Removing and installing/replacing intake adjuster (B38 engine) (Cooper Clubman base)

Special tools required: 

• 2 358 122
• 0 496 855
• 2 450 487
• 11 6 480

Preliminary work needed: 

• Check TIMING .
• Remove CATALYTIC CONVERTER .

Before removal, note  or write down the identification/part number of the intake adjuster.

Always, an intake adjuster with the same part number  must be reinstalled.

Mixed installation of the intake adjuster is not permitted!

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Overview illustration of the intake adjuster:

7 608 788 intake adjuster

8 617 692 intake adjuster

8 684 920 intake adjuster

Removal: 

For correct lining see repair instructions: CHECK TIMINGS .

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Remove chain tensioner (1).

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Version 1 

Use the reversible ratchet head (2) from special tool 0 496 855 with special tool 2 450 487 to release the central valve (1).

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Version 2 

Use special tool 0 496 855 to release the central valve (1).

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Release VANOS central valve (1) of exhaust camshaft adjuster.

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Release VANOS central valve (1) of intake camshaft adjuster.

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Remove VANOS central valve (1) of intake side.

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Remove intake adjuster (1) from intake camshaft.

Slightly tilt intake adjuster (1) and remove downwards.

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Installation: 

Danger of engine damage! 

Intake and exhaust camshaft adjusters are different.

VANOS has been highlighted with EX  for the exhaust camshaft.

VANOS has been highlighted with IN  for the intake camshaft.

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Feed intake adjuster (1) into timing chain (2) and position on intake camshaft (3).

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Abut VANOS central valve (1) of intake side.

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Install new chain tensioner.

Parts:  Chain tensioner

Tighten chain tensioner (1).

Tightening torque 11 31 1AZ .

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Tighten VANOS central valve of intake camshaft adjuster (1).

Tightening torque 11 36 1AZ .

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Tighten VANOS central valve of exhaust camshaft adjuster (1).

Tightening torque 11 36 1AZ .

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Remove all special tools.

Crank engine with special tool 11 6 480 twice in direction of engine rotation.

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Required reworking: 

• Check TIMING .
• Attach CATALYTIC CONVERTER .

When replacing the intake adjusters, the I level must be possibly 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