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
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200-1
200 Transmission-General
General 200-2
Drivetrain 200-2
Manual Transmission 200-2
Manual transmission (Cooper 2002-2004) 200-2
Manual transmission (Cooper 2005-2006) 200-2
M a n u a l t r a n s m i s s i o n ( C o o p e r S ) 2 0 0 - 3
A u t o m a t i c T r a n s m i s s i o n 2 0 0 - 3
Continuously Variable Transmission (CVT)
( C o o p e r ) 2 0 0 - 3
Automatic transmission with Agitronic
( C o o p e r S ) 2 0 0 - 3
T r a n s m i s s i o n L u b r i c a n t s 2 0 0 - 4
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240-1
240 Automatic Transmission
General 240-2
S p e c i a l t o o l s 2 4 0 - 2
Transmission Fluid Service 240-2
Transmission fluid level, checking (CVT) 240-3
Transmission fluid, replacing (CVT) 240-3
Transmission fluid level, checking
( a u t o m a t i c w i t h A g i t r o n i c ) 2 4 0 - 6
Transmission fluid, replacing
( a u t o m a t i c w i t h A g i t r o n i c ) 2 4 0 - 8
T r a n s m i s s i o n S e r v i c e ( C V T ) 2 4 0 - 9
Back-up light switch, locating 240-9
CVT switch, replacing 240-9
Drive axle seals, replacing 240-10
Transmission control module, replacing 240-11
Transmission fluid pan gasket, replacing .... 240-12
Transmission fluid screen, replacing 240-15
Ve h i c l e s p e e d s e n s o r, r e p l a c i n g 2 4 0 - 1 5
Transmission Service
( A u t o m a t i c w i t h A g i t r o n i c ) 2 4 0 - 1 6
Back-up light switch, locating 240-16
Drive axle seals, replacing 240-16
G e a r p o s i t i o n s w i t c h , r e p l a c i n g 2 4 0 - 1 7
Input shaft seal, replacing 240-19
Transmission control module (EGS),
replacing 240-19
V e h i c l e s p e e d s e n s o r s 2 4 0 - 2 0
Transmission Removal and
I n s t a l l a t i o n ( C V T ) 2 4 0 - 2 0
Transmission, removing and installing 240-20
Transmission Removal and Installation
( A u t o m a t i c w i t h A g i t r o n i c ) 2 4 0 - 2 2
Transmission, removing and installing 240-22
To r q u e c o n v e r t e r , r e m o v i n g a n d i n s t a l l i n g . . . 2 4 0 - 2 5
1
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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
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