2005 Mini Cooper Service and Repair Manual

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Covers all 2005 Cooper trims — Chili Hatchback 2-Door, S Hot Chili Hatchback 2-Door, S Convertible 2-Door +8 more ·
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2005 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
  • S Convertible 2-Door
  • Salt Hatchback 2-Door
  • Base Convertible 2-Door
  • S Salt Hatchback 2-Door
  • S Chili Hatchback 2-Door
  • Chili Convertible 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
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 #15V20500006/04/2015Component: AIR BAGS:FRONTAL

BMW of North America, LLC (BMW) is recalling certain model year 2005-2006 MINI Cooper and Cooper S vehicles manufactured January 5, 2005, to November 28, 2006, and 2005-2008 MINI Cooper Convertible an

Consequence

An improperly functioning mat may cause the passenger frontal air bag to be inactive when the seat i

Remedy

MINI will notify owners, and dealers will replace the front passenger seat occupant detection mat, f

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 #10059114

MINI: FAULTY SOFTWARE FOR THE TANK VENTILATION CONTROL DISPLAYS ENGINE THROTTLE REACTION WHEN TEMPERATURE IS HIGH OUTSIDE, AND MORE OBVIOUS IF THE TANK IS ONLY PARTLY FILLED. *MA

TSB #10059113

MINI: FAULTY SOFTWARE CAUSES THE CHECK CONTROL AND ENGINE POWER REDUCED LIGHT TO APPEAR. *MA

TSB #10059112

MINI: BECAUSE OF THE DME SOFTWARE, AND A DAMAGED CLUTCH, THE DRIVETRAIN MALFUNCTION CHECK MESSAGE APPEAR. *MA

TSB #10059111

MINI: DUE TO FAULTY DME SOFTWARE, THE SERVICE ENGINE LIGHTS COMES ON, INCLUDING THE CHECK CONTROL MESSAGE FOR MOTOR FORCE DECREASE. *MA

TSB #10059098

MINI: DIFFERENT FAULTS ACTIVATES ENGINE MALFUNCTION AND OIL WARNING. *MA

TSB #10059094

MINI: A MECHANICAL FAILURE AND DME SOFTWARE ERROR OF THE VANOS ACTUATORS CAUSE THE ENGINE TO RUN ROUGH WHICH ACTIVATES THE MALFUNCTION WARNING LIGHT. *MA

Showing the 8 most recent of 38 technical service bulletins on file with NHTSA.

20101113Component: STEERINGCrash reportedFire reported

FOLLOWING REAR END IMPACT, THERE WAS AN ENGINE COMPARTMENT FIRE, WHICH WAS LATER TRACED TO THE POWER STEERING PUMP. TERMINALS WERE BURNED OFF THE PUMP, AND ALTERNATOR ALSO FAILED AS A RESULT. NOTE:

20170221Component: STEERINGCrash reported

I REPORTED A FEW MONTHS AGO THAT MY POWER STEERING HAD FAILED. IT IS A 2005 MINI COOPER, AND SOME 2002-2005 MINI COOPERS WERE EFFECTED, BUT SUPPOSEDLY NOT MY MINI WITH MY VIN NUMBER. THE RECALL HAD EN

20170221Component: WHEELSCrash reported

I REPORTED A FEW MONTHS AGO THAT MY POWER STEERING HAD FAILED. IT IS A 2005 MINI COOPER, AND SOME 2002-2005 MINI COOPERS WERE EFFECTED, BUT SUPPOSEDLY NOT MY MINI WITH MY VIN NUMBER. THE RECALL HAD EN

20130711Component: STEERINGCrash reported

WHILE I WAS DRIVING ON THE HIGHWAY APPROXIMATELY 65 MPH MY STEERING GAVE OUT AND LOCKED UP, ALMOST SLAMMING ME INTO THE GUARD RAIL. I WAS FORTUNATE ENOUGH TO STOP BEFORE TRAGEDY. UNFORTUNATELY I WAS B

20130711Component: ELECTRONIC STABILITY CONTROL (ESC)Crash reported

WHILE I WAS DRIVING ON THE HIGHWAY APPROXIMATELY 65 MPH MY STEERING GAVE OUT AND LOCKED UP, ALMOST SLAMMING ME INTO THE GUARD RAIL. I WAS FORTUNATE ENOUGH TO STOP BEFORE TRAGEDY. UNFORTUNATELY I WAS B

Showing the 5 most serious of 440 complaints filed with NHTSA.

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