11 00 050 Removing and installing engine

NOTE:

For Special Tool identification, see ENGINE - SPECIAL TOOLS - COOPER (1.6L) R50/W10 , FUEL SYSTEM - SPECIAL TOOLS - COOPER (1.6L) R50/W10 or BODY EQUIPMENT - SPECIAL TOOLS - COOPER (1.6L) R50/W10 .

Special Tools Required:

11 8 352
11 8 401
11 8 402
13 5 280
13 5 281
51 2 160

Necessary Preliminary Tasks:

Disconnect battery. Refer to 12 00 DISCONNECTING AND CONNECTING BATTERY .
Remove battery container. Refer to 61 21 100 REMOVING AND INSTALLING/REPLACING BATTERY CONTAINER .
Remove front bumper trim. Refer to 51 11 156 REMOVING AND INSTALLING FRONT BUMPER TRIM .
Remove bumper bracket. Refer to 51 11 050 REMOVING AND INSTALLING/REPLACING CARRIER FOR FRONT BUMPER TRIM .
Remove air cleaner housing.
Release clutch cylinder. Refer to CLUTCH SLAVE CYLINDER .
Remove top stabilizer bar bracket. Refer to 22 11 040 REPLACING UPPER ENGINE CARRIER BRACKET .
Remove exhaust manifold with catalytic converter. Refer to 11 62 000 REMOVING AND INSTALLING, SEALING/REPLACING EXHAUST MANIFOLD .
Remove left drive shaft. Refer to DRIVE AXLE SHAFT (LEFT) .
Remove right drive shaft. Refer to DRIVE AXLE SHAFT (RIGHT) .
Remove alternator drive belt. Refer to 11 28 010 REPLACING ALTERNATOR DRIVE BELT (W10) .
Remove alternator drive belt for optional A/C system. Refer to 11 28 050 REMOVING A/C COMPRESSOR DRIVE BELT .
Drain coolant. Refer to 17 00 005 DRAINING AND ADDING COOLANT .

Remove upper engine hood support and fit special tool 51 2 160.

Fig 1: Identifying Special Tool 51 2 160

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Screw in front end module with special tools 11 8 401 and 11 8 402 and secure with snap ring against slipping back.

Fig 2: Locating Front End Module

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Detach coolant hoses (1).

Detach heating hoses (2).

Detach overflow hose (3).

Fig 3: View Of Coolant, Heating And Overflow Hoses

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Release fuel line (1).

WARNING: Fuel line is under pressure (approx. 3-5 bar).

Attach fuel line (1) special tool 13 5 281.

Seal off fuel pipe with special tool 13 5 280.

Recycling:

Catch and dispose of escaping fuel in a suitable container.

Observe country-specific waste-disposal regulations.

Fig 4: Attaching Plugs To Fuel Line

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Remove screw (1) for starter motor heat shield.

Lift out heat shield.

Fig 5: Identifying Starter Motor Heat Shield Retaining Screw

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Release connection of line (1) to brake booster and unclip at holder.

Press ring downwards, remove line (1) towards top.

Fig 6: View Of Brake Booster Line Connection

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Disconnect plug connector from fuse box (1).

Remove retaining screws (2) from fuse box.

Place fuse box to one side.

Tightening torque, refer to 61 13 1AZ in GENERAL ELECTRICAL SYSTEM - TIGHTENING TORQUES - COOPER (1.6L) R50/W10 .

Fig 7: Locating Fuse Box Retaining Screws

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Disconnect grounding cable from left spring strut (1).

Tightening torque, refer to 61 13 2AZ in GENERAL ELECTRICAL SYSTEM - TIGHTENING TORQUES - COOPER (1.6L) R50/W10 .

Disconnect circular connector (2).

Fig 8: Disconnecting Circular Connector

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Release retaining clips (1) for shift cables on housing.

Detach shift cables from ball joint (2).

Remove retaining screws (3) for shift cable stop and remove shift control housing (4).

Tightening torque, (21 N.m.).

Tightening torque, refer to 11 12 14AZ in ENGINE - TIGHTENING TORQUES- COOPER (1.6L) R50/W10 .

Tightening torque, refer to 11 12 15AZ in ENGINE - TIGHTENING TORQUES- COOPER (1.6L) R50/W10 .

Fig 9: Removing Shift Control Housing

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Release screws (1).

Remove stabilizer bar (2).

Tightening torque, refer to 11 12 16AZ in ENGINE - TIGHTENING TORQUES- COOPER (1.6L) R50/W10 .

Fig 10: Removing Stabilizer Bar

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Detach plug connector (1) from steering pump motor.

Fig 11: Detaching Plug Connector From Steering Pump Motor

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NOTE: Special equipment A/C system.

Detach plug connector from A/C compressor (1).

Release retaining screws (2).

Secure compressor (3) to front end module. Unclip high-pressure line of A/C system.

Tightening torque, refer to 64 52 1AZ in HEATING AND AIR CONDITIONING - TIGHTENING TORQUES - COOPER (1.6L) R50/W10 .

Fig 12: Detaching Plug Connector From A/C Compressor

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Stick suitable adhesive tape (1) onto both body frame rails to protect paintwork during removal of engine (risk of damage ).

CAUTION: Special equipment A/C system.

A/C lines are under pressure. Risk of injury.

Fig 13: Identifying Tape Application Areas On Body Frame Rails

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CAUTION: Secure transmission with a trolley jack (risk of damage).

Release retaining screws (1).

Tightening torque, (66 N.m.).

Release top screw on transmission bracket (2).

Remove transmission bracket (2).

Installation:

Tightening torque, (66 N.m.).

Fig 14: Locating Transmission Bracket Retaining Screws

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Release screws (1).

Remove transmission bracket (2).

Fig 15: Removing Transmission Bracket

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Mount special tool 11 8 352 on transmission.

CAUTION: Observe screw length for screws (1) 10 x 1.5 mm. Maximum length 20 mm. (Risk of damage).

Installation:

Tightening torque, (38 N.m.).

Fig 16: View Of Special Tool 11 8 352 On Transmission

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Mount special tool 11 8 351 on engine at front.

Use original screws (1).

Installation:

Tightening torque, refer to 11 12 9AZ in ENGINE - TIGHTENING TORQUES- COOPER (1.6L) R50/W10 .

Fig 17: Mounting Special Tool 11 8 351 On Engine

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Secure special tool 11 0 020 with special tools 11 8 351 and 11 8 352.

Attach engine lifting gear holder and chains to engine and suspend power unit from lifting gear.

Fig 18: Locating Engine Lifting Gear Holder And Chains

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Unscrew engine mount retaining nut (1).

Tightening torque, refer to 11 12 13AZ in ENGINE - TIGHTENING TORQUES- COOPER (1.6L) R50/W10 .

Remove engine. Refer to 11 00 050 REMOVING AND INSTALLING ENGINE .

Fig 19: Identifying Engine Mount Retaining Nut

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Assemble engine.

Fill transmission. Refer to LUBRICATION .

Fill cooling system. Refer to 17 00 005 DRAINING AND ADDING COOLANT .

Vent cooling system and check for leaks. Refer to 17 00 039 BLEEDING COOLING SYSTEM AND CHECKING FOR WATER LEAKS .

Check function of DME.