Mini Cooper Parts Catalog Mini Cooper Accessories Catalog Mini Cooper Technical Articles Mini Cooper Tech Forums
 
  Search our site:    
View Recent Cars  |   Cart  | Project List | Order Status | Help    
 >  >
Turbocharged Engine Thermostat Replacement
 
Bookmark and Share

Pelican Technical Article:

Turbocharged Engine Thermostat Replacement

Nick Czerula

Time:

3 hours3 hrs

Tab:

$150

Talent:

****

Tools:

Set of sockets 10, 11, 13mm, screwdrivers

Applicable Models:

R56 MINI Cooper S Hatchback (2007-11)

Parts Required:

Thermostat, hoses, engine coolant

Hot Tip:

Work with a cool engine

Performance Gain:

Car will cool down again or restore function of heater

Complementary Modification:

Change radiator hoses and/or water pipes.

The MINI R56 cooling system is filled through the plastic coolant expansion tank (or coolant reservoir) at the right front of the engine compartment. There is no cap on the radiator. Other components of the cooling system consist of:

Belt driven coolant pump bolted to the right side of the engine block.

Turbocharged engines: Electric coolant pump bolted to the left front of the engine block.

Turbocharged engines: Engine oil cooler attached to oil filter housing.

Electric cooling fan attached to rear of radiator. The cooling fan is controlled by the engine control module (ECM) via an output final stage.

Electrically heated thermostat.

Automatic transmission cooler (heat exchanger).

Coolant temperature sensor at cylinder head.

Coolant hose and lines.

The engine control module (ECM) (DME) controls and monitors operation of the thermostat. Controlling the thermostat function according to a map allows the engine management system (DME) to raise engine operating temperature quickly and precisely to the optimal range and to maintain it there for maximum efficiency and minimum emissions.

If a fault occurs in the thermostat, a fault code is stored in the ECM, usually with a description of "Map cooling circuit". A fault code can be present yet the vehicle will lack any cooling system issues, such as overheating. This is because the thermostat has a fail-safe mechanical function as well. If you have this fault code, replace your thermostat and bleed your cooling system. Other symptoms of a faulty thermostat are engine overheating, slow to warm up and lack of heat.

In this article I will describe how to replace the thermostat in your N14 MINI turbocharged engine. Be sure to work with a cool engine and confirm the cooling system lacks pressure before opening the cooling system.

NOTE: Now is a really good time to inspect and change out your water pipes. They are made of plastic and often crack over time or get baked onto the water pump due to heat in this area. 

Keep in mind that when your car was serviced before, parts may have been replaced with different size fasteners used in the replacement. The sizes of the nuts and bolts we give may be different from what you have, so be prepared with different size sockets and wrenches.

Protect your eyes, hands and body from fluids, dust and debris while working on your vehicle. If you're working with the electrical system, disconnect the battery before beginning. Always catch fluids in appropriate containers and properly dispose of any fluid waste. Recycle parts, packaging and fluids when possible. Do not work on your vehicle if you feel the task is beyond your ability.

Vehicle models change and evolve, as they grow older, so the vehicle shown in our illustrations may vary slightly from yours. If something seems different, let us know and share your info to help other users. Do you have questions or want to add to the article? Leave a comment below. When leaving a comment, please leave your vehicle information.

Drain the cooling system. See our tech article on cooling system draining and filling.

Working at the crankcase breather heating element, release the tab (red arrow) and disconnect the electrical connector.
Figure 1

Working at the crankcase breather heating element, release the tab (red arrow) and disconnect the electrical connector.

Then lift it up to detach the hose lock (red arrows) at the valve cover.
Figure 2

Then lift it up to detach the hose lock (red arrows) at the valve cover.

Remove the hose from the valve cover (red arrow).
Figure 3

Remove the hose from the valve cover (red arrow).

Working at the vacuum pump, press the brake booster line release tab (red arrow) and pull the vacuum line straight off the pump.
Figure 4

Working at the vacuum pump, press the brake booster line release tab (red arrow) and pull the vacuum line straight off the pump.

Loosen the intake air duct hose clamps (red arrows).
Figure 5

Loosen the intake air duct hose clamps (red arrows).

Remove the intake air duct from the turbocharger, then the intake air housing.
Figure 6

Remove the intake air duct from the turbocharger, then the intake air housing.

Disconnect the electrical connectors for the oil pressure sensor (red arrow) and the coolant temperature sensor housing (green arrow).
Figure 7

Disconnect the electrical connectors for the oil pressure sensor (red arrow) and the coolant temperature sensor housing (green arrow). Use a pick to pull the connector tab up and slide the connectors straight off.

Working at the left rear of the cylinder head, release the tab and disconnect the camshaft sensor electrical connector (red arrow).
Figure 8

Working at the left rear of the cylinder head, release the tab and disconnect the camshaft sensor electrical connector (red arrow). The intake sensor is shown. If your vehicle has an exhaust sensor, disconnect it too.

Remove the wiring harness housing (red arrow) from the mounting bracket (green arrow) by sliding it straight up.
Figure 9

Remove the wiring harness housing (red arrow) from the mounting bracket (green arrow) by sliding it straight up. Place it aside and out of the way.

Working at the front thermostat hoses, use hose clamp pliers (inset) to remove the hose clamps (red arrows).
Figure 10

Working at the front thermostat hoses, use hose clamp pliers (inset) to remove the hose clamps (red arrows). Slide the clamps away from the thermostat.

Pull the hoses (red arrows) straight off.
Figure 11

Pull the hoses (red arrows) straight off.

Working at the back of the thermostat, remove the hose using hose clamp pliers (green arrow).
Figure 12

Working at the back of the thermostat, remove the hose using hose clamp pliers (green arrow). Slide the clamps away from the thermostat and pull the hose straight off. Use a pick to pull the connector tab (red arrow) down (it's on the bottom), and slide the connector straight off.

Working at the back of the thermostat, remove the hose (green arrow) using sliding jaw pliers (red arrow).
Figure 13

Working at the back of the thermostat, remove the hose (green arrow) using sliding jaw pliers (red arrow). Slide the clamps away from the thermostat and pull the hose straight off.

Working at the back of the thermostat (green arrow) under the intake manifold (yellow arrow), remove the metal clip (red arrow) by pulling it straight up.
Figure 14

Working at the back of the thermostat (green arrow) under the intake manifold (yellow arrow), remove the metal clip (red arrow) by pulling it straight up.

This photo shows the clip removed from the thermostat (red arrow).
Figure 15

This photo shows the clip removed from the thermostat (red arrow).

Remove the three 10mm thermostat mounting fasteners (red arrows).
Figure 16

Remove the three 10mm thermostat mounting fasteners (red arrows). The rear fastener has a socket on it in the photo. Once the fasteners are removed, you will have to remove the small front hose clamp (green arrow).

Using hose clamp pliers (red arrow) slide the clamp away from the thermostat and pull the hose straight off.
Figure 17

Using hose clamp pliers (red arrow) slide the clamp away from the thermostat and pull the hose straight off. You will have to pull the hose off as you remove the thermostat from the engine.

This photo shows the thermostat fastener locations (red arrows).
Figure 18

This photo shows the thermostat fastener locations (red arrows).

Slide the small hose off the thermostat and remove the thermostat from the engine.
Figure 19

Slide the small hose off the thermostat and remove the thermostat from the engine.

Using a plastic scraper and a Scotch-Brite pad, clean the thermostat sealing surface.
Figure 20

Using a plastic scraper and a Scotch-Brite pad, clean the thermostat sealing surface. It is important not to use a metal scraper or razor blade here. You could damage the sealing surface and the thermostat seal (red arrow) will not seat properly, resulting in a leak. Once clean, confirm the sealing surface isn't pitted. It if is, it may not seal correctly. You may have to add some epoxy and sand it down to get a smooth and even sealing surface. I see this happen more on high mileage under-maintained MINIs. Replace the small hose (green arrow) if needed. Install the new thermostat and evenly tighten all the fasteners. Install the coolant hoses. Listen for an audible click to confirm the rear clip engages. Connect the thermostat and sensor electrical connectors. Install the cooling fan and fill and bleed the cooling system. Remember to check the cooling system for leaks and top up the coolant when complete.






Bookmark and Share
Comments and Suggestions:
Skua Comments: Thanks for the tips,
Easily took the thermostat out an hour ago. Ordered a new one from Germany at half the price Mini dealer sells it here in Spain. I think that maybe will have to change that pipe as well as Retired Miner, that pipe looks slightly dirt and now I suspect the leak was from that coupling instead of the thermostat to the block coupling. Anyway that will probably be a work for the mechanic since I cant lift the car and work from below. Will also change the water pump in that case.
It is a great help for me to read your articles. since then I serviced my Boxster 987 and now this Mini I bought to my son as a Christmas present, hope I have it fixed in time!
December 1, 2016
Retired Miner Comments: This article is good
Except you do not mention that the difficult removal of the thermostat from the water pipe from the water pump to the thermostat can dislodge the pipe from the water pump end and damage the pipe and O-ring. After a successful thermostat remove and replace I had a leak at the water pump end and had to remove the thermostat again to remove the water pipe. I have ordered the pipe and any suggestions on installation of the water pipe would be welcome. Thanks for the great articles and pictures even seasoned mechanics benefit from precise instructions and good pictures. I can take pictures of the damaged pipe if you need them to amend your tech article.
November 23, 2016
  Followup from the Pelican Staff: The thermostat should not difficult to remove. Unless someone used an adhesive when installing the one you are trying to remove. I would like to see photos of the themrostat side of pipe. - Nick at Pelican Parts  
Primevci Comments: Thanks this write up helped allot
July 9, 2016
  Followup from the Pelican Staff: Thanks for the feedback. Glad we could help.
- Nick at Pelican Parts
 

  Search our site:    

View Cart & CheckOut | Project List | Order Status |  Help    

 

[Home] [Customer Service] [Shopping Cart] [Project/Wish List]
  [Privacy Statement]  [Contact Us] [About Us] [Shipping] [Careers]

Copyright © Pelican Parts Inc. -    DMCA Registered Agent Contact Page

Page last updated: Fri 12/9/2016 02:53:16 AM