Engine - Repair - Cooper (W10 Engine): Other MINI Cooper I

11 00 039 Checking compression at all cylinders

Note. For Special Tool identification, see ENGINE - SPECIAL TOOLS - COOPER (1.6L) R50/W10 .

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.

Press securing clip (1) away.

Detach plug connector (2).

Scheme 12

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.

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

Scheme 13

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

Compression pressure.

Refer to ENGINE - TECHNICAL DATA - COOPER (1.6L) R50/W10 .

Scheme 14

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

Note. For Special Tool identification, see ENGINE - SPECIAL TOOLS - COOPER (1.6L) R50/W10 , FUEL SYSTEM - SPECIAL TOOLS - COOPER (1.6L) R50/W10 or BODY EQUIPMENT - SPECIAL TOOLS - COOPER (1.6L) R50/W10 .

Special Tools Required

1. 11 8 352
2. 11 8 401
3. 11 8 402
4. 13 5 280
5. 13 5 281
6. 51 2 160

Necessary Preliminary Tasks

1. Disconnect battery. Refer to «12 00 DISCONNECTING AND CONNECTING BATTERY»(ref-203047-S09116207412005103000000) .
2. Remove battery container. Refer to «61 21 100 REMOVING AND INSTALLING/REPLACING BATTERY CONTAINER»(ref-203084-S33222320542005103000000) .
3. Remove front bumper trim. Refer to «51 11 156 REMOVING AND INSTALLING FRONT BUMPER TRIM»(ref-203078-S15423190532005103000000) .
4. Remove bumper bracket. Refer to «51 11 050 REMOVING AND INSTALLING/REPLACING CARRIER FOR FRONT BUMPER TRIM»(ref-203078-S31279213672005103000000) .
5. Remove air cleaner housing.
6. Release clutch cylinder. Refer to «CLUTCH SLAVE CYLINDER»(ref-171403-S08966713922005020300000) .
7. Remove top stabilizer bar bracket. Refer to «22 11 040 REPLACING UPPER ENGINE CARRIER BRACKET»(ref-203069-S11947559112005103000000) .
8. Remove exhaust manifold with catalytic converter. Refer to «11 62 000 REMOVING AND INSTALLING, SEALING/REPLACING EXHAUST MANIFOLD»(ref-203045-S03080173832005103000000) .
9. Remove left drive shaft. Refer to «DRIVE AXLE SHAFT (LEFT)»(ref-163180-S35160065542004062200000) .
10. Remove right drive shaft. Refer to «DRIVE AXLE SHAFT (RIGHT)»(ref-163180-S34005917432004062200000) .
11. Remove alternator drive belt. Refer to «11 28 010 REPLACING ALTERNATOR DRIVE BELT (W10)»(ref-203045-S40060016012005103000000) .
12. Remove alternator drive belt for optional A/C system. Refer to «11 28 050 REMOVING A/C COMPRESSOR DRIVE BELT»(ref-203045-S17196587362005103000000) .
13. Drain coolant. Refer to «17 00 005 DRAINING AND ADDING COOLANT»(ref-203063-S08331852762005103000000) .

Remove upper engine hood support and fit special tool 51 2 160.

Scheme 15

Screw in front end module with special tools 11 8 401 and 11 8 402 and secure with snap ring against slipping back.

Scheme 16

Detach coolant hoses (1).

Detach heating hoses (2).

Detach overflow hose (3).

Scheme 17

Release fuel line (1).

Attach fuel line (1) special tool 13 5 281.

Seal off fuel pipe with special tool 13 5 280.

Recycling

Catch and dispose of escaping fuel in a suitable container.

Observe country-specific waste-disposal regulations.

Scheme 18

Remove screw (1) for starter motor heat shield.

Lift out heat shield.

Scheme 19

Release connection of line (1) to brake booster and unclip at holder.

Press ring downwards, remove line (1) towards top.

Scheme 20

Disconnect plug connector from fuse box (1).

Remove retaining screws (2) from fuse box.

Place fuse box to one side.

Tightening torque, refer to 61 13 1AZ in GENERAL ELECTRICAL SYSTEM - TIGHTENING TORQUES - COOPER (1.6L) R50/W10 .

Scheme 21

Disconnect grounding cable from left spring strut (1).

Tightening torque, refer to 61 13 2AZ in GENERAL ELECTRICAL SYSTEM - TIGHTENING TORQUES - COOPER (1.6L) R50/W10 .

Disconnect circular connector (2).

Scheme 22

Release retaining clips (1) for shift cables on housing.

Detach shift cables from ball joint (2).

Remove retaining screws (3) for shift cable stop and remove shift control housing (4).

Tightening torque, (21 N.m.).

Tightening torque, refer to 11 12 14AZ in ENGINE - TIGHTENING TORQUES- COOPER (1.6L) R50/W10 .

Tightening torque, refer to 11 12 15AZ in ENGINE - TIGHTENING TORQUES- COOPER (1.6L) R50/W10 .

Scheme 23

Release screws (1).

Remove stabilizer bar (2).

Tightening torque, refer to 11 12 16AZ in ENGINE - TIGHTENING TORQUES- COOPER (1.6L) R50/W10 .

Scheme 24

Detach plug connector (1) from steering pump motor.

Scheme 25

Note. Special equipment A/C system.

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

Release retaining screws (2).

Secure compressor (3) to front end module. Unclip high-pressure line of A/C system.

Tightening torque, refer to 64 52 1AZ in HEATING AND AIR CONDITIONING - TIGHTENING TORQUES - COOPER (1.6L) R50/W10 .

Scheme 26

Stick suitable adhesive tape (1) onto both body frame rails to protect paintwork during removal of engine ( risk of damage ).

A/C lines are under pressure. Risk of injury.

Scheme 27

Release retaining screws (1).

Tightening torque, (66 N.m.).

Release top screw on transmission bracket (2).

Remove transmission bracket (2).

Installation

Tightening torque, (66 N.m.).

Scheme 28

Release screws (1).

Remove transmission bracket (2).

Scheme 29

Mount special tool 11 8 352 on transmission.

Installation

Tightening torque, (38 N.m.).

Scheme 30

Mount special tool 11 8 351 on engine at front.

Use original screws (1).

Installation

Tightening torque, refer to 11 12 9AZ in ENGINE - TIGHTENING TORQUES- COOPER (1.6L) R50/W10 .

Scheme 31

Secure special tool 11 0 020 with special tools 11 8 351 and 11 8 352.

Attach engine lifting gear holder and chains to engine and suspend power unit from lifting gear.

Scheme 32

Unscrew engine mount retaining nut (1).

Tightening torque, refer to 11 12 13AZ in ENGINE - TIGHTENING TORQUES- COOPER (1.6L) R50/W10 .

Remove engine. Refer to 11 00 050 REMOVING AND INSTALLING ENGINE .

Scheme 33

Assemble engine.

Fill transmission. Refer to LUBRICATION .

Fill cooling system. Refer to 17 00 005 DRAINING AND ADDING COOLANT .

Vent cooling system and check for leaks. Refer to 17 00 039 BLEEDING COOLING SYSTEM AND CHECKING FOR WATER LEAKS .

Check function of DME.

11 00 050 Removing and installing engine (CVT)

Note. For Special Tool identification, see ENGINE - SPECIAL TOOLS - COOPER (1.6L) R50/W10 and FUEL SYSTEM - SPECIAL TOOLS - COOPER (1.6L) R50/W10 .

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

Necessary Preliminary Tasks

1. Disconnect battery. Refer to «12 00 DISCONNECTING AND CONNECTING BATTERY»(ref-203047-S09116207412005103000000) .
2. Remove battery container. Refer to «61 21 100 REMOVING AND INSTALLING/REPLACING BATTERY CONTAINER»(ref-203084-S33222320542005103000000) .
3. Remove exhaust manifold. Refer to «11 62 000 REMOVING AND INSTALLING, SEALING/REPLACING EXHAUST MANIFOLD»(ref-203045-S03080173832005103000000) .
4. Remove engine venting valve. Refer to «11 15 025 REMOVING OR REPLACING ENGINE VENT VALVE»(ref-203045-S09588319722005103000000) .

Remove retaining screw (1) for starter motor heat shield.

Release lambda oxygen sensor from wire retainer (2).

Remove heat shield.

Tightening torque, 12 41 1AZ in ENGINE ELECTRICAL SYSTEM - TIGHTENING TORQUES - COOPER (1.6L) R50/W10 .

Scheme 34

Detach connections (1) and (2) of starter motor.

Tightening torque, refer to 12 41 2AZ in ENGINE ELECTRICAL SYSTEM - TIGHTENING TORQUES - COOPER (1.6L) R50/W10 .

Tightening torque, refer to 12 41 3AZ in ENGINE ELECTRICAL SYSTEM - TIGHTENING TORQUES - COOPER (1.6L) R50/W10 .

Pay attention to routing of wiring harness.

Remove alternator drive belt. Refer to 11 28 010 REPLACING ALTERNATOR DRIVE BELT (W10) .

Remove cover from fuel rail.

Remove lower line of tank venting valve from stabilizer bracket.

Remove grounding cable from engine support block.

Scheme 35

Reduce fuel pressure in fuel line. Refer to 13 31 029 CHECKING FUEL PUMP DELIVERY PRESSURE .

Remove line from fuel distribution pipe and seal ends with special tool 13 5 280.

Detach line connection to brake booster from manifold and unclip from holder.

Press ring downwards to expose line (1).

Scheme 36

Remove fuse box cover.

Disconnect plug connector (1) from fuse box.

Scheme 37

Remove grounding cable from left spring strut (1).

Tightening torque, refer to 61 13 2AZ in GENERAL ELECTRICAL SYSTEM - TIGHTENING TORQUES - Cooper (1.6L) R50/W10 .

Detach plug connector (2).

Scheme 38

Drain coolant. Refer to 17 00 005 DRAINING AND ADDING COOLANT .

Detach both heater pipe connections and connection of expansion line to filler neck.

Remove top hose from radiator elbow.

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

Drain off transmission oil. Refer to 00 11 239 FLUID CHANGE IN AUTOMATIC TRANSMISSION (CVT) INCLUDING USED FLUID DISPOSAL .

Remove shift cable. Refer to SHIFT TOWER .

Remove screws (1) for lower stabilizer bracket and remove holder (2).

Tightening torque, refer to 11 12 16AZ in ENGINE - TIGHTENING TORQUES- COOPER (1.6L) R50/W10 .

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

Scheme 39

Detach plug connector (1) from steering pump motor.

Scheme 40

Remove impact tube.

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

Scheme 41

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

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, refer to 64 52 1AZ in HEATING AND AIR CONDITIONING - TIGHTENING TORQUE - COOPER (1.6L) R50/W10 .

Detach coolant hose from water pump.

Scheme 42

Detach plug connector from oil pressure switch.

Remove wiring harness clips and slide wiring harness to one side.

Pay attention to routing of wiring harness.

Detach plug connector of headlight sensor.

Remove sub-frame (a wheel alignment check is not required). Refer to SUSPENSION - FRONT .

Scheme 43

Remove oil cooler from transmission. Refer to 17 22 070 REMOVING AND INSTALLING OR REPLACING OIL COOLER PIPES (CVT) .

Remove fixture of lambda oxygen sensor and remove screw of coolant line.

Tightening torque, refer to 11 78 2AZ in ENGINE - TIGHTENING TORQUES- COOPER (1.6L) R50/W10 .

Tightening torque, refer to 11 53 1AZ in ENGINE - TIGHTENING TORQUES- COOPER (1.6L) R50/W10 .

Secure engine lifting equipment to engine holders (special tools 11 8 351 and 11 8 260).

Tightening torque, refer to 11 12 9AZ in ENGINE - TIGHTENING TORQUES- COOPER (1.6L) R50/W10 .

Scheme 44

Secure engine lifting equipment (special tools 11 0 001, 11 0 002, 11 0 003 and 11 0 009).

Attach engine lifting gear holder and chains to engine and suspend power unit from lifting gear.

Scheme 45

Unscrew engine mount retaining nut (1).

Tightening torque, refer to 11 12 13AZ in ENGINE - TIGHTENING TORQUES- COOPER (1.6L) R50/W10 .

Scheme 46

Remove screw (1) with which transmission is secured to upper mounting fixture.

Tightening torque, (66 N.m.).

Remove engine. Refer to 11 00 050 REMOVING AND INSTALLING ENGINE .

Lower engine and remove.

Scheme 47

11 12 000 Removing and installing/sealing cylinder head cover (W10)

Necessary preliminary tasks

1. Remove ignition coil block. Refer to «12 13 513 REPLACING IGNITION COIL»(ref-203047-S05817484172005103000000) .
2. Remove connector strip for fuel injectors.

Remove hose (1).

Detach crankcase breather valve (2).

Detach plug connector from ignition coil block (3).

Detach spark plug connectors (4).

Remove wiring harness retaining clips from valve cover screws.

Scheme 48

Remove valve cover screws.

Remove cylinder head cover. Refer to 11 12 000 REMOVING AND INSTALLING/SEALING CYLINDER HEAD COVER (W10) .

Scheme 49

Installation

Check valve cover seal, replace if necessary.

Remove retaining screws from cylinder head cover.

Check rubber elements, replace if necessary.

Clean mating surfaces with suitable materials.

Scheme 50

Installation

Tighten down bolts in sequence 1 to 12.

Tightening torque, refer to 11 12 1AZ in ENGINE - TIGHTENING TORQUES- COOPER (1.6L) R50/W10 .

Scheme 51

Assemble engine.

11 12 100 Removing and installing/sealing cylinder head W10

Note. For Special Tool identification, see ENGINE- SPECIAL TOOLS - COOPER (1.6L) R50/W10 , FUEL SYSTEM - SPECIAL TOOLS - COOPER (1.6L) R50/W10 and MAINTENANCE AND GENERAL INFORMATION - SPECIAL TOOLS - COOPER (1.6L) R50/W10 .

Special Tools Required

1. 00 9 120
2. 11 8 200
3. 11 8 250
4. 11 8 370
5. 13 5 280
6. 33 2 140

Necessary Preliminary Tasks

1. Drain coolant. Refer to «17 00 005 DRAINING AND ADDING COOLANT»(ref-203063-S08331852762005103000000) .
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. Disconnect battery. Refer to «12 00 DISCONNECTING AND CONNECTING BATTERY»(ref-203047-S09116207412005103000000) .
4. Remove battery container. Refer to «61 21 100 REMOVING AND INSTALLING/REPLACING BATTERY CONTAINER»(ref-203084-S33222320542005103000000) .
5. Remove tank vent valve with line. Refer to «13 90 500 REPLACING TANK VENTING VALVE»(ref-203052-S10207261352005103000000) .
6. Remove cylinder head. Refer to «11 12 100 REMOVING AND INSTALLING/SEALING CYLINDER HEAD W10»(ref-203045-S17178107502005103000000) .
7. Disconnect plug connector from DME.
8. Remove cover from fuel rail.
9. Release fuel injector wiring harness and place to one side.
10. Detach heating hoses on cylinder head.
11. Detach top water hose on thermostat.
12. Unfasten exhaust manifold.
13. Remove spark plugs. Refer to «12 12 011 REPLACING ALL SPARK PLUGS»(ref-203047-S16593721202005103000000) .

Remove fuel line from fuel rail; to do so, disconnect quick-release coupling (1) and connect special tool 13 5 280 to fuel rail and fuel line.

Unclip both lines on stabilizer bar bracket.

Scheme 52

Detach vacuum line to brake booster from manifold and unclip from holder.

Press ring downwards to expose line (1).

Scheme 53

Disconnect plug connector of camshaft sensor.

Remove dipstick.

Remove intake manifold screws (5-1).

Lift intake manifold over dipstick tube.

Disconnect line from filler neck to expansion tank, then the engine wiring harness can be moved around the thermostat housing.

Installation Note

Tightening torque, refer to 11 61 2AZ in ENGINE - TIGHTENING TORQUES- COOPER (1.6L) R50/W10 .

Scheme 54

Tie back intake manifold.

Note. (Scheme 55)

Scheme 55

Remove screws (1) for stabilizer bar bracket.

Remove stabilizer bar bracket.

Tightening torque, refer to 11 12 14AZ in ENGINE - TIGHTENING TORQUES - COOPER (1.6L) R50/W10 .

Scheme 56

Detach oxygen sensor plug connector (1).

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

Remove retaining screw (3) of coolant distributor pipe.

Detach plug connector (4) of coolant temperature sensor.

Scheme 57

Support engine with trolley jack and a rubber pad on oil sump.

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

Remove engine carrier.

Remove hydraulic engine mount with special tool 11 8 200.

Tightening torque, refer to 11 12 11AZ in ENGINE - TIGHTENING TORQUES- COOPER (1.6L) R50/W10 .

Scheme 58

Mount special tool 11 8 370 on cylinder block and body fixtures.

Note. (Scheme 59)

Scheme 59

Remove camshaft sensor (1).

Release screw plugs (2).

Tightening torque, refer to 11 12 7AZ in ENGINE - TIGHTENING TORQUES- COOPER (1.6L) R50/W10 .

Scheme 60

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

Mark vibration damper and timing case cover with paint.

Note. (Scheme 61)

Installation Note

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

Scheme 61

Secure special tool 11 8 250 to camshaft gear.

Slacken central bolt (1).

Scheme 62

Remove wiring harness holder (1).

Release timing chain tensioner (2).

Note. Remove clamping fixture.

Scheme 63

Unscrew central bolt for camshaft gear.

Remove camshaft gear from timing chain and secure timing chain to prevent it dropping down.

Release screws (1).

Remove clamping rail and chain guides (2).

Note. Shown without timing chain cover for purposes of clarity. This shows the layout of the timing chain guides (Scheme 64)

Scheme 64

Note. The timing chain cover is designed in such a way that the timing chain can remain on the crankshaft gear without gear teeth being skipped.

Do not rotate crankshaft.

Installation Note

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

Clean all engine oil ducts.

Release cylinder head mounting elements 11 and 12.

Slacken cylinder head bolts (1 to 10) working from outside in.

Remove cylinder head.

Scheme 65

Use a commercially available straight edge to check the diagonal and horizontal surface evenness of the cylinder head.

Max. permitted cylinder head distortion is 0.1 mm.

Scheme 66

Installation Note

Check dowel sleeves (1) for damage and replace if necessary.

The must be no oil or coolant in the tapped holes for the cylinder head bolts in the cylinder block.

If necessary, clean out holes with compressed air.

Scheme 67

Replace cylinder head gasket.

Pay attention to adjustment (1) of cylinder head gasket.

Install cylinder head.

Scheme 68

Insert cylinder head bolts (1 to 10) and tighten down in sequence ( 1-10 ).

Tightening torque: 11 12 3AZ in ENGINE - TIGHTENING TORQUES- COOPER (1.6L) R50/W10 .

Insert cylinder head bolts (11 to 12) and tighten down in sequence ( 11-12 ).

Tightening torque: 11 12 4AZ in ENGINE - TIGHTENING TORQUES- COOPER (1.6L) R50/W10 .

Tighten down cylinder head bolts with special tool 00 9 120.

Scheme 69

Install clamping rail and chain guides (2).

Install retaining screws (1) of guides.

Tightening torque, refer to 11 12 12AZ in ENGINE - TIGHTENING TORQUES- COOPER (1.6L) R50/W10 .

Place timing chain on camshaft gear.

Screw in central bolt.

Note. Shown without timing chain cover for purposes of clarity. This shows the layout of the timing chain (Scheme 70)

Scheme 70

Installation Note

Align camshaft and timing chain markings to each other.

Insert central bolt.

Scheme 71

Fit special tool 11 8 250.

Tighten down central bolt (1).

Tightening torque: 11 12 5AZ in ENGINE - TIGHTENING TORQUES- COOPER (1.6L) R50/W10 .

Scheme 72

Move timing chain tensioner into transition position.

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.

Replace cap (2) on clamping fixture.

Scheme 73

Install timing chain tensioner.

Tighten down screw plug (2).

Installation Note

Tightening torque: 11 12 6AZ in ENGINE - TIGHTENING TORQUES- COOPER (1.6L) R50/W10 .

Install cable holder (1).

Scheme 74

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

Scheme 75

Lever at clamping rail with special tool 33 2 140 until timing chain tensioner tensions timing chain.

Do not lever directly at timing chain. Risk of damage to timing chain.

Note. Shown without timing chain cover for purposes of clarity. This shows the layout of special tool 33 2 140 (Scheme 76)

Scheme 76

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

Scheme 77

Assemble engine.

Fill cooling system and check for leaks. Refer to 17 00 005 DRAINING AND ADDING COOLANT .

Replace engine oil if necessary. Refer to 00 00 ... CHANGING ENGINE OIL AND OIL FILTER .

Check function of DME.

11 12 260 Removing and installing spark plug well

Note. For Special Tool identification, see ENGINE- SPECIAL TOOLS - COOPER (1.6L) R50/W10 and ENGINE ELECTRICAL SYSTEM - SPECIAL TOOLS - COOPER (1.6L) R50/W10 .

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 (W10)»(ref-203045-S08541615102005103000000) .
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.

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.

Scheme 78

Clean area around spark plug well.

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

1 = Bead of sealing compound.

2 = 1 mm from end of well.

Scheme 79

Screw special tool 12 1 212 into spark plug hole.

Scheme 80

Carefully install spark plug well (1).

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.

Scheme 81

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 (W10)»(ref-203045-S08541615102005103000000) .

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

Scheme 82

Clean all sealing surfaces.

Installation Note

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

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

Lightly oil seals before installing cylinder head cover.

Scheme 83

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)

Note. For Special Tool identification, see ENGINE- SPECIAL TOOLS - COOPER (1.6L) R50/W10 .

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 W10»(ref-203045-S17178107502005103000000) .
2. Remove camshaft. Refer to «11 31 001 REPLACING CAMSHAFT»(ref-203045-S18481097562005103000000) .
3. Remove thermostat. Refer to «11 53 000 REMOVING AND INSTALLING/REPLACING COOLANT THERMOSTAT (W10)»(ref-203045-S02369164332005103000000) .

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

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

Note. Clean sealing surfaces.

Scheme 84

Close off coolant opening with special tool 11 8 432.

Scheme 85

Connect compressed air supply to special tool 11 8 432.

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.

Scheme 86

Assemble engine.

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

Note. For Special Tool identification, see ENGINE- SPECIAL TOOLS - COOPER (1.6L) R50/W10 .

Special Tools Required

1. 11 8 401
2. 11 8 402

Switch off ignition.

Disconnect battery. Refer to 12 00 DISCONNECTING AND CONNECTING BATTERY .

Remove alternator drive belt. Refer to 11 28 010 REPLACING ALTERNATOR DRIVE BELT (W10) .

Unscrew and remove splash guard.

Unscrew oil drain plug (1).

Drain engine oil.

Tightening torque, 11 13 1AZ in ENGINE - TIGHTENING TORQUES- COOPER (1.6L) R50/W10 .

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.

Scheme 87

Remove impact tube.

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

Scheme 88

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

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, refer to 64 52 1AZ in HEATING AND AIR CONDITIONING - TIGHTENING TOR .

Scheme 89

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

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

Tightening torque, refer to 11 12 16AZ in ENGINE - TIGHTENING TORQUES .

Tightening torque, refer to 11 12 19AZ in ENGINE - TIGHTENING TORQUES- COOPER (1.6L) R50/W10 .

Scheme 90

Remove retaining screws (1) for transmission.

Scheme 91

Note. Two shorter screws are inserted into oil sump. Tightening torque, (85 N.m.).

Installation

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

Replace gasket.

Scheme 92

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

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

Tightening torque, refer to 11 13 2AZ in ENGINE - TIGHTENING TORQUES- COOPER (1.6L) R50/W10 .

Scheme 93

Note. Position gasket in accordance with alignment lugs.

11 14 122 Removing and installing / replacing timing chain cover (W10/W11)

Note. For Special Tool identification, see ENGINE- SPECIAL TOOLS - COOPER (1.6L) R50/W10 .

Special Tools Required

1. 11 8 401
2. 11 8 402

Necessary Preliminary Tasks

1. Remove vibration damper. Refer to «11 23 010 REMOVING AND INSTALLING OR REPLACING VIBRATION DAMPER»(ref-203045-S14097053212005103000000) .
2. Remove tensioning device for alternator drive belt. Refer to «11 28 020 REMOVING AND INSTALLING/REPLACING ALTERNATOR DRIVE BELT TENSIONER»(ref-203045-S27830010522005103000000) .
3. Remove impact tube.

Lower front end module.

Attach special tools 11 8 401 and 11 8 402.

Scheme 94

Undo screws (1) holding coolant pump and shift coolant pump (2) so that the front cover is accessible.

Tightening torque, refer to 11 12 10AZ in ENGINE - TIGHTENING TORQUES- COOPER (1.6L) R50/W10 .

Scheme 95

Remove screws of timing chain cover in the specified order (11-1).

Installation note

When the timing chain cover is mounted on the engine block, align flat surfaces of oil pump rotors with flat surfaces on crankcase.

Tighten screws of timing chain cover in the specified order (1-11).

Tightening torque, refer to 11 14 1AZ in ENGINE - TIGHTENING TORQUES- COOPER (1.6L) R50/W10 .

Scheme 96

Note position of Torx shoulder screw (1), Torx round-head screw (2) and screw with seal (3).

Installation Note

Clean sealing surfaces.

Replace seal of screw (3) and lubricate with clean engine oil.

Scheme 97

Remove seals of timing chain cover.

1. Cover seal.
2. Oil pump inlet seal.
3. Oil pump outlet seal.

Installation Note

Clean all sealing surfaces and fit new seals.

Scheme 98

Installation Note

Fill the rotor cavity with engine oil before installing the oil pump.

Scheme 99

Assemble engine.

Check oil level and top up as required.

Start engine and check for leaks.

11 14 141 Replacing shaft seal below timing chain cover

Note. For Special Tool identification, see ENGINE- SPECIAL TOOLS - COOPER (1.6L) R50/W10 .

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»(ref-203045-S14097053212005103000000) .

Insert special tool 11 8 270 in crankshaft.

Scheme 100

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

Pull out shaft seal (1) by tightening screw.

Scheme 101

Remove special tool 11 8 270.

Screw special tool 11 8 242 into crankshaft (Scheme 102)

Scheme 102

Coat sealing lip of new shaft seal with oil.

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

Installation

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

Scheme 103

Assemble engine.

Check engine for leaks.

11 14 151 Replacing crankshaft radial seal

Note. For Special Tool identification, see ENGINE - SPECIAL TOOLS - COOPER (1.6L) R50/W10 and MAINTENANCE AND GENERAL INFORMATION - SPECIAL TOOLS - COOPER (1.6L) R50/W10 .

Special Tools Required

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

Remove transmission. Refer to REMOVAL & INSTALLATION - AUTOMATIC TRANSMISSION .

Remove flywheel. Refer to 11 22 500 REMOVING AND INSTALLING OR REPLACING FLYWHEEL .

Remove radial shaft seal with special tool 23 0 490.

Scheme 104

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 105

Installation

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

Scheme 106

Make sure radial shaft seal is flush with cylinder block.

Scheme 107

11 15 025 Removing or replacing engine vent valve

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

Disconnect hose (3 from valve.

Installation Note

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

Tightening torque, refer to 11 12 18AZ in ENGINE - TIGHTENING TORQUES- COOPER (1.6L) R50/W10 .

Scheme 108

11 21 500 Removing and installing/replacing crankshaft (W10)

Necessary Preliminary Tasks

1. Remove engine. Refer to «11 00 050 REMOVING AND INSTALLING ENGINE»(ref-203045-S11086901922005103000000) .
2. Remove cylinder head. Refer to «11 12 100 REMOVING AND INSTALLING/SEALING CYLINDER HEAD W10»(ref-203045-S17178107502005103000000) .
3. Remove flywheel. Refer to «11 22 500 REMOVING AND INSTALLING OR REPLACING FLYWHEEL»(ref-203045-S26071583162005103000000) .
4. Remove crankshaft main bearings. Refer to «11 21 531 REPLACING CRANKSHAFT MAIN BEARING SHELLS W10»(ref-203045-S40837431942005103000000) .

Release screws (1).

Fit incremental wheel (2) on new crankshaft.

Tightening torque: 11 21 1AZ in ENGINE - TIGHTENING TORQUES- COOPER (1.6L) R50/W10 .

Scheme 109

Assemble engine.

Installation Note

Lubricate all bearing points with engine oil.

11 21 531 Replacing crankshaft main bearing shells W10

Note. For Special Tool identification, see MAINTENANCE AND GENERAL INFORMATION - SPECIAL TOOLS - COOPER (1.6L) R50/W10 .

Special Tools Required

1. 00 2 590
2. 00 9 120

Necessary Preliminary Tasks

1. Remove engine. Refer to «11 00 050 REMOVING AND INSTALLING ENGINE»(ref-203045-S11086901922005103000000) .
2. Remove gearbox. Refer to «REMOVAL & INSTALLATION - AUTOMATIC TRANSMISSION»(ref-170110) .
3. Remove cylinder head. Refer to «11 12 100 REMOVING AND INSTALLING/SEALING CYLINDER HEAD W10»(ref-203045-S17178107502005103000000) .
4. Remove timing chain. Refer to «11 31 051 REPLACING TIMING CHAIN»(ref-203045-S38768079122005103000000) .
5. Remove oil sump. Refer to «11 13 000 REMOVING AND INSTALLING, SEALING OR REPLACING OIL SUMP»(ref-203045-S35454704642005103000000) .
6. Remove crankshaft radial seal. Refer to «11 14 151 REPLACING CRANKSHAFT RADIAL SEAL»(ref-203045-S14423185762005103000000) .

Release screws (1).

Remove oil intake pipe (2).

Installation

Replace O-ring (3).

Apply petroleum jelly to O-ring (3)

Scheme 110

Undo crankcase bolts along the lines (2) shown, working from the outside towards the inside.

Undo crankcase bolts along the lines (1) shown, working from the outside towards the inside.

Note. Use a plastic-headed hammer to release bottom section of crankcase.

Detach bottom section of crankcase.

Scheme 111

Remove crankcase (1) by lifting up in direction indicated by arrow.

Installation

Clean sealing surfaces.

Check fitted sleeves for damage and replace if necessary.

Scheme 112

Installation

Install main bearing shell with lubrication groove (1) in top section of crankcase.

Install main bearing shell without lubrication groove (2) in bottom section of crankcase.

Scheme 113

Checking Main Bearing Clearance

To check crankshaft bearing clearance, use old main bearing screws.

There must be no oil in the blind holes (risk of cracking).

Do not twist crankshaft.

Place special tool 00 2 590 (Plastigage model PG 1) on oil-free crankshaft.

Scheme 114

1. Tighten down all bolts in crankcase to jointing torque.
2. Tighten down all bolts in crankcase with special tool 00 9 120 to torsion angle.

Installation

Tightening torque, refer to 11 11 2AZ in ENGINE - TIGHTENING TORQUES- COOPER (1.6L) R50/W10 .

Scheme 115

Remove crankcase.

Read off main bearing clearance with measuring scale.

Main bearing play.

1. Remove plastic thread.
2. Lubricate bearing shells and bearing shells.

Installation

Always replace main bearing bolts.

Do not wash off bolt coating.

There must be no oil in the blind holes (risk of cracking).

Scheme 116

Install bearing shells with lubrication groove (1) in top section of crankcase.

Installation

Main bearing shell (2) is a thrust bearing and is mounted in the center of the upper section of the crankcase.

(Scheme 117)

Scheme 117

Installation

Apply bead of sealing compound (1).

Apply Loctite liquid sealant 518 thinly and evenly to sealing surfaces.

(Scheme 118)

Scheme 118

Install crankshaft.

Mount bottom section of crankcase.

Fit screws 1 to 10.

Tightening torque: 11 11 1AZ in ENGINE - TIGHTENING TORQUES- COOPER (1.6L) R50/W10 .

Fit screws 11 to 20.

Tightening torque: 11 11 2AZ in ENGINE - TIGHTENING TORQUES- COOPER (1.6L) R50/W10 .

Scheme 119

Checking Axial Clearance

Push onto crankshaft (1) in direction of arrow with plastic hammer at rear and front in order to center guide bearing.

Axial clearance: refer to ENGINE - TECHNICAL DATA - COOPER (1.6L) R50/W10 .

Scheme 120

Assemble engine.

11 22 000 Removing and installing or replacing drive discs (CVT)

Note. For Special Tool identification, see ENGINE - SPECIAL TOOLS - COOPER (1.6L) R50/W10 .

Special Tools Required

1. 11 2 150
2. 11 8 320

Necessary Preliminary Tasks

1. Remove transmission. Refer to «REMOVAL & INSTALLATION - AUTOMATIC TRANSMISSION»(ref-170110) .

Use special tool 11 2 150 and special tool 11 8 320 to hold crankcase vibration damper in position.

Scheme 121

Loosen flywheel in the sequence (8-1).

Remove flywheel. Refer to 11 22 500 REMOVING AND INSTALLING OR REPLACING FLYWHEEL .

Installation Note

Fit new flywheel screws.

Firmly tighten in the sequence (1-8).

Tightening torque, refer to 11 22 1AZ in ENGINE - TIGHTENING TORQUES- COOPER (1.6L) R50/W10 .

Scheme 122

Installation Note

Align marking (1) on crankcase with marking (2) on flywheel.

(Scheme 123)

Scheme 123

Assemble engine.

11 22 500 Removing and installing or replacing flywheel

Note. For Special Tool identification, see ENGINE- SPECIAL TOOLS - COOPER (1.6L) R50/W10 and ENGINE ELECTRICAL SYSTEM - SPECIAL TOOLS - COOPER (1.6L) R50/W10 .

Special Tools Required

1. 11 8 320
2. 12 2 150

Remove clutch. Refer to CLUTCH .

Use special tool 12 2 150 and special tool 11 8 320 to hold crankcase vibration damper in position.

Scheme 124

Release screws in sequence (8-1) and remove flywheel.

Scheme 125

Installation

Pay attention to position mark (1) on flywheel and position mark (2) on crankshaft.

Scheme 126

Note. Flywheel screws must be replaced.

Installation

Tighten down bolts in sequence (1-8).

Tightening torque, refer to 11 22 1AZ in ENGINE - TIGHTENING TORQUES- COOPER (1.6L) R50/W10 .

Scheme 127

11 24 571 Replacing all connecting rod bearings (W10)

Necessary Preliminary Tasks

1. Removing oil pan. Refer to «11 13 000 REMOVING AND INSTALLING, SEALING OR REPLACING OIL SUMP»(ref-203045-S35454704642005103000000) .

Undo connecting rod bolts (1)

Remove connecting rod bearing cap (2).

Tightening torque, refer to 11 24 1AZ in ENGINE - TIGHTENING TORQUES- COOPER (1.6L) R50/W10 .

Scheme 128

Install new connecting rod bearing shells.

Scheme 129

Check connecting rod bearing clearance: Piston in BDC position.

Place special tool 00 2 590 (Plastigage model PG 1) on oil-free crankshaft.

Reinstall bearing cap.

Scheme 130

Use the old connecting rod bolts to check connecting rod bearing clearance.

Tighten down connecting rod screws with special tool 00 9 120 or special tool 11 2 110.

Tightening torque: 11 24 1AZ in ENGINE - TIGHTENING TORQUES- COOPER (1.6L) R50/W10 .

Scheme 131

Remove connecting rod cover.

Read off bearing play at width of flattened plastic thread with assistance of measurement scale (connecting rod bearing clearance).

Remove plastic thread.

Scheme 132

Assemble engine.

Lubricate all bearing points with engine oil.

11 25 530 Removing and installing/replacing all pistons (W10)

Note. For Special Tool identification, see ENGINE- SPECIAL TOOLS - COOPER (1.6L) R50/W10 and MAINTENANCE AND GENERAL INFORMATION - SPECIAL TOOLS - COOPER (1.6L) R50/W10 .

Special Tools Required

1. 00 9 120
2. 11 2 260
3. 11 6 390

Necessary Preliminary Tasks

1. Remove cylinder head. Refer to «11 12 100 REMOVING AND INSTALLING/SEALING CYLINDER HEAD W10»(ref-203045-S17178107502005103000000) .
2. Remove oil pan. Refer to «11 13 000 REMOVING AND INSTALLING, SEALING OR REPLACING OIL SUMP»(ref-203045-S35454704642005103000000) .
3. Remove oil pipe.

Scheme 133

Release screws (1).

Remove conrod bearing cap (2).

Note. All conrods are cracked.

Do not mix up conrods and conrod bearing caps.

Scheme 134

Fit special tool 11 6 390 on conrod (1).

Pull out conrod (1) with piston to cylinder head side.

Scheme 135

Prior to installation, measure piston installation clearance

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

Measuring point A.

Scheme 136

Adjust micrometer to cylinder bore of engine block. Set internal caliper on micrometer to zero. Measure bottom, center 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.

Scheme 137

Fit special tool 11 6 390 on conrod.

Lightly coat pistons and piston rings with oil.

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

Press together piston rings using special tool 11 2 260.

Scheme 138

Insert piston so that arrow (1) points to cam drive.

Scheme 139

Position conrod with special tool 11 6 390 on crankshaft journal.

Remove special tool 11 6 390.

Scheme 140

Install conrod bearing cap (2) with conrod bearing shells.

Tighten conrod bearing bolts (1) hand-tight.

Scheme 141

Tighten down conrod bolts with special tool 00 9 120.

Tightening torque: 11 24 1AZ in ENGINE - TIGHTENING TORQUES- COOPER (1.6L) R50/W10 .

Scheme 142

Assemble engine.

Installation

Lubricate all crankshaft bearing positions with engine oil.

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

Necessary Preliminary Tasks

1. Remove pistons. Refer to «11 25 530 REMOVING AND INSTALLING/REPLACING ALL PISTONS (W10)»(ref-203045-S22354207912005103000000) .

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

Refer to ENGINE - TECHNICAL DATA - COOPER (1.6L) R50/W10 .

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

Scheme 143

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

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.

Scheme 144

Measure end clearance.

Refer to ENGINE - TECHNICAL DATA - COOPER (1.6L) R50/W10 .

Scheme 145

Installation

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

Scheme 146

Note. Picture shows a schematic representation.

Installation

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

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.

Scheme 147

Installation

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

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 148

11 28 010 Replacing alternator drive belt (W10)

Note. For Special Tool identification, see ENGINE- SPECIAL TOOLS - COOPER (1.6L) R50/W10 .

Special Tools Required

11 28 020 Removing and installing/replacing alternator drive belt tensioner

Necessary Preliminary Tasks

1. Remove alternator drive belt. Refer to «11 28 010 REPLACING ALTERNATOR DRIVE BELT (W10)»(ref-203045-S40060016012005103000000) .
2. Unscrew and remove splash guard. Refer to «51 47 490 REMOVING AND INSTALLING/REPLACING FRONT UNDERBODY PROTECTION (ENGINE)»(ref-203078-S25934204192005103000000) .
3. Remove wheel. Refer to «36 10 300 REMOVING OR INSTALLING FRONT OR REAR WHEEL»(ref-203076-S22577949262005103000000) .
4. Remove wheel arch trim. Refer to «51 71 040 REMOVING AND INSTALLING/REPLACING FRONT LEFT OR RIGHT WHEEL ARCH LINER»(ref-203078-S35135088012005103000000) .

Release retaining screws (1) on tensioner.

Tightening torque, refer to 11 28 1AZ in ENGINE - TIGHTENING TORQUES- COOPER (1.6L) R50/W10 .

Scheme 149

Assemble engine.

11 28 050 Removing A/C compressor drive belt

Note. For Special Tool identification, see ENGINE- SPECIAL TOOLS - COOPER (1.6L) R50/W10 .

Special Tools Required

1. 11 8 280
2. 11 8 390

Note. If the drive belt is to be reused, the direction of travel must be marked and the drive belt reinstalled accordingly.

Remove tank venting valve. Refer to 13 90 500 REPLACING TANK VENTING VALVE .

Relieve tension on belt with special tool 11 8 390 and lock belt tensioner with special tool 11 8 280.

Remove underpan. Refer to 51 47 490 REMOVING AND INSTALLING/REPLACING FRONT UNDERBODY PROTECTION (ENGINE) .

Remove drive belt.

Scheme 150

Installation

Check drive belt for coolant and oil residues, replace if necessary.

Course of drive belt Make sure drive belt is correctly seated in grooves of belt pulley.

Scheme 151

11 31 001 Replacing camshaft

Note. For Special Tool identification, see ENGINE - SPECIAL TOOLS - COOPER (1.6L) R50/W10 .

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 (W10)»(ref-203045-S08541615102005103000000) .
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 OR REPLACING HYDRAULIC CHAIN TENSIONER»(ref-203045-S38041884882005103000000) .
6. Remove rocker arm shafts. Refer to «11 33 020 REMOVING AND INSTALLING OR REPLACING ROCKER ARM SHAFT»(ref-203045-S18942521012005103000000) .

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

Scheme 152

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

Installation Note

Apply a thin coating of clean engine oil to seal.

Tightening torque, refer to 13 62 1AZ in FUEL SYSTEM - TIGHTENING TORQUES - COOPER (1.6L) R50/W10 .

Scheme 153

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

Note. (Scheme 154) The brass-colored links are of no importance to the timing.

Scheme 154

Secure special tool 11 8 250 to camshaft gear.

Slacken central bolt (1).

Scheme 155

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

Remove central bolt.

Tightening torque, refer to 11 12 5AZ in ENGINE - TIGHTENING TORQUES- COOPER (1.6L) R50/W10 .

Scheme 156

Remove all camshaft bearing caps and camshaft.

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

Scheme 157

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 - COOPER (1.6L) R50/W10 .

Scheme 158

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

Installation Note

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

Refer to ENGINE - TECHNICAL DATA - COOPER (1.6L) R50/W10 .

Scheme 159

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

Note. For Special Tool identification, see ENGINE- SPECIAL TOOLS - COOPER (1.6L) R50/W10 and MAINTENANCE AND GENERAL INFORMATION - SPECIAL TOOLS - COOPER (1.6L) R50/W10 .

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 (W10)»(ref-203045-S08541615102005103000000) .
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 OR REPLACING HYDRAULIC CHAIN TENSIONER»(ref-203045-S38041884882005103000000) .
5. Remove timing chain cover. Refer to «11 14 122 REMOVING AND INSTALLING / REPLACING TIMING CHAIN COVER (W10/W11)»(ref-203045-S14433293772005103000000) .
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 160

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

Unscrew plugs (2).

Scheme 161

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

Remove camshaft gear from timing chain.

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

Scheme 162

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 163

Installation Note

Shrink-fit crankshaft gear (1) onto crankshaft.

Check correct position of locating pin (2).

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

Scheme 164

Install timing chain.

Install clamping rail and guide rail (2).

Install retaining screws (1) of chain guides.

Tightening torque: 11 12 12AZ in ENGINE - TIGHTENING TORQUES- COOPER (1.6L) R50/W10 .

Place timing chain on camshaft gear.

Fit camshaft gear onto camshaft.

Fit central bolt for camshaft gear.

Tightening torque, refer to 11 12 5AZ in ENGINE - TIGHTENING TORQUES- COOPER (1.6L) R50/W10 .

Scheme 165

Installation Note

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

Scheme 166

Installation Note

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

Scheme 167

Scheme 168

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 or replacing hydraulic chain tensioner

Special Tools Required

1. 33 2 140

Switch off ignition.

Disconnect battery. Refer to 12 00 DISCONNECTING AND CONNECTING BATTERY .

Remove inspection hole cover. Refer to 11 12 000 REMOVING AND INSTALLING/SEALING CYLINDER HEAD COVER (W10) .

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

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

Scheme 169

Installation

Move timing chain tensioner back into transition position.

Place clamping fixture (1) on a level surface.

Remove cap (2) from clamping fixture.

Lay hand surface against clamping fixture and exert continuous pressure until clamping fixture is completely compressed.

Refit cap (2) on clamping fixture after resetting.

Scheme 170

Installation

Check/replace sealing ring of screw plug for clamping fixture.

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

Tightening torque, 11 12 6AZ in ENGINE - TIGHTENING TORQUES- COOPER (1.6L) R50/W10 .

Note. Transition position of clamping fixture.

Scheme 171

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.

Installation

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

Note. The timing chain cover does not have to be removed for this operation. This shows the layout of the timing chain guides (Scheme 172)

Scheme 172

Note. Release position of clamping fixture (1).

Scheme 173

11 33 020 Removing and installing or replacing rocker arm shaft

Disconnect battery. Refer to 12 00 DISCONNECTING AND CONNECTING BATTERY .

Remove cylinder head cover. Refer to 11 12 000 REMOVING AND INSTALLING/SEALING CYLINDER HEAD COVER (W10) .

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

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, refer to 11 33 1AZ in ENGINE - TIGHTENING TORQUES- COOPER (1.6L) R50/W10 .

Scheme 174

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

Detach rocker arm spacer.

Remove rocker arm from shaft.

Scheme 175

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 176

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)

Note. For Special Tool identification, see ENGINE - SPECIAL TOOLS - COOPER (1.6L) R50/W10 .

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 (W10)»(ref-203045-S08541615102005103000000) .
2. Remove camshaft. Refer to «11 31 001 REPLACING CAMSHAFT»(ref-203045-S18481097562005103000000) .

Mount cylinder head on special tool 11 9 000.

Scheme 177

Press down with special tool 11 8 421.

Remove valve collets (1).

Remove all valve springs.

Scheme 178

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

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

Scheme 179

Fit special tool 11 1 380.

Fit new valve stem seal (1).

Installation

Oil valve stem and valve stem seal.

Scheme 180

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

Installation

Valve stem seal must be flush.

Scheme 181

Assemble engine.

11 40 000 Checking engine oil pressure

Note. For Special Tool identification, see ENGINE- SPECIAL TOOLS - COOPER (1.6L) R50/W10 and FUEL SYSTEM - SPECIAL TOOLS - COOPER (1.6L) R50/W10 .

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

Replace sealing ring.

Tightening torque, refer to 11 42 1AZ in ENGINE - TIGHTENING TORQUES- COOPER (1.6L) R50/W10 .

Remove oil pressure switch.

Installation

Tightening torque, 12 61 1AZ in ENGINE ELECTRICAL SYSTEM - TIGHTENING TORQUES - COOPER (1.6L) R50/W10 .

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

Scheme 182

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.

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 - COOPER (1.6L) R50/W10 .

Scheme 183

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 / REPLACING TIMING CHAIN COVER (W10/W11)»(ref-203045-S14433293772005103000000) .

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

Remove oil pump cover.

Installation Note

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

Tightening torque, refer to 11 41 1AZ in ENGINE - TIGHTENING TORQUES- COOPER (1.6L) R50/W10 .

Scheme 184

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

Scheme 185

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.

Remove circlip and pressure relief valve.

Scheme 186

Remove pressure relief valve from oil pump cover.

Scheme 187

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

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

11 42 020 Removing and installing complete main flow oil filter

Comply with the waste disposal regulations applicable in the relevant countries.

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

Remove retaining screws (1) for exhaust manifold heat shield.

Remove heat shield.

Tightening torque, 11 62 1AZ in ENGINE - TIGHTENING TORQUES- COOPER (1.6L) R50/W10 .

Scheme 188

Remove oil filter housing (1).

Installation

Tightening torque, 11 42 1AZ in ENGINE - TIGHTENING TORQUES- COOPER (1.6L) R50/W10 .

Scheme 189

Note. Release and tighten down oil filter housing with a wrench only.

Release oil filter housing slowly enable oil to flow back into the oil sump.

Remove retaining screw (1) for starter motor heat shield.

Tightening torque, 12 41 1AZ in ENGINE ELECTRICAL SYSTEM - TIGHTENING TORQUES - COOPER (1.6L) R50/W10 .

Scheme 190

Detach plug connector (1) for oil pressure switch.

Scheme 191

Remove retaining screws (1) for oil filter housing and remove housing (2).

Installation

Check surface for damage.

Tightening torque, 11 42 2AZ in ENGINE - TIGHTENING TORQUES- COOPER (1.6L) R50/W10 .

Scheme 192

Installation

Replace sealing ring.

Check whether oil filter is pressed into oil filter housing and sealing ring is coated with oil.

Top up engine oil.

Scheme 193

11 43 000 Removing and installing/replacing oil dipstick guide tube

Necessary Preliminary Tasks

1. Remove intake manifold. Refer to «11 61 051 REMOVING AND INSTALLING INTAKE MANIFOLD»(ref-203045-S42921823842005103000000) .

Remove retaining screw (1) of guide tube.

Remove guide tube (2).

Scheme 194

Installation

Replace seal (1).

Coat sealing ring (1) with Syntheso Glep 1.

Insert guide tube (2) in cylinder head.

Tightening torque, 11 61 1AZ in ENGINE - TIGHTENING TORQUES- COOPER (1.6L) R50/W10 .

Make sure guide tube and gasket are correctly seated.

Scheme 195

Assemble engine.

11 51 000 Removing and installing or replacing water pump

Note. For Special Tool identification, see ENGINE - SPECIAL TOOLS - COOPER (1.6L) R50/W10 .

Special Tools Required

1. 11 8 401
2. 11 8 402

Turn off ignition

Disconnect battery. Refer to 12 00 DISCONNECTING AND CONNECTING BATTERY .

Drain coolant. Refer to 17 00 005 DRAINING AND ADDING COOLANT .

Remove alternator. Refer to 12 31 020 REMOVING AND INSTALLING/REPLACING ALTERNATOR .

Lower front end module.

Remove screws (1) from impact tubes.

Remove screws (2) securing impact tubes to chassis subframe and remove impact tubes.

Tightening torque, (22 N.m.).

Scheme 196

Attach special tools 11 8 401 and 11 8 402.

Scheme 197

Detach hoses (1) from water pump.

Release mountings or remove screws (2).

Remove water pump (3).

Tightening torque, 11 51 1AZ in ENGINE - TIGHTENING TORQUES- COOPER (1.6L) R50/W10 .

Scheme 198

11 53 000 Removing and installing/replacing coolant thermostat (W10)

Necessary Preliminary Tasks

1. Remove air cleaner housing.
2. Remove battery container. Refer to «61 21 100 REMOVING AND INSTALLING/REPLACING BATTERY CONTAINER»(ref-203084-S33222320542005103000000) .
3. Drain coolant. Refer to «17 00 005 DRAINING AND ADDING COOLANT»(ref-203063-S08331852762005103000000) .

Recycling: Catch and dispose of coolant in a suitable container. Observe country-specific waste-disposal regulations.

Detach coolant hoses from thermostat housing (1).

Undo screws (2) on thermostat housing.

Remove thermostat housing.

Remove thermostat and seal from housing.

Scheme 199

Installation Note

Note installation position of bleeder pin (1).

Scheme 200

Replace seal and thermostat if necessary.

1. Guides - thermostat/seal.
2. Basic position of thermostat/seal guide.

Tightening torque, refer to 11 12 2AZ in ENGINE - TIGHTENING TORQUES- COOPER (1.6L) R50/W10 .

Scheme 201

Assemble engine.

Fill cooling system. Refer to 17 00 039 BLEEDING COOLING SYSTEM AND CHECKING FOR WATER LEAKS .

Check cooling system for leaks and correct operation. Refer to 17 00 009 CHECKING COOLING SYSTEM FOR LEAKS (W10) .

11 61 051 Removing and installing intake manifold

Note. For Special Tool identification, see FUEL SYSTEM - SPECIAL TOOLS - COOPER (1.6L) R50/W10 .

Special Tools Required

1. 13 5 280

Disconnect battery; to do so, proceed in accordance with instructions for disconnecting and connecting battery. Refer to 12 00 DISCONNECTING AND CONNECTING BATTERY .

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

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

Remove cover from fuel rail.

Detach line to brake booster from intake manifold.

Press ring downwards to expose line (1).

Detach crankcase ventilation valve from inspection hole cover

Scheme 202

Remove fuel line from fuel rail; disconnect quick-release coupling for this purpose.

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

Detach knock sensor plug from fuel rail wiring harness.

Disconnect tank vent link and unclip at fuel rail.

Disconnect vacuum line from intake manifold.

Remove retaining screws of fuel rail, then remove fuel injectors and fuel rail from manifold. Seal off fuel pressure regulator with special tool 13 5 280. Support fuel rail with a suitable piece of wire or manufactured rod.

Remove dipstick.

Scheme 203

Release manifold screws (5-1) and remove manifold.

Unclip coolant line below manifold.

Installation

Check gaskets on all cylinders and replace if necessary.

Tighten down bolts in sequence (1-5).

Tightening torque, 11 12 8AZ in ENGINE - TIGHTENING TORQUES- COOPER (1.6L) R50/W10 .

Scheme 204

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 (W10) .

Disconnect both oxygen sensor connectors.

Scheme 205

Undo retaining screws (1) for heat shield.

Tightening torque, refer to 11 62 1AZ in ENGINE - TIGHTENING TORQUES- COOPER (1.6L) R50/W10 .

Scheme 206

Undo retaining screws (1) for heat shield.

Detach heat shield (2).

Note. Routing of wiring harness.

Scheme 207

Unscrew 8 retaining screws (1) at exhaust manifold.

Remove exhaust manifold. Refer to 11 62 000 REMOVING AND INSTALLING, SEALING/REPLACING EXHAUST MANIFOLD .

Installation Note

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

Fit new gasket.

Scheme 208

Tightening torque, refer to 11 62 2AZ in ENGINE - TIGHTENING TORQUES- COOPER (1.6L) R50/W10 .

11 78 510 Replacing oxygen sensor

Note. For Special Tool identification, see ENGINE - SPECIAL TOOLS - COOPER (1.6L) R50/W10 .

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 209

Remove oxygen sensors.

Scheme 210

1. Oxygen sensor (upstream).
2. Oxygen sensor (downstream).

Installation Note

Tighten oxygen sensor using special tool 11 7 030.

Tightening torque, refer to 11 78 1AZ in ENGINE - TIGHTENING TORQUES- COOPER (1.6L) R50/W10 .

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.

Scheme 211

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