)
- Body Molding
- Windshield Trim
- A Pillar Trim
- Air Intake Grills
- Washer Jets
- Wheel Arch and Sill Trim
- Headlamps
- Turn Signals
- Fog Lights
- Tail Lights
- Third Brake Light
- Reverse Lights
- Dashboard Assembly
- Dashboard
- Dashboard Upper Covering
- Dashboard Cross Car Beam
- Instrumentation
- Front Center Console
- Rear Center Console
- Window Regulators
- Door Glass
- Exterior Door Handle
- Interior Door Handle
- Sunroof
- Front Seats
- Seat Backboards
- Side `Thorax' Airbags
- Seat Belt Pre-Tensioners - Pyrotechnic
- Seat Heating
- Lumbar Support - Optional
- Rear Seat
- Seat Backrest Operation
- Backrest Removal
- Head Rests
- ISOFIX Brackets
- A Pillar/Sill Trim
- B Pillar Trim
- C Pillar Trim
- Rear Quarter Trim
- Luggage Compartment Lower Trim
- Parcel Shelf
- Headliner
- Body Glass
- Windshield
- Back Glass
- Quarter Glass
- DESCRIPTION & OPERATION
- BRAKE SYSTEM
- BRAKE BOOSTER
- MASTER CYLINDER WITH RESERVOIR
- FRONT WHEEL BRAKE ASSEMBLY
- REAR WHEEL BRAKE ASSEMBLY
- PARKING BRAKE ASSEMBLY
- BLEEDING PROCEDURES
- POWER BRAKE BOOSTER
- BRAKE LINING THICKNESS
- Removal & Installation
- CENTER CONSOLE (REAR)
- DISC PADS (FRONT)
- Removal
- Inspection
- Installation
- DISC PADS (REAR)
- ROTOR (FRONT)
- TORQUE SPECIFICATIONS
- DISC BRAKE SPECIFICATIONS
- Suspension
- Front Suspension
- Lower Control Arms
- Anti-Roll Bar and Links
- McPherson Struts
- Front Shocks
- Front Springs
- Top Mount
- General Suspension Data
- System Components
- Trailing Arms
- Lateral Links
- Rear Anti-Roll Bar
- Rear Springs
- Rear Shocks and Top Mounts
- Brake System
- Purpose of the System
- Brake Booster
- Master Cylinder with Reservoir
- Front Wheel Brake Assembly
- Parking Brake Assembly
- Brake Fluid
- Principle of Operation
- Parking Brake Adjustment
- Steering
- EHPS
- Rack and Pinion
- Steering Column
- Steering Wheel
- Traction Control Systems
- ABS
- Automatic Stability Control + Traction (ASC+T)
- Dynamic Stability Control (DSC)
- Hydraulic/Electronic Control Unit
- Wheel Speed Sensors
- Brake Light Switch
- Brake Fluid Level Switch
- ABS Warning LED
- ASC System
- ASC Switch
- ASC Warning LED
- DSC System
- Steering Angle Sensor
- DSC Sensor Cluster
- DSC Switch
- DSC Warning LED
- EBV (Electronic Brake Force Distribution)
- CBC
- MSR
- ASC
- DSC
- MINI CIP
- What is Coding?
- What is Programming?
- What is the Purpose of Coding and Programming?
- Where is Data Stored in a Control Module?
- EPROM (Electrically Programmable Read Only Memory)
- EEPROM (Electrically Programmable Read Only Memory)
- What is needed to Code and Program?
- Introduction
- ZCS Structure
- ZCS Stored Location in Vehicle
- ZCS Identification / Display
- Control Modules Flash (EEPROM) Programming
- Determination Process for DME EEPROM
- CIP (Coding, Individualization, and Programming)
- ZCS Codable Control Modules (w/ Progman v. 14 & 15)
- ZCS Coding a Module (w/ Progman v. 14 & 15)
- Accessing Stored ZCS Information (w/ Progman v. 16 & higher)
- ZCS Coding All Modules (w/ Progman v. 16 & higher)
- Manual Input of ZCS Data (w/ Progman v. 14 & 15)
- Vehicle - Service Function
- Retrofit
- Conversion
- CKM - Vehicle Memory (w/ Progman v. 16 & higher)
- Programming a Control Module (w/ Progman v. 16 & higher)
- Retrofits (w/ Progman v. 16 & higher)
- Management - Reports
- Management - Application - Test & Version
- Vehicle - Initialization
- INTRODUCTION
- MALFUNCTION INDICATOR LIGHT
- CHECK FILLER CAP INDICATOR LIGHT
- Emission Reduction Stages
- MINI DIAGNOSTIC HARDWARE
- DIS Plus
- Group Tester One (GT-1)
- Hard & Intermittent Failures
- OBD-II Diagnostics
- MINI Diagnostics
- OBD II Drive Cycles & Trips
- Readiness Flags
- RETRIEVING & ERASING DIAGNOSTIC TROUBLE CODES
- DIAGNOSTIC TROUBLE CODE CROSS-REFERENCE & TABLES
- TEST GROUP IDENTIFICATION
- General Description
- Measuring Principle, Segment Period Acquisition
- Leak Detection
- Canister Purge Valve Check
- General Overview
- Description Of The Strategy
- General Description Of Thermostat Monitoring (Test Group 2BMXV01.6R50, 3BMXV01.6R50 & 3BMXV01.6R5R)
- General Description Of Thermostat Monitoring (Test Group 4BMXV01.6R50)
- PLAUSIBILITY DIAGNOSIS
- Idle Speed Control Diagnosis
- Camshaft Sensor Diagnosis (Test Group 2BMXV01.6R50, 3BMXV01.6R50 & 3BMXV01.6R5R)
- Camshaft Sensor Diagnosis (Test Group 4BMXV01.6R50)
- Intake Manifold Pressure Sensor Diagnosis
- Motorized Throttle Diagnosis Controller Diagnosis
- Clutch Switch Diagnosis
- Coolant Temperature Sensor
- Air Intake System Diagnosis (Test Group 2BMXV01.6R50, 3BMXV01.6R50 & 3BMXV01.6R5R)
- COHERENCE DIAGNOSIS
- Throttle Position Sensors
- Pedal Position Sensor
- Brake Switches
- The Driveline
- Engine Derivatives
- Engine Construction
- Engine Block
- Crankshaft Assembly
- Crankshaft Bearings
- Pistons
- Oil Pan
- Introduction
- Cylinder Head Gasket
- Camshaft
- Rocker Arms and Rocker Shafts
- Valves
- Intake Valves
- Intake Valve Seat Inserts
- Exhaust Valves
- Exhaust Valve Seat Inserts
- Lubrication System
- Oil Circuit
- Piston Cooling - MINI COOPER S Only
- Oil Pump
- Oil Pressure Regulator
- Oil Filter Housing
- Cooling System
- Cooling System Operation
- MINI COOPER
- MINI COOPER S
- Thermostat
- Expansion Tank
- Radiator
- Heater Core
- Coolant Fan
- Oil Cooler (MINI COOPER S)
- Hydramount
- Hydrabush
- Top Stabilizer Bar
- Lower Stabilizer Bar
- Auxiliary Drive Belt
- Auxiliary Drive Belt Tensioner
- Supercharger History
- Supercharger Operation
- Intercooler (MINI COOPER S only)
- Operation
- Location
- Exhaust System
- Exhaust Manifold and Front Pipe
- Center Pipe and Rear Silencer.
- Clutch
- Pressure Plate
- Clutch Disc
- Clutch Hydraulic System
- Dual Mass Flywheel
- Clutch Release Bearing and Hydraulics
- Transmission
- Gears and Shafts
- Clutch Housing
- Rear Cover
- Principle of Operation
- First Gear
- Second Gear
- Third Gear
- Fourth Gear
- Fifth Gear
- Reverse Gear
- Service Information R65
- MINI COOPERS
- Gear Box Housing
- Shift Mechanism
- Service Information Getrag 285
- Automatic Transmission (MINI COOPER Only)
- Purpose of the System
- Group One
- Group Two
- Group Three
- Planetary Gear Set
- Multiplate Clutches
- Primary Pulley, Secondary Pulley, Steel Belt
- Pinion Shaft
- Differential
- Hydraulic Control
- Pitot Pressure
- Hydraulic Control Valves
- Ratio Control Motor
- Park/Neutral Switch
- Output Shaft Speed Sensor
- Instrument Cluster Display
- Selector Mechanism
- GIU (GearBox Interface Unit)
- Gearbox Interface Unit Inputs
- Selector Lever Switches
- CAN Communication
- CVT Principles
- Drive Plate
- Selector Lever in Park or Neutral
- Selector Lever in Drive Position
- Selector Lever in Reverse Position
- Electronic Controls
- Modes of Operation
- Target Engine Speed
- Sports Mode
- Manual Mode
- Fault Mode
- Transmission Adaptation
- Clutch Adaptation
- Ratio Adaptation
- Drain & Refill Procedure
- Service Information
- Diagnostics
- Driveshafts
- System Components
- Driveshaft Bar Shafts
- Outer Joints
- Inner Joints
- Front Hub
- Repair Information
- 12 00 Disconnecting and connecting battery
- 12 00... Instructions for disconnecting and connecting battery
- 12 00 ... Instructions for removing and installing electronic control units
- 12 12 011 Replacing all spark plugs
- 12 12 021 Replacing an ignition cable
- 12 13 513 Replacing ignition coil
- 12 14 537 Replacing camshaft pulse generator
- 12 14 550 Replacing control unit (DME)
- 12 14 550 Replacing control unit (EMS) (COOPER S)
- 12 14 600 Replacing knock sensor
- 12 14 650 Replacing suction pressure pipe sensor
- 12 14 650 Replacing temperature and manifold absolute pressure sensor (COOPER S)
- 12 14 651 Replacing manifold absolute pressure sensor (COOPER S)
- 12 14 705 Programming control unit (DME / DDE)
- 61 35... Note on replacing codable/programmable control units
- 12 31 009 Checking alternator (BSD)
- 12 31 009 Checking alternator and regulator switch
- 12 31 020 Removing and installing/replacing alternator (COOPER S)
- 12 41 020 Removing and installing/replacing starter motor
- 12 41 041 Replacing solenoid switch
- 61 12 001 Replacing positive battery lead (W11, W17)
- 12 62 500 Replacing coolant temperature sensor (DME)
- General information
- Engine Derivatives
- Engine Construction
- Engine Block
- Crankshaft Assembly
- Crankshaft Bearings
- Pistons
- Oil Pan
- Cylinder Head
- Cylinder Head Gasket
- Positive Crankcase Ventilation Pipe A.
- Positive Crankcase Ventilation Pipe B.
- Camshaft
- Valves
- Intake Valves
- Intake Valve Seat Inserts
- Exhaust Valves
- Exhaust Valve Seat Inserts
- Lubrication System
- Oil Circuit
- Piston Cooling - MINI COOPER S Only
- Oil Pump
- Oil Pressure Regulator
- Oil Filter Housing
- MINI COOPER
- MINI COOPER S
- Cooling System
- Cooling System Operation
- Thermostat
- Expansion Tank
- Radiator
- Heater Core
- Coolant Fan
- Oil Cooler MINI COOPER S
- Hydramount
- Hydrabush
- Top Stabilizer Bar
- Lower Stabilizer Bar
- Auxiliary Belt
- Intercooler (MINI COOPER S only)
- Operation
- Location
- Supercharger History
- Supercharger Operation
- Exhaust System
- Exhaust Manifold and Front Pipe
- Center Pipe and Rear Silencer.
- Driveshafts
- Purpose of the System
- System Components
- Driveshaft Bar Shafts
- Outer Joints
- Inner Joints
- Front Hub
- Repair Information
- 11 00 039 Checking compression at all cylinders
- 11 00 050 Removing and installing engine (COOPER S Automatic)
- 11 00 050 Removing and installing engine (COOPER S)
- 11 00 591 Remove and refit components to new engine (COOPER S)
- Securing engine in installation position with special tool (W10/W11)
- 11 12 000 Removing and installing, sealing cylinder head cover (COOPER S)
- 11 12 100 Removing and installing/sealing cylinder head (COOPER S)
- 11 12 260 Removing and installing spark plug well
- 11 12 264 Replacing seals for spark plug well
- 11 12 729 Checking cylinder head for water leaks (W10 /W11)
- 11 13 000 Removing and installing, sealing or replacing oil sump
- 11 14 122 Removing and installing, sealing / replacing timing case cover (COOPER S)
- 11 14 141 Replacing shaft seal below timing chain cover
- 11 14 151 Replacing crankshaft radial seal
- 11 15 025 Removing or replacing engine vent valve
- 11 22 500 Removing and installing or replacing flywheel (COOPER S)
- 11 23 010 Removing and installing or replacing vibration damper (COOPER S)
- 11 25 671 Replacing piston rings on all pistons (W10/W11)
- 11 28 020 Replacing alternator drive belt tensioner (COOPER S)
- 11 28 050 Removing A/C compressor drive belt (COOPER S)
- 11 31 001 Replacing camshaft
- 11 31 051 Replacing timing chain
- 11 31 091 Removing and installing/replacing hydraulic chain tensioner (COOPER S)
- 11 33 020 Removing and installing or replacing rocker arm shaft
- 11 33 031 Replacing rocker arms
- 11 34 560 Replacing all valve stem seals (W10/W11)
- 11 40 000 Checking engine oil pressure
- 11 41 000 Removing and installing or replacing oil pump
- 11 43 000 Removing and installing/replacing guide tube for oil dipstick (COOPER S)
- 11 44 000 Removing and installing/replacing oil - water heat exchanger (COOPER S)
- 11 51 000 Removing and installing/replacing water pump (COOPER S)
- 11 53 000 Removing and installing / replacing coolant thermostat (COOPER S)
- 11 61 051 Removing and installing intake manifold (COOPER S)
- 11 62 000 Removing and installing, sealing/replacing exhaust manifold
- 11 65 035 Removing and installing/replacing supercharger
- 11 78 510 Replacing oxygen sensor
- 11 00 039 Checking compression at all cylinders
- 11 00 050 Removing and installing engine
- 11 00 050 Removing and installing engine (CVT)
- Engine identification
- Securing engine in installation position with special tool (W10/W11)
- 11 12 000 Removing and installing/sealing cylinder head cover (W10)
- 11 12 100 Removing and installing/sealing cylinder head W10
- 11 12 260 Removing and installing spark plug well
- 11 12 264 Replacing seals for spark plug well
- 11 12 729 Checking cylinder head for water leaks (W10 /W11)
- 11 13 000 Removing and installing, sealing or replacing oil sump
- 11 14 122 Removing and installing / replacing timing chain cover (W10/W11)
- 11 14 141 Replacing shaft seal below timing chain cover
- 11 14 151 Replacing crankshaft radial seal
- 11 15 025 Removing or replacing engine vent valve
- 11 21 500 Removing and installing/replacing crankshaft (W10)
- 11 21 531 Replacing crankshaft main bearing shells W10
- 11 22 000 Removing and installing or replacing drive discs (CVT)
- 11 22 500 Removing and installing or replacing flywheel
- 11 23 010 Removing and installing or replacing vibration damper
- 11 24 571 Replacing all connecting rod bearings (W10)
- 11 25 530 Removing and installing/replacing all pistons (W10)
- 11 25 671 Replacing piston rings on all pistons (W10/W11)
- 11 28 010 Replacing alternator drive belt (W10)
- Special tools required
- 11 28 020 Removing and installing/replacing alternator drive belt tensioner
- 11 28 050 Removing A/C compressor drive belt
- 11 31 001 Replacing camshaft
- 11 31 051 Replacing timing chain
- 11 31 091 Removing and installing or replacing hydraulic chain tensioner
- 11 33 020 Removing and installing or replacing rocker arm shaft
- 11 33 031 Replacing rocker arms
- 11 34 560 Replacing all valve stem seals (W10/W11)
- 11 40 000 Checking engine oil pressure
- 11 41 000 Removing and installing or replacing oil pump
- 11 42 020 Removing and installing complete main flow oil filter
- 11 43 000 Removing and installing/replacing oil dipstick guide tube
- 11 51 000 Removing and installing or replacing water pump
- 11 53 000 Removing and installing/replacing coolant thermostat (W10)
- 11 61 051 Removing and installing intake manifold
- 11 62 000 Removing and installing, sealing/replacing exhaust manifold
- 11 78 510 Replacing oxygen sensor
- 12 00 ... Instructions on starting aid
- 61 00 ... Battery
- 61 00 ... Battery charging
- 61 00 ... Repairing airbag cables
- 61 00 ... Safety instructions for handling vehicle battery
- 61 13 .. Unlocking and disconnecting different plug connections
- 61 13 Special tools for wiring harness repairs
- 61 13 ... Base of tab connector housings
- 61 13 ... Crimping Micro Power Quadlock contacts (MPQ)
- 61 13 ... Crimping Micro Quadlock System contacts (MQS)
- 61 13 ... Crimping annular contacts
- 61 13 ... Crimping optical fibres
- 61 13 ... Cutting off, stripping insulation and cutting optical fibres to length
- 61 13 ... Opening plug housings and removing contacts of different plug systems
- 61 13 ... Relay carrier
- 61 13 ... Retaining bracket
- 61 13 ... Socket housing (radio plug), Hybrid System MQS/MPQ
- 61 13 051 Removing and installing/replacing fuse box in engine compartment
- 61 13 056 Removing and installing/replacing passenger compartment fusebox
- 12 00 ... Instructions for disconnecting and connecting battery
- 61 20 ... Threshold values for battery inspection of all battery (telephone except for telephone battery)
- 61 20 ... Battery open-circuit current test
- 61 21 010 Removing and installing battery
- 61 21 100 Removing and installing/replacing battery container
- 61 31 006 Removing and installing (replacing) fixture for steering column stalk
- 61 31 011 Removing and installing/replacing volute spring cassette
- 61 31 016 Removing and installing/replacing turn indicator/headlight dipping switch
- 61 31 020 Removing and installing/replacing ignition starter switch
- 61 31 040 Removing and installing/replacing switch for windscreen wipers
- 61 31 059 Removing and installing/replacing switch block in instrument panel
- 61 31 072 Removing and installing/replacing headlight vertical aim control switch
- 61 31 089 Removing and installing/replacing switch for tire pressure monitor (TPM)
- 61 31 090 Removing and installing / replacing switch for left or right seat heating
- 61 31 175 Removing/installing sunroof switch
- 61 31 185 Replacing petrol/gasoline pump emergency switch
- 61 31 222 Removing and installing/replacing fanfare horn switch
- 61 31 227 Replacing left and right switches on sport steering wheel
- 61 31 241 Removing and installing/replacing engine hood/bonnet contact switch
- 61 31 255 Removing switch for electrically adjustable door mirror
- 61 31 270 Removing/replacing reverse lamp switch
- 61 31 310 Replacing brake-light switch
- 61 31 348 Replacing microswitch for unlocking rear lid
- 61 33 000 Replacing horn (anti-theft alarm system)
- 61 35 ... Note on replacing codable/programmable control units
- 61 35 ... Notes on ESD protection (Electro Static Discharge)
- 61 35 175 Removing and installing/replacing rain sensor
- 61 35 510 Removing and installing or replacing electronic body module (ZKE)
- 61 35 680 Initializing rain sensor
- 61 35 790 Removing and installing/replacing control unit for headlight vertical aim adjustment
- 61 35 900 Removing and installing/replacing ring antenna of electronic immobilizer
- 61 35 910 Removing and installing/replacing control unit of electronic immobilizer
- Diagnosis Programming/Coding
- 61 61 010 Checking/adjusting contact angle of windscreen wiper arms on windscreen
- 61 61 041 Replacing both windscreen wiper blades
- 61 61 081 Removing and installing/replacing windscreen wiper arm
- 61 61 270 Removing and installing complete wiper console
- 61 62 020 Removing and installing/replacing rear wiper blade
- 61 62 030 Replacing (removing and installing) wiper arm for rear window wiper (from 07/2004)
- 61 62 030 Replacing (removing and installing) wiper arm for rear window wiper (up to 07/2004)
- 61 62 060 Removing and installing/replacing rear window wiper motor
- 61 62 100 Adjusting jet nozzle for rear window washer unit
- 61 67 000 Replacing fluid reservoir for headlight cleaning system
- 61 67 010 Removing and installing/replacing washer pump of headlight cleaning system
- 61 67 045 Removing and installing/replacing spray nozzles for left or right headlight cleaning system
- 61 71 004 Adjusting windscreen washer nozzles
- 61 71 015 Removing and installing/replacing a spray nozzle in windscreen washer system
- 61 71 061 Replacing fluid reservoir for windscreen washer system
- 61 71 100 Removing and installing/replacing windscreen washer pump
- 64 11 ... Installing servodrive
- 64 11 200 Removing and installing or replacing heater
- 64 11 207 Replacing heater core
- 64 11 210 Removing and installing heater fan
- 64 11 221 Replacing resistor for heater - A/C fan
- 64 11 222 Replacing resistor for heater - A/C fan (IHKA)
- 64 11 333 Removing and installing/replacing heater controls (IHR and IHKR)
- 64 11 334 Removing and installing/replacing heater controls (IHKA)
- 64 11 800 Removing and installing/replacing servodrive for flap control gear (IHKA)
- 64 11 805 Removing and installing/replacing servodrive for fresh-air/reirculated-air flap
- 64 11 861 Replacing servodrive for temperature control (IHKA)
- 64 11 889 Replacing sensor fan for interior temperature (IHKA)
- 64 11 932 Replacing evaporator temperature sensor (IHKR/IHKA)
- 64 11 939 Replacing temperature sensor for heater (IHKA)
- 64 11 992 Removing and installing/replacing solar sensor
- 64 22 135 Removing and installing/replacing left (or right) fresh air grill
- 64 22 136 Removing and installing/replacing right fresh-air grille
- 64 22 161 Removing and installing/replacing middle fresh air grill
- 64 31 009 Replacing microfilter for interior ventilation
- 64 50 ... Air conditioner test (R 134a)
- 64 50 ... Leak-testing with leak tester device
- 64 50 ... Safety instructions for handling refrigerant R 134a
- 64 50 ... Safety precautions when handling refrigerant oil (for refrigerant R 134a)
- 64 50 009 Drawing off, evacuating and filling A/C system (R 134a)
- 64 51 522 Removing and installing or replacing expansion valve
- 64 51 590 Removing and installing/replacing evaporator
- 64 52 ... Instructions for compressor replacement
- 64 52 520 Removing and installing/replacing complete A/C compressor
- 64 53 ... Notes on replacing drier bottle or drier insert
- 64 53 510 Removing and installing / replacing drier bottle for air conditioner
- 64 53 520 Replacing safety pressure switch
- 64 53 551 Removing and installing/replacing condenser for A/C system (W10, W11)
- 63 10 ... Test requirements for headlight vertical aim adjustment
- 63 10 004 Adjusting headlights
- 63 10 014 Adjusting fog lamps
- 63 12 007 Removing and installing/replacing left or right headlight (halogen headlight)
- 63 12 008 Removing and installing/replacing left or right headlight (xenon headlight, from 07/2004)
- 63 12 008 Removing and installing/replacing left or right headlight (xenon headlight, up to 07/2004)
- 63 12 862 Replacing control unit for left or right xenon headlight
- 63 13 150 Removing and installing/replacing complete front left or right turn signal lamp
- 63 13 200 Removing and installing/replacing front left or right auxiliary turn signal lamp
- 63 17 000 Removing and installing/replacing left or right foglamp insert
- 63 21 101 Replacing sealing frame for left or right rear light
- 63 21 180 Removing and installing/replacing left or right rear light
- 63 22 010 Removing and installing/replacing reversing light (up to 07/2004)
- 63 25 000 Removing and installing/replacing additional stop light
- 63 31 000 Removing and installing/replacing complete ceiling light
- 63 31 020 Removing and installing/replacing footwell light
- 63 31 080 Removing/installing replacing luggage compartment light
- 63 31 150 Removing and installing/replacing glovebox light
- 63 99 ... Instructions for handling light bulbs (exterior lights)
- 63 99 ... Instructions for replacing light bulbs (interior lights)
- 63 99 001 Replacing halogen bulb for left or right high-beam headlight
- 63 99 071 Replacing halogen-light bulb for left or right headlight
- 63 99 078 Replacing bulb for left or right xenon headlight (from 07/2004)
- 63 99 078 Replacing bulb for left or right xenon headlight (up to 07/2004)
- 63 99 131 Replacing bulb for left or right front parking light
- 63 99 201 Replacing halogen bulb for left or right fog lamp (from 07/2004)
- 63 99 201 Replacing halogen bulb for left or right fog lamp (up to 07/2004)
- 63 99 271 Replacing bulb for left or right front turn indicator
- 63 99 295 Replacing bulb for left or right auxiliary turn signal light
- 63 99 307 Replacing bulb for reversing light (up to 07/2004)
- 63 99 315 Replacing light bulb(s) for left or right rear light
- 63 99 401 Replacing bulb for left or right license plate light
- 63 99 431 Replacing light bulb(s) for ceiling light
- 63 99 437 Replacing light bulb for footwell light
- 63 99 451 Replacing light bulb for luggage compartment light
- 63 99 461 Replacing bulb for glovebox light
- APPLICATION
- DESCRIPTION
- LUBRICATION
- ON-VEHICLE SERVICE
- TROUBLESHOOTING
- REMOVAL, INSTALLATION, DISASSEMBLY & REASSEMBLY
- CLUTCH HOUSING
- Removal & Installation
- CLUTCH LEVER
- CLUTCH RELEASE UNIT
- COVER/5TH GEAR
- DIFFERENTIAL SHAFT SEAL
- DIFFERENTIAL TAPER ROLLER BEARING
- DRIVE (INPUT) SHAFT RADIAL SEAL
- GUIDE TUBE FOR CLUTCH RELEASE UNIT
- INPUT SHAFT
- INPUT & OUTPUT SHAFT BEARINGS
- INPUT SHAFT BEARINGS
- LEFT DRIVE SHAFT SEALING RING (5TH GEAR)
- LOCKING BODY/REVERSE GEAR FORK
- NEEDLE BEARING/5TH GEAR
- OUTPUT SHAFT
- Disassembly & Reassembly
- OUTPUT SHAFT BEARINGS
- REVERSING LIGHT SWITCH
- REVERSE GEAR LOCKING PISTON
- RIGHT AXLE SHAFT SEAL (5TH GEAR)
- SHIFT LEVER
- SHIFT SHAFTS/SHIFT FORKS
- SHIFTING UNIT
- TRANSMISSION BREATHER
- TRANSMISSION HOUSING
- 1ST/2ND & 3RD/4TH GEAR SYNCHROMESH
- 5TH GEAR DRIVE
- 5TH GEAR SYNCHROMESH
- TORQUE SPECIFICATIONS
- 52 10 ... Backrest adjustment not functioning
- 52 13 ... Removing and installing / replacing guide for left or right front seat head restraint
- 52 13 ... Removing and installing/replacing guide for front left or right head restraint (TU)
- 52 13 000 Removing and installing driver's or front passenger seat (normal / manual)
- 52 13 000 Removing and installing left or right front seat (TU)
- 52 13 020 Removing and installing/replacing seat frame on left or right front seat (TU)
- 52 13 030 Removing and installing / replacing backrest frame on driver's and front passenger seats (manual / electric)
- 52 13 030 Removing and installing/replacing backrest frame on left or right front seat (TU)
- 52 13 033 Replacing release handle on left or right front seat (TU)
- 52 13 041 Removing and installing / replacing inner panel on driver's and front passenger seats (manual / electric)
- 52 13 041 Removing and installing/replacing inner cover on left or right front seat (TU)
- 52 13 043 Removing and installing / replacing outer panel on driver's and front passenger seats (manual / electric)
- 52 13 043 Removing and installing/replacing outer cover (with seat height adjustment) on left or right front seat (TU)
- 52 13 043 Removing and installing/replacing outer cover on left or right front seat (TU)
- 52 13 055 Removing and installing lumbar support on front seat (TU)
- 52 13 055 Replacing lumbar support mechanism on left or right front seat (normal / manual)
- 52 13 198 Removing and installing / replacing backward backrest panel on left or right front seat (normal / manual)
- 52 13 198 Removing and installing/replacing rear panel on left or right front seat backrest (TU)
- 52 13 390 Removing and installing/replacing front left or right head restraint (TU)
- 52 13 400 Replacing seat cover for left or right front seat (TU)
- 52 13 400 Replacing seat cover on left or right front seat (normal/manual)
- 52 13 405 Removing and installing / replacing head restraint panel on driver's and front passenger seats (manual / electric seat adjustment)
- 52 13 405 Replacing backrest cover for left or right front seat (TU)
- 52 13 415 Replacing left or right support for front seat (normal / manual)
- 65 77 604 Replacing sensor mat (OC3 mat) for passenger seat occupancy detector
- 52 26 ... Adjusting striker for rear seat backrest
- 52 26 ... Replacing seat frame for rear seat
- 52 26 005 Removing and installing or replacing rear seat
- 52 26 015 Removing and installing or replacing left or right rear seat backrest
- 52 26 390 Removing and installing/replacing rear left or right head restraint
- 52 26 086 Removing and installing/replacing backrest frame for left or right rear seat
- 52 26 201 Removing and installing / replacing rear panel on rear seat backrest
- 52 26 303 Removing and installing/replacing actuating mechanism for rear seat backrest
- 52 26 311 Removing and installing/replacing lock for left or right rear seat backrest
- 52 26 390 Removing and installing or replacing left or right rear head restraint
- 52 26 413 Removing and installing/replacing backrest cover for left or right rear seat
- 52 26 751 Replacing Bowden cable for left or right rear seat backrest
- DESCRIPTION
- 31 33 095 MEASURING RIDE-LEVEL HEIGHT OF VEHICLE
- SPRING STRUT SHOCK ABSORBER
- WHEEL ALIGNMENT SPECIFICATIONS & PROCEDURES
- TROUBLE SHOOTING
- 31 11 001 REPLACING FRONT AXLE SUPPORT
- 31 00 ... INFORMATION ON REPLACING SHOCK ABSORBERS
- 31 31 000 REMOVING AND INSTALLING FRONT LEFT OR RIGHT SPRING STRUT
- 31 31 031 REPLACING FRONT LEFT OR RIGHT SPRING STRUT SHOCK ABSORBER (VEHICLES UP TO 03/2002)
- 31 31 031 REPLACING FRONT LEFT OR RIGHT SPRING STRUT SHOCK ABSORBER (VEHICLES FROM 03/2002)
- 31 12 000 REMOVING AND INSTALLING LEFT OR RIGHT CONTROL ARM
- 31 35 000 REMOVING AND INSTALLING/REPLACING FRONT STABILIZER
- 31 35 005 REMOVING AND INSTALLING/REPLACING PUSH ROD (STABILIZER LINK) FOR LEFT/RIGHT STABILIZER
- 31 35 021 REPLACING BOTH RUBBER MOUNTS FOR STABILIZER MOUNTING ON FRONT AXLE SUPPORT
- 32 21 231 REPLACING LEFT OR RIGHT TIE ROD
- 31 21 180 REPLACING BEARINGS (WHEEL HUB) FOR FRONT WHEEL