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Cooper 2002
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Mini Cooper 2002 Service Manual
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:
Owner's manual
(140 pages)
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Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
Technical Contact Information
Warning
Contents
General Warnings and Cautions
Vehicle Identification and VIN Decoder
Product Familiarization
General
Product Overview
2005 Model Year Changes
Technical Data
Powertrain
Engines
Transmissions
Body Exterior
Body Dimensions
Body Interior
Safety
Dashboard and Controls
Display Elements
Suspension, Steering, Brakes
MINI Convertible
John Cooper Works
Maintenance
Table of Contents
Warnings, Cautions and Notes
Basic Service Information
Diagnostic Trouble Codes (Dtcs), Accessing
Tightening Fasteners
Non-Reusable Fasteners
Parts
Genuine Mini Parts
Non-Returnable Parts
Tools
Special Tools
Identification Plates and Labels
Vehicle Identification Number (VIN)
Date of Manufacture
Raising Vehicle
Raising Vehicle Safety Using Vehicle Jack
Working under Vehicle Safety
Emergencies
Flat the Monitor
Changing a Tire
Jack Stands
Jump Starting
Indicator and Warning Lights
Towing
Spare Parts List
Engine Compartments Components
Engine Covers, Removing and Installing
Cooper
Cooper S
Air Filter Service
Air Filter, Replacing
Battery Service
Ari Filter, Assembly
Battery, Checking, Cleaning and Replacing
Brake Service
Brake Fluid, Replacing
Brake Pad/Rotor Wear, Checking
Parking Brake, Checking
Cooling System ,Checking
Engine Accessory Belt Service
Engine Coolant
Accessory Belt, Replacing
Accessory Belt, Replacing (Cooper S)
Engine Oil Service
Engine Oil, Checking Level
Engine Oil and Filter, Changing
Fuel System Service
Fuel Filter
Fuel Tank and Fuel Lines, Inspecting
Interior Ventilation Microfilter, Replacing
Power Steering Fluid, Checking
Spark Plugs, Replacing
Transmission Service
Transmission Service, Automatic
Transmission Service, Automatic (Agitronic)
Transmission Service, Manual
Other Mechanical Maintenance
Catalytic Converter and Oxygen Sensor
Clutch Fluid, Checking
Drive Axle Joint Boots
Exhaust System, Inspecting
Suspension, Inspecting
Tires, Checking Inflation Pressure
Tires, Rotating
Body and Interior Maintenance
Wheels, Aligning
Body and Hinges, Lubricating
Exterior Washing
Leather Upholstery and Trim
Polishing
Seat Belts
Special Cleaning
Waxing
Windshield Wiper Blade Maintenance
Service Intervals
Service Interval Display
SIA, Resetting
Inspection I, Inspection II
Maintenance Tables
Engine-General
Engine Specifications
Engine Identifying Features
Engine Construction
Engine Block
Crankshaft Assembly
Crankshaft Bearings
Connecting Rods
Feature Process
Pistons
Grafal Coating
Oil Pan
Cylinder Head
Positive Crankcase Ventilation
Cylinder Head Gasket
Cylinder Head Bolts
Valvetrain
Camshaft
Rocker Arms and Rocker Shafts
Valves
Intake Valves
Intake Valve Seat Inserts
Exhaust Valves
Timing Chain
Lubrication System
John Cooper Works Kit
Driveability Troubleshooting
System Voltage
Main Grounds
Engine Removal and Installation
Engine, Removing and Installing
Cylinder Head Removal and Installation
T I G H T E N I N G F a S T E N E R
T O O L
D a T E O F M a N U F a C T U R
J U M P S T a R T I N
F U E L Fi L T E
Intake Manifold, Removing and Installing
Remove Throttle Valve Assembly
Remove Fuel Rail Cover
Cylinder Head and Valvetrain
Cylinder Head Disassembly
Spark Plug Sleeve, Removing and Installing
Rocker Arm Shafts and Rocker Arms, Removing and Installing
Camsahft, Removing and Installing
Cylinder Head Service
Cylinder Head, Inspecting
Valves, Leak Test
Cylinder Head, Coolant Leak Test
Valves, Removing and Installing
Valve Stem Oil Seals
Valve Guides
Valve Seats
Valve Seat Dimensions
Valve Springs
Camshaft Timing Chain
H O W T O U S E T H I S M a N U a
R a I S I N G V E H I C L
T O W I N
W a S H I N G C H a S S I
Timing Chain Housing Cover
Crankshaft Vibration Damper, Removing and Installing
Timing Chain Housing Cover, Removing and Installing
Oil Pressure
Engine Oil Pressure
Oil Pressure Warning System, Testing
Crankshaft Seal, Crankshaft Front Seal, Removing and Installing
Crankshaft Rear Seal, Removing and Installing
Engine Oil Pan
Oil Pan, Removing and Installing
Component Replacement
Oil Pressure Warning Switch, Replacing
Oil Pump
Oil Pressure Relief Valve, Removing and Installing
Ignition System
Engine Management
Oscilloscope Diagnostic Diagrams
Warnings and Cautions
Ignition System Service
Ignition Firing Order
Disabling Ignition System
Ignition Wire
Ignition Coil Assembly
Crankshaft Position Sensor
Camshaft Position Sensor
Knock Sensor
Battery, Starter, Alternator
Engine Electrical System
Battery Safety Terminal
Battery
Battery Capacity
Battery Charging
Battery Maintenance
Battery Testing
Hydrometer Testing
Battery Open-Circuit Voltage Test
Battery Load Voltage Test
Battery, Removing and Installing
Battery Box, Removing and Installing
Battery Safety Terminal Replacement
Alternator
Charging System Troubleshooting
Charging System Quick Check
Charging System, Checking
Alternator, Removing and Installing
Fuel Injection
L I F T I N G V E H I C L
A I R F I L T E R S E R V I C
A I R Fi L T E R , R E P L a C I N G ( C O O P E
A I R Fi L T E R , R E P L a C I N G ( C O O P E R
E X T E R I O R W a S H I N
S P E C I a L C L E a N I N
W a X I N
Engine Control Module
Power Supply
EMS2000 Engine Management
Air Management
Fuel Management
Ignition Management
Emission Management
Pre-Catalyst Oxygen Sensor
Post-Catalyst Oxygen Sensor
Adaptation
Performance Controls
EWS Interface
Automatic Transmission Control
A/C Compressor Control
System Inputs
Cruise Control
Engine Cooling Fan
Accelerator Pedal Position Sensor
Sensor Inputs
T-MAP Sensor
Manifold Pressure Sensor
T-MAP and MAP Sensors
Air Intake Temperature Sensor
Engine Coolant Temperature Sensor
Throttle Position Feedback
Crankshaft Sensor
Reluctor Ring
Camshaft Sensor
Fuel Leakage Diagnosis System
Oxygen Sensors
Brake Light Switch
Clutch Switch
Automatic Transmission Sensors
Immobilizer
Transmission Control Module
Abs/Asc/Dsc
A/C Pressure Transducer
System Outputs
Multifunction Steering Wheel
Main Relay
Electronic Throttle Control
Idle Speed Control
EML Warning LED
Fuel Pump Relay and Inertia Switch
Fuel Injectors
Selective Injector Cut-Out
Evaporative Emissions Control
Oxygen Sensor Heating
OBD II Plug
Troubleshooting
Fuel Rail and Injectors, Removing and Installing
Fuel Pressure Regulator, Removing and Installing
Air Filter Housing, Removing and Installing
Air Filter Housing and Upgrade Kit
Throttle Housing, Removing and Installing
Supercharger Oil Service
Supercharge Rear Oil Reservoir, Adding Oil
Supercharger, Removing and Installing
T-MAP Sensor, Replacing
Electrical Components
Main Relay, Accessing
Fuel Pump Relay, Accessing
Engine Control Module, Accessing
ECM Pin Assignments
Fuel Tank and Fuel Pump
Fuel Filler Pipe
LDP/DMTL Unit
Radiator and Cooling System
Cooling System Overview
Coolant Pump
Thermostat
Radiator and Expansion Tank
Transmission Fluid Cooler
Electric Cooling Fan
Coolant Temperature Gauge
Cooling System Inspection
Cooling System Pressure Test
Combustion Chamber Leak Test
Cooling System Service
Thermostat Test
Coolant, Draining and Filling
Coolant, Filling
Coolant Pump, Replacing
Exhaust System
Exhaust System, Removing and Installing
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Table of Contents
Troubleshooting
John Cooper Works Kit
75
Alternator
216
Troubleshooting
250
Diagnostic buses
628
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This manual is also suitable for:
Cooper 2003
Cooper 2006
Cooper s 2002
Cooper s 2003
Cooper s 2004
Cooper s 2005
...
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Cooper s 2006
Convertible 2002
Convertible 2003
Convertible 2004
Convertible 2005
Convertible 2006
Cooper 2004
Cooper 2005
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