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

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.

Special tools required:

00 9 120
11 5 150
11 8 250
11 8 370
11 8 401
11 8 402
13 5 280
33 2 140

Necessary preliminary tasks:

Disconnect battery. Refer to 61 21 010 REMOVING AND INSTALLING BATTERY (COOPER S) .
Remove intercooler. Refer to 17 51 000 Removing and installing/replacing intercooler .
Disconnect plug connector from EMS/DME.
Remove air filter 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 cylinder head. Refer to 11 12 000 Removing and installing, sealing cylinder head cover (COOPER S) .
Remove tank venting valve. Refer to 13 90 500 REPLACING TANK VENTING VALVE .
Remove intake manifold. Refer to 11 61 051 Removing and installing intake manifold (COOPER S) .
Remove charger outlet pipe. Refer to 17 51 080 REMOVING AND INSTALLING/REPLACING TURBOCHARGER EXHAUST PIPE (RIGHT) .
Drain coolant. Refer to 17 00 005 DRAINING AND ADDING COOLANT (COOPER S) .
Detach exhaust manifold. Refer to 11 62 000 Removing and installing, sealing/replacing exhaust manifold .
Remove spark plugs. Refer to 12 12 011 REPLACING ALL SPARK PLUGS .
Remove wheel arch liner. Refer to 51 71 040 REMOVING AND INSTALLING/REPLACING FRONT LEFT OR RIGHT WHEEL ARCH LINER .

IMPORTANT: The fuel in the fuel lines is under pressure (approx. 3 bar).
Fit new cylinder head screws.
Do not wash off bolt coating.
There must be no oil in the blind holes (risk of cracking).

Recycling:

Catch and dispose of escaping fuel.

Catch and dispose of drained coolant.

Observe country-specific waste -disposal regulations.

Lower front end module.

Fig 1: Mounting Front End Module And Extensions

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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.

Fig 2: Disconnecting Fuel Line

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

Remove screws (1) for stabilizer bracket.

Fig 3: Removing Stabilizer Bracket

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Remove stabilizer bracket.

Detach oxygen sensor plug connector (1).

Fig 4: Removing Components

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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.

IMPORTANT: Support engine with trolley jack (risk of damage).

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

Fig 5: Removing Engine Carrier

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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).

Fig 6: Securing Special Tool To Engine Block

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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).

Fig 7: Securing Special Tool To Engine Block

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

IMPORTANT: Unclip ABS sensor cable on engine carrier at bottom.

Remove camshaft sensor (1).

Fig 8: Identifying Camshaft Sensor

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Release sealing screws in cylinder head (2).

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

Fig 9: Identifying Triangular Adjustment Mark On Camshaft Gear

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

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

IMPORTANT: Do not rotate crankshaft.

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

Fig 10: Locating Camshaft Retaining Bolt

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

Fig 11: Removing Wiring Harness Bracket

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

Fig 12: Identifying Timing Chain Cover

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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).

Fig 13: Identifying Cylinder Head Bolt Loosening Sequence

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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.

Fig 14: Checking Cylinder Block

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Max. permitted cylinder head distortion is 0.1 mm.

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

Fig 15: Checking Adapter Sleeves

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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.

Fig 16: Installing Cylinder Head Gasket

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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).

Fig 17: Identifying Cylinder Head Bolts Tightening Sequence

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

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

Fig 18: View Of Angle-Of-Rotation Tightening

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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.

Fig 19: Aligning Triangular Adjustment Mark

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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.

Fig 20: Resetting Clamping Fixture

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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.

Fig 21: Mounting Timing Chain Tensioner

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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.

Fig 22: Moving Timing Chain Guide

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

Fig 23: View Of Release Position

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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.