2002 MINI COOPER pressure

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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130-1
130 Fuel Injection
General 130-2
S p e c i a l t o o l s 1 3 0 - 3
Engine management 130-4
E n g i n e c o n t r o l m o d u l e ( E C M ) 1 3 0 - 5
P r i n c i p l e s o f o p e r a t i o n 1 3 0 - 6
S y s t e m i n p u t s 1 3 0 - 1 1
S y s t e m o u t p u t s 1 3 0 - 2 0
Troubleshooting 130-26
W a r n i n g s a n d c a u t i o n s 1 3 0 - 2 6
S u p e r c h a r g e r o i l s e r v i c e 1 3 0 - 3 4
Component Replacement 130-27Fuel rail and injectors,
removing and installing 130-27
Fuel pressure regulator,
removing and installing 130-29
Air filter housing,
r e m o v i n g a n d i n s t a l l i n g ( C o o p e r ) 1 3 0 - 2 9
Air filter housing,
r e m o v i n g a n d i n s t a l l i n g ( C o o p e r S ) 1 3 0 - 3 0
Air filter housing and upgrade kit (JCW) 130-31
Throttle housing (EDR),
r e m o v i n g a n d i n s t a l l i n g ( C o o p e r ) 1 3 0 - 3 2
Throttle housing (EDR),
r e m o v i n g a n d i n s t a l l i n g ( C o o p e r S ) 1 3 0 - 3 3
Supercharger, removing and installing 130-36
S u p e r c h a r g e r p u l l e y , r e m o v i n g 1 3 0 - 3 8
S e n s o r R e p l a c e m e n t 1 3 0 - 4 2
T - M A P s e n s o r , r e p l a c i n g ( C o o p e r ) 1 3 0 - 4 2 M A P s e n s o r, r e p l a c i n g ( C o o p e r S ) 1 3 0 - 4 3
T- M A P s e n s o r, r e p l a c i n g ( C o o p e r S ) 1 3 0 - 4 4
Engine coolant temperature (ECT) s e n s o r , r e p l a c i n g ( C o o p e r ) 1 3 0 - 4 4
Engine coolant temperature (ECT) s e n s o r , r e p l a c i n g ( C o o p e r S ) 1 3 0 - 4 5
E l e c t r i c a l C o m p o n e n t s 1 3 0 - 4 6
Main relay, accessing 130-46
Fuel pump relay, accessing 130-46
Engine control module (ECM),accessing 130-46
E C M p i n a s s i g n m e n t s 1 3 0 - 4 7
TA B L E S
a . E M S 2 0 0 0 i n p u t s / o u t p u t s 1 3 0 - 4
b. EMS2000 ECM pin assignment,
c o n n e c t o r X 6 0 0 0 ( 8 1 - p i n ) 1 3 0 - 4 8
c. EMS2000 ECM pin assignment, c o n n e c t o r X 6 0 0 0 4 ( 4 0 - p i n ) 1 3 0 - 5 0
1
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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
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