2002 Mini Cooper Service and Repair Manual

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Factory-Grade Data

2002 Mini Cooper service and repair manual — a detailed, factory-style reference for maintenance, diagnostics, and repair. Use it to confirm correct procedures, specifications, and system coverage before you start work.

Built for technicians and DIY owners, this manual helps you troubleshoot accurately, follow step-by-step repair procedures, and use wiring diagrams and system sections to diagnose problems faster.

What’s included

  • Step-by-step repair procedures and service information
  • Specifications and reference data (where provided)
  • Electrical coverage with wiring diagrams
  • Coverage across key systems: engine, transmission, brakes, steering, suspension, HVAC, and more

Trims covered

  • S Hatchback 2-Door
  • Luxury Hatchback 2-Door
  • Base Hatchback 2-Door
  • Sport Hatchback 2-Door

Engines covered

  • 1.6L 1600CC l4 GAS SOHC Supercharged
  • 1.6L 1600CC l4 GAS SOHC Naturally Aspirated

Index / Table of contents

  • Body
  • Brakes
  • Chassis Electrical
  • Driveline
  • Engine Cooling
  • Engine Electrical
  • Engine Mechanical
  • Engine Performance & Emission Controls
  • Fuel System
  • General Information & Identification
  • Heating, Ventilation, & Air Conditioning
  • Hybrid & Electric Vehicle Systems
  • Steering
  • Suspension
  • Transmission, Clutch, & Transfer Case
  • Wiring Diagrams

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Vehicle Safety Data

2002 Mini Cooper Recalls & Complaints

NHTSA #15V66000015/10/2015Component: STEERING:ELECTRIC POWER ASSIST SYSTEM

BMW of North America, LLC (BMW) is recalling certain model year 2002-2005 MINI Cooper and Cooper S vehicles and 2005 Cooper and Cooper S Convertible vehicles. The affected vehicles may experience tem

Consequence

If the vehicle experiences a loss of power steering assist, extra steering effort will be required a

Remedy

MINI will notify owners, and dealers will inspect the electro-hydraulic power steering system, repla

NHTSA #05V47000012/10/2005Component: EQUIPMENT:OTHER:LABELS

CERTAIN PASSENGER VEHICLES FAIL TO CONFORM TO THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 110, 'TIRE SELECTION AND RIMS.' THE STANDARD REQUIRES THAT THE RELATIONSHIP BETWEEN THE TIR

Consequence

TOO LOW OR TOO HIGH TIRE PRESSURE CAN CAUSE PREMATURE WEAR AND/OR TIRE DAMAGE, AND COULD LEAD TO UNF

Remedy

OWNERS WILL BE PROVIDED WITH NEW TIRE INFORMATION PLACARDS AND INSTALLATION INSTRUCTIONS. AT THE CU

NHTSA #08E05000011/08/2008Component: EXTERIOR LIGHTING:HEADLIGHTS

K2 MOTOR IS RECALLING 1,921 AFTERMARKET HEADLAMPS OF VARIOUS MODELS SOLD FOR USE ON THE ABOVE LISTED VEHICLES. THESE HEADLAMPS ARE MISSING THE AMBER SIDE REFLEX REFLECTOR WHICH FAILS TO CONFORM WITH

Consequence

WITHOUT THE AMBER SIDE REFLEX REFLECTORS, THE LIGHTING VISIBILITY MAY BE AFFECTED, POSSIBLY RESULTIN

Remedy

K2 MOTOR WILL NOTIFY OWNERS AND OFFER A FULL REFUND. THE RECALL BEGAN ON DECEMEBER 17, 2008. OWNER

NHTSA #09E02500011/05/2009Component: EXTERIOR LIGHTING:HEADLIGHTS

DOPE, INC. IS RECALLING 42,540 COMBINATION CORNER AND BUMPER LAMP ASSEMBLIES OF VARIOUS PART NUMBERS SOLD FOR USE AS AFTERMARKET EQUIPMENT FOR VARIOUS PASSENGER VEHICLES. THESE HEADLAMPS FAIL TO CONF

Consequence

DECREASED LIGHTING VISIBILITY MAY RESULT IN A VEHICLE CRASH.

Remedy

DOPE, INC. WILL NOTIFY OWNERS AND OFFER A FULL REFUND FOR THE NONCOMPLIANT COMBINATION LAMPS. THE S

TSB #10250378

The bar code on the vehicle identificatio nnumber (VIN) label (aka Manufacturer Compliance Label ) cannot be read.

TSB #10245428

Cavity protection applied to underside of the hood is leaking out onto the wheel arch trim and grille.

TSB #10151228

This Service Information bulletin supersedes SI 32 02 14 dated August 2014. SUBJECT Installation of Right-Hand Drive Steering Spindle in Left-Hand Drive Vehicle is No Longer Required. Left-hand drive steering spindles are currently availabl

TSB #10150304

State Inspection and Emission (I/M) Test Fails to Read 17-Character VIN. An affected vehicle may fail to pass a state-mandated Inspection and/or Emission (I/M) test due to a noncompliant 17-character vehicle identification number (VIN) bein

TSB #10150044

Electro-Hydraulic Power-Assist Steering Pump (EHPS) and Cooling Fan: Warranty Extension to 13 years/150,000 miles. On affected vehicles, the electro-hydraulic power steering (EHPS) pump can fail.

TSB #10150204

State Inspection and Emission (I/M) Test Fails Due to an Invalid VIN Number. The affected vehicle may fail to pass a State Inspection and Emission (I/M) test due to a noncompliant 17-digit vehicle identification number (VIN) stored in the D

TSB #10150086

Electro-Hydraulic Power-Assist Steering Pump (EHPS) and Cooling Fan: Warranty Extension to 13 years/150,000 miles. On affected vehicles, the electro-hydraulic power steering (EHPS) pump can fail.

TSB #10149392

MINI CVT Replacement Parts Warranty Extension: Additional 12 Months with Up to 50,000 Accumulated Miles. A MINI vehicle's CVT assembly or component that was previously repaired and/or replaced by an authorized MINI dealer or BMW center may

Showing the 8 most recent of 45 technical service bulletins on file with NHTSA.

20071226Component: AIR BAGSCrash reported3 injured

I JUST FOUND THIS WEB SITE AND AFTER READING THROUGH THE VARIOUS ISSUES OTHER PEOPLE ARE HAVING WITH THEIR MINI, I DECIDED I SHOULD ALSO GO AHEAD AND SHARE MY ISSUES AS WELL. BACK IN APRIL OF 2004, I

20071226Component: POWER TRAIN:AUTOMATIC TRANSMISSIONCrash reported3 injured

I JUST FOUND THIS WEB SITE AND AFTER READING THROUGH THE VARIOUS ISSUES OTHER PEOPLE ARE HAVING WITH THEIR MINI, I DECIDED I SHOULD ALSO GO AHEAD AND SHARE MY ISSUES AS WELL. BACK IN APRIL OF 2004, I

20131002Component: AIR BAGSCrash reported2 injured

I WAS EXITING FROM 35TH STREET IN NEWPORT NEWS, VA ONTO THE WARWICK BLVD OFF RAMP IN TRAFFIC, COASTING WITH THE BRAKES AT ABOUT 5 MPH, WHEN I WAS REAR ENDED BY A NAVY OPERATED FLAT NOSE SCHOOL BUS, WH

20131002Component: STRUCTURE:BODYCrash reported2 injured

I WAS EXITING FROM 35TH STREET IN NEWPORT NEWS, VA ONTO THE WARWICK BLVD OFF RAMP IN TRAFFIC, COASTING WITH THE BRAKES AT ABOUT 5 MPH, WHEN I WAS REAR ENDED BY A NAVY OPERATED FLAT NOSE SCHOOL BUS, WH

20131002Component: SEATSCrash reported2 injured

I WAS EXITING FROM 35TH STREET IN NEWPORT NEWS, VA ONTO THE WARWICK BLVD OFF RAMP IN TRAFFIC, COASTING WITH THE BRAKES AT ABOUT 5 MPH, WHEN I WAS REAR ENDED BY A NAVY OPERATED FLAT NOSE SCHOOL BUS, WH

Showing the 5 most serious of 220 complaints filed with NHTSA.

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