Engine - Repair - Cooper S (W11 Engine): Other MINI Cooper I

11 00 039 Checking compression at all cylinders

Special tools required

1. 11 0 224
2. 11 8 490

Note. Read out fault memory of EMS/DME control unit, check stored fault messages, rectify faults and clear fault memory.

Switch off ignition.

Detach plug connector from ignition coil unit.

Scheme 278

Press securing clip (1) away.

Detach plug connector (2).

Unscrew all spark plugs. Refer to 12 12 011 REPLACING ALL SPARK PLUGS .

Screw special tool 11 8 490 into spark plug thread and connect special tool 11 0 224.

Scheme 279

Make sure seal of adapter tool is in proper working order.

Press accelerator pedal to floor and actuate starter motor until compression pressure stops rising.

Scheme 280

Compression pressure, Refer to ENGINE - TECHNICAL DATA .

Note. Disconnect ignition unit; this results in a defect trouble code being output during starting.

Connect DIS and delete stored faults.

Note. Read out fault memory of EMS/DME control unit, check stored fault messages, rectify faults and clear fault memory.

11 00 050 Removing and installing engine (COOPER S Automatic)

Special tools required

1. 11 0 001
2. 11 0 002
3. 11 0 003
4. 11 0 009
5. 11 8 260
6. 11 8 351
7. 11 8 401
8. 11 8 402
9. 13 5 280

Switch off ignition.

Install guard for intercooler.

Remove air filter housing. Refer to 13 71 000 REMOVING AND INSTALLING INTAKE FILTER HOUSING (COOPER S) .

Remove drive belt for auxiliary assemblies. Refer to 11 28 020 Replacing alternator drive belt tensioner (COOPER S) .

Drain off transmission oil. Refer to DRAINING & REFILLING .

Release bolts (1) and remove bracket (2).

Scheme 281

Tightening torque 11 12 10AZ. Refer to ENGINE - TIGHTENING TORQUES .

Detach plug connector (1) from steering pump motor.

Scheme 282

Remove impact tube. Refer to 31 11 020 Removing and installing/replacing bumper bracket .

Lower front end module and secure special tools 11 8 401 and 11 8 402.

Scheme 283

Remove chassis subframe. Refer to 31 11 001 Replacing front axle support .

Remove drive shafts. Refer to DRIVE AXLE SHAFT (LEFT) .

Remove exhaust manifold. Refer to 11 62 000 Removing and installing, sealing/replacing exhaust manifold .

Release retaining screw (1) for heat shield of starter motor.

Remove shield (2).

Scheme 284

Tightening torque 12 41 1AZ. Refer to ENGINE ELECTRICAL SYSTEM - TIGHTENING TORQUES .

Disconnect connections (1) and (2).

Scheme 285

Tightening torque 12 41 2AZ. Refer to ENGINE ELECTRICAL SYSTEM - TIGHTENING TORQUES .

Tightening torque 12 41 3AZ. Refer to ENGINE ELECTRICAL SYSTEM - TIGHTENING TORQUES .

Detach plug connector from oil pressure switch.

Note. Pay attention to routing of wiring harness.

Remove wiring harness fastener from starter motor and coolant pipe.

Slide wiring harness to one side.

Remove starter motor.

Tightening torque 12 41 4AZ. Refer to ENGINE ELECTRICAL SYSTEM - TIGHTENING TORQUES .

Remove intercooler. Refer to 17 51 000 Removing and installing/replacing intercooler .

Remove throttle. Refer to 13 54 030 REMOVING AND INSTALLING/SEALING THROTTLE ASSEMBLY .

Remove lower line of tank venting valve from stabilizer bracket.

Scheme 286

Disconnect grounding cable from right engine support frame.

Reduce fuel pressure in fuel line.

Disconnect fuel line by detaching quick -connect coupling from fuel rail and secure special tool 13 5 280.

Remove fuse box cover.

Disconnect plug connector (1) from fuse box.

Scheme 287

Release grounding cable (1) from left spring strut.

Scheme 288

Tightening torque 61 13 2AZ. Refer to GENERAL ELECTRICAL SYSTEM - TIGHTENING TORQUES .

Disconnect plug connector (2).

Drain coolant. Refer to 17 00 005 DRAINING AND ADDING COOLANT (COOPER S) .

Detach heating pipe connections (1) from heat exchanger for heating system.

Scheme 289

Detach lines (2) to expansion tank at heating pipe connection.

Remove top hose from radiator.

Remove top stabilizer bar bracket. Refer to 22 11 040 REPLACING UPPER ENGINE CARRIER BRACKET .

Release cable lock nut (1).

Scheme 290

Tightening torque 24 11 8AZ. Refer to TORQUE SPECIFICATIONS .

Press retaining clip (1) together and remove cable from fixture (2).

Scheme 291

Installation

Adjusting gear lever is described in Removing and installing shift tower. Refer to 25 16 056 Removing and installing/replacing shift tower (AISIN) .

Detach plug connector (1) from A/C compressor.

Scheme 292

Release retaining screws (2). Lower compressor (3) and secure to front end module.

Tightening torque 64 52 1AZ. Refer to HEATING AND AIR CONDITIONING - TIGHTENING TORQUES .

Release bolt (1) of coolant line and detach plug connector (2) from intake manifold pressure sensor.

Scheme 293

Detach coolant line (3).

Tightening torque 11 78 2AZ. Refer to ENGINE - TIGHTENING TORQUES .

Tightening torque 11 53 1AZ. Refer to ENGINE - TIGHTENING TORQUES .

Release retaining screw (1) on turbocharger inlet and open clamp (2).

Scheme 294

Detach turbocharger inlet pipe (3) from feed lines (4).

Note. Disconnect pipes at quick-connect couplings.

Detach line to brake booster from engine.

Release nut (1) and screws (2).

Scheme 295

Remove engine support bracket.

Tightening torque 22 11 1AZ. Refer to ENGINE AND GEARBOX SUSPENSION - TIGHTENING TORQUES .

Secure special tools 11 8 351.

Scheme 296

Tightening torque 11 12 9AZ. Refer to ENGINE - TIGHTENING TORQUES .

Secure special tool 11 8 260.

Scheme 297

Tightening torque 11 12 9AZ. Refer to ENGINE - TIGHTENING TORQUES .

Secure special tools 11 0 001, 11 0 002, 11 0 003, 11 0 009 to engine lifting gear.

Scheme 298

Secure lifting gear and chains to engine.

Note. It is recommended to secure the longer chain to the right engine lifting lug.

Release bolt (1) of transmission mount on left.

Scheme 299

Tightening torque, 66 Nm.

Lower engine and remove.

11 00 050 Removing and installing engine (COOPER S)

Special tools required

1. 11 0 001
2. 11 0 002
3. 11 0 003
4. 11 0 009
5. 11 8 260
6. 11 8 351
7. 11 8 401
8. 11 8 402
9. 13 5 280
10. 23 4 010

Turn off ignition.

Fit intercooler protector.

Remove intake air filter housing. Refer to 13 71 000 REMOVING AND INSTALLING INTAKE FILTER HOUSING (COOPER S) .

Remove auxiliary drive belt. Refer to 11 28 020 Replacing alternator drive belt tensioner (COOPER S) .

Drain gearbox. Refer to 00 11 229 OIL CHANGE IN MANUAL TRANSMISSION .

Remove lower stabilizer bracket bolts (1) and remove bracket (2).

Scheme 300

Tightening torque 11 12 16AZ. Refer to ENGINE - TIGHTENING TORQUES .

Disconnect steering pump motor connectors (1).

Scheme 301

Remove crush tubes. Refer to 31 11 020 Removing and installing/replacing bumper bracket .

Slacken modular front end and fit special tools 11 8 401 and 11 8 402.

Scheme 302

Remove subframe. Refer to 31 11 001 Replacing front axle support .

Remove driveshafts. Refer to DRIVE AXLE SHAFT (LEFT) .

Remove exhaust manifold. Refer to 11 62 000 Removing and installing, sealing/replacing exhaust manifold .

Remove starter motor heat shield retaining bolt (1).

Scheme 303

Remove heat shield (2).

Tightening torque 12 41 1AZ. Refer to ENGINE ELECTRICAL SYSTEM - TIGHTENING TORQUES .

Remove starter motor connections (1) and (2).

Scheme 304

Tightening torque 12 41 2AZ. Refer to ENGINE ELECTRICAL SYSTEM - TIGHTENING TORQUES .

Tightening torque 12 41 3AZ. Refer to ENGINE ELECTRICAL SYSTEM - TIGHTENING TORQUES .

Remove oil pressure connector.

Note. Harness routing.

Remove harness brackets from starter motor and cooling pipe.

Move harness to one side.

Remove reverse lamp connector from gearbox.

Remove intercooler. Refer to 17 51 000 Removing and installing/replacing intercooler .

Remove throttle valve. Refer to 13 54 030 REMOVING AND INSTALLING/SEALING THROTTLE ASSEMBLY (COOPER S) .

Remove tank venting valve lower pipe from stabilizer bracket.

Scheme 305

Remove earth lead from right engine mounting bracket.

Release fuel pressure from fuel line.

Disconnect fuel line from fuel rail via quick fit connector and fit special tool 13 5 280.

Remove fusebox cover.

Disconnect connector (1) from fusebox.

Scheme 306

Disconnect earth lead (1) from left strut.

Scheme 307

Tightening torque 61 13 2AZ. Refer to GENERAL ELECTRICAL SYSTEM - TIGHTENING TORQUES .

Disconnect connector (2).

Drain coolant. Refer to 17 00 005 DRAINING AND ADDING COOLANT (COOPER S) .

Disconnect both heater pipe connections (1) from heater matrix.

Scheme 308

Disconnect both expansion tank pipes (2) at heater pipe junction.

Remove top hose from radiator.

Remove top stabilizer bracket. Refer to 22 11 040 REPLACING UPPER ENGINE CARRIER BRACKET .

Remove slave cylinder retaining bolts (1) and remove slave cylinder (2).

Scheme 309

Release gearshift cables (1) from ball joints with special tool 23 4 010.

Scheme 310

Release and remove gearshift cables from abutment bracket (2).

Disconnect connector from A/C compressor (1).

Scheme 311

Remove A/C compressor retaining bolts (2) and lower compressor (3). Secure compressor to modular front end.

Tightening torque 64 52 1AZ. Refer to HEATING AND AIR CONDITIONING - TIGHTENING TORQUES .

Remove coolant pipe bolt (1) and disconnect map sensor connector (2).

Scheme 312

Disconnect coolant pipe (3).

Tightening torque 11 78 2AZ. Refer to ENGINE - TIGHTENING TORQUES .

Tightening torque 11 53 1AZ. Refer to ENGINE - TIGHTENING TORQUES .

Fit engine brackets, special tool 11 8 351 and special tool 11 8 260.

Scheme 313

Tightening torque 11 12 9AZ. Refer to ENGINE - TIGHTENING TORQUES .

Remove supercharger inlet retaining bolt (1) and release hose clip (2).

Scheme 314

Remove supercharger inlet pipe (3) to access pipes (4).

Note. Disconnect pipes via quick fit connector.

Remove brake booster pipe from engine.

Release slave cylinder pipe from gearbox and move to one side.

Fit engine lifting tools 11 0 001, 11 0 002, 11 0 003 and 11 0 009.

Scheme 315

Attach engine lifting bracket and chains to engine and support power unit with hoist.

Note. It is recommended to use the longer link chain on the right engine bracket.

Remove engine mount retaining nut (1).

Scheme 316

Tightening torque 11 12 13AZ. Refer to ENGINE - TIGHTENING TORQUES .

Remove gearbox to upper mount retaining bolt (1).

Scheme 317

Tightening torque 23 71 2AZ. Refer to TORQUE SPECIFICATIONS .

Lower engine and remove.

11 12 000 Removing and installing, sealing cylinder head cover (COOPER S)

Turn ignition off.

Remove intercooler. Refer to 17 51 000 Removing and installing/replacing intercooler .

Remove bolts (1) securing left hand bracket and remove bracket (2).

Scheme 318

Tightening torque 11 12 20AZ. Refer to ENGINE - TIGHTENING TORQUES .

Remove bolts (1) securing right hand bracket and remove bracket (2).

Scheme 319

Tightening torque 11 12 21AZ. Refer to ENGINE - TIGHTENING TORQUES .

Disconnect hose (1).

Scheme 320

Disconnect PCV valve (2).

Disconnect connector to coil pack (3).

Remove plug caps (twist and pull) (4).

Remove harness clips from inspection cover bolts.

Remove coil pack. Refer to 12 13 513 REPLACING IGNITION COIL .

Remove 12 cylinder head cover bolts.

Scheme 321

Remove cylinder head cover.

Install hint

Replace cylinder head cover gasket if necessary.

Scheme 322

Clean mating faces with a suitable material.

Note. Cylinder head cover fixing screws are separate from the cylinder head cover.

Replace retaining screws and insulators if damaged.

Install hint

Install cylinder head cover and tighten screws to sequence.

Scheme 323

Tightening torque 11 12 1AZ. Refer to ENGINE - TIGHTENING TORQUES .

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

Special tools required

1. 00 9 120
2. 11 5 150
3. 11 8 250
4. 11 8 370
5. 11 8 401
6. 11 8 402
7. 13 5 280
8. 33 2 140

Necessary preliminary tasks

1. Disconnect battery. Refer to «61 21 010 REMOVING AND INSTALLING BATTERY (COOPER S)»(ref-203084-S15080282162005103000000) .
2. Remove intercooler. Refer to 17 51 000 Removing and installing/replacing intercooler .
3. Disconnect plug connector from EMS/DME.
4. Remove air filter housing. Refer to «13 71 000 REMOVING AND INSTALLING INTAKE FILTER HOUSING (COOPER S)»(ref-203052-S14046533302005103000000) .
5. Remove throttle. Refer to «13 54 030 REMOVING AND INSTALLING/SEALING THROTTLE ASSEMBLY (COOPER S)»(ref-203052-S08842154862005103000000) .
6. Remove cylinder head. Refer to «11 12 000 Removing and installing, sealing cylinder head cover (COOPER S)»(ref-204047-S06318885582005110800000) .
7. Remove tank venting valve. Refer to «13 90 500 REPLACING TANK VENTING VALVE»(ref-203052-S10207261352005103000000) .
8. Remove intake manifold. Refer to «11 61 051 Removing and installing intake manifold (COOPER S)»(ref-204047-S06174006432005110800000) .
9. Remove charger outlet pipe. Refer to «17 51 080 REMOVING AND INSTALLING/REPLACING TURBOCHARGER EXHAUST PIPE (RIGHT)»(ref-204052-S25711078822005110800000) .
10. Drain coolant. Refer to «17 00 005 DRAINING AND ADDING COOLANT (COOPER S)»(ref-203063-S08331852762005103000000) .
11. Detach exhaust manifold. Refer to «11 62 000 Removing and installing, sealing/replacing exhaust manifold»(ref-204047-S32559562982005110800000) .
12. Remove spark plugs. Refer to «12 12 011 REPLACING ALL SPARK PLUGS»(ref-203047-S16593721202005103000000) .
13. Remove wheel arch liner. Refer to «51 71 040 REMOVING AND INSTALLING/REPLACING FRONT LEFT OR RIGHT WHEEL ARCH LINER»(ref-203078-S35135088012005103000000) .

Recycling

Catch and dispose of escaping fuel.

Catch and dispose of drained coolant.

Observe country-specific waste -disposal regulations.

Lower front end module.

Scheme 324

Mount front end module and extensions

Special tools 11 8 401 and 11 8 402.

Disconnect fuel line by detaching quick -connect coupling from fuel rail and fit special tool 13 5 280.

Scheme 325

Detach both lines from stabilizer bracket and push to one side.

Remove screws (1) for stabilizer bracket.

Scheme 326

Remove stabilizer bracket.

Detach oxygen sensor plug connector (1).

Scheme 327

Remove holder for oxygen sensor plug connector from cylinder head (2).

Remove retaining screw (3) of coolant distributor pipe.

Detach plug connector (4) from coolant temperature sensor.

Detach coolant lines (5).

Disconnect plug connector of camshaft sensor.

Remove dipstick.

Remove bolts (1) for engine carrier and unscrew retaining nut (2) for engine mount.

Scheme 328

Remove engine carrier.

Old version

Remove engine hydraulic mount. Refer to 22 11 001 REPLACING RIGHT ENGINE MOUNT .

Secure special tool 11 8 370 to engine block with bolts (1).

Scheme 329

Screw in bolt (2) in position of engine mount.

New version

Remove engine hydraulic mount. Refer to 22 11 001 REPLACING RIGHT ENGINE MOUNT .

Secure special tool 11 8 370 to engine block with bolts (1).

Scheme 330

Screw in special tool 11 5 150 in position of engine mount.

Remove camshaft sensor (1).

Scheme 331

Release sealing screws in cylinder head (2).

Rotate crankshaft until triangular adjustment mark on camshaft gear is at 12 o'clock (1).

Scheme 332

For assembly, mark timing chain at triangular adjustment mark (2) with paint.

The copper-colored link must not be used for this operation.

Slacken camshaft retaining bolt (1) and secure camshaft gear with special tool 11 8 250, but do not remove.

Scheme 333

Remove wiring harness bracket (1), remove screw plug (2) for timing chain tensioner and remove clamping fixture.

Scheme 334

Unscrew retaining bolt for camshaft gear, then remove gear wheel and chain.

Scheme 335

Remove camshaft gear from chain and lower timing chain in crankcase.

Unscrew retaining bolts (1) of chain guides and remove both guides (2).

Note. The timing chain cover does not have to be removed for this operation. This illustration shows the layout of the timing chain guides.

Slacken cylinder head bolts and cylinder head mounts in sequence (12-1).

Scheme 336

Unscrew cylinder head bolts and remove cylinder head mountings.

Remove cylinder head and gasket.

Installation

Multilayer steel seals (MLS) require a scratch -free sealing surface, therefore proceed with care when cleaning aluminum engine components.

Clean all engine oil ducts.

Check cylinder head with a commercially available steel ruler diagonally and horizontally for surface evenness.

Scheme 337

Max. permitted cylinder head distortion is 0.1 mm.

Check whether the adapter sleeves (1) are undamaged and located in the correct positions.

Scheme 338

There must be no oil in the pocket holes of the threaded holes, clean bores if necessary (risk of cracking).

Replace cylinder head gasket. The larger holes (1) serve to align the gasket on the engine block guide pins.

Scheme 339

Install cylinder head.

Tighten down cylinder head bolts and cylinder head mounts in sequence (1-10).

Tightening torque 11 12 3AZ. Refer to ENGINE - TIGHTENING TORQUES .

Tighten down cylinder head bolts in sequence (11 -12).

Scheme 340

Tightening torque 11 12 4AZ. Refer to ENGINE - TIGHTENING TORQUES .

Use special tool 00 9 120 for angle-of-rotation tightening.

Scheme 341

Retrieve timing chain with magnet or manufactured hook from crankcase.

Place timing chain on camshaft flange.

Install timing chain guides.

Insert retaining screws of guides.

Tightening torque 11 12 12AZ. Refer to ENGINE - TIGHTENING TORQUES .

Align the triangular adjustment mark on the camshaft gear to the timing chain link which was assigned a color marking on disassembly.

Scheme 342

Place timing chain on camshaft gear.

Mount camshaft gear on camshaft flange and insert retaining bolt.

Tightening torque 11 12 5AZ. Refer to ENGINE - TIGHTENING TORQUES .

Move timing chain tensioner back into transition position.

Scheme 343

Place clamping fixture (1) on a level surface.

Remove cap (2) from clamping fixture.

Place palm of hand against clamping fixture and exert continuous pressure until clamping fixture is completely compressed.

Refit cap (2) on clamping fixture after resetting.

Mount timing chain tensioner (1) in housing and tighten down.

Scheme 344

Tightening torque 11 12 6AZ. Refer to ENGINE - TIGHTENING TORQUES .

Note. Transition position of clamping fixture.

Note. Make sure timing chain is correctly arranged inside channel of timing chain guides.

Do not lever directly at the chain. This can damage the timing chain.

Using special tool 33 2 140 lever at right (moving) timing chain guide until timing chain tensioner tensions chain.

Scheme 345

Pay attention to release position of clamping fixture (1).

Scheme 346

Installation

Provide plugs with new sealing rings and screw into cylinder head again.

Tightening torque 13 62 1AZ. Refer to FUEL SYSTEM - TIGHTENING TORQUES .

Install camshaft sensor.

Tightening torque 11 12 7AZ. Refer to ENGINE - TIGHTENING TORQUES .

Install hydraulic mount.

Tightening torque 11 12 11AZ. Refer to ENGINE - TIGHTENING TORQUES .

Mount engine carrier on cylinder head.

Tightening torque 11 12 9AZ. Refer to ENGINE - TIGHTENING TORQUES .

Mount engine carrier on engine mount.

Tightening torque 11 12 13AZ. Refer to ENGINE - TIGHTENING TORQUES .

Install stabilizer bracket.

Tightening torque 11 12 14AZ. Refer to ENGINE - TIGHTENING TORQUES .

Tightening torque 11 12 15AZ. Refer to ENGINE - TIGHTENING TORQUES .

Assemble engine.

11 12 260 Removing and installing spark plug well

Special tools required

1. 11 8 500
2. 12 1 211
3. 12 1 212

Necessary preliminary tasks

1. Remove cylinder head cover. Refer to «11 12 000 Removing and installing, sealing cylinder head cover (COOPER S)»(ref-204047-S06318885582005110800000) .
2. Remove spark plug. Refer to «12 12 011 REPLACING ALL SPARK PLUGS»(ref-203047-S16593721202005103000000) .

Fit special tool 11 8 500 in spark plug well.

Scheme 347

Firmly tighten retaining claws (1) with lock screw (2).

Screw on adapter (3).

Screw in impact weight with screw (4).

Note. Drive out spark plug well.

Installation note

Spark plug well must be replaced after disassembly.

Clean area around spark plug well.

Scheme 348

Apply 3 mm thick bead of Loctite 277 sealing compound at a distance of about 1 mm from the end of the well.

To be obtained from BMW Parts Service.

1 = Bead of sealing compound

2 = 1 mm from end of well

Screw special tool 12 1 212 into spark plug hole.

Scheme 349

Carefully install spark plug well (1).

Scheme 350

Fit well with special tool 12 1 211.

Use special tool 12 1 211 to drive in spark plug well.

Installation note

Spark plug well (1) is installed correctly when special tool 12 1 211 makes contact with special tool 12 1 212.

Assemble engine.

11 12 264 Replacing seals for spark plug well

Special tools required

1. 24 1 040

Necessary preliminary tasks

1. Remove cylinder head cover. Refer to «11 12 000 Removing and installing, sealing cylinder head cover (COOPER S)»(ref-204047-S06318885582005110800000) .

Use a suitable tool to carefully remove spark plug seals (1).

Scheme 351

Clean all sealing surfaces.

Installation note

Fit seals (1) with special tool 24 1 040.

Scheme 352

Only use hand force to press in seals (1).

Lightly oil seals before installing cylinder head cover.

Note. Ensure that the sealing surfaces of cylinder head cover are not damaged.

Replace seals if they show signs of hardening and cracking.

Assemble engine.

11 12 729 Checking cylinder head for water leaks (W10 /W11)

Special tools required

1. 11 8 431
2. 11 8 432
3. 11 8 433

Necessary preliminary tasks

1. Remove cylinder head. Refer to «11 12 100 Removing and installing/sealing cylinder head (COOPER S)»(ref-204047-S35461305632005110800000) .
2. Remove camshaft. Refer to «11 31 001 Replacing camshaft»(ref-204047-S31688989462005110800000) .
3. Remove thermostat.

Place special tools 11 8 431 on sealing surface of cylinder head.

Scheme 353

Secure special tools 11 8 431 with special tool 11 8 433.

Note. Clean sealing surfaces.

Close off coolant opening with special tool 11 8 432.

Scheme 354

Connect compressed air supply to special tool 11 8 432.

Scheme 355

Test pressure: 4.5 bar.

Immerse cylinder head in a water bath.

Check cylinder head for escaping air (cracks).

Note. If necessary, soften the bath water with a cleaning agent.

Assemble engine.

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

Special tools required

1. 11 8 401
2. 11 8 402

Switch off ignition.

Disconnect battery. Refer to 61 21 010 REMOVING AND INSTALLING BATTERY (COOPER S) .

Remove alternator drive belt.

Unscrew and remove splash guard.

Unscrew oil drain plug (1).

Scheme 356

Drain engine oil.

Tightening torque, 11 13 1AZ.

Top up engine oil.

Start engine and run until oil indicator lamp goes out.

Switch off engine and wait approx. 5 minutes.

Check engine oil level.

Top up if necessary.

Remove impact tube. Refer to 31 11 020 Removing and installing/replacing bumper bracket .

Lower front end module and fit special tools 11 8 401 and 11 8 402.

Scheme 357

Detach plug connector from A/C compressor (1).

Scheme 358

Remove retaining screws (2) of A/C compressor and lower compressor (3).

Secure compressor to front end module.

Unclip high -pressure line of A/C system.

Tightening torque 64 52 1AZ. Refer to HEATING AND AIR CONDITIONING - TIGHTENING TORQUES .

Remove screws (1) of lower stabilizer bar and remove stabilizer bar.

Scheme 359

Remove retaining screws (2) and remove bracket from oil sump.

Tightening torque 11 12 16AZ. Refer to ENGINE - TIGHTENING TORQUES .

Tightening torque 11 12 19AZ. Refer to ENGINE - TIGHTENING TORQUES .

Remove retaining screws (1) for transmission.

Scheme 360

Note. Two shorter screws are inserted into oil sump.

Tightening torque 21 11 1AZ. Refer to TORQUE SPECIFICATIONS .

Installation

Clean mating surfaces of oil sump and cylinder block and check for damage.

Scheme 361

Replace gasket.

Remove oil sump screws in specified sequence (13 -1) and remove oil sump.

Scheme 362

Tighten down oil sump screws in specified sequence (1 -13).

Tightening torque 11 13 2AZ. Refer to ENGINE - TIGHTENING TORQUES .

Note. Position gasket in accordance with alignment lugs.

11 14 122 Removing and installing, sealing / replacing timing case cover (COOPER S)

Remove alternator drive belt tensioner. Refer to 11 28 020 Replacing alternator drive belt tensioner (COOPER S) .

Remove idler pulley (1) from front timing cover.

Scheme 363

Tightening torque 11 14 2AZ. Refer to ENGINE - TIGHTENING TORQUES .

Remove timing cover in sequence (11 -1).

Scheme 364

Install hint

Align oil pump rotor flats with flats on crankshaft as you install the timing case cover to the cylinder block.

Tighten timing case cover in sequence (1 -11).

Tightening torque 11 14 1AZ. Refer to ENGINE - TIGHTENING TORQUES .

Note location of the Torx shoulder bolt (1), Torx round head bolt (2) and bolt with seal (3).

Scheme 365

Install hint

Clean sealing surface.

Replace seal on bolt (3) and lubricate with clean engine oil.

Remove timing case cover seals.

Scheme 366

1. Cover seal.

2. Oil pump inlet seal.

3. Oil pump outlet seal.

Install hint

Clean all sealing surfaces and install new seals.

Apply a 3 mm bead of Loctite RTV 5999 sealer to cylinder block/bearing ladder joint (1).

Scheme 367

Prime oil pump before installation by filling rotor cavity with engine oil.

Start engine and check for leaks.

11 14 141 Replacing shaft seal below timing chain cover

Special tools required

1. 11 2 320
2. 11 8 241
3. 11 8 242
4. 11 8 270
5. 11 8 290

Necessary preliminary tasks

1. Remove vibration damper. Refer to «11 23 010 Removing and installing or replacing vibration damper (COOPER S)»(ref-204047-S11929233792005110800000) .

Insert special tool 11 8 270 in crankshaft.

Scheme 368

Place special tool 11 8 290 on crankshaft and screw in until is firmly contacts shaft seal (1).

Scheme 369

Pull out shaft seal (1) by tightening screw.

Remove special tool 11 8 270.

Screw special tool 11 8 242 into crankshaft.

Scheme 370

Coat sealing lip of new shaft seal with oil.

Press in shaft seal with special tools 11 2 320 and 11 8 241.

Scheme 371

Installation

The shaft seal is correctly fitted when it is flush with the timing chain cover.

Assemble engine.

Check engine for leaks.

11 14 151 Replacing crankshaft radial seal

Special tools required

1. 00 5 500
2. 11 8 220
3. 11 8 230
4. 23 0 490

Remove transmission.

1. For automatic transmission, refer to «REMOVAL & INSTALLATION - AUTOMATIC TRANSMISSION»(ref-170110) .
2. For manual transmission, refer to «REMOVAL & INSTALLATION - COOPER S»(ref-170688) .

Remove flywheel. Refer to 11 22 500 Removing and installing or replacing flywheel (COOPER S) .

Remove radial shaft seal with special tool 23 0 490.

Scheme 372

Clean surfaces of cylinder block and crankshaft seal.

Installation

Fit special tool 11 8 220 on crankshaft.

Push radial shaft seal onto special tool 11 8 220.

Scheme 373

Installation

Install radial shaft seal with special tool 00 5 500 in conjunction with special tool 11 8 230 in cylinder block.

Scheme 374

Make sure radial shaft seal is flush with cylinder block.

Scheme 375

11 15 025 Removing or replacing engine vent valve

Remove retaining screw (1) and valve (2).

Scheme 376

Disconnect hose (3 from valve.

Installation note

Apply a thin coating of clean engine oil to O -ring.

Tightening torque 11 12 18AZ. Refer to ENGINE - TIGHTENING TORQUES .

11 22 500 Removing and installing or replacing flywheel (COOPER S)

Special tools required

1. 11 8 460

Remove clutch. Refer to CLUTCH .

Fit special tool 11 8 460 to retain crankshaft pulley.

Scheme 377

Slacken bolts in sequence (8 -1) and remove flywheel.

Scheme 378

Align flywheel location mark (1) with crankshaft location mark (2).

Scheme 379

Note. Flywheel bolts must be replaced.

Tighten bolts in sequence (1-8).

Scheme 380

Tightening torque 11 22 2AZ. Refer to ENGINE - TIGHTENING TORQUES .

11 25 671 Replacing piston rings on all pistons (W10/W11)

Necessary preliminary tasks

1. Remove pistons.

Measuring axial clearance of piston rings in piston ring groove (1 and 2)

Scheme 381

Refer to ENGINE - TECHNICAL DATA .

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

Remove piston rings (1 and 2) with piston ring compressing pliers.

Scheme 382

Note. It might not be possible to find the identification on used piston rings.

Installation

Put aside piston rings in correct sequence and installation position.

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

Measure end clearance.

Scheme 383

Refer to ENGINE - TECHNICAL DATA .

Installation

The taper face compression ring "top" is marked with an identification dot (1).

Scheme 384

Note. Picture shows a schematic representation.

Installation

Install piston rings with "identification dot" to piston crown.

Scheme 385

1. Plain compression ring
2. Taper face compression ring "identification dot"
3. Two-part oil scraper ring.

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

Installation

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

Scheme 386

Insert support spring (2) into piston ring groove and then fit steel band rings (1) so that contact points are offset by approx. 120°.

11 28 020 Replacing alternator drive belt tensioner (COOPER S)

Special tools required

1. 11 8 410
2. 11 8 470

Remove alternator drive belt. Refer to 11 28 050 Removing A/C compressor drive belt (COOPER S) .

Remove vibration damper. Refer to 11 23 010 Removing and installing or replacing vibration damper (COOPER S) .

Release drive belt tension with special tool 11 8 410 and remove locking pin 11 8 470.

Remove retaining bolts (1) and (2).

Scheme 387

Remove tensioner (3).

Tightening torque 11 28 1AZ. Refer to ENGINE - TIGHTENING TORQUES .

Tightening torque 11 28 2AZ. Refer to ENGINE - TIGHTENING TORQUES .

Tightening torque 11 28 3AZ. Refer to ENGINE - TIGHTENING TORQUES .

11 28 050 Removing A/C compressor drive belt (COOPER S)

Special tools required

1. 11 8 410
2. 11 8 470

Necessary preliminary tasks

1. Remove tank venting valve. Refer to «13 90 500 REPLACING TANK VENTING VALVE»(ref-203052-S10207261352005103000000) .
2. Remove underpan. Refer to «51 47 490 REMOVING AND INSTALLING/REPLACING FRONT UNDERBODY PROTECTION (ENGINE)»(ref-203078-S25934204192005103000000) .
3. Remove right front wheel. Refer to «36 10 300 REMOVING OR INSTALLING FRONT OR REAR WHEEL»(ref-203076-S22577949262005103000000) .
4. Remove right wheel arch liner. Refer to «51 71 040 REMOVING AND INSTALLING/REPLACING FRONT LEFT OR RIGHT WHEEL ARCH LINER»(ref-203078-S35135088012005103000000) .

Note. If special tool 11 8 410 is used in a car with an Aisin transmission, special tool 11 8 410 must be changed.

Modify special tool 11 8 410 at studs (1) to 5 mm.

Scheme 388

Pull dipstick out of dipstick tube.

Remove tank venting valve.

Insert special tool 11 8 410 as shown.

Scheme 389

Note. Make sure paintwork is not damaged.

Attach special tool 11 8 410 to tensioner (1).

Scheme 390

Relieve tension of drive belt and block tensioner with locking pin, special tool 11 8 470.

Note. A second person may be needed to hep install special tool 11 8 470 in the second bore hole.

Remove drive belt.

Examine drive belt for traces of coolant or oil, replace if necessary.

Assemble engine. Check that drive belt is in correct installation position.

11 31 001 Replacing camshaft

Special tools required

1. 11 8 250
2. 11 8 370

Necessary preliminary tasks

1. Remove spark plugs. Refer to «12 12 011 REPLACING ALL SPARK PLUGS»(ref-203047-S16593721202005103000000) .
2. Remove wheel arch liner. Refer to «51 71 040 REMOVING AND INSTALLING/REPLACING FRONT LEFT OR RIGHT WHEEL ARCH LINER»(ref-203078-S35135088012005103000000) .
3. Remove cylinder head cover. Refer to «11 12 000 Removing and installing, sealing cylinder head cover (COOPER S)»(ref-204047-S06318885582005110800000) .
4. Remove left engine mounting. Refer to «22 11 001 REPLACING RIGHT ENGINE MOUNT»(ref-203069-S28234750452005103000000) .
5. Remove hydraulic chain tensioner. Refer to «11 31 091 Removing and installing/replacing hydraulic chain tensioner (COOPER S)»(ref-204047-S03689452182005110800000) .
6. Remove rocker arm shafts. Refer to «11 33 020 Removing and installing or replacing rocker arm shaft»(ref-204047-S29371857512005110800000) .

Fit special tool 11 8 370 on cylinder block (1) and fixture of engine mounting (2).

Scheme 391

Disconnect plug connector of camshaft sensor. Remove retaining screw (1) and camshaft sensor (2).

Scheme 392

Installation note

Apply a thin coating of clean engine oil to seal.

Tightening torque 13 62 1AZ. Refer to FUEL SYSTEM - TIGHTENING TORQUES .

Rotate crankshaft until triangular adjustment mark (2) on camshaft gear is at 12 o'clock.

Scheme 393

Mark vibration damper and timing case cover with paint.

Note. The brass-colored links are of no importance to the timing.

Secure special tool 11 8 250 to camshaft gear.

Scheme 394

Slacken central bolt (1).

Make sure that the marking on the camshaft gear and the color marking are aligned.

Scheme 395

Remove central bolt.

Tightening torque 11 12 5AZ. Refer to ENGINE - TIGHTENING TORQUES .

Remove all camshaft bearing caps and camshaft.

Scheme 396

Note. Alignment and numbers (1 - 5) of camshaft bearing caps.

Measure cam wear (measurement of non -worn area minus measurement of worn area) and replace camshaft if the result is outside the permitted values.

Cam wear: refer to ENGINE - TECHNICAL DATA .

1. Non-worn area.
2. Wear.
3. Bearing journal.
4. Cam.
5. Wear zone.

Scheme 397

Installation note

Using a feeler gauge (1), measure the camshaft axial play between camshaft stub (2) and cylinder head (3).

Scheme 398

Refer to ENGINE - TECHNICAL DATA .

Installation note

1. Lubricate camshaft bearing journals with clean engine oil.
2. Install camshaft bearing caps in correct installation sequence.
3. Lubricate rocker arm rolling area with clean engine oil.

Assemble engine.

11 31 051 Replacing timing chain

Special tools required

1. 11 2 000
2. 11 8 250
3. 11 8 300
4. 11 8 370

Necessary preliminary tasks

1. Unscrew all spark plugs. Refer to «12 12 011 REPLACING ALL SPARK PLUGS»(ref-203047-S16593721202005103000000) .
2. Remove cylinder head cover. Refer to «11 12 000 Removing and installing, sealing cylinder head cover (COOPER S)»(ref-204047-S06318885582005110800000) .
3. Remove pulse generator on camshaft. Refer to «12 14 537 REPLACING CAMSHAFT PULSE GENERATOR»(ref-203047-S08172236812005103000000) .
4. Remove hydraulic chain tensioner. Refer to «11 31 091 Removing and installing/replacing hydraulic chain tensioner (COOPER S)»(ref-204047-S03689452182005110800000) .
5. Remove timing chain cover. Refer to «11 14 122 Removing and installing, sealing / replacing timing case cover (COOPER S)»(ref-204047-S26980237982005110800000) .
6. Remove left engine mounting. Refer to «22 11 001 REPLACING RIGHT ENGINE MOUNT»(ref-203069-S28234750452005103000000) .

Fit special tool 11 8 370 on cylinder block (1) and engine mounting (2).

Scheme 399

Release camshaft retaining bolt (1) and hold camshaft gear with special tool 11 8 250.

Scheme 400

Unscrew plugs (2).

Unscrew retaining bolt for camshaft gear, then remove gear wheel and chain.

Scheme 401

Remove camshaft gear from timing chain.

Unscrew retaining bolts (1) of chain guides and remove both guides (2).

Installation note

If the timing chain is replaced, the camshaft gear and crankshaft gear must also be replaced.

Remove crankshaft gear using special tool 11 8 300 together with 11 2 000.

Scheme 402

Installation note

Shrink-fit crankshaft gear (1) onto crankshaft.

Scheme 403

Check correct position of locating pin (2).

Use a hotplate to heat crankshaft gear to a maximum temperature of 150°C.

Install timing chain.

Scheme 404

Install clamping rail and guide rail (2).

Install retaining screws (1) of chain guides.

Tightening torque: 11 12 12AZ. Refer to ENGINE - TIGHTENING TORQUES .

Place timing chain on camshaft gear.

Fit camshaft gear onto camshaft.

Fit central bolt for camshaft gear.

Tightening torque 11 12 5AZ. Refer to ENGINE - TIGHTENING TORQUES .

Installation note

Triangular adjustment mark (1) on camshaft gear must be aligned with copper -colored timing chain links (2).

Scheme 405

Installation note

The two triangular adjustment marks (1) on crankshaft gear must be aligned with copper -colored timing chain links (2).

Scheme 406

1. Camshaft adjustment mark lines up with colored chain link.
2. Camshaft gear.
3. Left timing chain guide.
4. Right timing chain guide.
5. Tensioning device for timing chain.
6. Crankshaft gear.
7. Chain.
8. Crankshaft adjustment mark lines up with the two colored chain links.

Assemble engine.

11 31 091 Removing and installing/replacing hydraulic chain tensioner (COOPER S)

Special tools required

1. 33 2 140

Turn off ignition.

Disconnect battery. Refer to 61 21 010 REMOVING AND INSTALLING BATTERY (COOPER S) .

Remove inspection cover. Refer to 11 12 000 Removing and installing, sealing cylinder head cover (COOPER S) .

Remove right front road wheel. Refer to 36 10 300 REMOVING OR INSTALLING FRONT OR REAR WHEEL .

Remove timing chain tensioner plug (1) and tensioner.

Scheme 407

Install hint

Reset timing chain tensioner to the transit position.

Scheme 408

Place the tensioner (1) on a flat surface.

Remove tensioner reservoir cap (2).

Place the palm of your hand against the tensioner, with continuous pressure until the tensioner is fully compressed.

Refit tensioner reservoir cap (2) after reset.

Install hint

Check/replace sealing ring of tensioner plug.

Scheme 409

Install the timing chain tensioner (1) into its housing and tighten.

Tightening torque 11 12 6AZ. Refer to ENGINE - TIGHTENING TORQUES .

Note. Transit position of tensioner.

Ensure the timing chain is properly positioned within the channel of the timing chain guides.

Do not lever directly on chain. Damage to the timing chain may occur.

Install hint

Using special tool 33 2 140, lever on the right (movable) timing chain guides until the timing chain tensioner ratchets out to tension the chain.

Scheme 410

Note. The timing chain cover is not required to be removed for this process. This picture is used to illustrate the timing chain guide arrangement.

Scheme 411

Note. The released position of the tensioner (1).

11 33 020 Removing and installing or replacing rocker arm shaft

Disconnect battery. Refer to 61 21 010 REMOVING AND INSTALLING BATTERY (COOPER S) .

Remove cylinder head cover. Refer to 11 12 000 Removing and installing, sealing cylinder head cover (COOPER S) .

Remove screws from rocker arm shaft or camshaft bearing cap in sequence (10-1).

Scheme 412

Installation

Tighten down screws from rocker arm shaft or camshaft bearing cap in sequence (1 -10).

Step 1: Tighten uniformly hand -tight.

Step 2: Tightening torque 11 33 1AZ. Refer to ENGINE - TIGHTENING TORQUES .

Remove exhaust rocker arm shaft (1) and inlet rocker arm shaft (2).

Scheme 413

Detach rocker arm spacer.

Remove rocker arm from shaft.

Note. Lubricate rolling area or rocker arm and shaft with clean engine oil. Hydraulic valve tappets are replaced together with rocker arms. When tightening the rocker arm/camshaft bearing cap screws, make sure the bearing caps are correctly seated and the rocker arms are in the correct installation position.

Scheme 414

1. Inlet rocker arm shaft
2. Exhaust rocker arm shaft
3. Groove for identifying inlet rocker arm shaft
4. Groove for identifying exhaust rocker arm shaft

11 33 031 Replacing rocker arms

Remove rocker arms. Refer to 11 33 020 Removing and installing or replacing rocker arm shaft .

11 34 560 Replacing all valve stem seals (W10/W11)

Special tools required

1. 11 1 130
2. 11 1 380
3. 11 1 480
4. 11 8 421
5. 11 9 000

Necessary preliminary tasks

1. Remove cylinder head cover. Refer to «11 12 000 Removing and installing, sealing cylinder head cover (COOPER S)»(ref-204047-S06318885582005110800000) .
2. Remove camshaft. Refer to «11 31 001 Replacing camshaft»(ref-204047-S31688989462005110800000) .

Mount cylinder head on special tool 11 9 000.

Scheme 415

Press down with special tool 11 8 421.

Remove valve collets (1).

Scheme 416

Remove all valve springs.

Press special tool 11 1 480 onto valve stem seal (1).

Scheme 417

Remove the valve stem seal by turning and simultaneously pulling with the special tool 11 1 480.

Fit special tool 11 1 380.

Scheme 418

Fit new valve stem seal (1).

Installation

Oil valve stem and valve stem seal.

Press on valve stem seal with special tool 11 1 130 as far as it will go.

Scheme 419

Installation

Valve stem seal must be flush.

Assemble engine.

11 40 000 Checking engine oil pressure

Special tools required

1. 11 8 360
2. 13 3 061
3. 13 3 063
4. 13 6 051
5. 13 6 054

Note. To check engine oil pressure and oil pressure switch, install and connect special tools.

Unscrew oil filter cap; engine oil flows out of oil filter housing into oil sump.

If oil pressure is zero at idle, do not rev engine to 3000 RPM.

Installation

1. Replace sealing ring.
2. Tightening torque 11 42 1AZ. Refer to «ENGINE - TIGHTENING TORQUES»(ref-203120) .

Remove oil pressure switch.

Installation

1. Tightening torque, 12 61 1AZ. Refer to «ENGINE ELECTRICAL SYSTEM - TIGHTENING TORQUES»(ref-203122) .

Install special tool 11 8 360 with sealing ring (1) in place of oil pressure switch.

Scheme 420

Checking engine oil pressure with DIS Tester

Attach special tool 13 6 054 with sealing ring (1) and special tool 13 6 051 and connect to DIS Tester.

Scheme 421

Checking engine oil pressure with pressure measuring instrument

Fit special tools 13 3 063 and 13 3 061 (pressure measuring instrument).

Start engine and check engine oil pressure.

Refer to ENGINE - TECHNICAL DATA .

11 41 000 Removing and installing or replacing oil pump

Necessary preliminary tasks

1. Remove timing chain cover. Refer to «11 14 122 Removing and installing, sealing / replacing timing case cover (COOPER S)»(ref-204047-S26980237982005110800000) .

Unscrew retaining screws of oil pump cover in the specified order (10-1).

Scheme 422

Remove oil pump cover.

Installation note

Tighten retaining screws of oil pump cover in specified order (1 - 10).

Tightening torque 11 41 1AZ. Refer to ENGINE - TIGHTENING TORQUES .

Remove outer wheel (1) and inner wheel (2).

Scheme 423

Note. The outer wheel and inner wheel are mutually matched and must always be replaced together.

Use a suitable drift to press down the spacer until the circlip is no longer tensioned.

Scheme 424

Remove circlip and pressure relief valve.

Remove pressure relief valve from oil pump cover.

Scheme 425

1. Pressure relief valve
2. Coil spring
3. Bush
4. Circlip

Note. Check oil pump housing for signs of scoring and damage.

11 43 000 Removing and installing/replacing guide tube for oil dipstick (COOPER S)

Remove supercharger. Refer to 11 65 035 Removing and installing/replacing supercharger .

Pull guide tube (1) from cylinder block.

Scheme 426

Replace seal (1) on guide tube.

Scheme 427

Coat new sealing ring (1) with Syntheso Glep 1.

Insert guide tube (2) into cylinder block.

Note. Make sure that guide tube and seal are correctly located.

11 44 000 Removing and installing/replacing oil - water heat exchanger (COOPER S)

Only perform this work after engine has cooled down.

Release pressure cap on coolant expansion tank.

Remove right hand front road wheel. Refer to 36 10 300 REMOVING OR INSTALLING FRONT OR REAR WHEEL .

Drain coolant. Refer to 17 00 005 DRAINING AND ADDING COOLANT (COOPER S) .

Disconnect pipes (1) from heat exchanger (2) and catch and dispose of coolant.

Scheme 428

Remove heat exchanger retaining bolts (1) and remove heat exchanger.

Scheme 429

Tightening torque 11 44 1AZ. Refer to ENGINE - TIGHTENING TORQUES .

Remove sealing rings (1).

Scheme 430

Clean all sealing surfaces.

Install new sealing rings and refit heat exchanger.

Note. Heat exchanger location lugs (2).

Check engine oil level.

Bleed and top-up cooling system. Refer to 17 00 005 DRAINING AND ADDING COOLANT .

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

Remove supercharger. Refer to 11 65 035 Removing and installing/replacing supercharger .

Remove water pump retaining bolts (1).

Scheme 431

Tightening torque 11 51 2AZ. Refer to ENGINE - TIGHTENING TORQUES .

Align water pump drive (1) with supercharger drive (2).

Scheme 432

Install water pump to supercharger.

Install new sealing ring (1) to water pump.

Scheme 433

Lubricate sealing ring with Syntheso Glep 1.

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

Work on the cooling system should only be carried out when the engine has cooled down.

Remove coolant pressure cap from expansion tank.

Remove intake filter housing. Refer to 13 71 000 REMOVING AND INSTALLING INTAKE FILTER HOUSING (COOPER S) .

Drain coolant. Refer to 17 00 005 DRAINING AND ADDING COOLANT (COOPER S) .

Remove MAP sensor connector (1).

Scheme 434

Remove MAP sensor bracket bolts (2).

Tightening torque 11 12 2AZ. Refer to ENGINE - TIGHTENING TORQUES .

Remove heater hose (1).

Scheme 435

Remove top hose (2) from thermostat housing.

Remove retaining bolt (3) and remove thermostat housing (4).

Remove thermostat and gasket from housing.

Scheme 436

Note, location of bleeding pin (1).

Direction of installation (2).

Replace gasket and thermostat if necessary.

1. Thermostat to seal locating lugs.
2. Basic location of thermostat to seal lug.

Scheme 437

Refill coolant. Refer to 17 00 005 DRAINING AND ADDING COOLANT (COOPER S) .

11 61 051 Removing and installing intake manifold (COOPER S)

Disconnect battery. Refer to 61 21 010 REMOVING AND INSTALLING BATTERY (COOPER S) .

Remove air cleaner housing. Refer to 13 71 000 REMOVING AND INSTALLING INTAKE FILTER HOUSING (COOPER S) .

Remove throttle. Refer to 13 54 030 REMOVING AND INSTALLING/SEALING THROTTLE ASSEMBLY (COOPER S) .

Remove fuel rail. Refer to 13 64 541 REPLACING ALL FUEL INJECTORS .

Remove engine venting valve. Refer to 11 15 025 Removing or replacing engine vent valve .

Remove hose clamp (1) of EGR valve and detach hose.

Scheme 438

Disconnect plug connector of knock sensor and release from clip on manifold.

Disconnect air intake sensor on manifold.

Remove upper line from tank venting valve.

Detach plug connector from intake air temperature/manifold air pressure sensor (TMAP).

Unscrew manifold nuts (5 -1) and remove manifold.

Replace seal.

Installation

Tighten down nuts in sequence (1 -5).

Scheme 439

Tightening torque 11 12 8AZ. Refer to ENGINE - TIGHTENING TORQUES .

11 62 000 Removing and installing, sealing/replacing exhaust manifold

Detach exhaust system from manifold. Refer to 18 12 030 Removing and installing/replacing rear muffler (COOPER S) .

Disconnect both oxygen sensor connectors.

Scheme 440

Undo retaining screws (1) for heat shield.

Scheme 441

Tightening torque 11 62 1AZ. Refer to ENGINE - TIGHTENING TORQUES .

Undo retaining screws (1) for heat shield.

Scheme 442

Detach heat shield (2).

Note. Routing of wiring harness.

Unscrew 8 retaining screws (1) at exhaust manifold.

Scheme 443

Remove exhaust manifold.

Installation note

Make sure that the mating surfaces of cylinder head and manifold are clean.

Fit new gasket.

Tightening torque 11 62 2AZ. Refer to ENGINE - TIGHTENING TORQUES .

11 65 035 Removing and installing/replacing supercharger

Special tools required

1. 11 8 401
2. 11 8 402

Remove intercooler to inlet manifold pipe. Refer to 17 51 000 Removing and installing/replacing intercooler .

Remove supercharger outlet pipe. Refer to 17 51 080 Removing and installing/replacing turbocharger exhaust pipe (right) .

Remove auxiliary drive belt. Refer to 11 28 050 Removing A/C compressor drive belt (COOPER S) .

Slacken modular front end. Refer to 41 33 040 Replace - Modular front end (MFE) .

Remove crush tubes. Refer to 31 11 020 Removing and installing/replacing bumper bracket .

Fit special tools 11 8 401 and 11 8 402.

Scheme 444

Drain coolant. Refer to 17 00 005 DRAINING AND ADDING COOLANT (COOPER S) .

Remove alternator connection (1) and remove retaining bolts (2).

Scheme 445

Tightening torque 12 31 2AZ. Refer to ENGINE ELECTRICAL SYSTEM - TIGHTENING TORQUES .

Tightening torque 12 31 1AZ. Refer to ENGINE ELECTRICAL SYSTEM - TIGHTENING TORQUES .

Remove supercharger inlet pipe retaining bolt (1).

Scheme 446

Remove supercharger inlet pipe (2) to access pipes (3).

Note. Remove pipes via quick fit connectors.

Tightening torque 11 65 1AZ. Refer to ENGINE - TIGHTENING TORQUES .

Remove coolant pipes (1).

Scheme 447

Remove dipstick retaining bolt (1) and move dipstick to one side.

Scheme 448

Move clip (2) from coolant pipe.

Remove supercharger retaining bolts (3).

Remove supercharger (4).

Tightening torque 11 65 2AZ. Refer to ENGINE - TIGHTENING TORQUES .

Tightening torque 11 65 3AZ. Refer to ENGINE - TIGHTENING TORQUES .

Tightening torque 11 28 3AZ. Refer to ENGINE - TIGHTENING TORQUES .

Note. Install new water pump sealing ring prior to installing supercharger. Refer to 11 51 000 Removing and installing/replacing water pump (COOPER S) .

11 78 510 Replacing oxygen sensor

Special tools required

1. 11 7 030

Note. Connect DIS and read out fault code memory of EMS/DME control unit. Rectify faults and clear fault memory.

Switch off ignition.

Remove heat shield.

Detach connector from retaining clips.

Scheme 449

Remove oxygen sensors.

1 oxygen sensor (upstream)

2 oxygen sensor (downstream)

Scheme 450

Installation note

Tighten oxygen sensor using special tool 11 7 030.

Scheme 451

Tightening torque 11 78 1AZ. Refer to ENGINE - TIGHTENING TORQUES .

Installation note

If the oxygen sensor is reused, coat thread with only a thin and uniform layer of Never Seez compound.

Do not clean and do not coat with lubricant the monitor and control section of the oxygen sensor that protrudes into the exhaust tract (sensor ceramics).

Cover the oxygen sensor (masking tape) before applying undercoating.

Note. Connect DIS and read out fault code memory of EMS/DME control unit. Rectify faults and clear fault memory.