pedal mounting blockwtxmc.org/minicooperdocs/brake pedal assembly.pdf · the brake light switch...

2002-05 BRAKES

Pedal Assembly - Repair Instructions - Cooper

PEDAL MOUNTING BLOCK

35 11 000 REMOVING AND INSTALLING COMPLETE BEARING BLOCK FOR FOOT PEDAL

Necessary Preliminary Tasks:

Remove storage compartment. Refer to 51 16 392 REMOVING AND INSTALLING/REPLACING STORAGE COMPARTMENT IN INSTRUMENT PANEL TRIM (DRIVER'S SIDE) .

After completing work bleed clutch hydraulic system. Refer to BLEEDING .

Draw off brake fluid until level is below connection to clutch master cylinder.

Detach feed hose (1) for clutch hydraulics.

2006 MINI Cooper S

2002-05 BRAKES Pedal Assembly - Repair Instructions - Cooper

2006 MINI Cooper S


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Tuesday, February 16, 2010 9:57:24 AM © 2005 Mitchell Repair Information Company, LLC.

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Tuesday, February 16, 2010 9:57:28 AM Page 1 © 2005 Mitchell Repair Information Company, LLC.

Fig. 1: Identifying Feed Hose For Clutch Hydraulics Courtesy of BMW OF NORTH AMERICA, INC.

Remove line connection from clutch master cylinder (1).

Disconnect plug connection (2) on brake light switch.

If necessary, disconnect plug connection on clutch switch.

Remove bracket (3).

IMPORTANT: Collect brake fluid in a suitable container.

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Fig. 2: Locating Line Connection From Master Cylinder Courtesy of BMW OF NORTH AMERICA, INC.

Remove locking clip (1) and pull out pin (2).

Release nuts (3).

Installation:

Replace self-locking nuts

Tightening torque, (21 =/- 3 N.m.).

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Fig. 3: View Of Locking Clip And Pin Courtesy of BMW OF NORTH AMERICA, INC.

Unfasten screws (1).

Installation:

Tightening torque, refer to 35 11 1AZ in PEDALS - TIGHTENING TORQUES - COOPER (1.6L) R50/W10 .

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Fig. 4: Identifying Retaining Screws Courtesy of BMW OF NORTH AMERICA, INC.

IMPORTANT: Carefully feed line from expansion tank through bulkhead.

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Fig. 5: Locating Line From Expansion Tank In Bulkhead Courtesy of BMW OF NORTH AMERICA, INC.

Remove bearing block downwards.

When replacing bearing block:

Modify brake pedal. Refer to 35 21 000 REMOVING AND INSTALLING/REPLACING BRAKE PEDAL.

Modify clutch pedal. Refer to 35 31 000 REMOVING AND INSTALLING/REPLACING CLUTCH PEDAL.

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Fig. 6: View Of Bearing Block Courtesy of BMW OF NORTH AMERICA, INC.

BRAKE PEDAL WITH LINKAGE

35 21 000 REMOVING AND INSTALLING/REPLACING BRAKE PEDAL



The brake light switch must be modified when the brake pedal is replaced. Refer to 61 31 310 REPLACING BRAKE-LIGHT SWITCH .

Disconnect return spring.

Remove locking clip (1) and pull out pin (2).

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Installation:

Make sure locking clip (1) is correctly seated.

Fig. 7: View Of Locking Clip And Pin Courtesy of BMW OF NORTH AMERICA, INC.

Remove locking clip (1).

Pull bearing bush (2) out of brake pedal.

Remove brake pedal in direction of arrow downwards from bearing block.

Installation:

Make sure locking clip (1) is correctly seated.

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Fig. 8: Identifying Locking Pin For Bearing Bush Courtesy of BMW OF NORTH AMERICA, INC.

Installation:

Check bearing bushes (1) and replace if necessary.

Lightly grease bearing bush (1).

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Fig. 9: View Of Bearing Bush Courtesy of BMW OF NORTH AMERICA, INC.

CLUTCH PEDAL WITH LINKAGE

35 31 000 REMOVING AND INSTALLING/REPLACING CLUTCH PEDAL



Press bolt ends (1) together and remove bolt.

Unfasten screws (2).

Installation:

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Remove locking clip (3).

Fig. 10: Locating Locking Clip Courtesy of BMW OF NORTH AMERICA, INC.

Remove return spring (1).

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Fig. 11: Identifying Return Spring Courtesy of BMW OF NORTH AMERICA, INC.

Remove outer bearing (1) from clutch pedal.

Pull clutch pedal from pivot pin.

Remove inner bearing (2).

If necessary, carefully press hydraulic line (3) to one side slightly.

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Fig. 12: View Of Outer Bearing On Clutch Pedal Courtesy of BMW OF NORTH AMERICA, INC.

IMPORTANT: Note that there are different versions of the clutch pedal! Clutch pedal (1) (vehicles from 05/02) is curved in area (A). Clutch pedal (2) (vehicles up to 05/02) is straight in area (A). If a clutch pedal (2) for vehicles up to 05/02 is replaced, the bearing block must also be replaced.

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Fig. 13: Identifying Clutch Pedal (Vehicles From 05/02 And Vehicles Up To 05/02) Courtesy of BMW OF NORTH AMERICA, INC.

ACCELERATOR PEDAL ACTUATION

35 40 001 REMOVING AND INSTALLING/REPLACING ACCELERATOR PEDAL MODULE

When replacing control unit:

Observe programming/coding. Refer to DIAGNOSIS PROGRAMMING/CODING .

Press retaining tab (1) downwards and slide accelerator pedal module (2) in direction of arrow off adapter plate and remove.

Disconnect plug connection.

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Fig. 14: Removing Accelerator Pedal Module Courtesy of BMW OF NORTH AMERICA, INC.

35 40 503 REPLACING ADAPTER PLATE


Remove accelerator pedal module. Refer to 35 40 001 REMOVING AND INSTALLING/REPLACING ACCELERATOR PEDAL MODULE.

Unscrew bolt (1).

IMPORTANT: The adapter plate must be replaced if an accelerator pedal is removed. Refer to 35 40 503 REPLACING ADAPTER PLATE.

IMPORTANT: The adapter plate must be replaced if it is removed.

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Installation:


Disengage adapter plate from mounting fixture (2) and remove adapter plate.

Fig. 15: Removing Adapter Plate Courtesy of BMW OF NORTH AMERICA, INC.

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pedal mounting blockwtxmc.org/minicooperdocs/brake pedal assembly.pdf · the brake light switch...

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