Mini Workshop Manual - 5th Edition - Eng
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AMENDMENT INSTRUCTION SHEETMINI WORKSHOP MANUALPublication Number RCL 0193ENG - 2nd EditionAmendment Number: XN-001/97ENGDate: 12/96To ensure that this manual is kept up to date and that a record of amendments to this manual is available, anAmendment Instruction Sheet will be issued with each set of revised pages. The Title page of the Manual is re-issued, and the Part No. has been raised to the next edition. Except for theContents pages, all revised and new pages have the issue date at the foot of each page, together with anindication of whether the pages are revised or new. This Amendment Instruction Sheet must be inserted at the front of the manual to indicate that the amendmenthas been incorporated. Do not discard previous Amendment Instruction sheets. Your manual is only complete to this issue providing all prior Amendments are included. The filing instructions give section and page numbers affected. Additional pages or complete new sections maybe issued, insert the pages as instructed.FILING INSTRUCTIONSSectionDiscard ExistingPagesInsert New PagesReason for AmendmentIntroductionTitle PageTitle PageIntroduction of new sections. Part numberraised to next edition.InformationContents PageContents PageCorrections to existing information andaddition of new torque figures.General data,1Torque wrenchsettings, 1&3General data,1Torque wrenchsettings, 1-5Contents PageContents PageRepairs, 33-37Repairs, 33-41Emission ControlDescription andoperation, 1Repairs, 1Description andoperation, 1Repairs, 1Corrections to existing information.Engine ManagementSystem - MEMSContents PageContents PageCorrections to existing information.Description andoperation, 1-11Description andoperation, 1-11Contents PageContents PageRepairs, 1AdjustmentsRepairs, 1Cooling SystemRepairs, 3Repairs, 3Corrections to existing information.Manifold & ExhaustSystemsDescription andoperation, 3Description andoperation, 3Corrections to existing information.ClutchContents pageContents PageCorrections to existing information andaddition of new repair procedures.Adjustments, 1Repairs, 1-7Adjustments, 1Repairs,1-11EngineFuel Delivery SystemCorrections to existing information andaddition of new repair procedures.Corrections to existing information andintroduction of Adjustments section.Continued.
SectionDiscard ExistingPagesInsert New PagesReason for AmendmentManual GearboxContents pageContents PageCorrections to existing information andaddition of new repair procedures.Adjustments, 1-Adjustments, 1Repairs, 1-5Drive shaftsContents PageRepairs, 1-5New SectionContents pageContents PageCorrections to existing information andaddition of new repair procedures.Repairs, 1Adjustments, 1Repairs, 1-11-Contents PageAdjustments, 1Repairs, 1&3New Section.Contents PageContents PageCorrections to existing information andaddition of new repair procedures.Adjustments, 1Repairs, 1&3Adjustments, 1Repairs, 1-17Restraint SystemsDescription andoperation, 3Repairs, 3&5Description andoperation, 3Repairs, 3&5Corrections to existing information.BodyContents PageContents PageCorrections to existing information andaddition of new repair procedures.Exterior fittings,1&3Interior trimcomponents, 1Screens, 1-Exterior fittings,1-7Interior trimcomponents, 1-7Screens, 1Seats and seatbelts, 1&3SteeringSuspensionBrakesHeating & Ventilation--Contents PageRepairs, 1-7New Section.Wipers & WashersContents PageRepairs, 1Contents pageRepairs, 1-7Addition of new repair proceduresElectricalContents PageContents PageCorrections to existing information andaddition of new repair procedures.Description andoperation, 1Adjustments, 1Repairs, 1-19Description andoperation, 1Adjustments, 1Repairs, 1-27Repairs, 7Repairs, 7InstrumentsCorrections to existing information.
AMENDMENT INSTRUCTION SHEETMINI WORKSHOP MANUALPublication Number RCL0193ENG (3rd Edition)Amendment Number: XN003.98ENGDate: 11/98To ensure that this manual is kept up to date and that a record of amendments to this manual is available, anAmendment Instruction Sheet will be issued with each set of revised pages. The Title page of the Manual is re-issued, and the Part No. has been raised to the next edition. Except for theContents pages, all revised and new pages have the issue date at the foot of each page, together with anindication of whether the pages are revised or new. This Amendment Instruction Sheet must be inserted at the front of the manual to indicate that the amendmenthas been incorporated. Do not discard previous Amendment Instruction sheets. Your manual is only complete to this issue providing all prior Amendments are included. The filing instructions give section and page numbers affected. Additional pages or complete new sections maybe issued, insert the pages as instructed.FILING INSTRUCTIONSSectionDiscard ExistingPagesInsert New PagesReason for AmendmentTITLE PAGETitle pageTitle pagePart number raised to 4th Edition and yearof copyright amended.INSTRUMENTSContents pageContents pageAdditional jobs addedINSTRUMENTSPage 9Pages 9 and 11Speedometer cable upper and lower added
AMENDMENT INSTRUCTION SHEETMINI WORKSHOP MANUALPublication Number RCL0193ENG (4th Edition)Amendment Number: XN002.99ENGDate: 06/99To ensure that this manual is kept up to date and that a record of amendments to this manual is available, anAmendment Instruction Sheet will be issued with each set of revised pages. The Title page of the Manual is re-issued, and the Part No. has been raised to the next edition. Except for theContents pages, all revised and new pages have the issue date at the foot of each page, together with anindication of whether the pages are revised or new. This Amendment Instruction Sheet must be inserted at the front of the manual to indicate that the amendmenthas been incorporated. Do not discard previous Amendment Instruction sheets. Your manual is only complete to this issue providing all prior Amendments are included. The filing instructions give section and page numbers affected. Additional pages or complete new sections maybe issued, insert the pages as instructed.FILING INSTRUCTIONSSectionDiscard ExistingPagesInsert New PagesReason for AmendmentTITLE PAGETitle PageTitle PagePart number raised to 5th Edition.ELECTRICALContents pageAdjustments pages1&2Contents pageAdjustments pages1&2Repairs pages 1 &2Repairs pages 1 &2Repairs page 27Repairs pages 27& 28Contents changed.Auxiliary Drive Belt - Check and Adjust Caution regarding drive belt adjusting boltadded.Auxiliary Drive Belt - Remove and Refit Cautions regarding drive belt adjusting boltadded.CD Player - Remove and Refit - Newoperation issued herewith.
INTRODUCTIONGENERAL INFORMATIONINFORMATIONENGINEEMISSION CONTROLENGINE MANAGEMENT SYSTEMFUEL DELIVERY SYSTEMCOOLING SYSTEMWORKSHOPMANUALThis manual covers changes to Mini modelsmanufactured from VIN SAXXNNAZEBD 134455and should be used in conjunction with the followingmanuals.MANIFOLD & EXHAUST SYSTEMSCLUTCHMANUAL GEARBOXAKM 7169 Mini Repair ManualRCL 0194 Mini Electrical Circuit DiagramsDRIVE SHAFTSSTEERINGSUSPENSIONBRAKESRESTRAINT SYSTEMSBODYHEATING & VENTILATIONPublication Part No. RCL 0193ENG (5th Edition)Published by Rover Technical Communication 1998 Rover Group LimitedWIPERS & WASHERSELECTRICALINSTRUMENTS
INTRODUCTIONCONTENTSPageINTRODUCTIONINTRODUCTION .REPAIRS AND REPLACEMENTS .SPECIFICATION .ABBREVIATIONS AND SYMBOLS .1223
INTRODUCTIONINTRODUCTIONReferencesHow to use this ManualReferences to the LH or RH side given in thisManual are made when viewing the vehicle from therear. With the engine and gearbox assemblyremoved, the crankshaft pulley end of the engine isreferred to as the front.To assist in the use of this Manual the section title isgiven at the top and the relevant sub-section is givenat the bottom each page.Each major section starts with a contents page,listing the information contained in the relevantsub-sections. To assist filing of revised informationeach sub-section is numbered from page 1.The individual items comprising repair operationsare to be followed in the sequence in which theyappear. Items numbers in the illustration are referredto in the text.Adjustment and repair operations include referenceto Service tool numbers and the associatedillustration depicts the tool. Where usage is notobvious the tool is shown in use. Adjustment andrepair operations also include reference to wearlimits, relevant data, torque figures, and specialistinformation and useful assembly details. Eachadjustment or repair operation is given its RepairOperation Time number. WARNINGS, CAUTIONSand NOTES have the following meanings:Operations covered in this Manual do not includereference to testing the vehicle after repair. It isessential that work is inspected and tested aftercompletion and if necessary a road test of thevehicle is carried out particularly where safetyrelated items are concerned.DimensionsThe dimensions quoted are to design engineeringspecification with Service limits where applicable.WARNING: Procedures which must befollowed precisely to avoid the possibilityof injury.CAUTION: Calls attention to procedureswhich must be followed to avoid damageto components.NOTE: Gives helpful information.INTRODUCTION1
INTRODUCTIONREPAIRS AND REPLACEMENTSSPECIFICATIONWhen replacement parts are required it is essentialthat only Rover recommended parts are used.Rover are constantly seeking to improve thespecification, design and production of their vehiclesand alterations take place accordingly. While everyeffort has been made to ensure the accuracy of thisManual, it should not be regarded as an infallibleguide to current specifications of any particularvehicle.Attention is particularly drawn to the following pointsconcerning repairs and the fitting of replacementparts and accessories.Safety features and corrosion prevention treatmentsembodied in the car may be impaired if other thanRover recommended parts are fitted. In certainterritories, legislation prohibits the fitting of parts notto the manufacturer’s specification. Torque wrenchsetting figures given in this Manual must be used.Locking devices, where specified, must be fitted. Ifthe efficiency of a locking device is impaired duringremoval it must be renewed.Owners purchasing accessories while travellingabroad should ensure that the accessory and itsfitted location on the car conform to legalrequirements.The Terms of the vehicle Warranty may beinvalidated by the fitting of other than Roverrecommended parts.All Rover recommended parts have the full backingof the vehicle Warranty.Rover Dealers are obliged to supply only Roverrecommended parts.2INTRODUCTIONThis Manual does not constitute an offer for sale ofany particular vehicle. Rover Dealers are not agentsof Rover and have no authority to bind themanufacturer by any expressed or impliedundertaking or representation.
INTRODUCTIONABBREVIATIONS AND SYMBOLSAfter Bottom Dead CentreAfter Top Dead CentreAir conditioningAir fuel ratioAlternating currentAmperesAnti-lock brake systemAutomatic temperature controlABDCATDCA/CAFRacAABSATCBefore Bottom Dead CentreBefore Top Dead CentreBottom Dead CentreBritish StandardsBBDCBTDCBDCBSCamshaft PositionCarbon monoxideCelcius (Centigrade)CentimetreChlorofluorocarbonsCubic centimetresCrankshaft positionCMPCOCcmCFC’scm3CKPDegree (angle)Degree (temperature)Dial test indicatorDiameterDirect currentElectronic Control UnitExhaust gas recirculationEngine Control ModuleEngine coolant temperatureFuel Injection PumpGramme (mass)High compressionHigh TensionHourIdle Air Control ValveInertia Fuel Shut-offIntake air temperatureInternal diameterInternational Organisation -hand driveLight emitting diodeLitreLow Compressiondeg. or deg. or OkmkgLHLHDLEDllcManifold absolute pressureMass air flowMaximumMercuryMetreMetric unit of horse powerMiles per hourMillimetreMinimumMinus (of tolerance)Minute (angle)Model YearMulti-point injectionNegative (electrical)Newton Outside diametero.dia.PercentagePlus or minusPlus (tolerance)Positive (electrical)Positive crankcase ventilation% PCVRadiusRatioReferenceRevolutions per minuteRight-handRight-hand driveRover Engineering Standardsr:refrev/minRHRHDRESSecond (angle)Single overhead camshaftSpecific gravitySquare centimetresStandardSupplementary Restraint synchroThousandTop dead centreThrottle positionkTDCTPUnited KingdomUnited StatesUKUSVariable induction systemVehicle identification numberVoltVISVINVWattWINTRODUCTION3
GENERAL INFORMATIONCONTENTSPageVEHICLE IDENTIFICATION NUMBERVEHICLE IDENTIFICATION NUMBER . 1IDENTIFICATION NUMBER LOCATIONS . 1GENERAL PRECAUTIONS AND FITTING INSTRUCTIONSGENERAL PRECAUTIONS AND FITTING INSTRUCTIONS .Dangerous substances .Engine oils .Health Protection Precautions .Environmental Protection Precautions .SAFETY INSTRUCTIONS .111112FUEL HANDLING PRECAUTIONSFUEL HANDLING PRECAUTIONS . 1ELECTRICAL PRECAUTIONSELECTRICAL PRECAUTIONS . 1
GENERAL INFORMATIONVEHICLE IDENTIFICATION NUMBERPaint and Trim colour codesLocation3-letter codes identifying the original Paint and Trimcolours are stamped on the VIN plate.The Vehicle Identification Number (VIN) plate isattached to the RH inner wing valance.The VIN is also etched into the lower LH corners ofthe windscreen and rear window.PaintExample: H A MH Basic colourA Mark identifierM Colour/Shade nameTrimExample: L P RL Basic colourP Mark identifierR Colour/Shade nameVehicle identification numberExample: S A X X N N A Z E B D 134455IDENTIFICATION NUMBER LOCATIONSS Geographic areaEngine numberA CountryStamped on the front face of the cylinder blockadjacent to the alternator.X ManufacturerXN Marque/ModelGearbox numberN ClassShown on a label attached to the upper face of thefinal drive housing.A BodyBody numberZ EngineThe body number is stamped on a plate fixed to thebonnet locking platform.E Transmission and SteeringB Model changeD Assembly plant6 figures Serial numberVEHICLE IDENTIFICATION NUMBER1
GENERAL INFORMATIONHealth Protection PrecautionsGENERAL PRECAUTIONS AND FITTINGINSTRUCTIONSIgnition system safety precautionsWARNING: Before commencing work onan ignition system, all high tensionterminals, adapters and diagnosticequipment for testing should be inspected toensure that they are adequately insulated andshielded to prevent accidental personal contactsand minimise the risk of shock. Wearers ofsurgically implanted pacemaker devices shouldnot be in close proximity to ignition circuits ordiagnostic equipment.Dangerous substancesWARNING: Many liquids and othersubstances used in motor vehicles arepoisonous and should under nocircumstances be consumed and should, as faras possible, be kept from contact with the skin.These substances among others include acid,anti- freeze, asbestos, brake fluid, fuel,windscreen washer additives, lubricants,refrigerant and various adhesives.Always read carefully the instructions printed onlabels or stamped on components and obeythem implicitly. Such instructions are includedfor reasons of your health and personal safety.Never disregard them.Used engine oils: Prolonged exposure to usedengine oils can cause serious skin disorders,avoid excessive skin contact and always adhereto the following recommendations:Engine oilsProlonged and repeated contact with mineral oil willresult in the removal of natural fats from the skin,leading to dryness, irritation and dermatitis. Inaddition, used engine oil contains potentially harmfulcontaminants which may cause skin cancer.Adequate means of skin protection and washingfacilities must be provided. Avoid prolonged and repeated contact with oils,particularly used engine oils. Wear protective clothing, including imperviousgloves where practicable. Do not put oily rags in pockets. Avoid contaminating clothes, particularlyunderpants, with oil. Overalls must be cleaned regularly. Discardheavily soiled clothing and oil impregnatedfootwear. First aid treatment should be obtainedimmediately for open cuts and wounds. Use barrier creams, applying before each workperiod, to help the removal of oil from the skin. Wash with soap and water to ensure all oil isremoved (skin cleansers and nail brushes willhelp). Preparations containing lanolin replace thenatural skin oils which have been removed. Do not use petrol, kerosene, diesel fuel, gas oil,thinners or solvents for cleaning skin. If skin disorders develop, obtain medical advicewithout delay. Where practicable, degrease components priorto handling. Where there is a risk of eye contact, eyeprotection should be worn, for example, chemicalgoggles or face shields; in addition an eye washfacility should be provided.Environmental Protection PrecautionsIt is illegal to pour used oil on to the ground, downsewers or drains, or into water courses.Burning of used engine oil in small space heaters orboilers can be recommended only for units ofapproved design. The heating system must meet theregulatory standards of HMIP for small burners ofless than 0.4 MV. If in doubt check with theappropriate local authority and/or manufacturer ofapproved appliance.Dispose of used oil and used filters throughauthorised waste disposal contractors to licensedwaste disposal sites, or to the waste oil reclamationtrade. If in doubt, contact the Local Authority foradvice on disposal facilities.GENERAL PRECAUTIONS AND FITTING INSTRUCTIONS1
GENERAL INFORMATIONSAFETY INSTRUCTIONSBrake hydraulicsJackingThe recommended jacking points are given inLIFTING AND TOWING, always ensure that anylifting apparatus has adequate load and safetycapacity for the weight to be lifted. Ensure thevehicle is standing on level ground prior to lifting orjacking. Apply the handbrake and chock the wheels.Never rely on a jack as the sole means of supportwhen working beneath the vehicle. Use additionalsafety supports beneath the vehicle.Do not leave tools, lifting equipment, spilt oil, etc.around or on the work bench area.Precautions against damageAlways fit wing and seat covers before commencingwork. Avoid spilling brake fluid or battery acid onpaintwork. Wash off with water immediately if thisoccurs.Disconnect the battery earth lead before startingwork, see ELECTRICAL PRECAUTIONS.WARNING: It is imperative that the correctbrake fittings are used and that threads ofcomponents are compatible.Always use two spanners when slackening ortightening brake pipe or hose connections. Ensurethat hoses run in a natural curve and are not kinkedor twisted. Fit brake pipes securely in their retainingclips and ensure that the pipe run cannot contact apotential chafing point.Containers used for hyd
AMENDMENT INSTRUCTION SHEET MINI WORKSHOP MANUAL Publication Number RCL 0193ENG - 2nd Edition Amendment Number: XN-001/97ENG Date: 12/96 To ensure that this manual is kept up to date and that a record of amendments to this manual is available, an
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MINI MINI (R50, R53) Cooper, MINI MINI (R50, R53) One, MINI MINI Convertible (R52) Cooper, MINI MINI Convertible (R52) One The steps may slightly vary depending on the car design. WWW.AUTODOC.CO.UK 1-15 Important! REQUIRED TOOLS: WWW.AUTODOC.CO.UK 2-15 High-temperature anti-seize lubricant Drive socket # 10 Ratchet wrench
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