Fixed!!
Hey all
Had a similar problem to some others here - the fan quit and the mini overheated. Tracked it down to a fault in the relay, as mentioned on previous posts.
Mini (BMW) don't sell the relay on it's own - just the whole thermo fan unit. I did the following...
Checked the fuse for the Fan - all good. swapped the relay for the identical Battery Fan relay in the fuse box - no change, and switched it back.
Used a motorbike indicator to verify that power was getting as far as the plug connection, on the front left of the car, very near the hood release lever. All good.
This is serious now...
Download the Workshop Manual for the Cooper S - US$16.99 from emanuals, and an awesome product. Endorsed ;-)
Pulled the front bumper off - very easy. 10min?
Manual said to drain the coolant to pull the radiator, but I didn't need to.
Pulled the front aluminium crossbeam off - 5 x 13mm bolts and nuts each side - done.
two 10mm (?) socket bolts released the aircon condensor (the little radiator). Lowered the left corner to the ground gently and tied the left corner loosely so it would not fall over, therein damaging the hoses that it connects too.
Released the two plastic catches that hold the radiator in (noting that if you remove or unclick the air intake scoop from the plastic surround above the radiator, it is MUCH easir to get at the back of the three pronged bayonet on the car's left hand side!
removed the upper radiator hose only, (no coolant was sacrificed in the repair of the vehicle ;-)
Release all of the wiring harness from the previously mentioned plug fitting, all the way through to the thermo fan.
Tip the radiator towards your thigh then reach down and release the plastic hooks down the bottom, and, quite simply, slide the thermo fan out, freeing the electrical harness from fowling as you go (wifey very handy for this task).
Once release I cut the wires from the relay box to the fan motor at a point where I could easily rejoin them later with bullet fittings. Hooked the fan motor up to a battery pack (keep your finger clear!!) All good, works a treat.
two screws released the relay cover. The relay has 40Amp and a diagram on the back to show how the two small wires (the small plug you disconnected earlier) provide power to switch the big wire (big Plug) power supply between hi and low.
Raced down to the auto warehouse (AutoBarn), found a suitable 5Pin, 40Amp that would switch appropriately, (same diagram on the relay - easy), raced back and pushed it into the same relay receiver).
Tested - all good.
everything else was just the reassembly, electrical, heat shrink and zip ties.
Tip, tricky getting the locator spacers (they look like thick, domed washers on a bolt that fits into a hole on the cross member) to fit the cross member on reassembly. They are a loose fit and like to 'hang off the bolt. It will make sense when you see it. Get someone to hold one side on, in the right place (easily done), put the loop of a wire around the domed spacer and hold the two ends of the wire vertically above the cross member as you ease it into position. A vertical jiggle (technical term) of the wire will allow the spacer to find it's mark, the member slides on and you release one end of the wire, pulling free and start securing the bolts again.
$700 job cost $10.99. Parts required, Work Shop Manual, Phillips head screwdriver, socket set with 8mm, 10mm and 13mm sockets, vice grips (for the clip on the upper radiator hose, makes it easy), a bit of wire and a 40Amp , 5Pin Relay based on the one you 'pull'.
Takes about three hours with 4 beers, 2 hours with a coffee instead :biggrin:
Hope it helps. let me know if you have questions.