Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
41 33 600 Moving front panel into assembly position
Special tools required:
Necessary preliminary tasks:
- Remove COVER FROM FRONT GRILLE
- Remove the BUMPER PANEL COVER on left and right
- Remove CENTER COVER
- Release FRONT WHEEL ARCH TRIM COVER on bumper trim
Release clips (1) on left/right.
Installation note:
If necessary, replace faulty clips (1).
Release cable clip (1).
Disconnect plug connections (2) on A/C compressor.
Release screws (3).
Tightening torque 51 11 4AZ .
Unfasten screws (2).
Tightening torque 51 11 4AZ .
Version with headlight cleaning system:
Release plug connection (1) on the windscreen washer pump.
Release screw (1) on sidewall left/right.
Version with A/C system:
Unclip refrigerant line (1) from holder (2).
Unscrew bolt (1) and set expansion tank (2) aside.
Release the gaiter (3) from the lock carrier (4).
Open coupling (1) and disengage Bowden cable (2).
Release screws (3 and 4).
Tightening torque 51 11 7AZ .
Installation note:
The headlight tab for the screw (4) may not touch the front panel during installation.
Disconnect plug connection (1).
Release screws (4 and 5).
Tightening torque 51 11 7AZ .
COOPER S only:
Release clamp (2) and detach air duct (3).
Installation note:
The headlight tab for the screw (5) may not touch the front panel during installation.
Insert special tool 00 2 271 on the left and right in the sleeve (1).
If applicable, turn the special tool 00 2 271 until the screw can be inserted and tighten.
Unscrew nuts (2).
Tightening torque 51 11 3AZ .
Installation note:
Do not remove special tool 00 2 271 until the front panel has been completely removed.
Pull front panel (1) approx. 10 cm forwards and if necessary pay attention to further cable clips.
Insert special tool 00 2 272 left and right.
Installation note:
To ensure that front panel (1) is correctly seated, slide panel on left and right uniformly towards rear.
With a second person helping, slide front panel into position and secure.
When installing, pay attention to retaining tabs on headlight.
Installation note:
Adjust lights. See ADJUSTING HEADLIGHTS and ADJUSTING FOG LIGHTS .
NO RELATED
Use the Manual With the Right Hardware
Pair factory procedures with proven DIY tools so the instructions are easier to execute.
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.