113-1

113 Cylinder Head Removal and

Installation

1
General 11 3 - 2 Cylinder Head Removal and Installation
Special tools 11 3 - 2 (Cooper S) 11 3 - 2 0
C o o p e r S a i r i n t a k e c o m p o n e n t s 11 3 - 2 0
Diagnostic Te s t i n g 11 3 - 3 Intercooler, removing and installing 113-21
C y l i n d e r c o m p r e s s i o n , t e s t i n g 11 3 - 3 Valve cover, removing and installing
Wet compression test 11 3 - 5
(CooperS) 11 3 - 2 2
Cylinder leak down test 11 3 - 6 Intake manifold, removing and installing
Cylinder Head Removal and Installation (CooperS) 11 3 - 2 4
(Cooper) 11 3 - 6 Cylinder head, removing and installing
Valve cover, removing and installing (CooperS) 11 3 - 2 8
(Cooper) 11 3 - 6
Intake manifold, removing and installing
(Cooper) 11 3 - 8
Cylinder head, removing and installing
(Cooper) 11 3 - 11

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117 Camshaft Timing Chain

1
General 11 7 - 2 Crankshaft vibration damper,
Special tools 11 7 - 2 removing and installing (Cooper S) 117-10
Timing chain housing cover,
Ti m i n g C h a i n H o u s i n g C o v e r 11 7 - 5 removing and installing (Cooper S) 117-12
Crankshaft vibration damper,
removing and installing (Cooper) 117-5 Timing Chain 11 7 - 1 6
Timing chain housing cover, Timing chain, removing and installing 117-16
removing and installing (Cooper) 117-7

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130 Fuel Injection

1
General 130-2 Sensor Replacement 130-42
Special tools 130-3 T- M A P s e n s o r, r e p l a c i n g ( C o o p e r ) 1 3 0 - 4 2
Engine management 130-4 MAP sensor, replacing (Cooper S) 130-43
Engine control module (ECM) 130-5 T-MAP sensor, replacing (Cooper S) 130-44
Principles of operation 130-6 Engine coolant temperature (ECT)
System inputs 1 3 0 - 11 s e n s o r, r e p l a c i n g ( C o o p e r ) 1 3 0 - 4 4
System outputs 130-20 Engine coolant temperature (ECT)
Troubleshooting 130-26 s e n s o r, r e p l a c i n g ( C o o p e r S ) 1 3 0 - 4 5
Warnings and cautions 130-26 Electrical Components 130-46
Supercharger oil service 130-34
Main r e l a y, accessing 130-46
Component Replacement 130-27 F u e l p u m p r e l a y, a c c e s s i n g 130-46
Fuel rail and injectors, Engine control module (ECM),
removing and installing 130-27 accessing 130-46
Fuel pressure regulator, ECM pin assignments 130-47
removing and installing 130-29
Air filter housing, TABLES

removing and installing (Cooper) 130-29 a. EMS2000 inputs / outputs 130-4

Air filter housing, b. EMS2000 ECM pin assignment,
removing and installing (Cooper S) 130-30 connector X6000 (81-pin) 130-48
Air filter housing and upgrade kit (JCW) 130-31 c. EMS2000 ECM pin assignment,
Throttle housing (EDR), connector X60004 (40-pin) 130-50
removing and installing (Cooper) 130-32
Throttle housing (EDR),
removing and installing (Cooper S) 130-33
Supercharger, removing and installing 130-36
S u p e r c h a r g e r p u l l e y, r e m o v i n g 1 3 0 - 3 8

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160 Fuel Tank and Fuel Pump

1
General 160-2 F u e l Ta n k a n d F u e l L i n e s 1 6 0 - 1 0
Special tools 160-2 Fuel tank, draining 160-10
Fuel pump 160-3 Fuel tank, removing and installing 160-11
Fuel tank evaporative control system 160-3 Fuel filler pipe, removing and installing 160-13
Evaporative system troubleshooting 160-4 LDP / DMTL unit, removing and installing
Warnings and cautions 160-4 (2002-2004) 160-15
LDP / DMTL unit, removing and installing
F u e l S y s t e m Tr o u b l e s h o o t i n g 1 6 0 - 5
(2005-2006) 160-15
Fuel pressure, testing (Cooper) 160-5
Fuel pressure, testing (Cooper S) 160-6

Fuel Pump and Fuel Level Senders ... 160-7

Fuel level sender (left side) and fuel pump,
removing and installing 160-7
Fuel level sender (right side),
removing and installing 160-9

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