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General Electric System
General Electric System
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
TROUBLESHOOTING
12 00 ... INSTRUCTIONS ON STARTING AID
Preparation:
Conform with the following when starting engine with starting cable.
CAUTION: Never touch ignition system components and current - dangerous high
tension!
If the battery in the vehicle supplying power is weak, start the engine of this vehicle and let it run at idling
speed.
Carrying out:
Always conform with the procedures to avoid injury to persons or damage to parts.
CAUTION: Never connect second jump lead (black) to negative terminal of battery in
vehicle to be started. This would produce explosive gas which could be
ignited by sparks.
Danger Of Explosion!
Microsoft
Tuesday, February 16, 2010 12:05:52
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2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
After engine of vehicle to be started has started up, first disconnect the jump lead on the negative
terminal/ground connection. Then remove jump lead from positive terminals.
61 00 ... BATTERY
NOTE: Important notes and instructions for handling batteries can be found in:
In low-maintenance batteries, check the acid level at least once a year. If necessary, top up with distilled water
up to the top marking.
The increasing number of electronic control units in the car reduces the self-discharging time of the battery
(even in standby mode). To maintain the battery service life and to avoid exhaustive discharging, recharge laid-
up vehicles every 6 weeks at the latest. The time for self-discharging depends on vehicle type and equipment
specification.
Battery test:
The battery acid density can be used to measure the charge state. However this test produces uncertainty caused
by a design-related range of variation. The acid density e.g. for a charged battery is 1.28 kg/l (in the tropical
version the acid density is 1.23 kg/l).
Another interference factor is the acid lamination immediately after filling with distilled water.
Battery wear with partially sulfated and/or heavily contaminated plates will also lead to incorrect acid density
test results.
If a normal or quick charger is used to charge the battery, the battery must be disconnected from the vehicle
electrical system and removed. This prevents damage to paintwork and upholstery.
IMPORTANT: In order to prevent the intelligent battery sensor from malfunctioning, the
charging terminals in the engine compartment must be used without fail in
vehicles from E60 and should be used if possible in other vehicles.
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2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
IMPORTANT: Before charging the battery while it is installed, first carry out a closed-circuit
current test. 61 20 ... BATTERY OPEN-CIRCUIT CURRENT TEST. If here the
voltage is 10 V or less, one or more of the cells may be faulty or the entire
battery may already be damaged. In this case, always remove the battery as
escaping gases during charging could damage the interior equipment and trim.
Attempt to regenerate faulty cells with low charging current.
IMPORTANT: Only repair those cables which show visible signs of damage. In the event of
visible damage, make sure there is only one cable repair in effect after the
repair work. If no visible damage can be identified, the entire cable must be
replaced. When carrying out repairs to the airbag wiring harness, you must use
the spare parts offered in the Electronic Parts Catalogue (EPC).
Safety Regulations:
Safety regulations for handling components of airbag system. Refer to AIR BAG SAFETY PRECAUTIONS .
Instructions for disconnecting and connecting battery. Refer to 12 00 ... INSTRUCTIONS FOR
DISCONNECTING AND CONNECTING BATTERY.
Disconnect plug connection on airbag module or on adapter plug. It is absolutely vital to disconnect the contacts
in succession as there is a risk of them being mixed up! Cut through one cable after the other at an appropriate
position, do not under any circumstances cut through both cables at the same time. Insulate cables remaining in
wiring harness with insulating tape. Now disconnect plug connection on airbag control unit. Unpin contacts. Cut
through one cable after the other at an appropriate position and insulate with insulating tape, do not under any
circumstances cut through both cables at the same time. Pin contacts of repair cable for airbag control unit in
control unit plug, assignment of repair cables is relevant. Lay repair cable in car parallel to existing airbag lead.
Now pin in contacts for airbag control unit or contacts of adapter plug, assignment of repair cables is relevant.
Cut off excess length of repair cable in proximity (visible area) of airbag module or of adapter plug. Twist open
cables. With the connectors and shrink-fit hoses in the Electronic Parts Catalogue (EPC), reconnect the cables
with the same cable colors. Twist cables again, open length (twist) must not exceed 40 mm. Secure interface
(shrink-fit hoses) with insulating tape to prevent cables from twisting open.
Instructions for cutting off, insulating, crimping cables, installing and removing contacts, refer to:
Expose cable at damaged areas. Cut through one cable after the other at an appropriate position and insulate
cables no longer required in wiring harness with insulating tape, do not under any circumstances cut through
both cables at the same time. Now, depending on the scope of work, unpin contacts either on airbag control
unit/airbag module or on adapter plug. Cut off unpinned cables. Insulate cables remaining in wiring harness
with insulating tape. Now pin in contacts of repair cable, assignment of repair cables is relevant. Lay repair lead
in car parallel to existing airbag lead up to cutting point. Cut off excess length of repair lead. Twist open cables.
Connect cables with connectors and shrink-fit hoses in Electronic Parts Catalogue (EPC), assignment of repair
cables is relevant. Twist cables again, open length (twist) must not exceed 40 mm. Secure interface (shrink-fit
hoses) with insulating tape to prevent cables from twisting open.
Instructions for cutting off, insulating, crimping cables, installing and removing contacts:
Do not allow any battery acid to come into contact with the eyes, the skin or clothing. Therefore wear protective
clothing, gloves and goggles.
Do not tilt the battery, acid may emerge from the vent opening.
If acid is splashed into the eyes, rinse them immediately for several minutes with clear water. You must then
consult a doctor without delay.
If acid is splashed onto the skin or clothing, neutralize it immediately with a soapy solution and rinse with lots
of water.
Explosion Hazard:
A highly explosive mixture of electrolytic gas is created when batteries are charged. The rooms where charging
is carried out must therefore always be well ventilated.
Microsoft
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2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
Avoid the formation of sparks when handling cables, wiring and electrical devices.
Turn the ignition lock to the 0 position before disconnecting or connecting the battery.
Do not place tools or any similar object on the battery (danger of short-circuiting and explosion!).
Open clip in direction of arrow and disconnect plug connection in direction of arrow.
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2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
Microsoft
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2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
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2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
Microsoft
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2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
Microsoft
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2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
Microsoft
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2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
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2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
AUXILIARY CABLE
61 13 .. UNLOCKING AND DISCONNECTING DIFFERENT PLUG CONNECTIONS
Microsoft
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2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
NOTE: For Special Tool identification, see GENERAL ELECTRICAL SYSTEM - SPECIAL
TOOLS - COOPER (1.6L) R50/W10 .
61 1 150
61 1 190
61 4 320
61 8 084
61 9 020
61 9 029
61 9 041
61 9 042
61 9 043
61 9 044
NOTE: Operating instructions for the special tools contained in these repair ranges,
refer to manufacture's operating instructions.
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2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
Contents:
NOTE: Operating instructions for the special tools contained in the this repair range,
refer to manufacture's operating instructions.
Special tool 61 9 043 (wire stripper with wire cutter) for cutting and stripping wires.
Handling:
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2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
Special tool 61 9 041 (hand pliers) with special tool 61 9 042 (matrix) for crimping connectors and contact
tubes for fan connectors up to a wire cross-section of 2.5 mm2 and for pushing on contact tubes for fan
connectors.
Handling:
Microsoft
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2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
Special tool 61 9 041 (hand pliers) with special tool 61 9 044 (matrix) for crimping cable guide and strain relief
device on antenna elbow plug.
Handling:
Microsoft
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2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
Handling:
Opening plug housings and removing contacts of different plug systems. Refer to 61 13 ... OPENING PLUG
HOUSINGS AND REMOVING CONTACTS OF DIFFERENT PLUG SYSTEMS.
Microsoft
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2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
Repair kit for ignition cables and for crimping fan connector receptacles 4 mm2 .
Handling:
Microsoft
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2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
Cutting to length and stripping insulation from optical fibers. Refer to 61 13 ... CUTTING OFF,
STRIPPING INSULATION AND CUTTING OPTICAL FIBRES TO LENGTH.
Crimping optical fibers. Refer to 61 13 ... CRIMPING OPTICAL FIBRES.
Crimping MPQ contacts. Refer to 61 13 ... CRIMPING MICRO POWER QUADLOCK CONTACTS
(MPQ).
Microsoft
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2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
Special tool 61 1 190 pliers for insulation displacement connector for repairing ribbon cables.
Handling:
Microsoft
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2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
Unlock hook (1) with special tool 61 1 360 and slide plug housing downwards out of base.
Microsoft
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2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
NOTE: For Special Tool identification, see GENERAL ELECTRICAL SYSTEM - SPECIAL
TOOLS - COOPER (1.6L) R50/W10 .
61 4 320
To crimp MPQ contacts, use pliers 61 4 321 (1) in conjunction with crimping head 61 4 325 (2) from crimping
set 61 4 320.
NOTE: Pliers (1) open automatically as far as they will go when handles are pressed
together.
Microsoft
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2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
NOTE: Place contact (2) with utmost care in designated nest (observe cable cross-
section) in crimping head (3). Make sure it is exactly positioned.
Microsoft
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2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
NOTE: Follow procedure for cutting and stripping insulation from cables.
Microsoft
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2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
NOTE: For Special Tool identification, see GENERAL ELECTRICAL SYSTEM - SPECIAL
TOOLS - COOPER (1.6L) R50/W10 .
61 4 320
To crimp MQS contacts, use pliers 61 4 321 (1) in conjunction with crimping head 61 4 324 (2) from crimping
set 61 4 320.
NOTE: Pliers (1) open automatically as far as they will go when handles are pressed
together.
Microsoft
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2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
Microsoft
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2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
NOTE: Follow procedure for cutting and stripping insulation from cables.
Microsoft
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2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
Open contact carrier (2) gently and carefully remove MQS contact.
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2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
CrimpacII crimping pliers from repair kit 1 are used to crimp annular contacts.
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2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
NOTE: Place contact (2) in designated nest (observe wire cross-section) with particular
care. Make sure it is exactly positioned.
Microsoft
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2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
NOTE: Follow procedure for cutting and stripping insulation from cables.
Microsoft
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2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
NOTE: For Special Tool identification, see GENERAL ELECTRICAL SYSTEM - SPECIAL
TOOLS - COOPER (1.6L) R50/W10 .
61 4 320
To crimp optical fibres, use pliers 61 4 321 (1) in conjunction with crimping head 61 4 323 (2) from crimping
set 61 4 320.
NOTE: Pliers (1) open automatically as far as they will go when handles are pressed
together.
Microsoft
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2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
Move contact guide by means of stop lever (1) into corresponding position (pin contact or jack).
Microsoft
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2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
Place pin contact or jack (1) in crimping head and secure with locking lever (3).
Microsoft
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2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
NOTE: Follow procedure for cutting and stripping insulation from optical fibres. Refer
to 61 13 ... CUTTING OFF, STRIPPING INSULATION AND CUTTING OPTICAL
FIBRES TO LENGTH.
Insert stripped optical fibre (1) as far as it will go into pin contact or jack (2).
Microsoft
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2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
Right (A)
End of optical fibre (1) must be flush with tip of pin contact (2).
Wrong (B)
End of optical fibre (1) is not flush with tip of pin contact (2).
Microsoft
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2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
NOTE: For Special Tool identification, see GENERAL ELECTRICAL SYSTEM - SPECIAL
TOOLS - COOPER (1.6L) R50/W10 .
61 4 320
To cut off, strip insulation and cut optical fibres to length, use pliers 61 4 321 (1) in conjunction with crimping
head 61 4 322 (2) from crimping set 61 4 320.
NOTE: Pliers (1) open automatically as far as they will go when handles are pressed
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2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
together.
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2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
Microsoft
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2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
Slide optical fibre (1) into stripping device (2) until flush at point (3).
Open clamping lever (5) against direction of arrow again and remove optical fibre (1).
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2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
IMPORTANT: The cutting blade must be replaced prior to each cutting of the optical fibre.
Microsoft
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2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
Installation:
Microsoft
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2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
Slide optical fibre (1) into cutting device (2) until insulation of optical fibre (1) butts against clamping device.
Microsoft
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2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
Micro Power Quadlock electronic contacts for heavy loads with and without strand sealing
MPQ
Manufacturer: AMP
D 1.5 / 2.5 Round contacts of 1.5 mm or 2.5 mm diameter
Ultrasonic-Welded Connectors:
Ultrasonic-welded connectors (1) can be identified by the welds (2) on their longitudinal side.
NOTE: Special tools referred to in the repair instructions below are contained in the
following special tool kits:
Repair Instructions For Opening Plug Housings And Removing Contacts Of Different Plug Systems
Place special tool 61 1 153 on relay carrier (1) and carefully pull in direction of arrow until retaining lugs (2) on
relay carrier are raised.
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2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
Pull relay carrier (2) in direction of arrow into first catch (3).
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2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
Press down arrester hook (4) of appropriate contact and pull out cable with contact.
Press out double flat spring contact with special tool 61 1 136 or 61 1 137 (ejector).
Microsoft
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2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
Pull locking slide (2) out of fuse block (1) as far as it will go.
Microsoft
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2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
With special tool 61 1 136 or 61 1 137 (ejector), press back arrester hook (3) of appropriate contact and pull out
cable.
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2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
Manufactured By AMP: The following contact types without strand sealing can be fitted in the plug housings:
Microsoft
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2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
Pull wire (1) with socket contact out of radio plug (2).
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2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
Fig. 48: Removing Wire With Socket Contact Out Of Radio Plug
Courtesy of BMW OF NORTH AMERICA, INC.
Press lock (1) in direction of arrow and pull housing (2) out of radio plug.
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2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
Press lock (1) in direction of arrow. Pull contact carrier (2) out of housing (3).
NOTE: When the contact carrier is pulled out, the secondary locks of the socket
contacts are raised.
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2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
Hold down retaining hook (1) of socket contact in opening of contact carrier with a small screwdriver.
Pull wire with socket contact in direction of arrow as far as secondary lock (2).
NOTE: The illustration shows an 8-pin socket housing where removal of the contacts is
identical.
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2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
Hold down arrester hook in secondary lock (1) again. Pull wire with socket contact (2) out of contact carrier (3).
Microsoft
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2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
Fig. 52: Pulling Wire With Socket Contact Out Of Contact Carrier
Courtesy of BMW OF NORTH AMERICA, INC.
Remove contact carrier (1) with MQS contacts from radio plug.
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2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
Pull secondary lock (2) in direction of arrow completely out of contact carrier (3).
Microsoft
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2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
Press special tool 61 1 135 on inside of contact into contact carrier (2).
Pull wire with socket contact (1) out of contact carrier (2).
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2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
Fig. 55: Removing Wire With Socket Contact Out Of Contact Carrier
Courtesy of BMW OF NORTH AMERICA, INC.
Release retaining clips (1) and remove fuse box cover (2).
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2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
Microsoft
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2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
Installation:
Replacement only:
Microsoft
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2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
Remove front left entrance cover strip. Refer to 51 47 000 REMOVING AND INSTALLING/REPLACING
FRONT LEFT OR RIGHT ENTRANCE COVER STRIP (INSIDE) .
Microsoft
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2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
Install hint:
Microsoft
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2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
Replacement only:
BATTERY
12 00 ... INSTRUCTIONS FOR DISCONNECTING AND CONNECTING BATTERY
61 00 ... BATTERY
Microsoft
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2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
Operation is identical to: 61 00 ... SAFETY INSTRUCTIONS FOR HANDLING VEHICLE BATTERY.
Safety instructions for handling vehicle battery. Refer to 61 00 ... SAFETY INSTRUCTIONS FOR
HANDLING VEHICLE BATTERY.
NOTE: If battery was checked on the positive terminal in the engine compartment,
repeat check directly on battery for sake of safety.
NOTE: Observe safety instructions for handling vehicle battery. Refer to 61 00 ...
SAFETY INSTRUCTIONS FOR HANDLING VEHICLE BATTERY. Observe Service
Information Adapter for open-circuit current measurement.
Microsoft
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2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
The open-circuit current test is performed using the Diagnosis and Information System (DIS).
Microsoft
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2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
BATTERY/VAPOR SEPARATOR
61 21 010 REMOVING AND INSTALLING BATTERY
WARNING: Follow safety instructions for handling vehicle battery. Refer to 61 00 ...
SAFETY INSTRUCTIONS FOR HANDLING VEHICLE BATTERY.
This text deals with removing the battery from the engine compartment.
Removing the battery from the luggage compartment is performed in the same way.
IMPORTANT: Disconnect battery negative lead first, followed by battery positive lead (risk of
short circuit).
Release screw (2), tightening torque, refer to 61 21 1AZ in GENERAL ELECTRICAL SYSTEM -
TIGHTENING TORQUE - COOPER (1.6L) R50/W10 .
Release screw (3), tightening torque, refer to 61 21 1AZ in GENERAL ELECTRICAL SYSTEM -
TIGHTENING TORQUE - COOPER (1.6L) R50/W10 .
Release screws (4), tightening torque, refer to 61 21 2AZ in GENERAL ELECTRICAL SYSTEM -
TIGHTENING TORQUE - COOPER (1.6L) R50/W10 .
Installation:
Connect battery in reverse sequence. Connect battery positive lead first, followed by negative lead.
Make sure both battery leads run at an angle of 90° to the battery container because they are routed through
openings in the battery container cover.
Microsoft
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2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
Installation:
Initialize both power windows. Refer to 67 62 ... NOTES ON INITIALIZING POWER WINDOW UNIT
(FRONT) .
Remove suction filter housing. Refer to13 71 000 REMOVING AND INSTALLING INTAKE
FILTER HOUSING .
Remove battery. Refer to 61 21 010 REMOVING AND INSTALLING BATTERY.
Disconnect plug connector from EMS/DME control unit. Refer to 12 14 550 REPLACING CONTROL
UNIT (DME) .
Microsoft
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2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
Release screws (1) of battery container, tightening torque, refer to 61 21 3AZ in GENERAL ELECTRICAL
SYSTEM - TIGHTENING TORQUE - COOPER (1.6L) R50/W10 .
SWITCH
61 31 006 REMOVING AND INSTALLING (REPLACING) FIXTURE FOR STEERING COLUMN
STALK
WARNING: Move wheels into straight-ahead position and do not alter this position
during the repair work. With steering wheel removed, do not under any
circumstances turn/twist fixture for steering column stalk!
Remove top section of steering column casing. Refer to UPPER SECTION OF STEERING COLUMN
TRIM .
WARNING: Secure volute spring cassette (1) against rotating with adhesive tape (2).
If unauthorized rotation of volute spring cassette (1) cannot be ruled out, it is essential to return volute spring
cassette (1) to center position!
Microsoft
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2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
Replacement:
Microsoft
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2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
Remove fixture for steering column stalk. Refer to 61 31 006 REMOVING AND INSTALLING
(REPLACING) FIXTURE FOR STEERING COLUMN STALK.
Expand catches (1) and remove volute spring cassette (2) from fixture for steering column switch (3).
Replacement:
Break off turning lock (1) of new volute spring cassette (2).
WARNING: If the steering wheel is not reinstalled straight away, the new volute
spring cassette (2) must be secured against turning with adhesive tape!
Microsoft
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2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
Remove lower section of steering column trim. Refer to LOWER SECTION OF STEERING
COLUMN TRIM .
Remove top section of steering column casing. Refer to UPPER SECTION OF STEERING COLUMN
TRIM .
Microsoft
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2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
Microsoft
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2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
Installation:
Removing and installing/replacing turn indicator/headlight dipping switch. Refer to 61 31 016 REMOVING
Microsoft
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2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
Remove cover strips for front center console. Refer to 51 16 198 REMOVING/INSTALLING OR
REPLACING TRIM BETWEEN FRONT CENTER CONSOLE AND INSTRUMENT PANEL .
Remove screws (1) and pull switch block towards front to release rear retaining clips.
Microsoft
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2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
IMPORTANT: If the car has telephone provisions (optional extra), the plug connector is the
same as that of the switch block in the instrument panel. Make sure the correct
plug connector is reconnected.
Microsoft
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2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
Release retaining clips for sleeve of parking brake lever (the left side is shown here, mirror image for the right
side) and partially remove the sleeve to expose the rear side of the TPM switch.
Microsoft
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2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
Fig. 74: Identifying Retaining Clips For Sleeve Of Parking Brake Lever
Courtesy of BMW OF NORTH AMERICA, INC.
Microsoft
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2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
61 31 090 REMOVING AND INSTALLING / REPLACING SWITCH FOR LEFT OR RIGHT SEAT
HEATING
Up To 12/2001:
Remove rear center console. Refer to 51 16 217 REPLACING REAR CENTER CONSOLE .
From 12/2001:
Microsoft
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2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
Release switch unit (1) from front center console (in direction shown).
Install Hint:
Microsoft
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2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
Microsoft
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2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
Remove multiplug.
Microsoft
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2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
Microsoft
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2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
Fig. 80: Disconnecting Plug Connection From Petrol/Gasoline Pump Emergency Switch
Courtesy of BMW OF NORTH AMERICA, INC.
IMPORTANT: Make sure cables are correctly laid in steering wheel and cannot be trapped
during assembly.
Microsoft
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2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
Carefully insert screwdriver into slot (2) in order to release locking tongue of rear switch housing (3) from front
switch housing (4).
Microsoft
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2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
Microsoft
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2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
Microsoft
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2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
Disconnect associated plug connections and remove switches from steering wheel (2).
Microsoft
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2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
Installation:
Microsoft
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2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
Microsoft
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2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
Installation:
Microsoft
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2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
Remove air filter box. Refer to 13 71 000 REMOVING AND INSTALLING INTAKE FILTER
HOUSING .
Remove connector.
Microsoft
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2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
NOTE: Brake light switch (2) is situated above the brake pedal.
Pull brake light switch (2) in direction of arrow out of brake light switch holder (4).
Press catches (4) together and unclip brake light switch holder (3) from brake pedal.
Installation:
Slide brake light switch (2) as far as it will go into brake light switch holder (3).
Microsoft
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2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
Grip brake light switch holder (3), slowly return brake pedal to starting position and pull back to stop.
Remove strip handle (rear lid). Refer to 51 13 402 REMOVING AND INSTALLING/REPLACING
STRIP HANDLE (REAR LID) .
Installation:
Remove switch for unlocking rear lid (2) in direction of arrow from fixtures (3).
Microsoft
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2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
HORN
61 33 000 REPLACING HORN (ANTI-THEFT ALARM SYSTEM)
Release nuts (1), tightening torque, refer to 61 35 2AZ in GENERAL ELECTRICAL SYSTEM -
TIGHTENING TORQUE - COOPER (1.6L) R50/W10 .
Microsoft
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2006 MINI Cooper
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Microsoft
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2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
Release nut (1), tightening torque, refer to 61 35 3AZ in GENERAL ELECTRICAL SYSTEM -
TIGHTENING TORQUE - COOPER (1.6L) R50/W10 .
Microsoft
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2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
ECUS MODULES
61 35 ... NOTE ON REPLACING CODABLE/PROGRAMMABLE CONTROL UNITS
Replacement:
Programming.
Coding.
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2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
NOTE: For Special Tool identification, see ENGINE ELECTRICAL SYSTEM - SPECIAL
TOOLS .
12 7 060
E -Electro
S -Static
D -Discharge
NOTE: Humans can only detect a discharge starting from a level of approx. 3000 V. The
danger threshold for electrical components already starts from a level of
approx. 100 V.
Microsoft
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2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
Example:
Microsoft
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Microsoft
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2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
Microsoft
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2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
Pull out locks (1) in direction of arrow and remove rain sensor (2).
Installation:
If necessary, initialize rain sensor (2). Refer to 61 35 680 INITIALIZING RAIN SENSOR.
Microsoft
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2006 MINI Cooper
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Microsoft
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2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
Microsoft
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2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
Replacement:
Version up to 09/03:
It is necessary to adjust the headlights when ZKE (1) BC1 with ribbed metal housing is replaced by ZKE (2)
BCRD with plastic housing. Refer to 63 10 004 ADJUSTING HEADLIGHTS .
Microsoft
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2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
Microsoft
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2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
Release nuts (1), tightening torque, refer to 61 35 4AZ in GENERAL ELECTRICAL SYSTEM -
TIGHTENING TORQUE - COOPER (1.6L) R50/W10 .
Disconnect plug connection (2) and remove control unit for headlight vertical aim adjustment.
Fig. 103: Removing Control Unit For Headlight Vertical Aim Adjustment
Courtesy of BMW OF NORTH AMERICA, INC.
Replacement:
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2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
NOTE: For Special Tool identification, see GENERAL ELECTRICAL SYSTEM - SPECIAL
TOOLS - COOPER (1.6L) R50/W10 .
61 3 300
Attach special tool 61 3 300 so that flat end (A) points to ring antenna of electronic immobilizer.
Microsoft
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2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
Release nuts (1), tightening torque, refer to 61 35 1AZ in GENERAL ELECTRICAL SYSTEM -
TIGHTENING TORQUE - COOPER (1.6L) R50/W10 .
UK Vehicles Only:
The control unit of the electronic immobilizer is protected by a metal bracket. Nuts (1) are special tamperproof
nuts.
Replacement:
DIAGNOSIS PROGRAMMING/CODING
RELAYS
61 13 ... RELAY CARRIER
WINDSCREEN WIPERS
61 61 010 CHECKING/ADJUSTING CONTACT ANGLE OF WINDSCREEN WIPER ARMS ON
WINDSCREEN
00 9 220
00 9 230
61 6 100
NOTE: The wipe quality is improved by precise adjustment of the wiper arm contact
angle. Adjustment angle can be checked with special tool 00 9 230 or 61 6 100.
Before checking approach angle, briefly lift windscreen wiper arms off windscreen.
Place special tool 00 9 230 next to pivot point of wiper blade on windscreen.
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2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
NOTE: Tape off wiper arm with fabric adhesive tape to avoid damage.
Press special tools 00 9 220 in appropriate direction until correct contact/approach angle is obtained.
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2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
Using screw (2) and pressure plate (3), locate windscreen wiper arm (1) and position on windscreen.
NOTE: Windscreen wiper arm (1) must rest correctly on lower and side contact
surfaces (4) of angulometer 61 6 100. On right-hand-drive cars, screw (2) must
be located on left side of special tool 61 6 100.
Microsoft
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2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
Press special tools 00 9 220 in appropriate direction until correct contact/approach angle is obtained.
Microsoft
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2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
Press retaining spring in direction of arrow. Pull wiper blade in direction of wiper arm and remove.
Microsoft
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2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
NOTE: For Special Tool identification, see GENERAL ELECTRICAL SYSTEM - SPECIAL
TOOLS - COOPER (1.6L) R50/W10 .
61 2 100
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2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
Retaining lugs (1) and fasteners (2) of protective cap (3) must not be damaged.
Microsoft
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2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
Installation:
Microsoft
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2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
Microsoft
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2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
Set wiper arm to rest position and then tighten down wiper arm nut.
1. 59 mm.
2. 60 mm.
Microsoft
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2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
Installation:
Microsoft
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2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
Press wiper blade in direction of arrow to release blade from wiper arm.
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2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
61 62 030 REPLACING (REMOVING AND INSTALLING) WIPER ARM FOR REAR WINDOW
WIPER (FROM 07/2004)
NOTE: For Special Tool identification, see GENERAL ELECTRICAL SYSTEM - SPECIAL
TOOLS - COOPER (1.6L) R50/W10 .
61 6 210
IMPORTANT: To avoid damaging the spray nozzle, it is necessary in addition to the special
tool to use a suitable socket for detaching the rear window wiper from the
wiper motor.
Press off wiper arm (2) with special tool 61 6 210 and suitable socket (4).
Installation:
Adjust distance (1) between wiper arm and rear window edge.
1. 44 mm.
Replacement:
Remove and install rear window wiper blade. Refer to 61 62 020 REMOVING AND
INSTALLING/REPLACING REAR WIPER BLADE.
61 62 030 REPLACING (REMOVING AND INSTALLING) WIPER ARM FOR REAR WINDOW
WIPER (UP TO 07/2004)
NOTE: For Special Tool identification, see GENERAL ELECTRICAL SYSTEM - SPECIAL
TOOLS - COOPER (1.6L) R50/W10 .
Microsoft
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2006 MINI Cooper
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61 6 210
Open protective cap with integrated spray nozzle (1) to expose nut.
Engagement tongues (1) and inlet of spray nozzle (2) in protective cap (3) must not be damaged.
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2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
Installation:
Adjust distance (1) between wiper arm and rear window edge.
1. 44 mm.
Replacement:
Remove and install rear window wiper blade. Refer to 61 62 020 REMOVING AND
INSTALLING/REPLACING REAR WIPER BLADE.
Microsoft
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2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
Refer to 61 62 030 REPLACING (REMOVING AND INSTALLING) WIPER ARM FOR REAR
WINDOW WIPER (UP TO 07/2004).
Refer to 51 49 005 REMOVING AND INSTALLING/REPLACING TRIM FOR LOWER REAR LID .
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2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
Install hint:
NOTE: Inspect wiper motor spindle grommet for any signs of damage.
Adjustment measurements:
Microsoft
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2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
Mark contact point with adhesive tape. Adjust jet nozzle (1) with screwdriver in slot.
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2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
The fluid reservoir for the headlight cleaning system is located on the left side of the car.
Microsoft
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2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
Remove front left wheel arch trim. Refer to 51 71 040 REMOVING AND
INSTALLING/REPLACING FRONT LEFT OR RIGHT WHEEL ARCH LINER .
Detach hose (1) from holder on fluid reservoir for headlight cleaning system.
Remove retaining ring (2) from fluid reservoir for headlight cleaning system.
Installation:
Withdraw washer pump for headlight cleaning system from fluid reservoir for headlight cleaning system.
Open lock and detach hose from washer pump for headlight cleaning system.
Installation:
Coat sealing ring of washer pump for headlight cleaning system with antiseize agent.
Microsoft
Tuesday, February 16, 2010 12:05:48 PM Page 140 © 2005 Mitchell Repair Information Company, LLC.
2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
00 9 341
Pull nozzle carrier (1) out of headlight cleaning system (2) and secure with special tool 00 9 341.
Carefully lift off chrome cover (1) from trim (2) with screwdriver (3).
Microsoft
Tuesday, February 16, 2010 12:05:48 PM Page 141 © 2005 Mitchell Repair Information Company, LLC.
2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
Carefully press retaining lugs (1) together with pointed pliers (2) and remove trim (3).
Microsoft
Tuesday, February 16, 2010 12:05:48 PM Page 142 © 2005 Mitchell Repair Information Company, LLC.
2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
Release hose connection piece (1) by pressing release tongue (2) on headlight washer system (4).
Release fastening tongue (3), slide headlight cleaning system (4) in direction of arrow and remove.
Microsoft
Tuesday, February 16, 2010 12:05:48 PM Page 143 © 2005 Mitchell Repair Information Company, LLC.
2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
Installation:
Following parts of headlight cleaning system (1) must not be damaged or missing:
1. Fastening tongue.
2. Retaining lugs.
Microsoft
Tuesday, February 16, 2010 12:05:48 PM Page 144 © 2005 Mitchell Repair Information Company, LLC.
2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
Retaining lugs (1) and (2) of chrome cover (3) must not be damaged or missing.
Installation:
Position trim (4) under individual retaining lug (1) and clip in the other two retaining lugs (2).
Microsoft
Tuesday, February 16, 2010 12:05:48 PM Page 145 © 2005 Mitchell Repair Information Company, LLC.
2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
00 9 200
Mark contact points with adhesive tape or felt-tip marker and actuate windscreen washer system. The jet sprays
Microsoft
Tuesday, February 16, 2010 12:05:48 PM Page 146 © 2005 Mitchell Repair Information Company, LLC.
2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
Microsoft
Tuesday, February 16, 2010 12:05:48 PM Page 147 © 2005 Mitchell Repair Information Company, LLC.
2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
Detach hood/bonnet noise insulation in rear area. Refer to 51 48 001 REMOVING AND
INSTALLING/REPLACING ENGINE HOOD/BONNET SOUND INSULATION .
Press retainer (2) together and remove spray nozzle for windscreen washer system.
Microsoft
Tuesday, February 16, 2010 12:05:48 PM Page 148 © 2005 Mitchell Repair Information Company, LLC.
2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
Remove front right auxiliary turn indicator light. Refer to 63 13 200 REMOVING AND
INSTALLING/REPLACING FRONT LEFT OR RIGHT AUXILIARY TURN SIGNAL LAMP .
Remove front right wheel arch trim. Refer to 51 71 040 REMOVING AND
INSTALLING/REPLACING FRONT LEFT OR RIGHT WHEEL ARCH LINER .
Remove windscreen washer pump. Refer to 61 71 100 REMOVING AND
INSTALLING/REPLACING WINDSCREEN WASHER PUMP.
Release screw (1), tightening torque, refer to 61 61 3AZ in GENERAL ELECTRICAL SYSTEM -
TIGHTENING TORQUE - COOPER (1.6L) R50/W10 .
Microsoft
Tuesday, February 16, 2010 12:05:48 PM Page 149 © 2005 Mitchell Repair Information Company, LLC.
2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
Release screw and nut (1), tightening torque, refer to 61 61 3AZ in GENERAL ELECTRICAL SYSTEM -
TIGHTENING TORQUE - COOPER (1.6L) R50/W10 .
Pull underside of fluid reservoir for windscreen washer system forwards in direction of arrow.
Detach hoses/lines (2) from clips from fluid reservoir for windscreen washer system.
Installation:
Microsoft
Tuesday, February 16, 2010 12:05:49 PM Page 150 © 2005 Mitchell Repair Information Company, LLC.
2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
Detach front right wheel arch trim in rear area. Refer to 51 71 040 REMOVING AND
INSTALLING/REPLACING FRONT LEFT OR RIGHT WHEEL ARCH LINER .
Pull windscreen washer pump out of fluid reservoir for windscreen washer unit.
Microsoft
Tuesday, February 16, 2010 12:05:49 PM Page 151 © 2005 Mitchell Repair Information Company, LLC.
2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
Installation:
Microsoft
Tuesday, February 16, 2010 12:05:49 PM Page 152 © 2005 Mitchell Repair Information Company, LLC.
2006 MINI Cooper
2002-05 ACCESSORIES & EQUIPMENT Accessories Control Systems - Repair Instructions - Cooper (1.6L) R50/W10
Microsoft
Tuesday, February 16, 2010 12:05:49 PM Page 153 © 2005 Mitchell Repair Information Company, LLC.