2005 Mini Cooper Service and Repair Manual

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Factory-Grade Data

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

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Vehicle Safety Data

2005 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 #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 #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 51 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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