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BMW Mini Cooper Workshop Service & Repair Manual 2002-2006 # 1

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🏷️ Basic Information Identification Make: BMW (Mini) Model: Cooper / Cooper S Chassis Code Common: R50 (Cooper), R53 (Cooper S) Generation First Generation Designation: First Generation Mini (New MINI) Production Years Covered By Manual: 2002, 2003, 2004, 2005, 2006 Codes Vin Code Designation: WSM (Workshop Manual) 👋 Introduction Market Position Target Audience: DIY enthusiasts, independent repair shops, fleet maintenance personnel Competitive Analysis Value Proposition: Provides professional-level information at a fraction of the cost of authorized service center repairs, empowering owners to maintain and repair their vehicle effectively. Key Features Accessibility: Instant download facilitates immediate access to critical repair information, eliminating shipping delays and costs. User Friendliness: Designed for ease of use, with step-by-step instructions and detailed exploded diagrams. 📋 Manual Details Coverage Areas Coverage Scope: Comprehensive, covering all aspects of vehicle service and repair Specific Systems Listed: Engine, Gearbox & Clutch, Cooling System, Fuel System, Braking System, Suspension, Air Con, Electrical System, Audio & Navigation System, Body & Fixtures, Exhaust System, Wheels & Tyres, Trouble Codes, Maintenance, Wiring Diagrams, Technical Information & Specifications Page Count Estimated Page Count: Likely 1000+ pages (typical for comprehensive workshop manuals) Manual Type Type: Workshop Service and Repair Manual Language Language: English Format Format Type: Digital (PDF) 📖 Manual Coverage Systems Covered Engine Management: Detailed diagnostics, component testing, timing, emissions control, fuel injection, ignition systems Powertrain: Transmission (manual/automatic), clutch operation, driveline components, differential service Chassis And Suspension: Front and rear suspension components, steering system, wheel alignment specifications, shock absorber/strut replacement Braking System: Disc brake service (pads, rotors), hydraulic system bleeding, ABS system diagnostics and repair Climate Control: Air conditioning system servicing, refrigerant handling, HVAC component diagnostics and replacement Electrical And Electronics: Comprehensive wiring diagrams, component location charts, diagnostic procedures for all electrical circuits, ECU functions Body And Interior: Body panel removal/installation, door mechanisms, interior trim, glass replacement, structural repair information Procedures Included Maintenance: Scheduled maintenance tasks, fluid changes (oil, coolant, brake fluid, transmission fluid), filter replacements, inspection points Diagnostics: Trouble code interpretation and diagnostic flowcharts, symptom-based troubleshooting guides Repair: Step-by-step instructions for component removal, overhaul, and reinstallation Technical Specifications: Torque specifications for all fasteners, component tolerances, alignment data, electrical system voltages Technical Depth Depth Of Coverage: Advanced mechanical and electrical diagnostics, full engine and transmission rebuild procedures, bodywork and paint repair guidance 📊 Manual Specifications File Format Digital Format: PDF Print Quality Printability: High-resolution, suitable for clear printing of all diagrams and text Binding Type Binding Type: Not Applicable (Digital Format) Paper Type Paper Type: Not Applicable (Digital Format) ⚙️ Engine Specifications Primary Engine Cooper Engine Type Cooper: Naturally Aspirated Inline-4 (Tritec engine family) Displacement Cooper: 1.6 Liters (1598 cc) Horsepower Cooper: Approx. 115-120 hp @ 6000 rpm Torque Cooper: Approx. 118-120 lb-ft @ 4300 rpm Primary Engine Cooper S Engine Type Cooper S: Supercharged Inline-4 (Tritec engine family) Displacement Cooper S: 1.6 Liters (1598 cc) Horsepower Cooper S: Approx. 163-170 hp @ 6000 rpm Torque Cooper S: Approx. 155-159 lb-ft @ 4000 rpm Fuel System Fuel Delivery: Multi-point fuel injection (MPI) Recommended Fuel Octane: 91-93 Octane (for Cooper S, 89 Octane acceptable for Cooper) 🔧 Transmission Standard Transmission Type Cooper: 5-speed manual (Getrag) Transmission Type Cooper S: 6-speed manual (Getrag) Optional Transmission Type Optional Cooper: Continuously Variable Transmission (CVT) / Steptronic automatic Features Clutch Type: Hydraulically actuated single dry plate clutch 📐 Dimensions Exterior Length: Approx. 140-143 inches (3550-3630 mm) Width: Approx. 66 inches (1670 mm) Height: Approx. 56 inches (1420 mm) Weights Curb Weight Cooper: Approx. 2500-2600 lbs (1135-1180 kg) Curb Weight Cooper S: Approx. 2700-2800 lbs (1225-1270 kg) 🛡️ Safety Features Ratings NHTSA Front Impact Rating: 5-Star (for driver and front passenger) IIHS Side Impact Rating: Good (for models equipped with side airbags) Active Features Anti Lock Braking System: Standard (ABS) Electronic Brake Force Distribution: Standard (EBD) Traction Control: Standard (ASC+T on many models) Passive Features Airbags: Frontal airbags, optional side-impact airbags Seat Belts: Three-point seat belts with pretensioners 💡 Technology Features Infotainment Audio System: Standard AM/FM/CD player, optional Harman Kardon sound system Navigation System: Optional factory navigation system available on some models Driver Assistance Cruise Control: Available on most models Connectivity Auxiliary Input: Optional auxiliary input jack available on some audio systems 🔧 Maintenance Service Intervals Oil Change Interval: Typically 7,500 - 10,000 miles or 12 months, whichever comes first (refer to manual for specific conditions) Brake Fluid Change Interval: Every 2 years Spark Plug Replacement: Refer to manual, typically around 60,000 miles depending on type Fluid Specifications Engine Oil Specification: SAE 5W-30 or 0W-30, meeting BMW Longlife-01 or Longlife-04 specifications (verify with manual) Coolant Specification: BMW/Mini Blue Antifreeze/Coolant (G48 type), mixed 50/50 with distilled water Transmission Fluid Manual: GL-4 75W-90 Synthetic Gear Oil Transmission Fluid Automatic/Cvt: Specific ATF or CVT fluid (refer to manual for exact type and capacity) Known Issues Common Issue Supercharger S: Water pump failure, supercharger belt...
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Sku: 357761
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BMW Mini Cooper Workshop Service & Repair Manual 2002-2006 # 1
🏷️ Basic Information
Identification
Make:
BMW (Mini)
Model:
Cooper / Cooper S
Chassis Code Common:
R50 (Cooper), R53 (Cooper S)
Generation
First Generation Designation:
First Generation Mini (New MINI)
Production Years Covered By Manual:
2002, 2003, 2004, 2005, 2006
Codes
Vin Code Designation:
WSM (Workshop Manual)
👋 Introduction
Market Position
Target Audience:
DIY enthusiasts, independent repair shops, fleet maintenance personnel
Competitive Analysis
Value Proposition:
Provides professional-level information at a fraction of the cost of authorized service center repairs, empowering owners to maintain and repair their vehicle effectively.
Key Features
Accessibility:
Instant download facilitates immediate access to critical repair information, eliminating shipping delays and costs.
User Friendliness:
Designed for ease of use, with step-by-step instructions and detailed exploded diagrams.
📋 Manual Details
Coverage Areas
Coverage Scope:
Comprehensive, covering all aspects of vehicle service and repair
Specific Systems Listed:
Engine, Gearbox & Clutch, Cooling System, Fuel System, Braking System, Suspension, Air Con, Electrical System, Audio & Navigation System, Body & Fixtures, Exhaust System, Wheels & Tyres, Trouble Codes, Maintenance, Wiring Diagrams, Technical Information & Specifications
Page Count
Estimated Page Count:
Likely 1000+ pages (typical for comprehensive workshop manuals)
Manual Type
Type:
Workshop Service and Repair Manual
Language
Language:
English
Format
Format Type:
Digital (PDF)
📖 Manual Coverage
Systems Covered
Engine Management:
Detailed diagnostics, component testing, timing, emissions control, fuel injection, ignition systems
Powertrain:
Transmission (manual/automatic), clutch operation, driveline components, differential service
Chassis And Suspension:
Front and rear suspension components, steering system, wheel alignment specifications, shock absorber/strut replacement
Braking System:
Disc brake service (pads, rotors), hydraulic system bleeding, ABS system diagnostics and repair
Climate Control:
Air conditioning system servicing, refrigerant handling, HVAC component diagnostics and replacement
Electrical And Electronics:
Comprehensive wiring diagrams, component location charts, diagnostic procedures for all electrical circuits, ECU functions
Body And Interior:
Body panel removal/installation, door mechanisms, interior trim, glass replacement, structural repair information
Procedures Included
Maintenance:
Scheduled maintenance tasks, fluid changes (oil, coolant, brake fluid, transmission fluid), filter replacements, inspection points
Diagnostics:
Trouble code interpretation and diagnostic flowcharts, symptom-based troubleshooting guides
Repair:
Step-by-step instructions for component removal, overhaul, and reinstallation
Technical Specifications:
Torque specifications for all fasteners, component tolerances, alignment data, electrical system voltages
Technical Depth
Depth Of Coverage:
Advanced mechanical and electrical diagnostics, full engine and transmission rebuild procedures, bodywork and paint repair guidance
📊 Manual Specifications
File Format
Digital Format:
PDF
Print Quality
Printability:
High-resolution, suitable for clear printing of all diagrams and text
Binding Type
Binding Type:
Not Applicable (Digital Format)
Paper Type
Paper Type:
Not Applicable (Digital Format)
⚙️ Engine Specifications
Primary Engine Cooper
Engine Type Cooper:
Naturally Aspirated Inline-4 (Tritec engine family)
Displacement Cooper:
1.6 Liters (1598 cc)
Horsepower Cooper:
Approx. 115-120 hp @ 6000 rpm
Torque Cooper:
Approx. 118-120 lb-ft @ 4300 rpm
Primary Engine Cooper S
Engine Type Cooper S:
Supercharged Inline-4 (Tritec engine family)
Displacement Cooper S:
1.6 Liters (1598 cc)
Horsepower Cooper S:
Approx. 163-170 hp @ 6000 rpm
Torque Cooper S:
Approx. 155-159 lb-ft @ 4000 rpm
Fuel System
Fuel Delivery:
Multi-point fuel injection (MPI)
Recommended Fuel Octane:
91-93 Octane (for Cooper S, 89 Octane acceptable for Cooper)
🔧 Transmission
Standard
Transmission Type Cooper:
5-speed manual (Getrag)
Transmission Type Cooper S:
6-speed manual (Getrag)
Optional
Transmission Type Optional Cooper:
Continuously Variable Transmission (CVT) / Steptronic automatic
Features
Clutch Type:
Hydraulically actuated single dry plate clutch
📐 Dimensions
Exterior
Length:
Approx. 140-143 inches (3550-3630 mm)
Width:
Approx. 66 inches (1670 mm)
Height:
Approx. 56 inches (1420 mm)
Weights
Curb Weight Cooper:
Approx. 2500-2600 lbs (1135-1180 kg)
Curb Weight Cooper S:
Approx. 2700-2800 lbs (1225-1270 kg)
🛡️ Safety Features
Ratings
NHTSA Front Impact Rating:
5-Star (for driver and front passenger)
IIHS Side Impact Rating:
Good (for models equipped with side airbags)
Active Features
Anti Lock Braking System:
Standard (ABS)
Electronic Brake Force Distribution:
Standard (EBD)
Traction Control:
Standard (ASC+T on many models)
Passive Features
Airbags:
Frontal airbags, optional side-impact airbags
Seat Belts:
Three-point seat belts with pretensioners
💡 Technology Features
Infotainment
Audio System:
Standard AM/FM/CD player, optional Harman Kardon sound system
Navigation System:
Optional factory navigation system available on some models
Driver Assistance
Cruise Control:
Available on most models
Connectivity
Auxiliary Input:
Optional auxiliary input jack available on some audio systems
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically 7,500 - 10,000 miles or 12 months, whichever comes first (refer to manual for specific conditions)
Brake Fluid Change Interval:
Every 2 years
Spark Plug Replacement:
Refer to manual, typically around 60,000 miles depending on type
Fluid Specifications
Engine Oil Specification:
SAE 5W-30 or 0W-30, meeting BMW Longlife-01 or Longlife-04 specifications (verify with manual)
Coolant Specification:
BMW/Mini Blue Antifreeze/Coolant (G48 type), mixed 50/50 with distilled water
Transmission Fluid Manual:
GL-4 75W-90 Synthetic Gear Oil
Transmission Fluid Automatic/Cvt:
Specific ATF or CVT fluid (refer to manual for exact type and capacity)
Known Issues
Common Issue Supercharger S:
Water pump failure, supercharger belt wear, occasional oil leaks from supercharger snout
Common Issue Clutch Wear:
Clutch wear, especially in performance-oriented driving
Common Issue Electrical:
Window regulator failures, intermittent electrical gremlins (often related to door harnesses), sunroof drain blockages leading to water ingress.
Common Issue Cooling System:
Thermostat housing leaks, radiator fan failures
📚 Vehicle History
Brand Heritage
Brand Origin:
British automotive manufacturer with a long history, revived by BMW.
Model Evolution
New Mini Launch:
The first generation ('New MINI') was launched in 2001 (model year 2002), representing a modern interpretation of the classic Mini.
Cooper S Variant:
The Cooper S variant, introduced in 2002, offered a supercharged engine and sportier performance characteristics.
Production
Manufacturing Location:
Oxford, England
🏆 Awards & Recognition
Recognitions
Design Award:
The first generation Mini received numerous accolades for its distinctive design and driving dynamics.
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