Cooling System: Description and Operation

2004 Mini Cooper S (R53) L4-1.
6L SC (W11) Copyright © 2011, Page 1

Mini Cooper S (R53) L4-1.6L SC (W11) https://manuales-taller.sellfy.store/mini/ 1
Cooling System: Description and Operation
Cooling System
Engine cooling on the MINI comes in two forms, although the basic layout remains the same. Both systems use a 50/50 coolant solution with
standard Kevlar reinforced EPDM (Ethylene Propylene Diene Monomer) cooling hoses.
Cooling System Operation
When the engine is cold the thermostat is closed, preventing the coolant from circulating through the radiator. Coolant is able to circulate through
the heater core, expansion tank, and on the MINI COOPER S, the oil cooler.
the MINI COOPER S has a pressurized expansion tank, and allows coolant to enter the top via the heater core pipe, and exit the bottom of the tank
to join the heater core return pipe.
As the coolant temperature increases the thermostat gradually opens. This allows a bleed of coolant from the bottom hose into the cylinder block
via the coolant pump, and allows hot coolant to flow to the radiator via the top hose. the flow of hot and cold coolant is balanced to maintain the
optimum engine temperature. When the thermostat opens fully, the full flow of coolant passes through the radiator.
Radiator
the radiator installed in the MINI COOPER (COOPER S) is a conventional cross flow type. It is constructed from aluminum tubes, wavy
corrugated cooling strips and plastic end caps. Coolant flows from the top left to the bottom right (viewed from the front of the car).
There are two radiator arrangements for the MINI COOPER and only one for the COOPER S.
Heater Core
the heater core is constructed of aluminum and is of conventional design.
Coolant Fan
the Coolant Fan is a nine bladed fan measuring 400 mm in diameter, driven by a 350 watt motor and controlled by the EMS2000. This system has
two fan speeds.
Low speed is switched on at 105—C coolant temp and off when the temperature drops to 101—C.
High speed is switched on at 112—C and remains on until the system coolant temperature drops by 4—C at which point the system will revert to
Low speed.
the cooling fan will also operate on Low speed when the Air Conditioning is switched on and system pressure reaches 8 bar. Should the Air
Conditioning system pressure rise to 18 bar, the fan will automatically run on the High speed.
Oil Cooler (MINI COOPER S)
the MINI COOPER S is fitted with a plate type oil cooler mounted directly onto the oil filter housing. Engine oil from the filter housing and coolant
from the hoses flows through the cooler tubes adjacent to each other. This process takes place continuously: there is no thermostat control. the inlet
and outlet pipes are connected in parallel with the heater core pipes.
2004 Mini Cooper S (R53) L4-1.6L SC (W11) Copyright © 2011, Page 1
Cooling System: Component Tests and General Diagnostics
Checking Cooling System For Water Leaks (COOPER S)

Checking Cooling System For Water Leaks (COOPER S)
Special tools required:
^ 17 0 001
^ 17 0 008
^ 17 0 051
^ 17 0 052
Warning: Danger of scalding! Only perform this work after engine has cooled down.
Checking pressure drop in cooling system:
Remove pressure cap from expansion tank.
Attach special tool 17 0 051 to expansion tank. Attach special tool 17 0 001
Generate gauge pressure of 1.5 bar. Wait approximately 2 minutes.
Cooling system is impervious to leaks if pressure drop is max. 0.1 bar.
Checking pressure relief valve in cap:
Fit special tool adaptor 17 0 052 to pressure cap.
Remove rubber seal from special tool 17 0 001 and attach special tool 17 0 008 to pressure tester and pressure cap adaptor.
Pressurize cap.
Check cap relief pressure 0.89 - 1.20 bar (14 - 18 psi).
Checking For Combustion Chamber Leaks

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 C02 leak tester.
R53:
Remove pressure cap from expansion tank.
Check for leaks with C02 leak tester.
Follow equipment manufacturer's operating instructions.
Checking Cooling System for Leaks

17 00 009 - Checking cooling system for leaks (W11)
Special tools required:

- 17 0 002
- 17 0 008
- 17 0 051
- 17 0 052
Warning!
Risk of burning and scalding!
Only perform this work after engine has cooled down.

Checking pressure drop in cooling system:
Remove cap from expansion tank.
Connect special tool 17 0 051 to expansion tank. 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.
Checking pressure relief valve in cap:
Remove rubber seal from special tool 17 0 002 .
Connect special tools 17 0 052 , 17 0 008 and 17 0 002 to cap.
Pressurize cap.
Opening gauge pressure must be 0.89 - 1.20 bar.

Cooling System: Service and Repair
Coolant System Drain and Refill
Coolant System Drain and Refill
1. Remove pressure cap.

2. Remove lower hose from radiator, and heater hoses at bulkhead. Use caution when coolant is hot.
3. Reinstall hoses after coolant has drained.
4. Open the coolant bleed screws in the upper hose and the heater return hose (protect generator).
5. Fill engine with coolant (50/50 mix) through thermostat housing (expansion tank in COOPER S).
7. Continue to fill through thermostat housing (or expansion tank).
8. Fill expansion tank to "MAX".
9. Start engine and run at idle. Top up coolant as necessary.
10. Turn off engine and install pressure cap.
Coolant: Testing and Inspection
Checking For Leaks Between Cooling System and Combustion Chamber
Warning: Danger of scalding!
Only perform this work after engine has cooled down.
Caution: When engine is running with cooling system depressurized, this can create steam bubbles. These cause the engine to overheat.
Observe coolant temperature.
Carry out test with CO leak tester for cylinder head leak test in accordance with operating instructions of equipment manufacturer.
In the event of a leak, the color of the test liquid turns yellow by the carbon dioxide (combustion gas) entering the cooling system.
Coolant: Service and Repair
Draining And Adding Coolant (COOPER S)
Warning: Danger of scalding, work on the cooling system should only be carried out when the engine is cooled down.
Recycling:
Catch and dispose of drained coolant. Observe country specific waste disposal regulations.
Note: Follow instructions for working on the cooling system.

After topping-up the coolant, vent the cooling system and check for coolant tightness. See: Service and Repair/Venting Cooling System and
Checking For Leaks
Drain coolant:
Release pressure cap (1) on expansion tank.
Remove underguard.
Remove bottom hose connection on radiator (1).
Drain, catch and dispose of coolant.
Refit coolant hose (1).
Release vent screw in heater rail (1).

Heater bleed screw ........................................................................................................................................................................................ 4,5/6.5 Nm
Release vent screw (1) in top coolant hose.
Venting takes place during filling.
Add Coolant:
Fill coolant through expansion tank (1).
Tighten vent screws when coolant exits.

Expansion tank retaining nut
M6 ................................................................................................................................................................................................................ 5 Nm
Fill expansion tank to maximum level.
Start engine and allow to idle, top up expansion tank when level drops.
Continue to run engine, until the level ceases to drop.
Switch off engine.
Top-up expansion tank to max.
Note: Before filling, turn on ignition, set heater control to maximum temperature.
Set fan to low speed.
Perform filling operation slowly.
Use only recommended coolant.

Coolant Reservoir: Description and Operation
Expansion Tank
the plastic expansion tank for both models is located between the primary and secondary bulkheads. the MINI COOPER expansion tank is a
non-pressurized type, it is only used to collect excess coolant due to heat expansion, and this coolant will be drawn back into the system as the
coolant cools.˜
Both models use a pressure cap to pressurize the cooling system to 1.1 bar (16 psi) at which point the cap valve will lift to relieve pressure.
the MINI COOPER S is fitted with a conventional pressurized cap on the expansion tank.
Radiator Cooling Fan: Description and Operation
Engine Coolant Fan
the Coolant Fan is a nine bladed fan measuring 400 mm in diameter, driven by a 350 watt motor and controlled by the EMS2000. This system has
two fan speeds.
the Engine Coolant Fan is controlled by the EMS2000 through a relay and relay pack at two different speeds, Low and High.
In addition to maintaining coolant temperature, the fan is used to cool the A/C refrigerant and where applicable, the ECVT gearbox oil.
the cooling fan operates on Low speed when the AC is switched on and the system pressure reaches 8 bar. Should the AC system pressure rise
above 18 bar, the fan will automatically run on High speed.
For the engine coolant system the fan operates on Low speed at 105° C. When the temperature drops to 101° C the fan will switch off. High speed
is switched on at 112° C and will remain on until the system coolant temperature drops by 4° C at which point the system will revert to Low speed
fan.
the engine coolant fan is operated through two relays, a Low speed relay and a High speed relay. the Low speed relay is mounted in the engine
compartment fuse box and is energized any time fan operation is needed (Both Low and High speed). the High speed relay is mounted on the fan
housing in the relay pack. the relay pack contains the High speed relay and a voltage reducing resistor.
When Low speed fan operation is needed the EMS2000 energizes the Low speed relay. Voltage flows from the Low speed relay to the relay pack,
through the voltage dropping resistor, enabling Low speed fan operation.
When High speed fan operation is needed, the EMS2000 energizes the High speed fan relay in the relay pack mounted on the fan housing. (the low
speed relay remains energized). the fan is now run at full battery voltage and achieves high speed operation.
A diode is installed in the relay pack to prevent voltage feedback through the resistor.
Radiator Cooling Fan: Service and Repair
Removing and Installing/Replacing Fan Cowl
17 11 031 - Removing and installing/replacing fan cowl
Necessary preliminary tasks:

- Remove fan cowl with electric fan See: Removing and Installing/Replacing Fan Cowl With Electric Fan
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.
Unscrew nut (1).
Tightening torque 17 11 1AZ.

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 17 11 2AZ.
Radiator Cooling Fan: Service and Repair
Removing and Installing/Replacing Fan Cowl With Electric Fan
17 11 035 - Removing and installing/replacing fan cowl with electric fan (W10, W11)
Necessary preliminary tasks:

- Remove radiator
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.
Engine - Coolant Temperature Sensor/Switch: Service and Repair
Replacing Coolant Temperature Sensor (DME)
NOTE: Read out fault memory of EMS2000 control module, check stored fault memory, rectify faults, clear fault memory.
WARNING!
Danger of scalding.
Work on the cooling system should only be carried out when the engine has cooled down.
Turn off ignition.
R50 only:
Remove coolant pressure cap from fill tower.

Remove air intake filter housing.
Remove battery box.
Drain coolant below the level of the coolant sensor.
R53 only:
Remove coolant pressure cap from expansion tank.

Disconnect coolant sensor connector (1).

Remove coolant sensor (2), using a deep 19 mm socket.
Tightening torque: 17 Nm
Refill and bleed coolant system.
Coolant Temperature Sensor/Switch (For Computer): Description and Operation
Engine Coolant Temperature Sensor
Coolant Temp Sensor Resistance
The Engine Coolant Temperature Sensor is a Negative Temperature Coefficient (NTC) thermistor sensor located in the coolant system. The sensor
is located in the cylinder head next to the thermostat housing. It is accessed easier with the air box removed.
The Engine Coolant Temperature Sensor is a NTC type sensor. It is used to monitor the engine coolant temperature and has two wires both
connected to the EMS2000. The signal is used for fuel control and ignition timing dependent on the engine temperature. The signal is also used to
control the radiator fan speed as well as supplying a signal on the CAN-bus to drive the coolant temperature gauge in the instrument cluster. A 5
volt reference signal is supplied to the coolant temp sensor by the EMS2000.
-High voltage readings at the EMS2000 indicate high sensor resistance, or low temperature.
-Low voltage readings indicate low sensor resistance or high temperature.
Coolant Temperature Sensor Failure Symptoms

- The vehicle may be difficult to start, may run lean when the engine is cold or slightly rich when the engine is hot (default to 'emergency
program' mode).
- Driveability of the vehicle will be affected.
- If the sensor output signal fails open, shorted to ground, shorted to 12V or shorted to 5V the EMS2000 will replace the temperature value
with a default value.
- If the sensor ground is shorted to 12V or shorted to 5V, temperature gauge will go to full hot and engine cooling fan goes to high when fault
is recognized.
Coolant Temperature Sensor Testing

- Ensure that voltage changes and does not remain constant at 0 or 5 volts.
- Check Sensor Resistance.
Function
The sensor is an NTK with a negative temperature coefficient; it is located in the coolant system. The sensor monitors the engine-coolant
temperature and is linked to the engine control module by two leads. The signal is used to control the injection duration depending on the engine
temperature. The value determined is also used to control the radiator fan speed and to display the coolant temperature in the instrument cluster.
Installation location
The sensor is located to the side above the transmission on the engine block.
Failure
In the event an engine coolant temperature sensor failure, a fault code is entered in the engine control module and a substitute value is used. The
vehicle handling is negatively influenced by the substitute value in all driving states.
Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection
Engine Coolant Temperature Sensor
The Engine Coolant Temperature Sensor is a Negative Temperature Coefficient thermistor sensor located in the coolant system. The sensor is
located in the cylinder head next to the thermostat housing. It is accessed easier with the air box removed.
The Engine Coolant Temperature Sensor is a NTC type sensor. It is used to monitor the engine coolant temperature and has two wires both
connected to the EMS2000. The signal is used for fuel control and ignition timing dependent on the engine temperature. The signal is also used to
control the radiator fan speed as well as supplying a signal on the CAN-bus to drive the coolant temperature gauge in the instrument cluster. A 5
volt reference signal is supplied to the coolant temp sensor by the EMS2000. High voltage readings at the EMS2000 indicate high sensor
resistance, or low temperature. Low voltage readings indicate low sensor resistance or high temperature.
Coolant Temp Sensor Resistance
Coolant Temperature Sensor Failure Symptoms

- The vehicle may be difficult to start, may run lean when the engine is cold or slightly rich when the engine is hot (default to 'emergency
program' mode).
- Driveability of the vehicle will be affected.
- If the sensor output signal fails open, shorted to ground, shorted to 12V or shorted to 5V the EMS2000 will replace the temperature value
with a default value.
- If the sensor ground is shorted to 12V or shorted to 5V, temperature gauge will go to full hot and engine cooling fan goes to high when fault
is recognized.
Coolant Temperature Sensor Testing

- Ensure that voltage changes and does not remain constant at 0 or 5 volts
- Check Sensor Resistance
Coolant Temperature Sensor/Switch (For Computer): Service and Repair
Replacing Coolant Temperature Sensor (DME)
WARNING!
Danger of scalding.
Turn off ignition.
R50 only:
Remove coolant pressure cap from fill tower.

Remove battery box.
R53 only:

Disconnect coolant sensor connector (1).

Remove coolant sensor (2), using a deep 19 mm socket.
Tightening torque 17 Nm
Refill and bleed coolant system.
Fan Shroud: Service and Repair
Replacing Fan Cowl
Remove radiator.
Unclip fan housing (1) from radiator (2) and move fan housing to the top.
Remove fan housing.
Remove fan blade retaining nut (1).
Note: the fan blade retaining nut has a left hand thread.
Fan blade to motor retaining nut ............................................................................................................................................................................ 6 Nm
Remove fan motor retaining bolts (1) and remove resistor pack retaining bolts (2).
Remove fan motor and resistor pack and remove fan cowl.
Note harness routing.

Motor to housing retaining bolts ............................................................................................................................................................................ 5 Nm
Heater Core: Service and Repair
Replacing Heater Core
Remove instrument panel trim.
Remove screws (1).

Remove cover panel (2).
Remove screw (1).

Release pipes from clips (2).
Remove heater core (3).
Radiator: Service and Repair
Removing And Installing Radiator
Turn off ignition.
Caution: Danger of scalding.
Open pressure cap on fill tower, only after engine has cooled down.
Drain coolant.
Remove front carrier.
Remove oil cooler if fitted ECVT only.
Remove radiator top hose.
Remove condenser retaining bolts (1) and lift condenser unit from support/retaining lug (2).
Care could be taken, to ensure attached pipes are supported.
Disconnect radiator top hose.
Remove radiator retaining pins (1).
Move radiator forward at top.
Disconnect harness from cooling fan relay pack (1).

Lift radiator from bottom supports (1).

Thermostat: Description and Operation
Coolant thermostat monitoring
The task of the coolant thermostat is to speed up the engine reaching its operating temperature after starting up. The thermostat is closed after an
engine start-up in order to restrict the coolant circulation until the thermostat control temperature has been reached. The thermostat opens at this
temperature and the restriction of the coolant circulation is terminated.
If the thermostat jams open, the coolant circulation is not restricted after starting up. This leads to an increase in the engine warm-up period and can
also increase exhaust emissions. In order to take account of this consequence, a thermostat that jams when open must be detected. Other diagnostic
functions could be inhibited by this and/or the refrigerant might not reach its operating temperature window.
If the thermostat jams when closed, there is a danger that the engine will overheat. The driver is informed in that the coolant-temperature warning
lamp lights up. A fault memory entry is created.
Thermostat: Service and Repair
Removing And Installing/replacing Coolant Thermostat (COOPER S)
Warning: Danger of scalding!
Remove intake filter housing.
Drain coolant.
Remove MAP sensor connector (1).
Remove MAP sensor bracket bolts (2).

Thermostat to cylinder head
M6 .............................................................................................................................................................................................................. 12 Nm
Remove heater hose (1).
Remove top hose (2) from thermostat housing.
Remove retaining bolt (3) and remove thermostat housing (4).
Remove thermostat and gasket from housing.
Note:
location of bleeding pin (1).
Direction of installation (2).
Replace gasket and thermostat if necessary.
1. Thermostat to seal locating lugs.

2. Basic location of thermostat to seal lug.
Refill coolant.

Cooling System: Description and Operation

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Cooling System: Description and Operation

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2004 Mini Cooper S (R53) L4-1.

6L SC (W11) Copyright © 2011, Page 1

Cooling System Operation

the heater core is constructed of aluminum and is of conventional design.

Oil Cooler (MINI COOPER S)

Checking Cooling System For Water Leaks (COOPER S)

Checking pressure drop in cooling system:

Remove pressure cap from expansion tank.

Generate gauge pressure of 1.5 bar. Wait approximately 2 minutes.

Cooling system is impervious to leaks if pressure drop is max. 0.1 bar.

Checking pressure relief valve in cap:

Fit special tool adaptor 17 0 052 to pressure cap.

Check cap relief pressure 0.89 - 1.20 bar (14 - 18 psi).

Checking For Combustion Chamber Leaks

Observe coolant temperature.

Remove pressure cap from fill tower.

Check for leaks with C02 leak tester.

Remove pressure cap from expansion tank.

Check for leaks with C02 leak tester.

Follow equipment manufacturer's operating instructions.

Checking Cooling System for Leaks

Special tools required:

Only perform this work after engine has cooled down.

Checking pressure drop in cooling system:

Remove cap from expansion tank.

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

Checking pressure relief valve in cap:

Remove rubber seal from special tool 17 0 002 .

Connect special tools 17 0 052 , 17 0 008 and 17 0 002 to cap.

Opening gauge pressure must be 0.89 - 1.20 bar.

1. Remove pressure cap.

Warning: Danger of scalding!

Only perform this work after engine has cooled down.

Note: Follow instructions for working on the cooling system.

Release pressure cap (1) on expansion tank.

Remove bottom hose connection on radiator (1).

Drain, catch and dispose of coolant.

Refit coolant hose (1).

Release vent screw in heater rail (1).

Release vent screw (1) in top coolant hose.

Venting takes place during filling.

Fill coolant through expansion tank (1).

Tighten vent screws when coolant exits.

Fill expansion tank to maximum level.

Continue to run engine, until the level ceases to drop.

Switch off engine.

Top-up expansion tank to max.

Set fan to low speed.

Perform filling operation slowly.

Use only recommended coolant.

Necessary preliminary tasks:

Unscrew nut (1).

Tightening torque 17 11 1AZ.

Necessary preliminary tasks:

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

Turn off ignition.

Remove coolant pressure cap from fill tower.

Remove coolant pressure cap from expansion tank.

Disconnect coolant sensor connector (1).

Refill and bleed coolant system.

Coolant Temp Sensor Resistance

Coolant Temperature Sensor Failure Symptoms

Coolant Temperature Sensor Testing