17 00 ... Follow instructions for working on cooling system
| WARNING | Scalding hazard! Work on the cooling system may only be carried out on the engine after it has cooled down. |
| IMPORTANT | When 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. |
| IMPORTANT | Only 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 00 009 Checking cooling system for leaks (W10)
Note. For Special Tool identification, see COOLING SYSTEM - SPECIAL TOOLS - COOPER .
Special Tools Required
- 17 0 001
- 17 0 002
- 17 0 009
| WARNING | Risk 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 12
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 13
17 00 010 Checking for leaks between cooling system and combustion chamber
| CAUTION | Checking 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 14
Follow equipment manufacturer's operating instructions.
17 00 039 Bleeding cooling system and checking for water leaks
| WARNING | Danger 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.
- Add coolant. Refer to «17 00 005 DRAINING AND ADDING COOLANT»(ref-203063-S08331852762005103000000) .
- Checking cooling system for water leaks. Refer to «17 00 009 CHECKING COOLING SYSTEM FOR LEAKS (W10)»(ref-203063-S05657889922005103000000) .
Operation is identical to 17 00 009 CHECKING COOLING SYSTEM FOR LEAKS (W10) .
17 11 000 Removing and installing radiator
| WARNING | Danger of scalding! Only carry out work on the cooling system after the engine has cooled down! |
Necessary Preliminary Tasks
- Switch off ignition.
- Drain coolant. Refer to «17 00 005 DRAINING AND ADDING COOLANT»(ref-203063-S08331852762005103000000) .
- Remove front carrier. Refer to «51 11 050 REMOVING AND INSTALLING/REPLACING CARRIER FOR FRONT BUMPER TRIM»(ref-203078-S31279213672005103000000) .
- Remove oil cooler, if fitted (ECVT only).
- Remove upper radiator hose.
| IMPORTANT | Make 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 15
Remove upper radiator hose.
Remove retaining pins (1) of radiator.
Scheme 16
Tilt upper radiator forwards.
Disconnect wiring harness from fan relay block (1).
Scheme 17
Lift radiator out of lower fixtures (1).
Scheme 18
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
- Remove fan cowl with electric fan. Refer to «17 11 035 REMOVING AND INSTALLING/REPLACING FAN COWL WITH ELECTRIC FAN (W10, W11)»(ref-203063-S36633492972005103000000) .
| IMPORTANT | Make 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 19
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 20
17 11 035 Removing and installing/replacing fan cowl with electric fan (W10, W11)
Necessary Preliminary Tasks
- Remove radiator. Refer to «17 11 000 REMOVING AND INSTALLING RADIATOR»(ref-203063-S35281846662005103000000) .
| IMPORTANT | Make 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.
Remove fan cowl with electric fan. Refer to 17 11 035 REMOVING AND INSTALLING/REPLACING FAN COWL WITH ELECTRIC FAN (W10, W11) .
Scheme 21
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 .
| IMPORTANT | Make 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 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
- 13 5 281
- 13 5 282
Disconnect pipes (1) from oil cooler and connect special tools 13 5 281 and 13 5 282.
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
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)
Note. For Special Tool identification, see FUEL SYSTEM - SPECIAL TOOLS - COOPER (1.6L) R50/W10 and ENGINE- SPECIAL TOOLS - COOPER (1.6L) R50/W10 .
Special Tools Required
- 11 8 402
- 13 5 281
- 13 5 282
| WARNING | Danger of scalding! Only perform this work after the transmission has cooled. |
Check gearbox oil level. Refer to 00 11 239 FLUID CHANGE IN AUTOMATIC TRANSMISSION (CVT) INCLUDING USED FLUID DISPOSAL .
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
Disconnect pipes from gearbox and fit special tool 13 5 281.
Note colour coding sleeves on oil cooler pipes when disconnecting.
- Green.
- Black.
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.
