Replacing crankshaft (B48 and B46 engine) (Cooper S and John Cooper Works)

Special tools required:

11 6 250
2 288 054
00 2 010
11 6 480

IMPORTANT: Replace the main bearing with connecting rod bearing and connecting rod bolt.
When replacing the crankshaft, the main bearing shells and connecting rod bearing shells must be replaced.
There must be no oil in the blind holes (risk of cracking).
Do not wash off screw coating.
Incorrect assembly of the crankshaft bearing caps will result in damage to the crankcase.

Preliminary work needed:

Remove BOTH TIMING CHAINS .
Remove all PISTONS .

Removal:

Check crankshaft SIDE CLEARANCE . .

Fit special tool 11 6 250.

If the permitted side clearance is exceeded:

Check the crankshaft and guide bearing shells
Replace worn components

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Lever out both sealing caps (1) with screwdriver (2).

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Twist crankshaft on TDC first cylinder.

Mount special tool 2 288 054 and abut screws (1).

Observe installation note in next operation!

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NOTE: Make sure special tool 2 288 054 is properly seated in the guides (1) of the counterbalance shaft (2).
Slightly twist crankshaft if necessary.

Tighten special tool 2 288 054 to 20 Nm.

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Unscrew screw (1) of the intake side counterbalance shaft.

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Unscrew the screws (1).

Guide the special tool 2 288 054 out and remove.

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Pull out the intake side counterbalance shaft (1) from crankshaft (2) in the arrow direction.

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IMPORTANT: Carefully set intake side counterbalance shaft (1) aside.

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Position a clean, lint-free cleaning cloth (1) between the counterbalance shaft (2) on the intake side and the crankcase (3).

Ensure that the needle bearing (4) will not be damaged.

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Slacken nut (1).

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Installation note:

Equipment specification up to year of manufacture 07/16

Pull out and uninstall the idle gear (1).

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Installation note:

Equipment specification from year of manufacture 07/16

Pull out and uninstall the idle gear (1).

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NOTE: All crankshaft bearing caps (1) are labeled (bearing position 1 to 5).
Installation position must be maintained.

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Release main bearing screw connection of main bearing cap in the sequence 10 - 1.

Remove main bearing caps 1 - 5.

Fig 1: Main Bearing Cap Screws Loosening Sequence

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IMPORTANT: With the assistance of a second person, remove crankshaft and carefully place to one side.
Pay attention to oil hole in bearing shell.
Pay attention to installation position of CRANKSHAFT MAIN BEARING SHELLS .

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Installation:

CRANKSHAFT MAIN BEARING SHELLS .

Coat bearing shells (1 - 5) with fresh engine oil or.

Both locating grooves of bearing shells in crankcase and on crankshaft bearing cap must be mounted on one side.

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Insert crankshaft (1).

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IMPORTANT: Do not fit crankshaft bearing cap in incorrect position.
Risk of damage to the molding on the crankcase.

Align crankshaft bearing cap exactly.

Fit main bearing bolts.

Tighten main bearing bolts in sequence 1 - 10 (comply with tightening specifications).

Tightening torque: 11 11 1AZ .

Fig 2: Main Bearing Cap Bolts Tightening Sequence

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Feed out and remove the lint-free cleaning cloth (1) between the counterbalance shaft (2) on the intake side and the crankcase (3).

Ensure that the needle bearing (4) will not be damaged.

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Installation note:

Move or adjust the crankshaft (2) to the TDC position.

Position the counterbalance shaft (1) of the intake side in arrow direction on the crankshaft (2).

The mark on the gear (1) of the intake for the counterbalance shaft must point upwards , vertical to the oil sump sealing surface (3).

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Replace screw (1).

Parts : screw

Screw the screw (1) into the counterbalance shaft of the intake side.

NOTE: Do not tighten screw (1) because otherwise the counterbalance shafts cannot be positioned in the next operation.

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Twist crankshaft on TDC first cylinder .

Mount special tool 2 288 054 and abut screws (1).

Observe installation note in next operation!

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NOTE: Make sure special tool 2 288 054 is properly seated in the guides (1) of the counterbalance shaft (2).
Slightly twist crankshaft if necessary.
Tighten special tool 2 288 054 to 20 Nm.

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Tighten screw (1).

Tightening torque 11 27 1AZ .

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Release screws (1) and remove special tool 2 288 054.

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Parts: Replace sealing cap (1).

Ensure proper fit of O-ring.

Install both sealing caps (1).

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Installation note:

Equipment specification up to year of manufacture 07/16

Feed in and install the idle gear (1).

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NOTE: Equipment specification up to year of manufacture 07/16
The marks on the gear (1) the idler gear (2) must point upwards , vertical to the oil sump sealing surface (3).

Mark on the intermediate gear (2) of the counterbalance shaft on the exhaust side: One square
Mark on gear (1) of the exhaust side counterbalance shaft: two squares

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Installation note:

Equipment specification from year of manufacture 07/16

Feed in and install the idle gear (1).

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NOTE: Equipment specification from year of manufacture 07/16
The marks on the gear (1) the idler gear (2) must point upwards , vertical to the oil sump sealing surface (3).

Mark on the intermediate gear (2) of the counterbalance shaft on the exhaust side: One square
Mark on gear (1) of the exhaust side counterbalance shaft: one triangle

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Position the gear (1) on the gear (2) in the arrow direction .

Tighten nut (3).

Tightening torque 11 27 2AZ .

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Check SIDE CLEARANCE . .

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Check crankshaft COEFFICIENT OF FRICTION .

Screw in all screws of vibration damper manually.

Turn crankshaft evenly with special tool 00 2 010 and special tool 11 6 480.

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Required reworking:

Install all PISTONS .
Install BOTH TIMING CHAINS .
Assemble engine