2004 Mini Cooper Service and Repair Manual

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Factory-Grade Data

2004 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 1597CC 98Cu. In. l4 GAS SOHC Naturally Aspirated
  • 1.6L 1597CC 98Cu. In. l4 GAS SOHC Supercharged
  • 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

2004 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 #04V34800012/07/2004Component: TIRES:PRESSURE MONITORING AND REGULATING SYSTEMS

ON CERTAIN PASSENGER VEHICLES, THE FLAT TIRE MONITORING SYSTEM HAS NOT BEEN CORRECTLY PROGRAMMED. IN THE EVENT OF A FLAT TIRE, AN AUDIBLE SIGNAL WILL NOT SOUND TO ALERT THE DRIVER TO A FLAT TIRE.

Consequence

DUE TO THE LACK OF AN AUDIBLE SIGNAL, THE DRIVER MAY NOT BE AWARE OF A FLAT TIRE, WHICH COULD INCREA

Remedy

DEALERS WILL REPROGRAM THE VEHICLE'S SOFTWARE IN ORDER TO ACTUATE THE FLAT TIRE MONITORING SYSTEM'S

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 #10245428

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

TSB #10244507

MINI electrical systems have continued to develop over the past few years. As a result, the demand on the batteries has increased. Breakdowns due to an empty battery or problems in the vehicles electrical system can have various causes, mos

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 42 technical service bulletins on file with NHTSA.

20190930Component: UNKNOWN OR OTHERCrash reportedFire reported1 fatalities

MY WIFE WAS DRIVING OUR 2004 MINI COOPER HOME TRAVELING UPHILL ON A STEEP PAVED MOUNTAIN ROADWAY TRAVELING A MAXIMUM OF 15 MPH WHEN FOR SOME UNKNOWN REASON THE VEHICLE LEFT THE ROADWAY; STRUCK A TREE

20220426Component: STEERINGCrash reported

Mini felt like it was getting pushed by the wind . Realized wasn't wind Mini loss of completely all functions of steering wheel. On super busy highway. Devine intervention Was in far left car went le

20130601Component: STEERINGCrash reported

I WAS DRIVING 45-50 MILES AN HOUR ON I95S OVER THE Q BRIDGE NEAR NEW HAVEN. I TURNED GENTLY TO THE RIGHT HAND LANE AND COULD NOT STEER THE CAR TO STRAIGHTEN UP. I WAS UNABLE TO STEER THE CAR AT ALL.

20130524Component: STEERINGCrash reported

I WAS DRIVING TO WORK MY STEERING ALL OF A SUDDEN BECAME HARD TO TURN I HIT THE CURB AND BLEW TWO TIRES. *TR

20060819Component: SERVICE BRAKES, HYDRAULICCrash reported

BRAKE FAILURE - WHILE COASTING IN "BRAKE AND RELEASE TRAFFIC", THE BRAKE PEDAL DID NOT CATCH. LOOKING DOWN AT MY FOOT, I WATCHED MY FOOT FLOOR THE BRAKE PEDAL AND FELT NO BRAKE PEDAL CATCH. LOOKING

Showing the 5 most serious of 330 complaints filed with NHTSA.

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