2004 Mini Cooper Service and Repair Manual

This factory service and repair manual for the 2004 Mini Cooper covers a hatchback with 2 doors and a pair of gasoline engines, both 1.6L (98 cu in) inline-fours with a single overhead camshaft. Buyers chose between natural aspiration and a supercharged version, and eight trims are listed: Salt and Chili appear on both the base car and the S, Pepper on the base car only, and S Hot Chili rounds out the S side. Engine, fuel, ignition and cooling procedures sit alongside specifications and wiring diagrams for the transmission, steering, brakes, suspension and body.

Engines covered

• 1.6L inline-four (98 cu in) — SOHC, naturally aspirated, gasoline
• 1.6L inline-four (98 cu in) — SOHC, supercharged, gasoline

Body styles covered

• 2-door hatchback

Trims covered

• Base
• Chili
• Pepper
• S
• S Chili
• S Hot Chili
• S Salt
• Salt

Known issues on the 2004 Cooper. For the 2004 Cooper, NHTSA's record lists 2 recalls. One concerns certain 2004 Cooper vehicles in which the electro-hydraulic steering could stop assisting the driver, either briefly or permanently, which makes parking-speed turns heavy. The other covered certain vehicles, 1,193 of them, whose flat tire monitor had been programmed so that no warning tone would sound when a tire lost air; dealers reprogrammed the software. Owners lodged 529 complaints, and 448 of them name steering. Among them, 12 complaints reported a crash, 14 a fire, 3 an injury and 1 a death. The steering and electrical system diagnostics, wiring diagrams and specifications apply directly.