Just replaced the Dayco friction wheel on my partners 2008 Cooper. Dayco have changed the plug and socket arrangement with the new unit, therefore you will need to buy a new plug housing (12527543313). The procedure for replacing the existing plug housing with the new one is straight forwards.
Before we get onto the topic of changing the plug housing, I have added a number of articles covering the associated wiring, calling system operation and replacing the friction wheel, see below. This should provide enough information to help repair/replace items and diagnose issues.
Back tot he plug housing, first, unclip the lead from the engine so that you can work on it from above. With the lead unclipped remove the ‘u’ shaped plastic sheaf which you will not use again. Next, with a small bladed screwdriver pry the plastic retaining tab that holds the orange and white wires in the existing plug. Note their orientation which is as follows: white wire is at the flat edge side of the existing plug housing, marked as No. 2 and the orange wire which is at the round edge side of the existing plug housing, marked as No. 1.
With the two wires removed from the existing plug, place them into the new plug housing in the same orientation. That is, white wire goes into the hole on the flat side and the orange wire goes into the hole on the round side of the new plug housing. Again, this is No.2 and No. 1 respectively. Push the flap down on the new plug housing to hold the connectors in place and that’s it. You can put some tape round the wires and plug to stop water ingress or use shrink wrap.
Image 1: Old plug housing, both wires in their correct orientation. - note flat edge.
![Image]()
Image 2: Old plug housing, while wire removed - note flat edge.
![Image]()
Image 3: Old plug housing, face of plug with flat edge.
![Image]()
Image 4: New plug housing, while wire on flat edge side of housing.
![Image]()
.
Before we get onto the topic of changing the plug housing, I have added a number of articles covering the associated wiring, calling system operation and replacing the friction wheel, see below. This should provide enough information to help repair/replace items and diagnose issues.
Back tot he plug housing, first, unclip the lead from the engine so that you can work on it from above. With the lead unclipped remove the ‘u’ shaped plastic sheaf which you will not use again. Next, with a small bladed screwdriver pry the plastic retaining tab that holds the orange and white wires in the existing plug. Note their orientation which is as follows: white wire is at the flat edge side of the existing plug housing, marked as No. 2 and the orange wire which is at the round edge side of the existing plug housing, marked as No. 1.
With the two wires removed from the existing plug, place them into the new plug housing in the same orientation. That is, white wire goes into the hole on the flat side and the orange wire goes into the hole on the round side of the new plug housing. Again, this is No.2 and No. 1 respectively. Push the flap down on the new plug housing to hold the connectors in place and that’s it. You can put some tape round the wires and plug to stop water ingress or use shrink wrap.
Image 1: Old plug housing, both wires in their correct orientation. - note flat edge.
Image 2: Old plug housing, while wire removed - note flat edge.
Image 3: Old plug housing, face of plug with flat edge.
Image 4: New plug housing, while wire on flat edge side of housing.
