North American Motoring

Mini Cooper 2001-2006: How to Replace Cooling Fan

The cooling fan moves air past the radiator to lower the engine coolant temperature. Without it, the engine will overheat at speeds below 40 miles per hour. Replacement can be done at home with a basic tool kit and an afternoon.

By Weston Chadwick - June 29, 2016
Contributors: Steve

This article applies to the Mini Cooper R50 and R53 (2001-2006).

The cooling fan is controlled by the engine computer and changes speed based on the engine coolants temperature. This temperature must remain between 180 to 220 degrees for normal operation. Cooling fans can become problematic if they fail to change speed, stop rotating, or have cracked fins and blades. It's a good idea to check for battery voltage at the cooling fan connector before replacement with a digital multimeter. Wait for the coolant temperature to reach halfway on the gauge, then quickly make you measurement, not letting the engine overheat. If your Mini has only one cooling fan, you can instead turn your A/C to the max setting. If your Mini's fan is dead, it's time to replace it.

Mini Cooper 2001-2006: How to Replace Cooling Fan

Materials Needed

  • Wheel chocks
  • Floor jack
  • 2 jack stands
  • Phillips head screwdriver
  • 1/4" and 3/8" ratchet
  • 6" extension
  • 8mm socket
  • 13mm socket
  • T30 Torx driver
  • Pry bar or large flat blade screwdriver
  • Diagonal cutters or clip removal tool

Removal of the Aero kit bumper may have some differences.

Step 1 – Lift the front onto jack stands

  • Set the parking brake and place wheel chocks around the back wheels.
  • Use floor jack to raise the vehicle until a jack stand can be placed beneath.
  • You may want to jack at the frame with the floor jack, then place the jack stand below the pinch weld or vice versa. Use lift blocks if available.
mini cooper r50 r53 radiator cooling fan how to remove replace DIY change
Figure 1. Placing the jack stand onto a lift block.

Step 2 – Remove the front bumper

Open the hood and turn the wheel full lock to one side.

Remove the 8-10 screws at the bottom of the front bumper near the grille using a Phillips head screwdriver.

Remove the two 8mm bolts in each wheel well area near the headlights. You can reach these bolts from the bottom.

Remove the two T30 Torx screws near the outside edge of the front crossmember/crash bar.

To make disconnecting the turn signals, temperature sensor and fog lights easier, place a small platform near the front bumper to rest it on once it is disconnected from the body. Don't let the bumper hang by the wires! Lift the bumper upwards and away to disconnect the two clips at the top.

  • mini cooper r50 r53 radiator cooling fan how to remove replace DIY change
    Figure 2. The temp sensor location.
  • mini cooper r50 r53 radiator cooling fan how to remove replace DIY change
    Figure 3. Removing the 8mm bolts and Torx screws.

Step 3 – Remove the crash bar

There are ten 13mm bolts holding the crash bar to the frame. Use Figure 4 to locate and remove these bolts, then carefully detach the crash bar not entangling it in wiring. You'll need an extension with your socket.

mini cooper r50 r53 radiator cooling fan how to remove replace DIY change
Figure 4. Locating five of the bolts on the passenger side of the crash bar.

Step 4 – Remove the radiator push pins

The push pins are located at the upper corners of the radiator. Use diagonal cutter or a clip removal tool to separate the inner pin from the outer clip, then remove the outer clip.

mini cooper r50 r53 radiator cooling fan how to remove replace DIY change
Figure 5. One of the radiator push pins circled in blue.

Step 5 – Disconnect top radiator hose from the radiator

  • Don't remove the coolant hose with heat/pressure left in the cooling system!
  • You can use pliers designed to squeeze hoses closed to help keep coolant contained in the cooling system. Some coolant will still fall from the radiator. Put a drain pan beneath to catch it.
  • You may need pliers or screwdriver depending on the type of clamp you have.
mini cooper r50 r53 radiator cooling fan how to remove replace DIY change
Figure 6. Removing the upper radiator hose.

Step 6 – Remove the cooling fan

  • Apply light forward pressure to the radiator, seeing if some play is present. Watch the A/C condenser lines at the front right corner to make sure they do not bend.
  • If enough room is available to slide the cooling fan up, disengage the four tabs on the cooling fan from the holding bracket against the radiator. Unlike the top tabs, the bottom tabs will need to be pried outward slightly with a pry bar or screwdriver.
  • Unplug the cooling fan.
  • With the new fan removed, reverse the instructions to install the new fan.
  • Top off the cooling system at the radiator and overflow tank. Loosen the bleed screw at the upper radiator hose and start the engine with the heat on max high. Close the bleed screw once coolant exits through it.
  • Allow the engine to warm, keeping a close eye on the temperature. Don't let the temperature rise above 3/4 near the red mark! Adjust your level to the max mark in the overflow tank.

Use the last step in the article How to Replace Thermostat for more information.

mini cooper r50 r53 radiator cooling fan how to remove replace DIY change
Figure 7. The four clips on the outer edges of the cooling fan.

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