Removing and installing, sealing/replacing rear timing case cover (B48 and B46 engine) (Cooper S and John Cooper Works)

Special tools required:

11 4 470
2 469 803
11 8 815
11 9 182
11 9 184
11 9 181
2 360 215
11 9 183

Attention!

Engines with surface sealant:

The maximum processing time of the liquid sealing compound is 10 minutes .

Preliminary work needed:

Uninstall the ENGINE WITH TRANSMISSION .
Mount ENGINE ON ASSEMBLY JIG .
Remove FLYWHEEL .
Remove CYLINDER HEAD . .
Remove OIL SUMP .

REMOVAL:

Attention!

Magnet wheel (1) is magnetic.

Keep magnet wheel (1) in a plastic bag away from shavings.

Remove magnet wheel (1) from crankshaft.

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Unscrew the screws (1).

Remove coolant line (2).

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Unlock connector (1) and detach it off the crankshaft sensor.

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Release screws in the sequence 11 to 1 .

Fig 1: Rear Timing Case Cover Screws Loosening Sequence

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Loosen the timing case cover with a screwdriver (1) in the direction of the arrow.

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Loosen the timing case cover with a screwdriver (1) in the direction of the arrow.

Remove the timing case cover.

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Attention!

Do not use any metal-cutting tools (e.g. emery cloth).

Remove seal remnants from the crankcase with special tool 11 4 470.

Check that lining sleeves (2) are correctly fitted, replace if necessary.

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INSTALLATION:

Attention!

Damage to the crankshaft seal.

Taping the sealing lip (inner) and oiling the crankshaft seal will destroy it.

Do not tap the sealing lip (inner) of the crankshaft seal.
Do not oil the crankshaft seal.
Install the crankshaft seal dry.

Have special tool 2 469 803 ready.

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Apply sealing compound (1) on the special tool 2 469 803 as shown.

Parts : SEALING COMPOUND 2.2 .

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When replacing the rear timing case cover:

NOTE: The maximum processing time of the liquid sealing compound is 10 minutes.
Sealing bead thickness: 1.5 to 2.0 mm.

Apply the sealing bead (1) at the positions signaled (see illustration) on the inside of the timing case cover.

Parts:

Sealing bead (1): SEALING COMPOUND 2.2 .

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Pre-assemble special tool 11 8 815 on crankshaft.

Mount the timing case cover with crankshaft seal (1).

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Insert bolts.

Tighten bolts in the sequence 1 to 11.

Tightening torque: 11 14 1AZ .

Fig 2: Rear Timing Case Cover Bolts Tightening Sequence

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When reinstalling the timing case cover:

Support the timing case cover (1) from below.

Set the inner punch in the crankshaft seal (2).

Drive the crankshaft seal (2) outwards.

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NOTE: The maximum processing time of the liquid sealing compound is 10 minutes.
Thickness of sealing bead 1.5 to 2.0 mm.

Remove the gasket remnants from the timing case cover with the special tool 11 4 470.

Apply the sealing bead (1) at the positions signaled (see illustration) on the inside of the timing case cover.

Parts:

Sealing bead (1): SEALING COMPOUND 2.2 .

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Mount the timing case cover without the crankshaft seal.

Insert bolts.

Tighten bolts in the sequence 1 to 11.

Tightening torque: 11 14 1AZ .

Fig 3: Rear Timing Case Cover Bolts Tightening Sequence

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Position special tool 11 8 815 on crankshaft.

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Attention!

Damage to the crankshaft seal.

Taping the sealing lip (inner) and oiling the crankshaft seal will destroy it.

Do not tap the sealing lip (inner) of the crankshaft seal.
Do not oil the crankshaft seal.
Install the crankshaft seal dry.

Carefully slide the crankshaft seal (1) straight off the special tool 11 8 815 using a rotational movement until the crankshaft seal is positioned parallel on the timing case cover.

Remove the special tool 11 8 815.

Secure special tool 11 9 182 with special tool 11 9 184 on the crankshaft.

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Prepare special tool 11 9 181 for installation.

Attach special tool 2 360 215 to special tool 11 9 181.

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Retract the crankshaft sealing ring with special tools 11 9 181 and 2 360 215 in conjunction with special tool 11 9 183.

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Screw in crankshaft seal with special tool 11 9 183 to stop.

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Check O-ring (1) of coolant line (2) for damage.

In case the O-ring is faulty, the coolant line (2) needs to be replaced.

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Install coolant line (2).

Tighten down screws (1).

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Connect connector (1) to crankshaft sensor and lock.

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NOTE: Check the lining sleeve for damage.
Note the installation position of the magnet wheel.

Position magnet wheel (1) on crankshaft.

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Concluding tasks:

Mount the OIL PAN .
Mount the CYLINDER HEAD .
Mount the FLYWHEEL .
Remove engine from ASSEMBLY JIG .
Install ENGINE WITH TRANSMISSION .