Lowering/raising front axle support (Cooper Convertible)

Special tools required:

31 5251
00 2 030
31 5255
31 5 253

WARNING: Injury hazard!
Failure to comply with the following instructions may result in the vehicle slipping off the lifting platform and critically injuring other persons.
When supporting components, make sure that:

the vehicle can no longer be raised or lowered.
the vehicle does not lift off the locating plates on the vehicle hoist.

IMPORTANT: Before lowering/removing front axle support:
Observe safety instructions for raising the vehicle

Preliminary work needed:

Disconnect BATTERY GROUND LEAD.

Lowering:

Driver's footwell:

Release and remove nut (1).

Release nuts (2) 1 rotation. (Do not remove!)

Remove cover (3).

NOTE: In order to provide a better view, the graphic does not show the side footwell trim.

Side footwell trim must not be disassembled!

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IMPORTANT: If the steering shaft is separated from the steering box, this can result in damage to the steering column switch cluster when the steering wheel is turned!

Remove screw (1).

Swivel out bottom steering shaft universal joint (2) from steering gear.

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Secure the radiator on the centering pin (1) on the left and right using a suitable tool (2).

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Remove front WHEELS .
Remove THRUST FIELD .
Remove front TENSION STRUTS .
Remove front left and right WHEEL ARCH COVER .

Only for rear underbody protection:

Loosen screws.

Remove cover (1).

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Only for right ride height sensor:

Disconnect connector (1).

Release cable clip (2) from deformation element adapter.

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Release nut (1) of anti-roll bar link on left and right anti-roll bar, counter support on Torx socket if necessary.

Release anti-roll bar link from anti-roll bar.

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Spray rubber mount (1) with lubricant and release from holder on front axle support.

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You can reach the subsequent plug connections with your right arm through the left output shaft.

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Disconnect plug connections (1) on steering box.

IMPORTANT: Make sure when lowering the front axle that the cables are not damaged!

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Only on right side:

Release screws (3) from washer fluid reservoir holder (2).

Take off holder (2).

Right and left:

Release screws (1) of deformation element adapter on deformation element.

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Unlock guard control (1) of lock for charge air cooler holder on left and right.

Completely remove locks (2).

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Only for gasoline engines:

Press lock (2).

Disconnect purge air line (1).

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Only for gasoline engines:

Press lock (2).

Disconnect purge air line (1).

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Release screw (2) of engine mount (3) on front axle (1).

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Release screw (1) of holder for wishbone rubber mount on left and right on body.

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Fit the special tool 31 5 251 completely onto the universal jack 00 2 030 with a helper.

Insert special tools 31 5 255 in telescopic supports of a profile rail pair.

Insert special tools 31 5 253 in telescopic supports of other profile rail pair.

NOTE: In a profile rail pair, two profile rails are connected to one another by gearing.

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Align special tools 31 5 255 and 31 5 253 to front axle support.

Support front axle support by operating workshop jack 00 2 030.

IMPORTANT: The center of gravity of the front axle support must be positioned centrally over the workshop jack!

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Secure front axle support with luggage strap on special tool 31 5 251.

IMPORTANT: Risk of damage!

When lowering and raising the front subframe, it is absolutely essential to make sure that the torsion bar (1) of the electromechanical steering gear (EPS) does not collide with the cowl in the area (2)!

Collision with the bulkhead may result in damage to the electromechanical steering gear (EPS)!

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Release screws (1) (front axle support, rear).

Release screws (2) (front axle support, front, through loop in wishbone).

Bend the underbody planking to the side in the marked area (3).

When lowering, release charge air cooler from its rubber mounts.

Lower front axle support (maximum 100 mm).

Installation note:

Check threads for damage; if necessary, repair with HELICOIL THREAD INSERTS .

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Raising:

IMPORTANT: The seal (1) of the electromechanical steering gear (EPS) must always be replaced!

Remove gasket (1).

Clean surface on steering gear.

Replace gasket (1).

Parts : Gasket

Position and bond the new gasket (1).

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Position front axle support.

Bend the underbody planking to the side in the marked area (3).

Raise front axle support.

When raising, insert charge air cooler into its rubber mount on cross member.

Replace screws (1) and (2).

Parts : screw

Tighten down screws (1).

Tightening torque 31 11 2AZ .

Tighten down screws (2).

Tightening torque 31 11 1AZ .

Release luggage strap from front axle support.

Lower the workshop jack 00 2 030 with special tool 31 5 251 and lay to one side.

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Replace screws (1).

Parts : screw

Tighten screws (1) of holder for wishbone rubber mount on left and right.

Tightening torque 31 12 4AZ .

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Tighten screw (2) of engine mount (3) on front axle (1).

Tightening torque 22 11 5AZ .

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Only for gasoline engines:

Connect purge air line (1).

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Only for gasoline engines:

Connect the purge air line (1) on the vehicle underbody.

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Position locking mechanism (2).

Lock the safety catch (1) of the locking mechanism (2) of the holder for the left and right charge air cooler.

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Right and left:

Tighten screws (1) of deformation element adapter on deformation element.

Tightening torque 51 11 5AZ .

Only on right side:

Position washer fluid reservoir holder (2) on deformation element adapter.

Tighten down screws (3).

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You can reach the subsequent plug connections with your right arm through the left output shaft.

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Connect plug connections (1) on steering gear.

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Check rubber mount for damage, replace if necessary.

Parts : rubber mount

Spray rubber mount (1) with lubricant and slide onto holder on front axle support.

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Replace nut (1).

Parts : Nut

Secure anti-roll bar link to anti-roll bar on left and right using nuts (1).

Tightening torque 31 35 1AZ .

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Only for right ride height sensor:

Secure cable clip (2) on deformation element adapter.

Connect the connector (1).

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Only for rear underbody protection:

Position cover (1).

Tighten the screws.

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Install front left and right WHEEL ARCH COVER .
Install front TENSION STRUTS .
Install the THRUST FIELD .
Install front WHEELS .

Remove suitable tool (2) on centering pin (1) on left and right.

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Clean threads in universal joint to remove all remnants of screw locking agent.

Swivel universal joint (2) onto steering gear.

Replace screw (1).

Parts : screw

Tighten screw (1).

Tightening torque 32 31 2AZ .

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Align cover (2).

Tighten cap nuts (1).

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Required follow-up work:

Connect BATTERY GROUND LEAD.