41 33 600 Moving front panel into assembly position

Special tools required:

Necessary preliminary tasks:

Remove COVER FROM FRONT GRILLE
Remove the BUMPER PANEL COVER on left and right
Remove CENTER COVER
Release FRONT WHEEL ARCH TRIM COVER on bumper trim

Release clips (1) on left/right.

Installation note:

If necessary, replace faulty clips (1).

Fig 1: Identifying Clips

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Release cable clip (1).

Disconnect plug connections (2) on A/C compressor.

Release screws (3).

Tightening torque 51 11 4AZ .

Fig 2: Identifying Plug Connections, Cable Clip And Screws

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Unfasten screws (2).

Tightening torque 51 11 4AZ .

Version with headlight cleaning system:

Release plug connection (1) on the windscreen washer pump.

Fig 3: Identifying Plug Connection And Screws

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Release screw (1) on sidewall left/right.

Fig 4: Identifying Screw On Side Panel

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Version with A/C system:

Unclip refrigerant line (1) from holder (2).

Fig 5: Identifying Refrigerant Line And Holder

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Unscrew bolt (1) and set expansion tank (2) aside.

Release the gaiter (3) from the lock carrier (4).

Fig 6: Identifying Expansion Tank, Gaiter, Lock Carrier And Screw

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Open coupling (1) and disengage Bowden cable (2).

Release screws (3 and 4).

Tightening torque 51 11 7AZ .

Installation note:

The headlight tab for the screw (4) may not touch the front panel during installation.

Fig 7: Identifying Coupling, Bowden Cable And Screws

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Disconnect plug connection (1).

Release screws (4 and 5).

Tightening torque 51 11 7AZ .

COOPER S only:

Release clamp (2) and detach air duct (3).

Installation note:

The headlight tab for the screw (5) may not touch the front panel during installation.

Fig 8: Identifying Plug Connection, Clamp, Air Duct, And Screws

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Insert special tool 00 2 271 on the left and right in the sleeve (1).

If applicable, turn the special tool 00 2 271 until the screw can be inserted and tighten.

Unscrew nuts (2).

Tightening torque 51 11 3AZ .

Installation note:

Do not remove special tool 00 2 271 until the front panel has been completely removed.

Fig 9: Identifying Special Tool (00 2 271), Sleeve, And Nuts

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Pull front panel (1) approx. 10 cm forwards and if necessary pay attention to further cable clips.

Insert special tool 00 2 272 left and right.

Installation note:

To ensure that front panel (1) is correctly seated, slide panel on left and right uniformly towards rear.

With a second person helping, slide front panel into position and secure.

When installing, pay attention to retaining tabs on headlight.

Fig 10: Identifying Special Tool (00 2 271), Sleeve, And Nuts

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Installation note:

Adjust lights. See ADJUSTING HEADLIGHTS and ADJUSTING FOG LIGHTS .