Last night I topped up the coolant it took almost 3/4 gallon - I filled it, turn on car, shut off, refill, etc.. Once full, I put on the rad cap and left the hood open and idled the car.
I turned on the heat and it was definitely blowing hot air while warming up.
Once the coolant temperature approached 200°F, I could feel heat through the upper hose to the rad, proving that the thermostat and water pump are working. At 221°F, the fans came on, and temperatures started falling after 223°F.
No drips visible last night.
I did the same test today with similar results (but also some drips) and believe I have two problems:
Electrical - According to AllDataDIY, the rad fans are supposed to turn on low at 'approximately' 202°F, and high at 220°F. Mine didn't turn on at all until 221°, but I'm not sure if they were running in high or low speed. The fans are operated with three relays in the under-hood fuse box:
"R1 (MINI) COOL/FAN 1" - 4 prong Hella 12193614 / 3614
"R2 (MINI) COOL/FAN" - 5 prong Hella 12193612 / 3612
"R7 (MINI) COOL/FAN 2" - 4 prong Hella 12193614 / 3614
I swapped the R2 relay with an identical relay for the wipers - both relays ran the wipers, and neither caused the fans to run at 200-220°F. Any ideas, or is Alldatadiy wrong with respect to proper operation?
When running the AC, both fans run and temperatures stay stable (when parked) at around 207°F.
Drips - Coolant is dripping from the left (driver side) of the rad somewhere. The foam between the AC and coolant rad is wet at the far driver side, and there is a drip visible - see photo. I'll put the car back up on ramps on the weekend, but any suggestions on the source or how to get to it?
Thanks