sensor MINI COOPER 2002 Service Repair Manual

020 Maintenance
020-1
General 020-2
H o w t o u s e t h i s m a n u a l 0 2 0 - 2
W a r n i n g s , C a u t i o n s a n d N o t e s 0 2 0 - 3
B a s i c S e r v i c e I n f o r m a t i o n 0 2 0 - 3
Diagnostic trouble codes (DTCs), accessing .. 020-3
T i g h t e n i n g f a s t e n e r s 0 2 0 - 4
P a r t s 0 2 0 - 5
T o o l s 0 2 0 - 6
I d e n t i fi c a t i o n P l a t e s a n d L a b e l s 0 2 0 - 8
V e h i c l e I d e n t i fi c a t i o n N u m b e r ( V I N ) 0 2 0 - 8
Date of manufacture 020-8
E n g i n e a n d t r a n s m i s s i o n c o d e s 0 2 0 - 8
Raising Vehicle 020-8
Lifting vehicle 020-8
Raising vehicle safely using vehicle jack 020-9
W o r k i n g s a f e l y u n d e r v e h i c l e 0 2 0 - 9
E m e r g e n c i e s 0 2 0 - 1 0
F l a t t i r e m o n i t o r 0 2 0 - 1 0
Changing a tire 020-10
Jump starting 020-12 I n d i c a t o r a n d w a r n i n g l i g h t s 0 2 0 - 1 2
To w i n g 0 2 0 - 1 2
S p a r e p a r t s k i t 0 2 0 - 1 3
Engine Compartment Components .. 020-14
Engine covers, removing and installing 020-14
A i r F i l t e r S e r v i c e 0 2 0 - 1 5
A i r fi l t e r , r e p l a c i n g ( C o o p e r ) 0 2 0 - 1 5
A i r fi l t e r , r e p l a c i n g ( C o o p e r S ) 0 2 0 - 1 5
A i r fi l t e r , a s s e m b l y ( J C W ) 0 2 0 - 1 6
B a t t e r y S e r v i c e 0 2 0 - 1 6
Brake Service 020-18
Brake fluid, replacing 020-18
B r a k e p a d / r o t o r w e a r , c h e c k i n g 0 2 0 - 1 8
Brake system, inspecting 020-18
Parking brake, checking 020-19
Cooling System, Checking 020-19
E n g i n e A c c e s s o r y B e l t S e r v i c e 0 2 0 - 2 0
A c c e s s o r y b e l t , r e p l a c i n g ( C o o p e r ) 0 2 0 - 2 1
Accessory belt, replacing (Cooper S) 020-22
Engine Oil Service 020-23
Engine oil, checking level 020-24
Engine oil and filter, changing 020-24
F u e l S y s t e m S e r v i c e 0 2 0 - 2 6
F u e l fi l t e r 0 2 0 - 2 6
F u e l t a n k a n d l i n e s , i n s p e c t i n g 0 2 0 - 2 6
Interior Ventilation Microfilter,
Replacing 020-26
Power Steering Fluid Service,
Checking 020-27
S p a r k P l u g s , R e p l a c i n g 0 2 0 - 2 8
Transmission Service 020-29
Transmission service, automatic (CVT) 020-29
Transmission service, automatic (Agitronic).. 020-29
Transmission service, manual 020-30
O t h e r M e c h a n i c a l M a i n t e n a n c e 0 2 0 - 3 1
Catalytic converter and oxygen sensors .... 020-31
Clutch fluid, checking 020-31 Drive axle joint (CV joint) boots,
inspecting 020-31
Exhaust system, inspecting 020-32
Idle speed 020-32
Suspension, inspecting 020-32
Tires, checking inflation pressure 020-32
Tires, rotating 020-32
Wheels, aligning 020-33
B o d y a n d I n t e r i o r M a i n t e n a n c e 0 2 0 - 3 3
B o d y a n d h i n g e s , l u b r i c a t i n g 0 2 0 - 3 3
E x t e r i o r w a s h i n g 0 2 0 - 3 3
I n t e r i o r c a r e 0 2 0 - 3 3
L e a t h e r u p h o l s t e r y a n d t r i m 0 2 0 - 3 4
Polishing 020-34
S e a t b e l t s 0 2 0 - 3 4
Special cleaning 020-34
W a s h i n g c h a s s i s 0 2 0 - 3 4
Waxing 020-35
W i n d s h i e l d w i p e r b l a d e m a i n t e n a n c e 0 2 0 - 3 5
S e r v i c e I n t e r v a l s 0 2 0 - 3 6
S e r v i c e i n t e r v a l d i s p l a y ( S I A ) 0 2 0 - 3 6
SIA, resetting 020-36
Inspection I, Inspection II 020-36
M a i n t e n a n c e t a b l e s 0 2 0 - 3 7
TA B L E S
a. Oil service 020-37
b. Inspection I service 020-38
c. Inspection II service 020-40
©2006 BentleyPublishers.com—All Rights Reserved

340 Brakes
340-1
General 340-2
S p e c i a l t o o l s 3 4 0 - 2
M I N I b r a k e s y s t e m 3 4 0 - 4
A n t i l o c k B r a k i n g S y s t e m ( A B S ) 3 4 0 - 4
A u t o m a t i c S t a b i l i t y C o n t r o l ( A S C ) 3 4 0 - 6
D y n a m i c S t a b i l i t y C o n t r o l ( D S C ) 3 4 0 - 7
Troubleshooting 340-9
W a r n i n g s a n d c a u t i o n s 3 4 0 - 1 0
B l e e d i n g B r a k e s 3 4 0 - 1 1
Brakes, bleeding 340-12
Brake Pads, Calipers and Rotors 340-13
Front brake assembly components 340-13
Rear brake assembly components 340-14
JCW Tuning brake assembly components ... 340-15
Brake pads, calipers, rotors
removing and installing 340-16
B r a k e M a s t e r C y l i n d e r 3 4 0 - 2 1
Master cylinder, removing and installing 340-22
B r a k e B o o s t e r 3 4 0 - 2 3
Brake booster check valve,
removing and installing (Cooper) 340-23 Brake booster check valve,
removing and installing (Cooper S) 340-24
Brake booster, removing and installing 340-25
Parking Brake 340-28
Parking brake, checking and adjusting 340-29
Parking brake cables, removing and installing 340-30
A B S C o m p o n e n t R e p l a c e m e n t 3 4 0 - 3 2
ABS wheel speed sensor, front,
removing and installing 340-32
ABS wheel speed sensor, rear,
removing and installing 340-33
DSC motion sensor,
removing and installing 340-33
DSC steering angle sensor,
removing and installing 340-34
ABS hydraulic unit/control module,
removing and installing 340-35
TA B L E S
a . B r a k e s y s t e m t r o u b l e s h o o t i n g 3 4 0 - 0 9
b . B r a k e r o t o r s p e c i fi c a t i o n s 3 4 0 - 2 1
1
©2006 BentleyPublishers.com-AII Rights Reserved

515 Central Locking and Anti-theft
515-1
General 515-2
S p e c i a l t o o l s 5 1 5 - 2
Central locking 515-3
E l e c t r o n i c i m m o b i l i z e r ( E W S ) 5 1 5 - 4
A n t i - t h e f t a l a r m ( D W A ) 5 1 5 - 4
General module 515-5
Door Lock Component Replacement.. 515-6
D o o r l a t c h , r e m o v i n g 5 1 5 - 6
D o o r s t r i k e r , r e p l a c i n g 5 1 5 - 8
Door handle, removing and installing 515-8
Inside door handle,
removing and installing 515-9
Rear Hatch Lock
Component Replacement 515-10
Rear hatch lock emergency release 515-10
Emergency rear hatch lock release cable,replacing 515-10Rear hatch release switch, replacing 515-12
Rear hatch lock,
removing and installing 515-12
Rear hatch lock striker,
removing and installing 515-14
R e a r h a t c h l o c k , a d j u s t i n g 5 1 5 - 1 4
Electronic Immobilizer (EWS)
Component Replacement 515-15
E W S c o n t r o l m o d u l e , r e p l a c i n g 5 1 5 - 1 5
Ring antenna, removing 515-16
Anti-Theft Alarm (DWA)
Component Replacement 515-16
Tilt sensor, removing and installing 515-16
Ultrasound module,
removing and installing (Coupe) 515-17
Ultrasound modules,
removing and installing (Convertible) 515-18
Alarm siren, removing and installing 515-18
1
©2006 BentleyPublishers.com—All Rights Reserved

640-1
640 Heating and Air-conditioning
General 640-2
S p e c i a l t o o l s 6 4 0 - 2
H e a t i n g a n d a i r - c o n d i t i o n i n g s y s t e m s 6 4 0 - 3
R e f r i g e r a n t s y s t e m ( I H K S a n d I H K A ) 6 4 0 - 3
H e a t i n g s y s t e m 6 4 0 - 4
I H K S h e a t i n g a n d a i r d i s t r i b u t i o n 6 4 0 - 4
I H K A h e a t i n g a n d a i r d i s t r i b u t i o n 6 4 0 - 4
A / C s y s t e m w a r n i n g s a n d c a u t i o n s 6 4 0 - 6
H e a t i n g a n d A / C C o n t r o l s 6 4 0 - 7
Heating and air-conditioning control panel, removing and installing 640-7
Interior temperature sensor,
r e m o v i n g ( I H K A ) 6 4 0 - 8
Heater core temperature sensor,
r e m o v i n g ( I H K A ) 6 4 0 - 9
A/C evaporator temperature sensor,
removing 640-9
Solar sensor, removing and installing
(IHKA 640-10
V e n t s a n d A i r V a l v e s 6 4 0 - 1 0
Temperature control servo motor,
removing and installing 640-11
Recirculation control servo motor,
removing and installing 640-11
Air distribution control servo motor,
removing and installing 640-12 Dashboard center vent,
removing and installing 640-12
Dashboard outer fresh air vent,
removing and installing 640-13
B l o w e r C o m p o n e n t s 6 4 0 - 1 3
B l o w e r m o t o r o p e r a t i o n 6 4 0 - 1 4
Blower motor, removing and installing 640-15
Blower motor resistor,removing and installing 640-15
H e a t e r C o m p o n e n t s 6 4 0 - 1 6
H e a t e r c o r e , r e p l a c i n g 6 4 0 - 1 6
Heating and A/C housing,removing and installing 640-17
A i r - c o n d i t i o n i n g C o m p o n e n t s 6 4 0 - 2 0
A/C compressor, removing and installing 640-20
A/C condenser, removing and installing 640-23
A/C receiver drier,
removing and installing 640-24
A/C expansion valve,
removing and installing 640-25
A/C pressure sensor, accessing,
removing and installing 640-27
A/C evaporator, removing and installing 640-28
©2006 BentleyPublishers.com-AII Rights Reserved

Electrical Wiring Diagrams ELE-41
Automatic transmission (CVT)
Transmission speed sensor
(pagel of 1)
87 F04
15A
X8687
«
1.0
RT/WS X6000
0.5
SW
3 X 8 5 1 6 0.5
BR/OR
73 X6000 A6000
Digital motor electronics control unit
I
I
<*y
Y8516
Transmission rpm sensor
A6000 Digital motor electronics control unit
©2006 BentleyPublishers.com-AII Rights Reserved

Electrical Wiring Diagrams ELE-89
Convertible top
Sensors (from Sept. 2005)
(page 2 of 3)
5: :J1r yt}',A= 1]>—>31 iJ5
0.5
BR 1
0.5
RT
X01191 2
0.5
BR X011914
0.5
BR X01191
0.5
RT 0.5
RT
0.5
RT
101199
<$}■Hall sensor, calch
101188
^Hall sensor, con
vertible top closed
101187
^Hall
verl
dow senso
ble top
. con-
fcidsd
MC06ele22862b
5 2006 BentleyPublishers.com—All Rights Reserved

Electrical Wiring Diagrams ELE-121
Engine management (DME) Oxygen sensor (post-catalyst)
(pagel of 1)
Of
I
1.0
RT/GN F03
15A
0.75
BURT
1.0
BL/RT
f
0.5
BL/GE0.5
BL/GN
2 X 1 0 7 3 6 A6000
Digital motor electronics control unit
B62002
Heated oxygen sensor after catalytic converter
©2006 BentleyPublishers.com—All Rights Reserved

Electrical Wiring Diagrams ELE-215
Instruments
Seat belt warning light
(pagel of 1)
F40
I 1 5
| i L
5A
i_ _ —r
1X10203
<
0.5
GN/BL
16
iX11177
s
'•A21 1
!mControl module for instrument cluster
i LJ
9 X11177
0.5
B17GE
28
tX15
0.5
BL/GE
2
ir — — ■X10425
s
S58
Hall sensor, driver's seat belt buckle
•;. p^r'.pr >,?? ■&£ ;. 'r'v'"< ; '
©2006 BentleyPublishers.com—All Rights Reserved