benni mini workshop manual 2013 cap 2

Benni Mini 2013.01

Chassis

GROUP

2

2.1 Suspension System

2.1.1 Suspension System - General Information ....................................................................... 2.1.1-1

2.1.2 Front Suspension.............................................................................................................. 2.1.2-1

2.1.3 Rear Suspension .............................................................................................................. 2.1.3-1

2.1.4 Wheels and Tires .............................................................................................................. 2.1.4-1

2.2 Driveline System

2.2.1Driverline System - General Information............................................................................ 2.2.1-1

2.2.2 Driveshaft .......................................................................................................................... 2.2.2-1

2.2.3 Differential ......................................................................................................................... 2.2.3-1

2.3 Brake System

2.3.1 Brake System - General Informa- ..................................................................................... 2.3.1-1

2.3.2 Rear Drum Brake .............................................................................................................. 2.3.2-1

2.3.3 Front Disc Brake ............................................................................................................... 2.3.3-1

2.3.4Parking Brake and Actuation ............................................................................................. 2.3.4-1

2.3.5 Hydraulic Brake Actuation................................................................................................. 2.3.5-1

2.3.6 Power Brake Actuation ..................................................................................................... 2.3.6-1

2.3.7 Anti-lock Control................................................................................................................ 2.3.7-1

2.4 Steering System

2.4.1 Steering System - General Information............................................................................. 2.4.1-1

2.4.2 Power Steering System..................................................................................................... 2.4.2-1

2.4.3 Steering Linkage ............................................................................................................... 2.4.3-1

2.4.4 Steering Column ............................................................................................................... 2.4.4-1

SECTION TITLE Pages

Benni Mini 2013.01

Suspension System

2.1 Suspension System

2012 Benni Mini

2.1.1 Suspension System - General Information

Specifications ................................................................................................................................... 2.1.1-1

General Specifications.............................................................................................................. 2.1.1-1

Description and Operation ............................................................................................................... 2.1.1-2

System Overview...................................................................................................................... 2.1.1-2

General Procedures......................................................................................................................... 2.1.1-4

Wheel Bearing Inspection......................................................................................................... 2.1.1-4

Tie Rod Ball Joint Inspection .................................................................................................... 2.1.1-4

Front Control Arm Ball Joint Inspection .................................................................................... 2.1.1-5

Suspension Device Inspection ................................................................................................. 2.1.1-5

Vehicle Inspection..................................................................................................................... 2.1.1-5

Lift Vehicle Inspection............................................................................................................... 2.1.1-5

Worktable Test .......................................................................................................................... 2.1.1-6

Rear Shock Absorber Inspection.............................................................................................. 2.1.1-6

Road Test ................................................................................................................................. 2.1.1-6

Front Wheel Toe-in Inspection and Adjustment........................................................................ 2.1.1-7

Symptom Diagnosis and Testing...................................................................................................... 2.1.1-8

Inspection and verification ........................................................................................................ 2.1.1-8

Symptom Chart......................................................................................................................... 2.1.1-9

Vehicle Drift Diagnosis............................................................................................................ 2.1.1-14

Abnormal Driving Track Diagnosis (Vehicle Can Not Run Straight) ....................................... 2.1.1-17

Vehicle Swing Diagnosis ........................................................................................................2.1.1-20

Steering Wheel Off Center Diagnosis..................................................................................... 2.1.1-22

Abnormal Driving Track Diagnosis ......................................................................................... 2.1.1-23

Excessive Noise Diagnosis .................................................................................................... 2.1.1-24

Vibration Diagnosis................................................................................................................. 2.1.1-26

Incorrect Tire Wear Diagnosis ................................................................................................ 2.1.1-30

2.1.2 Front Suspension

Specifications ................................................................................................................................... 2.1.2-1

Torque Specifications................................................................................................................ 2.1.2-1


System Overview...................................................................................................................... 2.1.2-2

Table of Contents Pages

Benni Mini 2013.01

Suspension System

Location View............................................................................................................................2.1.2-2

Exploded View ..........................................................................................................................2.1.2-4

Symptom Diagnosis and Testing ......................................................................................................2.1.2-7

Disassembly and Assembly .............................................................................................................2.1.2-8

Strut and Spring Assembly........................................................................................................2.1.2-8

Removal and Installation ................................................................................................................2.1.2-10

Front Control Arm ...................................................................................................................2.1.2-10

Steering Knuckle..................................................................................................................... 2.1.2-11

Bearing ...................................................................................................................................2.1.2-14

Front Strut Assembly ..............................................................................................................2.1.2-16

2.1.3 Rear Suspension

Specifications ...................................................................................................................................2.1.3-1

Torque Specifications................................................................................................................2.1.3-1

Description and Operation................................................................................................................2.1.3-2

System Overview......................................................................................................................2.1.3-2

Location View............................................................................................................................2.1.3-3

Exploded View ..........................................................................................................................2.1.3-4


Removal and Installation ..................................................................................................................2.1.3-7

Rear Axle ..................................................................................................................................2.1.3-7

Rear Wheel Bearing ...............................................................................................................2.1.3-10

Rear Shock Absorber Assembly.............................................................................................2.1.3-12

Stabilizer Bar...........................................................................................................................2.1.3-13

Trailing Arm.............................................................................................................................2.1.3-14

2.1.4 Wheels and Tires

Specifications ...................................................................................................................................2.1.4-1

General Specifications ..............................................................................................................2.1.4-1



System Overview......................................................................................................................2.1.4-2

Exploded View ..........................................................................................................................2.1.4-3

General Procedures .........................................................................................................................2.1.4-4

Inspection and Identification .....................................................................................................2.1.4-4

Tire Wear Diagnosis .................................................................................................................2.1.4-4

Wheel Runout Inspection..........................................................................................................2.1.4-4

Initial Inspection Before Wheel Alignment ................................................................................2.1.4-5

Benni Mini 2013.01

Suspension System

Tire Wear Inspection................................................................................................................. 2.1.4-6


Inspection and Verification........................................................................................................ 2.1.4-9

Symptom Chart....................................................................................................................... 2.1.4-10

Removal and Installation................................................................................................................ 2.1.4-12

Wheels and Tires.................................................................................................................... 2.1.4-12

Benni Mini 2013.01

2.1.1-1 2.1.1-1Suspension System - General Information

Specifications

General Specifications

Item Specification

Front wheel alignment parameter

Front toe-in 0°10' ± 0°10

Front wheel camber angle 0.50° ± 0.50°

Front wheel caster angle 2.8° ± 0.5°

Front wheel kingpin inclination angle 12.5° ± 0.5°

Rear wheel alignment parameter

Rear toe-in 0° ( -0°20' ~ 0°20' )

Rear wheel camber angle0° ( -0.33° ~ 0.33°) or -0°20' ~

0°20'

2.1.1 Suspension System - General Information

2.1.1-2

Benni Mini 2013.01

2.1.1-2Suspension System - General Information

Description and Operation

System Overview

The primary aim of vehicle engineering is to

ensure the safety and reliability of steering and

suspension system. Every component should be

of enough strenghth to bear and absorb extreme

shock. Steering system and front & rear suspen-

sion system must keep certain geometrical rela-

tionship with vehicle body.

Steering and suspension system require the front

wheel to return automatically and minimize the

front wheel rolling resistance and road frication

force. It helps users control the vehicle directions

easily and comfortably.

Comprehensive wheel alignment inspection

includes measuring rear wheel front toe-in angle

and camber angle. 4-wheel alignment can make

sure all 4 wheels can turn to the same directions

accurately. After geometrical alignment, vehicle

can get best fuel economics and tire service life

and optimal steering performance.

1. Caster angle

Caster angle refers to the pitch or tip back capac-

ity from the highest point of steering axial line

deviating vertical surface, observed from the lat-

eral of vehicle. Tip back is positive and pitch is

negative. Caster angle influences the direction

control in steering but has no impact on the tire

wear. Too soft spring or overload will influence

caster angle. When the caster angle of the vehi-

cle is positive, pull the vehicle to its center. The

minimal positive caster angle will lead the side-

way and rolling of the vehicle. The measure unit

of caster angle is degree and can not be adjusted.

2. Camber angle

Camber angle is the angle of tire top deviating

vertical surface, observed from the head of vehi-

cle. The camber angle is positive when tire toes

out. When tire toes in, camber angle is negative.

Camber angle is the angle deviating vertical sur-

face. Camber angle will influence direction control

and tire wear. If vehicle positive camber angle is

too large, it will lead tire outer shoulder worn. If

vehicle negative camber angle is too large, it will

lead tire inner shoulder worn. Camber angle can

not be adjusted.

3. Toe-in description

Toe-in is the tire inner drifts from geometric center

line or thrust line and negative toe-in is the tire

outer drifts from geometric center line or thrust

line . Toe-in is used to ensure the smooth rolling

of tire. Toe-in can counteract the slight deviation

of the wheel supporting system in wheel rolling

forward. The specified toe-in angle is the setting

value of toe-in reaching 0 degree when vehicle

drives forward.

Incorrect toe-in or negative toe-in will lead tire

worn and reduce fuel economics. Because every

steering and suspension system component worn

will become serious with the increasing driving

mileage, the toe-in should be increased to com-

pensate the wear of these components. It is nec-

essary to cavibrate toe-in angle finally.

4. Steering axes inclination

Steering axes inclination (SAI) means the slope

capacity of steering knuckle top deviating vertical

surface. Obvering from vehicle head, steering

axes inclination is the angle of vertical surface

and the line of crossing column center and lower

ball joint. Steering axle inclination is helpful to

keep vehicle driving straightly and assist wheel to

return to right ahead. Steering axes inclination of

front wheel driving vehicle is negative.

5. Wrap angle

Obversing from vehicle head, wrap angle is the

angle between camber angle and the straight line

of crossing column center and lower ball joint.

Wrap angle is accounted according to angle. A lot

of alignment table can not measure wrap angle

directly. When cofirming wrap angle, substract

negative camber angle or add positive camber

angle from steering axes inclination.

6. Buffering tire radius

Buffering tire radius is the distance from vertical

surface to the line of crossing column center and

lower ball joint. Buffering tire radius is the design

feature of vehicle. Buffering tire radius can not be

adjusted.

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7. Rear dislocation

Rear dislocation is the distance of a front wheel

hub and bearing assembly falling behind another

front wheel hub and bearing assembly. Rear dis-

location is caused by road obstruction and crash.

8. Steering angle

Steering angle is the angle of every front wheel

related to vertical direction when steering.

WARNING: Ensure the tire pressure cor-

rectly at the beginning of inspection and

after inspection.

Excessive wear, sinking or imbalance of the tire

will cause vehicle vibration, shaking or unsmooth

running etc.

Uneven or wavy pavement also results in the

above-mentioned conditions. In case of the

above-mentioned conditions, run on different

pavements for confirmation.

When searching for the reasons of vehicle vibra-

tion, do not inspect the tire immediately, the fol-

lowing conditions may also cause the problem:

1. Front wheel bearing is loosened or worn.

2. Suspension or steering parts is loosened or

worn.

3. Overlarge beat amplitude of front brake disc.

4. Engine or drive axle bracket is loosened.

5. Engine accessories.

This section contains vibrations related to the

suspension and the tire etc.

Over-high vehicle noises are generally caused by

the friction between the flat worn part of the tire

and the ground. The sounds of the tire are differ-

ent from those of the drive axle for the latter

changes according to the load or speed. The tire

noises are unchanged at a certain speed range.

In order to confirm that the noises of the tire are

not related to vehicle vibration, fill redundant gas

into the tire to inspect if the sounds of the tire

change. The jolt amplitude and noises of the vehi-

cle change along with the tire pressure.

2.1.1-4

Benni Mini 2013.01


General Procedures

Wheel Bearing Inspection

Special Tool

General Tool

CAUTION: Do not mix up the front control

arm ball joint loose and bearing loose.

1. Lift the vehicle.

Refer to: Lifting (1.1.3 Traction and Lifting,

Description and Operation).

2. Swag wheel. Inspect whether the front wheel

bearing is loosened.

3. Rotate the wheel rapdily to make sure that

wheel rotates smoothly and peacefully.

4. Remove the front brake caliper and the

retaining plate.

Refer to: Caliper (2.3.1 Brake Sysem,

Removal and Installation).

5. Install a suitable dial indicator gauge retainer

or similar equipment, then push and pull the

wheel hub. Measure the axial clearance

between the wheel hub and the front wheel

bearing assemlby. There should be no axial

clearance. Replace the front wheel bearing if

it has the axial clearance.

6. Install the front brake caliper and the retaining

plate.

Tie Rod Ball Joint Inspection

CAUTION: Inspect the wear of the tie rod

ball joint first before the front suspension

inspection or alignment.

1. Inspect the air pressure of 4 tires.




Inspect whether the front suspension ball joint

and bracket is loosened, worn or damaged.

Relative information please refer to the front

control arm ball joint chapter. Tighten all

loosed nuts according to torque specification.

Replacing the components if necessary.

Refer to: Front Wheel Steering Knuclke

(2.1.2 Front Suspension, Removal and

Installation), Tie Rod Ball Joint (2.4.3

Steering Linkage, Removal and Installa-

tion).

3. Inspect whether the steering linkage and the

tie rod bar connection loose. Tighten

according to torque specifications. Replace

the ball if the tie rod ball joint is worn or

damaged.

Refer to: Tie Rod Ball Joint (2.4.3 Steering

Linkage, Removal and Installation).

4. Remove the front wheels. Inspect tie runout

capacity and monolateral worn. Carry tire

dynamic poise.

Clamp Stand of Dial

Indicator Gauge

205-044 (15-008)

Dial Indicator Gauge

CA205-044

A2101501

205-044

A2101502

Benni Mini 2013.01


5. Inspect the working situation of the

suspension device and its attachment.

Relative information please refer to the

inspection of the suspension assembly. The

locked suspension assembly can not reach

the normal position and will influence front

wheel alignment.

Front Control Arm Ball Joint

Inspection




2. Hold the outer end of the front control arm

and try to move up and down and observe

whether it moves. Free movement will

generally bring with click sound and will lead

damage.

3. Replace the ball joint if there is free

movement.

Refer to: Front Control Arm and Ball Pin

(2.1.2 Front Suspension, Removal and

Installation).

4. Carry out the front wheel alignment after

replacing the ball joint. Relative information

please refer to general flow.

Suspension Device Inspection

CAUTION: All vehicles are equiped with

low pressure gas-fluid suspension device.

This device can not be adjusted and

refilled.

1. Oil leakage. It is allowed to deposit a layer of

oil film (exudation) on front and rear shock

absorber, it is in normal. Oil leakage means a

layer of thick oil accumulating at the outside

of shock absorber shell. It is normally noticed

due to a collection of dust on it. The oil

leakage in shock absorption is normal

function and not necessary to replace shock

absorber. The leakage means the shock

absorber is covered by leaking oil and the oil

will drop on ground.

If this situation appears:

• Be sure the observing oil film is from the

shock absorption device.

• Replace it if the shock absorber is worn

or damaged.

2. Vehicle body subsidises. Generally replace

the front and rear shock absorber to solve this

problem. Because the shock absorber is

hydraulic pressure device which is not the

same to suspension spring and can not be

used to bear load. So replacing suspension

device can not slove this problem.

CAUTION: When one suspension is dam-

aged, it is unnecessary to replace in pairs.

In the past, we recommended that a pair of

shock absorbers is re-placed if one is

damaged. Now, due to new technology

and strengthened production manage-

ment, sealing technology is improved, so

the working reliability of the shock

absorber is greatly improved.

Vehicle Inspection

1. Inspect the air pressure of all tires.

2. Inspect tire to make sure the alignment of tie

rod ball joint and tire balance and whether

there are cracks and abnormal tubers on tire.

3. Inspect the suspension equipments that can

be selected, such as the suspension of truck

with heavy trailer. This suspension is firmer

than standard suspension in driving process.

4. Inspect whether vehicle is overload. Inspect

whether there are heavy objects in trunk.

5. After finishing the above steps, carry out road

test to verify the symptoms that are brought

forward by customer.

Lift Vehicle Inspection

1. Noise:

The loose of suspension and its attachment

may make noise. Inspect and tighten suspen-

sion assembly and its attechment. Replace

lower bracket bushing if it is damaged.

Inspect whether there is outer damage on

front and rear suspension assembly.

2. Bottom/Rebound:

Inspect the jounery of the rubber shock

absorption bushing. Install a new shock

absorption bushing if it is damaged or lost.

Inspect whether the shock absorption bush-

2.1.1-6

Benni Mini 2013.01


ing is overloaded. Replace it if such problem

appears.

3. Replace the damaged shock absorber if it is

worn.

Worktable Test

Shock absorber is full of compressed air, it is

completely extended when it is not limited. No

extension means shock absorber is damaged.

Install a new shock absorber. Inspect the length

of shock absorber. If it dose not satisfy the

requirement, it means the certain part of it is in

counter condition and shock absorption device

should be replaced. When suspension device is

in vertical position, compress suspension assem-

bly and allow it to spread for 3 times in order to

clean the air entering the pressing cabin in pro-

cessing.

WARNING: When removing dust boot or

limited block, avoid the shock absorber

push rod pushing down too much in order

not to cause damage to the inner compo-

nents.

Shock absorber should be set on clamp upright.

Compress shock absorber quickly with a large

journey. Every compressing action must be stable

and consistent. Spread resistance exceeds com-

pressing resistance is normal phenomena.

The following situations are abnormal:

• In the process of installing and returning

after installation, the shock absorber lags

and jumps.

• blocked.

• Noise, eliminiate light whizzing sound,

the click sound in rapid returning.

• Leakage.

• Shock absorber pull rod is completely

extended and its piston swags compared

to shock absorber shell.

If the shock absorber is still unstable after air

cleaning, please replace a new shock absorber.

Refer to: Front Strut Assembly (2.1.2 Front

Suspension, Removal and Installation),

Rear Shock Absorber Assembly/Rear

Screw Spring/Rear Screw Spring Upper

and Lower Base (2.1.3 Rear suspension,


Rear Shock Absorber Inspec-

tion

Inspect the rear shock abosrber in the following

aspects regularly:

1. Inspect whether there is oil leakage in the

rear shock absorber. (A layer of oil film is

allowed and make sure leakage is not from

other components).

2. Inspect working state of the rear shock

absorber.

3. Inspect the working state of upper and lower

bushings.

Road Test

The tire vibration diagnosis starts from road test.

Road test and communication with customer can

provide more information for vibration caused.

Road test should be carried out on flat ground.

Pay attention and record the following items if

vibration appears.

1. The vehicle speed when vibration appears.

2. The vibration types in all speed range.

3. Mechanical or items can be heard.

4. The following conditions will influence the

vibration:

• Engine torque.

• Vehicle speed.

• Engine speed.

• Vibration type - sensitivity: torque

sensitivity, vehicle speed sensitivity, or

engine speed sensitivity.

The following explanations are useful to differenti-

ate the vibration sources.

1. Torque sensitivity

It means the situations will become better or

worse due to acceleration, deceleration,

Benni Mini 2013.01


coasting, constant speed and engine torque

adding.

2. Vehicle speed sensitivity

It means the vibration always appears at the

same vehicle speed and will not be influ-

enced by engine torque, engine speed or the

choice of driving axle shaft.

3. engine speed sensitivity

It means the vibration appear at the speed in

different gears. The engine speed can be

increased or reduced in natural position and

tested when gear box stalls. If the symptom is

caused by engine speed, the reason may

have nothing to do with the tire.

If tire makes sob sound in road test but no

vibration and shake, the noise may be

caused by the contact between tire and road-

surface.

Large noise indicates a flat tire or something

soft contacting the road surface. The sob

sound of tire will be regarded as beam axle

noise by mistake. The tire sob will continously

sound at a certain vehicle speed.

Front Wheel Toe-in Inspection

and Adjustment

General Tool

Inspection

1. Use wheel alignment gauge to adjust toe-in

on flat ground according to the instructions.

• Inspect the suspension and the steering

components; make sure there is no worn.

• Inspect and adjust tire pressure if

necessary.

• Make sure the vehicle is in the state of

gross weight. Spare tire, jack and onbard

tool are equiped. Take out other tools or

goods.

• Press the vehicle up and down to set

suspension system in normal position.

Adjustment

1. Turn the steering wheel to the center position

and lock it.

2. Loosen the tie rod ball joint retaining nut.

Wheel Alignment Gauge

LOCK

A2101503

A2101504

2.1.1-8

Benni Mini 2013.01


3. Rotate the tie rod ball joint clockwise or

counter-clockwise to adjust toe-in .

4. Tighten tie rod ball joint retaining nut.

5. Inspect toe-in.

Symptom Diagnosis and Testing

Inspection and verification

1. Verify the customer concern.

2. Visually inspect for obvious signs of

mechanical damage.

Visual Inspection Chart

3. If an obvious cause for an observed or

reported concern is found, correct the cause

before proceeding to the next step.

4. If the cause is not visually evident, verify the

symptom and refer to the symptom chart.

A2101505

42.5 Nm

A2101506

Machanical

•Tire pressure

•Wheels and Tires

•Wheel steering knuckle

•Tie rod ball joint

•Front control arm and ball joint pin

•Front suspension lower control arm bearing

•Front strut and spring

•Front and rear balancing bar and linkage

•Rear spring

•Rear ahock absorber

•Rear suspension arm

Benni Mini 2013.01


Symptom Chart

If there is symptom but no diagnosis trouble code (DTC) stored in control module and can not confirm

the causes through the General Procedures, it is necessary to diagnose and fix the problem in the

sequence as shown in the following chart.

Symptom Possible Sources Action

Vehicle Drift

•Wheels and tires

•Wheel alignment

•Rear dislocation

•Driving height

•Wheel bearing

•Ball joint

•Brake drag

•Steering pull rod

•Rear suspension

Refer to: Vehicle Drift Diagnosis

(2.1.1 Suspenion System -

General Information, Symptom

Diagnosis and Testing).

Abnormal driving track

(Vehicle can not keep

driving straight)

•Wheels and tires

•Wheel alignment

•Wheel bearing

• Ball joint

•Control arm bushing

•Steering tie rod clearance

•Steering Linkage clearance

•Rear suspension

Refer to: Abnormal Driving

Track (Vehicle Can Not Run

Straight) Diagnosis (2.1.1

Suspenion System - General

Information, Symptom


Vehicle swing

•Tire unbalancing and excessive

worn

•Front wheel drive shaft worn

•Wheel bearing worn

•Steering system worn

•Suspension device assembly

loose and worn

•front control arm ball joint worn

•Front control arm bushing worn

and loose

•Stabilizer bar bushing worn

•Rear suspension and bushing

worn and loose

•Incorrect wheel alignment

Refer to: Vehicle Swing Diagno-

sis (2.1.1 Suspenion System -

General Information, Symptom


2.1.1-10

Benni Mini 2013.01


Vehicle shakes in driving

•Tire unbalance and excessive

worn

•Inspect the tire

Refer to: Tire Wear Inspection

(2.1.4 Wheels and Tires, Gen-

eral Procedures).

•Front wheel drive shaft worn

•Inspect the front wheel drive shaft

Refer to: Drive Shaft Inspection

(2.2.1 Driveline - General Infor-

mation, General Procedures).

•Wheel bearing worn •Replace the wheel bearing

•Steering system worn •Replace the steering system worn part


loose and worn

•Inspect the suspension device assembly

Refer to: Torque Specifications

(2.1.2 Front Suspension, Specifi-

cations), Torque Specifications

(2.1.3 Rear Suspension, Specifi-

cations).


bracket loose

•Tighten it according to torque requirement

Refer to: Torque Specifications

(2.1.2 Front Suspension, Specifi-

cations), Torque Specifications

(2.1.3 Rear Suspension, Specifi-

cations).

•Front control arm ball joint worn

•Replace the front arm ball joint

Refer to: Front Control Arm

(2.1.2 Front Suspension,


•Front control arm bushing worn

and loose

•Replace the front suspension control arm

bushing





•Replace the stablizer bar bushing





Benni Mini 2013.01


Vehicle shakes in driving

•Rear suspension and bushing

worn and loose

•Replace the suspension and bushing if

necessary

Refer to: Rear Axle (2.1.3 Rear

Suspension, Removal and

Installation), Rear Axle Bushing

(2.1.3 Rear suspension,



•Wheel alignment

Refer to: Wheel Alignment (2.1.1

Suspension System - General

Information, General Proce-

dures).

Steering wheel off center•Wheel alignment

•Steering system components•Steering Wheel Off Center Diagnosis

Excessive noise

•Suspension assembly bracket

loose or worn

•Wheel bearing worn

•Front control arm bushing

•Damper spring

•Tire

•Front control arm ball joint

Refer to: Excessive Noise Diag-

nosis (2.1.1 Suspension System

- General Information, Symptom


Incorrect tire wear

•Tire conversion

•Tire pressure

•Wheel distortion

•Unbalancing tire

•Wheel alignment

•Suspension components

•High speed driving

•Rear dislocation

•Overload

•Poor operation habit

Refer to: Incorrect Tire Wear

Diagnosis (2.1.1 Suspension

System - General Information,

Symptom Diagnosis and

Testing).


2.1.1-12

Benni Mini 2013.01


Heavy steering

•Positive camber angle too large

•Wheel alignment




dures).

•Incorrect vehicle driving height

(front or rear, up or down)

•Load meets the standard and replace the

standard spring components

•Steering Linkage or steering tie

bar worn

•Replace the steering system worn compo-

nents

•Front suspension front control arm

ball joint worn

•Replace front control arm ball joint




•Tire worn or unbalancing

•Inspect the tires



eral Procedures).

•Insufficient power steering force

•Inspect the oil pressure and supplement

of power steering system. Inspect power

steering system and replace worn compo-

nents.

Vehicle swag

•Front stabilizer bar or bearing

worn (if equipped)

•Replace the front stabilizer linkage or

bushing




•Front control arm bushing loose

and worn

•Repair or replace front control arm bush-

ing




•Suspension assembly loose or

worn

•Inspect the suspension assembly and

replace the worn components

Vehicle lean

•Front and rear damper spring

becomes soft and damaged

•Inspect the damper spring and replace it if

necessary

Refer to: Front Strut Assembly

Disassembly and Assembly


Removal and Installation), Rear

Shock Absorber Assembly



•Tire pressure is improper •Adjust the tire pressure


Benni Mini 2013.01


Rough ride

•Front and rear damper springs

become soft


necessary








•Front or rear suspension assem-

bly worn

•Replace the suspension assembly worn

components

Unstable direction

•Tire is unbalancing, damaged or

with too large runout

•Inspect the tires



eral Procedures).

•Toe-in out of specification

•Wheel alignment




dures).

•Steering system worn•Replace the steering system worn compo-

nents

•Front control arm ball joint dam-

aged

•Replace the front control arm ball joint




•Front and rear damper springs

become soft


necessary








•Front or rear suspension assem-

bly worn

•Replace the suspension assembly worn

components

•Rear suspension, bushing or bolt

loose or worn

•Replace the rear suspension worn com-

ponents


•Replace the stablizer bar bushing





2.1.1-14

Benni Mini 2013.01


Vehicle Drift Diagnosis

Steering wheel can not

return normally


•Wheel alignment




dures).

•Steering system worn

•Inspect the steering system

Refer to: (2.4.1 Steering System

- General Information, General

Procedures).

•Front suspension control arm ball

joint worn

•Replace the front suspension control arm

ball joint




Driving vibration

•Tire

•Front wheel bearing

•Rear wheel bearing

•Front hub

•Rear hub

Refer to: Driving Vibration Diag-

nosis (2.1.1 Suspension System

- General Information, Symptom


Test Conditions Details/Results/Actions

1.Inspect the left and right drift

WARNING: In order to avoid the personal injury caused by out of control operation, road

test should be taken by two persons together to keep safe driving.

CAUTION: When estimating the vehicle, the following conditions must be met.

A.Drive the vehicle on flat road at the speed of 88 km/

h.

B.Make sure there is no crosswind and strong wind in

driving.

C.Drive back and forth at least for 2 times.

D.If the vehicle deviating value is 12 ft within 7

seconds, it indicates vehicle drifts.

Does vehicle drift?

Y

Go to step 2.

N

Adjust the steering wheel to straight positon.


Benni Mini 2013.01


2. Inspect the tire

A.Inspect whether all the wheels and tires type are the

same.

B. Inspect whether all the tire worn levels are near.

C.Inspect whether the tire bubbles or cracks.

D.Inspect the tire pressure.

Whether the tire inspection is normal?

Y

Go to step 3.

N

Adjust or replace the tire.

3. Inspect the influence of tire to symptom

A.Swap the front suspension tires.

B.Install 4 tires in good state if necessary.

Does the vehicle drift?

Y

Go to step 4.

N

Replace the tire.

4.Inspect the left and right wheel tread

A.Inspect the left and right wheel tread.

Whether the wheel tread at both sides are the

same?

Y

Go to step 5.

N

Cavibrate the left and right wheel tread.

5.Inspect the steering linkage

A.Lift the vehicle.



B.Inspect whether the steering linkage is excessively

worn.

Whether the steering linkage is excessively worn?

Y

Replace or repair the damaged components.

N

Go to step 6.


2.1.1-16

Benni Mini 2013.01


6.Inspect the driving height

A.Inspect the driving height.

Whether the driving height is normal?

Y

Go to step 7.

N

Repair the fault due to inconsistent driving height.

7.Inspect the wheel alignment

A.Inspect the wheel alignment.

Whether the steering wheel is in central positon and

whether the wheel alignment data is in the specifi-

cation?

Y

Go to step 8.

N

If necessary, carry out the wheel alignment.

8.Inspect the brake drag

A.Lift the vehicle.



B.Inspect whether the wheel has brake lag.

Whether the wheel has brake lag?

Y

Repair the brake drag symptom.

Refer to: Brake Drag (2.3.1 Brake System -

General Information, Symptom Diagnosis

and Testing).

N

Go to step 9.


Benni Mini 2013.01


Abnormal Driving Track Diagnosis (Vehicle Can Not Run Straight)

9.Inspect the rear suspension

A.Inspect the rear suspension alignment parameter.

Whether the rear suspension alignment is normal?

Y

Inspect the suspension components wear. Replace

or repair the damaged components if necessary.

Refer to: Front Strut Assembly Disassem-

bly and Assembly (2.1.2 Front Suspen-

sion, Removal and Installation), Rear

Shock Absorber Assembly (2.1.3 Rear

suspension, Removal and Installation).

N

Adjust or repair the rear suspension incorrect align-

ment.



test should be taken by two persons together to keep safe. Be sure to keep the proper

control of steering wheel.

1.Inspect the tire


same.





Y

Go to step 2.

N





Does vehicle drift?

Y

Go to step 3.

N

Replace the tire.


2.1.1-18

Benni Mini 2013.01


3.Inspect the front control arm bushing

A.Inspect whether the front control arm bushing

cracks, looses or moves.

Whether the front control arm inspection is normal?

Y

Go to step 4.

N

Replace the front control arm bushing.

Refer to: Front Control Arm (2.1.2 Front

Suspension, Removal and Installation).

4.Inspect the steering linkage

A.Lift the vehicle.



B.Inspect whether the steering linkage is excessively

worn.

Whether the steering linkage is excessively worn?

Y

Replace or repair the damaged components.

N

Go to step 5.





cation?

Y

Go to step 6.

N



Benni Mini 2013.01


6.Inspect the steering linkage clearance

A.Lift the vehicle.



B.Inspect the steering linkage clearance.

Refer to: Steering Linkage Inspection

(2.4.1 Steering System - General Informa-

tion, General Procedures).

Whether the steering linkage clearance is normal?

Y

Go to step 7.

N

Repair or replace the failed component.




Y


or repair damaged components if necessary.

N

Adjust or repair the rear suspension alignment

abnormal.


2.1.1-20

Benni Mini 2013.01


Vehicle Swing Diagnosis



test should be taken by two persons together to keep safe. Be sure to keep the proper

control of steering wheel.

1. Inspect the tire


same.





Y

Go to step 2.

N





Does vehicle drift?

Y

Go to step 3.

N

Replace the tire.

3.Inspect the front control arm bushing

A.Inspect whether the front control arm bushing

cracks, looses or moves.

Whether the front control arm inspection is normal?

Y

Go to step 4.

N




Benni Mini 2013.01


4.Inspect the wheel bearing

A.Lift the vehicle.



B.Inspect the wheel bearing.

Refer to: Wheel Bearing Inspection (2.1.1

Suspension System - General Informa-


Whether the wheel bearing is normal?

Y

Go to step 5.

N

Replace the wheel bearing.

5.Inspect the stabilizer bar

A.Inspect whether the stablizier bushing cracks,

looses or lacks.

B.Inspect whether the stabilizer bar is damaged.

Whether the stabilizer bar inspection is normal?

Y

Go to step 6.

N

Repair or replace the stabilizer bar and bushing.





cation?

Y

Go to step 7.

N



2.1.1-22

Benni Mini 2013.01


Steering Wheel Off Center Diagnosis

7.Inspect the steering linkage clearance

A.Lift the vehicle.



B.Inspect the steering linkage clearance.

Refer to: Steering Linkage Inspection

(2.4.1 Steering System - General Informa-


Whether the steering linkage clearance is normal?

Y

Go to step 8.

N

Repair or replace the failed component.




Y


or repair damaged components if necessary.

N

Adjust or repair the rear suspension alignment

abnormal.


1.Inspect the steering components

A.Lift the vehicle.



B.Inspect whether the steering components are

excessively worn?

Whether the steering components are excessively

worn?

Y

Replace or repair the worn components.

N

Go to step 2.


Benni Mini 2013.01


Abnormal Driving Track Diagnosis





cation?

Y

Refer to: Abnormal Driving Track Diagno-

sis (2.1.1 Suspension System - General

Information, Symptom Diagnosis and

Testing).

N

Carry out the wheel alignment.


1.Inspect the front caster angle

A.Inspect the front caster angle.

Whether the front caster angle is within the speci-

fied range?

Y

Go to step 2.

N

Inspect the wear of the suspension components. If

necessary, replace or repair the worn components.


A.Measure the left and right wheel tread of vehicle.

B.Compare the measured values.

Whether the data are the same?

Y

Carry out the four-wheel alignment.

N

Inspect the wear of the rear suspension compo-

nents. If necessary, replace or repair the worn com-

ponents.

Refer to: (2.1.3 Rear Suspension,



2.1.1-24

Benni Mini 2013.01


Excessive Noise Diagnosis


1.Inspect the suspension

A.Lift the vehicle.



B.Inspect the mounting bolts of the suspension

components.

Whether the bolts loose or crack?

Y

Tighten or replace the bolts.

N

Go to step 2.

2. Inspect the damper spring

A.Inspect whether the damper spring is damaged.

Whether the damper spring is damaged?

Y

Replace the damper spring.

N

Go to step 3.

3.Inspect the front control arm

A.Inspect whether the front control arm bushing is

excessively worn or damaged.

whether the front control arm bushing is worn?

Y




N

Go to step 4.

Benni Mini 2013.01


4.Inspect the ball joint

A.Lift the vehicle.



B. Cinch the outer end of the front control arm and

move up and down and observe whether it moves.

No free movement is allowed.

Whether there is free movement?

Y

Replace the front control arm and the control arm

ball joint pin.



N

Go to step 5.

5.Inspect the tire

A.Inspect the tire uneven wear.

Whether the tire wear is uneven?

Y

Replace the tire. Wheel alignment.

N

Go to step 6.

6.Inspect the front wheel bearing

A.Inspect the front wheel bearing.

B.Hold the bottom and top of the wheel to swag

powerfully. Inspect whether the bearing is

excessively loose.

C.Rotate the front wheel and inspect working

situation.

Whether the bearing becomes loose or makes

noise?

Y

If necessary, replace the front wheel bearing.

N

Verify the customer concerns.


2.1.1-26

Benni Mini 2013.01


Vibration Diagnosis


1.Inspect the tire

A.Lift the vehicle.



B.Inspect whether the tire is damaged or excessively

worn.

Whether the tire is damaged or worn?

Y

Replace the tire.

N

Go to step 2.

2. Inspect the front wheel bearing

A.Inspect the front wheel bearing.



excessively loose.


situation.


noise?

Y

Go to step 3.

N

Go to step 4.

3.Measure the front bearing axial clearance

A.Remove the wheel, brake caliper and brake disc.

B.Install the dial indicator gauge with mounting

bracket and close to the front wheel hub.

C.Pull and push the wheel hub along axial direction

and inspect the axial clearance of wheel hub and

front wheel bearing.

Whether the axial clearance of the front wheel bear-

ing is in the specification?

Y

Inspect the ball joint. Go to step 4.

N

Replace the wheel hub and bearig assembly.

Benni Mini 2013.01


4.Inspect the rear wheel bearing

A.Inspect the rear wheel bearing.



excessively loose.


situation.


noise?

Y

Go to step 5.

N

Go to step 6.

5.Measure the axial clearance of the rear wheel bearing

A.Remove the rear wheel.

B.Install the dial indicator gauge with mounting

bracket and close to the rear brake drum.

C.Pull and push the wheel hub in axle direction and

inspect the axial clearance of wheel hub and rear

wheel bearing.

Whether the axial clearance of the rear wheel bear-

ing is in the specification?

Y

Go to step 6.

N

If necessary, replace the rear bearing.

Refer to: Rear Wheel Bearing (2.1.3 Rear


6: Inspect the wheel/tire runout value

A.Use the radial runout meter to measure the radial

runout of the wheels and tires and the crosswise

and radial runout value of assembly shold be no

less than 1.14 mm.

Whether the measured value is in the specification?

Y

Go to step 12.

N

Go to step 7.


2.1.1-28

Benni Mini 2013.01


7.Measuring the wheel/tire runout value

A.Measure the wheel with over 1.14 mm radial and

crosswise runout. Mark the positons of tire bolts

and relative bolt holes before removing wheel.

Remove wheel and install it on the tire balance

machine to measure runout value. The radial and

crosswise runout of the wheels and tires must be

less than 1.14 mm.

Whether the measuring value is in the specifica-

tion?

Y

Go to step 10.

N

Go to step 8.

8.Match the mounting position

A.Mark the highest runout position of tire and wheel.

Exhaust the air in tire and rotate for 180°. Charge

the tire and mesure its runout value.

Whether the runout positon of tire and wheel is

coincident?

Y

Carry out the tire dynamic balance.

N

If the twice runout top value is out of 101.6 mm,

replace the tire. If the value is in 101.6 mm,

Go to step 9.

9.Measure the wheel runout

A.Remove the wheel cover tyre and install it on the tire

balance machine. Measure the runout of the wheel

inner/outer edge. The runout of crosswise and

radial should be less than 1.14 mm.

Whether the runout is normal?

Y

Go to step 10.

N

Replace the wheel. Inspect the runout of new

wheel. If the runout of new wheel is in regualted

range. Search and mark the lowest point of runout.

Installing the tire and make the highest runout point

and lowest runout point match. Balance the wheel.


Benni Mini 2013.01


10.Inspect the radial runout of rear wheel hub and wheel bolt

A.Measure the hub flange runout (beyond 0.254 mm),

and the wheel bolt circle runout (beyond 0.08 mm).


tion?

Y

Go to step 11.

N

Replace the rear wheel hub.



11.Inspect the circle runout of front wheel hub and wheel bolt

A. Remove the front wheels.

B.Remove the brake disc.

C.Measure the radial runout of wheel bolt circule

(beyond 0.06 mm).


tion?

Y

Inspect the runout of brake disc.

Refer to: Brake Disc Runout Inspection

(2.3.1 Brake System - General Informa-


N

Replace the wheel hub.



12.Balance wheel

A.Balance the wheel. Road test.

Whethter the vehicle vibrates?

Y

Repair.

Refer to: (1.1.5 Noise, Vibration and

Harshness).

N

Confirm the repair.


2.1.1-30

Benni Mini 2013.01


Incorrect Tire Wear Diagnosis


1. Inspect the tire wear

A.Lift the vehicle.



B.Inspect the tire wear.

Whether the two front wheels are excessively

worn?

Y

Swap the wheel and replace them if necessary.

N

Go to step 2.

2. Inspect the tire

A.Inspect the tire pressure and type.

Whether the tire pressure is normal or tire type are

the same?

Y

Go to step 3.

N

Replace the tire in different type and adjsut the tire

pressure.

Refer to: General Specifications (2.1.4

Wheels and Tires, Specifications).

3.Inspect the wheel

A.Inspect whether the wheels are twisted.

B.Inspect the wheel runout.

Refer to: Wheel Runout Inspection (2.1.4

Wheels and Tires, General Procedures).

Is the runout nromal?

Y

Go to step 4.

N

Adjust or replace the wheel.

Benni Mini 2013.01


4.Inspect the wheel balance

A.Lift the vehicle.



B.Remove the tires.

C.Inspect the wheel balance on the balance machine.

Whether the wheel balance is normal?

Y

Go to step 5.

N

Balance the wheel and replace it if necessary.


A. Inspect the wheel alignment.

Whether the alignment parameter meets the speci-

fication?

Y

Go to step 6.

N

Adjsut the wheel alignment parameter.

6.Inspect the front and rear suspension components

A.Inspect whether the bolts of the front suspension is

tightened.

B.Inspect whether the front control arm bushing and

the stabilizer bar bushing crack, loose and lack.

C.Inspect whehter the front suspension ball joint

loose.

D.Inspect whether the bolts of the rear suspension is

tightened.

E.Inspect whether the rear suspension bushing

cracks, loose and lacks.

Whether the front and rear suspension components

are normal?

Y

Go to step 7.

N

Fix the front and rear suspension fault.


2.1.1-32

Benni Mini 2013.01


7.Inspect the rear wheelbase

A.Inspect the wheelbase at both sides of vehicle.

Whether the wheelbase at both sides are the

same?

Y

Check the vehicle load state and drive habit, correct

overload and incorrect drive habit.

N

Cavibrate the left and right wheel tread.


Benni Mini 2013.01

2.1.2-1 2.1.2-1Front Suspension

Specifications

Torque Specifications

Item Nm lb-ft lb-in

Steering rod ball joint retaining nut 42 31 -

Front stabilizer bar assembly to front con-

trol arm assembly connecting nut92 68 -

Front stringer lower bracket assembly to

raidator lower beam assembly connecting

nut

72 53 -


front cabin lower base connecting bolt72 53 -


front cabin lower base connecting nut

Front control arm ball joint pin to steering

knuckle connecting bolt50 37 -

Front control arm assembly to arm mount-

ing plate connecting bolt72 53 -

Wheel nut 85 63 -

Wheel hub retaining nut 275 203 -

Front strut to vehicle body connecting nut 37 27 -

Front strut to steering knuckle connecting

bolt and nut88 65 -

2.1.2 Front Suspension

2.1.2-2

Benni Mini 2013.01

2.1.2-2Front Suspension


System Overview

Front suspension is consisted of two front strut assemblies (including shock damping spring), front con-

trol arm assembly and stabilizer bar assembly.

Front control arm is welded by pressing the steel plate. Every piece is connected with bolt and control

arm mounting plate. The end of stablizier bar cross it and tighten with bolt.

Front control arm is connected with steering knuckle by ball joint.

Wheel steering kuncle is connected with suspension assembly and steering rod ball joint.

Front suspension is supported on upper mounting place with the rubber bushing over the top seat of

strut. Coil spring is mounted between two spring seats on suspension. Cylinder bar has a dust boot to

prevent from dirt and water. A cushion is mounted to pretect suspension in completed pressing state.

Location View

Front Suspension Assembly View

3

2

1

5

6

4

A2102001

Benni Mini 2013.01


Item Description Item Description

1 Front strut assembly 4 Front control arm

2 Front stabilizer bar 5 Halfshaft

3 Coil spring 6Front stabilizer bar mounting bracket

assembly

2.1.2-4

Benni Mini 2013.01


Exploded View

Front Suspension Exploded View 1

Item Description Qty.

1 Hexagon flange bearing surface toothed nut 2

2 Front strut assembly 1

3 Hexagon flange bolt 2

4 Hexagon flange bearing surface toothed nut 2

3

2

1

4

A2102002

Benni Mini 2013.01




1 Hexagon head bolt 1

2 Steering knuckle 1

3 Hexagon flange nut 1

4 Small washer 1

5 Light spring washer 1

6 Hexagon head bolt 1

7 Bushing 1

8 Front control arm assembly 1

9 Clamp 1

10 Dust cover 1

3

2

1

10

9

7

6

8

4

5

A2102003

2.1.2-6

Benni Mini 2013.01




1 Front control arm assembly 1

2 Front control arm retaining rubber bush 2

3 Hexagon head bolt and spring washer 4

4 Front control arm mounting bracket assembly (Right) 1

5 Front control arm connecting rubber bush 4

6 Front control arm connecting rubber bush washer 2

7 Hexagon slotted nut 1

8 split pin 2

8

3

1

3

4

6

2

5

5

7

A2102004

Benni Mini 2013.01



Refer to: Symptom Chart (2.1.1 Suspen-

sion System - General Information, Symp-

tom Diagnosis and Testing).

2.1.2-8

Benni Mini 2013.01



Strut and Spring Assembly

Disassembly

1. Use the coil damping spring compression tool

to press the coil spring partly.

CAUTION: Be careful to the coil spring in

extremely pressed state to avoid injury.

A2102023

Benni Mini 2013.01


Assembly

2. Disassemble the front shock absorber and

the coil spring

1. Remove the nuts.

Torque: 54 Nm

2. Remove the flat washer.

3. Remove the spring washer.

4. Remove the inner adapter sleeve assembly.

5. Remove the outer adapter sleeve assembly.

6. Remove the flat washer.

7. Remove the backup washer.

8. Remove the bearing.

9. Remove the fitting seat assembly.

10. Remove the spring washer.

11. Remove the coil spring.

12. Remove the anti-collision cushion.

13. Remove the front shock absorber assembly.

1. To assemble, reverse the disassemble

procedure.

CAUTION: Put spring end on spring seat

correctly.

2. Aligning wheels.

2

4

6

8

10

13

12

9

7

5

3

1

11

A2102024

2.1.2-10

Benni Mini 2013.01


Removal and Installation

Front Control Arm

Removal

Installation

1. To install, reverse the removal procedure.

1. Remove the wheel.

Refer to: Wheel and Tire (2.1.4 Wheels and

Tires, Removal and Installation).




3. Remove the stabilizer bar opening nut.

1. Remove the cotter pin.

2. Remove the stabilizer bar opening nut.

Torque: 92 Nm

4. Remove both sides of the stabilizer bar

rubberbush and the stabilizer bar seat

retaining bolts.

Torque: 72 Nm

5. Detach the front stabilizer bar.

6. Remove the retaining bolt (1) between the

front control arm and the steering knuckle.

Torque: 50 Nm

7. Remove the retaining bolt (2) between the

front control arm and the body bracket.

Torque: 72 Nm

8. Detach the front control arm.

A2102005

1

2

A2102006

Benni Mini 2013.01


Steering Knuckle

Removal

Special Tool

Ball Joint Puller

CA201-001







3. Remove the front wheel speed sensor and

the brake hose from the front strut assembly.

4. Remove the retaining bolt of the front wheel

speed sensor, and detach the wheel speed

sensor.

Torque: 15 Nm

CA201-001

A2102008

×2

A2102015

2.1.2-12

Benni Mini 2013.01


5. Remove the tie rod ball joint and the stabilizer

bar.

1.Detach the cotter pin and remove the tie rod

ball joint retaining nut.

Torque: 48 Nm

2.Detach the cotter pin and remove the stabi-

lizer bar retaining nut.

Torque: 92 Nm

CAUTION: Use soft cloth to protect the

ball joint to avoid damage.

6. Remove the front stabilizer bar assembly.

1.Remove both sides of the stabilizer bar seat

retaining bolts.

Torque: 72 Nm

2.Detach the front stabilizer bar assembly.

7. Remove the halfshaft retaining nut.

Torque: 275 Nm

8. Detach the front arm ball joint from the

steering knuckle.

1.Remove the retaining nut of the front arm

ball joint.

Torque: 50 Nm

2.Detach the front arm ball joint from the

steering knuckle.

9. Pull out the halfshaft from the steering

knuckle with a puller.

21

A2102010

1

2

A2202020

2

1

A2202021

A2102016

A2102013A2202022

Benni Mini 2013.01


Installation


10. Remove the brake caliper.

Refer to: Brake caliper (2.3.3 Front disc

brake, Removal and Installation).

11. Remove the brake disc.

Refer to: Brake Disc(2.3.3 Front disc


12. Remove the front strut assembly and the

steering knuckle bolt and nut.

Torque: 88 Nm

13. Detach the steering knuckle from the front

strut assembly.

A2102014

2.1.2-14

Benni Mini 2013.01


Bearing

Removal



Tires,Removal and Installation).

2. Remove the steering knuckle.

Refer to: Steering Knuckle (2.1.2 Front


3. Remove the hub.

CAUTION: Press out the hub using proper

removal tools, and do not damage the

spline in the hub.

4. Remove the snap ring.

5. Remove the bearing.

A2102017

A2102018

A2102019

Benni Mini 2013.01


Installation

1. Install the bearing.

CAUTION: Install the bearing into the

steering knuckle using proper installation

tools and ensure the force point of the

bearing is the bearing outer ring when

pressing it, otherwise it will damage it.

2. Install the snap ring.

3. Install the hub.

CAUTION: Install the hub into the bearing

using proper installation tools and ensure

the force point of the bearing is the

bearing inner ring when pressing the hub,

otherwise it will damage the bearing. After

installation in place, turn the hub and

there should be no jam.

4. Install the steering knuckle.

Refer to: Steering Knuckle (2.1.2 Front


5. Install the wheel.


Tires,Removal and Installation).

6. Align wheels.

A2102020

A2102021

A2102022

2.1.2-16

Benni Mini 2013.01


Front Strut Assembly

Removal

Installation








3. Remove the front wheel speed sensor and

the brake hose from the front strut assembly.

4. Remove the front strut and the steering

knuckle clevis bolt and nut.

Torque: 88 Nm

5. Detach the steering knuckle from the front

strut.

6. Remove the two retaining nuts on the front

strut and detach the front strut assembly.

Torque: 37 Nm

A2102008

A2102014

A2102007

Benni Mini 2013.01

2.1.3-1 2.1.3-1Rear Suspension

Specifications


Item Nm lb-ft lb-in

Rear shock absorber to body connecting

bolt88 65- -

Rear shock absorber to rear axle connect-

ing bolt88 65- -

Brake hose connector 16 12 -

Wheel nut 85 63 -

Wheel shaft retaining bolt 220 162 -

Longitudinal control arm to rear axle con-

necting bolt88 65 -

Longitudinal control arm to body connect-

ing bolt88 65 -

Stabilizer bar to body connecting bolt 45 33 -

Stabilizer bar to rear axle connecting bolt 45 33 -

Rear brake to rear axle assembly con-

necting bolt42 31 -

ABS rear wheel speed sensor head to

rear axle flange9 - 80

Brake hose M10 thread connecting 16 12 -

Brake hose M12 thread connecting 18 13 -

2.1.3 Rear Suspension

2.1.3-2

Benni Mini 2013.01

2.1.3-2Rear Suspension


System Overview

Rear suspension is twisting beam semi-independent suspension and consisted of coil spring, rear axle,

rear shock absorber, stabilizer bar and longitudinal control arm. The stabilizer bar is installed on the body

and the rear axle by a bushing to prevent the rear axle from transverse motion. The rear shock absorber

is installed between the body and the rear axle to slow down the vertical motion of the body.

Benni Mini 2013.01


Location View

Rear Suspension Assembly View


1 Longitudinal control arm 4 Stabilizer bar

2 Rear shock absorber assembly 5 Coil spring

3 Rear axle assembly 6 Rear brake assembly

6

2

1

5

4

3

A2103001

2.1.3-4

Benni Mini 2013.01


Exploded View

Rear Suspension Exploded View

24

Item Description Qty. Item Description Qty.

1 Rear suspension upper sping seat 2 13 Hexagon flange bolt M12×1.25×100 2

2 Rear suspension cushion 2 14Hexagon flange bearing surface

toothed nut M12×1.251

3Hexagon flange bearing surface

toothed nut M12×1.252 15 Longitudinal control arm (R) 1

4 Left rear shock absorber 1 16Hexagon flange bearing surface


5 Hexagon flange nut M12×1.25 1 17 Hexagon flange bolt M12×1.25×90 2


toothed nut M12×1.252 18 Hexagon flange bolt M12×1.25×90 1

7 Hexagon flange bolt M12×1.25×55 1 19 Washer 12 1

8 Hexagon flange bolt M12×1.25×90 2 20Hexagon flange bearing surface


9 Longitudinal control arm (L) 1 21 Rear suspension spring 2


toothed nut M12×1.251 22 Right rear shock absorber 1

11 Washer 2 23Hexagon flange bearing surface


18

17

4

7

1

2

8

14

16

20

19

109

11

23

22

621

5

3

1513

12

24

A2103002

Benni Mini 2013.01


12 Spring washer 2 24 Stabilizer bar 1


2.1.3-6

Benni Mini 2013.01



Refer to: Symptom Chart (2.1.1 Suspen-

sion System - General Information, Symp-


Benni Mini 2013.01



Rear Axle

Removal







3. Detach the brake hard pipes and the brake

hoses.

1.Detach the E-ring fastening brake hose.

2.Remove the brake hose and the brake hard

pipe joint.

Torque: 16 Nm

CAUTION: Plug the brake hose to avoid

dirt entering after detaching.

CAUTION: Drain the brake fluid into a suit-

able container.

CAUTION: The brake fluid is not allowed

to reach the painting surface.

4. Remove the brake bottom plate.

Refer to: Brake Bottom Plate (2.3.2 Rear

Drum Brake, Removal and Installation).

5. Support the rear axle with a jack.

A2103006

A2103003

2.1.3-8

Benni Mini 2013.01


6. Remove the lower retaining bolts of both rear

shock absorbers.

Torque: 87.5 Nm

7. Remove the stabilizer bar connecting nut to

the rear axle assembly .

Torque: 45 Nm

8. Loosen the trailing arm connecting nut to the

rear axle, but do not detach the connecting

bolt.

Torque: 87.5 Nm

A2103009

A2103012

A2103013

Benni Mini 2013.01


Installation

9. Lower the rear axle by adjusting the jack

gradually until the rear coil spring can be

removed.

10. Support the rear axle, appropriately lift the

jack, remove the trailing arm and the rear axle

connecting bolt.

11. Detach the rear axle from the chassis.

CAUTION: Only when the vehicle weight is

beared by wheels, the rear suspension

parts can be tightened finally.

CAUTION: Make the spring end fit the stair

portion of the rear axle spring seat when

installing the coil spring.

CAUTION: Avoid fingers crushed by

spring.


2. Bleed the brake system.

Refer to: Brake System Bleeding (2.3.1

Brake System - General Information, Gen-

eral Procedures).

3. Adjust the parking brake cable.

Refer to: Parking Brake Cable Adjustment

(2.3.4 Parking Brake and Control, General

Procedures).

A2103011

A2103003

2.1.3-10

Benni Mini 2013.01


Rear Wheel Bearing

Removal







3. Remove the brake drum.

Refer to: Brake Drum (2.3.2 Rear Drum

Brake, Removal and Installation).

4. Remove the grease seal cover.

5. Burst through the rear wheel bearing

retaining nut insurance using proper tools.

A2103015

A2103016

Benni Mini 2013.01


Installation

6. Remove the rear wheel bearing retaining nut

and detach the rear wheel bearing.

Torque: 220 Nm

CAUTION: Insure the rear wheel bearing

retaining nut insurance using proper

tools.





Procedures).

A2103017

2.1.3-12

Benni Mini 2013.01


Rear Shock Absorber Assembly

Removal

Installation






3. Remove the lower mounting nut of the rear

shock absorber.

Torque: 88 Nm

A2103003

A2103014

Benni Mini 2013.01


Stabilizer Bar

Removal

Installation


1. Remove the stabilizer bar and the left rear

axle connection.

1.Remove the stabilizer bar left connecting

bolt.

2.Remove the stabilizer bar right connecting

bolt and detach the flat washer.

Torque: 45 Nm

3.Detach the stabilizer bar.

21

A2103023

2.1.3-14

Benni Mini 2013.01


Trailing Arm

Removal

Installation






3. Remove the rear shock absorber assembly.

Refer to: Rear Shock Absorber Assembly

(2.1.3 Rear Suspension, Removal and

Installation).

4. Release the trailing arm 2 connecting nuts to

the rear axle , and detach the connecting bolt.

Torque: 87.5 Nm

5. Release the trailing arm connecting nut to the

vehicle body , and detach the connecting bolt.

Torque: 87.5 Nm

A2103003

×2

A2103008

A2103018

Benni Mini 2013.01

2.1.4-1 2.1.4-1Wheels and Tires

Specifications



Item Specification

Tire specification

Aluminum wheel 175/60 R13

Steer wheel with decorative

cover155/65 R13

Front tire pressureNon-load 210 kPa

Full load 230 kPa

Rear tire pressureNon-load 230 kPa

Full load 230kPa

Item Nm lb-ft lb-in

Wheel bolt 85 63 -

2.1.4 Wheels and Tires

2.1.4-2

Benni Mini 2013.01

2.1.4-2Wheels and Tires


System Overview

Tire Identification

The tire type, size, load and speed level are

coded with letters and numbers and printed on

the side wall of tire. Refer to “Tire Identification

Chart” to interpreate code. P155 / 65 R 13 73T is

used as an example. As for all-weather tire, M +

S, M&S or M-S (means mire and snow traction)

are printed on side wall. Overload and lightload

marks of “XL”or “LL” are possibly printed on the

tire side wall. The tire without “XL” or “LL” sign

can be identified as standard load tire.

Tire Identification Chart

Height/width radio = Height(2) ÷ Width(1)

P

Tire type

(available for some

tires)

P - Passenger

car

T - Spare tire

C - Commercial

vehicle

LT - Light truck

155 End face width In mm

65 Height-width ratioEnd face height/

end face width

R Structural typeR - Radial

B - Bias

13 Wheel diameter In inch

73 Load level

Consult the tire

manufacturer for

details

T Speed level

Consult the tire

manufacturer for

details

1

2

A2104001

Benni Mini 2013.01


Exploded View


1 Steel wheel cover assembly 1 6 Wheel centre cover 1

2 Combination bolt 1 7 Wheel nut 4

3 Steel wheel 1 8 Aluminium alloy wheel 1

4 Tire 155/65 R13 1 9 Tire 175/60 R13 1

5 Steel wheel balance block 1

2

3

4

6

89

5

7

1

A2104002

2.1.4-4

Benni Mini 2013.01


General Procedures

WARNING: It is forbidden to install the

tires with different types on the same vehi-

cle except in emergency (temporary use),

such as radial tire, bias tire and bias cord

tire.

WARNING: It is forbidden to start the

engine when replacing tires. Vehicle may

move if the wheels touch the ground.

WARNING: The tire sealant is inflammable.

Remind cutomers not use this kind of

materials.

WARNING: Wear safety goggles and veil in

the maintenance of wheel and tire assem-

bly.

WARNING: After replacing wheel and

wheel bolt becomes loose, tightened them

after driving for 800 km.

WARNING: Make sure to tighten wheel bolt

in regulated mileage, otherwise, the wheel

could leave from vehicle body in driving.

WARNING: Wheel shaft, wheel and tire all

have maximum weight. Overload is forbid-

den.

WARNING: It is forbidden to use wire wool

to grind the wheel. Use abluent to clean

aluminium alloy wheel.

WARNING: Before removing tire valve,

lower tire air pressure first.

Failure to follow above instructions may result in

personal injury.

Inspection and Identification

In order to get the best effect, inspect whether

the wheel pressure and wheel are normal. If

these evidences appear, it indicates that

dynamic balancing, exchange or front wheel

alignment is required. Regularly inspect whether

there is score, scrape, wear, sparging and any-

thing inserted in tire tread. If the temperature of

wheel rises rapidly or minces spread on rough

road surface, inspect the wheel more frequently.

The tire wear indicator at the bottom of tread can

be regarded as direct inspection of tire situation.

When tire wear indicator exposes, replace the

tire.

Tire Wear Diagnosis

When tire wear indicator exposes or tire shoul-

der seriously wears, the tire should be replaced.

Tire shoulder wear is always caused by too large

meridian tire camber angle or wheel toe-in.

Some times, incorrect rear wheel toe-in or dam-

aged standing pillar will cause the serious

“unken” and “ector” wear of undriving wheel.

Serious incorrect rear wheel toe-in will cause

other abnormal wear.

Wheel Runout Inspection

Use dial indicator gauge to measure wheel run-

out capacity on and off the vehicle. Make sure

installation surface is correct. The measurement

can be availiable after tire installation and with-

out tire installation. Measure radial runout and

end face runout in the inner side and outer side

of wheel flange. Fix dial indicator gauge on the

side of wheel and tire assembly, slowly rotate

wheel for a circle and record the read of dial indi-

cator gauge. If runout exceeds the following

specification, and the vibration can not be fixed

after wheel balance, replace the wheel.

Wheel

TypeRadial Runout

End Face

Runout

Steeliness 0.7 mm 0.9 mm

Aluminium 0.5 mm 0.5 mm

33

21

A2104003

Benni Mini 2013.01


Initial Inspection Before Wheel Alignment

Inspection Operation

Inspect whether tire type and wheel type are in

accordance.Inspect tire and wheel, replace them if necessary.

Inspect whether tire pressure and tire tread

wear are normal.

Charge tire with correct pressure. Replace wheel if neces-

sary.

Inspect whether wheel bearing looses.Tighten axle nut to the correct specification. Replace column

wheel bearing if necessary.

Inspect whether ball joint and steering tie rod

loose.Tighten ball joint and steering tie rod.

Inspect wheel and tire runout. Measure and calibrate tire runout.

Inspect the vehicle gross height. Calibrate the gross height. Calibrate before adjuting toe-in.

Inspect rear wheelbase. Calibrate rear wheelbase.

Inspect whether rack and small gear loose. Tighten mounting bracket of rack and small gear.

Inspect whether column operation is incorrect. Replace column assembly.

Inspect whether control arm looses.Tighten control arm joint bolt. Replace control arm bushing if

necessary.

2.1.4-6

Benni Mini 2013.01


Tire Wear Inspection

Symptom Cause

•Tire shoulder rapid wear•Insufficient inflation tire

•Not swap the tires

•Central rapid wear •Exessive inflation tire

•Not swap the tires

•Tire tread cracks

•Insufficient inflation tire

•Too high speed

A2104004A2104005

A2104006 A2104007

A2104008

Benni Mini 2013.01


Solution: Adjust pressure and swap tires according to the specification when tire is cold.

Single side wear •Too large camber

Solution: Adjust the camber to the specification.

•Feather wear •Incorrect toe-in

Solution: Adjust the toe-in to the specification.

•Small flower pattern polishing •Unbalanced wheel

•Tire defect

Symptom Cause

A2104009A2104010

A2104011 A2104012

A2104013 A2104014

2.1.4-8

Benni Mini 2013.01


Solution: Tire dynamic balancing.

•Large wear of edge flower pattern

•No swap tires

•Suspension worn and needs adjustment

Solution: Swap tires.

Solution: Adjust or repair suspension.

Symptom Cause

A2104015

Benni Mini 2013.01



Special Equipments

Inspection and Verification

Inspect whether the tire pressure and wheel are

abnormal to ensure the maximum efficiency of

the tire in running. Such phenomena prove that

the tire shall be adjusted on its dynamic balance,

wheel exchange or front wheel alignment. It is

necessary to inspect whether the tire has cuts,

scratches, blisters and inserts regularly. If the

tire is usually running on rough road surface with

obstructions or easily heated up within a short

period time, more frequent inspections shall be

conducted.

A tire indicator line is marked at the bottom of

the tire to inspect the tire more visually. The tire

shall be replaced when the tire wear indicator

line is exposed.

Tire Wear Diagnosis

When tire wear indicator exposes or tire shoul-

der seriously wears, the tire should be replaced.

Tire shoulder wear is always caused by too large

meridian tire camber angle or wheel toe-in.

Some times, incorrect rear wheel toe-in or dam-

aged standing pillar will cause the serious

“unken” and “ector” wear of undriving wheel.

Serious incorrect rear wheel toe-in will cause

other abnormal wear.

Road Test

The tire vibration diagnosis starts from road test.

Communicate with the customer (if possible) for

more information about vibration sources.

Road test should be carried out on flat ground.

Pay attention to and record the following items if

vibration appears.

• The vehicle speed when vibration

appears.

• The vibration types in all speed range.

• Mechanical or items can be heard.

What influence happens to the vibration when

the following conditions change:

• Engine torque

• Vehicle speed

• Engine speed

Vibration Type:

• Sensibility: Torque sensibility, vehicle

speed sensibility, engine speed

sensibility.

The following explanations are useful to differen-

tiate the vibration sources.

1. Torque sensitivity

It means the situations will become better

or worse due to acceleration, deceleration,

coasting, constant speed and engine torque.

2. Vehicle speed sensitivity

It means the vibration always appears at the

same vehicle speed and will not be

influenced by engine torque, engine speed or

gear position.

3. Engine speed sensitivity

It means the vibration appears at the speed in

different gears. This can be tested by

increasing or decreasing engine speed in

natural position or tested when the gear box

stalls. If the symptom is caused by engine

speed, it may have nothing to do with the tire.

If tire makes sob sound in road test but no

vibration and shake, the noise may be

caused by the contact between tire and road

surface.

Large noise indicates a flat tire or something

soft contacting the road surface. The sob

sound of tire will be regarded as axle noise by

mistake. The tire sob could continously sound

at a certain vehicle speed.

Four-wheel alignment device

Tire balance machine

Tire replacer

2.1.4-10

Benni Mini 2013.01


Symptom Chart

If there is symptom but no diagnosis trouble code (DTC) is stored in control module and can not con-

firm symptom reasons in the regular inspect, it is necessary to fix the fault in the order listed in the fol-

lowing chart.


Tire wear diagnosis

•Tire swap

•Tire pressure

•Wheel distortion

•Tire unlalanced

•Wheel alignment

•Suspension components

•High speed driving

•Rear axle

•Overload

• Incorrect operation habit

Refer to: Incorrect Tire Wear

Diagnosis (2.1.1 Suspension

System - General Informa-

tion, Symptom Diagnosis and

Testing).

Benni Mini 2013.01


Vibration caused by wheel

and tire

•Tire pressure too high •Adjust tire pressure.

•Unbalancing wheel or tire •Balance wheel and tire assembly.

•Uneven wear of tire•Install new tire if necessary to avoid

vibration.

•Unbalancing brake disc

•Inspect whether there is soil or pieces

on brake disc. If brake disc is not dam-

aged or there is no pieces, brake disc

may be covered by a lot of dirts.

•Water in tire •Drain water.

•Wheel distorted

•Install a new wheel. Repairing the

wheel could cause crack and reduce

the strength of wheel.

•Correct tire edge assembly

•Rotate the wheel on the vehicle.

Inspect the joint of tire and wheel. If

the parts swing in rotation, it means

that the wheel and tire are not assem-

bled very well. Remove tire and clean

the joint of wheel and tire.

•Wheel or tire radial runout too large

•Measure radial runout of tire and wheel

with dial indicator gauge. If the radial

runout is out of specification, inspect

the radial runout of wheel bolt.

Replace the wheel bolts if the runout is

out of specificiation.

•Wheel bolt looses or damaged or

wheel bolt hole enlarges.

•Tighten or replace components if nec-

essary.

•Foreign materials between mounting

surfaces of the wheel and wheel hub•Clean mounting surface.

•Wheel or tire radial runout too large

•Measure radial runout of tire and wheel

with dial indicator gauge. If the radial

runout is out of specification, inspect

the radial runout of wheel bolt.

Replace the wheel bolts if the runout is

out of specificiation.

•Front wheel bearing damaged

•Replace front wheel bearing.

Refer to: Front Wheel Hub

(2.1.4 Wheels and Tires,



2.1.4-12

Benni Mini 2013.01



Wheels and Tires

Removal

Installation


1. Loosen the wheel retaining nut in

anticlockwise direction.




3. Remove the wheels and tires.

Torque: 85 Nm

CAUTION: Do not heat to loosen the

blocked wheel nut. Heating may damage

wheel and wheel hub.

CAUTION: Clean the rusty stain and dust

on wheel, wheel hub and installation sur-

face of brake disc. All of these may loosen

wheel bolt and wheel in driving. Failure to

follow the instructions may cause per-

sonal injury.

×4

A2104016

Benni Mini 2013.01

Driveline System

2.2 Driveline System

2012 Benni Mini

2.2.1Driverline System - General Information


System Overview...................................................................................................................... 2.2.1-1


Driveshaft Inspection ................................................................................................................ 2.2.1-2

Driveshaft Oil Seal Inspection .................................................................................................. 2.2.1-2



Symptom Chart......................................................................................................................... 2.2.1-3

Driveshaft Noises ..................................................................................................................... 2.2.1-4

Clunk Noises at Acceleration After Neutral Position Coasting ................................................. 2.2.1-6

Shudder or Vibration During Acceleration ................................................................................ 2.2.1-7

Driveshaft Pullout ..................................................................................................................... 2.2.1-8

Driveshaft Swing....................................................................................................................... 2.2.1-9

Vehicle Shimmy At Low Speed............................................................................................... 2.2.1-10

2.2.2 Driveshaft

Specifications ................................................................................................................................... 2.2.2-1

Material specifications .............................................................................................................. 2.2.2-1

Capacity.................................................................................................................................... 2.2.2-1



System Overview...................................................................................................................... 2.2.2-2

Cautions for Halfshaft ............................................................................................................... 2.2.2-2

Exploded View.......................................................................................................................... 2.2.2-3


Disassembly and Assembly ............................................................................................................. 2.2.2-5

Inner Constant Velocity (CV) Joint and Rubber Boot ............................................................... 2.2.2-5

Outer Constant Velocity (CV) Joint and Rubber Boot............................................................... 2.2.2-8

Removal and Installation................................................................................................................ 2.2.2-12

Left-Hand Halfshaft................................................................................................................. 2.2.2-12

Right-Hand Halfshaft .............................................................................................................. 2.2.2-14


Benni Mini 2013.01

Driveline System

2.2.3 Differential

Specifications ...................................................................................................................................2.2.3-1

General Specifications ..............................................................................................................2.2.3-1



Exploded View ..........................................................................................................................2.2.3-2



Differential.................................................................................................................................2.2.3-4

Benni Mini 2013.01

2.2.1-1 2.2.1-1Driverline System - General Information


System Overview

Driveline system is of FF design and the differen-

tial is installed in the transmission assembly.

Driveshafts transfer power from the gearshift to

the front wheel. Each driveshaft assembly are

consisted of inner constant velocity (CV) joint and

outer constant velocity joint that connect to the

driveshaft. The inner constant velocity joint has

perfect flexibility and it can expand to the inside

and the outside. The outer constant velocity joint

is also flexible but can't be expanded. A male

spline is on the inner end of both driveshafts. This

male spline is interlocking with the gearshift drive-

shaft through clamp ring.

2.2.1Driverline System - General Information

2.2.1-2

Benni Mini 2013.01

2.2.1-2Driverline System - General Information

General Procedures

Driveshaft Inspection

1. Inspect and verify the outer ball joint has no

oversize end play.

2. Inspect and verify the inner ball joint steady

slide along the thrust direction.

3. Inspect and verify the inner ball joint has no

oversize radial end play.

4. Inspect whether the rubber boots are

damaged.

5. Inspect the snap ring at transmission side.

Driveshaft Oil Seal Inspection

1. Inspect whether the oil seal lip and the seal

spring are damaged.

2. Inspect whether the joint surface of the

driveshaft and oil seal is unsmooth for rust,

scratch, burr or other anomalies.

3. Inspect the transimission side oil seal

installation surface for rust, scratch, burr or

other anomalies.

A2201001

Benni Mini 2013.01




1. Verify customer concerns.

2. Visually inspect whether there is obvious mechanical damage.

3. If the inspection shows obvious evidence of the problem, the fault symptom should be cleared before

the next step.

4. If the visual inspection is ok, confirm the fault and go to the symptom chart.

Symptom Chart


Driveshaft noises

•Inadequate or contaminated

lube in driveshaft CV joint

Refer to: Driveshaft Noises

(2.2.1 Driverline System - Gen-

eral Information, Symptom

Diagnosis and Testing).•Another component contacting

driveshaft assembly

Clunk noises when accelera-

tion after neutral position

coasting

•CV joint rubber boot crack or

damage

Refer to: Clunk Noises At

Acceleration After Neutral Posi-

tion Coasting (2.2.1 Driverline


Symptom Diagnosis and Test-

ing).

•CV joint wear or damage

Vibration at high speed

•Wheels out of balance •Wheels balance

•Large radial runout of front

wheel •Refer to driveshaft removal and installa-

tion•Incorrect installation of

driveshaftdriveshaft

Shudder or vibration during

acceleration

•Improper assembling height

caused too large angle of tripod

CV joint

Refer to: Shudder or Vibration

During Acceleration (2.2.1 Driv-

erline System - General Infor-

mation, Symptom Diagnosis

and Testing).•Driveshaft excessively worn or

damaged

Tripod joint or slip ball joint

pullout

•Driveshaft retainer snap ring

missing or not correctly seated in

the differential

•Replace the retainer ring

•Engine/transmission misposi-

tioned

•Inspect the engine mounting bracket

whether it is worn or damaged

•Subframe or chassis distort or

bend•Measure the chassis

•Front suspension component

worn or damaged

•Inspect whether the axle bushing is worn

or the components are distorted (stabilizer

bar, suspension arm and etc.) and replace

them if necessary

2.2.1-4

Benni Mini 2013.01


Driveshaft Noises

Clicking, popping or grinding

noises while driving

•Inadequate or contaminated

lube in driveshaft CV joint•inspect, clean and lubricate as necessary

•Another component contacting

driveshaft assembly•Inspect and repair as necessary

•Wheel bearings, brake, suspen-

sion or steering components

worn or damaged

•Inspect and repair as necessary

Driveshaft pullout

•The joint retainer snap ring of

driveshaft and transmission is

distorted

•Driveshaft distorted

•Front strut distorted

•Driveshaft retaining nut dam-

aged

Refer to: Driveshaft Pullout

(2.2.1 Driverline System - Gen-

eral Information, Symptom


Vehicle shimmy at low speed

•Wrong tire dynamic balance

•Wrong wheel alignment

•Wheel hub bearing damaged

•Driveshaft damaged

•Strut damaged

•Stabilizer bar and bushing wear

or damaged

Refer to: Vehicle Shimmy At

Low Speed (2.2.1 Driverline


Symptom Diagnosis and Test-

ing).

Testing Conditions Details/Results/Actions

1.Inspect whether the driveshaft contacting other components

A.Lift the vehicle.



B.Inspect whether the driveshaft is twisted by other

debris.

C.Inspect whether the driveshaft contacts other parts.

Normal or not?

Y

Go to step 2.

N

Troubleshooting.


Benni Mini 2013.01


2.Inspect the driveshaft rubber boot

A.Inspect whether the driveshaft rubber boot is

damaged.

B.Inspect whether the driveshaft rubber boot is

correctly installed.

C.Inspect whether there is leakage for the driveshaft

joint lubrication.

Normal or not?

Y

Go to step 3.

N

Troubleshooting.

3.Inspect the driveshaft

A.Remove the driveshaft.

B.Inspect the driveshaft.

Refer to: Driveshaft Inspection (2.2.1

Driveline System - General Information,

General Procedures).

Normal or not?

Y

Refer to: (1.1.5 Noises, Vibration and

Harshness).

N

Replace the driveshaft assembly.


2.2.1-6

Benni Mini 2013.01


Clunk Noises at Acceleration After Neutral Position Coasting

CAUTION: Clunk during accelerating-coasting or start from standstill, may caused by worn

or damage of the wheel driveshaft inner CV joint. This damage normally caused by grease

lacking and/or foreign matter and dirt in the CV joint. It is normally caused by cracking or

damage of the inner CV joint sealing boot.




damaged.



C.Inspect whether there is leakage for driveshaft joint

lube.

Normal or not?

Y

Go to step 2.

N

Troubleshooting.







C.Any seized or blocked CV joint shows potential

damage that may lead to breakdown.

Normal or not?

Y


Harshness).

N


Benni Mini 2013.01


Shudder or Vibration During Acceleration


1.Inspect the front strut assembly height

A.Inspect whether the front strut assembly is distorted.

Normal or not?

Y

Go to step 2.

N

Troubleshooting. Replace the front strut assembly

as necessary.

2.Inspect the arm ball

A.Inspect whether there is clearance or damage of the

arm ball.

Normal or not?

Y

Go to step 3.

N

Replace the lower arm ball.

3.Inspect the arm and each mounting bolt

A.Remove all the mounting bolts of the arm and

inspect for looseness.

B.Inspect each arm bushing for damage.

Normal or not?

Y

Go to step 4.

N

Troubleshooting. Replace the arm assembly as

necessary.



damaged.



C.Inspect whether there is leakage for driveshaft joint

lube.

Normal or not?

Y

Go to step 5.

N

Troubleshooting.

2.2.1-8

Benni Mini 2013.01


Driveshaft Pullout







Normal or not?

Y


Harshness).

N





damaged.



Normal or not?

Y

Go to step 2.

N

Troubleshooting.

2.Inspect the driveshaft and the snap ring at transmission side


B.Inspect the snap ring at transmission side.




Normal or not?

Y

Go to step 3.

N



Benni Mini 2013.01


Driveshaft Swing

3.Inspect the front strut

A.Inspect whether the front strut assembly is

deformed.

Normal or not?

Y


Harshness).

N

Replace the front strut assembly.

4.Inspect the driveshaft retaining nut

A.Inspect whether the driveshaft retaining nut is

damaged.

Normal or not?

Y


Harshness).

N

Replace the retaining nut.




damaged.



C.Inspect whether the driveshaft is bend or deformed.

Normal or not?

Y

Go to step 2.

N

Troubleshooting.


2.2.1-10

Benni Mini 2013.01


Vehicle Shimmy At Low Speed

2.Inspect the driveshaft and the snap ring at transmission side


B.Inspect the snap ring at transmission side.




Normal or not?

Y

Go to step 3.

N



1.Inspect the wheel

A.Inspect whether the wheel runout is normal.

Refer to: Wheel Runout Inspection (2.1.4

Wheels and Tires, General Procedures).

Normal or not?

Y

Go to step 2.

N

Troubleshooting.


A.Inspect whether the wheel alignment is normal.

Normal or not?

Y

Go to step 3.

N

Troubleshooting.


Benni Mini 2013.01




damaged.



C.Inspect whether the driveshaft is bend or deformed.

Normal or not?

Y

Go to step 4.

N

Troubleshooting.

4.Inspect the suspension system

A.Inspect the suspension system.

Refer to: (2.1.1 Suspension System - Gen-

eral Information, General Procedures).

Normal or not?

Y


Harshness).

N

Troubleshooting.


Benni Mini 2013.01

2.2.2-1 2.2.2-1Driveshaft

Specifications

Material specifications

Capacity


Item Specification

High-performance grease (color: black), CV joint G.A.Cpalex GTE

Other alternative grease Molybdenum disulfide

High-performance grease, outer CV joint 70±10 g

High-performance grease, inner CV joint 65±10 g

Item Nm lb-ft lb-in

Tie rod ball joint to steering knuckle

retaining nut48 35 -

Front arm ball joint to knuckle bolt nut 50 37 -

Wheel hub bearing fixing nut 275 200 -

Tire nut 85 63 -

Front strut and shock absorption spring

assembly retaining nut37 27 -

2.2.2 Driveshaft

2.2.2-2

Benni Mini 2013.01

2.2.2-2Driveshaft


System Overview

The halfshafts have constant velocity (CV) joints

at both ends.

• Inner CV joints (composed of constant

velocity ball, spider joint, cylindrical roller,

steel ball and universal joint housing) are

installed on the drive axle.

• Outer CV joints (composed of steel ball,

ball retainer and universal joint housing)

are installed to the wheel side.

• Inner CV joints are fixed on the

differential through differential spring ring.

• Outer CV joints are fixed on the wheel

hub bearing.

The halfshaft transmits torque from the engine to

the wheels. In order to be adaptive to the vertical

motion of the wheel and the engine, the halfshaft

is required to rotate by different lengths and

angles.

The tripode joints allow for changes in halfshaft

length during axial movements.

Cautions for Halfshaft

CAUTION: The constant velocity joints are

not allowed to just clamp the drive axle.

CAUTION: Be very carefully when remov-

ing, installing, disassembling or assem-

bling the drive axle. The following

instruction must be followed:

• Do not push-and-pull the CV joint when

removing the halfshaft.

• The operating angle of the CV joint must

not be bent more than 22.5 degrees.

• Check whether the polished surface and

the spline are damaged.

• The rubber boot is prohibited to contact

with sharp edge and a hot engine or

exhaust system.

• Do not drop the halfshaft, since it may

caused inner damage to the rubber boot

with no visual evidence from the outside

inspection.

• Do not use the halfshaft as pry tool during

the installation of other components. Do

not hang the halfshaft randomly.

• Knock on the tripod housing can cause

damage to the universal joint.

Front wheel balance

WARNING: When the vehicle is completely

lifted off the ground, using the portable

wheel balancer may result in damage to

the constant velocity joint or the rubber

boot, which is caused by too large a bent

angle of the universal joint.

Place the push-type jack below the lower

cross arm when using the portable wheel bal-

ancer to avoid too large a bend of the univer-

sal joint during vehicle lifting.

Conditions permitting, it would be best to

remove the wheel on the fixed wheel bal-

ancer.

Lifting the vehicle

WARNING: It is forbidden to use the

universal joint or the halfshaft as jack.

Drag the vehicle

CAUTION: it is forbidden to bind the rope

on the halfshaft.

Body bottom protection and rust pre-

vention

CAUTION: Cover the rubber boot when

carrying out the body bottom protection or

rust prevention treatment.

Dirt on the rubber boot makes the material

age in advance, while foreign matter on the

halfshaft will cause the imbalance of the half-

shaft.

Benni Mini 2013.01


Exploded View


1 Halfshaft retaining nut 13 Differential spring ring

2 Fixed end cage universal joint 14 Halfshaft retaining nut

3 Fixed end large clamp 15 Fixed end cage universal joint

4 Fixed end rubber boot 16 Fixed end large clamp

5 Fixed end small clamp 17 Fixed end rubber boot

6 Damper 18 Fixed end small clamp

7 Damper clamp 19 Left shaft lever

8 Right shaft lever 20 Moveable end small clamp

9 Moveable end small clamp 21 Moveable end rubber boot

10 Moveable end rubber boot 22 Moveable end large clamp

11 Moveable end large clamp 23 Axially moveable universal joint

12 Axially moveable universal joint 24 Differential spring ring

141516

21 20

19

1

2 3

4

6

9

810

13

5

7

12

11

24

23

22

18

17

A2202016

2.2.2-4

Benni Mini 2013.01

2.2.2-4Driveshaft


Refer to: Symptom Chart (2.2.1 Driveline

System - General Information, Symptom


Benni Mini 2013.01



Inner Constant Velocity (CV) Joint and Rubber Boot

Removal

Special Tool

Material

Halfshaft Rubber Boot

Clamp Remover

CA201-002


Clamp Installer

CA201-008

Item Model

High

performance

grease

G.A.Cpalex GTE

1. Remove the halfshaft.

Refer to: Left-Hand Halfshaft (2.2.2 Drive

shaft, Removal and Installation).

2. Remove the ball joint assembly.

1. Remove the rubber boot clamp with a spe-

cial tool.

Special Tool: CA201-002

2. Disassemble the ball joint assembly.

3. Clear the grease in the CV joint.

CA201-002

CA201-008

2

1

1

A2202001

2.2.2-6

Benni Mini 2013.01

2.2.2-6Driveshaft

Installation

3. Use a suitable tool to remove the tripod

universal joint snap ring.

4. Remove the inner constant velocity (CV)

joint rubber boot and clean the grease.

CAUTION: All the snap rings and clamps

should be replaced.

1. Install the rubber boot/tripod universal joint.

1. Install the rubber boot.

2. Install the tripod universal joint.

3. Install the tripod universal joint snap ring.

2. Add grease in the ball joint assembly.

3. Install the ball joint assembly.

A2202002

1

2

3

A2202004

A2202005

Benni Mini 2013.01


4. Install the rubber boot clamp with a special

tool.


CAUTION: The size of the clamp mouth C

should not be more than 1.5 mm.

CAUTION: The tightening torque for 0.8

mm thick clamp is 12 Nm, the tightening

torque for 1.1 mm thick clamp is 20 Nm.

5. Install the halfshaft.



C

A2202008

2.2.2-8

Benni Mini 2013.01

2.2.2-8Driveshaft

Outer Constant Velocity (CV) Joint and Rubber Boot

Removal

Special Tool


Clamp Remover

CA201-002


Clamp Installer

CA201-008

Item Model

High

performance

grease

2LN584/L0K575 GS

1. Remove the halfshaft.



2. Remove the rubber boot clamp.

1. Remove the rubber boot clamp with a spe-

cial tool.


2. Detach the rubber boot.

3. Clean the grease.

CA201-002

CA201-008

2

11

A2202009

Benni Mini 2013.01


3. Take out the retainer ball cage and the

supporter from the case.

1.Use a needle nose pliers to shove off the

snap ring.

2.Remove the constant velocity universal

joint with tapping a copper bar.

4. Take out the drive shaft from the universal

joint.

1.Take out the drive shaft 1 from the universal

joint.

2.Take out the snap spring 2 from the univer-

sal joint.

3.Take out the rubber boot 3.

5. Take out the steel ball from the ball cage.

1. Rotate the retainer ball cage.

2. Take out the retainer ball cage.

6. Take out the steel ball from the ball cage.

7. Check the wear on the moving surface.

CAUTION: Ensure the ball cage, the case,

the ball bearing and the supporter will not

contact the grease and oil.

A2202010

1

3

2

A2202011

2

1

A2202012

A2202013

2.2.2-10

Benni Mini 2013.01

2.2.2-10Driveshaft

Installation

CAUTION: All the snap rings and clamps

should be replaced.

1. Install the steel ball on the ball cage

supporter.

2. Install the retainer ball cage.

1. Install the retainer ball cage into the case.

2. Rotate the retainer ball cage.

3. Put the halfshaft into the CV joint.

1. Install the rubber boot and the inner clamp.

2. Insert a new snap ring in the halfshaft CV

joint groove.

3.Insert the halfshaft into the halfshaft CV

joint until it meshes the snap spring .

4. Fill the halfshaft outer CV joint with high-

performance grease.

A2202013

1 2

A2202014

A2202015

Benni Mini 2013.01

2.2.2-11 2.2.2-11Driveshaft

5. Install the rubber boot.

6. Install the rubber boot clamp with a special

tool.


CAUTION: The size of the clamp mouth C

should not be more than 1.5 mm.

CAUTION: The tightening torque for 0.8

mm thick clamp is 12 Nm, the tightening

torque for 1.1 mm thick clamp is 20 Nm.

7. Install the halfshaft.



C

A2202008

2.2.2-12

Benni Mini 2013.01

2.2.2-12Driveshaft


Left-Hand Halfshaft

Removal

Special Tool

Halfshaft Remover

CA201-006







3. Remove the halfshaft retaining nut.

Torque: 275 Nm

4. Remove the tie rod ball joint and the stabilizer

bar.

1.Detach the cotter pin and remove the tie rod

ball joint retaining nut.

Torque: 48 Nm

2.Detach the cotter pin and remove the stabi-

lizer bar retaining nut.

Torque: 92 Nm

CA201-006

A2202019

1

2

A2202020

Benni Mini 2013.01

2.2.2-13 2.2.2-13Driveshaft


1.Remove both stabilizer bar seat retaining

bolts.

Torque: 72 Nm

2.Detach the front stabilizer bar assembly.

6. Detach the front arm ball joint from the

steering knuckle.

1.Remove the retaining nut of the front arm

ball joint.

Torque: 50 Nm

2.Detach the front arm ball joint from the

steering knuckle.

7. Use a proper puller. Detach the driveshaft

from the wheel hub.

CAUTION: Protect the driveshaft to

prevent damage to the constant velocity

(CV) joint. The inner CV joint operating

angle must not be bent more than 22.5

degrees. The outer CV joint operating

angle must not be bent more than 45

degrees.

8. Place a suitable container under the

transmission.

9. Remove the driveshaft from the transmission

using a special tool skillfully.


CAUTION: If it's hard to remove the inner

ball cage form the transmission, do not

force to pry and pull it. At this point, put

the driveshaft back to the transmission,

rotate for 90 degrees to remove it.

2

1

A2202021

A2202022

A2202018

201-006

A2202023

2.2.2-14

Benni Mini 2013.01

2.2.2-14Driveshaft

Installation

1. Install the halfshaft to the transaxle.

CAUTION: Protect the halfshaft to prevent

damage to the constant velocity (CV) joint.

The inner CV joint operating angle must

not be bent more than 22.5 degrees. The

outer CV joint operating angle must not be

bent more than 45 degrees.

CAUTION: When inserting the driveshaft,

use the oil seal installer (provided with oil

seal) to protect the oil seal.

CAUTION: Make sure the retainer ring is

installed in the groove already when

installing a new retainer ring.

2. Install the halfshaft to the wheel hub bearing.

3. Install the arm ball joint.

4. Install the wheel hub retaining nut.

5. Replace the tie rod ball joint.


7. Install the wheel.



8. Tighten the left front strut retaining nut.

Right-Hand Halfshaft



A2202024

A2202025

Benni Mini 2013.01

2.2.3-1 2.2.3-1Differential

Specifications



Item Specification

Transmission oil type BOT130M, GL-4, 75W/90

Manual transmission oil capacity 2.1 ± 0.1 L

Item Nm lb-ft lb-in

Final drive driven gear fixed bolt 90 -

2.2.3 Differential

2.2.3-2

Benni Mini 2013.01

2.2.3-2Differential


Exploded View


1 Differential left bearing 9 Differential cover

2 Differential bolt 10 Induction gear

3 Final drive gear 11 Differential right bearing

4 Differential halfshaft washer 12 Planetary gear shaft pin

5 Differential halfshaft gear 13 Differential halfshaft gear

6 Planetary gear washer 14 Planetary gear

7 Planetary gear 15 Planetary gear washer

8 Planetary gear washer 16 Planetary gear shaft

12

11

15

16

1

2

3

4

5

8

6

9

10

7 14

13

A2203001

Benni Mini 2013.01



Refer to: Symptom Chart (2.2.1 Driveline



2.2.3-4

Benni Mini 2013.01

2.2.3-4Differential


Differential

Disassembly

1. Remove the vehicle speed sensor signal

gear.

CAUTION: Remove the induction gear ring

or bearing with a suitable tool.

CAUTION: Use the vise holder protector

all the time when using the vise.

2. Remove the final drive gear bolts to the

differential.

3. Remove the differential left bearing.

CAUTION: Remove the bearing with a

suitable tool.

CAUTION: Use the vise holder protector

all the time when using the vise.

A2203002

×8

A2203003

A2203004

Benni Mini 2013.01


4. Remove the planetary gear shaft pin.

CAUTION: Remove the planetary gear

shaft pin with a suitable tool.

5. Remove the planetary gear shaft.

6. Rotate the drive shaft gear to remove the

planetary gear and the planetary gear gasket.

7. Remove the differential right halfshaft and the

differential halfshaft gasket.

A2203005

A2203006

A2203007

A2203008

2.2.3-6

Benni Mini 2013.01

2.2.3-6Differential

Assembly

8. Remove the differential left halfshaft and the

differential halfshaft gasket.

CAUTION: Clean and check all the compo-

nents carefully before assembling them.

And lubricating them with manual trans-

mission oil.

1. Install the differential left halfshaft gasket and

the differential left halfshaft.

2. Install the differential right halfshaft gasket

and the differential right halfshaft.

A2203009

A2203009

A2203008

Benni Mini 2013.01


3. Install the planetary gear and the gasket,

rotate the driveshaft gear.

4. Install the planetary gear shaft.

CAUTION: Align the planetary gear shaft

pin hole and the installing hole on the dif-

ferential case.

5. Install the planetary gear shaft pin.

CAUTION: Install the planetary gear shaft

pin with a suitable tool.

6. Install the final drive gear bolts to the

differential.

Torque: 90 Nm

CAUTION: Lock the ring gear fixing bolt

with hands and fasten it to the specified

torque with average strength.

CAUTION: Install the new ring gear fixing

bolt.

A2203010

A2203011

A2203012

×8

A2203016

2.2.3-8

Benni Mini 2013.01

2.2.3-8Differential

7. Install the differential left gear.

CAUTION: 1. Check whether the color of the tapered

roller bearing bottom changes.

2. Check the bearing for wear or rotating

clamping stagnation.

CAUTION: Install new bearing and differ-

ential oil seal if the above situation exists.

WARNING: All the gears and bearings

have directions. Do not use them wrongly.

8. Install the induction gear ring.

CAUTION: The induction gear ring has its

mounting position.

9. Install the differential right bearing.

CAUTION: 1.Check whether the color of

the bearing changes. 2. Check the bearing

for wear or rotating clamping stagnation.

CAUTION: Install the new bearing and the

differential oil seal if the above situation

exists.

WARNING: All the gears and the bearings

have directions. Do not use them wrongly.

A2203013

A2203014

A2203015

Benni Mini 2013.01

Brake System

2.3 Brake System

2012 Benni Mini

2.3.1 Brake System - General Informa

Specifications ................................................................................................................................... 2.3.1-1

Material Specifications.............................................................................................................. 2.3.1-1



System Overview...................................................................................................................... 2.3.1-2

Location View ........................................................................................................................... 2.3.1-3


Symptom Diagnosis and Testing.................................................................................................... 2.3.1-11

Inspection and Verification...................................................................................................... 2.3.1-11

Symptom Chart....................................................................................................................... 2.3.1-12

Uneven Brake - Deviation Diagnosis...................................................................................... 2.3.1-19

Shaking/Vibration While Braking Diagnosis ........................................................................... 2.3.1-21

Brake Pedal Go Down Quickly Diagnosis .............................................................................. 2.3.1-23

Low Brake Pedal or Feeling Like Sponge Diagnosis.............................................................. 2.3.1-24

Brake Lock While Slightly Depress the Brake Diagnosis ....................................................... 2.3.1-26

Depress the Brake Pedal and Hold It Down In Depressed Position, and the Pedal Eases Down

Slowly Diagnosis .................................................................................................................... 2.3.1-27

Brake Drag Diagnosis............................................................................................................. 2.3.1-29

2.3.2 Rear Drum Brake

Specification..................................................................................................................................... 2.3.2-1


Rear Drum Brake Specification ................................................................................................ 2.3.2-1



Brake System ........................................................................................................................... 2.3.2-2

Component Description ............................................................................................................ 2.3.2-2

Exploded View.......................................................................................................................... 2.3.2-3

Removal and Installation.................................................................................................................. 2.3.2-4

Brake Drum .............................................................................................................................. 2.3.2-4

Brake Shoe............................................................................................................................... 2.3.2-5

Brake Slave Cylinder ................................................................................................................ 2.3.2-9

Brake Bottom Plate................................................................................................................. 2.3.2-11


Benni Mini 2013.01

Brake System

2.3.3 Front Disc Brake

Specifications ...................................................................................................................................2.3.3-1

Material Specifications ..............................................................................................................2.3.3-1

Front Disc Brake Specification..................................................................................................2.3.3-1



System Overview......................................................................................................................2.3.3-2

Component Description ............................................................................................................2.3.3-2

Exploded View ..........................................................................................................................2.3.3-3


Brake Caliper ............................................................................................................................2.3.3-4


Brake Pad .................................................................................................................................2.3.3-6

Brake Caliper ............................................................................................................................2.3.3-8

Brake Disc ................................................................................................................................2.3.3-9

2.3.4Parking Brake and Actuation

Specifications ...................................................................................................................................2.3.4-1



System Overview......................................................................................................................2.3.4-2


Parking Brake Cable Adjustment ..............................................................................................2.3.4-3


Inspection and Verification........................................................................................................2.3.4-4

Symptom Chart .........................................................................................................................2.3.4-5

Parking Brake Not Work (Failure) Diagnosis/Poor Parking Brake ............................................2.3.4-6

Parking Brake Not Release (Lag) Diagnosis ............................................................................2.3.4-8

Parking Brake Indicator Always On Diagnosis .........................................................................2.3.4-9


Parking Brake Control.............................................................................................................2.3.4-12

Parking brake cable ................................................................................................................2.3.4-13

Parking Brake Warning Lamp Switch .....................................................................................2.3.4-15

2.3.5 Hydraulic Brake Actuation

Specification .....................................................................................................................................2.3.5-1

Material Specifications ..............................................................................................................2.3.5-1


Benni Mini 2013.01

Brake System


System Overview...................................................................................................................... 2.3.5-2



Brake Master Cylinder and Brake Fluid Reservoir ................................................................... 2.3.5-3

Brake, Clutch and Accelerator Pedal Assembly (MT) .............................................................. 2.3.5-5

Brake Pedal Assembly (AT)......................................................................................................2.3.5-8

2.3.6 Power Brake Actuation

Specifications ................................................................................................................................... 2.3.6-1



System Overview...................................................................................................................... 2.3.6-2

Location View ........................................................................................................................... 2.3.6-2


Brake Booster........................................................................................................................... 2.3.6-3

2.3.7 Anti-lock Control

Specifications ................................................................................................................................... 2.3.7-1




System Overview...................................................................................................................... 2.3.7-2





Intermittent Malfunction Diagnosis ........................................................................................... 2.3.7-8

ABS Warning Lamp Is OFF Diagnosis ................................................................................... 2.3.7-10

ABS Warning Lamp Always ON Diagnosis............................................................................. 2.3.7-11

DTC Diagnosis and Test ................................................................................................................ 2.3.7-13

Control Module Terminal List .................................................................................................. 2.3.7-13

DTC Code List ........................................................................................................................ 2.3.7-14

Data Stream List ..................................................................................................................... 2.3.7-15

Active Test List........................................................................................................................ 2.3.7-16

Diagnostic Tool Can Not Communicate With the Vehicle Diagnosis ...................................... 2.3.7-17

DTC Diagnosis Chart.............................................................................................................. 2.3.7-18

Power Supply Fault and Hydraulic Electrical Control Unit Assembly Internal Fault Diagnosis ..2.3.7-19

Benni Mini 2013.01

Brake System

Wheel Speed Sensor Diagnosis .............................................................................................2.3.7-20

Abnormal Data Bus Diagnosis ................................................................................................2.3.7-23

Brake Lamp Switch Fault ........................................................................................................2.3.7-25


Hydraulic Control Unit (HCU)..................................................................................................2.3.7-28

Rear Wheel Speed Sensor .....................................................................................................2.3.7-30

Front Wheel Speed Sensor.....................................................................................................2.3.7-32

Rear Wheel Speed Sensor Ring(s).........................................................................................2.3.7-33

Benni Mini 2013.01

2.3.1-1 2.3.1-1Brake System - General Information

Specifications

Material Specifications


WARNING: When the discard thickness has been reached, install a new brake disc. When the

discard thickness has not been reached, the brake disc should go through a polishing treat-

ment with much care.

WARNING: When the discard thickness has been reached, install a new brake drum. When

the discard thickness has not been reached, the brake drum should go through a polishing

treatment with much care.

Item Specification

Brake fluid HZY4

Front Disc Brake Specification

Brake disc diameter 236 mm

Brake disc normal thickness 12.5 mm

Brake disc discard thickness 9.7 mm

Maximum brake disc runout (Installed) 0.1 mm

Maximum brake disc thickness variation 0.015 mm

Brake caliper piston diameter 48 mm

Minimum brake friction block thickness 3 mm

Rear Drum Brake Specification

New brake drum normall diameter 180 mm

Brake drum discard diameter 182 mm

Brake cylinder inside diameter 117.46 (ABS), 15.87 (non-ABS) mm

New primary brake shoe friction lining surface

thickness4.5 mm

New secondary shoe friction lining surface thick-

ness4.5 mm

Brake shoe friction lining surface discard thick-

ness1.5 mm

2.3.1 Brake System - General Informa-

2.3.1-2

Benni Mini 2013.01

2.3.1-2Brake System - General Information


System Overview

The braking system is of a diagonally split, dual-

circuit design featuring front disc and rear drum

brakes.

Each pair of wheels is equipped with a hydraulic

system with a separate circuit. The front brake

caliper is of floating type disc brake design

installed on the steering knuckle to ensure the

brake forces acting on the two brake frictions are

equal.

The brake drum uses regular design. It consists

of the brake primary shoe adhesive with a lining

on the secondary shoe. It can not realize the

automatic adjustment of the brake clearance

when braking.

The parking brake control lever is located

between the two front seats, the rear brake is

controlled through the cable device. Opening the

decorative cover in front of the rear cup holder

can control the parking brake adjustment.

The brake master cylinder is of a longitudinal tan-

dem design and directly linked to a brake booster

which reduces the brake pedal effort. The longitu-

dinal tandem design will make sure that in the

event of one brake circuit failing the other will

remain fully operational. The brake master cylin-

der and the brake booster are located at the left

side of the engine compartment.

On the basis of the basic brake, the electronic

hydraulic control unit and the wheel speed sen-

sors are added to the anti-lock brake (ABS) sys-

tem equipped in the vehicle with higher

configuration. The hydraulic system has a sepa-

rate circuit for each wheel. The electronic control

unit collects the speed signal of the four wheels

through the speed sensors and adjusts the brake

pressure during the braking through the hydraulic

control unit so as to make sure that the rear

wheels will not be locked before the front wheels

to guarantee the safety.

The proportioning valve is located on the outlet

pipe of the brake master cylinder with base con-

figuration. The valve can control the hydraulic

pressure applied to the brake at the rear brake so

as to reduce the risk of locking the rear wheel dur-

ing braking.

Benni Mini 2013.01


Location View


1 Right front wheel speed sensor assembly 8 Right rear wheel speed sensor assembly

2 Electronic hydraulic control unit 9 Brake drum

3 Brake fluid reservoir 10 Left rear wheel speed sensor assembly

4 Brake booster 11 Left parking brake cable

5 Parking brake handle 12 Brake disc

6 Cable equalizer 13 Brake caliper

7 Right parking brake cable 14 Left front wheel speed sensor assembly

14 13 12

11

10 9

1 5

7 8

63 4

2

A2301001

2.3.1-4

Benni Mini 2013.01


General Procedures

General Procedures

Road Test

WARNING: The road test technicians must

be trained with good driving skills.

The road test is carried out to compare the actual

braking performance with standard performance

expected by the driver. The ability to compare and

judge the braking performance depends on the

technician's experience. The technician must

have thorough knowledge of the brake system

working principle and receive a systematic

instruction to make correct comparison and

detect problems.

Before a road test, confirm the vehicle meet the

conditions as follow.

• The tires have not been excessively

worn, with the same tire tread on both left

and right tires.

• The tire pressure is within the

specification range.

• Correct wheel alignment

• Normal brake fluid level

• The brake system indicator is normal

without any trouble code.

The road test must be done on a dry, clean and

even road. An experienced technician will always

establish a route that will be used for all brake

diagnosis road tests. The roads selected will be

reasonably smooth and flat rather than gravel or

rough road. Gravel or bumpy roads are not suit-

able because the surface does not allow the tires

to grip the road equally. Crowned roads should

be avoided because of the large amount of the

weight shifted to the low set of wheels on this type

of road. Once the route is established and consis-

tently used, the road surface variable can be elim-

inated from the test results.

Before a road test, obtain a complete description

of the customer concerns or suspected condition.

From the description, the technician can match

the possible sources with the symptoms. Certain

components will be tagged as possible suspect

problems while others will be eliminated by the

evidence. More importantly, according to the

description of the customer, the technician can

inspect or eliminate the potential hazards before

the road best. The technician can also put all

problems on some particular components, vehicle

speed or conditions, such approach helps deter-

mine a method of carrying a road test.

A road test always starts with the general inspec-

tion for the brake performance. According to the

description of the customer, the vehicle braking

should be inspected with different pedal pres-

sures under different vehicle speeds. To deter-

mine if the concern is in the front or rear brake

system, use the brake pedal and then use the

parking brake control. If the condition (pull, vibra-

tion, isolation) occurs only with the parking brake,

the concern is in the rear brake system.

During the road test, the brake locking should be

avoided. Such situation does not show the brake

works normally. A heavily braked and turning

wheel will stop the vehicle in a shorter distance

than locked brakes.

If the concern becomes evident during this check,

verify it fits the description given before the road

test. If the concern is not evident, attempt to dupli-

cate the condition using the information from the

description.

If a concern exists, use the symptom chart in

order to isolate it to a specific sub-system and

related condition description. From this descrip-

tion, a list of possible sources can be used to fur-

ther narrow the cause to a specific component or

condition.

Hydraulic Leak Inspection

CAUTION: In normal condition, the brake

fluid level goes down as the brake shoe is

worn. The brake fluid level will become

excessively lower if the brake shoe gets

worn beyond the specification. It shows

that there is brake fluid leak in the brake

system if the brake shoe wear is within the

specification and the brake fluid level also

gets excessively lower.

CAUTION: Since the brake and clutch

share the same brake fluid reservoir, the

brake fluid in the reservoir would decrease

due to the clutch leak.

Benni Mini 2013.01


CAUTION: When the vehicle is running on

a rainy or snowy day, the leak trace can be

washed away since the brake fluid is water

soluble.

Inspect by the approaches as follows:

1. Confirm whether the brake fluid level is

excessively low or goes down too fast.

2. Inspect the trace of the brake fluid leak

visually.

3. Remove the front wheels.

Refer to: (2.3.3 Front Disc Brake, Removal

and Installation).

Inspect the front brake slave cylinder for any

leak and the brake shoe for any wear.

4. Remove the rear wheels and the brake drum.

Refer to: (2.3.2 Rear Drum Brake, Removal

and Installation).

Inspect the rear brake slave cylinder for any

leak and the brake shoe for any wear.

5. Remove the brake master cylinder.

Refer to: (2.3.5 Hydraulic Brake Control,


Inspect the brake master cylinder piston seal

for any leak.

6. Service the possible breakdowns above and

carry out the brake system bleeding.



eral Procedures).

Brake Pedal Remaining Travel Inspec-tion

The brake pedal remaining travel should be

inspected when the excessive brake pedal travel

is felt or the pedal reaches the bottom during

applying the brake.

1. With the transmission in neutral position, pull

up the handle brake lever and run the engine

at idle speed.

2. Lightly depress the pedal for 3 or 4 times.

3. Keep 15 s to replenish the booster vacuum.

CAUTION: The increased resistance may

feel like the brake pedal has reached bot-

tom.

4. Depress the brake pedal until it stops moving

downwards or there is no increased

resistance.

5. Hold the brake pedal while increasing the

engine speed to 2,000 rpm.

CAUTION: The increasing of engine intake

manifold vacuum causes the brake pedal

to move downwards (additional move-

ment).

6. Release the accelerator pedal and then

observe the downward movement of the

brake pedal as the engine speed decreases

to idle.

Requirement: The application of the additional

travel to the brake master cylinder can not cause

the brake pedal to reach the bottom, otherwise:

Refer to: Long Brake Pedal Travel (2.3.1

Brake System - General Information,


Vacuum Booster Inspection

1. Inspect the brake fluid level.

2. With the transmission in neutral position, pull

up the parking brake and run the engine at

idle speed.

3. Shut down the engine, depress and release

the brake pedal for several times to eliminate

the vacuum in the system, then depress the

brake pedal and hold it.

2.3.1-6

Benni Mini 2013.01


4. Start the engine. The brake pedal moves

downwards if the vacuum system is

functioning. The vacuum system is not

functioning if the downward movement of the

pedal can not be felt.

5. Remove the vacuum hose at the side of the

brake booster. Manifold vacuum is available

at the brake booster end of the hose when

the engine runs at idle speed. Feel the

vacuum with hand or measure it with vacuum

meter. Inspect the vacuum hose for block,

sealing or leak if there is no or little vacuum.

Make sure that all unused vacuum outlets are

correctly capped, hose connectors are

secured and vacuum hoses are in good

condition, thus, the vacuum in the manifold is

functioning. Reconnect the vacuum hose to

the brake booster and repeat step 3. Install a

new brake booster if no downward movement

of the brake pedal is felt.

6. Run the engine for 10 seconds at fast idle

speed. Depress the brake pedal with an

approximately 889 N (20 lb) force 10 min after

the engine shuts down. The brake pedal

should be felt the same way when the engine

is running (normal boosting).

7. If the brake pedal feels hard, check and

confirm that the check valve works normally,

and then repeat the testing. If the brake pedal

still feels hard, install a new brake booster.

If brake pedal feels soft, discharge the brake sys-

tem.



eral Procedures).

Brake Master Cylinder Inspection

CAUTION: Before the diagnosis, make

sure that the brake fluid level and the

warning indicator work normally, there is

no trouble code in the brake system.

Generally, for any faults of the brake system,

the first and best way is feeling on the brake

pedal. For diagnosis of the brake master cyl-

inder, inspect the feeling on the brake pedal

as evidence. Inspect if the brake warning indi-

cator lamp flashes and inspect the brake liq-

uid level.

Normal Conditions

In normal condition, changes in the brake pedal

feel or travel indicates that something could be

wrong in the brake system. But the following con-

ditions are considered normal and indicate that

the brake master cylinder repair is not required.

• New brake system design is different

from the previous ones, with lighter force

on the brake pedal.

• The brake fluid level should raise when

the brake works normally, it goes down

when releasing the brake. The total

amount of the brake fluid will not change.

• There are signs of the brake fluid on the

brake booster shell under the master

cylinder retainer flange.

• The brake fluid level drops as the brake

pad and the brake shoe gets worn.

Benni Mini 2013.01


Abnormal Conditions

Changes in the brake pedal feel or travel indicate

that the brake system has a fault. The following

conditions are considered abnormal and indicate

that the brake master cylinder needs repair.

Bypass Condition Test

Observe the brake fluid level in the reservoir. If

the the brake fluid level remains the same when

the brake pedal is depressed for several times,

measure the wheel turning torque required to

rotate the wheels rearward with brakes applied as

follows:

1. Put the transmission at neutral position and

raise and support the vehicle.



2. Apply a force of 445 N and hold for

approximately 15 seconds. With the brakes still

applied, exert the torque on the wheels to 10.1

Nm. If either wheel rotates, install a new brake

master cylinder.

Non-Pressure Leak

In case the reservoir kettle is out of oil, it might be

caused due to the two non-pressure external

leaks.

Type 1: As the position of the washer and the

cover is incorrect, the brake master cylinder res-

ervoir kettle cover might be externally leaking.

Type 2: Brake reservoir mounting gasket might

be externally leaking. Install a new oil seal to

maintain the leaks of this kind.

SymptomBrake Master Cylin-

der

Depress the brake

pedal and the brake

pedal goes down fast.

•External leak (split,

connectors, seals)

Depress and hold the

brake pedal, and the

brake pedal goes down

slowly.

•External Leak

•Internal Leak (seals

aging of the master

cylinder)

The brake pedal is low

or feels soft when

depressing it.

•The blocking of the

inlet or reservoir vent

holes

•Air in the hydraulic

system

The brake pedal

returns slowly.

•Compensation hole

blocked

•Master cylinder spring

cracks (fatigue)

The rear brake locks up

when lightly depress-

ing the brake pedal.

•ABS system

Long brake pedal travel •Internal leak

2.3.1-8

Benni Mini 2013.01


Brake System Bleeding

WARNING: The brake fluid contains polyg-

lycol ether and polyglycol. Avoid contact

with the eyes and skin.

WARNING: If the brake fluid contacts the

eyes, flush the eyes for 15 minutes with

cold running water. Go to see the doctor

right away if the eyes still hurt.

WARNING: The brake fluid should be

washed away completely if the skin

touches the fluid.

WARNING: Drink some water and try vom-

iting, and go to see the doctor right away if

the brake fluid is swallowed.

WARNING: Wear glasses for safety.

CAUTION: The brake fluid should be

washed away with clean water if it is

splashed onto the paintwork.

CAUTION: Make sure that the vehicle is

parked on a flat ground.

CAUTION: Bleed as the following

sequence: Right rear, left front, left rear

and left front.

CAUTION: Depress the brake for 3 ~ 5

times or until the brake pedal force begins

to increase obviously to eliminate the

remaining vacuum in the brake booster

when the ignition switch is at the position

" " and the brake is in cold state.

CAUTION: During the bleeding, new and

clean brake fluid must be added to the

brake fluid reservoir to make sure that

brake fluid level remains at a position

above the middle of the scale.

CAUTION: Bleed the air in the brake mas-

ter cylinder if it is known or doubted that

air exists. And then, bleed the air in the

brake slave cylinder.

1. Place a rag under the master cylinder to

prevent the brake fluid from flowing to other

components.

2. Let the assistant slowly depress the brake

pedal to the bottom and hold it down with a

stable force.

3. Release a hose from the master cylinder and

bleed the air in the master cylinder.

4. Tighten the braking hose and then let the

assistant slowly release the brake pedal.

5. Repeat the step 2-4 until all air is bled from

the brake master cylinder.

6. Using the same method, bleed the air from

another brake master cylinder through

another main line connector.




8. Connect one end of the transparent bleeding

pipe to the right-rear brake slave cylinder

bleeding port.

9. Soak the other end of the bleeding pipe in the

brake fluid in the transparent bleeding bottle.

10. Place the bleeding bottle with its bottom 300

mm above the bleeding port to maintain the

fluid pressure and prevent the air going

through the screw thread at the port into the

brake system.

11. Let the assistant slowly depress the brake

pedal to the bottom and hold it down with a

stable force.

12. Loosen the bleeding valve to bleed the air in

the wheel hydraulic brake line.

13. Tighten the bleeding valve and let the

assistant slowly release the brake pedal.

14. Add the brake fluid in the reservoir.

15. Keep depressing the brake pedal and then

repeat the step 11~13 until the brake fluid

without air flows into the bleeding bottle.

16. After bleeding the air from the brake lines, the

bleeding port must be capped. Or, the

bleeding port may be blocked.

17. For other brake lines, repeat the procedures.

Benni Mini 2013.01


ABS Hydraulic Unit Bleeding

The Bleeding and Filling Test uses the Changan

Automobile special diagnostic tool to operate the

system electromagnetic valve circularly so as to

bleed the air from the assistant brake lines.

These brake lines are usually closed. When the

vehicle starts, they open only during the system

initiation and the operation of the anti-lock brake

system. The automatic bleeding procedure opens

these assistant brake lines to allow the air in the

pipes to flow to the brake slave cylinder.

CAUTION: Before apply the Bleeding and

Filling Test procedure, bleed the air for the

basic brake system.


Brake System, General Procedures).

CAUTION: It is recommended to perform

the Bleeding and Filling Test procedure in

any of the following conditions: a. The

basic brake system bleeding does not

acquire a correct pedal height or feel of

foot. b.It is doubted that there is air block-

ing in the assistant brake lines of the

hydraulic adjuster assembly.

CAUTION: Make sure that the vehicle is

parked on a flat ground.

CAUTION: When the ignition switch is at

the position " " and the brake is in cold

state, depress the brake pedal for 3 to 5

times or until the brake pedal force begins

to increase obviously to eliminate the

remaining vacuum in the brake booster.

CAUTION: During the bleeding, new and

clean brake fluid must be added to the

brake fluid reservoir to make sure that the

brake fluid level remains at a position

above the middle of the scale.

1. When the engine is turned off, turn the

ignition switch in position " ".

2. Install the Changan Automobile special

diagnostic tool.

3. Establish a communication through the

Changan Automobile special diagnostic tool

and the anti-lock braking system. Select the

Bleeding and Filling Test.




5. By following the diagnostic tool, operate the

brake system until the correct pedal height is

reached.

6. It indicates that the fault exists if the bleeding

procedure goes wrong. Read the diagnostic

trouble codes and repair it if there is any

trouble code.

Refer to: Trouble Code List (2.3.7 Anti-

Lock Control, DTC Diagnosis and Testing).

7. Depress the pedal and check whether it is

solid if the pedal has reached a correct

height. If the pedal feels spongy, repeat the

bleeding procedure.

8. Lower the vehicle.

9. Remove the Changan Automobile special

diagnostic tool.

10. Road test the vehicles. Meanwhile, inspect if

the pedal can maintain a correct height and

solidness.

2.3.1-10

Benni Mini 2013.01


Brake Disc Runout and Its ThicknessInspection

WARNING: Refer to: "Vehicle Lift Warning"

in Lifting (1.1.3 Traction and Lifting).

General Equipment




2. Remove the front wheel.

Refer to: Wheels and Tires (2.1.4 Wheels

and Tires, Removal and Installation).

3. Remove the brake pad.

Refer to: Brake Pad (2.3.3 Front Disc


4. Fix the tire nuts in a reversed sequence and

hold the brake disc in position.

5. Fix the micrometer and the holding fixture on

the suspension bracket.

6. Position the dial indicator gauge so that it

contacts the brake disc approximately 10 mm

from the outer edge at an angle of 90

degrees.

7. Rotate the brake disc until the dial indicator

reaches the minimum and return it to zero.

8. Slowly rotate the brake disc until the dial

indicator reaches the maximum. Note and

record the brake disc runout on both the inner

and outer faces of the brake disc.

Standard Value: 0.1 mm (metric system)

If any of the measurements exceeds the runout

specification, the runout of the wheel hub should

be inspected. If the wheel hub has a normal run-

out, install a new brake disc.

9. Inspect the wheel hub runout

Inspect the runout while slowly rotating the wheel

hub. If the runout exceeds the specified range,

make sure that the bearing clearance is normal

and install a new wheel hub.

10. Measure the brake disc thickness.

CAUTION: After the brake disc has a sur-

face finishing or is replaced, the brake pad

should be replaced too.

Measure the brake disc thickness 15 mm from the

outer face of the brake disc at 8 positions each

separated by an angle of 45 degrees with

micrometer.

If the variation reaches or exceeds 0.015 mm or

the brake disc thickness is less than the specified

minimum value, the brake disc needs a surface

finishing or to be replaced.

Dial indicator gauge holding fixture

Dial indicator gauge

Micrometer

A2301002

A2301003

A2301004

Benni Mini 2013.01




CAUTION: Before the diagnosis, verify if

the brake system warning indicator works

normally.


2. Visually inspect for obvious mechanical and

hydraulic damage.


3. Solve the known problems before the next

step.





symptom and refer to the symptom chart.

General Equipment

Mechanical

•Tire pressure(s)

•Wheels and tires

•Brake fluid level

•Brake line leakage

Digital Multimeter

Changan Auto special diagnostic tool

2.3.1-12

Benni Mini 2013.01


Symptom Chart

CAUTION: 1. Replace each component carefully since each component may influence the performance

of the brake system and lead to driving danger. Standard components produced by Changan

Automotive Corporation should be used.

2. It is very important to keep the components and the environment clean during the repair of

the brake system.

3. The component must be dismantled if any brake leak is found. If any abnormal condition is

found, install a new component.

4. Wrap the brake lines to prevent any dust, mud or other foreign matters from entering into

the lines when dismantling the brake components.

5. Do not damage or distort the brake lines when dismantling or fixing the brake lines.

6. During the installation of the brake lines or hoses, make sure that they are not distorted or

bent.

7. Keep the brake hoses away from the shock absorber oil and grease.

8. After installing the brake pipe and hoses, make sure that they are not interfered with other

components.

9. Do not stick the brake fluid to the body or paintwork. If the brake fluid leaks on the paint-

work, it should be cleaned immediately.

When a trouble occurs and the brake system operation indicator still works normally, the troubles should

be diagnosed and solved in the following sequence since it is impossible to verify the causes during the

general inspection and Diagnostic Trouble Codes (DTC) are not stored in the control module memory.

Benni Mini 2013.01


Symptom Possible Sources Solutions

Uneven braking force-devia-

tion

•Inconsistent tire thread and

pressure(s)

•Install new tires and adjust the tire

pressure(s).

•The distortion of the brake

pipe and hoses•Install new brake pipe and hoses.

•Brake shoe or brake pad

(crack, distortion or grease

spots)

•Damaged inside lining

•Clean or replace the brake shoe, the

brake pad as well as the inside lining.

Refer to: (2.3.2 Rear Drum

Brake, Removal and Installa-

tion) and (2.3.3 Front Disc


tion).

•The abnormal wear and dis-

tortion of the front brake disc

•Inspect the front brake disc.

Refer to: Brake Disc Runout and

Thickness Inspection (2.1.3

Brake System - General Infor-



tortion of the rear brake drum

•Install a new brake drum.



tion).

•Seized brake slave cylinder

or brake caliper

•Repair or install new brake slave cyl-

inders or brake calipers.



tion) or (2.3.3 Front Disc Brake,


•Anti-Lock control failure

•Inspect and repair the anti-lock control.

Refer to: (2.3.7 Anti-Lock Con-

trol, Symptom Diagnosis and

Testing).

•Incorrect wheel alignment •Aligning the wheels

2.3.1-14

Benni Mini 2013.01


Shaking or vibrating occurs

when applying the brake

•The brake shoe or the brake

pad is worn or damaged or

adhesive with grease.

•Install new brake shoes or brake

pads.






tortion of the front brake disc

•Install new front brake discs.

Refer to: Brake Disc Runout and

Thickness Inspection (2.1.3

Brake System - General Infor-


•The abnormal wear, distorted

circle and distortion of the

rear brake drum.




tion).

•The brake caliper mounting

bolts are loosening.

•Tighten the brake caliper mounting

bolts.

•Insufficient lubrication of the

sliding components•Fill lubrication if necessary.

•The loosening or loss of the

wheel hub bolts•Tighten or install new wheel hub bolts.


Benni Mini 2013.01


The brake pedal depressed

down quickly

•Hydraulic system leaks

•Repair the leaks, fill the brake fluid

and start the bleeding air.

Refer to: Brake System Bleed-

ing (2.3.1 Brake System - Gen-

eral Information, General

Procedures).

•Air exists in the brake system.

•Fill the brake fluid and start the bleed-

ing air.




Procedures).

•The brake master cylinder

piston is worn or the cylinder

cracks.

•Replace the brake master cylinder.

Refer to: Brake Master Cylinder

and Brake Fluid Reservoir (2.3.5

Hydraulic Brake Actuation,


•The excessive wear of the

brake pads or brake shoes


pads.





The brake pedal is low or

feels soft.


brake shoes or brake pads


pads.





•The vent holes on the reser-

voir cap get blocked or dirty.•Clean the vent holes.

•Air exists in the brake system.

•Fill the brake fluid and start the bleed-

ing air.




Procedures).


2.3.1-16

Benni Mini 2013.01


The brake lockup occurs

when slightly depressing the

brake.

•Incorrect tire pressure(s) •Adjust the tire pressure(s).

•Tire wear •Replace the tire.

•Incorrect installation of the

brake shoes or brake pads


pads.





•Anti-Lock control failure

•Inspect and repair the anti-lock control.

Refer to: (2.3.7 Anti-Lock Con-

trol, Symptom Diagnosis and

Testing).

Depress the pedal and hold it,

it would go down slowly.

•Leaks or air in the brake sys-

tem

•Repair the leaks, fill the brake fluid

and start the bleeding air.




Procedures).

•Brake master cylinder trouble

•Refer to this section to inspect the

brake master cylinder, install a new

master cylinder if any trouble is

found.

Refer to: (2.3.5 Hydraulic Brake

Actuation, Removal and Instal-

lation).

Long brake pedal travel


brake pads or brake shoes


pads.





•Rear wheel brake clearance

automatic adjustment mal-

function

•Repair the manual adjustment func-

tion


Benni Mini 2013.01


Brake drag

•Parking brake is functioning

when the hand brake has not

been completely released

yet.

•Release the hand brake.

•Seized brake caliper or brake

slave cylinder

•Repair or install new brake slave cyl-

inders or brake calipers.





•Seized brake pads or brake

shoes

•Repair or install new brake pads or

brake shoes.





•Seized parking brake cable.

•Install new parking brake cables.



tion).

•Seized vacuum booster •Adjust the length of the brake booster

actuating rod or install a new vacuum

booster.

Refer to: (2.3.6 Boost Booster,


•Brake pedal free travel (Insuf-

ficiency)

Poor efficiency of boosting

brake

•Leaks in the air intake system

•Inspect the air intake system for its

vacuum level and repair it if neces-

sary.

Refer to: (3.1.5 Air Intake Sys-

tem, General Procedures)

•The vacuum boosting hose

leaks.

Refer to: Vacuum Booster

Inspection (2.3.1 Brake System -

General Information, General

Procedures).

•Vacuum boosting hose one-

way valve failure


2.3.1-18

Benni Mini 2013.01


Noise in the brake system

•Brake shoes or brake pads (

they are excessively worn,

cracked, distorted, dirty and

glazed.)


pads.





•Brake disc guide plate (loos-

ened)•Repair or replace

•Brake caliper bracket retain-

ing bolts (loosened)•Tighten or replace

•Brake caliper retaining bolts

(loosened)•Tighten or replace

•Brake caliper floating pin

(worn)•Replace

•Abnormal wear, crack and

distortion of the front brake

disc

•Replace new front brake discs.

Refer to: Front Brake Disc (2.3.3

Front Brake Disc, Removal and

Installation).

Noise in the brake system

•Abnormal wear, distorted cir-

cle, crack and distortion of

the rear brake drum


Refer to: Brake Drum (2.3.2 Rear

Drum Brake, Removal and

Installation).

•Brake pedal return spring

fatigue•Install new return springs.

•The brake pedal push rod

gets bent or distorted.•Replace

•Vacuum booster


Inspection (2.3.1 Brake System -


Procedures).

•Brake master cylinder


Inspection (2.3.1Brake System-


Procedures)


Benni Mini 2013.01


Uneven Brake - Deviation Diagnosis

Test Condition Details/Results/Actions

1. Road test the vehicles

A.Carry out the road test.

B.Inspect for brake deviation.

Does the brake deviation exist?

Y

Go to step 2.

N

Vehicle is normal.

2. Inspect the tire tread and the tire pressure(s)

A.Inspect if the tire tread is the same.

B.Inspect if the tire pressure is normal.

Is the inspection normal?

Y

Go to step 3.

N

Install new tires and adjust the tire pressure(s).

3. Inspect the brake shoe or brake pad

A.Inspect if the brake shoe is oil leaking or unusually

worn.

B.Inspect the brake pad or the inner lining is unusually

worn.

Unusual wear or oil leaking?

Y

Clean or replace the brake shoe or brake pad.


and Installation) and (2.3.3 Front Disc


N

Go to step 4.

4. Inspect the front brake disc

A.Inspect if the front brake disc is unusually worn,

distorted or deformed.


N

Replace new front brake discs.

Refer to: Front Brake Disc (2.3.3 Front

Brake Disc, Removal and Installation).

Y

Go to step 5.

2.3.1-20

Benni Mini 2013.01


5. Inspect the rear brake drum

A.Inspect if the rear brake drum is unusually worn, or

deformed.


N

Install a new brake drum.


and Installation).

Y

Go to step 6.

6. Inspect the brake slave cylinder or the brake caliper

A.Inspect if the brake slave cylinder or the brake

caliper is seized.


N

Repair or install new brake slave cylinders or brake

calipers.


and Installation) or (2.3.3 Front Disc


Y

Go to step 7.

7. Inspect the brake pipe

A.Inspect if the brake hard pipe, hose is distorted or

deformed.


Y

Install new brake pipe and hoses.

N

Go to step 8.

8. Inspect the anti-lock control

A.Inspect the anti-lock control for failure.


Y

Inspect and repair the anti-lock control.

Refer to: (2.3.7 Anti-Lock Control, Symp-


N

Go to step 9.


Benni Mini 2013.01


Shaking/Vibration While Braking Diagnosis

9. Wheel alignment

A.Inspect whether the wheel alignment is normal.


N

Adjust the wheel alignment.

Refer to: (2.1.1 Suspension System - Gen-

eral Information, General Procedures).

Y

Confirm the maintenance is finished.



A.Carry out the road test to brake with a speed of 40 ~

80 km/h.

B.Inspect for the brake shaking/vibration.

Does the brake shaking/vibration exist?

Y

Go to step 2.

N

Vehicle is normal.


A.Inspect whether the brake shoe or the brake pad is

unusually worn, damaged or with oil.


Y

Go to step 3.

N

Replace new brake shoes or brake pads.





2.3.1-22

Benni Mini 2013.01


3. Inspect the front brake disc

A.Inspect if the front brake disc is unusually worn,

distorted or deformed.


N

Install new front brake discs.

Refer to: Front Brake Disc (2.3.3 Front

Brake Disc, Removal and Installation).

Y

Go to step 4.

4. Inspect the rear brake drum

A.Inspect if the rear brake drum is unusually worn, out

of round or deformed.


N

Replace a new brake drum.


and Installation).

Y

Go to step 5.


A.Inspect whether the brake caliper bolts is loosen.

B.Inspect if the sliding parts lack of lubrication.

C.The loosening or loss of the wheel hub bolts.


N

Fasten the bolts for the brake caliper; lubricate the

sliding parts; fasten or replace the hub bolts.

Y



Benni Mini 2013.01


Brake Pedal Go Down Quickly Diagnosis



A.Carry out the road test, and depress the brake

pedal.

B.Inspect if the action force on the pedal is normal.

Is the action force on the pedal normal?

Y

Vehicle is normal.

N

Go to step 2.

2. Inspect the brake fluid level

A.Inspect the brake fluid reservoir level.

Is it normal?

Y

Go to step 3.

N

Inspect if there is leaking at the sealing of the reser-

voir pipe.

Refer to: (2.1.1 Brake System-General

Information, General Procedures).

3. Brake system pressurizing

A.Depress the brake pedal quickly for five times.

Does the pedal height increase and hold?

Y

Inspect the parking brake and adjust it if necessary.


(2.3.4 Parking Brake and Actuation, Gen-

eral Procedures).

In case the fault still exists, bleed the brake system.



eral Procedures).

N

Go to step 4.

2.3.1-24

Benni Mini 2013.01


Low Brake Pedal or Feeling Like Sponge Diagnosis

4. Inspect for the leaking of the brake system

A.Inspect for the external leaking of brake system.

Is it leaking?

Y

Repair the leaking part and replace the correspond-

ing parts if necessary. Fill the brake fluid and bleed-

ing.

N

Go to step 5.

5. Inspect the bypass condition of the brake master cylinder

A.Bypass condition test.

Refer to: Bypass Condition Test (2.3.1


eral Procedures).


N

Replace the master brake cylinder.

Refer to: Brake Master Cylinder and Brake

Fluid Reservoir (2.3.5 Hydraulic Brake

Actuation, Removal and Installation).

Y





pedal.

B.Inspect if the brake pedal feels sponge.


Y

Vehicle is normal.

N

Go to step 2.


Benni Mini 2013.01


2. Inspect the brake fluid level.


Is it normal?

Y

Go to step 3.

N

Inspect if there is leaking at the sealing of the reser-

voir pipe.

Refer to: (2.1.1 Brake System - General

Information, General Procedures).

3. Inspect the vent hole on the reservoir cover

A.Inspect if the vent hole is blocked or dirty.

Blocked or dirty?

Y

Clean the cover.

N

Go to step 4.

4. Brake system bleeding

A.Inspect the air of the brake system.

Does air exist in the brake system?

Y

Brake System Bleeding.



eral Procedures).

N

Go to step 5.

5. Inspect the front wheel hub retaining nut

A.Inspect if the nuts are loosening.


N

Replace the nuts and fasten.

Y

Inspect the parking brake and adjust it.



eral Procedures).

Comfirm the maintenance is finished.


2.3.1-26

Benni Mini 2013.01


Brake Lock While Slightly Depress the Brake Diagnosis




pedal.

B.Inspect for the brake locking.


Y

Vehicle is normal.

N

Go to step 2.

2. Inspect the tire tread and the tire pressure(s)

A.Inspect if the tires are excessively worn or the tire

pressure is abnormal.

Is it normal?

Y

Go to step 3.

N

Replace the tire.

Refer to: Wheels and Tires (2.1.4 Wheels

and Tires, Removal and Installation).


A.Inspect if the brake shoe or pad is correctly installed

or polluted by oil or excessively worn.

Is it normal?

Y

Go to step 4.

N

Install new brake shoes or brake pads.




4. Inspect the anti-lock control

A.Inspect the anti-lock control for failure.


Y

Go to step 5.

N

Inspect and repair the anti-lock control.

Refer to: (2.3.7 Anti-Lock Control, Symp-


Benni Mini 2013.01


Depress the Brake Pedal and Hold It Down In Depressed Position,

and the Pedal Eases Down Slowly Diagnosis

5. Inspect the vacuum booster

A.Inspect if the brake booster is normal.


Y

Go to step 6.

N

Replace the brake booster.

Refer to: Brake Booster (2.3.7 Booster



A.Inspect if the sliding parts lack of lubrication.

Lack of lubrication?

Y

Lubricate the sliding parts.

N



1. Inspect if the fault exists

A.Depress the brake pedal and keep it, and inspect if

the pedal slowly goes down.


Y

Vehicle is normal.

N

Go to step 2.

2. Inspect the brake fluid level


Is it normal?

Y

Go to step 5.

N

Go to step 3.


2.3.1-28

Benni Mini 2013.01


3. Inspect for the leaking of the brake system

A.Inspect for the external leaking of brake system.

Is it leaking?

Y

Repair the leaking part and replace the correspond-

ing parts if necessary. Fill the brake fluid and bleed.

N

Go to step 4.

4. Inspect for the air of brake system

A.Inspect the air of the brake system.

Does air exist in the brake system?

Y

Brake System Bleeding.



eral Procedures).

N

Go to step 5.

5. Inspect the brake master cylinder

A.Inspect if the brake master cylinder is normal.

Is it normal?

N

Replace the master brake cylinder.




Y



Benni Mini 2013.01


Brake Drag Diagnosis


1. Inspect the parking brake

A.Release the parking brake handle and inspect if the

parking brake is completely released.

Is it normal?

Y

Go to step 2.

N

Inspect the parking brake cable seized and adjust

the parking brake.



eral Procedures).

2. Inspect the brake caliper or the brake slave cylinder

A.Inspect if the brake caliper or the brake slave

cylinder is seized.

Is it normal?

Y

Go to step 3.

N

Replace the brake caliper.

Refer to: Brake Caliper (2.3.3 Front Disc


Replace the brake slave cylinder.

Refer to: Brake Slave Cylinder (2.3.4 Rear


3. Inspect the brake pad or the brake shoe

A.Inspect if the brake pad or the brake shoe is seized.

Is it normal?

Y

Go to step 4.

N

Replace the brake pad.



Install new brake shoes.

Refer to: Brake Shoe (2.3.4 Rear Drum


2.3.1-30

Benni Mini 2013.01



4. Inspect the brake booster

A.Inspect if the brake booster is seized.

Is it normal?

Y

Go to step 5.

N

Adjust the length of the brake booster push rod or

replace a new brake booster.

Refer to: Brake Booster (2.3.6 Booster


5. Inspect the free travel of the brake pedal

A.Inspect if the free travel of the brake pedal is normal.

Is it normal?

N

Adjust the length of the push rod of vacuum booster.

Y


Benni Mini 2013.01

2.3.2-1 2.3.2-1Rear Drum Brake

Specification



WARNING: When the discard thickness has been reached, install a new brake drum. When

the discard thickness has not been reached, the brake drum should go through a polishing

treatment with much care.


Item Specification

Brake fluid HZY4


New brake drum nominal diameter 180 mm

Brake drum discard diameter 182 mm

Brake shoe plate width 30 mm

Brake slave cylinder hole diameter 17.46(ABS) 15.87(non-ABS) mm

New primary shoe friction lining surface thickness 4.5 mm

New secondary brake shoe friction lining surface thick-

ness4.5 mm

Brake shoe friction lining surface discard thickness 1.5 mm

Item Nm lb-ft lb-in

Wheel hub retaining nut 220 162 -

Tire nut 85 63 -

Brake slave cylinder retaining bolt 10 - 89

Brake oil hose connector 15 11 -

2.3.2 Rear Drum Brake

2.3.2-2

Benni Mini 2013.01

2.3.2-2Rear Drum Brake


Brake System

The rear drum brake assembly is of a secondary

shoe design with a single cylinder hydraulic oper-

ation. The two shoes are pressed tightly on the

brake slave cylinder piston and the retaining ful-

crum post support pin by the upper and lower

return springs. The former one is called "primary

shoe", the other toward the rear is called "second-

ary shoe". The brake slave cylinder is single-cyl-

inder design and installed at the top of the bottom

plate. The brake shoe clearance can be adjusted

manually, and the brake shoe plate wear will

increase the pedal travel so it needs manual

adjustment.

Component Description

Brake Shoe

Apply the mechanical output force from the

hydraulic brake slave cylinder to the friction sur-

face of the brake drum.

Brake Drum

By using the mechanical output force applied by

the brake shoes to the friction surface of the

brake drum, slow down the speed of tires and

wheels assembly to brake the vehicle.

Brake Slave Cylinder

Transmit the hydraulic pressure from the brake

master cylinder into mechanical output force

applied to the brake shoes.

Support Pin and Clearance Adjustment

Machinery

Support the brake shoes and manually adjust the

brake clearance.

Brake Shoe Upper and Lower Return

Spring

The two brake shoes are pressed tightly on the

brake slave cylinder piston and the retaining ful-

crum post support pin by with the upper and lower

return springs; when the brake master cylinder

returns, the upper spring enables the brake slave

cylinder piston to return automatically.

Rear Drum Brake Operation

When the brake pedal is depressed, the mechan-

ical output force from the hydraulic brake slave

cylinder piston is applied to the shoes. The brake

slave cylinder moves the two brake shoes out-

wards which move outwards with the retaining

support pin as the supporting point and stop the

wheels through rubbing with the brake drum.

When the wheels move forwards, the front brake

shoes unfold in the brake drum and produce self-

boosting force. When the wheels move back-

wards, the rear brake shoes produce self-boost-

ing force.

Benni Mini 2013.01


Exploded View

Rear Drum Brake


1 Brake bottom plate 3 Brake shoe

2 Brake slave cylinder 4 Brake drum

1

2

3

4

A2302001

2.3.2-4

Benni Mini 2013.01



Brake Drum

Removal

Material

Installation

Item Model

Brake fluid HZY 4

1. Remove the tires.



2. Release the parking brake lever.




4. Detach the brake drum.


CAUTION: Adjust the shoe clearance after

the brake drum installation.

A2302004

Benni Mini 2013.01


Brake Shoe

Removal

Material

Item Model

Grease SAM1C-9107-A




2. Remove the brake shoe setting spring.

3. Detach the brake shoe bottom bracket form

the brake shoe, and remove the bottom

return spring.

A2302006

A2302007

2.3.2-6

Benni Mini 2013.01


Installation

4. Remove the upper brake shoe return spring

and the jack stay, and detach the brake shoe.

CAUTION: Do not damage the brake slave

cylinder rubber boot when detach the

brake shoe.

5. Remove the parking brake cable, and detach

the brake shoe.

1. Clean, inspect and apply lubricant to the

brake bottom plate contact areas.

A2302008

A2302009

×6

A2302013

Benni Mini 2013.01


2. Install the parking brake cable.

3. Install the upper brake shoe jack stay and the

return spring.

4. Fix the brake shoe under the bottom bracket

and install the lower return spring.

A2302009

A2302016

A2302017

2.3.2-8

Benni Mini 2013.01


5. Install the brake shoe setting spring.

6. Install the brake drum.




eral Procedures).

A2302006

Benni Mini 2013.01



Removal

General Equipment

Brake Hose Clamp

1. Remove the brake shoe.



2. Clamp the brake hose with a proper brake

hose clamp.

3. Remove the brake slave cylinder.

1.Remove the brake hard pipe joint.

2.Remove the bolts.

3.Remove the brake slave cylinder.

A2302019

1

2 3

A2302020

2.3.2-10

Benni Mini 2013.01


Installation

1. Install the brake slave cylinder.

1.Install the brake slave cylinder bolts.

Torque: 10 Nm

2.Install the brake hard pipe joint.

Torque: 15 Nm

2. Install the brake hose clamp.

3. Brake system bleeding.



eral Procedures).

1

2

A2302021

Benni Mini 2013.01


Brake Bottom Plate

Removal

Installation


1. Remove the rear wheel bearing.







Refer to: Brake Slave Cylinder (2.3.2 Rear


4. Detach the parking brake cable.

1.Remove the retaining clamp.

2.Detach the brake cable.

5. Remove the brake bottom plate.

1.Remove the four retaining bolts on the

brake bottom plate and detach the brake bot-

tom plate.

Torque: 42.5 Nm

1

2

A2302022

×4

A2302023

Benni Mini 2013.01

2.3.3-1 2.3.3-1Front Disc Brake

Specifications



CAUTION: When the discard thickness has been reached, install a new brake disc. When the

discard thickness has not been reached, the brake disc should go through a polishing treat-

ment with much care.


Item Specification

Brake fluid HZY4


Brake disc diameter 236mm

Brake disc normal thickness 12.5 mm

Brake disc discard thickness 9.7 mm

Maximum brake disc runou (Installed) 0.1 mm

Maximum brake disc thickness variation 0.015 mm

Brake caliper piston diameter 48mm

Minimum brake friction block thickness 3mm

Item Nm lb-ft lb-in

Tire nut 85 63 -

Brake slave cylinder piston housing bolt 27 20 -

Brake caliper anchor plate bolts 83 61 -

Brake caliper brake hose connector 23 17 -

2.3.3 Front Disc Brake

2.3.3-2

Benni Mini 2013.01

2.3.3-2Front Disc Brake


System Overview

Installed on the steering knuckle with two mount-

ing bolts, the brake caliper of the front disc brake

is of single-piston type. The brake caliper moves

outward under the hydraulic pressure when

depressing the brake pedal. The braking pressure

pushes the brake pad to stick to the brake disc to

produce a friction force to reduce the rotating

speed of the wheel and tire assembly. The vehicle

will stop as a result. The piston moves further to

supplement the clearance when the brake pad is

worn. The piston rubber seal recovers to its origi-

nal shape to keep the original clearance between

the brake disc and the brake pad when the pres-

sure is released from the brake pedal and the

hydraulic pressure on the piston is released.


Disc Brake Pad

The mechanical output force from the hydraulic

brake caliper is applied to the brake disc friction

surface.

Disc Brake Pad Guide Plate

Located between the disc brake pad and brake

pad mounting bracket, it keeps a smooth move-

ment of the brake pad and eliminate noises.

Brake Disc

With the mechanical output force applied by the

disc brake pad to the brake disc friction surface,

the rotating speed of the wheel and tire is reduced

and the vehicle is stopped as a result.

Brake Caliper

The hydraulic pressure from the brake master cyl-

inder is transformed into mechanical output force

which is applied to the inner brake pad. The brake

caliper piston returns automatically when the

master cylinder returns.

Brake Caliper and Brake Pad Bracket

In order to keep a correct matching position with

the hydraulic brake caliper, it serves for fixing the

disc brake pad and brake caliper. The brake pad

slides when the mechanical output force is

applied to the brake pad.

Disc Brake Caliper Floating Pin

It serves for mounting hydraulic brake caliper and

fixing it at a correct matching position with the

brake caliper bracket. The brake caliper is pushed

to have a slide relative to the brake pad when the

mechanical output force is applied.

Front Disc Brake System Operation

The mechanical output force from the hydraulic

brake caliper piston is applied to the inner brake

pad. The brake caliper housing pulls the outer

brake pad inward to get even distribution of the

output force while the piston pushes the inner

brake pad outward. The brake pad applies the

output force to the both sides of the brake disc

friction surface to reduce the rotating speed of the

wheel and tire assembly. Whether the brake pad

guide plate and the brake caliper floating pin work

normally or not matters is quite important to the

even distribution of brake force.

Benni Mini 2013.01


Exploded View

Front Disc Brake


1 Brake disc 3 Brake pad

2 Brake caliper

1

2

3

A2303015

2.3.3-4

Benni Mini 2013.01



Brake Caliper

Disassembly

Material

Item Model

Brake fluid HZY 4

1. Pull the brake slave cylinder piston out of the

brake caliper housing by using compressed

air.

CAUTION: If the brake fluid is spilt on the

paintwork, the affected area must be

immediately washed down with cold water.

CAUTION: A wood block or a wood cush-

ion or some cloth is placed between the

brake slave cylinder piston and the brake

caliper housing to prevent damaging the

brake slave cylinder piston.

2. Remove and discard the dust-proof oil seal.

3. Remove and discard the piston oil seal.

4. Inspect the piston and the piston hole for any

damage and wear. Install a new brake caliper

if necessary.

A2303011

A2303012

A2303013

Benni Mini 2013.01


Assembly

1. Use the brake fluid to lubricate the piston

hole, the piston oil seal and the brake caliper.

2. Install a new piston oil seal into the piston

hole.

CAUTION: The piston oil seal must be

installed into the piston hole groove.

3. Install a new dust-proof oil seal on the brake

slave cylinder piston.

4. Assemble the brake slave cylinder piston into

the piston hole.

CAUTION: Do not scratch the piston when

assembling the piston into the piston hole.

A2303013

A2303014

A2303011

2.3.3-6

Benni Mini 2013.01



Brake Pad

Removal

Material

Item Model

Brake fluid HZY 4

1. Remove the tires.




1.Remove the lower retaining bolts of the

brake slave cylinder.

2.Rotate the brake slave cylinder upwards.


1

2

A2303001

A2303002

Benni Mini 2013.01


Installation

1. Use a special tool to compress the brake

slave cylinder piston.

Special Tool: 201-003

CAUTION: The brake fluid will spill out

from the brake master cylinder after the

brake slave cylinder position is com-

pressed tightly into the piston cylinder.

2. Install the brake pads.

3. Install the brake slave cylinder in place and

tighten the brake slave cylinder lower bolts.

Torque: 50 Nm

4. Depress the brake pedal forcibly for more

than 3 times.

5. Inspect the brake fluid level and add some

when necessary.

201-003

A2303003

A2303002

A2303004

2.3.3-8

Benni Mini 2013.01


Brake Caliper

Removal

General Equipment

Installation

Brake hose clamp

1. Detach the brake hose from the front strut.

2. Clamp the brake hose with a proper brake

hose clamp.


1.Remove the brake hose retaining bolt.

Torque: 23 Nm

2.Remove the brake caliper upper and lower

retaining bolts.

Torque: 83 Nm

CAUTION: If the brake fluid is spilt on the


immediately washed down with cold

water.

CAUTION: Seal the brake hose to prevent

the loss of fluid and the foreign materials

from entering.





eral Procedures).

A2303005

12

2

A2303006

Benni Mini 2013.01


Brake Disc

Removal

Installation





Refer to: Brake Caliper (2.3.3 Front Disc


3. Suspend the brake caliper.

CAUTION: Suspend the brake caliper to

prevent the brake hose from stretching.

4. Remove the brake disc.





eral Procedures).

A2303009

A2303010

Benni Mini 2013.01

2.3.4-1 2.3.4-1Parking Brake and Actuation

Specifications


Item Nm lb-ft lb-in

Parking brake cable adjustment nut 4 - 35

Parking brake control nut 23 17 -

2.3.4Parking Brake and Actuation

2.3.4-2

Benni Mini 2013.01

2.3.4-2Parking Brake and Actuation


System Overview

Parking braking is actuated by the rear brake.

The parking brake system consists of parking

brake, manual braking control mechanism and

parking brake cable.

Parking brake system is a mechanical system

controlling the rear drum brake through a parking

brake lever. The system is actuated by pulling up

the parking brake lever which allows the rear

drum brake shoes (primary shoes and secondary

shoes) to expand outward to apply parking brake

through the cables. The parking brake indicator in

the instrument cluster is turned on when the

parking brake lever is pulled up and connected to

the ignition switch. Pull up the lever and depress

the button on it. Put down lever to release the

parking brake and the parking brake indicator in

the instrument cluster is turned off.

Benni Mini 2013.01


General Procedures

Parking Brake Cable

Adjustment

CAUTION: Inspect the rear drum brake

shoes for not excessive wear before the

adjustment.

1. Remove the console.

Refer to: Console (5.1.6 Instrument Panel

and Console).


3. Loosen the adjustment nut.

4. Repeat depressing the brake pedal 6 times

and then release it.

5. Draw back the parking cable with all strength

4 times and then adjust the cable.

1.Pull up the parking brake lever with 4

creaks.

2.Tighten the adjustment nut.

Torque: 4 Nm

6. Test the parking brake for normal operation.

7. Install the parking brake control cover.

A2304007

A2304007

2.3.4-4

Benni Mini 2013.01




1. Verify the customer concerns.

2. Visually inspect for any obvious signs of

mechanical damage and hydraulic troubles.


3. Solve the known problems before the next

step.


reported concern is found, correct the

problem before proceeding to the next step.


symptom and refer to the Symptom Chart.

General Equipments

Mechanical

•Tire pressure (s)

•Wheel and tire

•Brake fluid level

•Brake line leak

Digital Multimeter

Benni Mini 2013.01


Symptom Chart


Parking brake failure

Poor parking brake force

•Excessive parking brake lever

travel

Refer to: Parking Brake Cable

Adjustment (2.3.4 Parking

Brake and Actuation, General

Procedures).

•Left and right parking brake cable

(seized and cracked)

•Repair or remove new parking brake

cables.


(2.3.4 Parking Brake and Actua-

tion, Removal and Installation).

•Cable equalizer (lossened,

crakced, distorted)•Install a new cable equalizer.

•Rear brake shoes (worn to the

limit)

•Install new brake shoes.

Refer to: Brake Shoe (2.3.2 Rear


Installation).

•Rear drum brake inner the fulcrum

post and parking control lever

(distorted and cracked)

•Install the fulcrum pin and parking control

lever.

Parking brake can not

release (lag)

•Insufficient parking brake lever

travel


Adjustment (2.3.4 Parking

Brake and Actuation, General

Procedures).

• Left and right parking brake

cables (seized)

•Repair or remove new parking brake

cables.

Refer to: Install New Parking

Brake Cables (2.3.4 Parking

Brake and Actuation, Removal

and Installation).

• Rear brake shoe (seized, cracked

and distorted)

•Repair or install new brake shoes.

Refer to: Brake Shoe (2.3.2 Rear


Installation).

•Rear brake return spring (fatigue

and cracked)•Install new return springs.

2.3.4-6

Benni Mini 2013.01


Parking Brake Not Work (Failure) Diagnosis/Poor Parking Brake

The parking brake indicator

is turned off when the

ignition switch is

in“ON”position and the

vehicle is under parking

state

•Instrument cluster fuse

•The diagnostic procedures for the switch-

off of the parking warning indicator when

the ignition switch is in ”ON” position and

the vehicle is in parking state.

Refer to: Symptom Chart (4.3.2

Instrument Cluster, Symptom


•Instrument wiring harness

connector

•Instrument power circuit

•nstrument ground circuit

•The wiring harness between the

parking brake warning indicator

switch and instrument cluster

•Parking brake switch

•Instrument cluster

The parking brake indicator

is always on

•Parking brake switch Refer to: Parking Brake Indica-

tor Always On (2.3.4 Parking

Brake and Actuation, Symptom


•The wiring harness between the

parking brake switch and the

instrument (wiring harness

connectors)

•Wiring harness (Instrument clus-

ter assembly-power supply and

ground)

•Instrument cluster


1. Inspect the travel of the parking brake control lever

A.Inspect if the travel of the parking brake control

lever is normal.

Is it normal?

Y

Go to step 2.

N

Adjust the travel of the parking brake control lever.



Procedures).


Benni Mini 2013.01


2. Inspect the parking brake cable

A.Inspect the parking brake cable for any damage or


Is it normal?

Y

Go to step 3.

N

Repair or replace the parking brake cable.

Refer to: Parking Brake Cable (2.3.4 Park-

ing Brake and Control, Removal and

Installation).

3. Inspect the thickness of the rear brake shoe

A.Inspect if the thickness of the brake shoe is normal.

Is it normal?

Y

Go to step 4.

N

Replace the brake shoe.



4. Inspect the return spring of the rear brake

A.Inspect if the return spring of the rear drum brake is

normal.

Is it normal?

Y


N

Inspect and repair the rear drum brake.


2.3.4-8

Benni Mini 2013.01


Parking Brake Not Release (Lag) Diagnosis


1. Inspect the travel of the parking brake control lever

A.Inspect if the travel of the parking brake control

lever is normal.

Is it normal?

Y

Go to step 2.

N

Adjust the travel of the parking brake control lever.



Procedures).

2. Inspect the parking brake cable

A.Inspect the parking brake cable for any damage or


Is it normal?

Y

Go to step 3.

N

Repair or replace the parking brake cable.

Refer to: Parking Brake Cable (2.3.4 Park-

ing Brake and Control, Removal and

Installation)

3. Inspect the rear brake shoe

,

A.Inspect if the thickness of the brake shoe is normal.

Is it normal?

Y

Go to step 4.

N

Replace the brake shoe.

Refer to: Brake Shoe (2.3.2 Rear drum


4. Inspect the return spring of the rear brake

A.Inspect if the return spring of the rear drum brake is

normal.

Is it normal?

Y


N

Inspect and repair the rear drum brake.

Benni Mini 2013.01


Parking Brake Indicator Always On Diagnosis


1. General inspection

A.Inspect for the brake fluid lack.

Is it normal?

Y

Go to step 2.

N

Inspect and repair the brake fluid level.

2. Inspect the parking brake switch

A.Turn the ignition switch to position "LOCK".

B.Disconnect the brake switch wiring harness

connector S11.

C.Inspect whether the switch is disconnected when

the parking brake lever is put down; and whether

the switch is connected when the parking brake

lever is pulled up.

Are all the conditions above satisfied?

Y

Go to step 3.

N

Inspect and repair the parking brake switch, and

replace it when necessary.

2.3.4-10

Benni Mini 2013.01


3. Inspect the circuit between the wiring harness connector S11 and P07

,


B.Disconnect the instrument cluster wiring harness

connector P07, the wiring harness connector C10

of the brake fluid level sensor, and the wiring

harness connector S11 of the brake switch.

C.Measure the resistance between the terminal 1 of

the brake switch wiring harness connector S11 and

the body ground with a multimeter.

Standard Resistant Value: 10 M or higher

Is the resistant value normal?

Y

Go to step 4.

N

Inspect and repair the failed circuit.

4. Replace the brake fluid level sensor


B.Disconnect the wiring harness connector C10 of the

brake fluid level sensor.

C.Inspect whether the brake fluid level sensor is

normal (The two pins shall not be conducted when

the brake fluid level is normal).

Is the brake fluid level sensor normal?

Y

Go to step 5.

N

Replace the brake fluid level sensor.


S11

1

A2304010

S11

P07

17

1

1 2 16

32

A2304011

1 2

C10

A2304012

Benni Mini 2013.01


5. Inspect the instrument cluster power supply

A.Turn the ignition switch to position "ON" and inspect

the power supply circuit of the terminal 7 of the

wiring harness connector P07 of the instrument

cluster.

Standard Voltage Value: 11~14 V

Is it normal?

Y

Replace the instrument cluster.

Refer to: Instrument Cluster (4.3.2 Instru-

ment Cluster, Removal and Installation).

N

Inspect and repair the instrument cluster circuit.


17

1 7 16

32

P07

A2304014

2.3.4-12

Benni Mini 2013.01



Parking Brake Control

Removal

1. Remove the console.

Refer to: Console (5.1.6 Instrument Clus-

ter and Console, Removal and Installa-

tion).


1.Loosen the adjustment nut.

Torque: 4 Nm

2.Adjust the parking brake cable.

3. Remove the parking brake lever retaining

bolt.

Torque: 23 Nm

4. Disconnect the parking brake indicator switch

connector and detach the parking brake lever.

1

2 2

A2304001

×2

A2304002

A2304003

Benni Mini 2013.01


Installation

Parking brake cable

Removal





eral Procedures).

1. Remove the center console.



tion).


1.Loosen the adjustment nut.

Torque: 4 Nm

2.Adjust the parking brake cable.

3. Remove the parking brake rear cable

retaining bolt as shown on the right

illustration.

Torque: 9 Nm

1

2 2

A2304001

×2

A2304004

2.3.4-14

Benni Mini 2013.01


Installation



illustration.

Torque: 9 Nm



illustration.

Torque: 9 Nm







8. Remove the parking brake cable.

1.Remove the retaining clamp.

2.Detach the brake cable.





eral Procedures).

A2304005

A2304006

1

2

A2302022

Benni Mini 2013.01


Parking Brake Warning Lamp Switch

Removal

Installation

1. Remove the center console.



tion).

2. Removal the switch.

1.Disconnect the switch connector.

2.Remove the switch retaining screw.

3.Detach the switch.





eral Procedures).

2

1

A2304008

Benni Mini 2013.01

2.3.5-1 2.3.5-1Hydraulic Brake Actuation

Specification



Item Specification

Brake fluid HZY4

Item Nm lb-ft lb-in

Brake master cylinder and pipe retaining

nut16 12 -

Brake master cylinder retaining nut 25 18 -

Brake pedal coupling spindle retaining nut 25 18 -

2.3.5 Hydraulic Brake Actuation

2.3.5-2

Benni Mini 2013.01

2.3.5-2Hydraulic Brake Actuation


System Overview

The vehicle is stopped as the brake pad presses

tightly the brake disc with a mechanical force

transformed from a hydraulic pressure by the

brake slave cylinder to which a hydraulic pressure

that is transformed from a mechanical force from

the brake pedal by the brake master cylinder is

delivered through the brake hard pipes and hoses

after the adjustment of the hydraulic electronic

control unit or proportioning valve.


Brake Pedal

The brake system input force is received, ampli-

fied and delivered from the driver.

Brake Pedal Push Rod

Deliver the increased brake pedal input force to

the vacuum booster.

Brake Master Cylinder Reservoir

Brake fluid used for the hydraulic brake system is

installed inside.

Brake Master Cylinder

Transform the mechanical input force into hydrau-

lic output force. The hydraulic output pressure is

distributed into two hydraulic brake tubes from the

master cylinder, providing brake fluid for the diag-

onal wheel brake tubes.

Brake Pipes and Brake Hose

Pass the brake fluid through each component of

the hydraulic brake system.


Transform the hydraulic input pressure into

mechanical output force.

Brake Fluid Low Level Warning Indicator

The instrument cluster turns on the brake fluid low

level warning indicator when it detects the exces-

sive brake fluid low level (The signal circuit is at

electronegative potential) or the parking brake

lever is not released.

Benni Mini 2013.01



Brake Master Cylinder and Brake Fluid Reservoir

Removal

Material

Item Model

Brake fluid HZY 4

CAUTION: If brake fluid is spilt on the



CAUTION: The reservoir must be clean.

1. Disconnect the brake fluid low level warning

lamp switch connector.

2. Remove the reservoir cap.

3. Drain the brake fluid from the reservoir.

1.Connect one end of a suitable piece of clear

plastic pipe to the system bleeding nozzle

and place the other end into a suitable con-

tainer.

2.Loosen the brake bleeding nozzle.

3.Depress the brake pedal until all the brake

fluid is drained from the brake fluid reservoir.

4.Tighten the brake bleeding nozzle.

CAUTION: Repeat the draining procedure

on the opposite side brake.

1

2

A2305001

2

1

43

A2305002

2.3.5-4

Benni Mini 2013.01


Installation

4. Remove the brake pipe from the brake

master cylinder.

Torque: 16 Nm

5. Remove the brake master cylinder and the

brake fluid reservoir assembly.

1.Remove the retaining nut.

Torque: 25 Nm

2.Take out the brake master cylinder.





eral Procedures).

CAUTION: Make sure that the brake

booster push rod is correctly located

before the installation.

CAUTION: Make sure that the brake mas-

ter cylinder vacuum seals are correctly

located before the installation.

×2

A2305003

A2305004

Benni Mini 2013.01


Brake, Clutch and Accelerator Pedal Assembly (MT)

Removal

1. Disconnect the battery negative cable.

Refer to: Battery Inspection (3.1.10 Charg-

ing System, General Procedures).

2. Remove the air cleaner assembly.

3. Release the clutch cable.

Torque: 4 Nm

4. Remove the clutch pedal external firewall

retaining bolts and nuts.

Torque: 25 Nm

5. Disconnect the stop lamp switch connector.

A2305005

A2305006

A2305007

2.3.5-6

Benni Mini 2013.01


6. Remove the throttle cable from the accelerator

pedal.

7. Remove the accelerator pedal from the brake,

clutch and accelerator pedal assembly.

1.Remove the accelerator pedal retaining

snap ring.

2.Detach the accelerator pedal.

8. Detach the clutch cable from the clutch pedal.

9. Remove the brake booster.

1.Remove the brake push rod and brake

pedal retaining clamp, detach the push rod

retaining pin.

2.Remove the four mounting bolts on the

brake booster.

Torque: 25 Nm

A2305008

A2305011

A2305009

2×4

1

A2306002

Benni Mini 2013.01


Installation


10. Remove the five mounting bolts and nuts on

the brake, clutch and accelerator pedal

assembly.

Torque: 25 Nm

11. Detach the brake, clutch and accelerator

pedal assembly.

A2305010

A2305012

2.3.5-8

Benni Mini 2013.01


Brake Pedal Assembly (AT)

Removal




2. Remove the clutch pedal external firewall

retaining bolts and nuts.

Torque: 25 Nm

3. Disconnect the stop lamp switch connector.

4. Remove the accelerator pedal position

sensor.

Refer to: Accelerator Pedal Position Sen-

sor (3.1.13 Electrical control System-ME7,



1.Remove the brake push rod and brake


retaining pin.

2.Remove the four mounting bolts on the

brake booster.

Torque: 25 Nm

6. Remove the five mounting bolts and nuts on

the brake pedal assembly.

Torque: 25 Nm

7. Remove the steering column.

Refer to: Steering Column (2.4.4 Steering

Column, Removal and Installation).

A2305006

2×4

1

A2306002

A2305013

Benni Mini 2013.01


Installation


8. Detach the pedal assembly.

A2305014

Benni Mini 2013.01

2.3.6-1 2.3.6-1Power Brake Actuation

Specifications


Item Nm lb-ft lb-in

Brake booster retaining bolt 25 18 -

Brake master cylinder retaining bolt 25 18 -

2.3.6 Power Brake Actuation

2.3.6-2

Benni Mini 2013.01

2.3.6-2Power Brake Actuation


System Overview

The brake system input force is increased by the brake pedal and delivered to the vacuum booster by

the brake pedal actuating rod, and then applied to the hydraulic brake master cylinder after the brake

booster assists power. Vacuum booster uses the vacuum source to assist power so as to reduce the

pedal effort for the driver when applying the brake.

Location View

Item Description

1 Brake booster

1

A2306004

Benni Mini 2013.01

2.3.6-3 2.3.6-3Power Brake Actuation


Brake Booster

Removal





tainer.







2. Remove the brake master cylinder.




CAUTION: If the brake fluid is spilled on

the paintwork, the affected area must be


3. Release the vacuum booster tube snap ring

and detach the vacuum booster tube.

2

1

43

A2305002

A2306001

2.3.6-4

Benni Mini 2013.01

2.3.6-4Power Brake Actuation

Installation


1.Remove the brake push rod and the brake


retaining pin.

2.Remove the 4 mounting bolts on the brake

booster.

Torque: 25 Nm






eral Procedures).





ter cylinder vacuum seal is correctly

located before the installation.

2×4

1

A2306002

A2306003

Benni Mini 2013.01

2.3.7-1 2.3.7-1Anti-Lock Control

Specifications



Item Specification

Brake fluid HZY4

Item Nm lb-ft lb-in

Electronic hydraulic control unit retaining

bolt9 - 80

Brake line and electronic hydraulic control

unit connection retaining bolt16 12 -

Front wheel speed sensor retaining bolt 9 - 80

Rear wheel speed sensor retaining bolt 23 17 -

2.3.7 Anti-lock Control

2.3.7-2

Benni Mini 2013.01

2.3.7-2Anti-Lock Control


System Overview

MK70-M Anti-lock Brake System (ABS)

The MK70-M type ABS is designed especially for small and medium-sized vehicles. Compared with the

MK20 ABS system, it greatly reduces the size of the electric control and hydraulic control unit (such as

hydraulic valve and solenoid valve), and the housing size. So the weight of the whole ABS hydraulic con-

trol unit greatly reduces. The hydraulic control unit comprises the pump, the valve body (which contains

eight hydraulic valves) and the electronic control unit. The ABS control module controls the ABS warning

lamp ON and OFF in the instrument panel via the K-line. The MK70-M type ABS is a system called "4/4".

That is the wheel speed of the four wheels is measured separately. (Use four wheel speed sensors.) The

ABS uses the independent control for four wheels.


1. Hydraulic Electronic Control Unit

CAUTION: There is a rubber damping pad between the mounting bolt and the bracket of the

hydraulic electronic control unit. The rubber damping pad is used to prevent from the hydrau-

lic electronic control unit from the vehicle vibration.

The hydraulic electronic control unit can not be disassembled but replaced as an assembly.

The main components of the hydraulic electronic control unit includes the ABS control module, the valve

body and the ABS pump.

23

1

A2307011

Benni Mini 2013.01


Function

As the closed-loop control system, the purpose of the ABS brake system is to prevent the failure of the

steering and the driving performance during the wheel brake lock.

ABS control module

The ABS control module compares the deceleration limit value of its own storage with the deceleration

value detected from each vehicle wheel speed sensor, so you can detect the locking tendency of each

wheel. If the ABS control module detects a wheel with the locking tendency, the corresponding hydraulic

valves of the valve body will be opened or closed. The ABS control module also sends the detected

wheel speed sensor signals to the power control module (PCM). The ABS control module opens the

ABS warning lamp located in the instrument panel when switching on the ignition switch. The warning

lamp will remain lit until the ABS completes the system self-test. The system failure warning lamp will

also be opened (as a warning). The ABS control module keeps monitoring any possible system failure, in

the event, it will automatically store. The DTC can be found by connecting the DLC with the WDS. The

ABS is connected with the DLC directly via the diagnosis data interface.

Valve assembly

The valve assembly includes four inlet valves with four oil outlet valves. Each wheel has an oil inlet valve

and an oil outlet valve.

The oil inlet valve is opened and the oil outlet valve is closed when it is out of power.

The valve assembly also includes a low pressure reservoir and a noise reduction chamber.

ABS pump

When the ABS pump works, the ABS pump provides sufficient pressure for the brake master pump to

ensure that the role of the independent adjustment of the respective channels.

ABS hydraulic control adjustment cycle

One ABS adjustment cycle consists of three stages:

First stage - packing stage:

The oil inlet valve is closed, the wheel brake (slave pump) pressure can be no longer changed, that is

the slave pump pressure will not be changed even you depress the brake pedal down again.

Second stage - decompression stage:

The oil outlet valve is temporarily opened, the pressure in the wheel brake (slave pump) is decreased in

a controlled manner.

Third stage - boosting stage:

The intake valve is gradually opened, the brake pressure is increased in a controlled manner to obtain

the best braking effect.


1 Pump 3 ABS control module

2 Valve body

2.3.7-4

Benni Mini 2013.01


Anti-lock Brake System (ABS) Hydraulic Line Schematic Diagram


AV Normally closed solenoid valve RR Right rear wheel

EV Normally open solenoid valve LR Left rear wheel

M Motor RF Right front wheel

LF Left front wheel A1 Pressure accumulator 1

A2 Pressure accumulator 2 B1 Buffer 1

B2 Buffer 2

RF LR RR LF

-

-

-

-

RFEV

RFAV

A2

FP2

MC2 MC1

pedal assistance

2 bar admission pressure

M－FP1

-

-LREV

-

-RREV

-

-LFEV

-LRAV

-

-

RRAV

A1

-LFAV

B1B2

A2307012

Benni Mini 2013.01


2. Wheel Speed Sensor

The wheel speed sensor is a passive two-wire sensor. With the wheel rotation, the ABS control module

uses the wheel speed signal to calculate the wheel speed and acceleration. The sensor obtains the

pulse signal from the ring gear, and the signal is transfered into a digital signal by the circuit integrated in

the sensor and then passed to the ABS control module. The front wheel ring gear is fixed on the halfshaft

as its integral. The rear wheel ring gear is fixed on the rear bearing.

3. Brake Lamp Switch

The brake lamp is on when the brake pedal is depressed, meanwhile, the brake signal is sent to the ABS

control module.

4. ABS Indicator Lamp

The ABS indicator lamp is located on the instrument cluster to inform the driver the ABS system failure

by ON. When the ABS works normally, the ignition switch turns from "OFF" to "ON", the ABS system per-

forms the self-test, the indicator lamp lights for about 2.0 s, and then goes out and always remains off.

When the following events occurs, the instrument cluster will light the ABS indicator lamp:

The ABS control module detects the ABS system failure.

The instrument cluster receives a request of lighting the indicator lamp from the ABS control module.

• The ABS performs a self-test at the beginning of each ignition cycle. The indicator lamp lights for

about 2.0 s.

• The instrument cluster detects a loss of communication with the ABS control module.

A2307013

2.3.7-6

Benni Mini 2013.01


5. EBD Indicator Lamp

It is located on the instrument cluster to inform the driver the EBD failure by ON. When the ABS indicator

lamp is on but the EBD indicator lamp is off, the system still has the EBD function. When the ABS indica-

tor lamp and the EBD indicator lamp are both on, both the ABS and the EBD functions are invalid.

Benni Mini 2013.01


General Procedures



2. Visually inspect for obvious mechanical or

electrical fault.


3. Solve the known problems before proceeding

to the next step.





symptom and refer to the Symptom Chart.

General Equipment

Mechanical Electrical

• Wheel speed sensor

• Wheel speed sensor

ring gear(s)

• Fuse

•Connector

•Wiring harness

Digital Multimeter

Changan Auto Special Diagnostic Tool

2.3.7-8

Benni Mini 2013.01



Intermittent Malfunction Diagnosis

CAUTION: 1. Clear the DTC.

2. Carry out the simulation test.

3. Inspect and shake the wiring harnesses, connectors and terminals.

When the malfunction can not be inspected by the DTC, it occurs occasionally while being used. Confirm

the circuit and components that may lead to malfunction. In many cases, through the performance of the

the basic inspections shown in the following flowchart, the fault can be quickly and efficiently located,

especially for the poor wiring harness connector contact and other faults. Malfunction definition: This

malfunction currently does not appear, but the historical malfunction diagnosis code record indicates that

the malfunction occurred before. Or the customer reports the malfunction, but as the malfunction is not

related to the malfunction diagnosis code, and currently the malfunction symptoms can not show again.


1. Vibration method

If driving on a tough roads, the malfunction occurs

or becomes more serious, or the engine starts

vibration, perform the following steps.

CAUTION: Some reasons may cause vehi-

cle or engine electrical failure. Inspect the

following items:

1. The connector is not fully in position.

2. The wiring harness does not have

enough clearance.

3. The wiring harness layout is across the

bracket or moving components.

4. The wiring harness lays too close to the

high temperature components.

CAUTION: Incorrect wiring, tight or loose

wiring harness will lead the connecting

cable to be squeezed between the compo-

nents.

CAUTION: The connector joint, the vibra-

tion location, the location of the wiring

harness crossing are all required for

focus inspection, such as: wiring harness

across the firewall and the body panels.

Benni Mini 2013.01


2. Inspection method of the switch connector or wiring harness

1.Connect the diagnostic tool to the data link

connector (DLC).

2.Turn the ignition switch to position "ON" (stop the

engine).

3.Access to the switch data stream that you are

inspecting.

4.Turn on the switch manually.

5.When monitoring the data stream, vertically,

horizontally gently shake each connector or wiring

harness.

If the data stream value is unstable, please inspect

if there is a bad connection.

3. Sensor connector or wiring harness inspection method


connector (DLC).


engine).

3.Access to the switch data stream that you are

inspecting.

4.When monitoring the data stream, vertically,

horizontally gently shake each connector or wiring

harness.

If the data stream value is unstable, please inspect

if there is a bad connection.

4. Inspect method of the actuator or relay


connector (DLC).


engine).

3.Perform the active test on the inspected actuator or

relay.

Refer to: Active Test List (2.3.7 Anti-lock

Control, DTC Control and Testing).


A2307014

A2307015

2.3.7-10

Benni Mini 2013.01


ABS Warning Lamp Is OFF Diagnosis

ABS warning lamp is off diagnosis

Refer to: Symptom Chart (4.3.2 Instrument Cluster, Symptom Diagnosis and Testing).

5. Perform the road test to simulate the failure and read the data stream.

1.Connect the diagnostic tool to to data link connector

(DLC).

2.Perform the road test to simulate the failure and

read the data stream.

Refer to: Data Stream List (2.3.7 Anti-lock

Control, DTC Control and Testing).

CAUTION: This work needs two people's

cooperation.

If the data stream value is unstable or fails, please

repair or replace the components.


Benni Mini 2013.01


ABS Warning Lamp Always ON Diagnosis


1. Read the ABS anti-lock control system fault codes

A.Connect the special diagnostic tool.

B.Turn the ignition switch to position "ON" and read

the DTC of the ABS anti-lock control system on the

special diagnostic tool.

Are there any ABS anti-lock control system fault

codes?

Y

Repair according to the instruction of the DTC.

Refer to: DTC Diagnosis Chart (2.3.7 Anti-

lock Control, DTC Diagnosis and Testing).

N

Go to step 2.

2. Inspect the wiring harness between the instrument and the ABS control module.

A.Turn the ignition switch to position "LOCK" and

disconnect the battery negative cable.

B.Disconnect the instrument cluster wiring harness

connector P07.

C.Disconnect the ABS control module wiring harness

connector C12.

D.Measure the resistance between the terminal 18 of

the instrument cluster wiring harness connector

P07 and the terminal 10 of the ABS control module

wiring harness connector C12.

Standard Resistance Value: less than 5

E.Measure the voltage between the terminal 18 of the

instrument cluster wiring harness connector P07

and the terminal 10 of the ABS control module

wiring harness connector C12 respectively.

Standard Voltage Value: 0 V

Is the resistance value normal?

Y

Go to step 3.

N

Inspect and repair the circuit fault of the circuit

between the terminal 18 of the instrument cluster

wiring harness connector P07 and the terminal 10

of the ABS control module wiring harness connec-

tor C12.

P07

C12

32

16

17 18

1

13

26

12

15

12 10

25 14

A2307016

2.3.7-12

Benni Mini 2013.01


3. Inspect the ABS control module power supply and ground



B.Disconnect the ABS control module wiring harness

connector C12.

C.Turn the ignition switch to position "ON", measure

the terminal 1 and 20 of the ABS control module

wiring harness for normal power supply.


D.Turn the ignition switch to position "LOCK".

Measure if the ground for the terminal 26 of the

ABS control module is normal.


Is it normal

Y

Replace the ABS control module.

Refer to: Hydraulic Control Unit (HCU)

(2.3.7 Anti-lock Control, Removal and

Installation).

If it is still not normal, go to step 4.

N

Repair the circuit. If it is still not normal, go to step

4.

4. Replace the instrument cluster control unit


disconnect the battery negative.

B.Replace the instrument cluster.



Verify the system is normal.


C12

13

26

12

15

12

2025 14

A2307017

C12

13

26

12

15

12

25 14

A2307018

Benni Mini 2013.01


DTC Diagnosis and Test

Control Module Terminal List

Terminal ID Wiring Terminal Description StatusSpecified

Conditions

1 4.0 WH/RD Battery voltage 12 V

2 0.5 LG Left rear wheel speed input 1

3 0.5 LG/BK Left rear wheel speed input 0

4 - - - -

5 0.5 GN/BK Right front wheel speed input 0

6 0.5 GN Right front wheel speed input 1

7 - - - -

8 0.5 BU Left front wheel speed input 0 -

9 0.5 BU/BK Left front wheel speed input 1 -

10 0.5 OG EBD warning lamp - -

11 0.5 VT/BK Right rear wheel speed input 0 -

12 0.5 VT Right rear wheel speed input 1 -

13 - - - -

14 - - - -

15 - - - -

16 0.5 GN/BN Brake lamp switch

17 - - - -

18 0.5 PK K-line For diagnosisIgnition

switch ON

19 0.5 SR/GN ABS warning lamp - -

13

26

12

15

12

25 14

C12

A2307019

2.3.7-14

Benni Mini 2013.01


DTC Code List

20 0.5 WH/GN Ignition switch wire 12VIgnition

switch ON

21 0.5 BU/BK CAN_L CAN bus -

22 - - - -

23 0.5 BU/WH CAN_H CAN bus -

24 - - - -

25 - - - -

26 3.0 BK Ground wire 0V -

Malfunction Description

0x0003 •Controller fault

0x3FD8 •Controller, RAM fault

0x3FD9 •Controller, external RAM fault

0x3FDB •Controller, EEPROM fault

0x3FDC •Controller, calibration and fault

0x3FDE •Controller, self-test fault

0x3FDF •Controller, program fault

0x3FE0 •Controller, electrical fault

0x3FE1 •Controller, function fault

0x3FE3 •Controller, watchdog timer

0x3FF4 •Controller, internal sensor fault

0x0412 •Controller uncoded

0x0414 •No controller code (byte code)

0x029C •Battery voltage KL30 fault

0x046A •ABS works abnormally.

0x0520 •Data bus works abnormally.

0x011B •Left front wheel speed sensor fault

0x011D •Right front wheel speed sensor fault

0x0122 •Left rear wheel speed sensor fault

0x011F •Right rear wheel speed sensor fault

0x020E •Brake lamp switch fault

0x04FC •Hydraulic pump

0x08A6 •Tire pressure warning (reserved)

Terminal ID Wiring Terminal Description StatusSpecified

Conditions

Benni Mini 2013.01


Data Stream List

By reading the "Data Stream List" on the fault diagnostic tool, do not remove any component, and

inspect the working state of the switches, the sensors, and the actuators. Before the fault diagnosis of

the engine electrical control system, the observation and analysis of the data is the first step in trouble-

shooting, this can reduce the troubleshooting time.

CAUTION: The following table lists the data under normal conditions, only for reference. Do

not determine the failure based on these standard values. Generally, use a normal vehicle to

compare a vehicle in diagnosis under the same state to determine the data of the diagnosis

vehicle under the current state normal or not.

1. Let the engine reach the normal operating temperature.

2. Turn the ignition switch to position "OFF".

3. Connect the fault diagnostic tool.

4. Turn the ignition switch to position "ON".

5. Select "Benni Mini/Continental ABS/Actual values".

6. Refer to the chart below to inspect all the data.

Diagnostic Tool Display Item Data

Left front wheel speed 0 km/h

Right front wheel speed 0 km/h

Left rear wheel speed 0 km/h

Right rear wheel speed 0 km/h

Brake lamp switch status Loose

Brake warning lamp status Disconnect

ABS warning lamp status Disconnect

2.3.7-16

Benni Mini 2013.01


Active Test List

Use the reading diagnostic tool to perform the active test, do not remove any components, inspect the

work state of the relay and the actuator that controlled by the ABS control module. Before the relevant

fault diagnosis of the ABS control system, the implementation of the action test is the precondition in

troubleshooting, this can reduce the troubleshooting time.

1. Let the engine reach the normal operating temperature.

2. Turn the ignition switch to position "OFF".

3. Connect the fault diagnostic tool.

4. Turn the ignition switch to position "ON".

5. Select Benni Mini/Continental ABS/Unit test and perform the test below:

Component test:

The valve control test and pump control test can be performed.

Hydraulic control unit test:

The control unit tests on the four wheels in accordance with the sequence of the left front wheel, the right

front wheel, the left rear wheel and the right rear wheel, and the testing process is performed in strictly

accordance with the steps.

Test conditions:

1. Test under voltage is not allowed.

2. The wheel speed can not exceed 20 km/h.

3. The test time shall not exceed 90s.

Diagnostic Tool

Display ItemPart Control Range Diagnostic Description

Left front normally

open valve

ABS left front oil inlet

valve solenoid coil

The solenoid valve is

open or closed.

The sound of the working

solenoid valve can be heard.

Right front normally

closed valve

ABS right front oil inlet

valve solenoid coil


open or closed.



Left front oil outlet

valve

ABS left front oil outlet

valve solenoid coil


open or closed.


solenoid coil can be heard.

Right front oil outlet

valve

ABS right front oil outlet

valve solenoid coil


open or closed.



Left rear oil inlet

valve

ABS left rear oil inlet

valve solenoid coil


open or closed.



Right rear oil inlet

valve

ABS right rear valve sole-

noid coil


open or closed.



Left rear oil outlet

valve

ABS left rear normally oil

outlet solenoid coil


open or closed.



Right rear oil outlet

valve

ABS right rear oil outlet

valve solenoid coil


open or closed.



Pump MotorThe motor acts or does

not act.


motor can be heard.

Benni Mini 2013.01


Procedures:

Confirm each sub-step in order.

1. Depress and hold the brake pedal.

2. The normally open valve is opened, the normally closed valve is closed, and the wheels are locked.

3. The normally open valve is closed, the normally closed valve is closed, and the wheels are locked.

4. The normally open valve is closed, the normally closed valve is opened, and the wheels are locked.

5. The normally open valve is closed, the normally closed valve is closed, and the wheels are locked.

6. The normally open valve is opened, the normally closed valve is closed, and the wheels are locked.

7. Release the brake pedal.

Bleeding and filling test:

First bleed the conventional brake system.

Refer to: (2.3.1 Brake System - General Information, General Procedures).

Then perform strictly in accordance with the following steps.

1. Depresses the brake pedal, and keep the hydraulic pump working.

2. Release the brake pedal, deflate the left and right front brake caliper.

3. Depress the brake pedal for 10 times.

4. Exist.

Diagnostic Tool Can Not Communicate With the Vehicle Diagnosis

CAUTION: The internal module short circuit can also cause the fault.

Refer to: Diagnostic Tool Can Not Communicate With ECM Diagnosis (4.3.15 On-board Net-

work, Symptom Diagnosis and Testing).

2.3.7-18

Benni Mini 2013.01


DTC Diagnosis Chart

Malfunction Description Diagnosis Procedures

0x0003 •Controller fault Refer to: Power Supply Fault and Hydraulic

Electrical Control Unit Assembly Internal Fault

Diagnosis (2.3.7 Anti-lock Control, DTC Diag-

nosis and Testing).

0x3FD8 •Controller, RAM fault

0x3FD9•Controller, external RAM

fault

0x3FDB•Controller, EEPROM

fault

0x3FDC•Controller, calibration

and fault

0x3FDE •Controller, self-test fault

0x3FDF •Controller, program fault

0x3FE0•Controller, electrical

fault

0x3FE1 •Controller, function fault

0x3FE3•Controller, watchdog

timer

0x3FF4•Controller, internal sen-

sor fault

0x0412 •Controller uncoded

0x0414•Wrong controller code

(byte code)

0x029C•Battery voltage KL30

fault

0x046A •ABS working abnormally

0x04FC •Hydraulic pump

0x011B•Left front wheel speed

sensor fault

Refer to: Wheel Speed Sensor Diagnosis (2.3.7

Anti-lock Control, DTC Diagnosis and Testing).

0x011D•Right front wheel speed

sensor fault

0x0122•Left rear wheel speed

sensor fault

0x011F•Right rear wheel speed

sensor fault

0x0520•Data bus works abnor-

mally

Refer to: Abnormal Data Bus Diagnosis (2.3.7

Anti-lock Control, DTC Diagnosis and Testing).

0x020E •Brake light switch fault

Refer to: Brake Lamp Switch Fault Diagnosis

(2.3.7 Anti-lock Control, DTC Diagnosis and

Testing).

Benni Mini 2013.01


Power Supply Fault and Hydraulic Electrical Control Unit Assem-

bly Internal Fault Diagnosis


1. Inspect the battery voltage

A.Turn the ignition switch to position "ST" and start the

engine.

B.Use the multimeter to measure the battery voltage

for normal value.


Is the voltage normal

Y

Go to step 2.

N

Refer to: Battery Undercharge Diagnosis,

Battery Overcharge Diagnosis (Charging

System, Symptom Diagnosis and Test-

ing).

2. ABS control module power supply and ground




connector C12.



wiring harness connector C12 for normal power

supply.


D.Turn the ignition switch to position "LOCK",

measure the terminal 26 of the ABS control module

wiring harness connector C12 for normal ground.


Is it normal

Y

Go to step 3.

N

Repair the circuit.

C12

13

26

12

15

12

2025 14

A2307017

C12

13

26

12

15

12

25 14

A2307018

2.3.7-20

Benni Mini 2013.01


Wheel Speed Sensor Diagnosis

CAUTION: The maintenance manual is only for the left front wheel speed sensor fault diagno-

sis, similar to the diagnostic way of the rest wheel speed sensors.

Refer to: (Left front wheel speed sensor fault diagnosis)

3. Use the special diagnostic tool to access the ABS control module

A.Use the special diagnostic tool to access the ABS

control module to perform the active test on the

ABS pump.

Can the sound of the working ABS pump be heard?

Y

System is normal.

N




Installation).


1. Inspect the installation of the left front wheel speed sensor

A.Inspect the installation of the left front wheel speed

sensor.

Is it loose?

Y

Tighten it.

N

Go to step 2.

2. Inspect the left front wheel speed sensor wheel speed data

A.Use the diagnostic tool to observe the wheel speed

sensor speed data.

Are the data the same as other wheels?

Y

Go to step 3.

N

Replace the left front wheel speed sensor.


Benni Mini 2013.01


3. Inspect the left front wheel speed sensor

A.Remove the left front wheel speed sensor.

B.Inspect the sensor head for scratches, foreign

matters and dirt.

C.Inspect the wheel speed sensor for normal

clearance.


Y

Clear or replace the sensors.

N

Go to step 4.

4. Inspect the wiring harness between the left front wheel speed sensor and the ABS control module




connector C12.

C.Disconnect the left front wheel speed sensor wiring

harness connector C07.

D.Measure the resistance value between the terminal

8 of the ABS control module wiring harness

connector C12 and the terminal 1 of the left front

wheel speed sensor wiring harness connector C07.

E.Measure the resistance value between the terminal

9 of the ABS control module wiring harness

connector C12 and the terminal 2 of the left front

wheel speed sensor wiring harness connector C07.


Is the resistance normal?

Y

Go to step 5.

N

Repair or replace the wiring harness.


C12

C07

1 2

13

26

12

15

12 8

25 14

A2307022

C12

C07

1 2

13

26

12

15

12 9

25 14

A2307023

2.3.7-22

Benni Mini 2013.01


5. Inspect the wiring harness of the left front wheel speed sensor



B.Disconnect the left front wheel speed sensor wiring

harness connector C07.

C.Measure the resistance between the terminal 1 and

2 of the wiring harness connector C07 of the

disconnected left front wheel speed sensor and the

vehicle body ground.

Standard Resistance Value: 10 M or higher

Is the resistance normal?

Y

Go to step 6.

N

Repair or replace the wiring harness.

6. Inspect the ring gear of the left front wheel speed sensor

A. Inspect the ring gear of the left front wheel speed

sensor for the phenomena of deformation and

missing teeth.


Y

Replace the ring gear of the left front wheel speed

sensor.

N

Go to step 7.

7. Inspect the wheel bearing clearance

A.Inspect the wheel bearing for normal clearance.


Y

Go to step 8.

N

Repair or replace the wheel bearing.

8. Replace the ABS control module

A.Replace the ABS control module.

Refer to: Hydraulic Control Unit Assembly

(HCU) (2.3.7 Anti-lock Control, Removal

and Installation).


1 2

C07

A2307024

Benni Mini 2013.01


Abnormal Data Bus Diagnosis


1. Inspect the DTC

A.Connect the diagnostic tool.

B.Use the diagnostic tool to diagnose the ABS

system.

Are there any DTC except for 0x0520?

Y

Refer to: DTC Diagnosis Chart (3.1.13

Electronic control System - ME7, DTC


N

Go to step 3.


A.Inspect the related wiring harness connectors for

signs of damage, poor contact, aging or loose.

Is it normal?

Y

Go to step 3.

N

Repair the fault.

3. Inspect the CAN bus for integrity

A.Inspect the CAN bus for integrity.

Refer to: CAN bus Integrity Inspection

(4.3.15 On-board Network System, Symp-


Is the result normal?

Y

Go to step 4.

N

Inspect and repair the circuit for open circuit.

2.3.7-24

Benni Mini 2013.01


4. ABS control module power supply and ground




connector C12.



wiring harness connector C12 for normal power

supply.




wiring harness connector C12 for normal

grounding.


Is it normal

Y

Go to step 5.

N

Repair the circuit.




ABS pump.


Y

System is normal.

N




Installation).


C12

13

26

12

15

12

2025 14

A2307017

C12

13

26

12

15

12

25 14

A2307018

Benni Mini 2013.01


Brake Lamp Switch Fault



A.Inspect the brake lamp switch wiring harness

connector and the brake lamp wiring harness

connector for signs of damage, poor contact, aging

and loose.

B.Inspect the filament and the lamp holder of the

brake lamp bulb for abnormal conditions such as

breakage and oxidation.

Is it normal?

Y

Go to step 2.

N

Repair the fault.

2. Inspect the fuse

A.Inspect the brake lamp fuse IF01.

Fuse Rated Capacity: 10 A

Is the fuse normal?

Y

Go to step 3.

N

Inspect and repair the fuse circuit, replace the fuse

in rated capacity.

3. Inspect the brake lamp switch

A.Depresses the brake pedal to see if the brake lamp

works.

Is it normal?

Y

Go to step 4.

N

Inspect and repair the brake lamp circuit for open

circuit.

Refer to: Brake Lamp Fault Diagnosis

(4.3.7 Lighting System, Symptom Diagno-

sis and Testing).

2.3.7-26

Benni Mini 2013.01


4. Inspect the circuit between the brake lamp switch and the ABS



B.Disconnect the brake lamp switch wiring harness

connector P17a.

C.Disconnect the ABS control module wiring harness

connector C12.

D.Measure the resistance between the terminal 2 of

the brake lamp switch wiring harness connector

P17a and the terminal 16 of the ABS control

module wiring harness connector C12.


Is it normal?

Y

Go to step 5.

N

Inspect and repair the open circuit of the circuit

between the terminal 2 of the brake lamp switch

wiring harness connector P17a and the terminal 16

of the ABS control module wiring harness connec-

tor C12.


P17a

1

3 4

2

C12

13

26

12

16 15

12

25 14

A2307025

Benni Mini 2013.01


5. The ABS control module power supply and ground




connector C12.



wiring harness C12 for normal power supply.




wiring harness connector C12 for normal ground.


Is it normal

Y

Go to step 6.

N

Repair the circuit.




ABS pump.


Y

System is normal.

N




Installation).


C12

13

26

12

15

12

2025 14

A2307017

C12

13

26

12

15

12

25 14

A2307018

2.3.7-28

Benni Mini 2013.01



Hydraulic Control Unit (HCU)

Removal

Material

Item Model

Brake fluid HZY4

CAUTION: If brake fluid is spilt on the



CAUTION: The reservoir must be clean.




2. Disconnect the brake fluid low level warning

lamp switch connector.

3. Remove the reservoir cap.





tainer.







5. Install the brake reservoir cap.

1

2

A2307001

A2307002

2 4

1

3

Benni Mini 2013.01


6. Disconnect the ABS control module wiring

harness connector.

7. Remove the six brake pipes from the

hydraulic control module.

CAUTION: Block the hydraulic control unit

(HCU) to prevent the brake fluid flowing or

any dirt entering into the brake pipes.

CAUTION: Cover the brake pipes to pre-

vent the brake fluid flowing or any dirt

entering into the brake pipes.

CAUTION: Note the position of the brake

pipes to aid installation.

8. Remove retaining bolts on the hydraulic

control module.

Torque: 8 Nm

A2307003

×6

A2307004

×2

A2307005

2.3.7-30

Benni Mini 2013.01


Installation

Rear Wheel Speed Sensor

Removal




Brake System-General Information, Gen-

eral Procedures).





ter pump vacuum seal is correctly located








3. Remove the rear wheel speed sensor from

both brake bottom plates.

1.Remove the rear wheel speed sensor

retaining bolts on the brake bottom plates.

Torque: 23.5 Nm

A2307006

Benni Mini 2013.01


Installation


4. Disconnect the wheel speed sensor wiring

harness connector.

5. Detach the wiring harness buckle from the

suspension arm and the vehicle body.

6. Detach the rear wheel speed sensor.

×3

A2307007

2.3.7-32

Benni Mini 2013.01


Front Wheel Speed Sensor

Removal

Installation








3. Remove the front wheel speed sensor from

both steering knuckles.

1.Remove the sensor retaining bolt on the

steering knuckle.

Torque: 23.5 Nm

2.Detach the sensor wiring harness on the

front strut.

4. Disconnect the front wheel speed sensor

wiring harness connector in front of the

firewall, and detach the sensor.

2

×2

1

A2307008

A2307009

Benni Mini 2013.01


Rear Wheel Speed Sensor Ring(s)

Removal

Installation

1. Remove the rear wheel bearing.



2. Remove and discard the rear wheel speed

sensor ring(s).

1. Use a suitable hydrostatic machine to install

the new wheel speed sensor ring(s).

CAUTION: Make sure the rings is not

knocked, damaged and stuck with metal

scraps during the operation.

CAUTION: Place a non-ferrous protection

slab to avoid any damage.

CAUTION: Make sure the brake drum is

sufficiently supported and not seized at

the wheel bolts.

CAUTION: During the installation, apply a

slow and even force until the brake drum

is completely settled.

2. Install the rear wheel bearing.



A2307010

Benni Mini 2013.01

Steering System

2.4 Steering System

2012 Benni Mini

2.4.1 Steering System - General Information

Specifications ................................................................................................................................... 2.4.1-1



System Overview...................................................................................................................... 2.4.1-2


Exploded View.......................................................................................................................... 2.4.1-6


Steering Linkage Inspection ..................................................................................................... 2.4.1-7

Steering Wheel Free Clearance Inspection .............................................................................. 2.4.1-7



Symptom Chart......................................................................................................................... 2.4.1-9

Steering Wheel Shaking While Braking Diagnosis ................................................................. 2.4.1-12

2.4.2 Power Steering System

Specifications ................................................................................................................................... 2.4.2-1




System Overview...................................................................................................................... 2.4.2-2



Steering Force Inspection......................................................................................................... 2.4.2-4



Intermittent Malfunction Diagnosis ........................................................................................... 2.4.2-6

Symptom Chart......................................................................................................................... 2.4.2-7

EPS Warning Lamp Always On Diagnosis ............................................................................... 2.4.2-9

DTC Diagnosis and Testing ........................................................................................................... 2.4.2-11

Control Module Terminal List .................................................................................................. 2.4.2-11

DTC Code List ........................................................................................................................ 2.4.2-12

Fault Diagnostic Tool Can Not Communicate With Vehicle Diagnosis ................................... 2.4.2-12


Benni Mini 2013.01

Steering System

DTC Diagnosis Chart ..............................................................................................................2.4.2-13

DTC C1 11, C1 13, C1 14, C1 15 .......................................................................................2.4.2-14

DTC C1 21, C1 23, C1 24....................................................................................................2.4.2-16

DTC C1 22.............................................................................................................................2.4.2-21

DTC C1 41, C1 42, C1 43, C1 44, C1 45, C1 51..............................................................2.4.2-24

DTC C1 52, C1 54, C1 55....................................................................................................2.4.2-27


EPS Control Module ...............................................................................................................2.4.2-29

Steering Gear..........................................................................................................................2.4.2-30

2.4.3 Steering Linkage

Specifications ...................................................................................................................................2.4.3-1



System Overview......................................................................................................................2.4.3-2


Steering Torque Inspection .......................................................................................................2.4.3-3

Return Ability Inspection ...........................................................................................................2.4.3-3

Pulsating Torque of The Tie Rod ..............................................................................................2.4.3-3

Bellows Inspection ....................................................................................................................2.4.3-3



Tie Rod Ball Joint......................................................................................................................2.4.3-5

Steering Gear Dust Boot...........................................................................................................2.4.3-7

2.4.4 Steering Column

Specifications ...................................................................................................................................2.4.4-1



System Overview......................................................................................................................2.4.4-2



Steering Column .......................................................................................................................2.4.4-4

Benni Mini 2013.01

2.4.1-1 2.4.1-1Steering System - General Information

Specifications


Item Specification

Minimum turning diameter 10.0 m

Tubular electric power steering 200W, 35A, 12V(DC)

2.4.1 Steering System - General Information

2.4.1-2

Benni Mini 2013.01

2.4.1-2Steering System - General Information


System Overview

The movement of the steering wheel is passed to the steering linkage through the steering column. The

steering linkage would convert this rotation into the straight-line movement through its internal gear rack.

The straight-line movement is passed to the wheel steering knuckle through the steering tie rod and its

outer ball joint.

A2401001

Benni Mini 2013.01



Steering Column

The steering column is equipped with a multi-direction steering wheel lock (or anti-theft lock) approved

by strict tests. The steering wheel is equipped with a safety lock. The steering column is equipped with

the steering power system, and the control module control the steering power motor to provide the steer-

ing power. The steering column and its top are fixed on the peripheral of the console.

The steering wheel is fixed on the steering column assembly by the retaining nut, and the steering pinion

connects the steering column by the flexible universal joint. The flexible universal joint is fixed on the pin-

ion by the retaining bolts and fixed on the steering column with the retaining bolts of the retainer and the

shaft locator assembly.

A2401002

2.4.1-4

Benni Mini 2013.01


Steering Linkage

The steering linkage is of the rack and gear design with the upper connecting to the steering column.

A2401003

Benni Mini 2013.01


Electric Power System (EPS)

The vehicle electric power system (referred to as EPS) make the power motor produce the auxiliary

force of the corresponding size acting on the steering column by the electronic control device (control

module) according to the torque signal and vehicle speed signal on the steering wheel on the basis of

the traditional mechanical steering system, so as to assist the driver control the steering and get the

servo system with the best steering characteristic. It mainly consists of the traditional mechanical steer-

ing column, the torque sensor, the electronic control module and the steering power motor.

A2401004

2.4.1-6

Benni Mini 2013.01


Exploded View

Item Description Qty Item Description Qty

1 EPS module 1 6Steering tubular column cover assem-

bly clamp1

2 Multifunction steering wheel 1 7 Cotter pin 2

3 Steering column assembly 1 8 Nut 2

4 Steering lower shaft assembly 1 9 Steering gear assembly 1

5Steering tubular column cover assem-

bly1 10 Rack side bracket 1

8

7

6

5

4

3

10

8

7

2

9

1

A2401005

Benni Mini 2013.01


General Procedures

Steering Linkage Inspection

Inspect if the dust boot of the steering linkage is damaged, corroded or distorted. Ensure that the dust

boot is safe and reliable. If necessary, replace the dust boot or the clamp.

1. Park the vehicle on the dry and flat ground and pull the parking brake. Central the steering wheel.

2. Shut down the engine and hold the steering wheel tightly with hands. Rock the steering wheel to four

directions powerfully (do not turn steering wheel), inspect the wear of the steering column bearing

and the loose of the steering coupling, the steering wheel and the steering column. If any, inspect the

retaining bolt torque of the steering column, the coupling and the steering wheel. The steering

column can not be repaired, if necessary replace it.

Refer to: Steering Column (2.4.4 Steering Column, Removal and Installation).

3. If the steering linkage is damaged, replace it if necessary.


The steering column can not be repaired, replace it if necessary.


As the clearance of the steering linkage cannot be adjusted, replace it if necessary.

Steering Wheel Free Clearance Inspection

When the engine shuts down, inspect the steering wheel with the vehicle fixed on the forward ground.

Steering Wheel Free Clearance Range: 0-30 mm (0-1.2in.)

If the steering wheel does not move in the free clearance range, inspect as the following example, if any

defect is found, replace.

1. If the steering tie rod ball is worn.

2. If the lower ball joint is worn.

3. If the steering shaft joint is worn.

4. If the pinion or the gear and rack is worn or cracked.

5. If other components are loose.

2.4.1-8

Benni Mini 2013.01




1. Verify the customer's concern.

2. Visually inspect for obvious signs of

mechanical damage.





4. If the concern is not visually evident, verify

the symptom and refer to the Symptom Chart.


•Tire pressure

•Tie rod end

•Tie rod

•Front strut and spring

assembly

•Front suspension front

swing arm ball joint

•Front suspension front

swing arm bushing

•Retaining bolts on steer-

ing column shaft flexible

joint

•Wheel and Tire

•Steering gear sleeve

•Electric power steering

column

•EPS control module

Benni Mini 2013.01


Symptom Chart

If there is a symptom but no diagnosis trouble code (DTC) is stored in control module and can not con-

firm the symptom reasons in basic inspect, it is necessary to diagnosis and eliminate the symptoms in

the following chart.


Noise in the steering col-

umn

•Turning interference

•Adjust it and if necessary, replace the steering

column.

Refer to: Steering Column (2.4.4

Steering Column, Removal and

Installation).

•Steering gear

•Steering power motor

•Replace the steering gear.

Refer to: Steering Gear (2.4.2 Power

Steering System, Removal and

Installation).

•Replace the steering power motor or the steer-

ing column.

•Steering linkage loosening •Tighten

Steering wheel shaking

while braking

•Brake disc and brake shoe

•Tire

•Wheel alignment

•Tie rod ball joint

•Front swing arm ball joint

•Steering gear

Refer to: Steering Wheel Shaking

While Braking Diagnosis (2.4.1

Steering System - General Informa-

tion, Symptom Diagnosis and Test-

ing).

2.4.1-10

Benni Mini 2013.01


Abnormal steering return

function

•Too large inner friction of the

tie rod ball joint

•Replace the tie rod ball joint.

Refer to: Tie Rod Ball Joint (2.4.3

Steering Linkage, Removal and

Installation).

•The plug is too tight. •Pre-tighten it again.

•Steering tie rod and ball joint

defect




Installation).

•The fixation between the

steering gear and the frame is

loose

•Re-tighten

•Rack bends.




Installation).

•The gear bearing is dam-

aged.




Installation).

•Abnormal electric power

steering system

•The tire pressure is too low.

•Inspect and repair the electric power steering

system.

•Inflate the wheel.


•Adjust the wheel alignment parameter to the

specified value.


Suspension System - General Infor-


Steering power failure

•Damaged electric power

steering column

•Damaged EPS control mod-

ule

•Damaged steering gear

•Seized suspension ball

Refer to: Steering Power Failure

Diagnosis (2.4.2 Electric Power

Steering, Symptom Diagnosis and

Testing).


Benni Mini 2013.01


The steering clearance

between the steering

wheels is too large and the

steering wheel is off the

center position.

•Damaged electric power

steering column

•Replace the electric power steering column.

Refer to: Steering Column (2.4.4

Steering Column, Removal and

Installation)

•The bolts on the steering

gear is loose.•Re-tighten

•The ball bolts on the steering

tie rod assembly are worn or

loose.

•Re-tighten and replace as necessary.



Installation).

Squeak between the rack

and the gear

•The steering gear mounting

bolts are loose.•Re-tighten

•The tie rod ball is loose. •Re-tighten

•The tie rod ball is worn and

aging.




Installation).


2.4.1-12

Benni Mini 2013.01


Steering Wheel Shaking While Braking Diagnosis


1. Inspect the wheel and tire

A.Inspect whether the tire type, the tire pressure and

the tire surface wear are close to each other and

the tire is uneven wear.

B.Inspect the wheel for twist, distortion and damage.

Are the tire and wheel normal?

Y

Go to step 2.

N

Adjust or replace the wheels and tires.

2. Inspect the brake disc and the brake pad

A.Inspect the brake disc.

Refer to: Brake Disc Runout Inspection

(2.3.1 Brake System - General Informa-


B.Inspect the brake pad.



Whether the brake disc and the brake pad is nor-

mal?

Y

Go to step 3.

N

Adjust or replace the brake disc and the brake pad.

3. Inspect the wheel alignment


Refer to: Wheel Alignment (2.1.1 Suspen-

sion System - General Information, Gen-

eral Procedures).

Whether the wheel alignment parameter is normal?

Y

Go to step 3.

N

Adjust the wheel alignment parameter.

Refer to: Front Wheel Toe-In Adjustment

(2.1.1 Suspension System - General Infor-


Benni Mini 2013.01


4. Inspect the tie rod ball joint and the front swing arm ball joint

A.Lift the vehicle.



B.Inspect the tie rod ball joint and the front swing arm

ball joint.

Is the ball joint normal?

Y

Replace the steering gear.


Steering System, Removal and Installa-

tion).

N

Replace the tie rod ball joint .


Linkage, Removal and Installation).

Replace the front swing arm ball joint .

Refer to: Front Swing Arm and Arm Ball

Joint Pin (2.1.2 Front Suspension,



Benni Mini 2013.01

2.4.2-1 2.4.2-1Power Steering

Specifications



Item Specification

Item Nm lb-ft lb-in

2.4.2 Power Steering System

2.4.2-2

Benni Mini 2013.01

2.4.2-2Power Steering


System Overview


1. EPS Controller


1

2

A2402001

Benni Mini 2013.01


2. Motor

3. Torque Sensor

4. VSS (Vehicle Speed Sensor)

5. Engine Speed Signal

2.4.2-4

Benni Mini 2013.01


General Procedures

Steering Force Inspection

1.

2.

3.

4.

Steering Force: more than 35N (3.5kg)

Benni Mini 2013.01




1.

2.


3.

4.

5.

General Equipment


2.4.2-6

Benni Mini 2013.01


Intermittent Malfunction Diagnosis

CAUTION: 1. Eliminate the DTC.

2. Carry out the simulation testing.

3. Inspect and shake the wiring harnesses, connectors and terminals.


CAUTION: Some reasons may cause the

electrical failure due to the vehicle or the

engine vibration. Inspect the following

items.

1. The connector is not fully in position.

2. The wiring harness does not have

enough clearance.

3. The wiring harness layout across the

bracket or moving components

4. The wiring harness lays are too close to

the high temperature components.

CAUTION: Incorrect wiring, tight or loose

wiring harness will lead the connecting

cable to be squeezed between the compo-

nents.

CAUTION: The connector joint, the vibra-

tion location, the location crossed by the

wiring harness are all required for focus

inspection, such as: the wiring harness

across the firewall and the body panels.

Benni Mini 2013.01


Symptom Chart


•

•

•

Refer to: Symptom Chart (4.3.2

Instrument Cluster, Symptom Diag-

nosis and Testing).

•

•

•

Refer to: EPS Warning Lamp

Always On Diagnosis (2.4.2 Power

Steering System Diagnosis, Symp-


• •


A2307014

A2307015

2.4.2-8

Benni Mini 2013.01


•

•

•

Refer to: Steering Power Failure

Diagnosis (2.4.1 Power Steering


Symptom Chart).


Benni Mini 2013.01


EPS Warning Lamp Always On Diagnosis


Y

N


Standard Resistance Value: 10 M or more

Y

N

P07

P06

32

16

17

131

87

61 3

A2402012

2.4.2-10

Benni Mini 2013.01




Y

Refer to: EPS Control Module (2.4.2

Power Steering System, Removal and

Installation).

N




P06

87

61

A2402013

P06

87

61

A2402014

Benni Mini 2013.01


DTC Diagnosis and Testing

Control Module Terminal List

Terminal ID WiringTerminal Descrip-

tionStatus

87

61

A2402015

2.4.2-12

Benni Mini 2013.01


DTC Code List

Fault Diagnostic Tool Can Not Communicate With Vehicle Diagno-

sis

CAUTION: The short circuit of the internal module may also cause the fault.

Refer to: Diagnostic Tool Can Not Communicate With ECM Diagnosis (4.3.13 On-Board Net-

work, Symptom Diagnosis and Testing).

Malfunction Description

Benni Mini 2013.01


DTC Diagnosis Chart

Malfunction Description Diagnosis Procedures

Refer to: C1111,

C1113, C1114, C1115

Refer to: C1121,

C1123, C1124

Refer to: C1122

Refer to: C1141,

C1142, C1143, C1144,

C1145, C1151

Refer to: C1152,

C1154, C1155

2.4.2-14

Benni Mini 2013.01


DTC C1111, C1113, C1114, C1115

1. Fault Code Description

2. Possible Sources

3. Diagnosis Procedures

Fault Code Description Definition

Fault

CodeTest Policy

Installation Conditions

(Control Tactics)Fault


Y

N

Benni Mini 2013.01


Y

N

Refer to: Intermittent Fault Diagnosis

(2.4.3 Steering Linkage Diagnosis, Symp-


Y

N

Y

N


2.4.2-16

Benni Mini 2013.01


DTC C1121, C1123, C1124




Y

N



Installation).



P06

87

61

A2402013

P06

87

61

A2402014

Benni Mini 2013.01


2. Possible Sources


Fault

CodeTest Policy


(Control Tactics)Fault Part


Y

N

Y

N




2.4.2-18

Benni Mini 2013.01



Y

N


C26

1 3

P06

87

651

A2402016

Benni Mini 2013.01




Y

N

Y

N


1 3

C26

A2402017

1 32

C26

A2402018

2.4.2-20

Benni Mini 2013.01




Y

N



Installation).


P06

87

61

A2402013

P06

87

61

A2402014

Benni Mini 2013.01


DTC C1122


2. Possible Sources



Fault

CodeTest Policy


(Control Tactics)Fault


Y

N

Y

N




2.4.2-22

Benni Mini 2013.01



Y

N


E01a

P06

87

641

3

5 4

2 1

86

25

44

63

24

43

62

81

A2402019

Benni Mini 2013.01




Y

N



Installation).


P06

87

61

A2402013

P06

87

61

A2402014

2.4.2-24

Benni Mini 2013.01


DTC C1141, C1142, C1143, C1144, C1145, C1151


2. Possible Sources



Fault

CodeTest Policy




Y

N

Benni Mini 2013.01


Y

N




Y

N

Refer to: Steering Column Assembly

(2.4.4 Steering Column, Removal and

Installation).


2.4.2-26

Benni Mini 2013.01




Y

N



Installation).


P06

87

61

A2402013

P06

87

61

A2402014

Benni Mini 2013.01


DTC C1152, C1154, C1155


2. Possible Sources



Fault

CodeTest Policy




Y

N

Y

N




2.4.2-28

Benni Mini 2013.01




Y

N



Installation).


P06

87

61

A2402013

P06

87

61

A2402014

Benni Mini 2013.01



EPS Control Module

Removal

Installation




2. Remove the driver side lower trim panel.

3. Disconnect the EPS control module wiring

harness 2 connectors.

4. Remove the EPS control module 2 retaining

bolts.

Torque: 8 Nm

5. Disconnect the EPS control module wiring

harness 1 connector.

6. Detach the EPS control module.


×2

×2

A2402005

A2402006

2.4.2-30

Benni Mini 2013.01


Steering Gear

Removal

1. Remove the two front wheels.






3. Remove the tie rod ball joint and the steering

knuckle connection.


Gear, Removal and Installation).

4. Remove the steering column cover assembly

clamp and detach down the steering column

cover assembly.

5. Remove the steering gear and steering

column retaining bolt.

Torque: 25 Nm

CAUTION: Make the two front wheels in

the straight-ahead state and the steering

wheel in the middle, and lock the steering

wheel with the steering wheel lock to

avoid damaging the clock spring before

disconnecting the power steering gear

and steering column connection.

A2402010

A2402007

Benni Mini 2013.01


Installation

6. Remove the front subframe assembly.

1.Remove the front subframe retaining nut.

Torque: 50 Nm

2.Remove the front subframe retaining bolt.

3.Release the front subframe retaining bolt

but do not detach it.

Torque: 50 Nm

7. Remove four retaining bolts on the steering

gear and detach the steering gear.

Torque: 60 Nm


CAUTION: Ensure the spline is meshed

properly when installing the steering gear

and steering colunm connection.

CAUTION: Inspect the front toe-in and

adjust it accordingly, and make four-wheel

alignment.

2

3

1

A2402008

×2×2

A2402009

Benni Mini 2013.01

2.4.3-1 2.4.3-1Steering Linkage

Specifications


Item Nm lb-ft lb-in

Steering tie rod ball joint retaining nut 43 32 -

Tie rod ball joint locknut 55 41 -

Wheel nut 85 63 -

2.4.3 Steering Linkage

2.4.3-2

Benni Mini 2013.01

2.4.3-2Steering Linkage


System Overview

The steering tie rod is connected with the steering linkage. The following components transfer the steer-

ing linkage movement to the wheel:

• Steering tie rod

• Tie rod ball joint

• Steering knuckle

The steering tie rod ball joint is connected with the tie rod with the retaining nut.


1 Steering tubular column cover assembly 6 Steering linkage dust boot

2Steering tubular column cover assembly

clamp7 Inner tie rod joint assembly

3 Steering gear assembly 8 Cotter pin

4 Steering rod retaining washer 9 Tie rod ball joint retaining nut

5 Steering linkage dust boot clamp 10 Tie rod ball joint

1

9

8

2

3

10

4 5

6

7

A2403006

Benni Mini 2013.01


General Procedures

Steering Torque Inspection

1. Turn the steering wheel and inspect the

mutation of the steering torque.

2. When the steering torque is exceeding,

inspect the following items:

• Inspect the dust boot and the tie rod ball

joint for damage.

• Inspect the pinion full torque of the

steering gear and the rotation starting

torque of the tie rod ball joint.

• Inspect the rotation starting torque of the

ball joint.

Return Ability Inspection

1. If the return angle is more than 120° when

driving the vehicle at speed of 25km/h-30km/

h and turning the steering wheel for 180°, it

indicates that the EPS has no problem, and if

the return angle is less than 120°, it indicates

the EPS works abnormally.

CAUTION: It is normal to feel very heavy

when rotating the steering wheel rapidly

Pulsating Torque of The Tie

Rod

1. Rotate the steering tie rod for about 10 times.

2. Use the spring meter to measure the

pulsating torque of the tie rod.

The pulsating torque of the tie rod shall be: 0.15

~ 0.5 kgf•m

3. If the measured value is exceeding, replace

the tie rod assembly.

CAUTION: The tie rod is still usable even

if the measured value is lower than the

standard and there is no too much rotation

clearance.

Bellows Inspection

1. Stretching the bellows, inspect for any

possible wear (especially pay attention to the

sunk part of the bellows).

2. Inspect whether the bellows are installed in

the correct position.

3. If any defect of the bellows is found, the

bellows must be replaced.

A2402004

2.4.3-4

Benni Mini 2013.01



Refer to: Symptom Chart (2.4.1 Steering


Diagnose and Testing).

Benni Mini 2013.01



Tie Rod Ball Joint

Removal

Special Tool

Tie Rod Ball Joint Puller

CA201-001

1. Remove the front wheels.






3. Release the tie rod ball joint.


Torque: 42.5 Nm

2. Remove the cotter pin.


Torque: 42.5 Nm

4. Remove the tie rod ball joint.

1.Remove the tie rod ball joint with a special

tool.


2.Screw off the retaining nut.

CAUTION: When the tie rod ball joint is

separated from the steering knuckle ball

joint connection, protect the oil seal.

CA201-001

2

1

3

A2403001

CA201-001

A2403002

2.4.3-6

Benni Mini 2013.01


Installation


CAUTION: Inspect the front toe-in and adjust

it accordingly, and make four-wheel alignment.

5. Remove the tie rod ball joint 1 and retaining

nut 2.

CAUTION: Record the number of turns

while removing the tie rod ball joint.

CAUTION: Make sure the number of tight-

ened turns of tie rod ball joint is the same

as that recorded while being removed. If

the number of turns is unknown, inspect if

the thread length is the same at two sides

while installing the tie rod.

1

2

A2403003

Benni Mini 2013.01


Steering Gear Dust Boot

Removal

Installation


CAUTION: Inspect the front toe-in and adjust

it accordingly, and make four-wheel alignment.




2. Remove the tie rod ball joint.


Gear, Removal and Installation).

CAUTION: Make sure the tie rod is clean

before removal of the dust boot.

3. Remove the steering gear dust boot.

1.Remove the inner clamp of dust boot.

2.Remove the outer clamp of dust boot.

3.Detach the dust boot on the tie rod.

22

A2403004

Benni Mini 2013.01

2.4.4-1 2.4.4-1Steering Column

Specifications


Item Nm lb-ft lb-in

Steering wheel retaining nut 33 24 -

Steering column retaining nut 24 18 -

Steering universal joint to steering column

retaining bolt25 18 -

2.4.4 Steering Column

2.4.4-2

Benni Mini 2013.01

2.4.4-2Steering Column


System Overview

The steering wheel is fixed on the steering column assembly by the retaining bolts. The power steering

system is installed on the steering column, and the control module controls the power steering motor to

provide the power while the steering pinion connects with the steering column through the flexible univer-

sal joint. The flexible universal joint is fixed on the pinion by the retaining bolts and fixed on the steering

column with the retaining bolts of the retainer and the shaft locator assembly.


1 Steering lower shaft assembly 2 Steering column assembly

2

1

A2404001

Benni Mini 2013.01



Refer to: Symptom Chart (2.4.1 Steering



2.4.4-4

Benni Mini 2013.01



Steering Column

Removal

WARNING: When removing or repairing

airbag system, it is necessary to cut off

the system power supply and keep it for

over 60s.

CAUTION: Make sure that steering wheel

is locked and wheels are at the forward

position to prevent the clock spring from

damage during removal.







3. Remove the steering column cover assembly

clamp and detach down the steering column

cover assembly.

4. Remove the steering column and steering

gear retaining bolt.

Torque: 25 Nm

CAUTION: Make the two front wheels in

the straight-ahead state and the steering

wheel in the middle, and lock the steering

wheel with the steering wheel lock to

avoid damaging the clock spring before

disconnecting the power steering gear

and the steering column connection.

A2402010

A2402007

Benni Mini 2013.01


5. Remove the driver air bag and the steering

wheel.

Refer to: Airbag (4.2.1 Airbag System,

Driver Airbag and Steering Wheel


6. Remove the driver side lower protection

panel.

7. Remove two retaining screws on the steering

lock cover.

8. Remove three retaining screws on the

steering lock cover side and detach the

steering lock cover.

9. Remove the lighting combination switch.

Refer to: Lighting Combination Switch

(4.3.7 Lighting System, Removal and

Installation).

10. Remove the wiper combination switch.

Refer to: Wiper Combination Switch (4.3.8

Wipers and Washers, Removal and Instal-

lation).

11. Remove the clock spring.

12. Disconnect the ignition switch wiring harness

connector.

13. Remove the EPS control module.

Refer to: EPS Control Module (2.4.2 Power

Steering System, Removal and Installa-

tion).

A2404002

×3

A2404003

A2404004

2.4.4-6

Benni Mini 2013.01


Installation

14. Remove two nuts fixed on the steering

column and the middle instrument cluster

bracket.

Torque: 25 Nm

15. Remove two nuts fixed on the steering

column and the upper instrument cluster

bracket.

Torque: 25 Nm


CAUTION: When installing steering col-

umn retaining bolt, do not fully tighten it

until all bolts are mounted to the suitable

positions; then tighten the bolts with the

specified torque.

CAUTION: Ensure the spline is meshed

properly when installing the steering gear

and the steering column connection.

CAUTION: Inspect the front toe-in and

adjust it accordingly, and make four-wheel

alignment.

A2404006

A2404007

benni mini workshop manual 2013 cap 2

Documents

brake system2

brake system general

steering system2

power steering system

rear suspension

system overview

parking brake

disc brake