2006 MINI Cooper S

2002-05 AUTOMATIC TRANSMISSION Removal & Installation

2002-05 AUTOMATIC TRANSMISSION

Removal & Installation

IDENTIFICATION

NOTE: For further information, see TRANSMISSION - OVERVIEW article.

VEHICLE IDENTIFICATION
Model (Chassis Code) Engine Size (Code)
2002-05
Cooper (R50) 1.6 L (W10)

REMOVAL & INSTALLATION

CAUTION: Disconnecting vehicle battery will cancel fault codes of control units. On
vehicles with radio codes, after disconnecting battery, radio codes must
be re-entered. Obtain radio code card from customer. Note stored stations
and restore then after connecting battery. Also, where applicable, initialize
sunroof and set steering angle.

AUTOMATIC TRANSMISSION

CAUTION: Use only the approved transmission fluid in this automatic transmission.
Failure to comply with this requirement will result in serious damage to the
automatic transmission. Catch and dispose properly escaping
transmission fluid.

NOTE: For filling and servicing, see SERVICING - A/T article.

NOTE: For further information on CVT, see OVERVIEW article.

Removal

NOTE: Remove purge pipe from retaining clips on injector rail and remove hose from
inspection cover.

NOTE: Numbers in text refer to numbers in figures.

1. Turn off ignition. Disconnect battery.

2. Remove engine. See REMOVAL & INSTALLATION ENGINE.
3. Remove throttle assembly. See THROTTLE ASSEMBLY .
4. Release coolant pipe clip (1) and remove coolant pipe (2) from coolant thermostat housing. See Fig. 1 .
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2002-05 AUTOMATIC TRANSMISSION Removal & Installation

5. Disconnect speed sensor connector (1) and disconnect connector (2) from inhibitor switch and remove
harness retaining clips. See Fig. 2 . Remove harness. Note harness routing.
6. Disconnect transmission connector (1) and remove harness retaining clips. See Fig. 3 . Remove harness.
Note harness routing.
7. Remove closure plate retaining bolts (1) and remove closure plate (2). See Fig. 4 .
8. Remove starter motor retaining bolts (1) and remove starter motor. See Fig. 5 . Starter motor retaining
bolts (1): 65 mm.
9. Remove transmission retaining bolts (1), (2), (3) and (4). See Fig. 6 .

Fig. 1: Removing Coolant Pipe From Coolant Thermostat Housing

Courtesy of BMW OF NORTH AMERICA, INC.

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 2006 MINI Cooper S
2002-05 AUTOMATIC TRANSMISSION Removal & Installation

Fig. 2: Disconnecting Speed Sensor Connector

Courtesy of BMW OF NORTH AMERICA, INC.

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 2006 MINI Cooper S
2002-05 AUTOMATIC TRANSMISSION Removal & Installation

Fig. 3: Disconnecting Transmission Connector

Courtesy of BMW OF NORTH AMERICA, INC.

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 2006 MINI Cooper S
2002-05 AUTOMATIC TRANSMISSION Removal & Installation

Fig. 4: Removing Closure Plate

Courtesy of BMW OF NORTH AMERICA, INC.

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 2006 MINI Cooper S
2002-05 AUTOMATIC TRANSMISSION Removal & Installation

Fig. 5: Removing Starter Motor

Courtesy of BMW OF NORTH AMERICA, INC.

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 2006 MINI Cooper S
2002-05 AUTOMATIC TRANSMISSION Removal & Installation

Fig. 6: Identifying Transmission Retaining Bolts

Courtesy of BMW OF NORTH AMERICA, INC.

Installation

CAUTION: Oil cooler and lines must always be flushed before a replacement
transmission is installed.

CAUTION: Different length of transmission retaining bolts. Serious damage can result
from incorrect bolt installation.

1. If replacing transmission, fit retaining clips for wiring harness and transportation lock for converter from
old transmission to new transmission.
2. Fit proper length transmission retaining bolts. See Fig. 6 . Length of bolts: (1) 50 mm (2) 60 mm (3 )65
mm (4) 75 mm. Tighten to specification. See TORQUE SPECIFICATIONS .
3. Install starter motor and tighten retaining bolts to specification. See TORQUE SPECIFICATIONS .
4. Install closure plate. Tighten retaining bolts to specification. See TORQUE SPECIFICATIONS .
5. To complete installation, reverse removal procedure. After completion of work, check transmission fluid
level. Top up if necessary.

THROTTLE ASSEMBLY

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 2006 MINI Cooper S
2002-05 AUTOMATIC TRANSMISSION Removal & Installation

NOTE: A faulty throttle valve causes the adaptation values stored in the DME control
unit to be modified. These adaptation values must be reset after the throttle
valve has been replaced.

Removal & Installation

1. Read out fault memory of DME control unit. Check stored fault messages. Switch off ignition.
2. Release clamp (1). See Fig. 7 . Detach intake fitting from intake filter housing. Loosen screws (2).
Release cable holders (3 and 4). Remove intake filter housing.
3. Release clip (3). See Fig. 8 . Detach vent hose (4) from intake fitting (2). Release clamps (1). Detach
intake fitting (2) from throttle assembly and intake filter housing.
4. Unlock line of tank venting valve on throttle valve assembly and disconnect. See Fig. 9 . Unlock plug (1)
and remove. Loosen screws (2). Remove throttle valve assembly (3).
5. Replacement only: Delete adaptation values and reset. Connect diagnosis system:
 Diagnosis

 Model

 DME engine

 Control unit function

 DME 2000

 Component activation

 Reset adaptation values

 Electronic throttle

Now clear the fault memory.

6. To install, reverse removal procedure. Replace sealing ring (1). See Fig. 10 . Tighten fasteners to
specification. See TORQUE SPECIFICATIONS .

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Fig. 7: Removing Intake Filter Housing

Courtesy of BMW OF NORTH AMERICA, INC.

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2002-05 AUTOMATIC TRANSMISSION Removal & Installation

Fig. 8: Removing Intake Fitting

Courtesy of BMW OF NORTH AMERICA, INC.

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Fig. 9: Removing Throttle Valve Assembly

Courtesy of BMW OF NORTH AMERICA, INC.

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Fig. 10: Locating Sealing Ring

Courtesy of BMW OF NORTH AMERICA, INC.

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application Ft. Lbs. (N.m)
Drain Plug-To-Gearbox Sump Pan 30 (40)
Gearbox-To-Engine Retaining Bolts 63 (85)
Starter Motor-To-Gearbox 63 (85)
INCH Lbs. (N.m)
Closure Plate Retaining Bolts 80 (9)
Intake Housing-To-Body 62-89 (7-10)
Throttle Body-To-Intake Manifold 80 (9)

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