11 12 100 Removing and installing/sealing cylinder head W10

WARNING: This page does not describe the selected car, but rather 7 other vehicles, including the 2008 MINI Cooper, 2007 MINI Cooper, 2006 MINI Cooper, 2005 MINI Cooper, and 2004 MINI Cooper. However, it is still accessible from the selected car via links, so may be relevant.

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:

00 9 120
11 8 200
11 8 250
11 8 370
13 5 280
33 2 140

Necessary Preliminary Tasks:

Drain coolant. Refer to 17 00 005 DRAINING AND ADDING COOLANT .
Remove wheel arch liner. Refer to 51 71 040 REMOVING AND INSTALLING/REPLACING FRONT LEFT OR RIGHT WHEEL ARCH LINER .
Disconnect battery. Refer to 12 00 DISCONNECTING AND CONNECTING BATTERY .
Remove battery container. Refer to 61 21 100 REMOVING AND INSTALLING/REPLACING BATTERY CONTAINER .
Remove tank vent valve with line. Refer to13 90 500 REPLACING TANK VENTING VALVE .
Remove cylinder head. Refer to 11 12 100 REMOVING AND INSTALLING/SEALING CYLINDER HEAD W10 .
Disconnect plug connector from DME.
Remove cover from fuel rail.
Release fuel injector wiring harness and place to one side.
Detach heating hoses on cylinder head.
Detach top water hose on thermostat.
Unfasten exhaust manifold.
Remove spark plugs. Refer to 12 12 011 REPLACING ALL SPARK PLUGS .

CAUTION: Fit new cylinder head screws. Do not wash off bolt coating. There must be no oil or coolant in the pocket holes (risk of cracking ). The fuel in the fuel lines is under pressure (approx. 3 bar). Catch and dispose of escaping fuel.

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.

Fig 1: Locating Plugs For Fuel Line

Courtesy of BMW OF NORTH AMERICA, INC.

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

Press ring downwards to expose line (1).

Fig 2: Detaching Vacuum Line To Brake Booster

Courtesy of BMW OF NORTH AMERICA, INC.

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 .

Fig 3: Identifying Intake Manifold Screws

Courtesy of BMW OF NORTH AMERICA, INC.

Tie back intake manifold.

NOTE: See Fig 4.

Fig 4: Tie Back Intake Manifold

Courtesy of BMW OF NORTH AMERICA, INC.

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 .

Fig 5: Removing Stabilizer Bar Bracket

Courtesy of BMW OF NORTH AMERICA, INC.

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.

Fig 6: Locating Plug Connector Of Coolant Temperature Sensor

Courtesy of BMW OF NORTH AMERICA, INC.

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

CAUTION: Risk of damage to 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 .

Fig 7: Identifying Engine Carrier Bolts

Courtesy of BMW OF NORTH AMERICA, INC.

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

NOTE: See Fig 8.

Fig 8: Mounting Support Arm On Cylinder Block

Courtesy of BMW OF NORTH AMERICA, INC.

Remove camshaft sensor (1).

Release screw plugs (2).

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

Fig 9: Locating Camshaft Sensor

Courtesy of BMW OF NORTH AMERICA, INC.

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

IMPORTANT: For assembly, mark timing chain at triangular adjustment mark (2) with paint (1).

Mark vibration damper and timing case cover with paint.

NOTE: See Fig 10.

Installation Note:

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

Fig 10: Aligning Crankshaft To Triangular Adjustment Mark

Courtesy of BMW OF NORTH AMERICA, INC.

Secure special tool 11 8 250 to camshaft gear.

Slacken central bolt (1).

CAUTION: Do not remove central bolt (1) yet.

Fig 11: Securing Pin Wrench To Camshaft Gear

Courtesy of BMW OF NORTH AMERICA, INC.

Remove wiring harness holder (1).

Release timing chain tensioner (2).

NOTE: Remove clamping fixture.

Fig 12: Locating Timing Chain Tensioner

Courtesy of BMW OF NORTH AMERICA, INC.

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, see Fig 13.

Fig 13: Removing Clamping Rail And Chain Guides

Courtesy of BMW OF NORTH AMERICA, INC.

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.

CAUTION: Do not rest cylinder head on sealing surface. Risk of damage to valves.

Fig 14: Removal Sequence For Cylinder Head Bolts

Courtesy of BMW OF NORTH AMERICA, INC.

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.

Fig 15: Checking Surface Evenness Of Cylinder Head

Courtesy of BMW OF NORTH AMERICA, INC.

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.

Fig 16: Checking Dowel Sleeves For Damage

Courtesy of BMW OF NORTH AMERICA, INC.

Replace cylinder head gasket.

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

Install cylinder head.

Fig 17: View Of Cylinder Head Gasket

Courtesy of BMW OF NORTH AMERICA, INC.

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.

Fig 18: Identifying Tightening Sequence Of Cylinder Head Bolts

Courtesy of BMW OF NORTH AMERICA, INC.

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, see Fig 19.

Fig 19: Installing Clamping Rail And Chain Guides

Courtesy of BMW OF NORTH AMERICA, INC.

Installation Note:

Align camshaft and timing chain markings to each other.

Insert central bolt.

Fig 20: Aligning Camshaft To Timing Chain Markings

Courtesy of BMW OF NORTH AMERICA, INC.

Fit special tool 11 8 250.

CAUTION: Risk of damage to timing chain.

Tighten down central bolt (1).

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

Fig 21: Tightening Central Bolt

Courtesy of BMW OF NORTH AMERICA, INC.

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.

Fig 22: Removing Cap From Clamping Fixture

Courtesy of BMW OF NORTH AMERICA, INC.

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).

Fig 23: Installing Cable Holder

Courtesy of BMW OF NORTH AMERICA, INC.

CAUTION: Timing chain tensioner (1) is in transition position.

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

Fig 24: Aligning Timing Chain Tensioner

Courtesy of BMW OF NORTH AMERICA, INC.

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, see Fig 25.

Fig 25: Positioning Clamping Rail Using Holder

Courtesy of BMW OF NORTH AMERICA, INC.

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

Fig 26: View Of Clamping Fixture

Courtesy of BMW OF NORTH AMERICA, INC.

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.