2006 MINI Cooper 2002-05 HVAC Air Conditioning & Heating Systems - Repair Instructions - Cooper (1.6L) R50/W10 & Cooper S 2002-05 HVAC Air Conditioning & Heating Systems - Repair Instructions - Cooper (1.6L) R50/W10 & Cooper S HEATER WITH OPERATION 64 11 ... INSTALLING SERVODRIVE Installation: If necessary, align shaft of flap(s) to be actuated to position of servodrive to be installed. Fig. 1: View Of Servodrive Courtesy of BMW OF NORTH AMERICA, INC.
006 MINI Cooper 2002-05 HVAC Air Conditioning & Heating Systems - Repair Instructions - Cooper (1.6L) R50/W10 & Cooper S Remove airbag module on front passenger side. Refer to PASSENGER-SIDE AIR BAG MODULE for model year 2002, or PASSENGER-SIDE AIR BAG MODULE for model year 2003, or PASSENGER-SIDE AIR BAG MODULE for model year 2004-05. Remove instrument carrier. Refer to 62 21 000 REMOVING AND INSTALLING/REPLACING INSTRUMENT CARRIER . Remove heater controls.
2006 MINI Cooper 2002-05 HVAC Air Conditioning & Heating Systems - Repair Instructions - Cooper (1.6L) R50/W10 & Cooper S Fig. 2: Identifying Instrument Panel Trim Retaining Screws Courtesy of BMW OF NORTH AMERICA, INC. Unfasten plug connection (1) and disconnect. Microsoft Tuesday, February 16, 2010 11:05:58 AM Page 3 © 2005 Mitchell Repair Information Company, LLC.
2006 MINI Cooper 2002-05 HVAC Air Conditioning & Heating Systems - Repair Instructions - Cooper (1.6L) R50/W10 & Cooper S Fig. 3: Locating Plug Connection Courtesy of BMW OF NORTH AMERICA, INC. Disconnect plug (1) from holder (2) on cross-member. Microsoft Tuesday, February 16, 2010 11:05:58 AM Page 4 © 2005 Mitchell Repair Information Company, LLC.
2006 MINI Cooper 2002-05 HVAC Air Conditioning & Heating Systems - Repair Instructions - Cooper (1.6L) R50/W10 & Cooper S Fig. 4: View Of Plug In Cross-Member Courtesy of BMW OF NORTH AMERICA, INC. Release screws (1), tightening torque, refer to 64 11 3AZ in HEATING AND AIR CONDITIONING TIGHTENING TORQUES - COOPER (1.6L) R50/W10 . Microsoft Tuesday, February 16, 2010 11:05:58 AM Page 5 © 2005 Mitchell Repair Information Company, LLC.
2006 MINI Cooper 2002-05 HVAC Air Conditioning & Heating Systems - Repair Instructions - Cooper (1.6L) R50/W10 & Cooper S Fig. 5: Identifying Retaining Screws Courtesy of BMW OF NORTH AMERICA, INC. Release screws (1), tightening torque, refer to 64 11 3AZ in HEATING AND AIR CONDITIONING TIGHTENING TORQUES - COOPER (1.6L) R50/W10 . Microsoft Tuesday, February 16, 2010 11:05:58 AM Page 6 © 2005 Mitchell Repair Information Company, LLC.
2006 MINI Cooper 2002-05 HVAC Air Conditioning & Heating Systems - Repair Instructions - Cooper (1.6L) R50/W10 & Cooper S Fig. 6: Locating Screws For Removal Courtesy of BMW OF NORTH AMERICA, INC. Vehicles With Automatic Air Conditioning Only: Disconnect plug connection (1) for solar sensor. Microsoft Tuesday, February 16, 2010 11:05:58 AM Page 7 © 2005 Mitchell Repair Information Company, LLC.
2006 MINI Cooper 2002-05 HVAC Air Conditioning & Heating Systems - Repair Instructions - Cooper (1.6L) R50/W10 & Cooper S Fig. 7: View Of Plug Connection For Solar Sensor Courtesy of BMW OF NORTH AMERICA, INC. IMPORTANT: Two people are needed to remove the heater. Remove heater from instrument panel trim. 64 11 207 REPLACING HEATER CORE WARNING: Follow instructions for working on cooling system! Refer to 17 00 ... FOLLOW INSTRUCTIONS FOR WORKING ON COOLING SYSTEM .
2006 MINI Cooper 2002-05 HVAC Air Conditioning & Heating Systems - Repair Instructions - Cooper (1.6L) R50/W10 & Cooper S diesel). Remove left storage compartment or panel for pedal assembly. Refer to 51 16 392 REMOVING AND INSTALLING/REPLACING STORAGE COMPARTMENT IN INSTRUMENT PANEL TRIM (DRIVER'S SIDE) . Release spring clamps (2) and detach coolant hoses (1). IMPORTANT: Carefully blow through aluminum twin pipe to remove remaining coolant from heat exchanger for heating system.
2006 MINI Cooper 2002-05 HVAC Air Conditioning & Heating Systems - Repair Instructions - Cooper (1.6L) R50/W10 & Cooper S Courtesy of BMW OF NORTH AMERICA, INC. Release screws (1). Remove cover (2). Fig. 9: Identifying Retaining Screws For Cover Courtesy of BMW OF NORTH AMERICA, INC. Release screws (1). Release clamps (2). Remove heater (3). Installation: Make sure heater (3) is correctly seated. Microsoft Tuesday, February 16, 2010 11:05:59 AM Page 10 © 2005 Mitchell Repair Information Company, LLC.
2006 MINI Cooper 2002-05 HVAC Air Conditioning & Heating Systems - Repair Instructions - Cooper (1.6L) R50/W10 & Cooper S Replace sealing rings. Coat new sealing rings with antiseize agent. Make sure sealing rings and clamps (2) are correctly seated. Fig. 10: View Of Heater Courtesy of BMW OF NORTH AMERICA, INC. 64 11 210 REMOVING AND INSTALLING HEATER FAN Necessary Preliminary Tasks: Remove instrument panel trim.
2006 MINI Cooper 2002-05 HVAC Air Conditioning & Heating Systems - Repair Instructions - Cooper (1.6L) R50/W10 & Cooper S Release screws (2) and remove heater fan. Fig. 11: Disconnecting Heater Fan Plug Connection Courtesy of BMW OF NORTH AMERICA, INC. 64 11 221 REPLACING RESISTOR FOR HEATER - A/C FAN Release screw (1). Remove resistor for heater - A/C fan (2). Microsoft Tuesday, February 16, 2010 11:05:59 AM Page 12 © 2005 Mitchell Repair Information Company, LLC.
2006 MINI Cooper 2002-05 HVAC Air Conditioning & Heating Systems - Repair Instructions - Cooper (1.6L) R50/W10 & Cooper S Fig. 12: Removing Resistor For Heater And A/C Fan Courtesy of BMW OF NORTH AMERICA, INC. 64 11 222 REPLACING RESISTOR FOR HEATER - A/C FAN (IHKA) NOTE: For purposes of clarity, illustration shows heater/air conditioner removed. The resistor for the heater - A/C fan is located in the right footwell. Unfasten plug connection (1) and disconnect. Release screw (2).
2006 MINI Cooper 2002-05 HVAC Air Conditioning & Heating Systems - Repair Instructions - Cooper (1.6L) R50/W10 & Cooper S Fig. 13: Removing Plug Connection Courtesy of BMW OF NORTH AMERICA, INC. 64 11 333 REMOVING AND INSTALLING/REPLACING HEATER CONTROLS (IHR AND IHKR) Necessary Preliminary Tasks: Remove radio receiver. Refer to 65 11 030 REMOVING AND INSTALLING/REPLACING RADIO RECEIVER (BUILT-IN UNIT) . Remove switch block on instrument panel.
2006 MINI Cooper 2002-05 HVAC Air Conditioning & Heating Systems - Repair Instructions - Cooper (1.6L) R50/W10 & Cooper S Fig. 14: Pressing Control Panel Towards Rear To Release Guide Pins Courtesy of BMW OF NORTH AMERICA, INC. NOTE: Pull left side of heater controls towards front to expose rear side of controls. Disconnect cable (1) of temperature regulator. Unfasten plug connection (2) and disconnect. Disconnect cable (3) of air-distribution controller.
2006 MINI Cooper 2002-05 HVAC Air Conditioning & Heating Systems - Repair Instructions - Cooper (1.6L) R50/W10 & Cooper S Fig. 15: Removing Heater Controls Courtesy of BMW OF NORTH AMERICA, INC. 64 11 334 REMOVING AND INSTALLING/REPLACING HEATER CONTROLS (IHKA) Necessary Preliminary Tasks: Remove radio receiver. Refer to 65 11 030 REMOVING AND INSTALLING/REPLACING RADIO RECEIVER (BUILT-IN UNIT) . Release switch block on instrument panel.
2006 MINI Cooper 2002-05 HVAC Air Conditioning & Heating Systems - Repair Instructions - Cooper (1.6L) R50/W10 & Cooper S Fig. 16: Releasing Heater Controls Guide Pins Courtesy of BMW OF NORTH AMERICA, INC. Pull out heater controls slightly. Unlock plug connections (1) and (2) and disconnect. Replacement: Remove sensor blower for interior temperature. Refer to 64 11 889 REPLACING SENSOR FAN FOR INTERIOR TEMPERATURE (IHKA).
2006 MINI Cooper 2002-05 HVAC Air Conditioning & Heating Systems - Repair Instructions - Cooper (1.6L) R50/W10 & Cooper S Fig. 17: Removing Sensor Blower For Interior Temperature Courtesy of BMW OF NORTH AMERICA, INC. 64 11 800 REMOVING AND INSTALLING/REPLACING SERVODRIVE FOR FLAP CONTROL GEAR (IHKA) Necessary Preliminary Tasks: Remove trim between front center console and instrument panel.
2006 MINI Cooper 2002-05 HVAC Air Conditioning & Heating Systems - Repair Instructions - Cooper (1.6L) R50/W10 & Cooper S INSTALLING/REPLACING SWITCH BLOCK IN INSTRUMENT PANEL . Unfasten plug connection (1) and disconnect. Release screws (2) and remove servodrive for flap control gear. Fig. 18: View Of Servodrive For Flap Control Gear Courtesy of BMW OF NORTH AMERICA, INC.
06 MINI Cooper 2002-05 HVAC Air Conditioning & Heating Systems - Repair Instructions - Cooper (1.6L) R50/W10 & Cooper S Detach plug connector (1). Remove screws (2). Pull servodrive forwards away from flap mechanism. Installation: The servodrive is seated in a keyway. Fig. 19: Detaching Plug Connector Courtesy of BMW OF NORTH AMERICA, INC.
2006 MINI Cooper 2002-05 HVAC Air Conditioning & Heating Systems - Repair Instructions - Cooper (1.6L) R50/W10 & Cooper S Fig. 20: Identifying Plug Connection Of Servodrive For Temperature Control Courtesy of BMW OF NORTH AMERICA, INC. Detach control lever (1) in direction of arrow. 2) Drag link. Installation: Ensure correct seating. Microsoft Tuesday, February 16, 2010 11:05:59 AM Page 21 © 2005 Mitchell Repair Information Company, LLC.
2006 MINI Cooper 2002-05 HVAC Air Conditioning & Heating Systems - Repair Instructions - Cooper (1.6L) R50/W10 & Cooper S Fig. 21: Locating Drag Link Courtesy of BMW OF NORTH AMERICA, INC. Slacken cable (1). Disengage drag link (2) in direction of arrow. Release catch (4). Disengage servodrive for temperature control with holder (3) and linkage towards bottom front. Installation: Ensure correct seating.
2006 MINI Cooper 2002-05 HVAC Air Conditioning & Heating Systems - Repair Instructions - Cooper (1.6L) R50/W10 & Cooper S Fig. 22: Disengaging Servodrive Courtesy of BMW OF NORTH AMERICA, INC. Separate drag link (1) from control lever (2). Release screws (4). Remove servodrive for temperature control (5) from holder (3). Installation: Ensure correct seating. Microsoft Tuesday, February 16, 2010 11:05:59 AM Page 23 © 2005 Mitchell Repair Information Company, LLC.
2006 MINI Cooper 2002-05 HVAC Air Conditioning & Heating Systems - Repair Instructions - Cooper (1.6L) R50/W10 & Cooper S Fig. 23: View Of Drag Link And Control Lever Courtesy of BMW OF NORTH AMERICA, INC. 64 11 889 REPLACING SENSOR FAN FOR INTERIOR TEMPERATURE (IHKA) Necessary Preliminary Tasks: Remove heater controls. Refer to 64 11 333 REMOVING AND INSTALLING/REPLACING HEATER CONTROLS (IHR AND IHKR) AND/OR 64 11 334 REMOVING AND INSTALLING/REPLACING HEATER CONTROLS (IHKA).
2006 MINI Cooper 2002-05 HVAC Air Conditioning & Heating Systems - Repair Instructions - Cooper (1.6L) R50/W10 & Cooper S Fig. 24: Identifying Sensor Fan For Interior Temperature Courtesy of BMW OF NORTH AMERICA, INC. 64 11 932 REPLACING EVAPORATOR TEMPERATURE SENSOR (IHKR/IHKA) Release screws (1). Remove cover (2). Microsoft Tuesday, February 16, 2010 11:05:59 AM Page 25 © 2005 Mitchell Repair Information Company, LLC.
2006 MINI Cooper 2002-05 HVAC Air Conditioning & Heating Systems - Repair Instructions - Cooper (1.6L) R50/W10 & Cooper S Fig. 25: Locating Retaining Screws For Cover Courtesy of BMW OF NORTH AMERICA, INC. Turn evaporator temperature sensor (1) counterclockwise (approx. 45°) and pull out. Unfasten plug connection (2) and disconnect. Installation: Make sure that opening (3) of evaporator temperature sensor (1) is correctly aligned.
2006 MINI Cooper 2002-05 HVAC Air Conditioning & Heating Systems - Repair Instructions - Cooper (1.6L) R50/W10 & Cooper S Fig. 26: Disconnecting Evaporator Temperature Sensor Plug Connection Courtesy of BMW OF NORTH AMERICA, INC. 64 11 939 REPLACING TEMPERATURE SENSOR FOR HEATER (IHKA) Necessary Preliminary Tasks: Remove heater controls. Refer to 64 11 333 REMOVING AND INSTALLING/REPLACING HEATER CONTROLS (IHR AND IHKR) AND/OR 64 11 334 REMOVING AND INSTALLING/REPLACING HEATER CONTROLS (IHKA).
2006 MINI Cooper 2002-05 HVAC Air Conditioning & Heating Systems - Repair Instructions - Cooper (1.6L) R50/W10 & Cooper S Fig. 27: Disconnecting Temperature Sensor Plug Connection Courtesy of BMW OF NORTH AMERICA, INC. 64 11 992 REMOVING AND INSTALLING/REPLACING SOLAR SENSOR Remove solar sensor (1) from instrument panel trim. Detach plug connector. Remove solar sensor. Microsoft Tuesday, February 16, 2010 11:05:59 AM Page 28 © 2005 Mitchell Repair Information Company, LLC.
2006 MINI Cooper 2002-05 HVAC Air Conditioning & Heating Systems - Repair Instructions - Cooper (1.6L) R50/W10 & Cooper S Fig. 28: Removing Solar Sensor Courtesy of BMW OF NORTH AMERICA, INC. NOZZLE AND OUTLETS 64 22 135 REMOVING AND INSTALLING/REPLACING LEFT (OR RIGHT) FRESH AIR GRILL Necessary Preliminary Tasks: Remove decorative trim for instrument panel (left or right).
2006 MINI Cooper 2002-05 HVAC Air Conditioning & Heating Systems - Repair Instructions - Cooper (1.6L) R50/W10 & Cooper S Fig. 29: Removing Air Vent From Air Duct Courtesy of BMW OF NORTH AMERICA, INC. 64 22 136 REMOVING AND INSTALLING/REPLACING RIGHT FRESH-AIR GRILLE Refer to removing and installing/replacing left fresh-air grille, see 64 22 135 REMOVING AND INSTALLING/REPLACING LEFT (OR RIGHT) FRESH AIR GRILL.
2006 MINI Cooper 2002-05 HVAC Air Conditioning & Heating Systems - Repair Instructions - Cooper (1.6L) R50/W10 & Cooper S Rims must snap into place correctly. Fig. 30: Identifying Trim Ring Of Air Vent Courtesy of BMW OF NORTH AMERICA, INC. Release clips (1) and remove air vent. Microsoft Tuesday, February 16, 2010 11:05:59 AM Page 31 © 2005 Mitchell Repair Information Company, LLC.
2006 MINI Cooper 2002-05 HVAC Air Conditioning & Heating Systems - Repair Instructions - Cooper (1.6L) R50/W10 & Cooper S Fig. 31: Removing Air Vent Clips Courtesy of BMW OF NORTH AMERICA, INC. MICROFILTER 64 31 009 REPLACING MICROFILTER FOR INTERIOR VENTILATION If necessary, release screws (1) on cover (2). Microsoft Tuesday, February 16, 2010 11:05:59 AM Page 32 © 2005 Mitchell Repair Information Company, LLC.
2006 MINI Cooper 2002-05 HVAC Air Conditioning & Heating Systems - Repair Instructions - Cooper (1.6L) R50/W10 & Cooper S Fig. 32: Removing Cover Retaining Screws Courtesy of BMW OF NORTH AMERICA, INC. Release catches (1) and remove cover (2). Installation: Ensure cover (2) is correctly seated. Microsoft Tuesday, February 16, 2010 11:05:59 AM Page 33 © 2005 Mitchell Repair Information Company, LLC.
2006 MINI Cooper 2002-05 HVAC Air Conditioning & Heating Systems - Repair Instructions - Cooper (1.6L) R50/W10 & Cooper S Fig. 33: Installing Cover Courtesy of BMW OF NORTH AMERICA, INC. Pull microfilter for interior ventilation downwards out of guides. Installation: Version: microfilter for interior ventilation with all-round rib: Feed in rib between guide (1) and guide (2) in area (A). Make sure filter is correctly seated.
2006 MINI Cooper 2002-05 HVAC Air Conditioning & Heating Systems - Repair Instructions - Cooper (1.6L) R50/W10 & Cooper S Fig. 34: Locating Guides For Microfilter Courtesy of BMW OF NORTH AMERICA, INC. AIR CONDITIONING SYSTEM 64 50 ... AIR CONDITIONER TEST (R 134A) Before A/C Efficiency Test, Satisfy Following Conditions : 1. Provide a MoDiC or DIS. Safeguard electrical system integrity by checking the fault memory (no faults in the fault memory). 2. Provide a thermometer with separate gauge. 3.
2006 MINI Cooper 2002-05 HVAC Air Conditioning & Heating Systems - Repair Instructions - Cooper (1.6L) R50/W10 & Cooper S Re 2: Position a thermometer with a separate gauge approx. 5 cm below the roofliner at the height of the B-pillar. Lay gauge outwards out of vehicle interior. Re 3: Heating up vehicle interior: A/C button is not activated during heating up. Close all windows and doors. Set recirculated air mode. Select air distribution mode for footwell and defrosting.
2006 MINI Cooper 2002-05 HVAC Air Conditioning & Heating Systems - Repair Instructions - Cooper (1.6L) R50/W10 & Cooper S If leaks not to be localized are already identified during evacuation, the A/C system must nevertheless be filled. Refer to 64 50 009 DRAWING OFF, EVACUATING AND FILLING A/C SYSTEM (R 134A). Then test for leaks with leak tester device. NOTE: Refrigerant is heavier than air. Therefore always conduct the leak test below the lines and components to be tested.
2006 MINI Cooper 2002-05 HVAC Air Conditioning & Heating Systems - Repair Instructions - Cooper (1.6L) R50/W10 & Cooper S working on the A/C system and the best possible evacuation (at least 30 minutes dehumidification from refrigerant circuit) before each filling of the A/C system. R 134a absorbs moisture very easily. Therefore seal off opened pipes, condenser, evaporator, compressor and drier bottle immediately with plugs.
2006 MINI Cooper 2002-05 HVAC Air Conditioning & Heating Systems - Repair Instructions - Cooper (1.6L) R50/W10 & Cooper S observed: Do not store in the vicinity of flames, heat sources or strongly oxidizing materials. Suitable extinguishants: carbon dioxide (CO2 ), dry extinguishant, foam. Recycling: Dispose of drawn-off refrigerant oil as hazardous waste. Observe country-specific waste-disposal regulations. Absorb escaping refrigerant oil with fluid-binding material.
2006 MINI Cooper 2002-05 HVAC Air Conditioning & Heating Systems - Repair Instructions - Cooper (1.6L) R50/W10 & Cooper S Recycling: Dispose of drawn-off refrigerant oil as hazardous waste. Observe country-specific waste-disposal regulations. Instructions For Evacuating Off A/C System: The evacuation procedure removes all traces of ambient air, water vapor and any other gases present from the A/C system. This enables subsequent system filling with refrigerant.
2006 MINI Cooper 2002-05 HVAC Air Conditioning & Heating Systems - Repair Instructions - Cooper (1.6L) R50/W10 & Cooper S Fig. 35: Identifying Rating Plate Courtesy of BMW OF NORTH AMERICA, INC. A/C HOUSING/EVAP., SWITCHING ELEMENTS 64 51 522 REMOVING AND INSTALLING OR REPLACING EXPANSION VALVE Necessary Preliminary Tasks: Draw off refrigerant from A/C system W10 only: Remove battery container. Refer to 64 50 009 DRAWING OFF, EVACUATING AND FILLING A/C SYSTEM (R 134A).
2006 MINI Cooper 2002-05 HVAC Air Conditioning & Heating Systems - Repair Instructions - Cooper (1.6L) R50/W10 & Cooper S Installation: Replace O-rings. Fig. 36: Detaching Refrigerant Lines Courtesy of BMW OF NORTH AMERICA, INC. Release screws (1), tightening torque, refer to 64 11 5AZ in HEATING AND AIR CONDITIONING TIGHTENING TORQUES - COOPER (1.6L) R50/W10 . Remove adapter block. Installation: Replace O-rings.
2006 MINI Cooper 2002-05 HVAC Air Conditioning & Heating Systems - Repair Instructions - Cooper (1.6L) R50/W10 & Cooper S Fig. 37: Locating Adapter Block Retaining Screws Courtesy of BMW OF NORTH AMERICA, INC. Release screws (1). Remove cover (2). Microsoft Tuesday, February 16, 2010 11:05:59 AM Page 43 © 2005 Mitchell Repair Information Company, LLC.
2006 MINI Cooper 2002-05 HVAC Air Conditioning & Heating Systems - Repair Instructions - Cooper (1.6L) R50/W10 & Cooper S Fig. 38: Identifying Cover Retaining Screws Courtesy of BMW OF NORTH AMERICA, INC. Detach expansion valve in direction of arrow (1) to engine compartment and remove in direction of arrow (2). Installation: Replace O-rings. Microsoft Tuesday, February 16, 2010 11:05:59 AM Page 44 © 2005 Mitchell Repair Information Company, LLC.
2006 MINI Cooper 2002-05 HVAC Air Conditioning & Heating Systems - Repair Instructions - Cooper (1.6L) R50/W10 & Cooper S Fig. 39: Detaching Expansion Valve Courtesy of BMW OF NORTH AMERICA, INC. 64 51 590 REMOVING AND INSTALLING/REPLACING EVAPORATOR NOTE: The heater is removed. Refer to 64 11 200 REMOVING AND INSTALLING OR REPLACING HEATER. Necessary Preliminary Tasks: Remove evaporator temperature sensor. Refer to 64 11 932 REPLACING EVAPORATOR TEMPERATURE SENSOR (IHKR/IHKA).
2006 MINI Cooper 2002-05 HVAC Air Conditioning & Heating Systems - Repair Instructions - Cooper (1.6L) R50/W10 & Cooper S Fig. 40: Identifying Wiring Harness From Air Intake Duct Courtesy of BMW OF NORTH AMERICA, INC. IHKA Only: Remove servodrive for temperature control. Refer in 64 11 861 REPLACING SERVODRIVE FOR TEMPERATURE CONTROL (IHKA). Release screws (1). Release clip (2). Remove air intake duct (3).
2006 MINI Cooper 2002-05 HVAC Air Conditioning & Heating Systems - Repair Instructions - Cooper (1.6L) R50/W10 & Cooper S Fig. 41: Locating Air Intake Duct Courtesy of BMW OF NORTH AMERICA, INC. Unfasten plug connection (1) and disconnect. Disconnect plug (2) for heater wiring harness from housing. Microsoft Tuesday, February 16, 2010 11:05:59 AM Page 47 © 2005 Mitchell Repair Information Company, LLC.
2006 MINI Cooper 2002-05 HVAC Air Conditioning & Heating Systems - Repair Instructions - Cooper (1.6L) R50/W10 & Cooper S Fig. 42: Identifying Plug Connection For Heater Wiring Harness Courtesy of BMW OF NORTH AMERICA, INC. Disengage air distribution actuating rod (1) from flap control (3). Disengage air distribution actuating rod (2) from flap control (3). Microsoft Tuesday, February 16, 2010 11:05:59 AM Page 48 © 2005 Mitchell Repair Information Company, LLC.
2006 MINI Cooper 2002-05 HVAC Air Conditioning & Heating Systems - Repair Instructions - Cooper (1.6L) R50/W10 & Cooper S Fig. 43: View Of Air Distribution Actuating Rod Courtesy of BMW OF NORTH AMERICA, INC. IHKA Only: Detach plug connection (1) from servomotor/air distribution. Detach wiring harness (2) from clip. Release screws (3). Microsoft Tuesday, February 16, 2010 11:05:59 AM Page 49 © 2005 Mitchell Repair Information Company, LLC.
2006 MINI Cooper 2002-05 HVAC Air Conditioning & Heating Systems - Repair Instructions - Cooper (1.6L) R50/W10 & Cooper S Fig. 44: Identifying Servomotor/Air Distribution Courtesy of BMW OF NORTH AMERICA, INC. Release screws (1). Microsoft Tuesday, February 16, 2010 11:05:59 AM Page 50 © 2005 Mitchell Repair Information Company, LLC.
2006 MINI Cooper 2002-05 HVAC Air Conditioning & Heating Systems - Repair Instructions - Cooper (1.6L) R50/W10 & Cooper S Fig. 45: Locating Retaining Screws Courtesy of BMW OF NORTH AMERICA, INC. Release screws (1). Microsoft Tuesday, February 16, 2010 11:05:59 AM Page 51 © 2005 Mitchell Repair Information Company, LLC.
2006 MINI Cooper 2002-05 HVAC Air Conditioning & Heating Systems - Repair Instructions - Cooper (1.6L) R50/W10 & Cooper S Fig. 46: View Of Retaining Screws Courtesy of BMW OF NORTH AMERICA, INC. NOTE: For purposes of clarity, illustration shows heat exchanger removed. Raise upper half of housing to expose connecting rod/air flap (1). Disengage connecting rod from air flap (2). Microsoft Tuesday, February 16, 2010 11:05:59 AM Page 52 © 2005 Mitchell Repair Information Company, LLC.
2006 MINI Cooper 2002-05 HVAC Air Conditioning & Heating Systems - Repair Instructions - Cooper (1.6L) R50/W10 & Cooper S Fig. 47: Locating Connecting Rod/Air Flap Courtesy of BMW OF NORTH AMERICA, INC. Remove evaporator (1) from lower half of housing (2). Replacement: Remove expansion valve from evaporator (1). Refer to 64 51 522 REMOVING AND INSTALLING OR REPLACING EXPANSION VALVE. Microsoft Tuesday, February 16, 2010 11:05:59 AM Page 53 © 2005 Mitchell Repair Information Company, LLC.
2006 MINI Cooper 2002-05 HVAC Air Conditioning & Heating Systems - Repair Instructions - Cooper (1.6L) R50/W10 & Cooper S Fig. 48: Removing Expansion Valve From Evaporator Courtesy of BMW OF NORTH AMERICA, INC. COMPRESSOR 64 52 ... INSTRUCTIONS FOR COMPRESSOR REPLACEMENT IMPORTANT: Compressors with plastic belt pulleys: Avoid impacts/knocks to plastic belt pulley (caused by tools, contact with base). Return faulty compressors in their original packaging only.
2006 MINI Cooper 2002-05 HVAC Air Conditioning & Heating Systems - Repair Instructions - Cooper (1.6L) R50/W10 & Cooper S Set all air vents in instrument cluster to "OPEN". Start engine and let it stabilize at idle speed. Set blower output to min. 75% of max. blower output. Switch on A/C system and run for at least 2 minutes at idle speed (risk of damage at higher speed!).
2006 MINI Cooper 2002-05 HVAC Air Conditioning & Heating Systems - Repair Instructions - Cooper (1.6L) R50/W10 & Cooper S Transfer the refrigerant oil remaining in the previous compressor via the filler plug completely into a measuring container. Fig. 50: Transferring Refrigerant Oil Into Measuring Container Courtesy of BMW OF NORTH AMERICA, INC. Measure the amount of refrigerant oil collected from the previous compressor.
2006 MINI Cooper 2002-05 HVAC Air Conditioning & Heating Systems - Repair Instructions - Cooper (1.6L) R50/W10 & Cooper S Fig. 51: Measuring Amount Of Refrigerant Oil Courtesy of BMW OF NORTH AMERICA, INC. Depending on its design, the new compressor is filled at the factory with 120 to 200 g refrigerant oil. Open filler plug and pour entire contents of compressor into a clean container. Installation: If necessary, replace gasket.
2006 MINI Cooper 2002-05 HVAC Air Conditioning & Heating Systems - Repair Instructions - Cooper (1.6L) R50/W10 & Cooper S Fig. 52: Identifying Refrigerant Oil Courtesy of BMW OF NORTH AMERICA, INC. From this refrigerant oil, pour the same amount (as drained from the previous compressor) + 10 g extra into a clean measuring container and pour again into the new compressor.
2006 MINI Cooper 2002-05 HVAC Air Conditioning & Heating Systems - Repair Instructions - Cooper (1.6L) R50/W10 & Cooper S Fig. 53: Measuring Refrigerant Oil Courtesy of BMW OF NORTH AMERICA, INC. The refrigerant oil drawn off from the oil separator of the service station and from the previous compressor must not be reused and must be correctly disposed of. Microsoft Tuesday, February 16, 2010 11:05:59 AM Page 59 © 2005 Mitchell Repair Information Company, LLC.
2006 MINI Cooper 2002-05 HVAC Air Conditioning & Heating Systems - Repair Instructions - Cooper (1.6L) R50/W10 & Cooper S Fig. 54: Identifying Correct Disposal Of Refrigerant Oil Courtesy of BMW OF NORTH AMERICA, INC. After installing the new compressor, it is essential before filling the A/C system to pour the same amount of the previously drawn off refrigerant oil into the system again, refer to 64 50 009 DRAWING OFF, EVACUATING AND FILLING A/C SYSTEM (R 134A).
2006 MINI Cooper 2002-05 HVAC Air Conditioning & Heating Systems - Repair Instructions - Cooper (1.6L) R50/W10 & Cooper S Fig. 55: Identifying Oil Separator Courtesy of BMW OF NORTH AMERICA, INC. Installation: If A/C system is opened for more than 24 hours: Replace drier bottle/drier insert. Refer to 64 53 510 REMOVING AND INSTALLING / REPLACING DRIER BOTTLE FOR AIR CONDITIONER.
2006 MINI Cooper 2002-05 HVAC Air Conditioning & Heating Systems - Repair Instructions - Cooper (1.6L) R50/W10 & Cooper S Disconnect battery negative lead. Refer to 12 00 DISCONNECTING AND CONNECTING BATTERY W10, W11 Only: Remove front underbody protection. Refer to 51 47 490 REMOVING AND INSTALLING/REPLACING FRONT UNDERBODY PROTECTION (ENGINE) . W10, W11 Only: Remove condenser for A/C system. Refer to 64 53 551 REMOVING AND INSTALLING/REPLACING CONDENSER FOR A/C SYSTEM (W10, W11).
2006 MINI Cooper 2002-05 HVAC Air Conditioning & Heating Systems - Repair Instructions - Cooper (1.6L) R50/W10 & Cooper S Detach radiator from lower mounts to expose A/C compressor and lines. Fig. 57: Identifying Guide Pins For Radiator Mounting Courtesy of BMW OF NORTH AMERICA, INC. Release screw (1) for pressure line, tightening torque, refer to 64 52 2AZ in HEATING AND AIR CONDITIONING - TIGHTENING TORQUES - COOPER (1.6L) R50/W10 . Disconnect pressure line.
2006 MINI Cooper 2002-05 HVAC Air Conditioning & Heating Systems - Repair Instructions - Cooper (1.6L) R50/W10 & Cooper S Fig. 58: View Of Pressure Line Retaining Screw Courtesy of BMW OF NORTH AMERICA, INC. Disconnect plug connection (1) for compressor clutch. Release wiring harness retaining clip (2) from bracket. Release bolt (3) at top right on A/C compressor, tightening torque, refer to 64 52 1AZ in HEATING AND AIR CONDITIONING - TIGHTENING TORQUES - COOPER (1.6L) R50/W10 .
2006 MINI Cooper 2002-05 HVAC Air Conditioning & Heating Systems - Repair Instructions - Cooper (1.6L) R50/W10 & Cooper S Fig. 59: Identifying Compressor Clutch Plug Connection Courtesy of BMW OF NORTH AMERICA, INC. Release bolt (1) at top left on A/C compressor, tightening torque, refer to 64 52 1AZ in HEATING AND AIR CONDITIONING - TIGHTENING TORQUES - COOPER (1.6L) R50/W10 . Microsoft Tuesday, February 16, 2010 11:05:59 AM Page 65 © 2005 Mitchell Repair Information Company, LLC.
2006 MINI Cooper 2002-05 HVAC Air Conditioning & Heating Systems - Repair Instructions - Cooper (1.6L) R50/W10 & Cooper S Fig. 60: Locating Bolt On A/C Compressor Courtesy of BMW OF NORTH AMERICA, INC. NOTE: Secure A/C compressor against falling out. Release lower retaining bolt (1) on A/C compressor, tightening torque, refer to 64 52 1AZ in HEATING AND AIR CONDITIONING - TIGHTENING TORQUES - COOPER (1.6L) R50/W10 . Remove A/C compressor.
2006 MINI Cooper 2002-05 HVAC Air Conditioning & Heating Systems - Repair Instructions - Cooper (1.6L) R50/W10 & Cooper S Fig. 61: Removing A/C Compressor Courtesy of BMW OF NORTH AMERICA, INC. Installation: If air conditioner has been opened for more than 24 hours, drier bottle must be replaced. Refer to 64 53 510 REMOVING AND INSTALLING / REPLACING DRIER BOTTLE FOR AIR CONDITIONER. Evacuate and fill A/C system. Refer to 64 50 009 DRAWING OFF, EVACUATING AND FILLING A/C SYSTEM (R 134A).
2006 MINI Cooper 2002-05 HVAC Air Conditioning & Heating Systems - Repair Instructions - Cooper (1.6L) R50/W10 & Cooper S 64 53 510 REMOVING AND INSTALLING / REPLACING DRIER BOTTLE FOR AIR CONDITIONER NOTE: A/C system is drawn off. Refer to 64 50 009 DRAWING OFF, EVACUATING AND FILLING A/C SYSTEM (R 134A). Follow instructions on replacing drier bottle. Refer to 64 53 ... NOTES ON REPLACING DRIER BOTTLE OR DRIER INSERT. Release screw (1). Release screws (2).
2006 MINI Cooper 2002-05 HVAC Air Conditioning & Heating Systems - Repair Instructions - Cooper (1.6L) R50/W10 & Cooper S 64 53 520 REPLACING SAFETY PRESSURE SWITCH NOTE: A/C system is drawn off. Refer to 64 50 009 DRAWING OFF, EVACUATING AND FILLING A/C SYSTEM (R 134A). Necessary Preliminary Tasks: W10 Only: Remove battery container. Refer to 61 21 100 REMOVING AND INSTALLING/REPLACING BATTERY CONTAINER . Unfasten plug connection (1) and disconnect.
2006 MINI Cooper 2002-05 HVAC Air Conditioning & Heating Systems - Repair Instructions - Cooper (1.6L) R50/W10 & Cooper S 64 53 551 REMOVING AND INSTALLING/REPLACING CONDENSER FOR A/C SYSTEM (W10, W11) NOTE: A/C system is drawn off. Refer to 64 50 009 DRAWING OFF, EVACUATING AND FILLING A/C SYSTEM (R 134A). Necessary Preliminary Tasks: Remove carrier for bumper trim at front. Refer to 51 11 050 REMOVING AND INSTALLING/REPLACING CARRIER FOR FRONT BUMPER TRIM .
2006 MINI Cooper 2002-05 HVAC Air Conditioning & Heating Systems - Repair Instructions - Cooper (1.6L) R50/W10 & Cooper S Fig. 64: View Of Condenser For A/C System Courtesy of BMW OF NORTH AMERICA, INC. Installation: If air conditioner has been opened for more than 24 hours, drier bottle must be replaced. Refer to 64 53 510 REMOVING AND INSTALLING / REPLACING DRIER BOTTLE FOR AIR CONDITIONER. Evacuate and fill A/C system. Refer to 64 50 009 DRAWING OFF, EVACUATING AND FILLING A/C SYSTEM (R 134A).
