MINI 2002-05

Intake Manifold

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Removal & Installation



Cooper Coupe
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  


CAUTION
Fuel system may still be under pressure; use caution when disconnecting any fuel system components. Be prepared to catch fuel spillage.

  1. Remove or disconnect the following:

    Battery
     
    Air cleaner housing
     
    Throttle assembly
     
    Cover from fuel rail
     
    Brake booster line from intake manifold (push attaching ring down to expose line)
     
    Crankcase vent valve from inspection hole cover
     
    Fuel line from fuel rail (quick-disconnect attachment)
     
    Plug connector from intake air temperature/manifold air pressure sensor (TMAP)
     
    Knock sensor plug from fuel rail wiring harness
     
    Tank vent line and unclip at fuel rail
     
    Vacuum line from intake manifold
     
    Retaining screws of fuel rail
     
    Injectors and fuel rail (plug all openings)
     
    Support or wire fuel rail assembly out of the way
     
    Dipstick
     
    Coolant line below intake manifold
     

  2.  
  3. Remove the intake manifold bolts, starting from the center and working outward in an alternating pattern.
  4.  
  5. Remove the intake manifold
  6.  

To install:

  1. Check all intake manifold gaskets and replace if necessary.
  2.  
  3. Install intake manifold and torque bolts to 19 ft. lbs. (26 Nm), in the sequence shown.
  4.  
  5. Install or connect the following:

    Coolant line below intake manifold
     
    Dipstick
     
    Fuel rail and injectors
     
    Intake manifold vacuum line
     
    Tank venting line on fuel rail
     
    Knock sensor plug to fuel rail wiring harness
     
    Connector to intake air temperature/manifold air pressure sensor (TMAP)
     
    Fuel line to fuel rail
     
    Crankcase vent valve to inspection hole cover
     
    Brake booster line to intake manifold
     
    Fuel rail cover
     
    Throttle assembly
     
    Air cleaner housing
     
    Battery
     

  6.  


    Click image to see an enlarged view

    Fig. Showing intake manifold bolt removal and tightening sequence-Cooper Coupe


  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Properly relieve the fuel system pressure.
    CAUTION
    Fuel system may still be under pressure; use caution when disconnecting any fuel system components. Be prepared to catch fuel spillage.

  4.  
  5. Remove or disconnect the following:

    Battery
     
    Air cleaner housing
     
    Throttle assembly
     
    Cover from fuel rail
     
    Brake booster line from intake manifold (push attaching ring down to expose line)
     
    Crankcase vent valve from inspection hole cover
     
    Fuel line from fuel rail (quick-disconnect attachment)
     
    Plug connector from intake air temperature/manifold air pressure sensor (TMAP)
     
    Knock sensor plug from fuel rail wiring harness
     
    Tank vent line and unclip at fuel rail
     
    Vacuum line from intake manifold
     
    Retaining screws of fuel rail
     
    Injectors and fuel rail (plug all openings)
     
    Support or wire fuel rail assembly out of the way
     
    Dipstick
     
    Coolant line below intake manifold
     

  6.  
  7. Remove the intake manifold bolts, starting from the center and working outward in an alternating pattern.
  8.  
  9. Remove the intake manifold
  10.  

To install:

  1. Check all intake manifold gaskets and replace if necessary.
  2.  
  3. Install intake manifold and torque bolts to 19 ft. lbs. (26 Nm), in the sequence shown.
  4.  
  5. Install or connect the following:

    Coolant line below intake manifold
     
    Dipstick
     
    Fuel rail and injectors
     
    Intake manifold vacuum line
     
    Tank venting line on fuel rail
     
    Knock sensor plug to fuel rail wiring harness
     
    Connector to intake air temperature/manifold air pressure sensor (TMAP)
     
    Fuel line to fuel rail
     
    Crankcase vent valve to inspection hole cover
     
    Brake booster line to intake manifold
     
    Fuel rail cover
     
    Throttle assembly
     
    Air cleaner housing
     
    Battery

    Click image to see an enlarged view

    Fig. Showing intake manifold bolt removal and tightening sequence-Cooper Coupe

     

  6.  

Cooper S Coupe
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the cooling system
  4.  
  5. Properly relieve the fuel system pressure.
  6.  


CAUTION
Fuel system may still be under pressure; use caution when disconnecting any fuel system components. Be prepared to catch fuel spillage.

  1. Remove or disconnect the following:

    Battery
     
    Air cleaner housing
     
    Throttle assembly
     
    Fuel injector rail
     
    Engine vent control valve
     
    Coolant hose from upper connection at intake manifold
     
    Knock sensor plug from manifold
     
    Air intake sensor connector at manifold
     
    Top tank vent valve line
     
    TMAP sensor connector
     

  2.  
  3. Remove the intake manifold nuts, starting from the center and working outward in an alternating pattern.
  4.  
  5. Remove the intake manifold
  6.  

To install:

  1. Position the intake manifold and install the nuts. Torque the nuts in an alternating pattern working outward from the center to 19 ft. lbs. (26 Nm).
  2.  
  3. Install or connect the following:

    TMAP sensor connector
     
    Top tank vent valve line
     
    Air intake sensor connector at manifold
     
    Knock sensor plug from manifold
     
    Coolant hose from upper connection at intake manifold
     
    Engine vent control valve
     
    Fuel injector rail
     
    Throttle assembly
     
    Air cleaner housing
     
    Battery
     

  4.  
  5. Refill the cooling system.
  6.  

  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Drain the cooling system
  4.  
  5. Properly relieve the fuel system pressure.
    CAUTION
    Fuel system may still be under pressure; use caution when disconnecting any fuel system components. Be prepared to catch fuel spillage.

  6.  
  7. Remove or disconnect the following:

    Battery
     
    Air cleaner housing
     
    Throttle assembly
     
    Fuel injector rail
     
    Engine vent control valve
     
    Coolant hose from upper connection at intake manifold
     
    Knock sensor plug from manifold
     
    Air intake sensor connector at manifold
     
    Top tank vent valve line
     
    TMAP sensor connector
     

  8.  
  9. Remove the intake manifold nuts, starting from the center and working outward in an alternating pattern.
  10.  
  11. Remove the intake manifold
  12.  

To install:

  1. Position the intake manifold and install the nuts. Torque the nuts in an alternating pattern working outward from the center to 19 ft. lbs. (26 Nm).
  2.  
  3. Install or connect the following:

    TMAP sensor connector
     
    Top tank vent valve line
     
    Air intake sensor connector at manifold
     
    Knock sensor plug from manifold
     
    Coolant hose from upper connection at intake manifold
     
    Engine vent control valve
     
    Fuel injector rail
     
    Throttle assembly
     
    Air cleaner housing
     
    Battery
     

  4.  
  5. Refill the cooling system.
  6.  

 
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