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2003 Mini Cooper CAR/TRUCK REPAIR PROCEDURES AND DIAGRAMS - WHAT Mini REPAIR SHOPS DON'T WANT YOU TO KNOW
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- Component Locations
- Wiring Diagrams
- Technical Service Bulletins
- Specifications
- Brake Service
- Fuel Filter Replacement
- Driveline, U-Joint & CV Axles Replacement
- Tire Pressure Monitoring System
- Starter & Alternator Replacement
- Cabin Air Filter Locations & Replacement
- Maintenance Lamp Reset
- Radiator & Hose Replacement
- Serpentine Belt Service
BRAKE SERVICE PROCEDURES FOR 2003 Mini Cooper AUTOMOBILES
Anti-lock Brakes -> System Service -> 745 -> Brake System Bleed -> Component Replacement -> Control Module -> Front Speed Sensor -> Hydraulic Unit -> M3, 325 & 330 -> M5, 525, 530, 540, 740 & 750 -> Rear Speed Sensor -> X5 -> Z3 -> Z8
Vehicle: 2003 Mini Cooper S 1.6 L4 GAS
Brake System Bleed
Refer to "Hydraulic Brake Systems," for procedures.
Component Replacement
Hydraulic Unit
M3, 325 & 330
- Remove end firewall and seal.
- Disconnect vacuum lines and electrical connector.
- Remove master cylinder as outlined in "Hydraulic Brake Systems" section.
- Mark brake lines for installation alignment.
- Disconnect brake lines.
- Disconnect connector.
- Remove brake lines with rubber grommet from body and press toward engine. Do not bend brake lines.
- Remove mounting bolts and hydraulic unit.
- Reverse procedure to install. Bleed brake system as outlined in "Hydraulic Brake Systems" section.
...
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FUEL FILTER REPLACEMENT PROCEDURES FOR 2003 Mini Cooper AUTOMOBILES
Mini -> Component Locations ->
Vehicle: 2003 Mini Cooper S 1.6 L4 GAS
The fuel filter is located on the righthand s...
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DRIVELINE, U-JOINT & CV AXLES REPLACEMENT PROCEDURES FOR 2003 Mini Cooper AUTOMOBILES
CV AXLE SHAFT, Replace
Vehicle: 2003 Mini Cooper S 1.6 L4 GAS
- Raise and support vehicle, then tire and wheel assemblies.
- Remove axle shaft nut.
- Drain transaxle oil into suitable container.
- Remove mounting bolts and support brake caliper aside. Do not stretch brake lines.
- Remove nut and disconnect steering tie rod end from knuckle using knuckle puller tool No. 32 3 090, or equivalent.
- Remove ABS sensor.
- Remove nut and disconnect lower cont...
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TIRE PRESSURE MONITORING SYSTEM PROCEDURES FOR 2003 Mini Cooper AUTOMOBILES
Component Locations
Vehicle: 2003 Mini Cooper 1.6 L4 GAS
Refer to Figs. ...
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STARTER & ALTERNATOR REPLACEMENT PROCEDURES FOR 2003 Mini Cooper AUTOMOBILES
Starter, Replace
Vehicle: 2003 Mini Cooper S 1.6 L4 GAS
- Disconnect battery ground cable.
- Loosen clamp and detach air intake hose.
- Unlock intake duct and detach from intake filter housing.
- Remove intake filter housing.
- Remove fuel tank vent valve, if equipped.
- Raise vehicle on suitable lift.
- Remove righthand wheel nuts.
- Remove bolts from vacuum tank and set to one side, if equipped.
- Discon...
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CABIN AIR FILTER LOCATIONS & REPLACEMENT PROCEDURES FOR 2003 Mini Cooper AUTOMOBILES
Cabin Air Filter Service -> Mini -> Cooper -> 2002-06 Coupe & 2005-08 Convertible -> 2007-09 Coupe & 2009 Convertible
Vehicle: 2003 Mini Cooper S 1.6 L4 GAS
2002-06 Coupe & 2005-08 Convertible
The Mini is equipped with a service interval indicator.
- Remove the four cabin air filter cover retaining screws. The cabin air filter cover is located at the lower righthand side of the instrument panel below the storage bin, Fig. .
- Disengage the cabin air filter cover retainers, then remove the cover, Fig. .
- Pull the cabin air filter downward to remove.
- Install the new cabin air filter element into the filter housing, Fig. . Ensure the filter element is properly located in the guides.
- Install the cabin air filter cover. Ensure the retainers are engaged, the...
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MAINTENANCE LAMP RESET PROCEDURES FOR 2003 Mini Cooper AUTOMOBILES
Mini -> Dynamic Stability Control (DSC) Warning Lamp ->
Vehicle: 2003 Mini Cooper 1.6 L4 GAS
The DSC warning lamp is used to warn of a system fault. It will be lit during engine start-up, but should go out when the self-diagnostic system determines that the system is functioning properly. The warning lamp will also flash when ...
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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR 2003 Mini Cooper AUTOMOBILES
Coolant Hose, Replace -> Lower -> Upper
Vehicle: 2003 Mini Cooper S 1.6 L4 GAS
Lower
- Drain coolant into a suitable container.
- Reposition clamp at radiator and remove hose.
- Reposition clamp at water pump and remove hose.
- Remove hose from vehicle.
- Reverse procedure to i...
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SERPENTINE BELT SERVICE PROCEDURES FOR 2003 Mini Cooper AUTOMOBILES
Serpentine Drive Belt, Replace
Vehicle: 2003 Mini Cooper S 1.6 L4 GAS
If drive belt is to be reused: Mark direction of travel and reinstall drive belt in same direction of travel.
- Remove tank venting valve.
- Remove underpan.
- Relie...
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COMPONENT LOCATION DIAGRAMS FOR 2003 Mini Cooper AUTOMOBILES
Component location diagrams for most 2003 Mini Cooper cars and light trucks sold in the U.S. from 1990+.
Rear Body Components Diagram for 2003 Mini Cooper 1.6 L4 GAS Components on diagram: |
Body Components Diagram for 2003 Mini Cooper 1.6 L4 GAS Components on diagram: |
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WIRING DIAGRAMS FOR 2003 Mini Cooper AUTOMOBILES
OEM drawn wiring diagrams for most 2003 Mini Cooper cars and light trucks sold in the U.S.
2003 Mini Cooper 1.6 L4 GAS Wiring Diagram Components on diagram: |
2003 Mini Cooper 1.6 L4 GAS Wiring Diagram Components on diagram: |
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TECHNICAL SERVICE BULLETINS FOR 2003 Mini Cooper AUTOMOBILES
OEM TSB listings for most 2003 Mini Cooper cars and light trucks sold in the U.S. from 1985+.
Document: SETTING OBD READINESS CODES PRIOR TO STATE INSPECTION Vehicle: 2003 Mini Cooper 1.6 L4 GAS Auto Systems: |
Document: RESTRICTED EXTERIOR MIRRORS ADJUSTMENT RANGE Vehicle: 2003 Mini Cooper 1.6 L4 GAS Symptoms: |
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COMPONENT/PARTS SPECIFICATIONS FOR 2003 Mini Cooper AUTOMOBILES
BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most 2003 Mini Cooper cars and light trucks sold in the U.S. and Canada from 1970+.
- Brake caliper mounting bolt torque
- Brake drum runout, machining, & discard specs
- Minimum brake lining thickness.
- Brake rotor runout, parallelism, machining, discard, & finish specs
A/C SYSTEM SPECIFICATIONS: Air conditioning refrigerant capacity and type as well as lubricant capacity for most 2003 Mini Cooper cars and light trucks sold in the U.S. and Canada from 1980+.
- Refrigerant capacity & type, compressor oil viscosity, total system oil capacity & compressor clutch gap
COOLING SYSTEM BLEED: Cooling system bleeder valve identification, bleeder type and bleed procedures for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1986+.
PREVENTIVE MAINTENANCE: Preventive maintenance recommendations and required services for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1980+. Includes severe and routine service schedules
QUICK-LUBE and ILLUSTRATIONS: Fluid recommendations, capacities, drain plug torques, tire data, and severe service recommended preventive maintenance schedules. Information covers most 2003 Mini Cooper cars and light trucks sold in the U.S. and Canada from 1980+. Engine and chassis service images.
- Automatic transmission/transaxles capacities, lubricant recommendations
- Differential/final drive capacities, lube recommendations, grades, & viscosities
- Final drive fill & drain plug torques
- Number of lubrication fittings & plugs
- Power steering, brake, & clutch fluid recommendations
- Manual transmission/transaxle capacities, lube recommendations, grades, & viscosities
- Number of lubrication fittings & plugs
- Power steering, brake, & clutch fluid recommendations
- Engine oil capacities, API grade recommendations, SAE viscosity recommendations, drain plug torque
- Severe service maintenance & interval recommendations
- Tire sizes, wheel nut/bolt torque, pressures & rim sizes
- Transfer case capacities, lube recommendations, grades, & viscosities
TUNE-UP & DRIVEABILITY SPECIFICATIONS: Most tune-up specifications for most 2003 Mini Cooper cars and light trucks sold in the U.S. and Canada from 1980+
- Airflow sensor electrical specifications
- Tensioning specifications for systems with automatic tensioners
- Barometric pressure sensor specs
- Battery group number and cranking performance
- Crankshaft & camshaft position sensor resistance
- Engine compression pressures
- Coolant temperature sensor specs
- Computer advance.
- Diesel fuel temperature sensor resistance.
- Distributor advance specifications
- Ignition pickup coil resistance
- Exhaust gas recirculation temperature sensor resistance
- Engine fastener torque values
- Firing order diagrams
- Fuel system pressures
- Generator (alternator) specs
- Intake air temperature sensor specs
- Ignition coil specifications
- Fuel injector resistance
- Engine idle speeds
- Knock sensor resistance
- Manifold absolute pressure sensor specs
- Mixture control solenoid resistance
- Voltage regulator specs
- Spark plug applications & gaps
- Starter motor electrical specs.
- Tensioning specifications for systems without automatic tensioners
- Throttle body temperature sensor resistance
- Ignition timing in degrees at rpm
- Transmission oil temperature sensor resistance
- Throttle position sensor specs
- Vacuum sensor valve specs
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