Benni Mini Workshop Manual 2013 Cap 2

GROUP
2
Chassis
SECTION TITLE
Pages
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
Benni Mini 2013.01
Suspension System
2.1 Suspension System

2012 Benni Mini
Table of Contents
Pages
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
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 Suspension System - General Information

2.1.1-1
Suspension System - General Information
2.1.1-1
Specifications
General Specifications
Item
Front wheel alignment parameter
Rear wheel alignment parameter
Specification
Front toe-in
010' 010
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 toe-in
0 ( -020' ~ 020' )
Rear wheel camber angle
0 ( -0.33 ~ 0.33) or -020' ~

020'
Benni Mini 2013.01
2.1.1-2
2.1.1-2
Description and Operation
3. Toe-in description
System Overview
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.
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 suspension system must keep certain geometrical relationship 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 capacity from the highest point of steering axial line
deviating vertical surface, observed from the lateral 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 vehicle is positive, pull the vehicle to its center. The
minimal positive caster angle will lead the sideway 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 vehicle. The camber angle is positive when tire toes
out. When tire toes in, camber angle is negative.
Camber angle is the angle deviating vertical surface. 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.
Benni Mini 2013.01
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 compensate the wear of these components. It is necessary 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.
2.1.1-3
2.1.1-3
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 dislocation 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 correctly 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 vibration, do not inspect the tire immediately, the following 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 different 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 vehicle change along with the tire pressure.
Benni Mini 2013.01
2.1.1-4
General Procedures
Wheel Bearing Inspection
2.1.1-4
clearance. Replace the front wheel bearing if

it has the axial clearance.
Special Tool
205-044
Clamp Stand of Dial

Indicator Gauge
205-044 (15-008)
CA205-044
General Tool
Dial Indicator Gauge
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.
A2101502
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.
A2101501
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
Benni Mini 2013.01
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 Installation).
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.
2.1.1-5
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.
2.1.1-5
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 damaged, 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 management, 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.
Refer to: Front Control Arm and Ball Pin

(2.1.2 Front Suspension, Removal and
Installation).
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.
4. Carry out the front wheel alignment after

replacing the ball joint. Relative information
please refer to general flow.
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.
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.
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 suspension 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 bushBenni Mini 2013.01
2.1.1-6
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 assembly and allow it to spread for 3 times in order to
clean the air entering the pressing cabin in processing.
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 components.
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 compressing resistance is normal phenomena.
The following situations are abnormal:
In the process of installing and returning

after installation, the shock absorber lags
and jumps.
2.1.1-6
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 Inspection

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:
blocked.
Noise, eliminiate light whizzing sound,

the click sound in rapid returning.
Engine torque.
Leakage.
Vehicle speed.
Shock absorber pull rod is completely

extended and its piston swags compared
to shock absorber shell.
Engine speed.
Vibration type - sensitivity: torque

sensitivity, vehicle speed sensitivity, or
engine speed sensitivity.
If the shock absorber is still unstable after air

cleaning, please replace a new shock absorber.
The following explanations are useful to differentiate the vibration sources.

1. Torque sensitivity
It means the situations will become better or
worse due to acceleration, deceleration,
Benni Mini 2013.01
2.1.1-7
coasting, constant speed and engine torque

adding.
2. Vehicle speed sensitivity
2.1.1-7
Adjustment
1. Turn the steering wheel to the center position
and lock it.
It means the vibration always appears at the

same vehicle speed and will not be influenced 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 roadsurface.
LOCK
A2101503
2. Loosen the tie rod ball joint retaining nut.
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
Wheel Alignment Gauge
Inspection
A2101504
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

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.
pressure if
Benni Mini 2013.01
2.1.1-8
3. Rotate the tie rod ball joint clockwise or

counter-clockwise to adjust toe-in .
2.1.1-8
Symptom Diagnosis and Testing
Inspection and verification

1. Verify the customer concern.
2. Visually inspect for
mechanical damage.
obvious
signs
of
Visual Inspection Chart

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
A2101505
Front strut and spring

4. Tighten tie rod ball joint retaining nut.
Front and rear balancing bar and linkage

Rear spring
Rear ahock absorber
Rear suspension arm
42.5 Nm
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.
A2101506
5. Inspect toe-in.
Benni Mini 2013.01
2.1.1-9
2.1.1-9
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
Wheels and tires
Wheel alignment
Rear dislocation
Action
Refer to: Vehicle Drift Diagnosis
(2.1.1 Suspenion System General Information, Symptom
Diagnosis and Testing).
Driving height
Vehicle Drift
Wheel bearing
Ball joint
Brake drag
Steering pull rod
Rear suspension
Wheels and tires
Wheel alignment
Wheel bearing
Abnormal driving track

(Vehicle can not keep
Ball joint
driving straight)
Control arm bushing
Refer to: Abnormal Driving

Track (Vehicle Can Not Run
Straight)
Diagnosis
(2.1.1
Suspenion System - General
Information,
Symptom
Steering tie rod clearance

Steering Linkage clearance
Rear suspension
Tire unbalancing and excessive
worn
Front wheel drive shaft worn
Wheel bearing worn
Refer to: Vehicle Swing Diagnosis (2.1.1 Suspenion System General Information, Symptom
Steering system worn
Vehicle swing
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
Benni Mini 2013.01
2.1.1-10
Symptom
Possible Sources
2.1.1-10
Action
Inspect the tire
Tire unbalance and excessive

worn
Refer to: Tire Wear Inspection

(2.1.4 Wheels and Tires, General Procedures).
Inspect the front wheel drive shaft
Front wheel drive shaft worn
Refer to: Drive Shaft Inspection

(2.2.1 Driveline - General Information, General Procedures).
Wheel bearing worn
Replace the wheel bearing
Replace the steering system worn part

Inspect the suspension device assembly

loose and worn
Refer to: Torque Specifications

(2.1.2 Front Suspension, Specifications), Torque Specifications
(2.1.3 Rear Suspension, Specifications).
Tighten it according to torque requirement
Vehicle shakes in driving

bracket loose
Refer to: Torque Specifications

(2.1.2 Front Suspension, Specifications), Torque Specifications
(2.1.3 Rear Suspension, Specifications).
Replace the front arm ball joint
Front control arm ball joint worn
Refer to: Front Control Arm

(2.1.2
Front
Suspension,
Replace the front suspension control arm
bushing
Front control arm bushing worn

and loose

(2.1.2
Front
Suspension,
Replace the stablizer bar bushing
Benni Mini 2013.01

(2.1.2
Front
Suspension,
2.1.1-11
Symptom
Possible Sources
2.1.1-11
Action
Replace the suspension and bushing if
necessary
Rear suspension and bushing

worn and loose
Vehicle shakes in driving
Refer to: Rear Axle (2.1.3 Rear

Suspension,
Removal
and
Installation), Rear Axle Bushing
(2.1.3
Rear
suspension,
Wheel alignment
Steering wheel off center
Wheel alignment
Steering system components
Suspension assembly bracket
loose or worn
Wheel bearing worn
Excessive noise
Front control arm bushing
Refer to: Wheel Alignment (2.1.1

Suspension System - General
Information, General Procedures).
Steering Wheel Off Center Diagnosis
Refer to: Excessive Noise Diagnosis (2.1.1 Suspension System
- General Information, Symptom
Damper spring
Tire
Front control arm ball joint
Tire conversion
Tire pressure
Wheel distortion
Unbalancing tire
Incorrect tire wear
Refer to: Incorrect Tire Wear

Diagnosis (2.1.1 Suspension
System - General Information,
Symptom
Diagnosis
and
Testing).
Wheel alignment
Suspension components
High speed driving
Rear dislocation
Overload
Poor operation habit
Benni Mini 2013.01
2.1.1-12
Symptom

Possible Sources
2.1.1-12
Action
Wheel alignment
Positive camber angle too large
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
Replace the steering system worn compo-
bar worn
nents
Replace front control arm ball joint

Heavy steering
Front suspension front control arm

(2.1.2
Front
Suspension,
ball joint worn
Inspect the tires

Tire worn or unbalancing
Insufficient power steering force
Inspect the oil pressure and supplement

of power steering system. Inspect power
steering system and replace worn components.
Replace the front stabilizer linkage or
bushing
Front stabilizer bar or bearing

(2.1.2
Front
Suspension,
worn (if equipped)
Repair or replace front control arm bush-
Vehicle swag
ing
Front control arm bushing loose

and worn
Suspension assembly loose or

worn

(2.1.2
Front
Suspension,
Inspect the suspension assembly and
replace the worn components
Inspect the damper spring and replace it if
necessary
Vehicle lean
Front and rear damper spring

becomes soft and damaged
Tire pressure is improper
Benni Mini 2013.01
Refer to: Front Strut Assembly

Disassembly and Assembly
(2.1.2
Front
Suspension,
Removal and Installation), Rear
Shock
Absorber
Assembly
(2.1.3
Rear
suspension,
Adjust the tire pressure
2.1.1-13
Symptom

Possible Sources
2.1.1-13
Action
necessary
Rough ride
Front and rear damper springs

become soft
Front or rear suspension assembly worn

(2.1.2
Front
Suspension,
Shock
Absorber
Assembly
(2.1.3
Rear
suspension,
Replace the suspension assembly worn
components
Inspect the tires
Tire is unbalancing, damaged or

with too large runout

Wheel alignment
Toe-in out of specification

Replace the steering system worn components
Replace the front control arm ball joint

Front control arm ball joint damaged
Unstable direction

(2.1.2
Front
Suspension,
necessary
Front and rear damper springs

become soft

(2.1.2
Front
Suspension,
Shock
Absorber
Assembly
(2.1.3
Rear
suspension,
Front or rear suspension assembly worn
Replace the suspension assembly worn

components
Rear suspension, bushing or bolt

loose or worn
Replace the rear suspension worn components

Replace the stablizer bar bushing

(2.1.2
Front
Suspension,
Benni Mini 2013.01
2.1.1-14
Symptom
Possible Sources
2.1.1-14
Action
Wheel alignment
Inspect the steering system

Steering wheel can not
return normally
Refer to: (2.4.1 Steering System

- General Information, General
Procedures).
Replace the front suspension control arm

ball joint
Front suspension control arm ball
joint worn

(2.1.2
Front
Suspension,
Tire
Refer to: Driving Vibration Diagnosis (2.1.1 Suspension System

- General Information, Symptom
Front wheel bearing

Driving vibration
Rear wheel bearing

Front hub
Rear hub
Vehicle Drift Diagnosis

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
2.1.1-15

Test Conditions
2.1.1-15
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.
Benni Mini 2013.01
2.1.1-16

Test Conditions
2.1.1-16
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 specification?
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
2.1.1-17

Test Conditions
2.1.1-17
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 Disassembly and Assembly (2.1.2 Front Suspension, Removal and Installation), Rear
Shock Absorber Assembly (2.1.3 Rear
suspension, Removal and Installation).
N
Adjust or repair the rear suspension incorrect alignment.
Abnormal Driving Track Diagnosis (Vehicle Can Not Run Straight)

Test Conditions
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.
Benni Mini 2013.01
2.1.1-18

Test Conditions
2.1.1-18
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.

Y
Go to step 6.
N
Benni Mini 2013.01
2.1.1-19

Test Conditions
2.1.1-19
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 Information, 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.
Benni Mini 2013.01
2.1.1-20
2.1.1-20
Vehicle Swing Diagnosis

Test Conditions
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
2.1.1-21

Test Conditions
2.1.1-21
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 Information, General Procedures).
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.

Y
Go to step 7.
N
Benni Mini 2013.01
2.1.1-22

Test Conditions
2.1.1-22
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 Information, General Procedures).
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.
Steering Wheel Off Center Diagnosis

Test Conditions
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
2.1.1-23

Test Conditions
2.1.1-23

Y
Refer to: Abnormal Driving Track Diagnosis (2.1.1 Suspension System - General
Information, Symptom Diagnosis and
Testing).
N
Carry out the wheel alignment.
Abnormal Driving Track Diagnosis

Test Conditions
1.Inspect the front caster angle

A.Inspect the front caster angle.
Whether the front caster angle is within the specified 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 components. If necessary, replace or repair the worn components.
Refer to: (2.1.3 Rear

Suspension,
Benni Mini 2013.01
2.1.1-24
2.1.1-24
Excessive Noise Diagnosis

Test Conditions
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
2.1.1-25

Test Conditions
2.1.1-25
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.
Benni Mini 2013.01
2.1.1-26
2.1.1-26
Vibration Diagnosis
Test Conditions
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 bearing 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
2.1.1-27

Test Conditions
2.1.1-27
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 bearing 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.
Benni Mini 2013.01
2.1.1-28

Test Conditions
2.1.1-28
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 specification?
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
2.1.1-29

Test Conditions
2.1.1-29
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).
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).
Y
Inspect the runout of brake disc.
Refer to: Brake Disc Runout Inspection

(2.3.1 Brake System - General Information, General Procedures).
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.
Benni Mini 2013.01
2.1.1-30
2.1.1-30
Incorrect Tire Wear Diagnosis

Test Conditions
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
2.1.1-31

Test Conditions
2.1.1-31
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 specification?
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.
Benni Mini 2013.01
2.1.1-32

Test Conditions
2.1.1-32
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 Front Suspension

2.1.2-1
Front Suspension
2.1.2-1
Specifications
Torque Specifications
Item
Nm
lb-ft
lb-in
Steering rod ball joint retaining nut
42
31
Front stabilizer bar assembly to front control arm assembly connecting nut
92
68
Front stringer lower bracket assembly to

raidator lower beam assembly connecting
nut
72
53
72
53
Front control arm ball joint pin to steering

knuckle connecting bolt
50
37
Front control arm assembly to arm mounting plate connecting bolt
72
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 nut
88
65

front cabin lower base connecting bolt
front cabin lower base connecting nut
Benni Mini 2013.01
2.1.2-2
Front Suspension
2.1.2-2
System Overview
Front suspension is consisted of two front strut assemblies (including shock damping spring), front control 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
1
6
5
4
A2102001
Benni Mini 2013.01
2.1.2-3
Front Suspension
Item
Description
2.1.2-3
Item
Description
Front strut assembly
Front control arm
Front stabilizer bar
Halfshaft
Coil spring
Front stabilizer bar mounting bracket

assembly
Benni Mini 2013.01
2.1.2-4
Front Suspension
2.1.2-4
Exploded View
Front Suspension Exploded View 1
2
4
3
A2102002
Item
Description
Qty.
Hexagon flange bearing surface toothed nut
Front strut assembly
Hexagon flange bolt
Hexagon flange bearing surface toothed nut
Benni Mini 2013.01
2.1.2-5
Front Suspension
2.1.2-5
3
10
8
9
4
5
7
6
A2102003
Item
Description
Qty.
Hexagon head bolt
Steering knuckle
Hexagon flange nut
Small washer
Light spring washer
Hexagon head bolt
Bushing
Front control arm assembly
Clamp
10
Dust cover
Benni Mini 2013.01
2.1.2-6
Front Suspension
2.1.2-6
1
3
3
5
5
7
6
A2102004
Item
Description
Qty.
Front control arm assembly
Front control arm retaining rubber bush
Hexagon head bolt and spring washer
Front control arm mounting bracket assembly (Right)
Front control arm connecting rubber bush
Front control arm connecting rubber bush washer
Hexagon slotted nut
split pin
Benni Mini 2013.01
2.1.2-7
Front Suspension
2.1.2-7

Refer to: Symptom Chart (2.1.1 Suspension System - General Information, Symptom Diagnosis and Testing).
Benni Mini 2013.01
2.1.2-8
Front Suspension
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
2.1.2-8
2.1.2-9
Front Suspension
2.1.2-9
2. Disassemble the front shock absorber and

the coil spring
1
1. Remove the nuts.
Torque: 54 Nm
2
4
2. Remove the flat washer.
5
12
3. Remove the spring washer.
6
7
4. Remove the inner adapter sleeve assembly.

5. Remove the outer adapter sleeve assembly.
8
9
6. Remove the flat washer.

7. Remove the backup washer.
10
8. Remove the bearing.
11
13
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.
A2102024
Assembly
1. To assemble,
procedure.
reverse
the
disassemble
CAUTION: Put spring end on spring seat

correctly.
2. Aligning wheels.
Benni Mini 2013.01
2.1.2-10
Front Suspension
2.1.2-10
Removal and Installation
Front Control Arm

Removal
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.
A2102005
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.
A2102006
Installation
1. To install, reverse the removal procedure.
Benni Mini 2013.01
2.1.2-11
Front Suspension
2.1.2-11
Steering Knuckle
Removal
Special Tool
Ball Joint Puller

CA201-001
CA201-001

3. Remove the front wheel speed sensor and
the brake hose from the front strut assembly.
A2102008
4. Remove the retaining bolt of the front wheel

speed sensor, and detach the wheel speed
sensor.
Torque: 15 Nm
A2102015
Benni Mini 2013.01
2.1.2-12
Front Suspension
2.1.2-12
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 stabilizer bar retaining nut.
Torque: 92 Nm
CAUTION: Use soft cloth to protect the
ball joint to avoid damage.
A2202020
A2102010
6. Remove the front stabilizer bar assembly.

1.Remove both sides of the stabilizer bar seat
retaining bolts.
Torque: 72 Nm
1
2.Detach the front stabilizer bar assembly.
2
A2202021
7. Remove the halfshaft retaining nut.

Torque: 275 Nm
A2102016
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.
A2102013
A2202022
Benni Mini 2013.01
2.1.2-13
Front Suspension
2.1.2-13
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
Installation
Benni Mini 2013.01
2.1.2-14
Front Suspension
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.
A2102017
4. Remove the snap ring.
A2102018
5. Remove the bearing.
A2102019
Benni Mini 2013.01
2.1.2-14
2.1.2-15
Front Suspension
2.1.2-15
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.
A2102020
2. Install the snap ring.
A2102021
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.
A2102022

Tires,Removal and Installation).
6. Align wheels.
Benni Mini 2013.01
2.1.2-16
Front Suspension
Front Strut Assembly

Removal
3. Remove the front wheel speed sensor and
the brake hose from the front strut assembly.
A2102008
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.
A2102014
6. Remove the two retaining nuts on the front

strut and detach the front strut assembly.
Torque: 37 Nm
A2102007
Installation
Benni Mini 2013.01
2.1.2-16
2.1.3 Rear Suspension

2.1.3-1
Rear Suspension
2.1.3-1
Specifications
Item
Nm
lb-ft
lb-in
Rear shock absorber to body connecting

bolt
88
65-
Rear shock absorber to rear axle connecting bolt
88
65-
Brake hose connector
16
12
Wheel nut
85
63
Wheel shaft retaining bolt
220
162
Longitudinal control arm to rear axle connecting bolt
88
65
Longitudinal control arm to body connecting bolt
88
65
Stabilizer bar to body connecting bolt
45
33
Stabilizer bar to rear axle connecting bolt
45
33
Rear brake to rear axle assembly connecting bolt
42
31
ABS rear wheel speed sensor head to

rear axle flange
80
Brake hose M10 thread connecting
16
12
Brake hose M12 thread connecting
18
13
Benni Mini 2013.01
2.1.3-2
Rear Suspension
2.1.3-2
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
2.1.3-3
Rear Suspension
2.1.3-3
Location View
Rear Suspension Assembly View
A2103001
Item
Description
Item
Description
Longitudinal control arm
Stabilizer bar
Rear shock absorber assembly
Coil spring
Rear axle assembly
Rear brake assembly
Benni Mini 2013.01
2.1.3-4
Rear Suspension
2.1.3-4
Exploded View
Rear Suspension Exploded View
1
2
5
4
3
23
21
10
22
7
20
24
19
11
18
17
12
16
13
15
14
A2103002
24
Item
Description
Qty.
Item
Description
Qty.
Rear suspension upper sping seat
13
Hexagon flange bolt M121.25100
Rear suspension cushion
14
Hexagon flange bearing surface

toothed nut M121.25

toothed nut M121.25
15
Longitudinal control arm (R)
Left rear shock absorber
16

toothed nut M121.25
Hexagon flange nut M121.25
17

toothed nut M121.25
18
19
Washer 12
20

toothed nut M121.25
Longitudinal control arm (L)
21
Rear suspension spring
10

toothed nut M121.25
22
Right rear shock absorber
11
Washer
23

toothed nut M121.25
Benni Mini 2013.01
2.1.3-5
Item
12
Rear Suspension
Description
Spring washer
Qty.
Item
24
2.1.3-5
Description
Stabilizer bar
Qty.
1
Benni Mini 2013.01
2.1.3-6
Rear Suspension

Refer to: Symptom Chart (2.1.1 Suspension System - General Information, Symptom Diagnosis and Testing).
Benni Mini 2013.01
2.1.3-6
2.1.3-7
Rear Suspension
2.1.3-7
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 suitable container.
A2103006
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.
A2103003
Benni Mini 2013.01
2.1.3-8
Rear Suspension
6. Remove the lower retaining bolts of both rear

shock absorbers.
Torque: 87.5 Nm
A2103009
7. Remove the stabilizer bar connecting nut to

the rear axle assembly .
Torque: 45 Nm
A2103012
8. Loosen the trailing arm connecting nut to the

rear axle, but do not detach the connecting
bolt.
Torque: 87.5 Nm
A2103013
Benni Mini 2013.01
2.1.3-8
2.1.3-9
Rear Suspension
2.1.3-9
9. Lower the rear axle by adjusting the jack

gradually until the rear coil spring can be
removed.
A2103011
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.
A2103003
Installation
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, General Procedures).
3. Adjust the parking brake cable.
Refer to: Parking Brake Cable Adjustment
(2.3.4 Parking Brake and Control, General
Procedures).
Benni Mini 2013.01
2.1.3-10
Rear Suspension
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.
A2103015
5. Burst through the rear wheel bearing

retaining nut insurance using proper tools.
A2103016
Benni Mini 2013.01
2.1.3-10
2.1.3-11
Rear Suspension
2.1.3-11
6. Remove the rear wheel bearing retaining nut

and detach the rear wheel bearing.
Torque: 220 Nm
A2103017
Installation
CAUTION: Insure the rear wheel bearing
retaining nut insurance using proper
tools.
Procedures).
Benni Mini 2013.01
2.1.3-12
Rear Suspension
Rear Shock Absorber Assembly

Removal
A2103003
3. Remove the lower mounting nut of the rear

shock absorber.
Torque: 88 Nm
A2103014
Installation
Benni Mini 2013.01
2.1.3-12
2.1.3-13
Rear Suspension
2.1.3-13
Stabilizer Bar
Removal
1. Remove the stabilizer bar and the left rear
axle connection.
1.Remove the stabilizer bar left connecting
bolt.
1
2.Remove the stabilizer bar right connecting

bolt and detach the flat washer.
Torque: 45 Nm
3.Detach the stabilizer bar.
A2103023
Installation
Benni Mini 2013.01
2.1.3-14
Rear Suspension
2.1.3-14
Trailing Arm
Removal
3. Remove the rear shock absorber assembly.
Refer to: Rear Shock Absorber Assembly
(2.1.3 Rear Suspension, Removal and
Installation).
A2103003
4. Release the trailing arm 2 connecting nuts to

the rear axle , and detach the connecting bolt.
Torque: 87.5 Nm
A2103008
5. Release the trailing arm connecting nut to the

vehicle body , and detach the connecting bolt.
Torque: 87.5 Nm
A2103018
Installation
Benni Mini 2013.01
2.1.4 Wheels and Tires

2.1.4-1
Wheels and Tires
2.1.4-1
Specifications
Item
Tire specification
Specification
Aluminum wheel
175/60 R13
Steer wheel with decorative

cover
155/65 R13
Non-load
210 kPa
Full load
230 kPa
Non-load
230 kPa
Full load
230kPa
Front tire pressure
Rear tire pressure
Item
Wheel bolt
Nm
lb-ft
lb-in
85
63
Benni Mini 2013.01
2.1.4-2
Wheels 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 XLor 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
P - Passenger
car
Tire type
P
T - Spare tire
(available for some

tires)
C - Commercial
vehicle
LT - Light truck
155
End face width
In mm
65
Height-width ratio
End face height/

end face width
Structural type
13
Wheel diameter
In inch
Load level
Consult the tire

manufacturer for
details
Speed level
Consult the tire

manufacturer for
details
73
R - Radial
B - Bias
Height/width radio = Height(2) Width(1)
A2104001
Benni Mini 2013.01
2.1.4-2
2.1.4-3
Wheels and Tires
2.1.4-3
Exploded View
1
4
7
5
6
9
A2104002
Item
Description
Qty.
Item
Description
Qty.
Steel wheel cover assembly
Wheel centre cover
Combination bolt
Wheel nut
Steel wheel
Aluminium alloy wheel
Tire 155/65 R13
Tire 175/60 R13
Steel wheel balance block
Benni Mini 2013.01
2.1.4-4
Wheels and Tires
General Procedures
WARNING: It is forbidden to install the
tires with different types on the same vehicle 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 assembly.
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 forbidden.
2.1.4-4
When tire wear indicator exposes, replace the

tire.
Tire Wear Diagnosis

When tire wear indicator exposes or tire shoulder 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 damaged 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 runout capacity on and off the vehicle. Make sure
installation surface is correct. The measurement
can be availiable after tire installation and without 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 indicator gauge. If runout exceeds the following
specification, and the vibration can not be fixed
after wheel balance, replace the wheel.
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 anything 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.
Benni Mini 2013.01
A2104003
Wheel
Type
Radial Runout
End Face
Runout
Steeliness
0.7 mm
0.9 mm
Aluminium
0.5 mm
0.5 mm
2.1.4-5
Wheels and Tires
2.1.4-5
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 necessary.
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.
Benni Mini 2013.01
2.1.4-6
Wheels and Tires
2.1.4-6
Tire Wear Inspection

Symptom
Tire shoulder rapid wear
Cause
Insufficient inflation tire
Not swap the tires
A2104004
Central rapid wear
A2104005
Exessive inflation tire

Not swap the tires
A2104006
A2104007
Tire tread cracks
Insufficient inflation tire

Too high speed
A2104008
Benni Mini 2013.01
2.1.4-7
Wheels and Tires

Symptom
2.1.4-7
Cause
Solution: Adjust pressure and swap tires according to the specification when tire is cold.
Single side wear
A2104009
Too large camber
A2104010
Solution: Adjust the camber to the specification.
Feather wear
A2104011
Incorrect toe-in
A2104012
Solution: Adjust the toe-in to the specification.
Small flower pattern polishing
Unbalanced wheel
Tire defect
A2104013
A2104014
Benni Mini 2013.01
2.1.4-8
Wheels and Tires

Symptom
2.1.4-8
Cause
Solution: Tire dynamic balancing.
Large wear of edge flower pattern
No swap tires
Suspension worn and needs adjustment
A2104015
Solution: Swap tires.

Solution: Adjust or repair suspension.
Benni Mini 2013.01
2.1.4-9
Wheels and Tires

Special Equipments
Four-wheel alignment device
Tire balance machine
Tire replacer
2.1.4-9
What influence happens to the vibration when

the following conditions change:
Engine torque
Vehicle speed
Engine speed
Vibration Type:
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 shoulder 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 damaged 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
appears.
speed
when
The vibration types in all speed range.
Mechanical or items can be heard.
Sensibility: Torque sensibility, vehicle

speed
sensibility,
engine
speed
sensibility.
The following explanations are useful to differentiate 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.
vibration
Benni Mini 2013.01
2.1.4-10
Wheels and Tires
2.1.4-10
Symptom Chart
If there is symptom but no diagnosis trouble code (DTC) is stored in control module and can not confirm symptom reasons in the regular inspect, it is necessary to fix the fault in the order listed in the following chart.
Symptom
Possible Sources
Tire swap
Tire pressure
Wheel distortion
Tire unlalanced
Tire wear diagnosis
Wheel alignment
Suspension components
High speed driving
Rear axle
Overload
Incorrect operation habit
Benni Mini 2013.01
Action
Refer to: Incorrect Tire Wear
Diagnosis (2.1.1 Suspension
System - General Information, Symptom Diagnosis and
Testing).
2.1.4-11
Symptom
Wheels and Tires
2.1.4-11
Possible Sources
Action
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.
Inspect whether there is soil or pieces

Unbalancing brake disc
Water in tire
on brake disc. If brake disc is not damaged or there is no pieces, brake disc
may be covered by a lot of dirts.
Drain water.
Install a new wheel. Repairing the
Wheel distorted
wheel could cause crack and reduce

the strength of wheel.
Rotate the wheel on the vehicle.

Correct tire edge assembly
Vibration caused by wheel

and tire
Inspect the joint of tire and wheel. If

the parts swing in rotation, it means
that the wheel and tire are not assembled very well. Remove tire and clean
the joint of wheel and tire.
Measure radial runout of tire and wheel

Wheel or tire radial runout too large
Wheel bolt looses or damaged or

wheel bolt hole enlarges.
Foreign materials between mounting

surfaces of the wheel and wheel hub
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.
Tighten or replace components if necessary.
Clean mounting surface.

Measure radial runout of tire and wheel
Wheel or tire radial runout too large
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.
Replace front wheel bearing.

Front wheel bearing damaged
Refer to: Front Wheel Hub

(2.1.4 Wheels and Tires,
Benni Mini 2013.01
2.1.4-12
Wheels and Tires
2.1.4-12
Wheels and Tires

Removal
1. Loosen the wheel
anticlockwise direction.
retaining
nut
in

4
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 surface of brake disc. All of these may loosen
wheel bolt and wheel in driving. Failure to
follow the instructions may cause personal injury.
Installation
Benni Mini 2013.01
A2104016
Driveline System
2.2 Driveline System

2012 Benni Mini
Table of Contents
Pages
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
2.2.1Driverline System - General Information

2.2.1-1
Driverline System - General Information
2.2.1-1
System Overview
Driveline system is of FF design and the differential 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 driveshaft through clamp ring.
Benni Mini 2013.01
2.2.1-2
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
damaged.
the
rubber
boots
are
5. Inspect the snap ring at transmission side.
A2201001
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.
Benni Mini 2013.01
2.2.1-2
2.2.1-3
2.2.1-3

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
Symptom
Driveshaft noises
Possible Sources
Inadequate or contaminated
lube in driveshaft CV joint
Another component contacting
driveshaft assembly
Clunk noises when acceleration after neutral position

coasting
CV joint rubber boot crack or

damage
CV joint wear or damage
Wheels out of balance

Vibration at high speed
Large radial runout of front

wheel
Incorrect installation of
driveshaftdriveshaft
Shudder or vibration during

acceleration
Improper assembling height

caused too large angle of tripod
CV joint
Driveshaft excessively worn or
damaged
Tripod joint or slip ball joint

pullout
Action
Refer to: Driveshaft Noises
(2.2.1 Driverline System - General
Information,
Symptom
Refer to: Clunk Noises At
Acceleration After Neutral Position Coasting (2.2.1 Driverline
Symptom Diagnosis and Testing).
Wheels balance
Refer to driveshaft removal and installation
Refer to: Shudder or Vibration

During Acceleration (2.2.1 Driverline System - General Information, Symptom Diagnosis
and Testing).
Driveshaft retainer snap ring

missing or not correctly seated in
the differential
Replace the retainer ring
Engine/transmission mispositioned
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
Benni Mini 2013.01
2.2.1-4

Symptom
Clicking, popping or grinding

noises while driving
Possible Sources
Action
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, suspension or steering components

worn or damaged
Inspect and repair as necessary
The joint retainer snap ring of

driveshaft and transmission is
distorted
Driveshaft pullout
2.2.1-4
Refer to: Driveshaft Pullout

(2.2.1 Driverline System - General
Information,
Symptom
Driveshaft distorted
Front strut distorted
Driveshaft retaining nut damaged
Wrong tire dynamic balance
Refer to: Vehicle Shimmy At

Low Speed (2.2.1 Driverline
Symptom Diagnosis and Testing).
Wrong wheel alignment

Wheel hub bearing damaged
Vehicle shimmy at low speed
Driveshaft damaged
Strut damaged
Stabilizer bar and bushing wear
or damaged
Driveshaft Noises
Testing Conditions
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
2.2.1-5

Testing Conditions
2.2.1-5
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.
Benni Mini 2013.01
2.2.1-6
2.2.1-6
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.
Testing Conditions

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
2.2.1-7
2.2.1-7
Shudder or Vibration During Acceleration

Testing Conditions
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.
Benni Mini 2013.01
2.2.1-8

Testing Conditions
2.2.1-8


Normal or not?
Y

Harshness).
N
Driveshaft Pullout
Testing Conditions

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
2.2.1-9

Testing Conditions
2.2.1-9
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.
Driveshaft Swing
Testing Conditions

damaged.
C.Inspect whether the driveshaft is bend or deformed.
Normal or not?
Y
Go to step 2.
N
Troubleshooting.
Benni Mini 2013.01
2.2.1-10

Testing Conditions
2.2.1-10
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
Vehicle Shimmy At Low Speed

Testing Conditions
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
2.2.1-11

Testing Conditions
2.2.1-11

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 - General Information, General Procedures).

Normal or not?
Y

Harshness).
N
Troubleshooting.
Benni Mini 2013.01
2.2.2 Driveshaft
2.2.2-1
Driveshaft
2.2.2-1
Specifications
Material specifications
Item
Specification
High-performance grease (color: black), CV joint
G.A.Cpalex GTE
Molybdenum disulfide
Other alternative grease
Capacity
High-performance grease, outer CV joint
7010 g
High-performance grease, inner CV joint
6510 g
Item
Nm
lb-ft
lb-in
Tie rod ball joint to steering knuckle

retaining nut
48
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 nut
37
27
Benni Mini 2013.01
2.2.2-2
Driveshaft
2.2.2-2
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.
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 removing, installing, disassembling or assembling 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.
Benni Mini 2013.01
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 balancer to avoid too large a bend of the universal joint during vehicle lifting.
Conditions permitting, it would be best to
remove the wheel on the fixed wheel balancer.
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 prevention

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 halfshaft.
2.2.2-3
Driveshaft
2.2.2-3
Exploded View
1
2
3
4
5
6
7
8
9
10
11
12
13
24
23
22
21
20
19
18
17
16 15
14
A2202016
Item
Description
Item
Description
Halfshaft retaining nut
13
Differential spring ring
Fixed end cage universal joint
14
Halfshaft retaining nut
Fixed end large clamp
15
Fixed end cage universal joint
Fixed end rubber boot
16
Fixed end large clamp
Fixed end small clamp
17
Fixed end rubber boot
Damper
18
Fixed end small clamp
Damper clamp
19
Left shaft lever
Right shaft lever
20
Moveable end small clamp
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
Benni Mini 2013.01
2.2.2-4
Driveshaft

Refer to: Symptom Chart (2.2.1 Driveline
System - General Information, Symptom
Benni Mini 2013.01
2.2.2-4
2.2.2-5
Driveshaft
2.2.2-5
Inner Constant Velocity (CV) Joint and Rubber Boot

Removal
Special Tool
Halfshaft Rubber Boot

Clamp Remover
CA201-002
CA201-002

Clamp Installer
CA201-008
CA201-008
Material
Item
High
performance
grease
Model
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.
2
1. Remove the rubber boot clamp with a special tool.

Special Tool: CA201-002
2. Disassemble the ball joint assembly.
3. Clear the grease in the CV joint.
1
1
A2202001
Benni Mini 2013.01
2.2.2-6
Driveshaft
2.2.2-6
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.
A2202002
Installation
CAUTION: All the snap rings and clamps
should be replaced.
2
1. Install the rubber boot/tripod universal joint.
1. Install the rubber boot.

2. Install the tripod universal joint.
3
3. Install the tripod universal joint snap ring.
A2202004
2. Add grease in the ball joint assembly.

3. Install the ball joint assembly.
A2202005
Benni Mini 2013.01
2.2.2-7
Driveshaft
2.2.2-7
4. Install the rubber boot clamp with a special

tool.
C
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.
A2202008

Benni Mini 2013.01
2.2.2-8
Driveshaft
2.2.2-8
Outer Constant Velocity (CV) Joint and Rubber Boot

Removal
Special Tool

Clamp Remover
CA201-002
CA201-002

Clamp Installer
CA201-008
CA201-008
Item
High
performance
grease
Model
2LN584/L0K575 GS
1. Remove the halfshaft.

2. Remove the rubber boot clamp.
2
1. Remove the rubber boot clamp with a special tool.

2. Detach the rubber boot.
3. Clean the grease.
1
A2202009
Benni Mini 2013.01
2.2.2-9
Driveshaft
2.2.2-9
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.
A2202010
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 universal joint.
3.Take out the rubber boot 3.
2
A2202011
5. Take out the steel ball from the ball cage.

1. Rotate the retainer ball cage.
2. Take out the retainer ball cage.
1
2
A2202012
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.
A2202013
Benni Mini 2013.01
2.2.2-10
Driveshaft
2.2.2-10
Installation
CAUTION: All the snap rings and clamps
should be replaced.
1. Install the steel ball on the ball cage
supporter.
A2202013
2. Install the retainer ball cage.

1. Install the retainer ball cage into the case.
2. Rotate the retainer ball cage.
A2202014
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 highperformance grease.
A2202015
Benni Mini 2013.01
2.2.2-11
Driveshaft
2.2.2-11
5. Install the rubber boot.

6. Install the rubber boot clamp with a special
tool.
C

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.
A2202008
7. Install the halfshaft.

Benni Mini 2013.01
2.2.2-12
Driveshaft
2.2.2-12
Left-Hand Halfshaft
Removal
Special Tool
Halfshaft Remover
CA201-006
CA201-006

3. Remove the halfshaft retaining nut.
Torque: 275 Nm
A2202019
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 stabilizer bar retaining nut.
Torque: 92 Nm
A2202020
Benni Mini 2013.01
2.2.2-13
Driveshaft
2.2.2-13

1.Remove both stabilizer bar seat retaining
bolts.
Torque: 72 Nm
1
2.Detach the front stabilizer bar assembly.
2
A2202021
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.
A2202022
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
transmission.
container
under
the
A2202018
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.
201-006
A2202023
Benni Mini 2013.01
2.2.2-14
Driveshaft
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.
A2202024
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.
A2202025
8. Tighten the left front strut retaining nut.
Right-Hand Halfshaft
Benni Mini 2013.01
2.2.2-14
2.2.3 Differential
2.2.3-1
Differential
2.2.3-1
Specifications
Item
Specification
Transmission oil type
BOT130M, GL-4, 75W/90
Manual transmission oil capacity
2.1 0.1 L
Item
Final drive driven gear fixed bolt
Nm
90
lb-ft
lb-in
-
Benni Mini 2013.01
2.2.3-2
Differential
2.2.3-2
Exploded View
1
2
3
4
16
5
6
15
14
8
13
12
10
11
A2203001
Item
Description
Item
Description
Differential left bearing
Differential cover
Differential bolt
10
Induction gear
Final drive gear
11
Differential right bearing
Differential halfshaft washer
12
Planetary gear shaft pin
Differential halfshaft gear
13
Differential halfshaft gear
Planetary gear washer
14
Planetary gear
Planetary gear
15
16
Planetary gear shaft
Benni Mini 2013.01
2.2.3-3
Differential
2.2.3-3

Refer to: Symptom Chart (2.2.1 Driveline
Benni Mini 2013.01
2.2.3-4
Differential
2.2.3-4
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.
A2203002
2. Remove the final drive gear bolts to the

differential.
A2203003
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.
A2203004
Benni Mini 2013.01
2.2.3-5
Differential
2.2.3-5
4. Remove the planetary gear shaft pin.

CAUTION: Remove the planetary gear
shaft pin with a suitable tool.
A2203005
5. Remove the planetary gear shaft.
A2203006
6. Rotate the drive shaft gear to remove the

planetary gear and the planetary gear gasket.
A2203007
7. Remove the differential right halfshaft and the

differential halfshaft gasket.
A2203008
Benni Mini 2013.01
2.2.3-6
Differential
8. Remove the differential left halfshaft and the

differential halfshaft gasket.
A2203009
Assembly
CAUTION: Clean and check all the components carefully before assembling them.
And lubricating them with manual transmission oil.
1. Install the differential left halfshaft gasket and
the differential left halfshaft.
A2203009
2. Install the differential right halfshaft gasket

and the differential right halfshaft.
A2203008
Benni Mini 2013.01
2.2.3-6
2.2.3-7
Differential
2.2.3-7
3. Install the planetary gear and the gasket,

rotate the driveshaft gear.
A2203010
4. Install the planetary gear shaft.

CAUTION: Align the planetary gear shaft
pin hole and the installing hole on the differential case.
A2203011
5. Install the planetary gear shaft pin.

CAUTION: Install the planetary gear shaft
pin with a suitable tool.
A2203012
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.
A2203016
Benni Mini 2013.01
2.2.3-8
Differential
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 differential oil seal if the above situation exists.
WARNING: All the gears and bearings
have directions. Do not use them wrongly.
A2203013
8. Install the induction gear ring.

CAUTION: The induction gear ring has its
mounting position.
A2203014
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.
Benni Mini 2013.01
A2203015
2.2.3-8
Brake System
2.3 Brake System

2012 Benni Mini
Table of Contents
Pages
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 Brake System - General Informa2.3.1-1
Brake System - General Information
2.3.1-1
Specifications
Material Specifications
Item
Brake fluid
Specification
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
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 treatment with much care.
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

thickness
4.5 mm
New secondary shoe friction lining surface thickness
4.5 mm
Brake shoe friction lining surface discard thickness
1.5 mm
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.
Benni Mini 2013.01
2.3.1-2
System Overview
The braking system is of a diagonally split, dualcircuit 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 tandem design and directly linked to a brake booster
which reduces the brake pedal effort. The longitudinal tandem design will make sure that in the
event of one brake circuit failing the other will
remain fully operational. The brake master cylinder 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 sensors are added to the anti-lock brake (ABS) system equipped in the vehicle with higher
configuration. The hydraulic system has a separate 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 configuration. 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 during braking.
Benni Mini 2013.01
2.3.1-2
2.3.1-3
2.3.1-3
Location View
2
3
10
11
14
13
12
A2301001
Item
Description
Item
Description
Right front wheel speed sensor assembly
Right rear wheel speed sensor assembly
Electronic hydraulic control unit
Brake drum
Brake fluid reservoir
10
Left rear wheel speed sensor assembly
Brake booster
11
Left parking brake cable
Parking brake handle
12
Brake disc
Cable equalizer
13
Brake caliper
Right parking brake cable
14
Left front wheel speed sensor assembly
Benni Mini 2013.01
2.3.1-4
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

specification range.
Correct wheel alignment
Normal brake fluid level
The brake system indicator is normal

without any trouble code.
is
within
the
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 suitable 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 consistently used, the road surface variable can be eliminated 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
Benni Mini 2013.01
2.3.1-4
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 determine a method of carrying a road test.
A road test always starts with the general inspection for the brake performance. According to the
description of the customer, the vehicle braking
should be inspected with different pedal pressures under different vehicle speeds. To determine 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, vibration, 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 duplicate 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 description, a list of possible sources can be used to further 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.
2.3.1-5
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.
2.3.1-5
Brake Pedal Remaining Travel Inspection

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 bottom.
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 movement).
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.
Benni Mini 2013.01
2.3.1-6
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 system.
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 cylinder, inspect the feeling on the brake pedal
as evidence. Inspect if the brake warning indicator lamp flashes and inspect the brake liquid level.
Benni Mini 2013.01
2.3.1-6
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 conditions 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.
2.3.1-7
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.
Symptom
Depress the brake
pedal and the brake
pedal goes down fast.
Depress and hold the
brake pedal, and the
brake pedal goes down
slowly.
The brake pedal is low

or feels soft when
depressing it.
The brake pedal

returns slowly.
Brake Master Cylinder

External leak (split,
connectors, seals)
External Leak
Internal Leak (seals
aging of the master
cylinder)
2.3.1-7
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 reservoir 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.
The blocking of the

inlet or reservoir vent
holes
Air in the hydraulic
system
Compensation
blocked
hole
Master cylinder spring

cracks (fatigue)
The rear brake locks up

when lightly depressing the brake pedal.
ABS system
Long brake pedal travel
Internal leak
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
Benni Mini 2013.01
2.3.1-8
Brake System Bleeding

WARNING: The brake fluid contains polyglycol 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 vomiting, 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 master 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.
Benni Mini 2013.01
2.3.1-8
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.
2.3.1-9
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.
2.3.1-9

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.
CAUTION: Before apply the Bleeding and

Filling Test procedure, bleed the air for the
basic brake system.
Refer to: Trouble Code List (2.3.7 AntiLock Control, DTC Diagnosis and Testing).

Brake System, General Procedures).
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.
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 blocking in the assistant brake lines of the
hydraulic adjuster assembly.
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.
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.
Benni Mini 2013.01
2.3.1-10
Brake Disc Runout and Its Thickness

Inspection
WARNING: Refer to: "Vehicle Lift Warning"
in Lifting (1.1.3 Traction and Lifting).
2.3.1-10
record the brake disc runout on both the inner

and outer faces of the brake disc.
Standard Value: 0.1 mm (metric system)
Dial indicator gauge holding fixture
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 runout, install a new brake disc.
Dial indicator gauge
9. Inspect the wheel hub runout
Micrometer
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.
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.
A2301003
10. Measure the brake disc thickness.

CAUTION: After the brake disc has a surface 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.
A2301002
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.
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
A2301004
Benni Mini 2013.01
2.3.1-11
2.3.1-11

CAUTION: Before the diagnosis, verify if
the brake system warning indicator works
normally.
2. Visually inspect for obvious mechanical and
hydraulic damage.
Mechanical
Tire pressure(s)
Wheels and tires
Brake fluid level
Brake line leakage
3. Solve the known problems before the next

step.
symptom and refer to the symptom chart.
General Equipment
Digital Multimeter
Changan Auto special diagnostic tool
Benni Mini 2013.01
2.3.1-12
2.3.1-12
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 paintwork, 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
2.3.1-13
Symptom
2.3.1-13
Possible Sources
Solutions
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 Installation) and (2.3.3 Front Disc
Inspect the front brake disc.
The abnormal wear and distortion of the front brake disc

Uneven braking force-deviation
Refer to: Brake Disc Runout and

Thickness Inspection (2.1.3
Install a new brake drum.
The abnormal wear and distortion of the rear brake drum

Repair or install new brake slave cylinders or brake calipers.
Seized brake slave cylinder

or brake caliper

Brake, Removal and Installation) or (2.3.3 Front Disc Brake,
Inspect and repair the anti-lock control.
Anti-Lock control failure
Refer to: (2.3.7 Anti-Lock Control, Symptom Diagnosis and

Testing).
Aligning the wheels
Benni Mini 2013.01
2.3.1-14
Symptom

Possible Sources
2.3.1-14
Solutions
Install new brake shoes or brake

pads.
The brake shoe or the brake
pad is worn or damaged or
adhesive with grease.

Install new front brake discs.
The abnormal wear and distortion of the front brake disc
Shaking or vibrating occurs

when applying the brake
Benni Mini 2013.01
The abnormal wear, distorted

circle and distortion of the
rear brake drum.
Refer to: Brake Disc Runout and

Thickness Inspection (2.1.3
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.
2.3.1-15
Symptom

Possible Sources
2.3.1-15
Solutions
Repair the leaks, fill the brake fluid

and start the bleeding air.
Hydraulic system leaks
Refer to: Brake System Bleeding (2.3.1 Brake System - General

Information,
General
Procedures).
Fill the brake fluid and start the bleeding air.
Air exists in the brake system.

The brake pedal depressed
down quickly

Information,
General
Procedures).
Replace the brake master cylinder.
The brake master cylinder

piston is worn or the cylinder
cracks.
Refer to: Brake Master Cylinder

and Brake Fluid Reservoir (2.3.5
Hydraulic
Brake
Actuation,
pads.
The excessive wear of the

brake pads or brake shoes

pads.

brake shoes or brake pads
The brake pedal is low or

feels soft.
The vent holes on the reservoir cap get blocked or dirty.
Air exists in the brake system.

Clean the vent holes.
Fill the brake fluid and start the bleeding air.

Information,
General
Procedures).
Benni Mini 2013.01
2.3.1-16
Symptom
The brake lockup occurs

when slightly depressing the
brake.
Possible Sources
2.3.1-16
Solutions
Incorrect tire pressure(s)
Adjust the tire pressure(s).
Tire wear
Replace the tire.

pads.
Incorrect installation of the

brake shoes or brake pads

Anti-Lock control failure
Refer to: (2.3.7 Anti-Lock Control, Symptom Diagnosis and

Testing).
Repair the leaks, fill the brake fluid
and start the bleeding air.
Leaks or air in the brake system
Depress the pedal and hold it,

it would go down slowly.
Brake master cylinder trouble

Information,
General
Procedures).
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 Installation).
pads.

brake pads or brake shoes
Long brake pedal travel
Rear wheel brake clearance

automatic adjustment malfunction
Benni Mini 2013.01

Repair the manual adjustment function
2.3.1-17
Symptom

Possible Sources
Parking brake is functioning
when the hand brake has not
been completely released
yet.
2.3.1-17
Solutions
Release the hand brake.
Repair or install new brake slave cylinders or brake calipers.

Seized brake caliper or brake
slave cylinder
Brake drag

Repair or install new brake pads or
brake shoes.
Seized brake pads or brake

shoes

Install new parking brake cables.
Seized parking brake cable.
Seized vacuum booster

Brake pedal free travel (Insufficiency)
Leaks in the air intake system

Adjust the length of the brake booster
actuating rod or install a new vacuum
booster.
Refer to: (2.3.6 Boost Booster,
Inspect the air intake system for its
vacuum level and repair it if necessary.
Refer to: (3.1.5 Air Intake System, General Procedures)
Poor efficiency of boosting

brake
The vacuum boosting hose

leaks.
Refer to: Vacuum Booster

Inspection (2.3.1 Brake System General Information, General
Procedures).
Vacuum boosting hose oneway valve failure
Benni Mini 2013.01
2.3.1-18
Symptom

Possible Sources
Solutions
Brake shoes or brake pads (

they are excessively worn,
cracked, distorted, dirty and
glazed.)
Noise in the brake system

Repair or replace
Brake caliper bracket retaining bolts (loosened)
Tighten or replace
Brake caliper retaining bolts

(loosened)
Tighten or replace
Brake caliper
(worn)
Replace
floating
pin
Abnormal wear, distorted circle, crack and distortion of

the rear brake drum
Benni Mini 2013.01

pads.
Brake disc guide plate (loosened)
Abnormal wear, crack and

distortion of the front brake
disc
Noise in the brake system
2.3.1-18
Replace new front brake discs.

Refer to: Front Brake Disc (2.3.3
Front Brake Disc, Removal and
Installation).
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 General Information, General
Procedures).
Brake master cylinder

Inspection (2.3.1Brake SystemGeneral Information, General
Procedures)
2.3.1-19
2.3.1-19
Uneven Brake - Deviation Diagnosis

Test Condition
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.
Benni Mini 2013.01
2.3.1-20

Test Condition
2.3.1-20
5. Inspect the rear brake drum

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

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
Refer to: (2.3.7 Anti-Lock Control, Symptom Diagnosis and Testing).

N
Go to step 9.
Benni Mini 2013.01
2.3.1-21

Test Condition
2.3.1-21
9. Wheel alignment
A.Inspect whether the wheel alignment is normal.
N
Adjust the wheel alignment.
Refer to: (2.1.1 Suspension System - General Information, General Procedures).

Y
Confirm the maintenance is finished.
Shaking/Vibration While Braking Diagnosis

Test Condition

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.

Benni Mini 2013.01
2.3.1-22

Test Condition
2.3.1-22
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
2.3.1-23
2.3.1-23
Brake Pedal Go Down Quickly Diagnosis

Test Condition

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 reservoir pipe.
Refer to: (2.1.1 Brake System-General

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, General Procedures).
In case the fault still exists, bleed the brake system.

N
Go to step 4.
Benni Mini 2013.01
2.3.1-24

Test Condition
2.3.1-24
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 corresponding parts if necessary. Fill the brake fluid and bleeding.
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

N
Replace the master brake cylinder.
Refer to: Brake Master Cylinder and Brake

Fluid Reservoir (2.3.5 Hydraulic Brake
Y
Low Brake Pedal or Feeling Like Sponge Diagnosis

Test Condition

pedal.
B.Inspect if the brake pedal feels sponge.
Y
Vehicle is normal.
N
Go to step 2.
Benni Mini 2013.01
2.3.1-25

Test Condition
2.3.1-25
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 reservoir pipe.
Refer to: (2.1.1 Brake System - General

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.

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.

Comfirm the maintenance is finished.
Benni Mini 2013.01
2.3.1-26
2.3.1-26
Brake Lock While Slightly Depress the Brake Diagnosis

Test Condition

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
Refer to: (2.3.7 Anti-Lock Control, Symptom Diagnosis and Testing).
Benni Mini 2013.01
2.3.1-27

Test Condition
2.3.1-27
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
Depress the Brake Pedal and Hold It Down In Depressed Position,

and the Pedal Eases Down Slowly Diagnosis
Test Condition
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.
Benni Mini 2013.01
2.3.1-28

Test Condition
2.3.1-28
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 corresponding 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.

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
2.3.1-29
2.3.1-29
Brake Drag Diagnosis

Test Condition
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.

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

Benni Mini 2013.01
2.3.1-30

Test Condition
2.3.1-30
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 Rear Drum Brake

2.3.2-1
Rear Drum Brake
2.3.2-1
Specification
Item
Specification
Brake fluid
HZY4
Rear Drum Brake Specification

Rear Drum Brake
Specification
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 thickness
4.5 mm
Brake shoe friction lining surface discard thickness
1.5 mm
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
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
Benni Mini 2013.01
2.3.2-2
Rear Drum Brake
2.3.2-2
Rear Drum Brake Operation
Brake System
When the brake pedal is depressed, the mechanical output force from the hydraulic brake slave
cylinder piston is applied to the shoes. The brake
slave cylinder moves the two brake shoes outwards 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 selfboosting force. When the wheels move backwards, the rear brake shoes produce self-boosting force.
The rear drum brake assembly is of a secondary

shoe design with a single cylinder hydraulic operation. The two shoes are pressed tightly on the
brake slave cylinder piston and the retaining fulcrum post support pin by the upper and lower
return springs. The former one is called "primary
shoe", the other toward the rear is called "secondary shoe". The brake slave cylinder is single-cylinder 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 surface 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 fulcrum 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.
Benni Mini 2013.01
2.3.2-3
Rear Drum Brake
2.3.2-3
Exploded View
Rear Drum Brake
1
2
3
A2302001
Item
Description
Item
Description
Brake bottom plate
Brake shoe
Brake slave cylinder
Brake drum
Benni Mini 2013.01
2.3.2-4
Rear Drum Brake
Brake Drum
Removal
Material
Item
Brake fluid
Model
HZY 4
1. Remove the tires.

2. Release the parking brake lever.
4. Detach the brake drum.
A2302004
Installation
CAUTION: Adjust the shoe clearance after
the brake drum installation.
Benni Mini 2013.01
2.3.2-4
2.3.2-5
Rear Drum Brake
2.3.2-5
Brake Shoe
Removal
Material
Item
Grease
Model
SAM1C-9107-A

2. Remove the brake shoe setting spring.
A2302006
3. Detach the brake shoe bottom bracket form

the brake shoe, and remove the bottom
return spring.
A2302007
Benni Mini 2013.01
2.3.2-6
Rear Drum Brake
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.
A2302008
5. Remove the parking brake cable, and detach

the brake shoe.
A2302009
Installation
1. Clean, inspect and apply lubricant to the
brake bottom plate contact areas.
A2302013
Benni Mini 2013.01
2.3.2-6
2.3.2-7
Rear Drum Brake
2.3.2-7
2. Install the parking brake cable.
A2302009
3. Install the upper brake shoe jack stay and the

return spring.
A2302016
4. Fix the brake shoe under the bottom bracket

and install the lower return spring.
A2302017
Benni Mini 2013.01
2.3.2-8
Rear Drum Brake
5. Install the brake shoe setting spring.

6. Install the brake drum.
A2302006
Benni Mini 2013.01
2.3.2-8
2.3.2-9
Rear Drum Brake
2.3.2-9

Removal
General Equipment
Brake Hose Clamp
1. Remove the brake shoe.

2. Clamp the brake hose with a proper brake
hose clamp.
A2302019
3. Remove the brake slave cylinder.

1
1.Remove the brake hard pipe joint.

2.Remove the bolts.
3.Remove the brake slave cylinder.
2
A2302020
Benni Mini 2013.01
2.3.2-10
Rear Drum Brake
2.3.2-10
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.
Benni Mini 2013.01
A2302021
2.3.2-11
Rear Drum Brake
2.3.2-11
Brake Bottom Plate

Removal
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.
2
1
A2302022
5. Remove the brake bottom plate.

1.Remove the four retaining bolts on the
brake bottom plate and detach the brake bottom plate.
Torque: 42.5 Nm
A2302023
Installation
Benni Mini 2013.01
2.3.3 Front Disc Brake

Front Disc Brake
2.3.3-1
2.3.3-1
Specifications
Item
Specification
Brake fluid
HZY4
Front Disc Brake Specification

Front Disc Brake
Specification
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
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 treatment with much care.
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
Benni Mini 2013.01
2.3.3-2
Front Disc Brake
2.3.3-2
Disc Brake Caliper Floating Pin
System Overview
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.
Installed on the steering knuckle with two mounting 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 original shape to keep the original clearance between
the brake disc and the brake pad when the pressure 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 movement 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 cylinder 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.
Benni Mini 2013.01
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.
Front Disc Brake
2.3.3-3
2.3.3-3
Exploded View
Front Disc Brake
3
2
1
A2303015
Item
Description
Brake disc
Brake caliper
Item
3
Description
Brake pad
Benni Mini 2013.01
2.3.3-4
Front Disc Brake
Brake Caliper
Disassembly
Material
Item
Brake fluid
Model
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 cushion or some cloth is placed between the
brake slave cylinder piston and the brake
caliper housing to prevent damaging the
brake slave cylinder piston.
A2303011
2. Remove and discard the dust-proof oil seal.
A2303012
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.
A2303013
Benni Mini 2013.01
2.3.3-4
2.3.3-5
Front Disc Brake
2.3.3-5
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.
A2303013
3. Install a new dust-proof oil seal on the brake

slave cylinder piston.
A2303014
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.
A2303011
Benni Mini 2013.01
2.3.3-6
Front Disc Brake
Brake Pad
Removal
Material
Item
Brake fluid
Model
HZY 4
1. Remove the tires.

1.Remove the lower retaining bolts of the
brake slave cylinder.
2.Rotate the brake slave cylinder upwards.
2
A2303001
A2303002
Benni Mini 2013.01
2.3.3-6
2.3.3-7
Front Disc Brake
2.3.3-7
Installation
1. Use a special tool to compress the brake
slave cylinder piston.
Special Tool: 201-003
201-003
CAUTION: The brake fluid will spill out

from the brake master cylinder after the
brake slave cylinder position is compressed tightly into the piston cylinder.
A2303003
2. Install the brake pads.
A2303002
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.
A2303004
Benni Mini 2013.01
2.3.3-8
Front Disc Brake
2.3.3-8
Brake Caliper
Removal
General Equipment
Brake hose clamp
1. Detach the brake hose from the front strut.

2. Clamp the brake hose with a proper brake
hose clamp.
A2303005

1.Remove the brake hose retaining bolt.
Torque: 23 Nm
2.Remove the brake caliper upper and lower
retaining bolts.
2
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.
Installation
Benni Mini 2013.01
A2303006
2.3.3-9
Front Disc Brake
2.3.3-9
Brake Disc
Removal
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.
A2303009
4. Remove the brake disc.
A2303010
Installation
Benni Mini 2013.01
2.3.4Parking Brake and Actuation

2.3.4-1
Parking Brake and Actuation
2.3.4-1
Specifications
Item
Nm
lb-ft
lb-in
Parking brake cable adjustment nut
35
Parking brake control nut
23
17
Benni Mini 2013.01
2.3.4-2
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
2.3.4-2
2.3.4-3
General Procedures
2.3.4-3
7. Install the parking brake control cover.
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.
A2304007
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
A2304007
6. Test the parking brake for normal operation.
Benni Mini 2013.01
2.3.4-4

1. Verify the customer concerns.
2. Visually inspect for any obvious signs of
mechanical damage and hydraulic troubles.
Mechanical
Tire pressure (s)
Wheel and tire
Brake fluid level
Brake line leak
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
Digital Multimeter
Benni Mini 2013.01
2.3.4-4
2.3.4-5
2.3.4-5
Symptom Chart
Symptom
Possible Sources
Excessive parking brake lever
travel
Action
Refer to: Parking Brake Cable
Adjustment
(2.3.4
Parking
Brake and Actuation, General
Procedures).
Repair or remove new parking brake
cables.
Left and right parking brake cable

(seized and cracked)
Parking brake failure
Poor parking brake force
Cable equalizer (lossened,

crakced, distorted)

(2.3.4 Parking Brake and Actuation, Removal and Installation).
Install a new cable equalizer.
Install new brake shoes.
Rear brake shoes (worn to the

limit)
Rear drum brake inner the fulcrum

post and parking control lever
(distorted and cracked)
Insufficient parking brake lever

travel
Refer to: Brake Shoe (2.3.2 Rear

Installation).
Install the fulcrum pin and parking control
lever.

Adjustment
(2.3.4
Parking
Brake and Actuation, General
Procedures).
Repair or remove new parking brake
cables.
Parking brake can not

release (lag)
Left and right parking brake

cables (seized)
Refer to: Install New Parking

Brake Cables (2.3.4 Parking
Brake and Actuation, Removal
and Installation).
Repair or install new brake shoes.
Rear brake shoe (seized, cracked

and distorted)
Rear brake return spring (fatigue

and cracked)
Refer to: Brake Shoe (2.3.2 Rear

Installation).
Install new return springs.
Benni Mini 2013.01
2.3.4-6
Symptom
Possible Sources
2.3.4-6
Action
Instrument cluster fuse

Instrument wiring harness
connector
The parking brake indicator
is turned off when the
ignition switch is
inONposition and the
vehicle is under parking
state
The diagnostic procedures for the switchoff of the parking warning indicator when
the ignition switch is in ON position and
the vehicle is in parking state.
Instrument power circuit

nstrument ground circuit
The wiring harness between the
parking brake warning indicator
switch and instrument cluster
Refer to: Symptom Chart (4.3.2

Instrument Cluster, Symptom
Parking brake switch

Instrument cluster
Parking brake switch
The parking brake indicator

is always on
Refer to: Parking Brake Indicator 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 cluster assembly-power supply and
ground)
Instrument cluster
Parking Brake Not Work (Failure) Diagnosis/Poor Parking Brake

Test Conditions
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
2.3.4-7

Test Conditions
2.3.4-7
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 Parking 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.
Benni Mini 2013.01
2.3.4-8
2.3.4-8
Parking Brake Not Release (Lag) Diagnosis

Test Conditions
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 Parking 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
2.3.4-9
2.3.4-9
Parking Brake Indicator Always On Diagnosis

Test Conditions
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.
Benni Mini 2013.01
2.3.4-10

Test Conditions
2.3.4-10
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?
S11
A2304010
Go to step 4.
N
Inspect and repair the failed circuit.
S11
1
P07
17
1 2
32
16
A2304011
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).
C10
Is the brake fluid level sensor normal?

Y
Go to step 5.
N
A2304012
Benni Mini 2013.01
Replace the brake fluid level sensor.
2.3.4-11

Test Conditions
2.3.4-11
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?
P07
17
1
Y
7
32
16
Replace the instrument cluster.
Refer to: Instrument Cluster (4.3.2 Instrument Cluster, Removal and Installation).
A2304014
N
Inspect and repair the instrument cluster circuit.
Benni Mini 2013.01
2.3.4-12
2.3.4-12
Parking Brake Control

Removal
1. Remove the console.
Refer to: Console (5.1.6 Instrument Cluster and Console, Removal and Installation).
1.Loosen the adjustment nut.
Torque: 4 Nm
2.Adjust the parking brake cable.
A2304001
3. Remove the parking brake lever retaining

bolt.
Torque: 23 Nm
A2304002
4. Disconnect the parking brake indicator switch

connector and detach the parking brake lever.
A2304003
Benni Mini 2013.01
2.3.4-13
2.3.4-13
Installation
Parking brake cable

Removal
1. Remove the center console.
1.Loosen the adjustment nut.
Torque: 4 Nm
2.Adjust the parking brake cable.
A2304001
3. Remove the parking brake rear cable

retaining bolt as shown on the right
illustration.
Torque: 9 Nm
A2304004
Benni Mini 2013.01
2.3.4-14
2.3.4-14

illustration.
Torque: 9 Nm
A2304005

illustration.
Torque: 9 Nm
A2304006
8. Remove the parking brake cable.

1.Remove the retaining clamp.
2.Detach the brake cable.
2
1
A2302022
Installation
Benni Mini 2013.01
2.3.4-15
2.3.4-15
Parking Brake Warning Lamp Switch

Removal
1. Remove the center console.
2. Removal the switch.
1.Disconnect the switch connector.
2.Remove the switch retaining screw.
3.Detach the switch.
1
2
A2304008
Installation
Benni Mini 2013.01
2.3.5 Hydraulic Brake Actuation

2.3.5-1
Hydraulic Brake Actuation
2.3.5-1
Specification
Item
Specification
Brake fluid
HZY4
Item
Nm
lb-ft
lb-in
Brake master cylinder and pipe retaining

nut
16
12
Brake master cylinder retaining nut
25
18
Brake pedal coupling spindle retaining nut
25
18
Benni Mini 2013.01
2.3.5-2
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, amplified 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 hydraulic output force. The hydraulic output pressure is
distributed into two hydraulic brake tubes from the
master cylinder, providing brake fluid for the diagonal 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 excessive brake fluid low level (The signal circuit is at
electronegative potential) or the parking brake
lever is not released.
Benni Mini 2013.01
2.3.5-2
2.3.5-3
2.3.5-3
Brake Master Cylinder and Brake Fluid Reservoir

Removal
Material
Item
Brake fluid
Model
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.
1
2
A2305001
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 container.
2
3
4
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.
A2305002
Benni Mini 2013.01
2.3.5-4
2.3.5-4
4. Remove the brake pipe from the brake

master cylinder.
Torque: 16 Nm
A2305003
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.
A2305004
Installation
CAUTION: Make sure that the brake
booster push rod is correctly located
before the installation.
CAUTION: Make sure that the brake master cylinder vacuum seals are correctly
located before the installation.
Benni Mini 2013.01
2.3.5-5
2.3.5-5
Brake, Clutch and Accelerator Pedal Assembly (MT)

Removal
1. Disconnect the battery negative cable.
Refer to: Battery Inspection (3.1.10 Charging System, General Procedures).
2. Remove the air cleaner assembly.
3. Release the clutch cable.
Torque: 4 Nm
A2305005
4. Remove the clutch pedal external firewall

retaining bolts and nuts.
Torque: 25 Nm
A2305006
5. Disconnect the stop lamp switch connector.
A2305007
Benni Mini 2013.01
2.3.5-6
2.3.5-6
6. Remove the throttle cable from the accelerator

pedal.
A2305008
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.
A2305011
8. Detach the clutch cable from the clutch pedal.
A2305009
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
A2306002
Benni Mini 2013.01
2.3.5-7
2.3.5-7
10. Remove the five mounting bolts and nuts on

the brake, clutch and accelerator pedal
assembly.
Torque: 25 Nm
A2305010
11. Detach the brake, clutch and accelerator

pedal assembly.
A2305012
Installation
Benni Mini 2013.01
2.3.5-8
2.3.5-8
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
sensor.
the
accelerator
pedal
position
Refer to: Accelerator Pedal Position Sensor (3.1.13 Electrical control System-ME7,
A2305006

1.Remove the brake push rod and brake
retaining pin.
2.Remove the four mounting bolts on the

brake booster.
Torque: 25 Nm
A2306002
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).
A2305013
Benni Mini 2013.01
2.3.5-9
2.3.5-9
8. Detach the pedal assembly.
A2305014
Installation
Benni Mini 2013.01
2.3.6 Power Brake Actuation

2.3.6-1
Power Brake Actuation
2.3.6-1
Specifications
Item
Nm
lb-ft
lb-in
Brake booster retaining bolt
25
18
Brake master cylinder retaining bolt
25
18
Benni Mini 2013.01
2.3.6-2
2.3.6-2
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
A2306004
Item
1
Description
Brake booster
Benni Mini 2013.01
2.3.6-3
2.3.6-3
Brake Booster
Removal
2
3
4


A2305002
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.
A2306001
Benni Mini 2013.01
2.3.6-4
2.3.6-4

1.Remove the brake push rod and the brake
retaining pin.
2.Remove the 4 mounting bolts on the brake

booster.
Torque: 25 Nm
A2306002
A2306003
Installation
CAUTION: Make sure that the brake master cylinder vacuum seal is correctly
located before the installation.
Benni Mini 2013.01
2.3.7 Anti-lock Control

Anti-Lock Control
2.3.7-1
2.3.7-1
Specifications
Item
Specification
Brake fluid
HZY4
Item
Nm
lb-ft
lb-in
Electronic hydraulic control unit retaining

bolt
80
Brake line and electronic hydraulic control

unit connection retaining bolt
16
12
Front wheel speed sensor retaining bolt
80
Rear wheel speed sensor retaining bolt
23
17
Benni Mini 2013.01
2.3.7-2
Anti-Lock Control
2.3.7-2
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 control 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 hydraulic 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.
A2307011
Benni Mini 2013.01
Anti-Lock Control
2.3.7-3
Item
Description
Pump
Valve body
Item
3
2.3.7-3
Description
ABS control module
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.
Benni Mini 2013.01
Anti-Lock Control
2.3.7-4
2.3.7-4
Anti-lock Brake System (ABS) Hydraulic Line Schematic Diagram
2 bar admission pressure

pedal assistance
MC2
MC1
B2
B1
FP2
FP1
RFEV
A2
LREV
RFAV
A1
LRAV
RF
RREV
LR
RRAV
LFAV
RR
LF
A2307012
Item
Description
Item
Description
AV
Normally closed solenoid valve
RR
Right rear wheel
EV
Normally open solenoid valve
LR
Left rear wheel
Motor
RF
Right front wheel
LF
Left front wheel
A1
Pressure accumulator 1
A2
Pressure accumulator 2
B1
Buffer 1
B2
Buffer 2
Benni Mini 2013.01
LFEV
2.3.7-5
Anti-Lock Control
2.3.7-5
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.
A2307013
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 performs 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.
Benni Mini 2013.01
2.3.7-6
Anti-Lock Control
2.3.7-6
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 indicator lamp and the EBD indicator lamp are both on, both the ABS and the EBD functions are invalid.
Benni Mini 2013.01
Anti-Lock Control
2.3.7-7
2.3.7-7
General Procedures

2. Visually inspect for obvious mechanical or
electrical fault.
Mechanical
Electrical
Wheel speed sensor
Fuse
Wheel speed sensor

ring gear(s)
Connector
Wiring harness
3. Solve the known problems before proceeding

to the next step.
symptom and refer to the Symptom Chart.
General Equipment
Digital Multimeter
Changan Auto Special Diagnostic Tool
Benni Mini 2013.01
Anti-Lock Control
2.3.7-8
2.3.7-8
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.
Test Conditions
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 vehicle 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 components.
CAUTION: The connector joint, the vibration 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
Anti-Lock Control
2.3.7-9
Test Conditions
2.3.7-9
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.
A2307014
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.
A2307015
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).
Benni Mini 2013.01
Anti-Lock Control
2.3.7-10
Test Conditions
2.3.7-10
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.
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).
Benni Mini 2013.01
Anti-Lock Control
2.3.7-11
2.3.7-11
ABS Warning Lamp Always ON Diagnosis

Test Conditions
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 Antilock 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.
P07
17 18
1
32
16
B.Disconnect the instrument cluster wiring harness

connector P07.
C.Disconnect the ABS control module wiring harness
connector C12.
13
12
26
25
10
C12
A2307016
15
14
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 connector C12.
Benni Mini 2013.01
Anti-Lock Control
2.3.7-12
Test Conditions
2.3.7-12
3. Inspect the ABS control module power supply and ground

B.Disconnect the ABS control module wiring harness
connector C12.
13
12
26
25
20
15
14
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.
C12
A2307017

Is it normal
Y
Replace the ABS control module.
13
12
26
25
15
14
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.
C12
A2307018
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.
Benni Mini 2013.01
Anti-Lock Control
2.3.7-13
2.3.7-13
DTC Diagnosis and Test
Control Module Terminal List
13
12
26
25
15
14
C12
A2307019
Terminal ID
Wiring
Terminal Description
Status
Specified
Conditions
4.0 WH/RD
Battery voltage
12 V
&RQVWDQW
SRZHUVXSSO\
0.5 LG
Left rear wheel speed input 1
,QSXW
0.5 LG/BK
Left rear wheel speed input 0
,QSXW
0.5 GN/BK
Right front wheel speed input 0
,QSXW
0.5 GN
Right front wheel speed input 1
,QSXW
0.5 BU
Left front wheel speed input 0
,QSXW
0.5 BU/BK
Left front wheel speed input 1
,QSXW
10
0.5 OG
EBD warning lamp
11
0.5 VT/BK
Right rear wheel speed input 0
,QSXW
12
0.5 VT
Right rear wheel speed input 1
,QSXW
13
14
15
16
0.5 GN/BN
Brake lamp switch
,QSXW
'HSUHVVWKH
EUDNHSHGDO
17
18
0.5 PK
K-line
For diagnosis
Ignition
switch ON
19
0.5 SR/GN
ABS warning lamp
Benni Mini 2013.01
Anti-Lock Control
2.3.7-14
2.3.7-14
Terminal ID
Wiring
Status
Specified
Conditions
20
0.5 WH/GN
Ignition switch wire
12V
Ignition
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
DTC Code List

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)
Benni Mini 2013.01
Anti-Lock Control
2.3.7-15
2.3.7-15
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 troubleshooting, 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
Benni Mini 2013.01
Anti-Lock Control
2.3.7-16
2.3.7-16
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.
Diagnostic Tool
Display Item
Part
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 solenoid 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
Motor
The motor acts or does

not act.

motor can be heard.
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.
Benni Mini 2013.01
2.3.7-17
Anti-Lock Control
2.3.7-17
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 Network, Symptom Diagnosis and Testing).
Benni Mini 2013.01
Anti-Lock Control
2.3.7-18
2.3.7-18
DTC Diagnosis Chart

Malfunction
Description
Diagnosis Procedures
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
Wrong controller code

(byte code)
0x029C
Battery voltage KL30

fault
0x046A
ABS working abnormally
0x04FC
Hydraulic pump
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
0x0520
Data bus works abnormally
Refer to: Abnormal Data Bus Diagnosis (2.3.7

Anti-lock Control, DTC Diagnosis and Testing).
Brake light switch fault
Refer to: Brake Lamp Switch Fault Diagnosis

(2.3.7 Anti-lock Control, DTC Diagnosis and
Testing).
0x020E
Benni Mini 2013.01
Refer to: Power Supply Fault and Hydraulic

Electrical Control Unit Assembly Internal Fault
Diagnosis (2.3.7 Anti-lock Control, DTC Diagnosis and Testing).
Refer to: Wheel Speed Sensor Diagnosis (2.3.7

Anti-lock Control, DTC Diagnosis and Testing).
Anti-Lock Control
2.3.7-19
2.3.7-19
Power Supply Fault and Hydraulic Electrical Control Unit Assembly Internal Fault Diagnosis
Test Conditions
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 Testing).
2. ABS control module power supply and ground
connector C12.
13
12
26
25
20
15
14

wiring harness connector C12 for normal power
supply.
C12
D.Turn the ignition switch to position "LOCK",

measure the terminal 26 of the ABS control module
wiring harness connector C12 for normal ground.
A2307017

Is it normal
Y
13
12
Go to step 3.
26
25
15
14
N
Repair the circuit.
C12
A2307018
Benni Mini 2013.01
Anti-Lock Control
2.3.7-20
Test Conditions
2.3.7-20
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).
Wheel Speed Sensor Diagnosis

CAUTION: The maintenance manual is only for the left front wheel speed sensor fault diagnosis, similar to the diagnostic way of the rest wheel speed sensors.
Refer to: (Left front wheel speed sensor fault diagnosis)
Test Conditions
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
Anti-Lock Control
2.3.7-21
Test Conditions
2.3.7-21
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
C07
1

connector C12.
C.Disconnect the left front wheel speed sensor wiring

harness connector C07.
C12
13
12
26
25
15
14
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.
A2307022
C07
1
Is the resistance normal?

Y
C12
Go to step 5.
13
12
26
25
15
14
Repair or replace the wiring harness.
A2307023
Benni Mini 2013.01
Anti-Lock Control
2.3.7-22
Test Conditions
2.3.7-22
5. Inspect the wiring harness of the left front wheel speed sensor
B.Disconnect the left front wheel speed sensor wiring
harness connector C07.
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?
A2307024
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).
Benni Mini 2013.01
Anti-Lock Control
2.3.7-23
2.3.7-23
Abnormal Data Bus Diagnosis

Test Conditions
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, Symptom Diagnosis and Testing).
Is the result normal?
Y
Go to step 4.
N
Inspect and repair the circuit for open circuit.
Benni Mini 2013.01
Anti-Lock Control
2.3.7-24
Test Conditions
2.3.7-24
4. ABS control module power supply and ground

connector C12.
13
12
26
25
20
15
14

wiring harness connector C12 for normal power
supply.
C12

wiring harness connector C12 for normal
grounding.
A2307017

Is it normal
13
12
26
25
15
14
Y
Go to step 5.
N
Repair the circuit.
C12
A2307018
ABS pump.
Y
System is normal.
N

Installation).
Benni Mini 2013.01
Anti-Lock Control
2.3.7-25
2.3.7-25
Brake Lamp Switch Fault

Test Conditions
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 Diagnosis and Testing).
Benni Mini 2013.01
Anti-Lock Control
2.3.7-26
Test Conditions
2.3.7-26
4. Inspect the circuit between the brake lamp switch and the ABS
1
3
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.
P17a

Is it normal?
Y
Go to step 5.
N
13
12
26
25
16 15
14
C12
A2307025
Benni Mini 2013.01
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 connector C12.
Anti-Lock Control
2.3.7-27
Test Conditions
2.3.7-27
5. The ABS control module power supply and ground

connector C12.
13
12
26
25
20
15
14

wiring harness C12 for normal power supply.
wiring harness connector C12 for normal ground.
C12
A2307017

Is it normal
Y
Go to step 6.
13
12
26
25
15
14
Repair the circuit.
C12
A2307018
ABS pump.
Y
System is normal.
N

Installation).
Benni Mini 2013.01
2.3.7-28
Anti-Lock Control
2.3.7-28
Hydraulic Control Unit (HCU)

Removal
Material
Item
Brake fluid
Model
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.
1
2
A2307001

2
3

1

5. Install the brake reservoir cap.
Benni Mini 2013.01
A2307002
2.3.7-29
Anti-Lock Control
2.3.7-29
6. Disconnect the ABS control module wiring

harness connector.
A2307003
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.
6
CAUTION: Cover the brake pipes to prevent the brake fluid flowing or any dirt
entering into the brake pipes.
CAUTION: Note the position of the brake
pipes to aid installation.
A2307004
8. Remove retaining bolts on the hydraulic

control module.
Torque: 8 Nm
A2307005
Benni Mini 2013.01
2.3.7-30
Anti-Lock Control
Installation
Brake System-General Information, General Procedures).
CAUTION: Make sure that the brake master pump vacuum seal is correctly located
Rear Wheel Speed Sensor

Removal
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
2.3.7-30
2.3.7-31
Anti-Lock Control
2.3.7-31
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.
A2307007
Installation
Benni Mini 2013.01
2.3.7-32
Anti-Lock Control
2.3.7-32
Front Wheel Speed Sensor

Removal
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.
A2307008
4. Disconnect the front wheel speed sensor

wiring harness connector in front of the
firewall, and detach the sensor.
A2307009
Installation
Benni Mini 2013.01
2.3.7-33
Anti-Lock Control
2.3.7-33
Rear Wheel Speed Sensor Ring(s)

Removal
1. Remove the rear wheel bearing.
2. Remove and discard the rear wheel speed
sensor ring(s).
A2307010
Installation
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.
Benni Mini 2013.01
Steering System
2.4 Steering System

2012 Benni Mini
Table of Contents
Pages
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 C111, C113, C114, C115 .......................................................................................2.4.2-14
DTC C121, C123, C124....................................................................................................2.4.2-16
DTC C122 .............................................................................................................................2.4.2-21
DTC C141, C142, C143, C144, C145, C151 ..............................................................2.4.2-24
DTC C152, C154, C155....................................................................................................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 Steering System - General Information

2.4.1-1
Steering System - General Information
2.4.1-1
Specifications
Item
Minimum turning diameter
Tubular electric power steering
Specification
10.0 m
200W, 35A, 12V(DC)
Benni Mini 2013.01
2.4.1-2
2.4.1-2
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
2.4.1-3
2.4.1-3
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 steering 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 pinion by the retaining bolts and fixed on the steering column with the retaining bolts of the retainer and the
shaft locator assembly.
A2401002
Benni Mini 2013.01
2.4.1-4
2.4.1-4
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
2.4.1-5
2.4.1-5
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 steering column, the torque sensor, the electronic control module and the steering power motor.
A2401004
Benni Mini 2013.01
2.4.1-6
2.4.1-6
Exploded View
3
5
6
10
A2401005
Item
Description
Qty
Item
Description
Qty
EPS module
Steering tubular column cover assembly clamp
Multifunction steering wheel
Cotter pin
Steering column assembly
Nut
Steering lower shaft assembly
Steering gear assembly
Steering tubular column cover assembly
10
Rack side bracket
Benni Mini 2013.01
2.4.1-7
2.4.1-7
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.
Benni Mini 2013.01
2.4.1-8

1. Verify the customer's concern.
2. Visually inspect for
mechanical damage.
obvious
signs
of

Mechanical
Electrical
Tire pressure
Tie rod end
Tie rod
Front strut and spring
assembly
Front suspension front

swing arm ball joint
Electric power steering

column
Front suspension front
EPS control module
swing arm bushing
Retaining bolts on steering column shaft flexible

joint
Wheel and Tire

Steering gear sleeve
4. If the concern is not visually evident, verify
the symptom and refer to the Symptom Chart.
Benni Mini 2013.01
2.4.1-8
2.4.1-9
2.4.1-9
Symptom Chart
If there is a symptom but no diagnosis trouble code (DTC) is stored in control module and can not confirm the symptom reasons in basic inspect, it is necessary to diagnosis and eliminate the symptoms in
the following chart.
Symptom
Possible Sources
Solutions
Adjust it and if necessary, replace the steering
column.
Turning interference
Refer to: Steering Column (2.4.4

Steering Column, Removal and
Installation).
Replace the steering gear.
Noise in the steering column
Steering gear
Steering power motor
Refer to: Steering Gear (2.4.2 Power

Steering System, Removal and
Installation).
Replace the steering power motor or the steering column.
Steering linkage loosening

Brake disc and brake shoe
Tire
Steering wheel shaking
while braking
Wheel alignment
Tie rod ball joint
Tighten
Refer to: Steering Wheel Shaking
While Braking Diagnosis (2.4.1
Steering System - General Information, Symptom Diagnosis and Testing).
Front swing arm ball joint

Steering gear
Benni Mini 2013.01
2.4.1-10
Symptom

Possible Sources
2.4.1-10
Solutions
Replace the tie rod ball joint.
Too large inner friction of the

tie rod ball joint
The plug is too tight.
Refer to: Tie Rod Ball Joint (2.4.3

Steering Linkage, Removal and
Installation).
Pre-tighten it again.
Steering tie rod and ball joint

defect
The fixation between the
steering gear and the frame is
loose

Installation).
Re-tighten
Abnormal steering return

function
Rack bends.

Installation).
The gear bearing is damaged.

Installation).
Abnormal electric power

steering system
Inspect and repair the electric power steering

system.
The tire pressure is too low.
Inflate the wheel.

Adjust the wheel alignment parameter to the
specified value.
Steering power failure

Suspension System - General Information, General Procedures).
Damaged electric power

steering column
Refer to: Steering Power Failure

Diagnosis (2.4.2 Electric Power
Steering, Symptom Diagnosis and
Testing).
Damaged EPS control module

Damaged steering gear
Seized suspension ball
Benni Mini 2013.01
2.4.1-11
Symptom

Possible Sources
2.4.1-11
Solutions
Replace the electric power steering column.
Damaged electric power

steering column
The steering clearance
between the steering
wheels is too large and the
steering wheel is off the
center position.
The bolts on the steering

gear is loose.
Refer to: Steering Column (2.4.4

Steering Column, Removal and
Installation)
Re-tighten
Re-tighten and replace as necessary.
The ball bolts on the steering

tie rod assembly are worn or
loose.

Installation).
The steering gear mounting

bolts are loose.
Re-tighten
The tie rod ball is loose.
Re-tighten
Squeak between the rack

and the gear

The tie rod ball is worn and
aging.

Installation).
Benni Mini 2013.01
2.4.1-12
2.4.1-12
Steering Wheel Shaking While Braking Diagnosis

Test Conditions
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 Information, General Procedures).
B.Inspect the brake pad.

Whether the brake disc and the brake pad is normal?
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 Suspension System - General Information, General 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 Information, General Procedures).
Benni Mini 2013.01
2.4.1-13

Test Conditions
2.4.1-13
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

Steering System, Removal and Installation).
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 Power Steering System

2.4.2-1
Power Steering
2.4.2-1
Specifications
Item
Specification
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lb-ft
lb-in
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Benni Mini 2013.01
2.4.2-2
Power Steering
2.4.2-2
System Overview
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1
2
A2402001
Item

Description
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Item

Description
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1. EPS Controller
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Benni Mini 2013.01
2.4.2-3
Power Steering
2.4.2-3
2. Motor
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3. Torque Sensor
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4. VSS (Vehicle Speed Sensor)

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5. Engine Speed Signal

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Benni Mini 2013.01
2.4.2-4
Power Steering
General Procedures
Steering Force Inspection

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3. 6WDUWWKHHQJLQH
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VSULQJJDXJHRIWKHVWHHULQJZKHHOLQWDQJHQW
GLUHFWLRQDWWKHHQJLQHLGOHVSHHG
Steering Force: more than 35N (3.5kg)
Benni Mini 2013.01
2.4.2-4
2.4.2-5
Power Steering
2.4.2-5

1. 9HULI\WKHFXVWRPHUFRQFHUQ
2. 9LVXDOO\LQVSHFWIRUREYLRXVPHFKDQLFDOIDXOW
Mechanical
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Electrical
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General Equipment
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Benni Mini 2013.01
2.4.2-6
Power Steering
2.4.2-6
Intermittent Malfunction Diagnosis

CAUTION:
1. Eliminate the DTC.
2. Carry out the simulation testing.
3. Inspect and shake the wiring harnesses, connectors and terminals.
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Test Conditions
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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 components.
CAUTION: The connector joint, the vibration 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
2.4.2-7
Power Steering
Test Conditions
2.4.2-7
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Symptom Chart
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Symptom
Possible Sources
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Solutions
Refer to: Symptom Chart (4.3.2
Instrument Cluster, Symptom Diagnosis and Testing).
Refer to: EPS Warning Lamp
Always On Diagnosis (2.4.2 Power
Steering System Diagnosis, Symptom Diagnosis and Testing).
5HSODFHWKHSRZHUVWHHULQJFROXPQDVVHPEO\
Benni Mini 2013.01
2.4.2-8
Symptom
Power Steering
Possible Sources
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Benni Mini 2013.01
2.4.2-8
Solutions
Refer to: Steering Power Failure
Diagnosis (2.4.1 Power Steering
Symptom Chart).
2.4.2-9
Power Steering
2.4.2-9
EPS Warning Lamp Always On Diagnosis

Test Conditions
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7
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Standard Resistance Value: 10 M or more
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Benni Mini 2013.01
2.4.2-10
Power Steering
Test Conditions
2.4.2-10
,QVSHFWWKH(36FRQWUROPRGXOHSRZHUVXSSO\DQGJURXQG
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P06
A2402013

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Y
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Refer to: EPS Control Module (2.4.2

Power Steering System, Removal and
Installation).
6
P06
A2402014
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N
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Benni Mini 2013.01
2.4.2-11
Power Steering
2.4.2-11
DTC Diagnosis and Testing
Control Module Terminal List
7
1
8
6
A2402015
Terminal ID
Wiring
Status
3.
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Benni Mini 2013.01
2.4.2-12
Power Steering
2.4.2-12
DTC Code List

Malfunction
Description
&
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&
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VSHHGVLJQDOLQSXWIRUV
&
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&
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&
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&
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&
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&
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&
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&
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&
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Fault Diagnostic Tool Can Not Communicate With Vehicle Diagnosis

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 Network, Symptom Diagnosis and Testing).
Benni Mini 2013.01
2.4.2-13
Power Steering
2.4.2-13
DTC Diagnosis Chart

Malfunction
Description
Diagnosis Procedures
&
7RUTXHVHQVRUPDLQFLUFXLWVLJQDOIDXOW
&
*UHDWGLIIHUHQFHEHWZHHQWKHWRUTXHVHQVRUPDLQFLUFXLW
DQGDX[LOLDU\FLUFXLWVLJQDO
&
7RUTXHVHQVRUSRZHUVXSSO\YROWDJHIDXOW
&
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&
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IRUPLQ
&
&
&
(QJLQHVSHHGVLJQDOORVVQRHQJLQHVSHHGVLJQDOLQSXW
Refer to: C1122
&
0RWRUIDXOW7RRKLJKRUORZPRWRUYROWDJH
&
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&
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Refer
to:
C1141,
C1142, C1143, C1144,
C1145, C1151
&
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PDQGEXWWKHPRWRUGRHVQRWDFW
&
0RWRUIDXOW7KHDFWXDOFXUUHQWIORZLQJWKURXJKWKHPRWRU
LVORZHUWKDQWKHFXUUHQWGHWHFWHGE\WKH(36FRQWUROER[
&
0RWRUFOXWFKIDXOW
&
(36FRQWUROER[IDXOW
&
3RZHUVXSSO\FLUFXLWRIWKH(36FRQWUROER[ORZEDWWHU\
YROWDJH
&
(36FRQWUROER[IDXOW
Refer
to:
C1111,
C1113, C1114, C1115
Refer
to:
C1123, C1124
Refer
to:
C1154, C1155
C1121,
C1152,
Benni Mini 2013.01
2.4.2-14
Power Steering
2.4.2-14
DTC C1111, C1113, C1114, C1115

1. Fault Code Description
Fault Code
Description
Definition
&
7RUTXHVHQVRUPDLQFLUFXLWVLJQDO
IDXOW
&
*UHDWGLIIHUHQFHEHWZHHQWKH
WRUTXHVHQVRUPDLQFLUFXLWDQGDX[
LOLDU\FLUFXLWVLJQDO
&
7RUTXHVHQVRUSRZHUVXSSO\YROW
DJHIDXOW
&
7RUTXHVHQVRUDX[LOLDU\FLUFXLWVLJ
QDOIDXOW
7KH(36FRQWUROPRGXOHGHWHFWVWKDWWKHWRUTXHVHQVRU
PDLQFLUFXLWRUDX[LOLDU\FLUFXLWVLJQDORUSRZHUVXSSO\YROW
DJHDUHLQFRUUHFWRUH[FHHGWKHLQWHUQDOVSHFLILHGYDOXH
UDQJHRIWKH(36FRQWUROPRGXOH
2. Possible Sources
Fault
Code
Test Policy
&
&
&
+DUGZDUHFLUFXLWLQVSHF
WLRQ
&
Installation Conditions
(Control Tactics)
Fault
7KHSULPDU\DQGVHFRQGDU\VLJ
QDOVH[FHHGWKHDQDORJYROWDJH
UDQJHRI9'&a9'&
6HQVRUFLUFXLWIDXOW
7KHWRUTXHVHQVRUSRZHUVXSSO\
YROWDJHLVPRUHWKDQ9'&
(36FRQWUROPRGXOHIDXOW
6HQVRUIDXOW
3. Diagnosis Procedures
Test Conditions
*HQHUDOLQVSHFWLRQ
$,QVSHFWWKHUHODWHGZLULQJKDUQHVVFRQQHFWRUVIRU
VLJQVRIGDPDJHSRRUFRQWDFWDJLQJRUORRVH
%,QVSHFWWKHVWHHULQJFROXPQIRUH[FHVVLYHZHDU
,VWKH,QVSHFWQRUPDO"
Y
*RWRVWHS
N
5HSDLUWKHIDLOHGSDUWDQGUHSODFHLWLIQHFHVVDU\
Benni Mini 2013.01
2.4.2-15
Power Steering
Test Conditions
2.4.2-15
(OLPLQDWHWKHIDXOWFRGH
$&RQQHFWWKH&KDQJDQ$XWRVSHFLDOGLDJQRVWLFWRRO
%8VHWKHGLDJQRVLVWRROWRGHOHWHWKH'7&
&'LDJQRVHWKHGDWDOLQNFRQQHFWRUDQGWKH(36
FRQWUROPRGXOHWRUTXHVHQVRUE\VKDNLQJSXOOLQJ
DQGSUHVVLQJWKHP
'8VHWKHGLDJQRVWLFWRROWRUHDGWKH'7&DJDLQ
'RHVWKH'7&RI&&&&VWLOO
H[LVW"
Y
*RWRVWHS
N
Refer to: Intermittent Fault Diagnosis

(2.4.3 Steering Linkage Diagnosis, Symptom Diagnosis and Testing).
,QVSHFWWKHFLUFXLWEHWZHHQWKHWRUTXHVHQVRUDQGWKH(36
%'LVFRQQHFWWKHZLULQJKDUQHVVFRQQHFWRURIWKH
WRUTXHVHQVRUWRWKH(36FRQWUROPRGXOH
&0HDVXUHWKHZLULQJKDUQHVVIRUVKRUWFLUFXLWDQG
RSHQFLUFXLW
Y
5HSDLUWKHFLUFXLWIDXOW
N
*RWRVWHS
,QVSHFWWKHWRUTXHVHQVRU
5HSODFHWKHWRUTXHVHQVRU
,VWKHV\VWHPQRUPDO"
Y
N
*RWRVWHS
Benni Mini 2013.01
2.4.2-16
Power Steering
Test Conditions
2.4.2-16
FRQQHFWRU3
&'LVFRQQHFWWKHEDWWHU\QHJDWLYHFDEOHDQGPHDVXUH
WKHYROWDJHEHWZHHQWKHWHUPLQDORIWKH(36
FRQWUROPRGXOHZLULQJKDUQHVVFRQQHFWRU3DQG
WKHUHOLDEOHJURXQG

'0HDVXUHWKHYROWDJHEHWZHHQWKHWHUPLQDORIWKH
(36FRQWUROPRGXOHZLULQJKDUQHVVFRQQHFWRU3
P06
A2402013

,VLWQRUPDO
Y
*RWRVWHS
N
,QVSHFWDQGUHSDLUWKHFLUFXLWIDXOWRIWKH(36FRQWURO
PRGXOHSRZHUVXSSO\DQGJURXQG
6
P06
A2402014
,QVSHFWWKH(36FRQWUROPRGXOH

Installation).
DTC C1121, C1123, C1124

Fault Code
Description
&
9VVFLUFXLW
&
&
Benni Mini 2013.01
Definition
7KHHQJLQHUXQVDWVSHHGRIUPLQRUKLJKHURUWKH
HQJLQHUXQVDWVSHHGRIUPLQRUKLJKHULPPHGLDWHO\
DIWHUVWDUWLQJDQGQRYHKLFOHVSHHGVLJQDOLVLQSXWHGRUWKH
YHKLFOHVSHHGVLJQDOLVXQVWDEOHIRUPLQ
2.4.2-17
Power Steering
2.4.2-17
2. Possible Sources
Fault
Code
Test Policy
&
&
+DUGZDUH&LUFXLW,QVSHF
WLRQ
&
(Control Tactics)
9VVFLUFXLW7KHHQJLQHUXQVDW
VSHHGRIUPLQRUKLJKHURU
WKHHQJLQHUXQVDWVSHHGRI
UPLQRUKLJKHULPPHGLDWHO\
DIWHUVWDUWLQJDQGQRYHKLFOH
VSHHGVLJQDOLVLQSXWHGIRU
PLQ
Fault Part
6HQVRUFLUFXLWIDXOW
6HQVRUIDXOW
1RVTXDUHVLJQDOZLWK9SHDN
YDOXHLVGHWHFWHGDWKLJKRUORZ
VSHHG
Test Conditions
*HQHUDOLQVSHFWLRQ
,VWKH,QVSHFWQRUPDO"
Y
*RWRVWHS
N
5HSDLUWKHIDXOW
FRQWUROPRGXOHYHKLFOHVSHHGVHQVRUE\VKDNLQJ
SXOOLQJDQGSUHVVLQJWKHP
'RHVWKH'7&RI&&&VWLOOH[LVW"
Y
*RWRVWHS
N

Benni Mini 2013.01
2.4.2-18
Power Steering
Test Conditions
2.4.2-18
,QVSHFWWKHFLUFXLWEHWZHHQWKHYHKLFOHVSHHGVHQVRUDQGWKH(36
7
1
%'LVFRQQHFWWKH(36FRQWUROPRGXOHZLULQJKDUQHVV
FRQQHFWRU3
5 6
&'LVFRQQHFWWKHZLULQJKDUQHVVFRQQHFWRU&RIWKH
YHKLFOHVSHHGVHQVRU
WKH(36FRQWUROPRGXOHZLULQJKDUQHVVFRQQHFWRU
3DQGWKHWHUPLQDORIWKHYHKLFOHVSHHGVHQVRU
ZLULQJKDUQHVVFRQQHFWRU&$QGLQVSHFWIRURSHQ
FLUFXLW
P06

Y
*RWRVWHS
N
C26
A2402016
Benni Mini 2013.01
,QVSHFWDQGUHSDLUWKHRSHQFLUFXLWIDXOWRIWKHFLUFXLW
EHWZHHQWKHWHUPLQDORIWKH(36FRQWUROPRGXOH
ZLULQJKDUQHVVFRQQHFWRU3DQGWKHWHUPLQDORI
WKHYHKLFOHVSHHGVHQVRUZLULQJKDUQHVVFRQQHFWRU
&
2.4.2-19
Power Steering
Test Conditions
2.4.2-19
,QVSHFWWKHYHKLFOHVSHHGVHQVRUSRZHUVXSSO\DQGJURXQG
%'LVFRQQHFWWKHZLULQJKDUQHVVFRQQHFWRU&RIWKH
YHKLFOHVSHHGVHQVRU
&7XUQWKHLJQLWLRQVZLWFKWRSRVLWLRQ21DQG
YHKLFOHVSHHGVHQVRUZLULQJKDUQHVVFRQQHFWRU&
C26

'7XUQWKHLJQLWLRQVZLWFKWRSRVLWLRQ/2&.DQG
YHKLFOHVSHHGVHQVRUZLULQJKDUQHVVFRQQHFWRU&
A2402017

,VLWQRUPDO
Y
*RWRVWHS
C26
,QVSHFWDQGUHSDLUWKHRSHQFLUFXLWIDXOWRIWKHYHKL
FOHVSHHGVHQVRUSRZHUVXSSO\DQGWKHJURXQGFLU
FXLW
A2402018
,QVSHFWWKHYHKLFOHVSHHGVHQVRU
5HSODFHWKHYHKLFOHVSHHGVHQVRU
,VWKHV\VWHPQRUPDO"
Y
N
*RWRVWHS
Benni Mini 2013.01
2.4.2-20
Power Steering
Test Conditions
2.4.2-20
FRQQHFWRU3
WKHUHOLDEOHJURXQG

P06
A2402013

,VLWQRUPDO
Y
*RWRVWHS
N
6
P06
A2402014

Installation).
Benni Mini 2013.01
2.4.2-21
Power Steering
2.4.2-21
DTC C1122
Fault Code
&
Description
Definition
(QJLQHVSHHGVLJQDOORVVQR
HQJLQHVSHHGVLJQDOLQSXW
7KH(36FRQWUROPRGXOHFDQQRWGHWHFWWKHVSHHGVLJQDO
IURPWKHHQJLQHDIWHUWKHHQJLQHVWDUWV
2. Possible Sources
Fault
Code
&
Test Policy
WLRQ
(Control Tactics)
7KH(36FDQQRWUHFHLYHWKH
VTXDUHVLJQDOZLWK9SHDN
YDOXHRIWKHHQJLQHRUWKHSXOVH
VLJQDODIWHUWKHHQJLQHVWDUWV
Fault
6HQVRUFLUFXLWIDXOW
6HQVRUIDXOW
Test Conditions
*HQHUDOLQVSHFWLRQ
,VWKH,QVSHFWQRUPDO"
Y
*RWRVWHS
N
5HSDLUWKHIDXOW
&'LDJQRVHWKHZLULQJKDUQHVVFRQQHFWRUVRIWKH
HQJLQHFRQWUROPRGXOHDQGWKH(36FRQWUROPRGXOH
E\VKDNLQJSXOOLQJDQGSUHVVLQJWKHP
'RHVWKH'7&RI&VWLOOH[LVW"
Y
*RWRVWHS
N

Benni Mini 2013.01
2.4.2-22
Power Steering
Test Conditions
2.4.2-22
,QVSHFWWKHFLUFXLWEHWZHHQWKH(&0DQGWKH(36
FRQQHFWRU3
&'LVFRQQHFWWKH%&0FRQWUROPRGXOHZLULQJKDUQHVV
FRQQHFWRU(D
WKH(36FRQWUROPRGXOHZLULQJKDUQHVVFRQQHFWRU
3DQGWKHWHUPLQDORIWKH%&0FRQWUROPRGXOH
ZLULQJKDUQHVVFRQQHFWRU(DDQGLQVSHFWLIWKHUH
LVDQ\RSHQFLUFXLWRFFXUULQJLQWKHFLUFXLW
P06

Y
*RWRVWHS
N
6
24
5
25
43
44
62
63
81
E01a
A2402019
Benni Mini 2013.01
,QVSHFWDQGUHSDLUWKHRSHQFLUFXLWIDXOWRIWKHFLUFXLW
EHWZHHQWKHWHUPLQDORIWKH(36FRQWUROPRGXOH
ZLULQJKDUQHVVFRQQHFWRU3DQGWKHWHUPLQDORI
WKH%&0FRQWUROPRGXOHZLULQJKDUQHVVFRQQHFWRU
(D
2.4.2-23
Power Steering
Test Conditions
2.4.2-23
FRQQHFWRU3
WKHUHOLDEOHJURXQG

P06
A2402013

,VLWQRUPDO
Y
*RWRVWHS
N
6
P06
A2402014

Installation).
Benni Mini 2013.01
2.4.2-24
Power Steering
2.4.2-24
DTC C1141, C1142, C1143, C1144, C1145, C1151

Fault Code
&
&
&
&
&
Description
Definition
0RWRUIDXOW7RRKLJKRUORZPRWRU
YROWDJH
0RWRUIDXOW7RRKLJKPRWRUFXU
UHQW
0RWRUIDXOW7KHFXUUHQWGHWHFWHG
E\WKH(36FRQWUROER[LVPXFKGLI
IHUHQWIURPWKHDFWXDOFXUUHQWIORZ
LQJLQWRWKHPRWRU
0RWRUIDXOW7KH(36FRQWUROER[
VHQGVWKHURWDWLRQFRPPDQGEXW
WKHPRWRUGRHVQRWDFW
&
7KH(36FRQWUROPRGXOHGHWHFWVWKDWZKHQWKHSRZHU
PRWRULVZRUNLQJWKHDFWXDOGDWDLQFOXGLQJWKHPRWRUFXU
UHQWWKHPRWRUYROWDJHDUHQRWFRUUHFWRUH[FHHGWKH
LQWHUQDOVWDQGDUGYDOXHUDQJHRIWKH(36FRQWUROXQLW
0RWRUIDXOW7KHDFWXDOFXUUHQW
IORZLQJWKURXJKWKHPRWRULVORZHU
WKDQWKHFXUUHQWGHWHFWHGE\WKH
(36FRQWUROER[
0RWRUFOXWFKIDXOW
2. Possible Sources
Fault
Code
Test Policy
(Control Tactics)
WLRQ
:KHQVWHHULQJWKH(36FRQWURO
PRGXOHFDQQRWGHWHFWWKHSXOVH
VLJQDOSXOVHZLGWKYDULDEOHZLWK
9SHDNYDOXHRIWKH(36PRWRU
RUWKHDFWXDOYROWDJHDQGFXUUHQW
DUHDEQRUPDO
Fault Part
&
&
&
&
&
&LUFXLWIDXOW
(36PRWRU
&
Test Conditions
*HQHUDOLQVSHFWLRQ
,VWKH,QVSHFWQRUPDO"
Y
*RWRVWHS
N
5HSDLUWKHIDXOW
Benni Mini 2013.01
2.4.2-25
Power Steering
Test Conditions
2.4.2-25
FRQWUROPRGXOHDQGWKH(36PRWRUE\VKDNLQJ
SXOOLQJDQGSUHVVLQJWKHP
'RHVWKH'7&RI&&&&
&&VWLOOH[LVW"
Y
*RWRVWHS
N

,QVSHFWWKHFLUFXLWRIWKH(36WRWKH(36PRWRU
$6WDUWWKHHQJLQH
%7XUQWKHVWHHULQJZKHHOPHDVXUHWKHSXOVHVLJQDO
YROWDJHRI9EHWZHHQWKHEDFNIDFHRIWKH(36
PRWRUZLULQJKDUQHVVFRQQHFWRUDQGWKHUHOLDEOH
JURXQGDQGLQVSHFWIRURSHQFLUFXLW
,VWKHYROWDJHQRUPDO
Y
*RWRVWHS
N
,QVSHFWDQGUHSDLUWKHRSHQIDXOWUHSODFHWKH(36
PRWRUDVQHFHVVDU\
Refer to: Steering Column Assembly

(2.4.4 Steering Column, Removal and
Installation).
Benni Mini 2013.01
2.4.2-26
Power Steering
Test Conditions
2.4.2-26
FRQQHFWRU3
WKHUHOLDEOHJURXQG

DQGWKHUHOLDEOHJURXQGLQJ
P06
A2402013

,VLWQRUPDO
Y
*RWRVWHS
N
6
P06
A2402014

Installation).
Benni Mini 2013.01
2.4.2-27
Power Steering
2.4.2-27
DTC C1152, C1154, C1155

Fault Code
Description
Definition
&
(36FRQWUROER[IDXOW
&
3RZHUVXSSO\FLUFXLWRIWKH(36
FRQWUROER[ORZEDWWHU\YROWDJH
&
(36FRQWUROER[IDXOW
7KH(36FRQWUROPRGXOHGHWHFWVWKDWWKHDEQRUPDOSRZHU
VXSSO\DQGJURXQGLQJRUWKHLQWHUQDOSURJUDPHUURUSUR
FHVVLQJPDOIXQFWLRQ
2. Possible Sources
Fault
Code
Test Policy
(Control Tactics)
&
&
WLRQ
Fault Part
&LUFXLWIDXOW
(36PRWRU
&
Test Conditions
*HQHUDOLQVSHFWLRQ
,VWKH,QVSHFWQRUPDO"
Y
*RWRVWHS
N
5HSDLUWKHIDXOW
FRQWUROPRGXOHE\VKDNLQJSXOOLQJDQGSUHVVLQJ
WKHP
'RHVWKH'7&RI&&&VWLOOH[LVW"
Y
*RWRVWHS
N

Benni Mini 2013.01
2.4.2-28
Power Steering
Test Conditions
2.4.2-28
FRQQHFWRU3
WKHUHOLDEOHJURXQG

P06
A2402013

,VLWQRUPDO
Y
*RWRVWHS
N
6
P06
A2402014

Installation).
Benni Mini 2013.01
2.4.2-29
Power Steering
2.4.2-29
EPS Control Module

Removal
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
2
A2402005
5. Disconnect the EPS control module wiring

harness 1 connector.
6. Detach the EPS control module.
A2402006
Installation
Benni Mini 2013.01
2.4.2-30
Power Steering
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.
A2402010
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.
A2402007
Benni Mini 2013.01
2.4.2-30
2.4.2-31
Power Steering
2.4.2-31
6. Remove the front subframe assembly.

1.Remove the front subframe retaining nut.
Torque: 50 Nm
2.Remove the front subframe retaining bolt.

1
3.Release the front subframe retaining bolt

but do not detach it.
Torque: 50 Nm
3
A2402008
7. Remove four retaining bolts on the steering

gear and detach the steering gear.
Torque: 60 Nm
A2402009
Installation
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.
Benni Mini 2013.01
2.4.3 Steering Linkage

2.4.3-1
Steering Linkage
2.4.3-1
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
Benni Mini 2013.01
2.4.3-2
Steering Linkage
2.4.3-2
System Overview
The steering tie rod is connected with the steering linkage. The following components transfer the steering 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.
5
6
3
7
8
9
10
A2403006
Item
Description
Item
Description
Steering linkage dust boot

clamp
Inner tie rod joint assembly
Steering gear assembly
Cotter pin
Steering rod retaining washer
Tie rod ball joint retaining nut
Steering linkage dust boot clamp
10
Tie rod ball joint
Benni Mini 2013.01
2.4.3-3
Steering Linkage
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.
2.4.3-3
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.
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 kgfm
A2402004
3. If the measured value is exceeding, replace

the tie rod assembly.
Benni Mini 2013.01
2.4.3-4
Steering Linkage

Refer to: Symptom Chart (2.4.1 Steering
Diagnose and Testing).
Benni Mini 2013.01
2.4.3-4
2.4.3-5
Steering Linkage
2.4.3-5
Tie Rod Ball Joint

Removal
Special Tool
Tie Rod Ball Joint Puller

CA201-001
CA201-001
1. Remove the front wheels.

3. Release the tie rod ball joint.
Torque: 42.5 Nm
2. Remove the cotter pin.
1

2
Torque: 42.5 Nm
3
A2403001
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
A2403002
Benni Mini 2013.01
2.4.3-6
Steering Linkage
2.4.3-6
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 tightened 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.
Installation
CAUTION: Inspect the front toe-in and adjust
it accordingly, and make four-wheel alignment.
Benni Mini 2013.01
2
1
A2403003
2.4.3-7
Steering Linkage
2.4.3-7
Steering Gear Dust Boot

Removal
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.
2
2
A2403004
Installation
CAUTION: Inspect the front toe-in and adjust
it accordingly, and make four-wheel alignment.
Benni Mini 2013.01
2.4.4 Steering Column

2.4.4-1
Steering Column
2.4.4-1
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 bolt
25
18
Benni Mini 2013.01
2.4.4-2
Steering Column
2.4.4-2
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 universal 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.
A2404001
Item
1
Description
Steering lower shaft assembly
Benni Mini 2013.01
Item
2
Description
Steering column assembly
2.4.4-3
Steering Column
2.4.4-3

Refer to: Symptom Chart (2.4.1 Steering
Benni Mini 2013.01
2.4.4-4
Steering Column
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.
A2402010
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.
Benni Mini 2013.01
A2402007
2.4.4-4
2.4.4-5
Steering Column
2.4.4-5
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.
A2404002
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 Installation).
A2404003
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 Installation).
A2404004
Benni Mini 2013.01
2.4.4-6
Steering Column
14. Remove two nuts fixed on the steering

column and the middle instrument cluster
bracket.
Torque: 25 Nm
A2404006
15. Remove two nuts fixed on the steering

column and the upper instrument cluster
bracket.
Torque: 25 Nm
A2404007
Installation
CAUTION: When installing steering column 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.
Benni Mini 2013.01
2.4.4-6

Benni Mini Workshop Manual 2013 Cap 2

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Benni Mini Workshop Manual 2013 Cap 2

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GROUP

2.1 Suspension System

2.2 Driveline System

2.3 Brake System

2.4 Steering System

Benni Mini 2013.01

2.1 Suspension System

2.1.1 Suspension System - General Information

Benni Mini 2013.01

Benni Mini 2013.01

Benni Mini 2013.01

2.1.1 Suspension System - General Information

Suspension System - General Information

Front wheel alignment parameter

Rear wheel alignment parameter

Front wheel camber angle

Front wheel caster angle

Front wheel kingpin inclination angle

Rear wheel camber angle

0 ( -0.33 ~ 0.33) or -020' ~

Benni Mini 2013.01

Suspension System - General Information

Description and Operation

Toe-in is the tire inner drifts from geometric center

The primary aim of vehicle engineering is to

Benni Mini 2013.01

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

Suspension System - General Information

Benni Mini 2013.01

Suspension System - General Information

Wheel Bearing Inspection

clearance. Replace the front wheel bearing if

Clamp Stand of Dial

CAUTION: Do not mix up the front control

6. Install the front brake caliper and the retaining

Tie Rod Ball Joint Inspection

3. Rotate the wheel rapdily to make sure that

Benni Mini 2013.01

Refer to: Front Wheel Steering Knuclke

Suspension System - General Information

5. Inspect the working situation of the

Front Control Arm Ball Joint

Replace it if the shock absorber is worn

2. Vehicle body subsidises. Generally replace

Refer to: Front Control Arm and Ball Pin

2. Inspect tire to make sure the alignment of tie

4. Carry out the front wheel alignment after

3. Inspect the suspension equipments that can

Suspension Device Inspection

Be sure the observing oil film is from the

4. Inspect whether vehicle is overload. Inspect

Lift Vehicle Inspection

Suspension System - General Information

ing is overloaded. Replace it if such problem

In the process of installing and returning

Refer to: Front Strut Assembly (2.1.2 Front

Rear Shock Absorber Inspection

Noise, eliminiate light whizzing sound,

Shock absorber pull rod is completely

Vibration type - sensitivity: torque

If the shock absorber is still unstable after air

The following explanations are useful to differentiate the vibration sources.

Benni Mini 2013.01

Suspension System - General Information