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MINI Cooper 2003 Manuals
Manuals and User Guides for MINI Cooper 2003. We have
1
MINI Cooper 2003 manual available for free PDF download: Service Manual
MINI Cooper 2003 Service Manual (1080 pages)
Brand:
MINI
| Category:
Automobile
| Size: 73.83 MB
Table of Contents
Technical Contact Information
3
Warning
3
Contents
4
General Warnings and Cautions
6
Vehicle Identification and VIN Decoder
8
Product Familiarization
9
General
9
Product Overview
9
2005 Model Year Changes
10
Technical Data
11
Powertrain
12
Engines
12
Transmissions
13
Body Exterior
14
Body Dimensions
16
Body Interior
17
Safety
19
Dashboard and Controls
20
Display Elements
20
Suspension, Steering, Brakes
21
MINI Convertible
22
John Cooper Works
24
Maintenance
25
Table of Contents
25
Warnings, Cautions and Notes
27
Basic Service Information
27
Diagnostic Trouble Codes (Dtcs), Accessing
27
Tightening Fasteners
28
Non-Reusable Fasteners
28
Parts
29
Genuine Mini Parts
29
Non-Returnable Parts
29
Tools
30
Special Tools
31
Identification Plates and Labels
32
Vehicle Identification Number (VIN)
32
Date of Manufacture
32
Raising Vehicle
32
Raising Vehicle Safety Using Vehicle Jack
33
Working under Vehicle Safety
33
Emergencies
34
Flat the Monitor
34
Changing a Tire
34
Jack Stands
34
Jump Starting
36
Indicator and Warning Lights
36
Towing
36
Spare Parts List
37
Engine Compartments Components
38
Engine Covers, Removing and Installing
38
Cooper
38
Cooper S
38
Air Filter Service
39
Air Filter, Replacing
39
Battery Service
40
Ari Filter, Assembly
40
Battery, Checking, Cleaning and Replacing
40
Brake Service
42
Brake Fluid, Replacing
42
Brake Pad/Rotor Wear, Checking
42
Parking Brake, Checking
43
Cooling System ,Checking
43
Engine Accessory Belt Service
44
Engine Coolant
44
Accessory Belt, Replacing
45
Accessory Belt, Replacing (Cooper S)
46
Engine Oil Service
47
Engine Oil, Checking Level
48
Engine Oil and Filter, Changing
48
Fuel System Service
50
Fuel Filter
50
Fuel Tank and Fuel Lines, Inspecting
50
Interior Ventilation Microfilter, Replacing
50
Power Steering Fluid, Checking
51
Spark Plugs, Replacing
52
Transmission Service
53
Transmission Service, Automatic
53
Transmission Service, Automatic (Agitronic)
53
Transmission Service, Manual
54
Other Mechanical Maintenance
55
Catalytic Converter and Oxygen Sensor
55
Clutch Fluid, Checking
55
Drive Axle Joint Boots
55
Exhaust System, Inspecting
56
Suspension, Inspecting
56
Tires, Checking Inflation Pressure
56
Tires, Rotating
56
Body and Interior Maintenance
57
Wheels, Aligning
57
Body and Hinges, Lubricating
57
Exterior Washing
57
Leather Upholstery and Trim
58
Polishing
58
Seat Belts
58
Special Cleaning
58
Waxing
59
Windshield Wiper Blade Maintenance
59
Service Intervals
60
Service Interval Display
60
SIA, Resetting
60
Inspection I, Inspection II
60
Maintenance Tables
61
Engine-General
65
Engine Specifications
66
Engine Identifying Features
67
Engine Construction
67
Engine Block
67
Crankshaft Assembly
68
Crankshaft Bearings
69
Connecting Rods
69
Feature Process
69
Pistons
70
Grafal Coating
70
Oil Pan
70
Cylinder Head
70
Positive Crankcase Ventilation
71
Cylinder Head Gasket
71
Cylinder Head Bolts
71
Valvetrain
72
Camshaft
72
Rocker Arms and Rocker Shafts
72
Valves
73
Intake Valves
73
Intake Valve Seat Inserts
73
Exhaust Valves
73
Timing Chain
74
Lubrication System
74
John Cooper Works Kit
75
Driveability Troubleshooting
75
System Voltage
75
Main Grounds
76
Engine Removal and Installation
77
Engine, Removing and Installing
80
Cylinder Head Removal and Installation
103
T I G H T E N I N G F a S T E N E R
103
T O O L
103
D a T E O F M a N U F a C T U R
103
J U M P S T a R T I N
103
F U E L Fi L T E
103
Intake Manifold, Removing and Installing
110
Remove Throttle Valve Assembly
111
Remove Fuel Rail Cover
111
Cylinder Head and Valvetrain
142
Cylinder Head Disassembly
145
Spark Plug Sleeve, Removing and Installing
145
Rocker Arm Shafts and Rocker Arms, Removing and Installing
146
Camsahft, Removing and Installing
147
Cylinder Head Service
154
Cylinder Head, Inspecting
154
Valves, Leak Test
154
Cylinder Head, Coolant Leak Test
155
Valves, Removing and Installing
155
Valve Stem Oil Seals
156
Valve Guides
157
Valve Seats
158
Valve Seat Dimensions
158
Valve Springs
159
Camshaft Timing Chain
160
H O W T O U S E T H I S M a N U a
160
R a I S I N G V E H I C L
160
T O W I N
160
W a S H I N G C H a S S I
160
Timing Chain Housing Cover
164
Crankshaft Vibration Damper, Removing and Installing
164
Timing Chain Housing Cover, Removing and Installing
166
Oil Pressure
185
Engine Oil Pressure
185
Oil Pressure Warning System, Testing
186
Crankshaft Seal, Crankshaft Front Seal, Removing and Installing
187
Crankshaft Rear Seal, Removing and Installing
188
Engine Oil Pan
189
Oil Pan, Removing and Installing
189
Component Replacement
191
Oil Pressure Warning Switch, Replacing
191
Oil Pump
191
Oil Pressure Relief Valve, Removing and Installing
192
Ignition System
193
Engine Management
195
Oscilloscope Diagnostic Diagrams
197
Warnings and Cautions
199
Ignition System Service
200
Ignition Firing Order
200
Disabling Ignition System
200
Ignition Wire
201
Ignition Coil Assembly
201
Crankshaft Position Sensor
202
Camshaft Position Sensor
203
Knock Sensor
204
Battery, Starter, Alternator
205
Engine Electrical System
206
Battery Safety Terminal
207
Battery
209
Battery Capacity
209
Battery Charging
209
Battery Maintenance
210
Battery Testing
211
Hydrometer Testing
211
Battery Open-Circuit Voltage Test
212
Battery Load Voltage Test
212
Battery, Removing and Installing
213
Battery Box, Removing and Installing
214
Battery Safety Terminal Replacement
215
Alternator
216
Charging System Troubleshooting
216
Charging System Quick Check
216
Charging System, Checking
217
Alternator, Removing and Installing
219
Fuel Injection
225
L I F T I N G V E H I C L
225
A I R F I L T E R S E R V I C
225
A I R Fi L T E R , R E P L a C I N G ( C O O P E
225
A I R Fi L T E R , R E P L a C I N G ( C O O P E R
225
E X T E R I O R W a S H I N
225
S P E C I a L C L E a N I N
225
W a X I N
225
Engine Control Module
229
Power Supply
230
EMS2000 Engine Management
231
Air Management
232
Fuel Management
232
Ignition Management
232
Emission Management
233
Pre-Catalyst Oxygen Sensor
233
Post-Catalyst Oxygen Sensor
233
Adaptation
233
Performance Controls
234
EWS Interface
234
Automatic Transmission Control
234
A/C Compressor Control
234
System Inputs
235
Cruise Control
235
Engine Cooling Fan
235
Accelerator Pedal Position Sensor
236
Sensor Inputs
237
T-MAP Sensor
237
Manifold Pressure Sensor
237
T-MAP and MAP Sensors
238
Air Intake Temperature Sensor
238
Engine Coolant Temperature Sensor
239
Throttle Position Feedback
239
Crankshaft Sensor
239
Reluctor Ring
240
Camshaft Sensor
240
Fuel Leakage Diagnosis System
241
Oxygen Sensors
241
Brake Light Switch
242
Clutch Switch
242
Automatic Transmission Sensors
242
Immobilizer
243
Transmission Control Module
243
Abs/Asc/Dsc
243
A/C Pressure Transducer
243
System Outputs
244
Multifunction Steering Wheel
244
Main Relay
244
Electronic Throttle Control
244
Idle Speed Control
245
EML Warning LED
245
Fuel Pump Relay and Inertia Switch
245
Fuel Injectors
246
Selective Injector Cut-Out
248
Evaporative Emissions Control
248
Oxygen Sensor Heating
249
OBD II Plug
249
Troubleshooting
250
Fuel Rail and Injectors, Removing and Installing
251
Fuel Pressure Regulator, Removing and Installing
253
Air Filter Housing, Removing and Installing
253
Air Filter Housing and Upgrade Kit
255
Throttle Housing, Removing and Installing
256
Supercharger Oil Service
258
Supercharge Rear Oil Reservoir, Adding Oil
259
Supercharger, Removing and Installing
260
T-MAP Sensor, Replacing
268
Electrical Components
270
Main Relay, Accessing
270
Fuel Pump Relay, Accessing
270
Engine Control Module, Accessing
270
ECM Pin Assignments
271
Fuel Tank and Fuel Pump
276
Fuel Filler Pipe
289
LDP/DMTL Unit
290
Radiator and Cooling System
292
Cooling System Overview
293
Coolant Pump
293
Thermostat
293
Radiator and Expansion Tank
294
Transmission Fluid Cooler
294
Electric Cooling Fan
294
Coolant Temperature Gauge
294
Cooling System Inspection
296
Cooling System Pressure Test
297
Combustion Chamber Leak Test
297
Cooling System Service
298
Thermostat Test
298
Coolant, Draining and Filling
298
Coolant, Filling
298
Coolant Pump, Replacing
300
Exhaust System
307
Exhaust System, Removing and Installing
308
Exhaust Manifold
309
Exhaust System Diagrams
312
Cooper S Exhaust System
313
Transmission-General
314
S E R V I C E I N T E R V a L
314
Drivetrain
315
Manual Transmission
315
Automatic Transmission
316
Continuously Variable Transmission
316
Automatic Transmission with Agitronic
316
Transmission Lubricants
317
Clutch
318
Clutch Hydraulics
320
Clutch Hydraulic System, Bleeding and Flushing
320
Clutch Master Cylinder, Replacing
322
Clutch Slave Cylinder
323
Clutch Mechanical
324
Clutch, Removing and Installing
324
Input Shaft Seal, Replacing
337
Transmission Removal and Installation
337
Front Subframe
338
B a T T E R y S E R V I C
346
Transmission Fluid Level, Checking
352
Transmission Fluid Level, Replacing
353
Back-Up Light Switch
354
CVT Switch
354
Drive Axle Seals, Replacing
355
Left Drive Axle Seal
355
Right Drive Axle Seal
355
Transmission Fluid Pan Gasket
357
Transmission Fluid Screen
360
Vehicle Speed Sensor
360
Drive Axle Seals
361
Gear Position Switch
362
Torque Converter, Removing and Installing
370
Gearshift Linkage
371
Transmission Gearshift
372
Gearshift Knob, Removing and Installing
372
Gearshift Dust Boot
373
Front Center Console
373
Gearshift Assembly
375
Shift Cables
377
Gearshift
377
Shift Cable
380
Suspension, Steering and Brakes
383
R E P L a C I N
383
I N S P E C T I N
383
I D L E S P E E
383
S E a T B E L T
383
M a I N T E N a N C E T a B L E
383
Tire and Wheel Information
387
Electronic Brake and Stability Control Systems
388
Antilock Braking System
388
Automatic Stability Control
388
Ride Height
388
Front Suspension, Drive Axles
390
Front Suspension Design
393
Front Suspension Components
393
Front Strut Assembly Components
401
Front Strut, Disassembling and Assembling
402
Strut Brace
404
Control Arms
406
Control Arm, Removing and Installing
406
Stabilizer Bar
409
Stabilizer Bar Links, Removing and Installing
409
Front Wheel Bearings
410
Front Drive Axles
411
Front Drive Axle Components
412
Drive Axle
412
Steering and Wheel Alignment
418
C H E C K I N
418
Steering Wheel
420
Airbag Warning
421
Steering Wheel, Removing and Installing
421
Steering Column
423
Steering Column Components
423
Ignition Lock Cylinder
423
Steering Column Upper Cover
424
Steering Column Lower Cover
425
Shift Interlock Cable
425
Steering System Components
430
Steering System, Bleeding and Filling
430
Electrohydraulic Steering Pump
431
Rear Suspension
440
C H a N G I N G a T I R
440
Rear Suspension Design
441
Rear Suspension Components
442
Rear Subframe
442
Trailing Arms
442
Shock Absorbers and Springs
443
Rear Control Arms
443
Rear Stabilizer Bar
443
Rear Strut Assembly
444
Rear Strut Assembly Components
445
Rear Strut, Disassembling and Assembling
445
Brakes
456
E M E R G E N C I E
456
MINI Brake System
459
ABS Operation
460
Body - General
494
E N G I N E O I L S E R V I C
494
Body Assembly
495
Body Cage
496
Door Locks and Handles
496
Airbags
496
Security
497
Interior Features
498
Seats
498
Body Control Electronics
499
Heating and Air-Conditioning
499
Fenders, Engine Hood
500
Front Fenders
501
Engine Hood
502
Hood Raiding to Service Position
502
Hood Removing and Installing
503
Hood Aligning
504
Hood Latch, Adjusting
505
Right Hood Latch
506
Left Hood Latch
506
Hood Grill
506
Hood Scoop Trim, Replacing
507
Doors
508
Door Removing and Installing
509
Door Adjusting
510
Door Trim Panels
511
Door Trim Panel Removing and Installing
511
Continued for All Vehicles
512
Rear Hatch
513
Rear Hatch Strut
514
Rear Hatch Removing and Installing
515
Rear Hatch Aligning
515
Rear Hatch Lower Trim
516
Rear Hatch Side Removing
517
Rear Hatch Upper Trim
518
Rear Hatch Seal Removing
518
Rear Spoiler Removing
519
Rear Lid Trim Panel Removing and Installing
519
Exterior Trim, Bumpers
522
I N T E R I O R C a R
522
Front Bumper Cover
526
Front Bumper Carrier
528
Modular Front End
529
MFE, Loosening
529
Door Windows
534
Interior Trim
542
Interior Trim Repairs
543
Center Consoles
544
Front Console
544
Rear Console
545
Center Console Armrest
546
Dashboard
547
Glove Compartment
547
Dashboard Components
548
Dashboard Removing and Installing
549
Center Dashboard Face Trim
554
Left Dashboard Face Trim
554
Right Dashboard Face Trim
555
Central Locking and Anti-Theft
562
Central Locking
564
Electronic Immobilizer
565
Anti-Theft Alarm
565
Door Striker
569
Door Handle
569
Inside Door Handle
570
Rear Hatch Lock Component Replacement
571
Rear Hatch Lock Emergency Release
571
Emergency Rear Hatch Lock Release Cable
571
Rear Hatch Release Switch
573
Rear Hatch Lock Striker
575
Rear Hatch Lock Adjusting
575
Electronic Immobilizer Component Replacement
576
EWS Control Module
576
Anti-Theft Alarm Component Replacement
577
Ring Antenna
577
Ultrasound Module
578
Front Seats
582
Front Seat Adjustment
582
Front Seat Options
583
Rear Seat
583
Rear Seat Backrest Operation
583
Child Safety Seat Anchors
583
Front Seat Components
584
Front Seat, Removing and Installing
584
Rear Seat Components
586
Rear Seat Cushion, Manual Folding
586
Rear Seat Cushion
587
Rear Seat Backrest
588
Sunroof
589
Sunroof Motor
590
Sunroof Emergency Closing
590
Sunroof Panel Adjusting
591
Horizontal Alignment
591
Vertical Adjustment
591
Sunroof Components
592
Sunroof Glass Panel
593
Sunroof Switch
593
Sunroof Motor Removing and Installing
594
Sunroof Interior Trim
594
Glass Panel Gasket
594
Convertible Top
595
Convertible Top Overview
596
Convertible Top Operation
596
Loading Aid
597
Convertible Top Emergency Operation
598
Function Checking
602
Function Conditions, Folding Roof
602
Convertible Top Components
603
Convertible Top Frame Components
603
Stowage Lock Drive
603
Sensors and Switches
603
Rollover Bar
604
Hydraulic System Overview
604
Electronic Controls
605
Electronic Component Overview
605
System Circuit Diagram
606
Body Gaps, Front and Side
607
Body Gaps, Rear
607
Rear Power Window
608
Rear Power Window Regulator
608
Parallelism
614
Longtitudinal Adjustment
614
Gap between Side Window and Side Panel
615
Pre-Tension of Side Window Inclination
616
Convertible Top Adjustment
617
Main Bearing Adjustment
617
Tension Bar Bearing Adjustment
617
Front Bow Base Plate Adjustment
618
Electrical System
620
P a R K I N G B R a K E , C H E C K I N
620
C L U T C H Fl U I D , C H E C K I N
620
Electrical Test Equipment
621
Electrical Wiring Diagrams
621
MINI Acronyms
622
Electrical System Safety Precautions
623
MINI Electrical System
624
Bus Systems
625
CAN-Bus
626
K-Bus
627
Diagnostic Buses
628
Electrical Troubleshooting
628
Voltage and Voltage Drops
629
Voltage, Measuring
629
Voltage Drop
630
Continuity, Checking
630
Short Circuits
630
Short Circuit, Testing with Ohmmeter
631
Short Circuit, Testing with Voltmeter
631
Wipers and Washers
632
Wiper Switch
634
Wiper Relays
635
Wiper Blade Cleaning Problems
635
Wiper Blade Replacing
635
Wiper Arm Replacing
637
Wiper Motor and Linkage
637
Wiper Motor Removing and Installing
638
Windshield Washer Nozzle, Replacing
639
Windshield Washer Nozzle, Adjusting
639
Washer Nozzle, Adjusting
639
Washer Pump, Replacing
640
Washer Reservoir
640
Headlight Washer Assembly
641
Switches
644
Steering Column Switches
647
EWS Ring Antenna
647
Ignition Switch
648
Windshield Wiper Switch
648
Turn Signal/Headlight Switch
648
Pedal Cluster Switches
649
Other Interior Switches
649
Fascia Switch Module
649
Seat Heater Switches
650
Outside Mirror Switch, Removing and Installing
650
Tire Pressure Warning Switch, Removing and Installing
651
Convertible Switches
651
Overhead Console Switches
651
Luggage Compartment Light Switch
652
Rear Lid Unlock Switch
652
Convertible Top Tension Bar Switch
652
Convertible Top Rear Window Shelf Switch
653
Instruments
654
Instrument Cluster and Carrier
655
Lights
658
Bulb Applications
659
Headlights
660
Headlight Aim
660
Headlight Leveling Module
661
Headlight Bulb Replacing
661
A/C System Warnings and Cautions
679
Heating and A/C Controls
680
Interior Temperature Sensor, Removing
681
Heater Core Temperature Sensor
682
A/C Evaporator Temperature Sensor
682
Solar Sensor
683
Vents and Air Valves
683
Temperature Control Servo Motor
684
Recirculation Control Servo Motor
684
Air Distribution Control Servo Motor
685
Dashboard Center Vent
685
Dashboard Outer Fresh Air Vent
686
Blower Components
686
Blower Motor Operation
687
Ihks
687
Ihka
687
Blower Motor, Removing and Installing
688
Blower Motor Resistor
688
Heater Components
689
Heater Core
689
Heating and A/C Housing
690
Radio
704
S P a R E P a R T S K I
704
Sound System
705
Navigation System
705
Radio and CD Changers
706
Radio Removing and Installing
706
CD Changer
706
Speakers
707
Tweeter Removing
707
Front Speaker Removing
707
Rear Speaker Removing
707
Antenna
708
Diversity Antenna Components
708
Roof Antenna
708
Antenna Removing and Installing
710
Antenna Amplifier
710
Diversity Amplifier
710
Navigation Computer
711
Front Seat Belts
716
Front Seat Belt Assembly
716
Front Seat Belt Removing and Installing
717
Front Seat Belt Buckle
718
Front Seat Belt Height Adjuster
719
Rear Seat Belts
720
Rear Seat Belt Assembly
720
Rear Seat Belt Removing and Installing
721
Rear Set Belt Buckle
721
Airbag System
723
Multiple Restraint Systems
724
Airbag System Components
725
Principles of Operation
726
Airbag Deactivation
727
Triggered Airbags
727
Airbag Electronics
728
MRS Control Module
728
Side Impact Crash Sensor
729
Driver Airbag, Removing and Installing
729
Passenger Airbag
730
Advanced Head Protection System Airbag
730
ECL Electrical Component Locations
732
Engine Compartment Components
732
F U E L S y S T E M S E R V I C
732
T R a N S M I S S I O N S E R V I C
732
O I L S E R V I C
732
I N S P E C T I O N I S E R V I C
732
I N S P E C T I O N I I S E R V I C
732
Fuse Locations
744
F100 Fuse
744
Fuse and Relay Panel 2
744
Fuse and Relay Panel 3
746
Relay Panels
747
Ground Locations
748
Grounds Overview
748
DME Grounds
751
Ground Buses
751
Component Location Illustrations
752
Sound System and Diversity Antenna Ground
752
Engine Compartment Components
753
Cooper Engine Compartment
753
Cooper S Engine Compartment
754
Headlight Assembly
755
A/C Pressure Sensor
755
Back
755
Brake Switches
756
DME Sensors
756
Oil Pressure Switch
756
Automatic Transmission Switch
757
Outside Temperature Sensor
757
Front Wheel Speed Sensor
757
Rear Wheel Speed Sensor
758
Headlight Vertical Aim Sensor
758
Headlight Vertical Air Sensor, Rear
758
Heating and A/C Components
759
Leak Diagnosis Pump
759
Heating and A/C Housing Components
759
Electrical Terminal Designations
769
Electrical Schematic Symbols
770
Sample Wiring Schematic
771
Central Locking Rear Driver's Side
771
Electrical Wiring Diagram
772
Abs/Asc
776
B R a K E S E R V I C
1044
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