2003 Mini Cooper Service and Repair Manual

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Factory-Grade Data

2003 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

  • Chili Hatchback 2-Door
  • S Hot Chili Hatchback 2-Door
  • Salt Hatchback 2-Door
  • S Salt Hatchback 2-Door
  • S Chili Hatchback 2-Door
  • S Hatchback 2-Door
  • Base Hatchback 2-Door
  • Pepper Hatchback 2-Door

Engines covered

  • 1.6L 1600CC l4 GAS SOHC Naturally Aspirated
  • 1.6L 1597CC 98Cu. In. l4 GAS SOHC Supercharged
  • 1.6L 1600CC l4 GAS SOHC Supercharged

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

2003 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 #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

NHTSA #03V08600010/03/2003Component: SUSPENSION:REAR:SHOCK ABSORBER

ON CERTAIN VEHICLES, THE LOWER SCREW CONNECTION OF THE REAR STRUTS TO THE CHASSIS MAY FAIL. THE HEAD (TOP) OF THE SCREW SECURING THIS CONNECTION MAY BREAK. THE REMAINING PORTION OF THE SCREW WILL ST

Consequence

IF LEFT UNATTENDED OVER A PERIOD OF TIME, AND DEPENDING ON DRIVING CONDITIONS, THE REMAINING PORTION

Remedy

DEALERS WILL REPLACE THE LOWER SCREW CONNECTION OF THE REAR STRUTS. OWNER NOTIFICATION BEGAN APRIL

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

TSB #10148439

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

Showing the 8 most recent of 46 technical service bulletins on file with NHTSA.

20120307Component: ELECTRICAL SYSTEMCrash reportedFire reported1 injured

CAR IMPACTED THE REAR END OF A JEEP AT LOW RATE OF SPEED (WAS BRAKING TO AVOID CRASH IN THE FRONT). UPON IMPACT THE CAR BURST INTO FLAMES. THE AIR BAG DEPLOYED. LUCKILY THE OCCUPANT OF THE VEHICLE WAS

20070104Component: AIR BAGSCrash reported1 injured

TL*- THE CONTACT'S VEHICLE WAS INVOLVED IN A CRASH ON 12-28-06 WHILE DRIVING AT 55 MPH, AND THE AIR BAGS DID NOT DEPLOY. THE CONTACT'S VEHICLE WAS HIT ON THE DRIVER'S SIDE, THE CAR THEN SPUN, AND HI

20150711Component: VEHICLE SPEED CONTROLCrash reported

THE CAR STALLS(REDUCES SPEED 0-10MPH) IT MAY SHUT COMPLETELY DOWN AT TIMES THIS HAS BEEN THE SAME CONSISTENT PROBLEM SINCE DATE OF PURCHASE THE USED CAR DEALERSHIP HAS BEEN INFORMED OF THIS PROBLE

20170410Component: ENGINEFire reported

TL* THE CONTACT OWNED A 2003 MINI COOPER. WHILE THE VEHICLE WAS PARKED IN THE PARKING LOT, THE NEIGHBORS NOTICED THAT IT CAUGHT FIRE AND CALLED THE FIRE DEPARTMENT. THE POLICE ARRIVED AND FILED A REPO

20151231Component: STEERINGFire reported

LOST POWER STEERING WITH BURNING SMELL AND LOTS OF SMOKE. AS EVIDENCED ON THE ATTACHED DOCUMENT, THE ENGINE WIRING HARNESS WAS BURNT. THE CAR COULD HAVE LOST ALL POWER. THE REPAIR BILL WAS $4097.91. I

Showing the 5 most serious of 388 complaints filed with NHTSA.

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