Removing and installing/replacing counterbalance shafts (B48 and B46 engine) (Cooper S and John Cooper Works)

Special tools required:

00 2 300
2 288 054
2 458 114
64 1 020

Preliminary work needed:

NOTE: For better disassembly and installation, turn the engine using special tool 00 2 300 in a favorable position rotate.
The engine is rotated 180 degrees in the following steps. Bottom points upwards.

Removal:

Release all bolts (arrows).

Guide out and remove the oil deflector (1).

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

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Twist the crankshaft to the lower dead center of the first cylinder.

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

Observe installation note in next operation!

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NOTE: Ensure that special tool 2 288 054 fits correctly in guides (1) of counterbalance shaft (2).
Slightly twist crankshaft if necessary.

Tighten special tool 2 288 054 to 20 Nm.

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Unscrew the screws (1).

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Loosen screws (1).

Feed out and remove the special tool 2 288 054.

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NOTE: The gear is pressed onto the counterbalance shaft with a taper and can be released only using special tool 2 458 114.

Screw special tool 2 458 114 into the gear of the counterbalance shaft and counterhold it with open-end wrench (1).

Release counterbalance shaft with screw (2) from gear.

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Attention!

Risk of damage on crankcase!

Never let counterbalance shafts (1) fall into the bearing positions!

Carefully remove counterbalance shafts (1) from crankcase towards front.

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Check all needle bearings of the counterbalance shafts.

If necessary, detach and replace all needle bearing of the counterbalance shafts.

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Remove gear (1).

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Remove gear (1).

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Slacken nut (1).

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Remove gear (1).

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Installation:

NOTE: All marks on the gears (1 and 2) and on the intermediate gear wheel (3) must point vertically towards the oil sump sealing surface (upwards).

Mark on gear (1) on intake side: Triangle
Mark on gear (2) on exhaust side: Two rectangles
Marking on intermediate wheel (3) at exhaust side: a square

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Parts : Replace gear (1).

Install gear (1).

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Align gear (1) with the contact surface on gear (2) in the arrow direction.

Tighten nut (1).

Tightening torque 11 27 2AZ .

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Attention!

Risk of mixing up similar parts gears!

Gear (1) is marked with an (A) and has to be installed on the exhaust side!

Parts : Replace gear (1).

Mount gear (1).

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Attention!

Risk of mixing up similar parts gears!

Gear (1) is marked with an (E) and has to be installed on the intake side!

Parts : Replace gear (1).

Mount gear (1).

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Attention!

Risk of damage on crankcase!

Never let counterbalance shafts (1) fall into the bearing positions!

Install counterbalance shafts (1) carefully in the crankcase against the arrow direction.

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Slide special tool 64 1 020 or another suitable tool into the counterbalance shaft through the gear.

Insert counterbalance shaft (1) carefully into the gear on the intake side.

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Slide special tool 64 1 020 or another suitable tool into the counterbalance shaft through the gear.

Insert counterbalance shaft (1) carefully into the gear on the exhaust side.

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Screw the two screws (1) into the left and right counterbalance shafts.

NOTE: Do not tighten screws (1) as otherwise it may not be possible to position the counterbalance shafts in the next step.

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Twist the crankshaft to the lower dead center of the first cylinder.

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

Observe installation note in next operation!

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NOTE: Ensure that special tool 2 288 054 fits correctly in guides (1) of counterbalance shaft (2).
Slightly twist crankshaft and/or counterbalance shafts if necessary.
Tighten special tool 2 288 054 to 20 Nm.

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Tighten down screws (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: Replacing sealing cap (1).

Ensure proper fit of O-ring.

Install both sealing caps (1).

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Parts : Replace screws.

Insert and install oil deflector (1).

Tighten all bolts (arrows).

Tightening torque: 11 41 3AZ /11 41 4AZ .

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Required follow-up work:

Install OIL PUMP .
Install the REAR TIMING CASE COVER .
Install VIBRATION DAMPER .
Remove engine from ASSEMBLY JIG .
Install ENGINE WITH TRANSMISSION .