Notes for work on the cooling system (Cooper)

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WARNING: Risk of burning!
Only carry out repair on the cooling system after the engine has cooled down!

IMPORTANT: Wear hand protection and safety goggles.

IMPORTANT: Service life coolant filling:
Never reuse used coolant!

When replacing and removing components which rely on the corrosion protection effect of the coolant, it is essential to change the coolant. The cooling system must therefore be drained and refilled.

In the case of other removal work involving the draining of part quantities of coolant, replace these quantities which have been drained with new coolant.

IMPORTANT: Open cooling system only when it has cooled down.

Opening the cooling system while hot can result in air entering the system.

This can cause overheating with permanent damage to the engine.

IMPORTANT: When carrying out repair work on the oil, coolant or fuel circuit, the alternator must be protected against dirt contamination.

Cover alternator with suitable materials.

Failure to comply with this procedure may result in an alternator malfunction.

IMPORTANT: Do not fill coolant expansion tank over maximum level, as overfilling will cause the coolant to overflow. This may give rise to traces of residual coolant on the expansion tank or in the engine compartment and wrongly suggest possible leaks.

IMPORTANT: Make sure without fail that coolant hoses are correctly routed. Risk of damage due to sharp edges or chafing.

Recycling:

Catch and dispose of drained coolant.

Observe country-specific waste disposal regulations.

Set of special tools 17 2 050 for removing and installing the spring holder clamps for coolant hoses.

(1) Release tool
(2) Pliers (bent version)
(3) Pliers (straight version)

Loosen spring strap (1) with the pliers (2).

Unlock spring strap (1) with the release tool (2).

NOTE: To disconnect coolant hoses, use commercially available disconnect tools such as HAZET brand tools (see table).

HAZET number:	Description
4590-1	Length of disconnect pliers (mm): 150
4590-2	Length of disconnect pliers (mm): 180
4590-3	Length of disconnect pliers (mm): 253
4590/2	Set of clamping pliers
4590/3	Set of clamping pliers

Notes for disassembly/assembly of coolant hose quick-release couplings

Dismantling of quick-release coupling

Pull out lock (1) and (2). Detach hose.

Installation note:

Check O-rings (1).

Do not coat O-rings (1) with lubricant.

Assembly of quick-release coupling

Press in lock (1) before installing quick-release coupling.

Push on hose.

Quick-release couplings must clearly snap audibly into place.