MINI Cooper Haynes Manual - Sample Page Of

1-22
Chapter 1 Tune-up and routine maintenance
18.1 Press-in the buttons to disconnect the hoses from the tank
vent valve
16 Engine management system
check
1
This check is part of the manufacturer’s
maintenance schedule, and involves testing
the engine management system using special
dedicated test equipment. Such testing will
allow the test equipment to read any Diagnostic Trouble Codes stored in the electronic control unit memory.
2
Unless a fault is suspected, this test is
not essential, although it should be noted that
it is recommended by the manufacturers.
3
If access to suitable test equipment is
not possible, make a thorough check of all
ignition, fuel and emission control system
components, hoses and wiring for security
and obvious signs of damage. Further details
of the fuel system, emission control system,
ignition system and engine management system can be found in Chapters 4, 5 and 6.
17 Road test
Instruments and electrical
equipment
1
Check the operation of all instruments
and electrical equipment.
2
Make sure that all instruments read correctly, and switch on all electrical equipment
in turn, to check that it functions properly.
18.5a Engage a 3/8-inch drive ratchet with the square hole in the
drivebelt tensioner arm
7
Listen for any unusual noises from the
engine, clutch and transmission.
8
Make sure that the engine runs smoothly
when idling, and that there is no hesitation
when accelerating.
9
Check that the clutch action is smooth
and progressive, that the drive is taken up
smoothly, and that the pedal travel is not
excessive. Also listen for any noises when the
clutch pedal is depressed.
10 Check that all gears can be engaged
smoothly without noise, and that the gear
lever action is smooth and not abnormally
vague or notchy.
cal connector from the tank vent valve at the
right-hand end of the engine (see illustration).
2
Remove the right-hand front engine
mount retaining bolt, and move the tank vent
valve and bracket to one side.
3
Loosen the right-hand wheel bolts, then
raise the front of the vehicle and support
securely on jackstands. Remove the wheel,
then remove the screws, pry out the plastic
rivets and remove the wheelwell liner.
4
Remove the screws and remove the
engine undershield.
Braking system
Refer to illustrations 18.5a, 18.5b, 18.6
and 18.7
5
Insert a 3/8” drive ratchet into the square
hole in the auxiliary belt tensioner arm (see
illustrations).
6
Using the ratchet, rotate the tensioner
arm counterclockwise, until a 4 mm diameter rod/bolt approximately 30 mm long can
be inserted into the hole in the casing to
lock the tensioner arm in place (see illustration). Access to the locking hole is restricted.
Attaching a length of welding rod to the end
to the rod/bolt may allow greater control when
inserting the locking rod/bolt. Slide the belt
from the pulleys. If the belt is to be re-used,
mark its direction of rotation, and ensure it’s
11 Make sure that the vehicle does not pull
to one side when braking, and that the wheels
do not lock when braking hard.
12 Check that there is no vibration through
the steering when braking (if there is, suspect
disc runout; see Chapter 9).
18 Drivebelt replacement
Mk I models
Refer to illustration 18.1
1
Open the hood, depress the retaining
clips and disconnect both hoses and the electri-
Steering and suspension
3
Check for any abnormalities in the steering, suspension, handling or road feel.
4
Drive the vehicle, and check that there
are no unusual vibrations or noises.
5
Check that the steering feels positive,
with no excessive sloppiness, or roughness,
and check for any suspension noises when
cornering and driving over bumps.
Drivetrain
6
Check the performance of the engine,
clutch, transmission and driveaxles.
18.5b Drivebelt
tensioner arm square
hole (engine removed
for clarity)
Cooper
Chapter 1 Tune-up and routine maintenance
1-23
18.7 Drivebelt routing - 2006
and earlier Cooper models
1
2
3
4
5
Alternator
Water pump
Air conditioning
compressor
Crankshaft pulley
Tensioner
18.6 Lock the tensioner arm in place
using a 4 mm bolt. We attached a length
of welding rod to the bolt to give greater
control in the restricted access
installed in the same direction of travel.
7
Install the drivebelt around the pulleys, hold the arm in place using the ratchet,
then withdraw the locking rod and allow the
tensioner to rotate and tension the belt (see
illustration).
18.9a Drivebelt tensioner tool Cooper S models
MINI Cooper S
Refer to illustrations 18.9a, 18.9b, 18.9c,
18.9d, 18.10 and 18.12
8
Pull the engine oil level dipstick from the
guide tube.
9
In order to relieve the tension on the
belt, a MINI special tool (11 8 410) is available to compress the tensioner spring. In the
absence of this tool, fabricate a home-made
equivalent using two lengths flat steel bar.
Drill a 20 mm hole and bolt the two lengths
together as shown. Fit the hole in the tool
over the tensioner arm pivot bolt and lever
against the lower edge of the tensioner arm
(see illustrations). Take great care to ensure
the lower end of the tool doesn’t slip when
compressing the spring.
18.9b The tool should look like this
18.9c Locate the tool over the tensioner
arm pivot bolt head . . .
18.9d . . . ensure the lower end of the tool
doesn’t slip from the bottom of the arm