Engine - Repair - Cooper S (N14 Engine): Other MINI Cooper I

00 Danger of poisoning if oil is ingested/absorbed through the skin

Danger of poisoning!

Ingesting oil or absorbing through the skin may cause poisoning!

Possible symptoms are

1. Headaches
2. Dizziness
3. Stomach aches
4. Vomiting
5. Diarrhoea
6. Cramps/fits
7. Unconsciousness

Protective measures/rules of conduct

1. Pour oil only into appropriately marked containers
2. Do not pour oil into drinking vessels (drinks bottles, glasses, cups or mugs)
3. Observe country-specific safety regulations

First aid measures

1. Do not induce vomiting. If the person affected is still conscious, he/she must rinse out their mouth with water, drink plenty of water and consult a doctor immediately. If the person affected is unconscious, do not administer anything by mouth, place the person in the recovery position and seek immediate medical attention.

00 Risk of injury if oil comes into contact with eyes and skin

Danger of injury!

Contact with eyes or skin may result in injury!

Possible symptoms are

1. Impaired sight
2. Irritation of the eyes
3. Reddening of the skin
4. Rough and cracked skin

Protective measures/rules of conduct

1. Wear protective goggles
2. Wear oil-resistant protective gloves
3. Observe country-specific safety regulations

First aid measures

1. Eye contact: Rinse eyes immediately with plenty of water for at least 15 minutes; if available, use an eye-rinsing bottle. If irritation of the eyes persists, consult a doctor.
2. Skin contact: Wash off with soap and water immediately. If irritation persists, consult a doctor. NOTE: Do not use solvents/thinners.

00 Safety information for working on vehicles with automatic engine start-stop system (MSA)

Observe safety precautions when working on MSA vehicles.

Before carrying out practical work on the engine, always ensure that the MSA function is deactivated so as to prevent automatic engine starting while work is being carried out in the engine compartment.

MSA function is deactivated by

Scheme 838

1. Deactivate MSA by means of button (1) in passenger compartment
2. Open seat belt buckle and driver's door
3. Open engine bonnet/hood and ensure that engine hood/bonnet contact is not in workshop mode Workshop mode A = 10 mm Basic setting (engine hood/bonnet open) B = 7 mm To make sure that the engine hood/bonnet contact is at the basic setting, if necessary press the hood/bonnet contact up to the stop before starting work and slowly release.

When working with diagnosis tools

Scheme 839

1. Observe instructions in diagnosis tool

00 Safety instructions for handling oil

Recycling

Observe country-specific waste-disposal regulations.

Measures if oil is unintentionally released

1. Personal precautionary measures: Danger of slipping! Keep non-involved persons away from the work area. Wear personal protective clothing/equipment.
2. Environmental protection measures: Prevent oil from draining into drain channels, sewerage systems, pits, cellars, water and the ground.
3. Limiting spread: Use oil blocks to prevent the surface spread of oil.
4. Cleaning procedure: Bind and dispose of escaped oil with nonflammable absorbents. NOTE: Do not flush oil away with water or aqueous cleaning agents.

11 00 Removing and installing/replacing acoustic cover (N14)

Release screws (1).

For tightening torque refer to 11 12 11AZ in 11 12 CYLINDER HEAD WITH COVER .

Release acoustic cover at retainers (2).

Lift off acoustic cover in direction of arrow.

Scheme 840

11 00 039 Checking compression of all cylinders (N12, N14)

1. Read out fault memory of DME control unit
2. Check stored faults
3. Rectify faults
4. Clear fault memory

Necessary preliminary tasks

1. «Remove Spark Plugs»(ref-265696-S07166824512007092500000) .

Unscrew tip (1) from special tool 11 0 222.

Scheme 841

Prepare special tool 11 0 222 in conjunction with 11 8 732 and 11 8 731.

Scheme 842

Screw special tool 11 8 730 onto special tool 11 0 222 to 10 Nm.

Scheme 843

Screw special tool 11 0 222 by hand into spark plug thread and connect special tool 11 0 224.

Use adapter lead (1) if the compression pressure is being checked with the BMW diagnosis system.

Depress accelerator pedal and actuate starter until compression pressure stops rising.

1. Nominal values, compression pressure

Assemble engine

Now clear the fault memory.

Scheme 844

11 00 050 Removing and installing engine (N14)

Special tools required

1. 11 0 260

Necessary preliminary tasks

1. Remove «Exhaust System»(ref-265700-S18292653762007092500000) .
2. Drain «Engine Oil»(ref-265694-S12499659642007092500000) .
3. Disconnect negative battery lead.
4. Remove both «Left»(ref-264959-S40511705722007092000000) and «Right»(ref-264959-S35831629852007092000000) output shafts .
5. Remove «Air Cleaner Housing»(ref-265697-S00426862422007092500000) .
6. Detach all coolant hoses from engine.
7. Detach vacuum line from brake booster.
8. Unfasten «Engine Wiring Harness»(ref-265696-S41113250242007092500000) and lay to one side.
9. Remove complete «Front Panel»(ref-264966-S33352003252007092000000)

Attach special tool 11 0 260 to lifting eye (1) on engine.

Note. Pictures show N12.

Scheme 845

Attach special tool 11 0 260 to lifting eye (1) at transmission end.

Note. Pictures show N12.

Scheme 846

Remove engine with special tool 11 0 260 towards front.

Note. Pictures show N12.

Scheme 847

Assemble engine.

Check function of DME.

11 12 000 Removing and installing/sealing cylinder head cover (N14)

Necessary preliminary tasks

1. Unclip «Ignition Wiring Harness»(ref-265696-S41113250242007092500000) on cylinder head.
2. Remove «Rod-Type Ignition Coils»(ref-265696-S08635810082007092500000) .
3. Remove «Suction Filter Housing»(ref-265697-S00426862422007092500000) .

Unclip engine wiring harness with holders (1).

Scheme 848

Unclip engine wiring harness holder (1).

Scheme 849

Release oxygen sensors on cylinder head (1).

Scheme 850

Detach grounding cable at bolt connection (2).

Undo cylinder head cover bolts in the sequence 13 to 1.

Scheme 851

Replace seal (1).

Replace all seals (2).

Installation

Clean all sealing surfaces.

Installation

Seal all edges and joints on the cylinder head with sealing compound Drei Bond 1209.

Note. Pictures show N12.

Scheme 852

Secure bolts for cylinder head cover in sequence 1 to 13.

For tightening torque refer to 11 12 4AZ in 11 12 CYLINDER HEAD WITH COVER .

Assemble engine.

11 12 100 Removing and installing/sealing cylinder head (N14)

Special tools required

1. 11 2 250
2. 11 4 471
3. 11 4 472
4. 11 9 590
5. 11 9 630

Necessary preliminary tasks

1. Remove «Exhaust System»(ref-265700-S18292653762007092500000) .
2. Drain «Coolant»(ref-265699-S07723707932007092500000) .
3. Drain «Engine Oil»(ref-265694-S12499659642007092500000) .
4. Remove intake air «Manifold»(ref-265695-S39012197852007092500000) .
5. Remove «Oil Dipstick»(ref-265695-S33065666382007092500000) .
6. Detach coolant hoses from cylinder head.
7. Remove oil dipstick «Guide Tube»(ref-265695-S33065666382007092500000) .
8. Remove «Cylinder Head Cover»(ref-265695-S22424985522007092500000) .
9. Remove solenoid valve from adjustment unit.
10. Remove «Inlet Adjustment Unit»(ref-265695-S15389816162007092500000) .

Secure crankshaft with special tool 11 9 590 .

Scheme 853

Note. Remove and install cylinder head in installed state.

Suspend engine with engine crane (1) from lifting eye (2).

Scheme 854

Note. Remove and install cylinder head in installed state. Move front panel into Assembly Position .

Release upper Alternator Screws , do not remove alternator.

Remove right engine mount .

Secure special tool 11 9 630 with standard bolts (1 and 2).

Scheme 855

Release screws (1).

Installation

Only during assembly is the timing chain lifted out with a hook.

Scheme 856

Release screw (1).

Scheme 857

Release cylinder head bolts with special tool 11 2 250 .

Release cylinder head bolts from outside inwards (10 to 1).

Note. Remove shims with a magnet. Illustration shows camshafts removed.

Scheme 858

Use special tool 11 4 471 to remove coarse gasket remnants from sealing faces of cylinder head and crankcase.

Scheme 859

Remove fine gasket remnants with special tool 11 4 472 .

There must not be any coolant, water or oil present in the pocket holes (risk of corrosion and cracking) .

Clean all pocket holes.

Replace Cylinder Head Gasket .

Scheme 860

Secure cylinder head bolts from inside outwards (1 to 10).

For tightening torque refer to 11 12 2AZ in 11 12 CYLINDER HEAD WITH COVER .

Secure bolts (1).

For tightening torque refer to 11 12 1AZ in 11 12 CYLINDER HEAD WITH COVER .

Tighten the screw (1).

For tightening torque refer to 11 12 3AZ in 11 12 CYLINDER HEAD WITH COVER .

Scheme 861

Assemble engine.

11 12 101 Replacing cylinder head gasket (N14)

Special tools required

1. 11 4 470

Necessary preliminary tasks

1. Remove «Cylinder Head.»(ref-265695-S02156565622007092500000)

Remove remnants of oil and dirt from pocket holes (1).

Note. Illustration shows N52.

Scheme 862

Identification (1) of head gasket (N14).

Scheme 863

Check adapter sleeves (1) for damage and firm seating.

Lay cylinder head gasket on engine block.

Scheme 864

Note. Check cylinder head for Deviation From Flatness . Check cylinder head for Water Leaks .

Assemble engine.

11 12 719 Resurfacing cylinder head sealing face (N14)

Necessary preliminary tasks

1. Remove «Cylinder Head»(ref-265695-S02156565622007092500000) .
2. Remove «exhaust camshaft»(ref-265695-S02061122602007092500000) .
3. Remove «Inlet Camshaft»(ref-265695-S15955192902007092500000) .

Check evenness of cylinder head sealing face with a standard straight-edge (1).

Note. Max. deviation from level (longitudinal) 0.10 mm Illustration shows N52.

Scheme 865

Check evenness of cylinder head sealing face with a standard straight-edge (1).

Note. Max. deviation from level (transversal) 0.05 mm Illustration shows N52.

Scheme 866

Check cylinder head for Water Leaks .

11 12 729 Checking cylinder head for water leaks (N14)

Special tools required

1. 11 9 521
2. 11 9 522
3. 11 9 523

Necessary preliminary tasks

1. Remove «Cylinder Head»(ref-265695-S02156565622007092500000) .
2. Disassemble «Inlet»(ref-265695-S15955192902007092500000) and «Exhaust»(ref-265695-S02061122602007092500000) cylinder heads .

Mount special tool 11 9 521 with bolts 11 9 523 .

Installation

Install special tool 11 9 521 so that all water ducts are sealed.

Scheme 867

Secure bolts 11 9 523 to 25 Nm .

Scheme 868

Screw special tool 11 9 522 into place with existing screws (1 and 3) of coolant thermostat.

Note. Sealing flange 11 9 522 must rest flat. Compressed air at valve (2) must not exceed 3 bar . Heat cylinder head to 60°. Check for bubble formation in a water bath.

Scheme 869

Assemble engine.

11 13 000 Removing and installing, sealing or replacing oil sump (N14)

Special tools required

1. 11 4 470
2. 11 9 581
3. 11 9 582

Necessary preliminary tasks

1. Drain «Engine Oil»(ref-265694-S12499659642007092500000) .

Release oil sump bolts in area of line (1).

For tightening torque refer to 11 13 2AZ in 11 13 OIL PAN .

Scheme 870

Release screw (1) over exhaust manifold with special tools 11 9 582 and 11 9 581 .

Scheme 871

Clean sealing face (1) with special tool 11 4 470 .

Scheme 872

Remove protruding or sticking-out sealing beads (1) with a sharp knife.

Installation

Do not use liquid seal.

A metal substrate gasket is available for repairs.

Scheme 873

Assemble engine.

11 14 005 Replacing front crankshaft radial seal (N14)

Special tools required

1. 11 9 601
2. 11 9 602
3. 11 9 603

Necessary preliminary tasks

1. Remove A/C line from compressor.
2. Remove vibration damper.

If the central bolt is released, the sprocket wheels of the timing chain and the oil pump will no longer be non-positively connected to the crankshaft. The camshafts can warp in relation to the crankshaft (risk of damage!) .

Scheme 874

Drive PTFE ring inwards with a drift (1) until PTFE ring tilts outwards at bottom.

Scheme 875

Secure special tool 11 9 601 with screws (1) to crankshaft to 15 Nm.

Scheme 876

Installation

Apply a light coating of oil to special tool 11 9 601 .

Position PTFE ring (2) with supporting ring (1) on special tool 11 9 601 .

Push PTFE ring (2) over supporting ring (1) in direction of arrow up to crankcase.

Scheme 877

Remove supporting ring from special tool 11 9 601 .

Note. Supporting ring is no longer needed.

Scheme 878

Draw in PTFE ring with special tool 11 9 602 in conjunction with special tool 11 9 603 until flush.

Scheme 879

Assemble engine.

11 14 151 Replacing crankshaft radial seal (N14)

Special tools required

1. 11 9 611
2. 11 9 612
3. 11 9 613

Necessary preliminary tasks

1. Remove «Transmission.»(ref-264956-S12201361422007092000000)
2. Remove «Flywheel.»(ref-265695-S07293895622007092500000)

Brake off PTFE ring (2) with a drift (1).

Scheme 880

Secure special tool 11 9 611 with supplied screws (1) to crankshaft.

Scheme 881

Position PTFE ring (1) with supporting ring (2) on special tool 11 9 611 .

Push PTFE ring (1) in direction of arrow over supporting ring (2) onto crankshaft.

Scheme 882

Attach special tool 11 9 612 .

Draw in PTFE ring with special tool 11 9 613 .

Scheme 883

Screw in special tool 11 9 612 up to engine block.

Scheme 884

Assemble engine.

11 21 500 Replacing crankshaft (N14)

Special tools required

1. 00 9 120
2. 11 4 471
3. 11 4 472
4. 11 6 251
5. 11 6 252
6. 23 1 240

It is absolutely essential to follow the procedure described below and the instructions on handling the special tools.

Necessary preliminary tasks

1. Remove «Engine»(ref-265695-S00322512042007092500000) .
2. Mount engine on «Assembly Stand»(ref-265695-S14425507132007092500000) .
3. Remove «Vibration Damper»(ref-265695-S27220438182007092500000) .
4. Removing «Oil Pan»(ref-265695-S30013393602007092500000) .
5. Remove «Oil Pump»(ref-265695-S21535124962007092500000) .
6. Remove «Timing Chain»(ref-265695-S20433827812007092500000) .
7. Remove «Cylinder Head»(ref-265695-S02156565622007092500000) .
8. Remove «Flywheel»(ref-265695-S07293895622007092500000) .

Release screws (1).

For tightening torque refer to 11 13 5AZ in 11 13 OIL PAN .

Remove oil deflector (2).

Remove all pistons .

Scheme 885

Drive out cover plates (1) with a cross-chisel (2).

Scheme 886

Release screws (28 to 11).

Release screws (10 to 1).

Scheme 887

Release crankcase lower half in direction of arrow with a regular screwdriver (2) and an open-end wrench (1).

Scheme 888

Remove both radial shaft seals (1).

Scheme 889

Remove crankshaft (1).

Remove main bearing shells, replace if necessary.

Scheme 890

Clean sealing faces with special tools 11 4 471 and 11 4 472 .

Scheme 891

Check guide sleeves (1) for damage and correct seating.

Scheme 892

Apply sealing bead (1) to crankcase lower half (Scheme 893) with Loctite 5970 sealing compound.

Installation

Follow manufacturer's instructions (Loctite).

Scheme 893

Apply sealing bead (1) to crankcase upper half (Scheme 894) with Loctite 5970 sealing compound.

Installation

Follow manufacturer's instructions (Loctite).

Scheme 894

Insert crankshaft (1).

Lubricate all bearings from 1 to 5 with engine oil.

Install crankcase lower half.

Scheme 895

Tighten bolts (1 to 10).

For tightening torque refer to 11 11 1AZ in 11 11 ENGINE BLOCK .

Tighten bolts (11 to 28).

For tightening torque refer to 11 11 2AZ in 11 11 ENGINE BLOCK .

Tighten bolts exclusively with special tool 00 9 120 .

Scheme 896

Apply a thin coating of Loctite 273 to cover sleeve (1) in area (2).

Scheme 897

Drive cover sleeves firmly home with special tool 23 1 240 .

Scheme 898

Determine crankshaft axial clearance.

Attach special tool 11 6 252 with magnet.

Set special tool 11 6 251 to zero.

Press crankshaft in direction of rotation up to stop.

Refer to ENGINE - TECHNICAL DATA -- N14 ENGINE .

Scheme 899

Replace radial shaft seal at Front .

Replace radial shaft seal at Rear .

Assemble engine.

11 21 531 Replacing all crankshaft main bearings (N14)

Special tools required

1. 11 4 470

Necessary preliminary tasks

1. Remove «Crankshaft»(ref-265695-S35732477052007092500000) .

Installation

Bearing shell (1) with lubricant groove must be fitted in crankcase upper section.

Bearing shell (2) without lubricant groove must be fitted in crankcase lower section (bedplate).

Scheme 900

Bearings (1 to 5).

Bearing (2) is a guide bearing.

Clean sealing faces with special tool 11 4 470 only.

Scheme 901

Insert guide rings (1) in crankcase at bearing block (2) with groove facing outwards.

If necessary, attach with engine oil to crankcase.

Scheme 902

Bearings (1 to 5).

Clean sealing faces with special tool 11 4 470 only.

Scheme 903

Bearing classification on crankcase upper half

Bearing allocation 1-5: the designations on the crankcase and crankshaft are always required.

Refer to COLOR CODE CHART for the color code.

Example

Bearing 1. Letter P

Bearing 2. Letter K

Bearing 3. Letter I

Bearing 4. Letter N

Bearing 5. Letter N

Scheme 904

Bearing classification on crankcase upper half

Bearing allocation 1-5: the designations on the crankcase and crankshaft are always required.

Refer to BEARING COLOR CODE CHART: UPPER HALF for the color code.

Example

Bearing 1. Letter T

Bearing 2. Letter Q

Bearing 3. Letter Q

Bearing 4. Letter R

Bearing 5. Letter R

Scheme 905

BEARING COLOR CODE CHART: UPPER HALF

Crankshaft bearing colours

BL= Blue.

SW= Black.

Gr= Green.

Ge Yellow.

Or Orange.

Bearing classification on crankcase lower half

Bearing allocation 1-5: the designations on the crankcase and crankshaft are always required.

Refer to BEARING COLOR CODE CHART: LOWER HALF for the color code.

Example

Bearing 1. Letter P

Bearing 2. Letter K

Bearing 3. Letter I

Bearing 4. Letter N

Bearing 5. Letter N

Bearing classification on crankcase lower half

Bearing allocation 1-5: the designations on the crankcase and crankshaft are always required.

Refer to BEARING COLOR CODE CHART: LOWER HALF for the color code.

Example

Bearing 1. Letter T

Bearing 2. Letter Q

Bearing 3. Letter Q

Bearing 4. Letter R

Bearing 5. Letter R

BEARING COLOR CODE CHART: LOWER HALF

Crankshaft bearing colours

BL= Blue.

SW= Black.

Gr= Green.

Ge Yellow.

Or Orange.

Example: Crankcase upper half

Combining the dots of the designations of the crankshaft and crankcase produces the following color combinations.

Bearing 1: The letters (P and T) produce in the crankcase upper half the color Ge= Yellow with lubricant groove.

Bearing 2: K and Q= Ge= Yellow.

Bearing 3: I and Q= Ge= Yellow.

Bearing 4: N and R= Gr= Green.

Bearing 5: N and R= Gr= Green.

Example: Crankcase lower half

Combining the dots of the designations of the crankcase and crankshaft produces the following color combinations.

Bearing 1: The letters P. and T. produce in the crankcase lower half the color Gr= Green without lubricant groove.

Bearing 2: K and Q= Gr= Green.

Bearing 3: I and Q= Gr= Green.

Bearing 4: N and R= Gr= Green.

Bearing 5: N and R= Gr= Green.

Check spray nozzle (2) for damage, replace if necessary.

Release screw (1).

For tightening torque refer to 11 11 8AZ in 11 11 ENGINE BLOCK .

Remove oil spray nozzle (2).

Installation

Oil spray nozzle (2) is turned when screw (1) is tightened and then rests with its upper corner against crankcase.

Scheme 906

Install Crankcase Lower Section .

Assemble engine.

11 22 500 Removing and installing or replacing flywheel (N14)

Special tools required

1. 11 9 590

Necessary preliminary tasks

1. Remove «Transmission»(ref-264956-S12201361422007092000000) .
2. Remove «Clutch»(ref-264954-S31701373092007092000000) .

Lock flywheel with special tool 11 9 590 .

Scheme 907

Flywheel for automatic transmission.

Release flywheel bolts (1).

For tightening torque refer to 11 22 1AZ in 11 22 FLYWHEEL .

Installation

Flywheel is secured with a dowel pin.

Fit new flywheel screws.

Clean crankshaft thread for flywheel screws.

Scheme 908

Flywheel for manual gearbox.

Flywheel with and without dual-mass: release flywheel bolts (1).

For tightening torque refer to 11 22 2AZ in 11 22 FLYWHEEL .

Installation

Flywheel is secured with a dowel pin.

Replace flywheel bolts (1).

Clean crankshaft thread for flywheel screws.

Scheme 909

Installation

Sensor gear (1) is loose on crankshaft and is first secured to flywheel.

Dowel pin (2) for securing sensor gear/flywheel.

Scheme 910

Assemble engine.

11 24 571 Replacing conrod bearings (N14)

Necessary preliminary tasks

1. Remove all «Pistons»(ref-265695-S03359228072007092500000) .

Install new conrod bearing shells.

Insert conrod bearing shells (1 and 2).

Scheme 911

Assemble engine.

11 25 530 Removing and installing/replacing all pistons (N14)

Special tools required

1. 00 9 120
2. 11 9 620
3. 11 9 670

Necessary preliminary tasks

1. Remove «Engine»(ref-265695-S00322512042007092500000) .
2. Mount engine on «Assembly Stand»(ref-265695-S14425507132007092500000) .
3. Remove intake air manifold.
4. Remove «Cylinder Head»(ref-265695-S02156565622007092500000) .
5. Remove «Engine Oil Sump»(ref-265695-S30013393602007092500000) .
6. Remove «Oil Pump»(ref-265695-S21535124962007092500000) .

Note. In event of heavy oil carbon residue: Carefully remove oil carbon residue from cylinder wall.

Note. Illustrations show N46.

Scheme 912

Note. Mark all pistons and conrods with a pen prior to removing.

Example

Direction of arrow (1) points to camshaft drive.

Cylinder allocation (2) per cylinder.

Scheme 913

Note. Mark all pistons and conrods with a pen prior to removing.

Example

Mark cylinder allocation (1) per cylinder.

Direction of arrow (2) points to camshaft drive.

Scheme 914

Release connecting rod bolts (1).

For tightening torque refer to 11 24 1AZ in 11 24 CONNECTING RODS AND BEARINGS .

Remove conrod bearing cap.

Scheme 915

Attach special tool 11 9 620 in conrod big end.

Press out connecting rod and piston to cylinder head side.

Scheme 916

Lever out piston pin circlip with a screwdriver in direction of arrow.

Scheme 917

If necessary, replace connecting rods.

Installation

The gudgeon pin must be able to be pressed through the liner by hand with little force and must not display any significant play.

Scheme 918

Measure piston installation clearance

Measure piston diameter with micrometer at measuring point A from bottom edge of piston and offset at 90° to the axis of the gudgeon pin.

Piston diameter at measuring point A.

Scheme 919

Adjust micrometer to cylinder bore of engine block. Set internal calliper on micrometer to zero. Measure bottom, centre and top of cylinder bore in direction of travel and direction of engine rotation.

Diameter of cylinder bore.

Piston installation clearance.

Total permissible wear tolerance.

If necessary, replace piston.

Scheme 920

Install all Piston Rings .

Install all Bearing Shells .

Coat piston and piston rings with oil .

Pre-install piston in special tool 11 9 670 .

Screw special tool 11 9 620 into conrod.

Installation

Check protective lugs on special tool 11 9 620 for correct position and damage.

Scheme 921

Insert piston with connecting rod in cylinder.

Insert piston (1) so that arrow on piston crown points to camshaft drive.

If reusing the pistons, assign cylinder allocation (2) to correct cylinder.

Press in piston with special tool 11 9 670 .

Scheme 922

Both pairing letters (2) must be together on one side.

Scheme 923

Apply a light coat of oil to crank pin.

Assemble connecting rod and crank pin.

Remove special tool 11 9 620 .

Fit bearing caps (2) so that pairing letters match up.

Check cylinder identification markings (1).

Direction of arrow (2) points to camshaft drive.

Install new connecting rod bolts (1).

Carry out torsion angle tightening of conrods with special tool 00 9 120 .

For tightening torque refer to 11 24 1AZ in 11 24 CONNECTING RODS AND BEARINGS

Assemble engine.

11 25 671 Replacing piston rings on all pistons (N14)

Special tools required

1. 11 9 670

Necessary preliminary tasks

1. Remove all «Pistons»(ref-265695-S03359228072007092500000) .

Measuring axial clearance of piston rings in piston ring groove.

ENGINE - TECHNICAL DATA -- N14 ENGINE

Note. It is not possible to measure the axial clearance of the oil scraper rings.

Scheme 924

Remove compression ring and stepped ring upwards with piston ring pliers.

Oil scraper ring comprises two steel band rings and a support spring.

Note. Oil scraper ring cannot be removed with piston ring pliers. Put aside piston rings in correct sequence and installation position. It might not be possible to find the identification on used piston rings.

Scheme 925

Installation

New pistons may only be installed together with new piston rings.

Determine gap with a feeler gauge. See ENGINE - TECHNICAL DATA -- N14 ENGINE .

Scheme 926

Installation

Piston rings with "TOP" identification must point to piston crown.

Scheme 927

Installation

Piston rings with "TOP" identification must point to piston crown.

Scheme 928

1. Plain compression ring
2. Taperface ring
3. Two-part oil scraper ring

Note. Oil control ring comprises two steel band rings (1) and a support spring (2).

Installation

Insert support spring (2) into piston ring groove and then fit steel band rings (1) so that contact points are offset by approx.

120°.

Scheme 929

Offset the contact points (1) of the piston rings by approx. 120° to each other but do not position above the piston pin boss.

Coat special tool 11 9 670 with sufficient engine oil. Risk of damage to piston rings!

Note. (Scheme 930)

Scheme 930

Assemble engine.

11 28 010 Replacing alternator drive belt (N14)

Necessary preliminary tasks

1. Remove «Right Wheel Arch Cover»(ref-264967-S28420334812007092000000)
2. Remove «Halogen»(ref-264972-S16789757782007092000000) or «Xenon»(ref-264972-S26425621502007092000000) right headlight
3. Remove «Lock Bridge»(ref-264966-S30859366812007092000000)

Bring belt tensioner (1) with wrench (2) into assembly position.

Secure assembly position of belt tensioner (1) by sliding locating pin (3) in direction of arrow.

Remove drive belt (4) from alternator.

Note. For reasons of clarity, illustration and text show front wall removed.

Scheme 931

Move friction wheel (2) into servicing position.

In order to release the frictional connection between crankshaft and coolant pump, it is necessary to move the friction gear (2) into the servicing position.

Firmly pull handle (1) in direction of arrow until friction gear (2) is separated from belt pulley.

Scheme 932

To secure friction gear in servicing position, suspend pull cable (1) on housing (2).

Scheme 933

Assemble engine.

Installation

Check that drive belt for is in correct installation position - risk of damage .

11 28 012 Replacing drive belt (without A/C system)

Necessary preliminary tasks

1. Remove right «Wheel Arch Line»(ref-264967-S28420334812007092000000) .

Cut through ribbed V-belt (1) with a suitable tool (2).

Scheme 934

Position supplied tool (1) on vibration damper (see arrow in (Scheme 935) ).

Scheme 935

Attach installation tool in direction of arrow and slide further in direction of arrow.

Scheme 936

Bring installation tool (1) on vibration damper into installation position.

Scheme 937

Place ribbed V-belt (1) on alternator (2).

Scheme 938

Place ribbed V-belt (1) in direction of arrow on vibration damper.

Note. (Scheme 939)

Scheme 939

Turn vibration damper in direction of arrow.

Press ribbed V-belt (1) inwards by hand or with a tyre iron (see arrow in (Scheme 940) ).

Scheme 940

Turn vibration damper until ribbed V-belt is fully engaged.

Remove installation tool (1) from vibration damper.

Note. Installation tool is no longer needed.

Scheme 941

Add final details to vehicle.

11 28 020 Replacing tensioning device for alternator drive belt (N14)

Necessary preliminary tasks

1. Bring «Front Panel»(ref-265695-S10962659312007092500000) into service position.
2. Disconnect lambda oxygen sensor cable.

Pretension tensioning device (1) with tool (2) in direction of arrow.

Press in locking pin (3) in direction of arrow and hold.

Release tool (2) slowly and secure locking pin (3) in position.

Note. Locking pin (3) holds tensioning device (1) at pretension.

Release screws (2).

For tightening torque refer to 11 28 1AZ in 11 28 V-RIBBED BELT WITH TENSION AND DEFLECTION ELEMENT .

Remove tensioner (3).

Scheme 942

Installation

Lever tensioning device (1) with tool (2) in direction of arrow.

Locking pin (3) is pretensioned with a spring and is automatically relieved during unlocking.

Assemble engine.

11 28 035 Removing and installing/replacing friction gear (N14)

Special tools required

1. 11 9 581
2. 11 9 583

Necessary preliminary tasks

1. Remove «Right Wheel Arch Cover»(ref-264967-S28420334812007092000000)

Pull out friction gear with mechanical release (3) in direction of arrow and lock on locking hook.

Friction gear (1) lifts mechanically off belt drive.

Disconnect plug connection (2) on friction gear.

Note. Picture shows friction gear removed.

Scheme 943

Move friction wheel (2) into servicing position.

To secure friction gear in servicing position, suspend pull cable (1) on housing (2).

Secure belt pulley of water pump with an oil filter band (1).

Release bolts (2) with special tools 11 9 581 and 11 9 583 .

For tightening torque refer to 11 51 2AZ in 11 51 WATER PUMP AND DRIVE .

Scheme 944

Release bolts (1) with special tools 11 9 583 and 11 9 581 .

Note. Drive belt does not have to be removed.

Scheme 945

Remove friction gear (1) towards bottom.

Disconnect plug connection (2).

Scheme 946

Assemble engine.

Installation

Check cable routing for correct installation position (risk of damage!) .

11 31 005 Checking camshaft timing (N14)

Special tools required

1. 11 9 522
2. 11 9 551
3. 11 9 590

Necessary preliminary tasks

1. Remove «Cylinder Head Cover»(ref-265695-S22424985522007092500000) .

Rotate crankshaft at central bolt.

Position crankshaft with special tool 11 9 590 .

Do not remove special tool 11 9 590 during repair work.

Both camshafts are in the correct installation position when the designation (IN) for inlet camshaft points upwards.

In the case of the exhaust camshaft, the designation (EX) must point upwards.

Note. Pictures show N12.

Scheme 947

Position of inlet camshaft (1) points at an angle to the right in an upper inward direction.

Scheme 948

Position of exhaust camshaft (1) points at an angle to the right in an upper inward direction.

Scheme 949

Position special tool 11 9 551 (exhaust) on twin surface of exhaust camshaft and secure with a screw (1).

Scheme 950

Mount special tool 11 9 522 on cylinder head.

Position special tool 11 9 551 (inlet) on twin surface of inlet camshaft and secure with two screws.

Scheme 951

If necessary, adjust Valve Timing .

11 31 025 Removing and installing/replacing inlet camshaft (N14)

Special tools required

1. 11 4 480
2. 11 9 000
3. 11 9 551
4. 11 9 552
5. 11 9 661
6. 11 9 662

Necessary preliminary tasks

1. Remove «Cylinder Head Cover»(ref-265695-S22424985522007092500000) .
2. Check «Timing»(ref-265695-S28844060872007092500000) .
3. Remove «Chain Tensioner»(ref-265695-S33117497532007092500000) .

To release central bolts, always use special tool 11 9 551 of exhaust camshaft.

Position special tool 11 9 551 on twin surface of exhaust camshaft.

Secure special tool 11 9 551 with a screw (1).

Mount special tool 11 9 551 on inlet and exhaust camshafts.

Screw in special tool 11 9 552 on cylinder head with a screw.

To release central bolts, always use special tool 11 9 551 .

Release screws (2).

Remove clamping rail (1).

Scheme 952

Release screw (1).

For tightening torque refer to 11 11 3AZ in 11 11 ENGINE BLOCK .

Scheme 953

Release central bolt (3).

For tightening torque refer to 11 36 2AZ in 11 36 VARIABLE CAMSHAFT CONTROL .

Feed out sprocket wheel (2) from timing chain (1) towards front.

Scheme 954

Release central bolt (3).

For tightening torque refer to 11 36 1AZ in 11 36 VARIABLE CAMSHAFT CONTROL .

Set down VANOS adjustment unit on special tool 11 4 480 .

Scheme 955

Screw special tool 11 9 661 with special tools 11 9 662 into spark plug holes.

Turn eccentric shaft (1) in direction of ring and lock.

Scheme 956

Release all screws on bearing caps (1).

For tightening torque refer to 11 12 6AZ in 11 12 CYLINDER HEAD WITH COVER .

Bearing cap (2) is a thrust bearing and has the number (5).

All bearing caps (1) are identified with numbers from (6 to 9).

Scheme 957

Inlet camshaft is identified with designation (IN).

Insert inlet camshaft so that designation (IN) can be read from above.

Scheme 958

Position inlet camshaft (1) so that cam of inlet camshaft (1) points upward at an angle.

Installation

Lubricate all bearing points with engine oil.

Scheme 959

Assemble engine.

Installation

Adjust Valve Timing .

11 31 028 Removing and installing/replacing exhaust camshaft (N14)

Special tools required

1. 11 9 000
2. 11 9 551
3. 11 9 552
4. 11 9 661
5. 11 9 662

Necessary preliminary tasks

1. Remove cylinder head cover.
2. Check timing.
3. Remove «Chain Tensioner»(ref-265695-S33117497532007092500000) .

To release central bolts, always use special tool 11 9 551 of exhaust camshaft.

Position special tool 11 9 551 on twin surface of exhaust camshaft.

Secure special tool 11 9 551 with a screw (1).

Mount special tool 11 9 551 on inlet and exhaust camshafts.

Screw in special tool 11 9 552 on cylinder head with a screw.

To release central bolts, always use special tool 11 9 551 .

Release screws (2).

Remove clamping rail (1).

Release screw (1).

For tightening torque refer to 11 11 3AZ in 11 11 ENGINE BLOCK .

Release central bolt (3).

For tightening torque refer to 11 36 2AZ in 11 36 VARIABLE CAMSHAFT CONTROL .

Feed out sprocket wheel (2) from timing chain (1) towards front.

Note. Do not remove VANOS adjustment unit.

Release central bolt (3).

For tightening torque refer to 11 36 1AZ in 11 36 VARIABLE CAMSHAFT CONTROL .

Screw special tool 11 9 661 with special tools 11 9 662 into spark plug holes.

Scheme 960

Release all screws on bearing caps (1 and 2).

For tightening torque refer to 11 12 7AZ in 11 12 CYLINDER HEAD WITH COVER .

Bearing cap (1) is a thrust bearing and has the number (0).

All bearing caps (2) are identified with numbers from (1 to 4).

Scheme 961

Exhaust camshaft is identified with designation (EX).

Insert exhaust camshaft so that designation (EX) can be read from above.

Position exhaust camshaft (1) so that cam of exhaust camshaft (1) points inward at an angle.

Installation

Lubricate all bearing points with engine oil.

Assemble engine.

Installation

Adjust Valve Timing .

11 31 051 Replacing timing chain (N14)

Special tools required

1. 00 9 120
2. 11 9 280
3. 11 9 550
4. 11 9 590

Necessary preliminary tasks

1. Remove «Cylinder Head Cover»(ref-265695-S22424985522007092500000) .
2. Remove all spark plugs.
3. Remove «Vibration Damper»(ref-265695-S27220438182007092500000) .
4. Remove «Chain Tensioner»(ref-265695-S33117497532007092500000) .
5. Remove «VANOS Adjustment Unit»(ref-265695-S15389816162007092500000) .
6. Remove sprocket wheel for exhaust camshaft.
7. Remove «PTFE Ring»(ref-265695-S09004444932007092500000) at front.
8. Remove «Belt Tensioner»(ref-265695-S19204159642007092500000) .

Position crankshaft with special tool 11 9 590 .

Do not remove special tool 11 9 590 during repair work.

Do not remove special tool 11 9 550 .

Fit special tool 11 9 280 on hub for vibration damper with screws (2).

Release central bolt (1).

Scheme 962

Release central bolt in direction of arrow.

For tightening torque refer to 11 21 1AZ in 11 21 CRANKSHAFT AND BEARINGS .

Scheme 963

Release bearing pins (1 and 2).

For tightening torque refer to 11 31 6AZ in 11 31 CAMSHAFT

Scheme 964

Remove hub (3) towards front.

Remove chain module with timing chain.

Using a hook (2), pull oil pump chain (1) upwards.

Scheme 965

Sprocket wheel (1) of timing chain.

Sprocket wheel (2) of oil pump.

Scheme 966

Secure chain module (1) with rubber (3) to facilitate assembly.

Pull timing chain (2) upwards until sprocket wheel (4) rests against chain guide (1).

Install timing chain (2) and sprocket wheel (4) in this position.

Installation

Always keep timing chain (2) tensioned; it is possible for timing chain (2) to jam on chain module (1).

Scheme 967

Installation position of both sprocket wheels.

Sprocket wheel (1) of oil pump.

Guide rail (2) of timing chain.

Hub (3) on crankshaft.

Sprocket wheel (4) of timing chain.

Scheme 968

Attach oil pump sprocket wheel (2) in direction of arrow to crankshaft (1).

Insert chain module with timing chain and secure.

Attach crankshaft hub.

Screw in central bolt.

Scheme 969

Remove special tool 11 9 280 from hub.

Secure central bolt with special tool 00 9 120 .

Scheme 970

Install VANOS Adjustment Unit .

Install sprocket wheel for exhaust camshaft.

Crank engine twice.

Check Timing .

Install PTFE Ring .

Assemble engine.

11 31 090 Installing and removing/replacing chain tensioner piston (N14)

Release chain tensioner (1).

For tightening torque refer to 11 31 4AZ in 11 31 CAMSHAFT .

Installation

No sealing ring is fitted during series-production assembly.

A sealing ring must be fitted by service personnel when the chain tensioner is fitted.

Scheme 971

If the chain tensioner is reused, its oil chamber must be drained. Place chain tensioner on a level working surface and slowly compress.

Repeat procedure twice.

Scheme 972

Assemble engine.

11 31 505 Adjusting camshaft timing (N14)

Special tools required

1. 00 9 120
2. 00 9 250
3. 11 9 340
4. 11 9 551
5. 11 9 590

Necessary preliminary tasks

1. Remove «Cylinder Head Cover.»(ref-265695-S22424985522007092500000)

Rotate crankshaft at central bolt.

Slide in special tool 11 9 590 in direction of arrow and block crankshaft.

Release chain tensioner (have a cleaning cloth ready).

For tightening torque refer to 11 31 4AZ in 11 31 CAMSHAFT .

To open central bolts (3), mount special tool 11 9 551 on camshafts.

Release central bolts (3).

For tightening torque refer to 11 36 2AZ in 11 36 VARIABLE CAMSHAFT CONTROL .

To open central bolts (3), mount special tool 11 9 551 on camshafts.

Release central bolts (3).

For tightening torque refer to 11 36 1AZ in 11 36 VARIABLE CAMSHAFT CONTROL .

The designations for the inlet camshaft (IN) and exhaust camshaft (EX) point upwards.

Both camshafts (inlet and exhaust) have three machined surfaces to enable special tool 11 9 551 to be mounted.

The fourth surface is not machined and is crescent-shaped - it must point downwards.

Note. Picture shows N12

Position of exhaust camshaft (1) points at an angle to the right in a lower inward direction.

Note. Picture shows sprocket wheel removed.

Position of inlet camshaft (1) points at an angle to the left in an upper inward direction.

Note. Picture shows VANOS adjustment unit removed.

Screw special tool 11 9 340 into cylinder head.

Pretension timing chain with special tool 00 9 250 to 0.6 Nm.

Scheme 973

Secure central bolt (1) with special tool 00 9 120 or an electronic torque wrench.

For tightening torque refer to 11 36 1AZ in 11 36 VARIABLE CAMSHAFT CONTROL .

Scheme 974

Secure central bolt (1) with special tool 00 9 120 or an electronic torque wrench.

For tightening torque refer to 11 36 2AZ in 11 36 VARIABLE CAMSHAFT CONTROL .

Scheme 975

Remove all special tools.

Assemble engine.

11 33 050 Removing and installing/replacing all cam followers (N14)

Special tools required

1. 11 4 480

Necessary preliminary tasks

1. Remove «Cylinder Head Cover.»(ref-265695-S22424985522007092500000) .
2. Remove «Inlet Camshaft»(ref-265695-S15955192902007092500000) .
3. Remove «Exhaust Camshaft»(ref-265695-S02061122602007092500000) .

Scheme 976

Detach roller cam followers (1) from HVCA element and remove.

Place roller cam followers (1) in neat order in special tool 11 4 480 .

Installation

Before installing camshafts, make sure roller cam followers are correctly seated (see arrow in (Scheme 977) ).

Scheme 977

Assemble engine.

11 34 552 Removing and installing or replacing all valves (N14)

Special tools required

1. 11 4 480

Necessary preliminary tasks

1. Remove «Cylinder Head»(ref-265695-S02156565622007092500000) .
2. Remove «Inlet Camshaft»(ref-265695-S15955192902007092500000) .
3. Remove «Exhaust Camshaft»(ref-265695-S02061122602007092500000) .
4. Remove «Roller Cam Follower»(ref-265695-S10424024372007092500000) .
5. Remove «Valve Springs»(ref-265695-S30416671822007092500000) .
6. Remove «Valve Stem Seals»(ref-265695-S17774781452007092500000) .

Arrangement

1. Valve
2. Valve stem seal with spring plate, bottom
3. Valve spring
4. Top plate spring
5. Valve tapers

If the valves are to be reused, set then down in special tool 11 4 480 in a tidy and orderly fashion.

Scheme 978

Assemble engine.

Check function of DME.

11 34 560 Replacing all valve stem seals (N14)

Special tools required

1. 11 1 480
2. 11 6 380

Necessary preliminary tasks

1. Remove «Cylinder Head»(ref-265695-S02156565622007092500000) .
2. Remove «Inlet Camshaft»(ref-265695-S15955192902007092500000) .
3. Remove «Exhaust Camshaft»(ref-265695-S02061122602007092500000) .
4. Remove «Roller Cam Follower»(ref-265695-S10424024372007092500000) .
5. Remove «All Valve Springs»(ref-265695-S30416671822007092500000) .

Firmly press special tool 11 1 480 onto old valve stem seals.

Detach valve stem seal from valve stem by turning and simultaneously pulling special tool 11 1 480 .

Installation

Insert all Valves .

Scheme 979

Note. For use on the N54 engine, special tool 11 6 380 must be remachined according to the sketch with a 10 mm dia. drill bit to a depth of B = approx. 23 mm. This modification has already been taken into account for reordering.

Scheme 980

Installation

Fit the mounting sleeves (plastic sleeves) supplied in the spare part on the valve stem end

Lubricate mounting sleeve.

Press on valve stem seal by hand with special tool 11 6 380 as far as it will go.

Scheme 981

Assemble engine.

11 34 715 Replacing all valve springs (N14)

Special tools required

1. 11 4 480
2. 11 9 000
3. 11 9 006
4. 11 9 007
5. 11 9 017

Necessary preliminary tasks

1. Remove «Cylinder Head Cover.»(ref-265695-S22424985522007092500000) .
2. Remove «Cylinder Head.»(ref-265695-S02156565622007092500000)
3. Remove «Exhaust Camshaft.»(ref-265695-S02061122602007092500000)
4. Remove «Inlet Camshaft.»(ref-265695-S15955192902007092500000)
5. Remove «Roller Cam Follower.»(ref-265695-S10424024372007092500000)

Place cylinder head (1) on special tool 11 9 000 .

Note. Illustration shows: N12.

Scheme 982

Prepare special tool 11 9 007 on special tool 11 9 006 .

Scheme 983

Align special tool 11 9 006 .

Lock eccentrics (1) on special tool 11 9 000 in direction of arrow.

Scheme 984

Press down valve spring and spring retainer (1) with special tool 11 9 017 .

Scheme 985

Remove valve tapers with a magnet.

Remove valve spring and spring retainer.

Set down on special tool 11 4 480 in a tidy and orderly fashion.

Scheme 986

Color marking (1) is normally on lower end of valve spring.

The larger diameter must point downwards to the valve stem seal.

Scheme 987

Arrangement

1. Valve
2. Valve stem seal with spring plate, bottom
3. Valve spring
4. Top plate spring
5. Valve tapers

Assemble engine.

Check function of DME.

11 36 655 Removing and installing/replacing both solenoid valves (N14)

Necessary preliminary tasks

1. Remove acoustic cover

Disconnect plug connection for solenoid valve (3) - inlet.

Release screw (1).

Remove solenoid valve (2) for inlet side.

Scheme 988

Installation

Replace sealing ring on solenoid valve.

Scheme 989

Assemble engine.

Check function of DME.

11 40 000 Checking engine oil pressure (N14)

Special tools required

1. 11 7 020
2. 11 9 560
3. 13 3 061
4. 13 3 063
5. 13 6 051
6. 13 6 054

Disconnect plug connection on oil pressure switch (1)

Scheme 990

Release oil pressure switch (1) with special tool 11 7 020 .

For tightening torque refer to 12 61 1AZ in 11 61 INTAKE MANIFOLD .

Scheme 991

Screw in special tool 11 9 560 with sealing ring on cylinder head.

Secure pressure gauge 13 3 063 to special tool 11 9 560 .

Scheme 992

Check engine oil pressure with diagnosis tester.

Connect special tools 11 9 560 / 13 6 054 and 13 6 051 .

Check engine oil pressure with pressure gauge.

Connect special tools 11 9 560 / 13 3 063 and 13 3 061 .

Start engine and check engine oil pressure.

Specified values.

Scheme 993

Assemble engine.

11 41 000 Removing and installing oil pump (N14)

Necessary preliminary tasks

1. Removing «Oil Pan»(ref-265695-S30013393602007092500000) .

Pull off cover (1) in direction of arrow.

Installation

Replace cover (1).

Scheme 994

Release screw (1).

For tightening torque refer to 11 41 2AZ in 11 41 OIL PUMP WITH STRAINER AND DRIVE .

Grip crankshaft central bolt (2) to release central bolt (1).

Scheme 995

Release screws (1).

For tightening torque refer to 11 41 1AZ in 11 41 OIL PUMP WITH STRAINER AND DRIVE .

Scheme 996

Assemble engine.

11 43 000 Removing and installing/replacing guide tube for dipstick (N14)

Necessary preliminary tasks

1. Pull dipstick out of guide tube.

Release screw (2).

For tightening torque refer to 11 43 1AZ in 11 43 OIL DIPSTICK .

Pull dipstick (1) up in direction of arrow.

Installation

Replace O-ring.

Scheme 997

Assemble engine.

Check engine oil level, top up if necessary

11 51 000 Removing and installing/replacing water pump (N14)

Recycling

Catch and dispose of drained coolant.

Observe country-specific waste-disposal regulations.

Necessary preliminary tasks

1. Remove «Friction Gear»(ref-265695-S29337389262007092500000) .

Release screws (1).

Installation

Replace seal.

Clean sealing surfaces.

Scheme 998

Assemble engine.

Vent Cooling System and check for leaks.

11 53 000 Removing and installing/replacing coolant thermostat (N14)

Special tools required

1. 17 2 050

Recycling

Catch and dispose of drained coolant.

Observe country-specific waste-disposal regulations.

Necessary preliminary tasks

1. Drain «Coolant»(ref-265699-S07723707932007092500000) from radiator.
2. Remove intake air «Manifold»(ref-265695-S39012197852007092500000) .

Release lock (1) on coolant pipe in direction of arrow.

Note. Release metal hose clamps with special tool 17 2 050 .

Disconnect plug connection (1) on coolant thermostat.

Scheme 999

Disconnect plug connection (1) on coolant temperature sensor.

Unfasten screws (2 and 3).

Scheme 1000

Installation

Replace seal (1).

Scheme 1001

For tightening torque refer to 11 53 1AZ in 11 53 THERMOSTAT AND CONNECTIONS .

Assemble engine.

11 53 590 Removing and installing/replacing auxiliary water pump (N14)

Special tools required

1. 17 2 052

Necessary preliminary tasks

1. Drain «Coolant»(ref-265699-S07723707932007092500000) from radiator.

Release hose clamps (1 and 2) with special tool 17 2 052 .

Detach coolant hoses from auxiliary water pump.

Disconnect plug connection (4).

Release screws (3).

For tightening torque refer to 11 53 3AZ in 11 53 THERMOSTAT AND CONNECTIONS .

Scheme 1002

Vent Cooling System .

Assemble engine.

11 61 050 Removing and installing intake air manifold (N14)

Necessary preliminary tasks

1. Disconnect «Battery Negative»(ref-264970-S35357489842007092000000) lead.
2. Remove suction filter housing.

Note. Picture shows EPPC removed.

Disconnect vacuum lines on vacuum connection (1 and 2).

Disconnect plug connection at EPPC.

Installation

OUT connector (1) is identified with a green ring.

Scheme 1003

Disconnect plug connection (1) on tank vent valve (2).

Detach hose from tank vent valve (2).

Scheme 1004

Unscrew nuts (1).

For tightening torque refer to 11 61 1AZ in 11 61 INTAKE MANIFOLD .

Scheme 1005

Installation

OUT connector on EPPC is identified with a green ring.

Vacuum line (1) is fitted with a green ring (OUT).

Vacuum line (2) without green ring (VAC).

Scheme 1006

Installation

Replace all seals.

Assemble engine.

11 61 365 Replacing left charge-air duct (N14)

Release screw and disengage coolant expansion tank (1) from rubber mount.

Lay expansion tank (1) to one side (do not remove).

Installation

Make sure bearing journal is installed in correct position in rubber mount.

Release clamp (2) and detach charge-air hose (3).

Scheme 1007

Release clamp and detach charge-air hose (1).

Scheme 1008

Release screw and remove charge-air duct (1).

Scheme 1009

11 61 362 Replacing right charge-air duct (N14)

Necessary preliminary tasks

1. Remove «Halogen»(ref-264972-S16789757782007092000000) or «Xenon»(ref-264972-S26425621502007092000000) right headlight

Release screw and remove holder (1).

Scheme 1010

Release bolt.

Scheme 1011

Release clamp and detach charge-air hose (1).

Installation

Fit charge-air hose dry and without grease.

Scheme 1012

Release bolt.

Release screws (1).

For tightening torque refer to 51 23 3AZ in 51 23 HOOD/BONNET LOCKS .

Release screw (2).

Scheme 1013

Release bolt.

Release screws (1).

For tightening torque refer to 51 11 7AZ in 51 11 FRONT BUMPER .

Unlock connector (2) and remove.

Release clamp (3).

Raise lock carrier (4) slightly.

Detach charge-air duct (5) from hose and remove.

Installation

Fit charge-air hose dry and without grease.

Scheme 1014

11 65 020 Removing and installing/replacing exhaust turbocharger (N14)

Necessary preliminary tasks

1. Remove «Exhaust Manifold»(ref-265700-S25409859502007092500000)

Installation

Replace seal.

Scheme 1015

Assemble engine.

11 66 000 Removing and installing/replacing vacuum pump (N14)

Release vacuum connection to brake booster.

Release screws (1).

For tightening torque refer to 11 66 1AZ in 11 66 VACUUM PUMP .

Scheme 1016

Installation

Replace sealing ring (1).

Scheme 1017

Assemble engine.

11 78 510 Removing and installing/replacing control sensor (N14)

Special tools required

1. 11 7 020

Installation

If an oxygen sensor is to be reused, only apply a thin and uniform coat of Never Seez Compound to thread.

The part of the oxygen control sensor which projects into the exhaust system branch (sensor ceramic) must not be cleaned or come into contact with lubricant.

Disconnect plug connection for control sensor.

Release oxygen sensor (1) with special tool 11 7 020 .

For tightening torque refer to 11 78 1AZ in 11 78 EMISSIONS CONTROL, CONTROL SENSOR / MONITOR SENSOR .

Scheme 1018

Assemble engine.

Check function of DME.

11 78 545 Removing and installing/replacing monitor sensor (N14)

Special tools required

1. 11 7 020

Installation

If an oxygen sensor is to be reused, only apply a thin and uniform coat of Never Seez Compound to thread.

The part of the oxygen monitor sensor which projects into the exhaust system branch (sensor ceramic) must not be cleaned or come into contact with lubricant.

Disconnect plug connection for monitor sensor.

Release monitor sensor (1) with special tool 11 7 020 .

For tightening torque refer to 11 78 1AZ in 11 78 EMISSIONS CONTROL, CONTROL SENSOR / MONITOR SENSOR .

Scheme 1019

Assemble engine.

Check function of DME.