2002 MINI COOPER steering

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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320-1
320 Steering and Wheel Alignment
General 320-2
S p e c i a l t o o l s 3 2 0 - 2
S t e e r i n g s y s t e m 3 2 0 - 3
Steering Wheel 320-3
A i r b a g w a r n i n g s 3 2 0 - 4 Steering wheel, removing and installing 320-4
Steering Column 320-6
S t e e r i n g c o l u m n c o m p o n e n t s 3 2 0 - 6
Ignition lock cylinder, removing and installing 320-6
Steering column upper cover, removing 320-7
Steering column lower cover, removing 320-8
Shift interlock cable,
r e m o v i n g a n d i n s t a l l i n g ( C V T o n l y ) 3 2 0 - 8
Lower steering shaft,
removing and installing 320-10
P o w e r S t e e r i n g S y s t e m 3 2 0 - 1 2
Steering system warnings and cautions 320-12
S t e e r i n g s y s t e m c o m p o n e n t s 3 2 0 - 1 3
Steering system, bleeding and filling 320-13Electrohydraulic steering pump (EHPS), removing and installing 320-14
Steering pump fan, removing and installing 320-16
Steering rack, removing and installing 320-16
Tie-rod or rack boot,
removing and installing 320-19
Wheel Alignment 320-21
TA B L E S
a. Front wheel alignment specifications 320-21
b. Rear wheel alignment specifications 320-22
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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
1
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