MINI Cooper, Cooper S, Clubman (R55, R56, R57) Service Manual: 2007-2013 - Table of Contents

Important Safety Notice......................................................................................... ii Foreword ............................................................................................................. iv Index ................................................................................................ rear of manual

0 1 2 3 4 5 6 7

General Data and Maintenance

001 Warnings and Cautions 002 Vehicle Identification and VIN Decoder

010 Product Familiarization 020 Maintenance

Engine

100 Engine–General 110 Engine Removal and Installation 113 Cylinder Head Removal and Installation 117 Camshaft Timing Chain 119 Lubrication System

120 121 130 160 170 180

Transmission

200 Transmission–General 210 Clutch 230 Manual Transmission

240 Automatic Transmission 250 Gearshift Linkage

Suspension, Steering and Brakes

300 Suspension, Steering and Brakes–General 310 Front Suspension, Drive Axles

320 Steering and Wheel Alignment 330 Rear Suspension, Drive Axles 340 Brakes

400 Body–General 410 Fenders, Engine Hood

411 Doors 412 Rear Hatch, Tailgate, Split Rear Doors

Body Equipment

510 512 513 515

Exterior Trim, Bumpers Door Windows Interior Trim Central Locking and Anti-theft

520 Seats 540 Sunroof 541 Convertible Top

Electrical System

600 611 612 620

Electrical System–General Wipers and Washers Switches Instruments

630 Lights 640 Heating and Air-conditioning 650 Radio

Equipment and Accessories

720 Seat Belts 721 Airbag System (SRS)

Body

ECL ELE OBD

ECL Electrical Component Locations ELE Electrical Wiring Diagrams OBD On-Board Diagnostics

Ignition System Battery, Starter, Alternator Fuel Injection Fuel Tank and Fuel Pump Radiator and Cooling System Exhaust System

established 1950 Automotive Reference™

BentleyPublishers .com

MINI Cooper (R55, R56, R57) Service Manual: 2007-2013

Cooper, Cooper S, John Cooper Works (JSW) including Clubman and Convertible Price: $139.95 Bentley Stock Number: BM13 Publication Date: 2014.10.01 ISBN: 978-0-8376-1730-5 Hardcover, 8 3/8 in. x 11 in. Case quantity: 5 1064 pages, 1845 photos, illustrations and diagrams Includes color MINI Cooper familiarization section The MINI Cooper Service Manual: 2007-2013 is a comprehensive source of service information and specifications for MINI Cooper models from 2007 to 2013 (Mk II). The aim throughout this manual has been simplicity, clarity and completeness, with practical explanations, step-by-step procedures and accurate specifications. Whether you’re a professional or a do-it-yourself MINI owner, this manual will help you understand, care for and repair your car. Step-by-step instructions for resetting CBS service items. 020 Maintenance

Features: • Procedures for everything from changing the ATF to replacing a dirty cabin microfilter and resetting the CBS (condition based service) system. This manual tells you what to do and how and when to do it. • Engine and cylinder head service with variable camshaft timing (VANOS) setup and adjustment, including Valvetronic service on N12, N16, and N18 engines. • Driveability troubleshooting and detailed repair information for the Siemens DME Engine Management Systems. • Turbocharger and intercooler information, including component removal and replacement (Cooper S, JCW). • Drivetrain maintenance, including troubleshooting, adjustment and repair of clutch, gearshift linkage and drive axles. • Suspension repairs, including strut and control arm replacement procedures. • Manual and automatic transmission removal, installation, seal replacement and external service. • System repair information for antilock brakes (ABS), automatic stability control (ASC) and dynamic stability control (DSC). • Heating and air conditioning repair (IHKS / IHKA), including component replacement. • Body adjustments and repairs for sunroof and convertible, including resetting of the rollover protection system. • Electrical system service, including an easy to use electrical component section with detailed illustrations and photos. • Comprehensive wiring schematics, including fuses and grounds. • MINI OBD II diagnostic trouble codes, SAE-defined and OBD II P-Codes, as well as basic scan tool information and OBD II Diagnostic Trouble Codes (DTCs). • MINI factory tolerances, wear limits, adjustments, and tightening torques.

High pressure fuel system service on turbo engine, including replacing HP fuel pump. 160 Fuel Tank and Fuel Pump

Detailed engine service, including VANOS camshaft timing adjustment. 117 Camshaft Timing Chain

Models & engines covered: Cooper: Cooper S:

1.6 liter normally aspirated engine (engine codes N12, N16) 1.6 liter supercharged engine (engine codes N14, N18)

Transmissions covered: Manual: 6-speed Getrag (GS6-55BG for Cooper, GS6-53BG for Cooper S) Automatic: 6-speed with Agitronic, Aisin (GA6F21WA)

Bentley Publishers, 1734 Massachusetts Avenue, Cambridge, MA 02138-1804 USA Tel: 617-547-4170 • Toll Free: 800-423-4595 • Fax: 617-876-9235 http://www.bentleypublishers.com/contact-us bentley_bm13_new.product.announcement.pdf