Cylinder Head Assembly: Service and Repair
Removing And Installing/Sealing Cylinder Head (COOPER S)
Special tools required:
^ 00 9 120
^ 11 8 200
^ 11 8 250
^ 11 8 370
^ 11 8 401
^ 11 8 402
^ 13 5 280
^ 33 2 140
Disconnect battery.
Remove intercooler.
Remove EMS2000 ECU connectors.
Remove intake filter housing.
Slacken modular front end.
Install modular front end extensions; special tools 11 8 401 and 11 8 402.
Remove throttle assembly.
Remove cylinder head cover. Service and Repair
Caution: the fuel in the fuel line is pressurized (approximately 3 bar) catch and dispose of escaping fuel.
Remove tank venting valve. 17 00 039 Venting Cooling System and Checking For Leaks
Release fuel pressure from fuel rail.
Disconnect fuel line from fuel rail, via quick fit connector and fit special tool 13 5 280
Release both pipes from stabilizer bracket and move to one side.
Remove inlet manifold. Service and Repair
Remove supercharger outlet pipe.
Remove stabilizer support bracket bolts (1).
Remove stabilizer bracket.
Release coolant pressure cap from expansion tank.
Drain coolant.
Disconnect oxygen sensor connector (1).
Remove oxygen sensor connector bracket from cylinder head (2).
Remove coolant rail support bolt (3).
Disconnect coolant sensor connector (4).
Disconnect coolant pipes (5).
Disconnect camshaft sensor connector.
Remove dipstick.
Remove exhaust heat shield.
Remove exhaust manifold retaining bolts from cylinder head. Service and Repair
Remove spark plugs.
Support engine with trolley jack.
Remove engine support bracket bolts (1) and engine mount retaining nut (2).
Remove engine mount support bracket.
Remove engine hydra mount with special tool 11 8 200.
Using special tool 11 8 370, install to cylinder block fixings and engine mount chassis fixing.
Remove camshaft sensor (1).
Remove plugs from cylinder head (2).
Remove wheel arch liner.
Rotate engine until the camshaft gear triangular timing mark is at 12 o'clock position (1).
For reassembly purposes paint timing chain to triangular timing mark (2).
The copper colored link has no relation to this process.
Note: the design of the timing chain cover will allow the timing chain to stay on the crankshaft gear, without skipping any teeth.
Do not rotate engine.
Slacken camshaft retaining bolt (1) hold camshaft gear with special tool 11 8 250 , but do not remove.
Remove harness bracket (1) and timing chain tensioner plug (2) and tensioner.
Remove camshaft gear retaining bolt and remove gear and chain.
Remove camshaft gear from chain and drop timing chain into crankcase.
Remove chain guide retaining bolts (1), and remove both guides (2).
Note: the timing chain cover is not required to be removed for this process. This picture is used to illustrate the timing chain guide arrangement.
Slacken cylinder head bolts and cylinder head fixings in sequence (12-1).
Remove cylinder head bolts and cylinder head fixings.
Remove cylinder head and gasket.
Note: Multi-Layer Steel (MLS) head gaskets require a scratch free sealing surface, care must be taken when cleaning aluminum engine components.
Clean all engine oil passages.
Check cylinder head flatness in diagonal and horizontal plane with commercially available straight edge.
Maximum cylinder head distortion must be 0.1 mm.
The cylinder head bolts are of stretched design and can be reused provided the bolt thread is not stretched.
Check thread for elongation with straight edge.
Install hint:
Installation of the cylinder head is described separately from removal.
Check dowel sleeves (1) are undamaged and correctly located.
No oil is permitted in the cylinder head bolt thread bores of the cylinder block, clean out as necessary.
Replace cylinder head gasket, note the larger holes (1) are used for aligning gasket to the cylinder block dowels.
Refit cylinder head.
Install head bolts.
Tighten cylinder head bolts and cylinder head fixings in sequence (1-10).
Cylinder head bolts to crankcase
Jointing torque 40 Nm
Torque angle 90°
Tighten cylinder head bolts in sequence (11-12).
Cylinder head bolts to crankcase
M8 28 Nm
The cylinder head must be tightened in a two stage sequence.
For torque angle tightening, use special tool 00 9 120 Retrieve timing chain from crankcase with a magnet or fabricated hook.
Rest timing chain on camshaft flange.
Install timing chain guides.
Install guide retaining bolts.
Guide and tensioning rail to cylinder head
M8 28 Nm
Align triangular timing mark on camshaft gear with the timing chain link that was painted during dismantling.
Install timing chain on camshaft gear.
Install camshaft gear on camshaft flange and refit retaining bolt.
Camshaft gear to camshaft
M12 102 Nm
Caution: Do not use an impact wrench for tightening the camshaft gear bolt. Damage to the camshaft timing pin can result. Use a hand wrench only.
Reset timing chain tensioner to the transit position.
Place the tensioner (1) on a flat surface.
Remove tensioner reservoir cap (2).
Place the palm of your hand against the tensioner, with continuous pressure until the tensioner is fully compressed.
Refit tensioner cap (2) after reset.
Install the timing chain tensioner (1) into its housing and tighten.
Seal plug, chain tensioner 63 Nm
Note: Transit position of tensioner.
Note: Ensure the timing chain is properly positioned within the channel of the timing chain guides.
Do not pry directly on chain. Damage to the timing chain may occur.
Using special tool 33 2 140 , lever on the right (movable) timing chain guide until the timing chain tensioner ratchets out to tension the chain.
Note the released position of the tensioner (1).
Install hint:
Install new sealing washers to cylinder head closure plugs and refit.
Pulse generator, sensor to cylinder head
M6 9 Nm
Install camshaft sensor.
Seal plug to cylinder head 18 Nm
Install hydra mount.
Hydraulic-mount to body 100 Nm
Install engine mount support bracket to cylinder head.
Engine carrier to cylinder block 100 Nm
Install engine support bracket to engine mount.
Engine mounting to engine mount 68 Nm
Install stabilizer bracket.
Cylinder head bolts to crankcase
M8 28 Nm
Camshaft gear to camshaft
M12 102 Nm