DESCRIPTION & OPERATION
Generator is mounted to the block with 3 bolts. The Cooper S generator is situated in a lower position to accommodate the supercharger.
BELT TENSION
Mini Cooper belt tensioner uses a torsional spring to apply load to belt and a friction damper to reduce the pulsating vibrations from engine. Mini Cooper S belt tensioner uses a compression spring to apply load to belt and a hydraulic damper to control engine pulsation.
TROUBLE SHOOTING
Note. See TROUBLE SHOOTING article in GENERAL INFORMATION.
ON-VEHICLE TESTING
Note. Use BMW's GROUP TESTER ONE (GT-1) or DISplus hardware system to test and diagnose system.
GENERATOR OSCILLOSCOPE CHECKS
For generator Oscilloscope checks (Scheme 1)- (Scheme 7).
Scheme 1
Scheme 2
Scheme 3
Scheme 4
Scheme 5
Scheme 6
Scheme 7
REMOVAL & INSTALLATION
| CAUTION | When battery is disconnected, vehicle computer and memory systems may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle. See COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION before disconnecting battery. |
Removal & Installation (Cooper)
Turn ignition off. Disconnect battery. Remove drive belt. Remove intake manifold. See INTAKE MANIFOLD. Unlock plug and disconnect connector. Remove nut and remove battery positive lead. (Scheme 8) Remove bolts and remove generator. (Scheme 9) To install, reverse removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS.
Scheme 8
Scheme 9
Removal & Installation (Cooper S)
Turn ignition off. Disconnect battery. Remove drive belt. Remove front bumper trim. See FRONT BUMPER TRIM. Lower front end module and install Special Tools (118401 and 118402). (Scheme 10) Remove nut and disconnect positive battery lead from generator. Disconnect generator electrical connector. (Scheme 11) Remove 3 bolts and remove generator. (Scheme 12) To install, reverse removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS.
Scheme 10
Scheme 11
Scheme 12
Release clamp. Detach intake fitting from intake filter housing. Loosen screws. Release cable holders. Remove air filter housing. (Scheme 13)
Scheme 13
Remove bolts and screws from bumper lower spoiler to Modular Front End (MFE). (Scheme 14) Remove hood release handle securing clip. Remove hood release handle. Remove bumper-to-Modular Front End (MFE) screws. Remove rivets securing bumper to wheel arch liners. Remove bolts securing bumper to bumper height adjustment mounting. (Scheme 15) Release bumper clips from bumper carrier. Disconnect position light connectors. Disconnect direction indicator connectors. Disconnect ambient air temperature sensor connector. (Scheme 16) Remove bumper trim. To install, reverse removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS.
Scheme 14
Scheme 15
Scheme 16
Scheme 17
Scheme 18
Scheme 19
- Turn ignition off. Disconnect battery. Remove air cleaner housing. See «AIR CLEANER HOUSING»(/mini/cooper-s/i-2000-2006/remont/charging-system/#generators-regulators). Remove throttle assembly. See «THROTTLE ASSEMBLY»(/mini/cooper-s/i-2000-2006/remont/charging-system/#generators-regulators). Remove cover from fuel rail. Detach line to brake booster from intake manifold. Press ring downward to expose line. (Scheme 17) Detach crankcase ventilation valve from inspection hole cover. Remove fuel line from fuel rail; disconnect quick-release coupling for this purpose. Catch and dispose of escaping fuel. Detach plug connector from intake air temperature/manifold air pressure sensor.
- Detach knock sensor plug from fuel rail wiring harness. Disconnect tank vent link and unclip at fuel rail. Disconnect vacuum line from intake manifold. Remove retaining screws of fuel rail, then remove fuel injectors and fuel rail from manifold. Seal off fuel pressure regulator with Special Tool (135280). (Scheme 18) Support fuel rail with a suitable piece of wire or manufactured rod. Remove dipstick. Remove manifold screws and remove manifold. Unclip coolant line below manifold. To install, reverse removal procedure. Tighten intake manifold bolts in sequence. (Scheme 19) Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(/mini/cooper-s/i-2000-2006/remont/charging-system/#generators-regulators__torque-specifications).
Note. A faulty throttle valve causes the adaptation values stored in the DME control unit to be modified. These adaptation values must be reset after the throttle valve has been replaced. Use BMW scan tool to reset adaptation values.
Turn ignition off. Disconnect battery. Remove air cleaner housing. See AIR CLEANER HOUSING. Remove intake air boot. Unlock line of tank venting valve on throttle valve assembly and disconnect. Unlock plug and remove. Loosen bolts. Remove throttle valve assembly. (Scheme 20) To install, reverse removal procedure. Replace sealing ring. (Scheme 21) Tighten bolts to specification. See TORQUE SPECIFICATIONS.
Scheme 20
Scheme 21
GENERATOR SPECIFICATIONS
| Application | Specification | |
|---|---|---|
| Amperage | 120 Amps | |
| Brush Length (1) | .20" (5 mm) | |
| Voltage | 13.2-15.0 Volts | |
| (1) (Scheme 22) | ||
| (1) | (Scheme 22) |
GENERATOR SPECIFICATIONS
Scheme 22
TORQUE SPECIFICATIONS
| Application | Ft. Lbs. (N.m) |
|---|---|
| Generator-To-Crankcase Retaining Bolt | 18 (25) |
| Intake Manifold-To-Cylinder Head Bolt | 19 (26) |
| INCH Lbs. (N.m) | |
| Bumper Adjuster-To-Bumper Bolt | 53 (6) |
| Front Bumper-To-Modular Front End (MFE) Bolt | 44 (5) |
| Front Bumper Lower Spoiler-To-Modular Front End (MFE) Bolts & Screws | 53 (6) |
| Power Lead-To-Generator Stud Nut | 88 (10) |
| Throttle Body-To-Intake Manifold Bolt | 80 (9) |
TORQUE SPECIFICATIONS
Scheme 23
Scheme 24
Scheme 25
See also:
• INTAKE MANIFOLD
• TORQUE SPECIFICATIONS