Removing and installing cylinder head (B38 engine) (Cooper Clubman base)

Special tools required:

2 414 691
2 357 071
11 8 580
11 4 471
11 4 472
2 364 711
11 4 470
00 9 120

Attention!

When replacing the cylinder head:

In all vehicles, the Digital Motor Electronics (DME) must possibly be reprogrammed/recoded after the replacement of the cylinder head.

Attention!

When replacing the cylinder head, there may be damage to the valve train due to a lack of motor oil.

It is imperative that you observe the REPAIR NOTES FOR REPLACING THE ENGINE .

Attention!

Make sure there is no coolant, water or motor oil in the threaded holes in the engine block.

Fit new cylinder head bolts.

Do not wash off screw coating.

Joining torque and angle of rotation must be observed without fail (risk of damage!) .

NOTE: When replacing cylinder head:

The complete valve timing and the Valvetronic servomotor are already pre-assembled.

Preliminary work needed:

Remove FAN COWL .
Remove EXHAUST TURBOCHARGER .
Remove INTAKE PLENUM .
Remove INTAKE ADJUSTER AND EXHAUST CAMSHAFT ADJUSTER
Drain COOLANT .

Removal:

Unlock coolant line (1) and detach.

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Prepare special tool 2 414 691 together with the special tool 2 357 071.

Attach special tool 2 414 691 on the front axle mount and correctly align the special tool 2 357 071 below the oil sump and tighten.

Uniformly rotate special tool 2 414 691 on the adjustment screws until the special tool 2 357 071 lies on the oil pan.

Tighten all adjustment screws of special tools 2 414 691 and 2 357 071.

Release screw connection (1) of right engine mount.

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Unscrew the screws (1). Remove holder from cylinder head.

NOTE: Shown with engine mount removed for purposes of clarity.

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Unscrew the screws (1).

Remove guide rail (2).

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Fix intake camshaft with an open-end wrench (1).

Release screw (2).

Remove the camshaft sensor wheel (3).

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Disassemble the roller tappet (1) from the high pressure pump bracket (3).

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Unscrew the screws (1).

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Use special tool 11 8 580 to slacken the cylinder head bolts.

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Slacken cylinder head bolts in sequence 8 to 1.

Remove cylinder head.

Fig 1: Slacken Cylinder Head Bolts Loosening Sequence

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Installation:

NOTE: The oil ducts must be sealed before cleaning the sealing surfaces using special tools 11 4 471 and 11 4 472.

Attention!

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

Seal front oil duct with special tool (B) from tool set 2 364 711.

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Remove coarse residues on sealing surfaces with special tool 11 4 471 from cylinder head and crankcase.

Attention!

Do not use any metal-cutting tools.

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Remove fine residues on sealing surfaces with special tool 11 4 472 from cylinder head and crankcase.

Attention!

Do not use any metal-cutting tools.

There must be no coolant, water or motor oil in the pocket holes.

Risk of cracking and corrosion!

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Clean all blind holes.

Replace CYLINDER HEAD GASKET .

Check lining sleeves (1) for damage and correct installation position.

Clean sealing surfaces on the cylinder head and crankcase using special tool 11 4 470.

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Attention!

There must be no coolant, water and motor oil in any of the threaded holes in the engine block.

Fit new cylinder head bolts.

Do not wash off screw coating.

Lightly oil screw head support.

Joining torque and angle of rotation must be observed without fail (risk of damage!) .

Fit cylinder head and secure with new bolts, tightening in the sequence 1 to 8.

Tightening torque: 11 12 1AZ .

Fig 2: Cylinder Head Bolts Tightening Sequence

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Secure cylinder head bolts (1) with special tool 00 9 120 and 11 8 580.

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Install and tighten down screws (1).

Tightening torque: 11 12 2AZ .

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Mount the roller tappet (1) on the high pressure pump bracket (3).

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Fix intake camshaft with an open-end wrench (1).

Position the camshaft sensor wheel (3).

Tighten down screw (2).

Tightening torque 11 31 2AZ .

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Install guide rail (2).

Tighten the screws.

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Fit holder to cylinder head. Tighten down screws (1).

Tightening torque 22 11 3AZ .

NOTE: Shown with engine mount removed for purposes of clarity.

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Secure engine mounting bracket to engine mount with screws (1).

Tightening torque 22 11 1AZ .

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Remove the special tool 2 414 691.

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Connect coolant line (1) and clip in.

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Required follow-up work:

INSTALL INTAKE ADJUSTER AND EXHAUST CAMSHAFT ADJUSTER
Install EXHAUST TURBOCHARGER .
Install INTAKE PLENUM .
Install FAN COWL .
Add COOLANT .
Check engine for leak tightness

When replacing the cylinder head, the I level must possibly be coded and programmed .

Connect diagnosis system and follow the diagnosis instructions .
Service functions
Drive
Engine electronics
Reset VANOS adaptation values
Code and program I level if necessary