MINI 2002-05

Cylinder Head

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Removal & Installation



Cooper Coupe
  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Wheel well liners
     
    Battery and battery container
     
    Vent hose and engine control DME connector from cylinder head
     
    Fuel rail cover
     
    Fuel injector wiring harness (move aside)
     
    Heater hoses from cylinder head
     
    Top hose from thermostat housing
     
    Exhaust manifold from block
     
    Spark plugs
     
    Fuel line from fuel rail (plug openings)
     
    Lines from stabilizer bar bracket
     
    Vacuum line to brake booster from intake manifold
     
    CMP sensor connector
     
    Dipstick
     

  6.  
  7. Remove the intake manifold bolts in reverse of the order as shown (start with bolt 5), then lift the manifold over the dipstick tube.
  8.  
  9. Disconnect the line from the filler neck to the expansion tank, then the engine wiring harness can be moved around the thermostat housing.
  10.  
  11. Tie back the intake manifold from the cylinder head.
  12.  
  13. Remove or disconnect the following:

    Engine stabilizer bar bracket
     
    Oxygen sensor plug connector
     
    Holder for oxygen sensor plug from cylinder head
     
    Coolant distributor pipe screw
     
    Coolant temperature sensor connector
     

  14.  
  15. Support the engine with a trolley jack and rubber pad on the oil pan. Use caution so oil pan is not damaged.
  16.  
  17. Remove the engine carrier bolts and engine mount nut.
  18.  
  19. Remove the engine carrier.
  20.  
  21. Use a special tool, 11-8-200, and remove the hydraulic engine mount.
  22.  
  23. Mount a special engine holding tool, 11-8-370, on the cylinder block and body fixtures, as shown.
  24.  
  25. Remove the camshaft sensor.
  26.  
  27. Remove the plugs from the cover on each side of the camshaft.
  28.  
  29. Rotate the crankshaft until the triangular adjustment mark on the camshaft gear is at 12 o-clock. Apply a paint reference mark from camshaft and across timing chain for reassembly reference.
    NOTE
    The brass-colored chain links are of no importance to the timing.

  30.  
  31. Install a special clamping fixture tool, 11-8-250, to camshaft gear. Slacken, but do not remove the center bolt from the camshaft gear.
  32.  
  33. Remove the wiring harness holder, timing chain tensioner and clamping fixture tool.
  34.  
  35. Remove center bolt from camshaft gear.
  36.  
  37. Remove the camshaft gear from the timing chain and secure the chain to prevent it from falling.
  38.  
  39. Remove the bolts from timing chain guides (through the plug openings).
  40.  
  41. Remove the clamping rail and timing chain guides.
    NOTE
    The timing chain cover is designed so that the timing chain can remain on the crankshaft gear without any gear teeth being skipped.


    CAUTION
    DO NOT rotate crankshaft.

  42.  
  43. Remove the cylinder head retainers 11 and 12 first, then remove the cylinder head bolts in reverse of the order shown.
  44.  
  45. Remove the cylinder head.

    Click image to see an enlarged view

    Fig. Showing intake manifold bolt tightening sequence-Cooper Coupe



    Click image to see an enlarged view

    Fig. Mounting special holding tool on engine-Cooper Coupe



    Click image to see an enlarged view

    Fig. Cylinder head bolt tightening sequence-Cooper Coupe

  46.  

To install:

  1. Clean all sealing material from mating faces
    CAUTION
    There must be no oil in the cylinder head bolt holes in the block and timing case cover or there is a possibility of cracking and distorting torque values.

  2.  
  3. Install a new cylinder head gasket.
  4.  
  5. Position the cylinder head onto the block and install new cylinder head bolts (do not clean compound applied to new bolts).
  6.  
  7. Tighten cylinder head bolts, following the sequence shown for bolts 1 through 10, in 2 steps, to the following:
    1. Step 1: 30 ft. lbs. (40 Nm)
    2.  
    3. Step 2: Additional 90 degrees
    4.  

  8.  
  9. Tighten cylinder head retainers number 11 and 12 to 21 ft. lbs. (28 Nm).
  10.  
  11. Install or connect the following:

    Clamping rail and timing chain guides
     
    Chain guide bolts; torque to 21 ft. lbs. (28 Nm)
     
    Timing chain onto camshaft gear
     
    Center bolt in camshaft gear
     

  12.  
  13. Align the camshaft and timing chain paint marks made during removal.
  14.  
  15. Install camshaft gear holding special tool, 11-8-250, then torque center camshaft gear bolt to 75 ft. lbs. (102 Nm).
  16.  
  17. Move the timing chain tensioner into transition position. Place the timing chain tensioner clamping fixture (1) on a level surface and remove the cap (2).
  18.  
  19. Place palm of hand against the clamping fixture and exert continuous pressure until fixture is completely compressed. Replace clamping fixture cap. Position the clamping fixture in place.
  20.  
  21. Install the timing chain tensioner and torque screw plug to 46 ft. lbs. (63 Nm). Install the cable holder.
    CAUTION
    Timing chain tensioner is in the transition position. Ensure timing chain is correctly arranged inside the channel of the timing chain guides.

  22.  
  23. Use a prybar to lever the clamping rail until the timing chain tensioner applies tension to the timing chain (do not lever directly on the timing chain).
  24.  
  25. Exam the released position of the clamping fixture as shown.
  26.  
  27. Complete installation in reverse of the removal procedure.
  28.  
  29. Refill the cooling system.

    Click image to see an enlarged view

    Fig. Aligning camshaft and timing chain reference marks-Cooper Coupe



    Click image to see an enlarged view

    Fig. Reassembling timing chain tensioner clamping fixture-Cooper Coupe



    Click image to see an enlarged view

    Fig. Showing the released position of the timing chain clamping fixture (with tension on the timing chain)-Cooper Coupe

  30.  

Cooper S Coupe
  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Disconnect or remove the following:

    Battery
     
    Intercooler
     
    ECU connectors
     
    Intake filter housing
     

  4.  
  5. Slacken the module front end (MFE) and install the extension tools, 11-8-401/2 to keep MFE extended for access.
  6.  
  7. Disconnect or remove the following:
    CAUTION
    Fuel system may be under pressure; be prepared to open line cautiously and ready to catch spilling fuel.



    Throttle assembly
     
    Cylinder head cover
     
    Fuel tank venting valve
     
    Fuel line from fuel rail (quick-disconnect fitting); plug openings
     

  8.  
  9. Release both pipes from the engine stabilizer bracket and move to one side.
  10.  
  11. Disconnect or remove the following:

    Intake manifold
     
    Supercharger outlet pipe
     
    Engine stabilizer support bracket
     
    Cap from coolant reservoir
     
    Drain the cooling system
     
    Oxygen sensor connector (1)
     
    Oxygen sensor connector bracket from cylinder head (2)
     
    Coolant rail support bolt (3)
     
    Coolant sensor connector (4)
     
    Coolant hoses (5)

    Click image to see an enlarged view

    Fig. Showing components to remove from coolant housing area of engine-Cooper S Coupe

     

  12.  
  13. Disconnect the camshaft (CMP) sensor connector.
  14.  
  15. Remove the dipstick.
  16.  
  17. Remove the exhaust heat shield and exhaust manifold bolts from cylinder head.
  18.  
  19. Remove the spark plugs.
  20.  
  21. Support the engine with a suitable jack.
  22.  
  23. Remove the engine mount support bracket.
  24.  
  25. Remove the engine hydra-mount, with special tool, 11-8-200.
  26.  
  27. Install a special engine retainer brace, 11-8-370, to cylinder block and engine mount chassis location.
  28.  
  29. Remove the CMP sensor.
  30.  
  31. Remove both plugs from the front of the cylinder head.
  32.  
  33. Remove both fender well liners.
  34.  
  35. Rotate the engine until the camshaft gear triangular timing mark is at the 12 o-clock position. Make a paint mark across the timing mark and timing chain for reassembly reference.
    NOTE
    The copper colored link has no relation to timing. The design of the timing chain cover will allow the chain to stay on the crankshaft gear without skipping any teeth.


    CAUTION
    DO NOT rotate the engine with timing chain disconnected.

  36.  
  37. Install camshaft gear holding tool, 11-8-250, then slacken, but do not remove, the camshaft gear center bolt.
  38.  
  39. Remove the wiring harness holder, timing chain tensioner and clamping fixture tool.
  40.  
  41. Remove center bolt from camshaft gear.
  42.  
  43. Remove the camshaft gear from the timing chain and secure the chain to prevent it from falling.
  44.  
  45. Remove the bolts from timing chain guides (through the plug openings).
  46.  
  47. Remove the clamping rail and timing chain guides.
    NOTE
    The timing chain cover is designed so that the timing chain can remain on the crankshaft gear without any gear teeth being skipped.


    CAUTION
    DO NOT rotate crankshaft.

  48.  
  49. Remove the cylinder head retainers 11 and 12 first, then remove the cylinder head bolts in reverse of the order shown.
  50.  
  51. Remove the cylinder head.
  52.  

To install:

  1. Clean all sealing material from mating faces
    CAUTION
    There must be no oil in the cylinder head bolt holes in the block and timing case cover or there is a possibility of cracking and distorting torque values.

  2.  
  3. Install a new cylinder head gasket.
  4.  
  5. Position the cylinder head onto the block and install new cylinder head bolts (do not clean compound applied to new bolts).
  6.  
  7. Tighten cylinder head bolts, following the sequence shown for bolts 1 through 10, in 2 steps, to the following:
    1. Step 1: 30 ft. lbs. (40 Nm)
    2.  
    3. Step 2: Additional 90 degrees
    4.  

  8.  
  9. Tighten cylinder head retainers number 11 and 12 to 21 ft. lbs. (28 Nm).
  10.  
  11. Install or connect the following:

    Clamping rail and timing chain guides
     
    Chain guide bolts; torque to 21 ft. lbs. (28 Nm)
     
    Timing chain onto camshaft gear
     
    Center bolt in camshaft gear
     

  12.  
  13. Align the camshaft and timing chain paint marks made during removal.
  14.  
  15. Install camshaft gear holding special tool, 11-8-250, then torque center camshaft gear bolt to 75 ft. lbs. (102 Nm).
  16.  
  17. Move the timing chain tensioner into transition position. Place the timing chain tensioner clamping fixture (1) on a level surface and remove the cap (2).
  18.  
  19. Place palm of hand against the clamping fixture and exert continuous pressure until fixture is completely compressed. Replace clamping fixture cap. Position the clamping fixture in place.
  20.  
  21. Install the timing chain tensioner and torque screw plug to 46 ft. lbs. (63 Nm). Install the cable holder.
    CAUTION
    Timing chain tensioner is in the transition position. Ensure timing chain is correctly arranged inside the channel of the timing chain guides.

  22.  
  23. Use a prybar to lever the clamping rail until the timing chain tensioner applies tension to the timing chain (do not lever directly on the timing chain).
  24.  
  25. Exam the released position of the clamping fixture as shown.
  26.  
  27. Complete installation in reverse of the removal procedure.
  28.  
  29. Refill the cooling system.
  30.  

 
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