2002 MINI COOPER brake

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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300-1
300 Suspension, Steering and Brakes-General
General 300-2
Special tool 300-2
Suspension 300-2Front suspension 300-2
F r o n t d r i v e a x l e s 3 0 0 - 2
R e a r s u s p e n s i o n 3 0 0 - 3
JCW suspension kit 300-3
Steering 300-3
Steering wheel and steering column 300-4
Electrohydraulic power steering (EHPS) 300-4
B r a k e S y s t e m 3 0 0 - 4
W h e e l s a n d T i r e s 3 0 0 - 4
T i r e p r e s s u r e s 3 0 0 - 4
Tire and wheel information 300-5
Electronic Brake and Stability
C o n t r o l S y s t e m s 3 0 0 - 6
Ride Height 300-6
Ride height, measuring 300-6
TA B L E
a. Ride height 300-6
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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
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ELE-1
General ele-2
S p e c i a l t o o l s E L E - 3
C i r c u i t a n d t e r m i n a l d e s c r i p t i o n s E L E - 3
E l e c t r i c a l s c h e m a t i c s y m b o l s E L E - 5
S a m p l e w i r i n g s c h e m a t i c E L E - 6
Electrical wiring diagram
c o m p o n e n t i d e n t i fi e r E L E - 7
Electrical wiring diagrams
ABS/ASC ELE-11
A B S / D S C E L E - 1 6
A i r b a g s y s t e m E L E - 1 9
Air-conditioning ELE-181
A u t o m a t i c t r a n s m i s s i o n ( A i s i n ) E L E - 2 8
A u t o m a t i c t r a n s m i s s i o n ( C V T ) E L E - 3 7
B a t t e r y E L E - 4 8
Brake light switch ELE-53
B u s s y s t e m ( K - b u s / C A N - b u s ) E L E - 5 6
Central locking ELE-70
C h a r g i n g s y s t e m E L E - 7 8
Clutch switch ELE-53
Convertible top ELE-81 E l e c t r o c h r o m i c r e a r v i e w m i r r o r E L E - 9 1 E l e c t r o n i c i m m o b i l i z e r ( E W S ) E L E - 9 3
Engine cooling ELE-97
Engine management ELE-100
E x t e r i o r l i g h t s E L E - 1 3 0
G e n e r a l M o d u l e ( B o d y C o m p u t e r ) E L E - 1 5 2
H e a t e d s e a t s E L E - 1 7 9
Heating and Air-conditioning ELE-181
H o r n s
E L E - 1 9 4
I n s t r u m e n t s E L E - 1 9 6
I n t e r i o r l i g h t s / i l l u m i n a t i o n E L E - 2 2 3
M i r r o r s E L E - 2 3 1
M u l t i f u n c t i o n ( M F L ) s t e e r i n g w h e e l E L E - 2 3 4
N a v i g a t i o n s y s t e m E L E - 2 4 0
O n - b o a r d c o m p u t e r E L E - 2 4 2
P a r k d i s t a n c e c o n t r o l E L E - 2 4 3
P o w e r s t e e r i n g E L E - 2 4 7
P o w e r w i n d o w s E L E - 2 4 8 R a d i o / C D c h a n g e r E L E - 2 5 2
R e a r w i n d o w d e f o g g e r E L E - 2 6 1
S t a r t e r E L E - 2 6 5
Sunroof ELE-266
W i p e r / w a s h e r s E L E - 2 6 7
Electrical Component Locations
Relay and fuse positions, component and ground locations .see Repair Group ECL
NOTE—
• Common MINI acronyms are explained in 600 Electrical System—General.
• Airbags systems, formerly known by the acronym SRS (sup
plemental restraint system), are currently referred to by the
BMW acronym MRS (multiple restraint system).
• Every attempt has been made in this repair manual to stan
dardize component names. However, in some cases, the
same component may appear with different names. Regard
less of the component name, the alphanumeric component
designation used on the wiring diagrams is consistentthroughout.
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