Home ReviewsRefund
Home/MINI/Cooper S/MINI Cooper S I (2000-2006)/Repair manual/Cooling System (mechanical)/Cooling System - Repair - Cooper (w10 Engine)
Contents Section: Cooling System (mechanical) All sections

Cooling System - Repair - Cooper (w10 Engine) MINI Cooper S I

Cooling System (mechanical) 27 illustrations ~1647 words

17 00 ... Follow instructions for working on cooling system

WARNINGScalding hazard! Work on the cooling system may only be carried out on the engine after it has cooled down.
IMPORTANTWhen working on oil, coolant or fuel lines, make sure no oil, coolant or fuel drips onto the alternator. Cover alternator with suitable material. Otherwise there may be alternator malfunctions.
IMPORTANTOnly open the cooling system when the coolant is no longer hot. Air may enter the cooling system if it is opened while the coolant is still hot. This may cause the engine to overheat and result in permanent damage.

Recycling

Catch and dispose of drained coolant.

Comply with the waste disposal regulations applicable in the relevant countries.

17 00 005 Draining and adding coolant

WARNINGWork on the cooling system may only be carried out on the engine after it has cooled down.

Recycling

Catch and dispose of drained coolant.

Comply with the waste disposal regulations applicable in the relevant countries.

Note. Follow instructions for working on cooling system. Refer to 17 00 ... FOLLOW INSTRUCTIONS FOR WORKING ON COOLING SYSTEM .

After adding coolant, vent cooling system and check for leaks.

Refer to appropriate article about venting cooling system and checking for leaks.

Draining Coolant

Unscrew pressure relief cap (1) from filler neck.

Scheme 1

Scheme 1
Scheme 1

Disconnect lower hose connection on radiator (1).

Drain, catch and dispose of coolant.

Scheme 2

Scheme 2
Scheme 2

Release connection of heater hose (1).

Drain, catch and dispose of coolant.

Scheme 3

Scheme 3
Scheme 3

Release vent screw (1) in heating distributor pipe.

Scheme 4

Scheme 4
Scheme 4

Release vent screw (1) in upper radiator hose.

The cooling system is vented during filling.

Scheme 5

Scheme 5
Scheme 5

Adding Coolant

Pour in coolant at filler neck (1).

Tighten down vent screws as soon as coolant emerges.

Tightening torque, refer to 17 00 1AZ in COOLING SYSTEM - TIGHTENING TORQUES - COOPER .

Pour in coolant at filler neck until level reaches lower sealing surface (no bubbles visible).

Scheme 6

Scheme 6
Scheme 6

Fill expansion tank up to maximum level (1).

Scheme 7

Scheme 7
Scheme 7

Start engine and run at idle; top up coolant at filler neck if level drops.

Continue running engine until liquid level stops dropping.

Switch off engine.

Top up coolant at filler neck to lower sealing surface.

Top up expansion tank to maximum level (if necessary).

Note. Before filling, turn on ignition and set heating control to maximum temperature. Set fan to slow setting. Add coolant slowly.

Use only approved coolant.

17 00 009 Checking cooling system for leaks (W10)

Note. For Special Tool identification, see COOLING SYSTEM - SPECIAL TOOLS - COOPER .

Special Tools Required

  1. 17 0 001
  2. 17 0 002
  3. 17 0 009
WARNINGRisk of burning and scalding! Only perform this work after engine has cooled down.

Checking Pressure Drop In Cooling System

Unscrew cap from filler neck.

Connect special tool 17 0 009 to filler neck. Connect special tool 17 0 002.

Pressurize cooling system to 1.5 bar and wait approx. 2 minutes.

Cooling system is tight if pressure drop does not exceed 0.1 bar.

Scheme 8

Scheme 8
Scheme 8

Checking Pressure Relief Valve In Cap

Connect special tools 17 0 001 and 17 0 002 to cap.

Pressurize cap.

Opening gauge pressure must be 0.95 - 1.24 bar.

Scheme 9

Scheme 9
Scheme 9

17 00 010 Checking for leaks between cooling system and combustion chamber

CAUTIONChecking for leaks while the engine is running creates the risk of engine overheating. Observe coolant temperature.

R50

Remove pressure cap from fill tower.

Check for leaks with CO2 leak tester.

R53

Remove pressure cap from expansion tank.

Check for leaks with CO2 leak tester.

Scheme 10

Scheme 10
Scheme 10

Follow equipment manufacturer's operating instructions.

17 00 039 Bleeding cooling system and checking for water leaks

WARNINGDanger of scalding - only remove cover when engine has cooled down.

Checking Coolant Level

Allow engine to cool down before checking coolant level.

Coolant temperature must not be more than 30° C.

If ambient temperature exceeds 30° C, wait until engine has cooled down to ambient temperature.

Use only recommended coolant.

Check coolant level and top up if necessary.

  1. Add coolant. Refer to «17 00 005 DRAINING AND ADDING COOLANT»(/mini/cooper-s/i-2000-2006/remont/cooling-system-mechanical/#cooling-system-repair-cooper-w10-engine__17-00-005-draining-and-adding) .
  2. Checking cooling system for water leaks. Refer to «17 00 009 CHECKING COOLING SYSTEM FOR LEAKS (W10)»(/mini/cooper-s/i-2000-2006/remont/cooling-system-mechanical/#cooling-system-repair-cooper-w10-engine__17-00-009-checking-cooling-system) .

17 11 000 Removing and installing radiator

WARNINGDanger of scalding! Only carry out work on the cooling system after the engine has cooled down!

Necessary Preliminary Tasks

  1. Switch off ignition.
  2. Drain coolant. Refer to «17 00 005 DRAINING AND ADDING COOLANT»(/mini/cooper-s/i-2000-2006/remont/cooling-system-mechanical/#cooling-system-repair-cooper-w10-engine__17-00-005-draining-and-adding) .
  3. Remove front carrier. Refer to «51 11 050 REMOVING AND INSTALLING/REPLACING CARRIER FOR FRONT BUMPER TRIM»(/mini/cooper-s/i-2000-2006/remont/mirrors/#body-equipment-repair-cooper-r50-cooper-s-r53-convertible-r52__51-11-050-removing-and-installingreplacing) .
  4. Remove oil cooler, if fitted (ECVT only).
  5. Remove upper radiator hose.
IMPORTANTMake sure without fail that coolant hoses are correctly routed, risk of damage by sharp edges or abrasion.

Remove retaining screws (1) of condenser and lift condenser out of fixture/retaining lug (2).

Work carefully so as not to damage connected lines.

Scheme 11

Scheme 11
Scheme 11

Remove upper radiator hose.

Remove retaining pins (1) of radiator.

Scheme 12

Scheme 12
Scheme 12

Tilt upper radiator forwards.

Disconnect wiring harness from fan relay block (1).

Scheme 13

Scheme 13
Scheme 13

Lift radiator out of lower fixtures (1).

Scheme 14

Scheme 14
Scheme 14

17 11 001 Replacing radiator

Operation is identical to

Removing and installing/replacing fan shroud with electric fan. Refer to 17 11 035 REMOVING AND INSTALLING/REPLACING FAN COWL WITH ELECTRIC FAN (W10, W11) .

17 11 031 Removing and installing/replacing fan cowl

Necessary Preliminary Tasks

  1. Remove fan cowl with electric fan. Refer to «17 11 035 REMOVING AND INSTALLING/REPLACING FAN COWL WITH ELECTRIC FAN (W10, W11)»(/mini/cooper-s/i-2000-2006/remont/cooling-system-mechanical/#cooling-system-repair-cooper-w10-engine__17-11-035-removing-and-installingreplacing) .
IMPORTANTMake sure without fail that coolant hoses are correctly routed, risk of damage by sharp edges or abrasion.

Note. Nut (1) for fan blade has a left-hand thread.

Unscreew nut (1).

Tightening torque, refer to 17 11 1AZ in COOLING SYSTEM - TIGHTENING TORQUES - COOPER .

Scheme 15

Scheme 15
Scheme 15

Undo screws (1) for fan motor and screws (2) for series resistor block.

Remove fan motor, series resistor block and fan shroud.

Installation

Fit wiring loom correctly.

If fitted, do not remove metal tabs (balance weight) on fan wheel (imbalance).

Tightening torque, refer to 17 11 2AZ in COOLING SYSTEM - TIGHTENING TORQUES - COOPER .

Scheme 16

Scheme 16
Scheme 16

17 11 035 Removing and installing/replacing fan cowl with electric fan (W10, W11)

Necessary Preliminary Tasks

  1. Remove radiator. Refer to «17 11 000 REMOVING AND INSTALLING RADIATOR»(/mini/cooper-s/i-2000-2006/remont/cooling-system-mechanical/#cooling-system-repair-cooper-w10-engine__17-11-000-removing-and-installing) .
IMPORTANTMake sure without fail that coolant hoses are correctly routed, risk of damage by sharp edges or abrasion.

Unclip fan housing (1) on radiator (2) and move upward.

Scheme 17

Scheme 17
Scheme 17

17 11 100 Removing and installing/replacing coolant expansion tank

Note. Follow instructions for working on cooling system. Refer to 17 00 ... FOLLOW INSTRUCTIONS FOR WORKING ON COOLING SYSTEM .

IMPORTANTMake sure without fail that coolant hoses are correctly routed, risk of damage by sharp edges or abrasion.

Remove hose from filler neck (1).

Unscrew retaining nut (2) on coolant expansion tank and lift expansion tank out of mountings (3) and (4).

Installation

Check coolant level. Refer to 17 00 005 DRAINING AND ADDING COOLANT .

Tightening torque, refer to 17 00 2AZ in COOLING SYSTEM - TIGHTENING TORQUES - COOPER .

Scheme 18

Scheme 18
Scheme 18

17 21 500 Flushing oil cooler with lines (automatic transmission)

Note. For Special Tool identification, see COOLING SYSTEM - SPECIAL TOOLS - COOPER .

Special Tools Required

  1. 17 2 018
  2. 17 2 019

Note. Carry out the work steps listed when: Fitting a new or replacement transmission. Flushing can only be carried out with the automatic transmission removed.

Procedure

Automatic transmission removed.

Connect appropriate adapters (see description below) to oil lines exiting from automatic transmission.

Connect the connecting line 17 2 019 from the oil collection unit with the quick-release coupling.

Connect drain line 17 2 018 using quick-release coupling.

Feed open end of drain line into a suitable collection container.

Using oil collection unit, flush approx. 1 liter of transmission fluid through oil lines and oil cooler.

Reposition quick-release couplings.

Flush oil lines/oil cooler in opposite direction with approx. 1 liter of transmission fluid.

Disconnect quick-release couplings, remove adapters.

Note. Dispose of flushing oil properly; do not under any circumstances reuse it.

Arrangement of flushing device for transmissions A5S 310Z, A5S 560Z, A5S 360R/390R, A4S 200R, A5S 325Z, GA6HP26Z

Scheme 19

Scheme 19
Scheme 19

Arrangement of flushing device for transmission A4S 310R

Scheme 20

Scheme 20
Scheme 20

Arrangement of flushing device for transmission A4S 300J

Scheme 21

Scheme 21
Scheme 21

Arrangement of flushing device for transmission A5S 440Z

Scheme 22

Scheme 22
Scheme 22

17 22 060 Removing and refitting or replacing oil cooler (CVT)

Note. For Special Tool identification, see FUEL SYSTEM - SPECIAL TOOLS - COOPER .

Special Tools Required

  1. 13 5 281
  2. 13 5 282

Disconnect pipes (1) from oil cooler and connect special tools 13 5 281 and 13 5 282.

Scheme 23

Scheme 23
Scheme 23

Remove bolt (1) and remove from mounting (2) in direction shown.

Remove oil cooler (3).

Tightening torque, refer to 17 21 1AZ in COOLING SYSTEM - TIGHTENING TORQUES - COOPER .

Scheme 24

Scheme 24
Scheme 24

Note. Check gearbox oil level, if the oil cooler has been replaced or drained. Refer to 00 11 239 FLUID CHANGE IN AUTOMATIC TRANSMISSION (CVT) INCLUDING USED FLUID DISPOSAL .

17 22 070 Removing and installing or replacing oil cooler pipes (CVT)

Special Tools Required

  1. 11 8 402
  2. 13 5 281
  3. 13 5 282
WARNINGDanger of scalding! Only perform this work after the transmission has cooled.

Remove left crush tube.

Remove right crush tube retaining bolt to modular front end.

Fit special tool 11 8 402 to left side of modular front end.

Move modular front end approximately 50 mm forward to allow more access to the gearbox oil pipes.

Scheme 25

Scheme 25
Scheme 25

Disconnect pipes from gearbox and fit special tool 13 5 281.

Note colour coding sleeves on oil cooler pipes when disconnecting.

  1. Green.
  2. Black.

Scheme 26

Scheme 26
Scheme 26

Disconnect pipes (1) from oil cooler and fit special tool 13 5 282 on oil cooler.

Remove pipes from modular front end.

Note routing of oil cooler pipes.

Scheme 27

Scheme 27
Scheme 27

More articles — Engine