MCS thermostat removal/install w/ JCW airbox
 

MINI COOPER S (w/ JCW air box)
Thermostat & housing removal & installation

JCW AIR FILTER BOX COVER REMOVAL
· 6mm, loosen air inlet hose clamp
· Lift hood seal up and out of way
· Untuck battery terminal cables from side of box, may need to remove ziptie
· Disconnect vacuum line at front of air box
· #25 torx driver, loosen (2) screws at front of air box
· Push air box back (about ½”), lift up, disconnect two vacuum lines, unclip vacuum switch and set aside, remove air box

DISCONNECT COMPUTER HARNESS CONNECTIONS
· 10mm socket, remove bolt holding computer harness cable
· Remove computer box cover
· Slide t-handle connectors forward and rearward, respectively and lift up on plugs, set aside

AIRSCOOP REMOVAL
· Using screwdriver, disconnect air tube to air box bottom (push down on tab)
· Wiggle air scoop up and out (rear tube up, lift up and get drain out, then pry clockwise to remove front of scoop – install reverse order)

AIRBOX BOTTOM REMOVAL
· Lift up 1-2”, box should be clear to remove (you’ll see 2 rubber grommets on the bottom that fit over two ½” pegs)

UNDO WIRING CLIPS AROUND T-STAT HOUSING
· Using 3mm allen wrench, remove (2) screws holding down wiring plug directly about t-stat housing
· Disconnect plug and set aside

DISCONNECT IGNITION COIL WIRE
· Slide red locking clip LEFT, disconnect wire from coil
· Lift up on two retaining clips along cable, set aside

REMOVE LOWER ENGINE SHIELD
· Using Phillips screwdriver and 10mm socket, remove (2) screws and (3) bolts hold lower engine shield
· Slide shield reward, set aside

DRAIN COOLANT
***allow engine to cool sufficiently before removing***
· Place catch pan below lower radiator hose
· Using channel locks, loosen hose clamp
· Remove lower radiator hose (may need to use small screwdriver to free hose from fitting, be careful not to puncture hose with screwdriver)
· Allow coolant to drain
· Reattach lower radiator hose & clamp

REINSTALL LOWER ENGINE SHIELD
· Slide panel forward into place, align rear screw holes
· Using Phillips screwdriver, reinstall (2) rear screws
· Using 10mm socket, reinstall (3) front bolts (this order will allow for proper fit alignment of panel)

T-STAT HOUSING REMOVAL / INSTALLATION
· Using 10mm socket, remove (3) housing bolts
· Remove t-stat housing
· Clean up engine block surface (I used some 400grit sand paper)
· Properly align t-stat and gasket in old/new housing (spring goes toward engine block)
· Reinstall housing AND metal bracket
· Torque appropriately (can’t remember value)

REINSTALL REMAINING ITEMS IN REVERSE ORDER