Engine Cooper 2006 Al 2008

2008 MINI Cooper
2007 ENGINE Engine - Repair Instructions - Cooper
2007 ENGINE
Engine - Repair Instructions - Cooper
00 ENGINE, GENERAL
00 DANGER OF POISONING IF OIL IS INGESTED/ABSORBED THROUGH THE SKIN
Danger of poisoning!
Ingesting oil or absorbing through the skin may cause poisoning!
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Possible symptoms are:
Headaches
Dizziness
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Stomach aches
Vomiting
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Diarrhoea
Cramps/fits
Unconsciousness
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Protective measures/rules of conduct:

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Pour oil only into appropriately marked containers

Do not pour oil into drinking vessels (drinks bottles, glasses, cups or mugs)
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Observe country-specific safety regulations
First aid measures:
Do not induce vomiting.
If the person affected is still conscious, he/she must rinse out their mouth with water, drink plenty of
water and consult a doctor immediately.
If the person affected is unconscious, do not administer anything by mouth, place the person in the
recovery position and seek immediate medical attention.
00 RISK OF INJURY IF OIL COMES INTO CONTACT WITH EYES AND SKIN
Danger of injury!
Contact with eyes or skin may result in injury!
Possible symptoms are:
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2008 MINI Cooper
Impaired sight
Irritation of the eyes
Reddening of the skin
Rough and cracked skin
Protective measures/rules of conduct:
Wear protective goggles

Wear oil-resistant protective gloves
Observe country-specific safety regulations
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First aid measures:
Eye contact: Rinse eyes immediately with plenty of water for at least 15 minutes; if available, use an eye-
rinsing bottle. If irritation of the eyes persists, consult a doctor.
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Skin contact: Wash off with soap and water immediately. If irritation persists, consult a doctor.
NOTE: Do not use solvents/thinners.

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00 SAFETY INFORMATION FOR WORKING ON VEHICLES WITH AUTOMATIC ENGINE
START-STOP SYSTEM (MSA)
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WARNING: If the engine hood/bonnet contact is pulled upwards (workshop mode),

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the information "switch closed" is output. The automatic engine start-stop

function is active.
An automatic engine start may ensue.
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Observe safety precautions when working on MSA vehicles.
Before carrying out practical work on the engine, always ensure that the MSA function is deactivated so as to
prevent automatic engine starting while work is being carried out in the engine compartment.
MSA function is deactivated by:
Deactivate MSA by means of button (1) in passenger compartment

Open seat belt buckle and driver's door
Monday, June 25, 2012 8:54:25 AM Page 2 © 2011 Mitchell Repair Information Company, LLC.
2008 MINI Cooper
Fig. 1: Identifying MSA Means Of Button

Courtesy of BMW OF NORTH AMERICA, INC.
Open engine bonnet/hood and ensure that engine hood/bonnet contact is not in workshop mode
Workshop mode
A = 10 mm
Basic setting (engine hood/bonnet open)
B = 7 mm
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To make sure that the engine hood/bonnet contact is at the basic setting, if necessary press the hood/bonnet
contact up to the stop before starting work and slowly release.
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Fig. 2: Identifying Engine Hood/Bonnet Contact Setting

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When working with diagnosis tools:
Observe instructions in diagnosis tool
NOTE: For further information on automatic engine start-stop system (MSA):
Refer to ELECTRICAL SYSTEMS .
00 SAFETY INSTRUCTIONS FOR HANDLING OIL
WARNING: Refer to 00 DANGER OF POISONING IF OIL IS INGESTED/ABSORBED

THROUGH THE SKIN and 00 RISK OF INJURY IF OIL COMES INTO
CONTACT WITH EYES AND SKIN.
Recycling:
2008 MINI Cooper
Observe country-specific waste-disposal regulations.
Measures if oil is unintentionally released:
Personal precautionary measures: Danger of slipping! Keep non-involved persons away from the work
area. Wear personal protective clothing/equipment.
Environmental protection measures: Prevent oil from draining into drain channels, sewerage systems,
pits, cellars, water and the ground.
Limiting spread: Use oil blocks to prevent the surface spread of oil.
Cleaning procedure: Bind and dispose of escaped oil with nonflammable absorbents.
NOTE: Do not flush oil away with water or aqueous cleaning agents.
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11 00 REMOVING AND INSTALLING/REPLACING ACOUSTIC COVER (N12)
Release screws (1).
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Tightening torque: See ENGINE - TIGHTENING TORQUES .
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Release acoustic cover at retainers (2).
Lift off acoustic cover in direction of arrow.

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Fig. 3: Lifting Acoustic Cover

11 00 050 REMOVING AND INSTALLING ENGINE WITH TRANSMISSION (N12)
Special tools required:
11 0 260
Necessary preliminary tasks:
2008 MINI Cooper
Lift engine hood into assembly position.

Remove exhaust system.
Drain engine oil.
Disconnect negative battery lead.
Remove both drive shafts.
Remove air cleaner housing.
Remove fan cowl with electric fan.
Detach all coolant hoses from engine.
Detach vacuum line from brake booster.
Unfasten engine wiring harness and lay to one side.
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Remove complete front panel
Attach special tool 11 0 260 to lifting eye (1) at engine end
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Fig. 4: Identifying Special Tool (11 0 260) To Lifting Eye To Engine

Attach special tool 11 0 260 to lifting eye (1) at transmission end
Fig. 5: Identifying Special Tool (11 0 260) On Transmission
2008 MINI Cooper
Release transmission and engine mounts.
Remove engine with special tool 11 0 260 towards front.
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Fig. 6: Identifying Special Tool (11 0 260) On Engine
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Assemble engine.
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Check function of DME.

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11 00 670 SECURING ENGINE IN INSTALLATION POSITION (N12, N14)

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00 0 200
00 0 202
00 0 204
00 0 208
00 0 490
WARNING: Risk of injury!

Observe following instructions relating to special tool:
1. Prior to each use, check the special tools for defects, modifications
and operational reliability.
2. Damaged/modified special tools must not be used!
3. No changes or modifications may be made to the special tools!
4. Keep special tools dry, clean and free of grease.
2008 MINI Cooper
Remove lock bridge.
Assemble cross member 00 0 200 with special tools 00 0 202 , 00 0 204 , 00 0 208 .
Modification:
Remove front supports (1).
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Fig. 7: Identifying Special Tools (00 0 200)
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Attach special tool 00 0 490 on left and right to cross member 00 0 200 .
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Fig. 8: Identifying Special Tools (00 0 490)

IMPORTANT: Do not damage Bowden cable (1)!
With the aid of an assistant, place cross member 00 0 200 on spring strut tower and secure special tool 00 0 490
with knurled screws (2) on engine support.
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Fig. 9: Placing Cross Member (00 0 200) On Spring Strut Tower
IMPORTANT: Avoid a change of engine position in the transverse or longitudinal direction.

Always make sure there is sufficient clearance between the engine (or its
attachment parts) and the body.
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Align cross member 00 0 200 such that the spindle 00 0 202 is positioned correctly over the lifting eye.
Secure suitable chain to spindle 00 0 200 and attach to lifting eye (1).
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Fig. 10: Identifying Special Tool (00 0 200 And 00 0 202)

WARNING: Risk of injury!

Tighten all adjusting screws, knurled screws and nuts on cross member
00 0 200 and on special tool 00 0 490 .
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IMPORTANT: Bolts must be slackened to prevent elongation of rubber mounts in bracket (1)!
Slacken bolts (2, 3).

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Installation:
Low engine first onto engine or transmission mounts and then tighten down bolts (2, 3).
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Fig. 12: Identifying Rubber Mounts In Bracket With Slacken Bolts

Left side only:
Remove transmission support bracket
Right side only:
2008 MINI Cooper
Unscrew nut (1).
Installation:
Replace self-locking nut.
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Fig. 13: Identifying Self-Locking Nut
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Raise engine approx. 10 mm with crossmember.

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ENGINE IDENTIFICATION
Drive in engine numbers at marked surface with impact tool.

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M47 / M47TU / M47T2
Fig. 14: Identifying Engine Identification Number - M47 / M47TU / M47T2

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M57 / M57TU / M57T2
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Fig. 15: Identifying Engine Identification Number - M57 / M57TU / M57T2
M67 / M67TU
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Fig. 16: Identifying Engine Identification Number - M67 / M67TU

N47
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Fig. 17: Identifying Engine Identification Number - N47
M52 / M52TU
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Fig. 18: Identifying Engine Identification Number - M52 / M52TU

M54
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Fig. 19: Identifying Engine Identification Number - M54
M56
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Fig. 20: Identifying Engine Identification Number - M56

N40 / N45
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Fig. 21: Identifying Engine Identification Number - N40 / N45
N42 / N46 / N46T
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Fig. 22: Identifying Engine Identification Number - N42 / N46 / N46T

N51 / N52 / N52K / N53 / N54
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Fig. 23: Identifying Engine Identification Number - N51 / N52 / N52K / N53 / N54
N62
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N73
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S54
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Fig. 26: Identifying Engine Identification Number - S54

S85
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Fig. 27: Identifying Engine Identification Number - S85
W10 / W11
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Fig. 28: Identifying Engine Identification Number - W10 / W11

W17
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Fig. 29: Identifying Engine Identification Number - W17
Assemble engine.
MOUNTING ENGINE ON ASSEMBLY STAND (N12)

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00 2 300
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11 9 530
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Remove engine.
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Bolt engine or engine block to special tool 11 9 530 .
Mount engine with special tool 11 9 530 on special tool 00 2 300 .
Fig. 30: Identifying Special Tool (11 9 530 And 00 2 300) On Engine Block
2008 MINI Cooper
12 CYLINDER HEAD WITH COVER

11 12 000 REMOVING AND INSTALLING/SEALING CYLINDER HEAD COVER (N12)
Remove acoustic cover

Remove rod-type ignition coils.
Disconnect plug connection at ignition coils (1).
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Unfasten engine wiring harness (2) at cylinder head cover.
Release ground connection (3).
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Fig. 31: Identifying Ignition Coils, Engine Wiring Harness And Ground Connection
Disconnect plug connections (2 and 3).
If necessary, release sensors (4 and 6).
2008 MINI Cooper
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Fig. 32: Identifying Ignition Coils, Engine Wiring Harness And Plug Connections With Sensors
Unfasten engine vent hose at lock (1) in direction of arrow.
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Detach engine vent hose in direction of arrow.
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Fig. 33: Detaching Engine Vent Hose

2008 MINI Cooper
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Fig. 34: Identifying Engine Wiring Harness
Disconnect plug connection (1) at coolant sensor.
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Fig. 35: Identifying Plug Connection

Release bolts in areas (1 and 2).
2008 MINI Cooper
Fig. 36: Identifying Engine Bolts

Replace seal (1).
Replace all seals (2).
Installation:
Clean all sealing surfaces.
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Fig. 37: Identifying Seals

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Installation:
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Observe tightening sequence (1 to 13).
Fig. 38: Identifying Tightening Sequence For Engine Bolts

Assemble engine.
2008 MINI Cooper
11 12 100 REMOVING AND INSTALLING/SEALING CYLINDER HEAD (N12)
11 2 250
11 4 471
11 4 472
11 9 590
11 9 630
IMPORTANT: Fit new cylinder head screws.
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Do not wash off bolt coating.
There must not be any coolant, water or oil present in the pocket holes (risk of
corrosion and cracking) .

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Drain coolant.
Drain engine oil.
Remove exhaust manifold.
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Remove intake air manifold.

Remove oil dipstick.
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Detach coolant hoses from cylinder head.

Remove cylinder head cover. Refer to 12 CYLINDER HEAD WITH COVER.
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Remove inlet and exhaust adjustment unit.
Secure crankshaft with special tool 11 9 590 .
Fig. 39: Identifying Special Tool (11 9 590) On Crankshaft

2008 MINI Cooper
NOTE: Remove and install cylinder head in installed state.

Suspend engine with engine crane (1) from lifting eye (2).
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Fig. 40: Lifting Engine With Crane
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NOTE: Remove and install cylinder head in installed state.

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Move front panel into assembly position.
Release upper alternator screws, do not remove alternator.

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Remove right engine mount.

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Secure special tool 11 9 630 with standard bolts (1 and 2).

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Fig. 41: Identifying Special Tool (11 9 630)

Release screws (1).
IMPORTANT: If the timing chain is stowed in the gear case, the crankshaft must no longer be
2008 MINI Cooper
rotated.
The timing chain may jam on the crankshaft gear.
Installation:
Only during assembly is the timing chain lifted out with a hook.
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Fig. 42: Identifying Screws (Timing Chain)
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Release screw (1).

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Fig. 43: Identifying Screws

Release cylinder head bolts with special tool 11 2 250.
2008 MINI Cooper
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Release cylinder head bolts from outside inwards (10 to 1).
NOTE: Remove shims with a magnet.
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Illustration shows camshafts removed.
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Fig. 45: Identifying Cylinder Head Bolts

Use special tool 11 4 471 to remove coarse gasket remnants from sealing faces of cylinder head and crankcase.
IMPORTANT: Do not use any metal-cutting tools.
2008 MINI Cooper
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Remove fine gasket remnants with special tool 11 4 472 .
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IMPORTANT: Do not use any metal-cutting tools.
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There must not be any coolant, water or oil present in the pocket holes (risk of corrosion and cracking) .
Clean all pocket holes.

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Replace cylinder head gasket.

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IMPORTANT: Fit new cylinder head screws.

Do not wash off bolt coating.
Attach shims to cylinder head bolts.
2008 MINI Cooper
Shims can drop into the engine (risk of damage!) .
Secure cylinder head bolts from inside outwards (1 to 10).
NOTE: Illustration shows camshafts removed.
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Secure bolts (1).

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Fig. 49: Identifying Bolts

Tighten the screw (1).
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Assemble engine.
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11 12 101 REPLACING CYLINDER HEAD GASKET (N12)
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11 4 470
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Remove cylinder head .
Remove remnants of oil and dirt from pocket holes (1).

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IMPORTANT: Work on sealing face on engine block and on cylinder head with special tool 11
4 470 only.
Do not use any metal-cutting tools.
NOTE: Illustration shows N52.
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Fig. 51: Identifying Cylinder Head Holes
Note identification marking on head gasket.
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IMPORTANT: Rubber coating on cylinder head gasket must not be damaged under any
circumstances.
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If the cylinder head is remachined, a thicker coating + 0.3 mm is also available
for service personnel.
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Gasket (1) is a sheet-metal gasket

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Fig. 52: Identifying Cylinder Head Gasket

Check adapter sleeves (1) for damage and firm seating.
Lay cylinder head gasket on engine block.
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Fig. 53: Identifying Adapter Sleeves
NOTE: Check cylinder head for deviation from flatness.

Check cylinder head for water leaks. Refer to 11 12 729 CHECKING CYLINDER
HEAD FOR WATER LEAKS (N12).
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Assemble engine.
11 12 719 RESURFACING CYLINDER HEAD SEALING FACE (N12)

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Remove cylinder head.

Remove exhaust camshaft.
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Remove intermediate lever on inlet side.
Check evenness of cylinder head sealing faces with a standard straight-edge (1).
NOTE: Max. deviation from level (longitudinal) 0.10 mm Picture show N52.
2008 MINI Cooper
Fig. 54: Identifying Cylinder Head Sealing Faces

Check evenness of cylinder head sealing faces with a standard straight-edge (1).
NOTE: Max. deviation from level (transversal) 0.05 mm Picture show N52.
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Fig. 55: Identifying Cylinder Head Sealing Faces
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Check cylinder head for water leaks. Refer to 11 12 729 CHECKING CYLINDER HEAD FOR WATER
LEAKS (N12).
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Assemble engine.
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11 12 729 CHECKING CYLINDER HEAD FOR WATER LEAKS (N12)
11 9 521
11 9 522
11 9 523

Disassemble cylinder head.
Install special tool 11 9 521 with special tool 11 9 523 .
Installation:
Install special tool 11 9 521 so that all water ducts are sealed.
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Secure special tool 11 9 523 to 25 Nm .
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Screw special tool 11 9 522 into place with existing screws (1 and 3) of coolant thermostat.
Sealing flange must rest flat.
NOTE: Compressed air at valve (2) must not exceed 3 bar .

Heat cylinder head to 60°.
Visually check for bubble formation in a water bath.
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Fig. 58: Identifying Special Tool (11 9 522) With Existing Screws
Assemble engine.
13 OIL SUMP
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11 13 000 REMOVING AND INSTALLING, SEALING OR REPLACING OIL SUMP (N12)

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11 4 470
11 9 581
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11 9 582
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Drain engine oil.
Release oil sump bolts in area of line (1).
Tightening torque: Refer to ENGINE - TIGHTENING TORQUES .
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Fig. 59: Identifying Oil Sump Bolts
Release screw (1) over exhaust manifold with special tools 11 9 582 and 11 9 581 .
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Tightening torque: Refer to ENGINE - TIGHTENING TORQUES .
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Fig. 60: Identifying Special Tools (11 9 582 And 11 9 581)

Clean sealing face (1) with special tool 11 4 470 .
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Fig. 61: Identifying Sealing Face
IMPORTANT: Do not use adhesive sealing bead.
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Remove protruding or surplus sealing beads (1) with a suitable tool.
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Installation:
Do not use liquid seal.

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A metal substrate gasket is available for repairs (see BMW Parts Service).
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Fig. 62: Identifying Sealing Beads

Assemble engine.
14 HOUSING COVER
11 14 005 REPLACING FRONT CRANKSHAFT RADIAL SEAL (N12)
2008 MINI Cooper
11 9 601
11 9 602
11 9 603
IMPORTANT: PTFE ring is supplied with a supporting ring.

Supporting ring is required as an installation tool.
Do not touch inner sealing face of PTFE ring with fingers (risk of damage) .
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Remove vibration damper.
Remove A/C line from compressor.
IMPORTANT: Do not release central bolt.
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If the central bolt is released, the sprocket wheels of the timing chain and the oil pump will no longer be non-
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positively connected to the crankshaft. The camshafts to the crankshaft can warp (risk of damage) .
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Fig. 63: Identifying Crankshaft Central Bolt

Drive PTFE ring inwards with a drift (1) until PTFE ring tilts outwards at bottom.
IMPORTANT: PTFE ring can slip inwards.
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Fig. 64: Identifying PTFE Ring Inwards With Drift
Secure special tool 11 9 601 with screws (1) to crankshaft to 15 Nm.
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Fig. 65: Identifying Special Tool (11 9 601) To Crankshaft

Installation:
Apply a light coating of oil to special tool 11 9 601 .
Position PTFE ring (2) with supporting ring (1) on special tool 11 9 601 .
Push PTFE ring (2) over supporting ring (1) in direction of arrow up to crankcase.
2008 MINI Cooper
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Fig. 66: Pushing PTFE Ring Over Supporting Ring To Crankcase
Remove supporting ring from special tool 11 9 601 .
NOTE:
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Supporting ring is no longer needed.
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Fig. 67: Identifying Special Tool (11 9 601) On Supporting Ring

Draw in PTFE ring with special tool 11 9 602 in conjunction with special tool 11 9 603 until flush.
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Assemble engine.
11 14 151 REPLACING CRANKSHAFT RADIAL SEAL (N12)
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11 9 611
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11 9 612
11 9 613
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Remove transmission.
Remove flywheel.
Brake off PTFE ring (2) with a drift (1).
IMPORTANT: Risk of damage to crankcase and to crankshaft!
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Fig. 69: Identifying PTFE Ring With Drift
Secure special tool 11 9 611 with supplied screws (1) to crankshaft.
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Fig. 70: Identifying Special Tool (11 9 611) To Crankshaft

Position PTFE ring (1) with supporting ring (2) on special tool 11 9 611 .
Push PTFE ring (1) in direction of arrow over supporting ring (2) onto crankshaft.
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Fig. 71: Identifying PTFE Ring Supporting Ring Into Crankshaft
Attach special tool 11 9 612 .
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Draw in PTFE ring with special tool 11 9 613 .
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Screw in special tool 11 9 612 up to engine block.
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Assemble engine.
21 CRANKSHAFT WITH BEARING

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11 21 500 REPLACING CRANKSHAFT (N12)

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00 9 120
11 4 471
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11 4 472
11 6 251
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11 6 252
23 1 240
WARNING: Rotating components (danger or injury!).

It is absolutely essential to follow the procedure described below and the
instructions on handling the special tools.
IMPORTANT: Jointing torque and angle of rotation must be observed without fail (risk of
damage) .
Remove engine.
Mount engine on assembly stand.
Removing oil pan.
Remove oil pump.
2008 MINI Cooper
Remove timing chain.

Remove flywheel.
Release screws (1).
Remove oil deflector (2).
Remove all pistons.
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Fig. 74: Identifying Oil Deflector And Screws

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Drive out cover plates (1) with a cross-chisel (2).
Fig. 75: Identifying Cover Plates With Cross-Chisel

Release screws (26 to 11).
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Release screws (10 to 1).
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Release crankcase lower half in direction of arrow with a regular screwdriver (2) and an open-end wrench (1).
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Fig. 77: Removing Crankcase

Remove both radial shaft seals (1).
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Fig. 78: Identifying Radial Shaft Seals
Remove crankshaft (1).
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IMPORTANT: Remove crankshaft with aid of a second person.
Weight of crankshaft approx. 19 kg.
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Remove main bearing shells, replace if necessary.
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Fig. 79: Identifying Crankshaft Main Bearing Shells

IMPORTANT: Do not clean sealing faces with a metal-cutting tool.
Clean sealing faces with special tools 11 4 471 and 11 4 472 .
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Fig. 80: Identifying Special Tools (11 4 471 And 11 4 472) On Sealing Faces
Check guide sleeves (1) for damage and correct seating.
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Fig. 81: Identifying Guide Sleeves

Apply sealing bead (1) to crankcase lower half.
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Fig. 82: Identifying Crankcase Lower Half Sealing Bead

Apply sealing bead (1) to crankcase upper half.
Apply a light coating of engine oil to bearings.
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Fig. 83: Identifying Crankcase Upper Half Sealing Bead
Insert crankshaft (1).

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IMPORTANT: Rotating component (danger of injury!)

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Insert crankshaft with aid of a second person.

Weight of crankshaft approx. 19 kg.
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Fig. 84: Identifying Crankshaft Main Bearing Shells

Lubricate all bearings from 1 to 5 with engine oil.
Install crankcase lower half.
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Fig. 85: Identifying Crankshaft Bearings
Tighten bolts (1 to 10).
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Tighten bolts (11 to 26).

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Tighten bolts exclusively with special tool 00 9 120 .
IMPORTANT: Jointing torque and angle of rotation must be observed without fail.
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Apply a thin coating of Loctite 273 to cover sleeve (1) in area (2).
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Fig. 88: Identifying Cover Sleeve Area

Drive cover sleeves firmly home with special tool 23 1 240 .
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Fig. 89: Identifying Special Tool (23 1 240) On Cover Sleeves

Determine crankshaft axial clearance.
Attach special tool 11 6 252 with magnet.
Set special tool 11 6 251 to zero.
Press crankshaft in direction of rotation up to stop.
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Fig. 90: Identifying Special Tool (11 6 252 And 11 6 251) On Crankshaft
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Replace radial shaft seal at front.

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Replace radial shaft seal at rear.
Assemble engine.
11 21 531 REPLACING ALL CRANKSHAFT MAIN BEARINGS (N12)
11 4 470
IMPORTANT: Modified assignment of bearings.

Bearing (1) is at the output end (clutch end)
Determine main bearing colors; the designations on the crankcase and
crankshaft are always required and can only determined using the table.
Remove crankshaft .
2008 MINI Cooper
Installation:
Bearing shell (1) with lubricant groove must be fitted in crankcase upper section.
Bearing shell (2) without lubricant groove must be fitted in crankcase lower section (bedplate).
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Fig. 91: Identifying Bearing Shell
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Bearings (1 to 5).
Bearing (2) is a guide bearing.

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IMPORTANT: Clean sealing surfaces.

Do not clean sealing faces with a metal-cutting tool.
Clean sealing faces with special tool 11 4 470 only.
Fig. 92: Identifying Crankcase Bearing Groove

2008 MINI Cooper
Insert guide rings (1) in crankcase at bearing block (2) with groove facing outwards.
If necessary, attach with engine oil to crankcase.
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Fig. 93: Identifying Guide Rings
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Bearings (1 to 5).
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IMPORTANT: Clean sealing surfaces.

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Do not clean sealing faces with a metal-cutting tool.
Clean sealing faces with special tool 11 4 470 only.

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Bearing classification on crankcase upper half:
Bearing allocation 1-5: the designations on the crankcase and crankshaft are always required.
Refer to the table for the color code.
Example:
Bearing 1. Letter P
Bearing 2. Letter K
Bearing 3. Letter I
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Bearing 4. Letter N
Bearing 5. Letter N
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Fig. 95: Identifying Bearing Classification Color Code

Bearing classification on crankcase upper half:
Example:
Bearing 1. Letter T
Bearing 2. Letter Q
Bearing 3. Letter Q
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Bearing 4. Letter R
Bearing 5. Letter R
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CRANKSHAFT BEARING COLOR CHART
Table overview of bearing classification: upper half
Identifying letter of crankshaft
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Bearings 1-5 A B C d E G H I K M N P Q R S T U
A Gr Gr Gr Gr Gr Sw Sw Sw Sw Sw Sw Sw Sw Bl Bl Bl Bl
B Gr Gr Gr Gr Gr Gr Sw Sw Sw Sw Sw Sw Sw Sw Bl Bl Bl
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C Gr Gr Gr Gr Gr Gr Gr Sw Sw Sw Sw Sw Sw Sw Sw Bl Bl
D Gr Gr Gr Gr Gr Gr Gr Gr Sw Sw Sw Sw Sw Sw Sw Sw Bl
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E Ge Gr Gr Gr Gr Gr Gr Gr Gr Sw Sw Sw Sw Sw Sw Sw Sw
G Ge Ge Gr Gr Gr Gr Gr Gr Gr Gr Sw Sw Sw Sw Sw Sw Sw
H Ge Ge Ge Gr Gr Gr Gr Gr Gr Gr Gr Sw Sw Sw Sw Sw Sw
I Ge Ge Ge Ge Gr Gr Gr Gr Gr Gr Gr Gr Sw Sw Sw Sw Sw
K Ge Ge Ge Ge Ge Gr Gr Gr Gr Gr Gr Gr Gr Sw Sw Sw Sw
M Ge Ge Ge Ge Ge Ge Gr Gr Gr Gr Gr Gr Gr Gr Sw Sw Sw
Crankcase
N Ge Ge Ge Ge Ge Ge Ge Gr Gr Gr Gr Gr Gr Gr Gr Sw Sw
P Ge Ge Ge Ge Ge Ge Ge Ge Gr Gr Gr Gr Gr Gr Gr Gr Sw
Q Or Ge Ge Ge Ge Ge Ge Ge Ge Gr Gr Gr Gr Gr Gr Gr Gr
R Or Or Ge Ge Ge Ge Ge Ge Ge Ge Gr Gr Gr Gr Gr Gr Gr
S Or Or Or Ge Ge Ge Ge Ge Ge Ge Ge Gr Gr Gr Gr Gr Gr
T Or Or Or Or Ge Ge Ge Ge Ge Ge Ge Ge Gr Gr Gr Gr Gr
U Or Or Or Or Or Ge Ge Ge Ge Ge Ge Ge Ge Gr Gr Gr Gr
X Or Or Or Or Or Or Ge Ge Ge Ge Ge Ge Ge Ge Gr Gr Gr
Y Or Or Or Or Or Or Or Ge Ge Ge Ge Ge Ge Ge Ge Gr Gr
Z Or Or Or Or Or Or Or Or Ge Ge Ge Ge Ge Ge Ge Ge Gr
2008 MINI Cooper
Crankshaft bearing colours:

BL= Blue.
SW= Black.
Gr= Green.
Ge Yellow.
Or Orange.
Crankshaft bearing colors:
BL= Blue.
SW= Black.
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Gr= Green.
Ge Yellow.
Or Orange.
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Bearing classification on crankcase lower half:
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Example:
Bearing 1. Letter P
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Bearing 2. Letter K
Bearing 3. Letter I
Bearing 4. Letter N
Bearing 5. Letter N
2008 MINI Cooper
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Bearing classification on crankcase lower half:
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Example:
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Bearing 1. Letter T
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Bearing 2. Letter Q
Bearing 3. Letter Q
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Bearing 4. Letter R
Bearing 5. Letter R
2008 MINI Cooper
CRANKSHAFT BEARING COLOR CHART

Table overview of bearing classification: lower half
Crankshaft
Bearings 1-5 A B C d E G H I K M N P Q R S T U
A Gr Sw Sw Sw Sw Sw Sw Sw Sw Bl Bl Bl Bl Bl Bl Bl Bl
B Gr Gr Sw Sw Sw Sw Sw Sw Sw Sw Bl Bl Bl Bl Bl Bl Bl
C Gr Gr Gr Sw Sw Sw Sw Sw Sw Sw Sw Bl Bl Bl Bl Bl Bl
D Gr Gr Gr Gr Sw Sw Sw Sw Sw Sw Sw Sw Bl Bl Bl Bl Bl
E Gr Gr Gr Gr Gr Sw Sw Sw Sw Sw Sw Sw Sw Bl Bl Bl Bl
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G Gr Gr Gr Gr Gr Gr Sw Sw Sw Sw Sw Sw Sw Sw Bl Bl Bl
H Gr Gr Gr Gr Gr Gr Gr Sw Sw Sw Sw Sw Sw Sw Sw Bl Bl
I Gr Gr Gr Gr Gr Gr Gr Gr Sw Sw Sw Sw Sw Sw Sw Sw Bl
K Ge Gr Gr Gr Gr Gr Gr Gr Gr Sw Sw Sw Sw Sw Sw Sw Sw
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M Ge Ge Gr Gr Gr Gr Gr Gr Gr Gr Sw Sw Sw Sw Sw Sw Sw
Crankcase
N Ge Ge Ge Gr Gr Gr Gr Gr Gr Gr Gr Sw Sw Sw Sw Sw Sw
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P Ge Ge Ge Ge Gr Gr Gr Gr Gr Gr Gr Gr Sw Sw Sw Sw Sw
Q Ge Ge Ge Ge Ge Gr Gr Gr Gr Gr Gr Gr Gr Sw Sw Sw Sw
R Ge Ge Ge Ge Ge Ge Gr Gr Gr Gr Gr Gr Gr Gr Sw Sw Sw
S Ge Ge Ge Ge Ge Ge Ge Gr Gr Gr Gr Gr Gr Gr Gr Sw Sw
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T Ge Ge Ge Ge Ge Ge Ge Ge Gr Gr Gr Gr Gr Gr Gr Gr Sw
U Or Ge Ge Ge Ge Ge Ge Ge Ge Gr Gr Gr Gr Gr Gr Gr Gr
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X Or Or Ge Ge Ge Ge Ge Ge Ge Ge Gr Gr Gr Gr Gr Gr Gr
Y Or Or Or Ge Ge Ge Ge Ge Ge Ge Ge Gr Gr Gr Gr Gr Gr
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Z Or Or Or Or Ge Ge Ge Ge Ge Ge Ge Ge Gr Gr Gr Gr Gr
Crankshaft bearing colours:
BL= Blue.
SW= Black.
Gr= Green.
Ge Yellow.
Or Orange.
Example: Crankcase upper half:
Combining the dots of the designations of the crankshaft and crankcase produces the following color
combinations.
Bearing 1: The letters (P and T) produce in the crankcase upper half the color Ge= Yellow with lubricant
groove.
Bearing 2: K and Q= Ge= Yellow.
Bearing 3: I and Q= Ge= Yellow.
2008 MINI Cooper
Bearing 4: N and R= Gr= Green.
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Example: Crankcase lower half:
Combining the dots of the designations of the crankcase and crankshaft produces the following color
combinations.
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Bearing 1: The letters P. and T. produce in the crankcase lower half the color Gr= Green without lubricant
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groove.
Bearing 2: K and Q= Gr= Green.

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Bearing 3: I and Q= Gr= Green.
2008 MINI Cooper

Install crankcase lower section.
Assemble engine.
11 22 500 REMOVING AND INSTALLING OR REPLACING FLYWHEEL (N12)
11 9 590
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Remove clutch.
Lock flywheel with special tool 11 9 590 .

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Flywheel for automatic transmission.
Release flywheel bolts (1).
Installation:
Flywheel (1) is secured with an alignment pin.
Fit new flywheel screws.
2008 MINI Cooper
Clean crankshaft thread for flywheel screws.
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Fig. 102: Identifying Flywheel Bolts
Flywheel for manual gearbox.
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Flywheel with and without dual-mass: release bolts (1).
Installation:
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Flywheel is secured with a dowel pin.

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Fig. 103: Identifying Flywheel Screws

Installation:
2008 MINI Cooper
Sensor gear (1) is loose on crankshaft and is first secured to flywheel.
Dowel pin (2) for securing sensor gear/flywheel.
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Fig. 104: Identifying Sensor Gear And Dowel Pin
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Assemble engine.
22 FLYWHEEL
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11 22 500 REMOVING AND INSTALLING OR REPLACING FLYWHEEL (N12)

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11 9 590
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Remove clutch.
Lock flywheel with special tool 11 9 590 .
2008 MINI Cooper
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Flywheel for automatic transmission.
Release flywheel bolts (1).
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Installation:
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Flywheel (1) is secured with an alignment pin.

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Clean crankshaft thread for flywheel screws.

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Fig. 106: Identifying Flywheel Bolts

Flywheel for manual gearbox.
2008 MINI Cooper
Flywheel with and without dual-mass: release bolts (1).
Installation:
Flywheel is secured with a dowel pin.
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Fig. 107: Identifying Flywheel Screws
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Installation:
Sensor gear (1) is loose on crankshaft and is first secured to flywheel.

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Dowel pin (2) for securing sensor gear/flywheel.
Fig. 108: Identifying Sensor Gear And Dowel Pin

2008 MINI Cooper
Assemble engine.
23 VIBRATION DAMPER
11 23 010 REMOVING AND INSTALLING OR REPLACING VIBRATION DAMPER (N12)
Remove drive belt.
Release screws (1).
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Fig. 109: Identifying Vibration Damper Screws

Assemble engine.
24 CONNECTING ROD WITH BEARING

11 24 571 REPLACING CONROD BEARINGS (N12)
IMPORTANT: Modified procedure; the bearing shell colors are the same at the top and
bottom.
Remove all pistons.
Install new conrod bearing shells.
2008 MINI Cooper
Insert conrod bearing shells (1 and 2).
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Fig. 110: Identifying Bearing Shells
Install all pistons with conrods.

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Assemble engine.
25 PISTON WITH RINGS AND

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11 25 530 REMOVING AND INSTALLING/REPLACING ALL PISTONS (N12)

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00 9 120
11 9 620
11 9 670
WARNING: Protective goggles must be worn when working on the gudgeon pin
circlip.
IMPORTANT: If pistons, connecting rods and bearing shells are reused, they must be
reinstalled in the same places.
connecting rods and connecting rod bearing caps are denoted with the same
pairing letters; mixing them up will result in engine damage.
Piston and gudgeon pins are paired and must not be fitted individually.
Remove engine.
Mount engine on assembly stand.
2008 MINI Cooper
Remove intake air manifold.

Remove engine oil sump.
Remove oil pump.
NOTE: In event of heavy oil carbon residue:

Carefully remove oil carbon residue from cylinder wall.
NOTE: Illustrations show N46.
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Fig. 111: Locating Cylinder Wall

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NOTE: Mark all pistons and conrods with a pen prior to removing.
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Example N14:
Direction of arrow (1) points to camshaft drive.
Cylinder allocation (2) per cylinder.
2008 MINI Cooper
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Fig. 112: Identifying Camshaft Points
NOTE: Mark all pistons and conrods with a pen prior to removing.
Example:
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Mark cylinder allocation (1) per cylinder.

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Fig. 113: Identifying Camshaft Bearing Positions

Release connecting rod bolts (1).
Remove conrod bearing cap.
IMPORTANT: connecting rods and connecting rod bearing caps are denoted with the same
pairing letters; mixing them up will result in engine damage.
2008 MINI Cooper
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Fig. 114: Identifying Connecting Rod Bolts
Attach special tool 11 9 620 in conrod big end.
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Press out connecting rod and piston to cylinder head side.
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WARNING: Protective goggles must be worn for the next work step.
WARNING: Protective goggles must be worn.
IMPORTANT: Piston and gudgeon pins are paired and must not be fitted individually.
Lever out piston pin circlip with a screwdriver in direction of arrow.
2008 MINI Cooper
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Fig. 116: Identifying Piston Pin
If necessary, replace connecting rods.
Installation:
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The gudgeon pin must be able to be pressed through the liner by hand with little force and must not display any
significant play.
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Fig. 117: Identifying Gudgeon Pin

Measure piston installation clearance:
Measure piston diameter with micrometer at measuring point A from bottom edge of piston and offset at 90° to
the axis of the gudgeon pin.
Piston diameter at measuring point A.
2008 MINI Cooper
Fig. 118: Identifying Piston Diameter

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Adjust micrometer to cylinder bore of engine block. Set internal calliper on micrometer to zero. Measure
bottom, center and top of cylinder bore in direction of travel and direction of engine rotation.
Diameter of cylinder bore.
Piston installation clearance.

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Total permissible wear tolerance.
If necessary, replace piston.

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Fig. 119: Identifying Cylinder Bore Diameter

Install all piston rings.
Install all bearing shells.
Coat piston and piston rings with oil.
Pre-install piston in special tool 11 9 670 .
2008 MINI Cooper
Screw special tool 11 9 620 into conrod.
Installation:
Check protective lugs on special tool 11 9 620 for correct position and damage.
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Insert piston with connecting rod in cylinder.

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IMPORTANT: Danger of piston ring failure.

Press in piston with finger pressure only, do not drive in (see arrows).
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Insert piston (1) so that arrow on piston crown points to camshaft drive.
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If reusing the pistons, assign cylinder allocation (2) to correct cylinder.
Press in piston with special tool 11 9 670 .
Fig. 121: Pressing Piston With Special Tool (11 9 670)

2008 MINI Cooper
IMPORTANT: Point of fracture (1) on conrod.

Conrod and conrod bearing cap are identified with pairing letters (2) and must
not be mixed up.
Mixing them up or incorrectly fitting the conrod bearing cap on the big end will result in engine damage .
Both pairing letters (2) must be together on one side.
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Fig. 122: Identifying Bearing Cap Pairing Letters
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Apply a light coat of oil to crank pin.

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Assemble connecting rod and crank pin.
Remove special tool 11 9 620 .

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Fit bearing caps (2) so that pairing letters match up.
2008 MINI Cooper
Check cylinder identification markings (1).
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Fig. 124: Identifying Camshaft Bearing Positions
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Install new connecting rod bolts (1).
Carry out torsion angle tightening of conrods with special tool 00 9 120 .
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Fig. 125: Identifying Connecting Rod Bolts

Assemble engine.
11 25 671 REPLACING PISTON RINGS ON ALL PISTONS (N12)
2008 MINI Cooper
11 9 670
Remove all pistons.
Measuring axial clearance of piston rings in piston ring groove.
Technical Data.
NOTE: It is not possible to measure the axial clearance of the oil scraper rings.
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Fig. 126: Identifying Piston Rings Groove Clearance

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Remove compression ring and stepped ring upwards with piston ring pliers.
Oil scraper ring comprises two steel band rings and a support spring.
NOTE: Oil scraper ring cannot be removed with piston ring pliers.
Put aside piston rings in correct sequence and installation position.
It might not be possible to find the identification on used piston rings.
Installation:
New pistons may only be installed together with new piston rings.
2008 MINI Cooper
Fig. 127: Removing Piston Ring
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Determine gap with a feeler gauge.
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Fig. 128: Identifying Piston Ring Gap With Feeler Gauge

Installation:
Piston rings with "TOP" identification must point to piston crown.
2008 MINI Cooper
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Fig. 129: Identifying Piston Rings With "TOP" Identification Point
Installation:
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Piston rings with "TOP" identification must point to piston crown.
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1. Plain compression ring
2. Taper face ring
3. Two-part oil scraper ring
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IMPORTANT: Contact point on oil scraper ring (3) can overlap - risk of damage! - during
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installation in cylinder.
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Fig. 130: Identifying Compression Ring, Taper Face Ring And Two-Part Oil Scraper Ring
NOTE: The oil control ring comprises a steel band ring (1) and a support spring (2).
Installation:
2008 MINI Cooper
Insert support spring (2) in piston ring groove and then fit steel band ring (1) so that end faces point to each
other.
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Fig. 131: Identifying Support Spring And Steel Band Ring
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Offset the contact points (1) of the piston rings by approx. 120° to each other but do not position above the
piston pin boss. Coat special tool 11 9 670 with sufficient engine oil. Risk of damage to piston rings!
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Fig. 132: Identifying Contact Points Of Piston Rings

Assemble engine.
28 V-RIBBED BELT WITH TENSIONER

11 28 010 REPLACING ALTERNATOR DRIVE BELT (N12)
Remove right wheel arch cover

Remove right headlight
Remove lock bridge
2008 MINI Cooper
Bring belt tensioner (1) with wrench (2) into assembly position.
Secure assembly position of belt tensioner (1) by sliding locating pin (3) in direction of arrow.
WARNING: Danger of injury!

Remove wrench (1) again from belt tensioner.
Remove drive belt (4) from alternator.
NOTE: For reasons of clarity, illustration and text show front wall removed.
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Fig. 133: Identifying Belt Tensioner Position And Sliding Pin

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Move friction wheel (2) into servicing position.

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In order to release the frictional connection between crankshaft and coolant pump, it is necessary to move the
friction gear (2) into the servicing position.
Firmly pull handle (1) in direction of arrow until friction gear (2) is separated from belt pulley.
2008 MINI Cooper
Fig. 134: Pulling Handle

To secure friction gear in servicing position, suspend pull cable (1) on housing (2).
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Fig. 135: Pulling Cable On Housing
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Assemble engine.
Installation:
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Check that drive belt for is in correct installation position - risk of damage .
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11 28 012 REPLACING DRIVE BELT (WITHOUT A/C SYSTEM)

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11 9 680
Remove right wheel arch line.
Cut through ribbed V-belt with a suitable tool (2).
2008 MINI Cooper
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Fig. 136: Identifying Ribbed V-Belt
Position special tool 11 9 680 on vibration damper (see arrow).
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Fig. 137: Identifying Special Tool (11 9 680) On Vibration Damper

Attach special tool 11 9 680 in direction of arrow and slide further in direction of arrow.
2008 MINI Cooper

Move special tool 11 9 680 on vibration damper into assembly position.
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Place ribbed V-belt (1) on alternator (2).
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Fig. 140: Identifying Ribbed V-Belt On Alternator

Place ribbed V-belt (1) in direction of arrow on vibration damper.
2008 MINI Cooper
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Fig. 141: Identifying Ribbed V-Belt In Vibration Damper
Turn vibration damper in direction of arrow.
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Press ribbed V-belt (1) inwards by hand (see arrow).
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IMPORTANT: Danger of injury!
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Fig. 142: Identifying Ribbed V-Belt

Turn vibration damper until drive belt on alternator and on vibration damper has fully jumped.
Remove special tool 11 9 680 from vibration damper.
Check correct seating of drive belt.
2008 MINI Cooper
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Fig. 143: Identifying Special Tool (11 9 680) From Vibration Damper
Add final details to vehicle.
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11 28 020 REPLACING TENSIONING DEVICE FOR ALTERNATOR DRIVE BELT (N12)
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WARNING: Tensioning device subject to spring bias (danger of injury!) .
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Bring front panel into service position.

Disconnect lambda oxygen sensor cable.
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Pretension tensioning device (1) with tool (2) in direction of arrow.
Press in locking pin (3) in direction of arrow and hold.
Slowly release tool (2) and secure in position.
NOTE: Locking pin (3) holds tensioning device (1) at pretension.
2008 MINI Cooper
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Release screws (2).
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Remove tensioning device (3).
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Fig. 145: Identifying Tensioning Device

Installation:
Lever tensioning device (1) with tool (2) in direction of arrow.
Locking pin (3) is pretensioned with a spring and is automatically relieved during unlocking.
Ensure drive belt is in correct installation position.
2008 MINI Cooper
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Assemble engine.
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11 28 035 REMOVING AND INSTALLING/REPLACING FRICTION GEAR (N12)
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11 9 581
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11 9 583

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Remove right wheel arch cover

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Pull out friction gear with mechanical release (3) in direction of arrow and lock on locking hook.
Friction gear (1) lifts mechanically off belt drive.
Disconnect plug connection (2) on friction gear.
NOTE: Picture shows friction gear removed.
2008 MINI Cooper
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Fig. 147: Pulling Friction Gear
Move friction gear (2) into servicing position.
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To secure friction gear in servicing position, suspend pull cable (1) on housing (2).
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Fig. 148: Pulling Cable On Housing

Secure belt pulley of water pump with an oil filter band (1).
Release bolts (2) with special tools 11 9 581 and 11 9 583 .
2008 MINI Cooper
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Fig. 149: Identifying Oil Filter Band And Bolts
Release bolts (1) with special tools 11 9 583 and 11 9 581 .
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Fig. 150: Identifying Special Tools (11 9 583 And 11 9 581) On Bolts
Remove friction gear (1) towards bottom.
Disconnect plug connection (2).
2008 MINI Cooper
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Fig. 151: Identifying Friction Gear And Plug Connection
Assemble engine.
Installation:
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Check cable routing for correct installation position - risk of damage .

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31 CAMSHAFT
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11 31 005 CHECKING CAMSHAFT TIMING

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11 9 540
11 9 590
IMPORTANT: Modified procedure for timing adjustment.

The timing is not determined at firing TDC of cylinder no. 1.
All pistons are in the 90° position.
Check locking of adjustment units.
Remove cylinder head cover.

Remove front splash guard.
IMPORTANT: Danger of mixing up special tool bore.

Balance hole and special tool bore can be mixed up; all pistons must be in the
90° position.
2008 MINI Cooper
If necessary, determine by means of spark plug bore.
Rotate crankshaft at central bolt.
Position crankshaft with special tool 11 9 590 .
Do not remove special tool 11 9 590 during repair work.
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IMPORTANT: Check locking on VANOS adjustment units.

Attempt to rotate camshaft in direction of rotation at hexagon head.
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The adjustment units are locked in the initial position when the camshafts are
non-positively connected to the adjustment units.
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If no fixed connection to the camshaft can be established, the adjustment unit

is faulty and must be replaced.
Both camshafts are in the correct installation position when the designation (IN) for inlet camshaft points
upwards.
In the case of the exhaust camshaft, the designation EX must point upwards.
2008 MINI Cooper
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Fig. 153: Identifying (IN And EX) Camshaft Installation Position
Position of exhaust camshaft (A) points at an angle to the right in an upper outward direction
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Fig. 154: Identifying Exhaust Camshaft Right In Upper Position

Position of inlet camshaft (E) points at an angle to the left in an upper outward direction
2008 MINI Cooper
Fig. 155: Identifying Inlet Camshaft Left In Upper Position

Position special tool 11 9 540 (exhaust) on direction of exhaust camshaft and secure with a bolt (1).
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Fig. 156: Identifying Special Tool (11 9 540) On Exhaust Camshaft
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Position special tool 11 9 540 (inlet) on direction of inlet camshaft and secure with a bolts (1 and 2).
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Fig. 157: Identifying Special Tool (11 9 540) On Inlet Camshaft

If necessary, adjust valve timing.
Assemble engine.
11 31 025 REMOVING AND INSTALLING/REPLACING INLET CAMSHAFT (N12)
11 4 481
2008 MINI Cooper
11 9 551

Remove adjusting unit for inlet camshaft.
Remove intermediate lever.
IMPORTANT: The screws of the bearing bridge must not be opened.

Releasing the bearing bridge will result in damage to the cylinder head.
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Fig. 158: Identifying Camshaft Stop

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Bearing cap (1) marked 5 is a thrust bearing.
Release screws of bearing caps (1 to 5).
Set all bearing caps down in special tool 11 4 481 in a tidy and orderly fashion.
Remove camshaft (6).
Installation:
Clean all bearing points and lubricate with oil.
Check plain compression rings for damage.
2008 MINI Cooper
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Fig. 159: Identifying Bearing Caps
If necessary, replace plain compression rings (1).
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The plain compression rings have catches at the joint.
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Press plain compression rings (1) apart upwards and downwards and removed towards front.
IMPORTANT: Plain compression rings (1) can easily break.

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Make sure plain compression rings (1) can move freely.

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Fig. 160: Identifying Plain Compression Rings

IMPORTANT: Both camshafts have different identifications.

Mixing up the two camshafts will result in engine damage .
EX Exhaust camshaft.
IN Inlet camshaft.
2008 MINI Cooper
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Insert camshaft (E) so that IN marking points upwards.
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Position inlet camshaft (E) so that cams point upwards at an angle.
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Attach special tool 11 9 551 to twin surface.
Make sure plain compression rings cable can move freely.

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All bearing caps are identified from 5 to 10.
Pay attention to pairing letters (1).
2008 MINI Cooper
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Fig. 163: Identifying Pairing Letters
Tighten bearing caps from inside outwards.
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Adjust valve timing.
Assemble engine.
11 31 028 REMOVING AND INSTALLING/REPLACING EXHAUST CAMSHAFT (N12)
11 4 480
11 9 000
11 9 590
11 9 650
2008 MINI Cooper
11 9 652
IMPORTANT: It is absolutely essential to follow an exact procedure for removing and

installing the exhaust camshaft.
Modified procedure for timing adjustment.
Risk of damage!

Remove vacuum pump.
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Remove exhaust adjusting unit for exhaust camshaft.
Release central bolt of inlet adjustment unit.
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IMPORTANT: The screws of the bearing bridge must not be opened.
Releasing the bearing bridge will result in damage to the cylinder head.
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Fig. 165: Identifying Camshaft Stop

IMPORTANT: Risk of damage to spark plug bores.

Check special tool 11 9 652 for damage.
Secure special tool 11 9 650 on cylinder head with screws 1 in spark plug holes.
2008 MINI Cooper
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Fig. 166: Identifying Special Tool (11 9 650) On Cylinder Head
IMPORTANT: Release bearing caps with special tool 11 9 650 only.

Shown without special tools for purposes of clarity.
Release bearing cap screws from 10 to 1.

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Set all bearing caps down in special tool 11 4 480 in a tidy and orderly fashion.
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Fig. 167: Identifying Bearing Cap Screws


IN Inlet camshaft.
2008 MINI Cooper
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Check plain compression rings (1) for damage and replace if necessary.
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Plain compression rings (1) are engaged at joint.
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Press plain compression rings (1) apart upwards and downwards and removed towards front.
IMPORTANT: Plain compression rings (1) can easily break.

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Fig. 169: Identifying Plain Compression Rings

IMPORTANT: Removal on engine:

Block engine with special tool 11 9 590 .
Removed cylinder head:
When using special tool 11 9 000 , it will be necessary to remove the aluminum profile insert.
2008 MINI Cooper
Installation:
Before installing exhaust camshaft, make sure roller rocker arm is correctly seated HVCA element and valve.
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Fig. 170: Identifying Roller Rocker Arm
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Installation:
Lubricate all bearing points with engine oil.

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Insert camshaft (1).

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Pay attention to installation position (2).

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Fig. 171: Identifying Camshaft Installation Position


IN Inlet camshaft.
2008 MINI Cooper
Designation (EX) on exhaust camshaft points upwards.
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Make sure plain compression rings (1) can move freely.
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Align plain compressing rings (1) in downward direction.
Lubricate all bearing points (2) with engine oil.

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Fig. 173: Identifying Plain Compression Rings And Bearing Lubricating Points
Secure special tool 11 9 650 on cylinder head with screws 1 in spark plug holes.
Pretension camshaft (2).
Fit and secure bearing bridges.
2008 MINI Cooper
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Fig. 174: Identifying Special Tool (11 9 650) On Cylinder Head
Bearing bridges, allocation of exhaust camshaft from (0 to 4).
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Fig. 175: Identifying Exhaust Camshaft

Fit all bearing bridges from 0 to 4.
Secure screws in sequence (1 to 10).
NOTE: Shown without special tool 11 9 650 for purposes of clarity.
2008 MINI Cooper
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Fig. 176: Identifying Bearing Cap Screws
Adjust valve timing.
Assemble engine.
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11 31 051 REPLACING TIMING CHAIN (N14)

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00 9 120
11 9 280
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11 9 540
11 9 590
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Remove all spark plugs.
Remove chain tensioner.
Remove both VANOS adjustment units.
Remove PTFE ring at front.
Remove belt tensioner.
Position crankshaft with special tool 11 9 590 .
2008 MINI Cooper
Do not remove special tool 11 9 590 during repair work.
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Do not remove special tool 11 9 540 .
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IMPORTANT: Employ a second person for gripping when releasing central bolt (1).
Fit special tool 11 9 280 on hub for vibration damper with screws (2).
2008 MINI Cooper
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Fig. 179: Identifying Special Tool (11 9 280) On Hub Into Vibration Damper
Release central bolt in direction of arrow.
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Fig. 180: Tightening Central Bolt

Release bearing pins (1 and 2).
2008 MINI Cooper
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Fig. 181: Identifying Bearing Pins
Remove hub (3) towards front.
Remove chain module with timing chain.
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Using a hook (2), pull oil pump chain (1) upwards.
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Fig. 182: Identifying Chain Module With Timing Chain

Sprocket wheel (1) of timing chain.
Sprocket wheel (2) of oil pump.
2008 MINI Cooper
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Fig. 183: Identifying Sprocket Wheel With Timing Chain
Secure chain module (1) with rubber (3) to facilitate assembly.
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Pull timing chain (2) upwards until sprocket wheel (4) rests against chain guide (1).
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Install timing chain (2) and sprocket wheel (4) in this position.
Installation:
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Always keep timing chain (2) tensioned; it is possible for timing chain (2) to jam on chain module (1).
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Fig. 184: Identifying Timing Chain And Sprocket Wheel Installation Position
Installation position of both sprocket wheels.
Sprocket wheel (1) of oil pump.
Guide rail (2) of timing chain.
2008 MINI Cooper
Hub (3) on crankshaft.
Sprocket wheel (4) of timing chain.
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Fig. 185: Identifying Sprocket Wheels Installation Position
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Attach oil pump sprocket wheel (2) in direction of arrow to crankshaft (1).
Insert chain module with timing chain and secure.

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Attach crankshaft hub.

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Screw in central bolt.

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Fig. 186: Identifying Oil Pump Sprocket Wheel And Crankshaft

Remove special tool 11 9 280 from hub.
Secure central bolt with special tool 00 9 120 .
2008 MINI Cooper
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Fig. 187: Identifying Special Tool (11 9 280) From Hub
Install VANOS adjustment units.
Crank engine twice.
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Check timing.
Install PTFE ring.

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Assemble engine.
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11 31 090 INSTALLING AND REMOVING/REPLACING CHAIN TENSIONER PISTON (N12)

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Remove throttle valves.
Release chain tensioner (1).
IMPORTANT: Have a cleaning cloth ready. A small quantity of engine oil will emerge after the
screw connection has been released.
Make sure no oil runs onto the belt drive.
Installation:
Replace sealing ring.
2008 MINI Cooper
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Fig. 188: Identifying Chain Tensioner
If the chain tensioner is reused, its oil chamber must be drained. Place chain tensioner on a level working
surface and slowly compress.
Repeat procedure twice.

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Fig. 189: Placing Chain Tensioner On Level Working Surface

Assemble engine.
11 31 505 ADJUSTING CAMSHAFT TIMING (N12)
00 9 120
00 9 250
11 9 340
11 9 450
2008 MINI Cooper
11 9 540
11 9 590
32 2 100

To open the central bolt at the camshaft, grip hexagon on rear of camshaft.
Risk of damage!
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Check timing.
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IMPORTANT: Danger of mixing up special tool bore.
Balance hole and special tool bore can be mixed up; all pistons must be in the
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90° position.
If necessary, determine by means of spark plug bore.
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Slide in special tool 11 9 590 in direction of arrow and block crankshaft.

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IMPORTANT: Risk of damage!
To open central bolt, mount special tool 11 9 540 on camshaft.
If the setting gauges cannot be positioned, grip the camshaft with an open-end wrench to release the central bolt.
2008 MINI Cooper
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Release chain tensioner (have a cleaning cloth ready).
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To open central bolts (1 and 2), mount special tool 11 9 540 on camshafts.
Release central bolts (1 and 2).
2008 MINI Cooper
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Fig. 193: Identifying Central Bolts
The designations for the inlet camshaft (IN) and exhaust camshaft (EX) point upwards.
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Both camshafts (inlet and exhaust) have three machined surfaces to enable special tool 11 9 450 to be mounted.
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The fourth surface is not machined and is crescent-shaped - it must point downwards.
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Position of exhaust camshaft (EX) points at an angle to the right in an upper outward direction.
2008 MINI Cooper
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Fig. 195: Identifying Exhaust Camshaft Right In Upper Position
Position of inlet camshaft (E) points at an angle to the left in an upper outward direction.
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Rotate exhaust camshaft with special tool 32 2 100 in direction of arrow.
2008 MINI Cooper
Fig. 197: Identifying Special Tool (32 2 100) On Exhaust Camshaft

Pretension camshaft with special tool 32 2 100 .
Attach special tool 11 9 540 (exhaust side) to direction and secure with bolt (1).
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Attach special tool 11 9 540 (inlet side) to direction and secure with bolts (1 and 2).
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Screw special tool 11 9 340 into cylinder head.
Pretension timing chain with special tool 00 9 250 to 0.6 Nm .
2008 MINI Cooper
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Fig. 200: Identifying Special Tool (11 9 340) Into Cylinder Head
Secure central bolt (1) with special tool 00 9 120 or an electronic torque wrench.
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Fig. 201: Identifying Special Tool (00 9 120) On Central Bolt

Secure central bolt (1) with special tool 00 9 120 or an electronic torque wrench.
2008 MINI Cooper
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Remove all special tools.
Assemble engine.
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33 ROCKER ARM WITH BEARING
11 33 050 REMOVING AND INSTALLING/REPLACING ALL CAM FOLLOWERS (N12)
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11 4 480

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IMPORTANT: Rocker arms (1) are divided into bearing categories.

The tolerance classes are designated as illustrated with numbers from 1 to 5.
Already used rocker arms (1) may only be reused in the same position.
2008 MINI Cooper
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Fig. 203: Identifying Rocker Arms
Remove HVCA element in direction of arrow.
Installation:
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If the HVCA elements are to be reused, set them down in special tool 11 4 480 in a tidy and orderly fashion
with the roller cam followers.
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Fig. 204: Identifying HVCA Element

IMPORTANT: Rocker arms (1) are divided into bearing categories.

The tolerance classes are designated as illustrated with numbers from 1 to 5.
Already used rocker arms (1) may only be reused in the same position.
Detach roller cam followers (1) from HVCA element and remove.
Set all roller cam followers down in special tool 11 4 480 in a tidy and orderly fashion.
Installation:
2008 MINI Cooper
Before installing exhaust camshaft and intermediate lever, make sure roller cam followers are correctly seated
(see arrows).
Assemble engine.
Check function of DME; if necessary, readjust uniform mixture distribution.
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Fig. 205: Identifying Roller Rocker Arm
34 VALVES WITH SPRINGS

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11 34 552 REMOVING AND INSTALLING OR REPLACING ALL VALVES (N12)

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11 4 480

Remove eccentric shaft.
Remove inlet camshaft.
Remove roller cam follower.
Remove valve springs.
Remove valve stem seals.
Arrangement:
1. Valve
2. Valve stem seal with spring plate, bottom
2008 MINI Cooper
3. Valve spring
4. Top plate spring
5. Valve tapers
If the valves are to be reused, set then down in special tool 11 4 480 in a tidy and orderly fashion.
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Fig. 206: Identifying Valves Components Arrangement Sequence
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Assemble engine.
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11 34 560 REPLACING ALL VALVE STEM SEALS (N52)

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11 1 480
11 6 380

Remove eccentric shaft.
Firmly press special tool 11 1 480 onto old valve stem seals (1).
Detach valve stem seal from valve stem by turning and simultaneously pulling special tool 11 1 480 .
2008 MINI Cooper
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Fig. 207: Identifying Special Tool (11 1 480) Onto Old Valve Stem Seals
Installation:
Insert all valves .
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Fit the mounting sleeves (plastic sleeves) supplied in the spare part on the valve stem end
Lubricate mounting sleeve.

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Press on valve stem seal by hand with special tool 11 6 380 as far as it will go.
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Fig. 208: Identifying Special Tool (11 6 380) On Valve Stem Seal
Assemble engine.
11 34 715 REPLACING ALL VALVE SPRINGS (N12)
2008 MINI Cooper
11 4 480
11 9 000
11 9 006
11 9 007
11 9 017

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Place cylinder head (1) on special tool 11 9 000 .
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Fig. 209: Identifying Cylinder Head On Special Tool (11 9 000)

Prepare special tool 11 9 007 on special tool 11 9 006 .
2008 MINI Cooper
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Align special tool 11 9 006.
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Lock eccentrics (1) on special tool 11 9 000 in direction of arrow.
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Press down valve spring and spring retainer (1) with special tool 11 9 017 .
2008 MINI Cooper
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Fig. 212: Identifying Special Tool (11 9 017) On Spring Retainer
Remove valve tapers with a magnet.
Remove valve spring and spring retainer.
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Set down on special tool 11 4 480 in a tidy and orderly fashion.
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2008 MINI Cooper
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Fig. 213: Removing Valve Spring And Spring Retainer

IMPORTANT: Incorrect installation possible.

Incorrect installation will result in valve spring breakage.
Color marking (1) is normally on lower end of valve spring.
Only the diameter pointing to the spring retainer at the bottom is required for correct installation of the valve
spring.
2008 MINI Cooper
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Fig. 214: Identifying Valve Spring Diameter
Arrangement:
1. Valve
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2. Valve stem seal with spring plate, bottom
3. Valve spring
4. Top plate spring
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5. Valve tapers
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Fig. 215: Identifying Valves Components Arrangement Sequence

Assemble engine.
36 VARIABLE CAMSHAFT TIMING

11 36 046 REMOVING AND INSTALLING/REPLACING INLET AND EXHAUST ADJUSTMENT
UNITS (N12)
2008 MINI Cooper
00 9 120
11 9 340
11 9 540
11 9 590
IMPORTANT: Always release both central bolts to adjust the timing. The timing is not
determined at firing TDC of cylinder no. 1.
Modified procedure for timing adjustment.
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Check timing.
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Slide in special tool 11 9 590 in direction of arrow and block crankshaft.

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Release screws (1).
Remove slide rail (2).
2008 MINI Cooper
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Fig. 217: Identifying Slide Rail With Screws
IMPORTANT: Risk of damage!

To open central bolt, mount special tool 11 9 540 on camshaft.
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If the setting gauges cannot be positioned, grip the camshaft with an open-end
wrench to release the central bolt.
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Release chain tensioner (1) (have a cleaning cloth ready).
2008 MINI Cooper
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Release bearing pin (1) on guide rail.
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Installation:

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Fig. 220: Identifying Bearing Pin

Release central bolts of inlet adjustment unit (1) and exhaust adjustment unit (2).
Detach inlet adjustment unit from inlet camshaft.
Detach exhaust adjustment unit from exhaust camshaft.
2008 MINI Cooper
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IMPORTANT: Danger of mixing up adjustment units .
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Mixing up the adjustment units will result in engine damage.
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The inlet and exhaust adjustment units are different.
VANOS is marked with IN for the inlet camshaft.

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VANOS is marked with EX for the exhaust camshaft.

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Fig. 222: Identifying Inlet Camshaft And Exhaust Camshaft

Place adjustment units of exhaust camshaft marked EX on timing chain.
Position adjustment unit on exhaust camshaft and secure with central bolt (3).
The installation position of the adjustment units can be freely selected.
2008 MINI Cooper
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Fig. 223: Identifying Central Bolt
Place adjustment units of inlet camshaft marked IN on timing chain.
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Position adjustment unit on inlet camshaft and secure with central bolt (1).
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The installation position of the adjustment units can be freely selected.
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Install slide rail (2).
Insert screws (1).
2008 MINI Cooper
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Fig. 225: Identifying Slide Rail With Screws
Screw special tool 11 9 340 into cylinder head.
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Pretension timing chain with special tool to 0.4 Nm .
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Fig. 226: Identifying Special Tool (11 9 340) Into Cylinder Head
Secure central bolt (1) with special tool 00 9 120 .
2008 MINI Cooper
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Secure central bolt (1) with special tool 00 9 120 .
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Fit chain tensioner.
Check timing.
Assemble engine.
11 36 655 REMOVING AND INSTALLING/REPLACING BOTH SOLENOID VALVES (N12)
IMPORTANT: Always check that the solenoid valves are clean during removal and
installation.
Possible malfunction if valves are contaminated:
2008 MINI Cooper
Rough running.
OBD fault entry.
Exhaust emission behavior.
Low engine power.
Remove acoustic cover
Disconnect plug connection for solenoid valve (3) - inlet.
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Release screw (1).
Remove solenoid valve (2) for inlet side.
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Fig. 229: Identifying Plug Connection For Solenoid Valve

Disconnect plug connection for solenoid valve - exhaust.
Release screw (2).
Remove solenoid valve (1) for exhaust side.
2008 MINI Cooper
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Fig. 230: Identifying Solenoid Valve
Installation:
Replace sealing rings on solenoid valves.
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Fig. 231: Identifying Sealing Rings On Solenoid Valves

Assemble engine.
37 VARIABLE VALVE GEAR

11 37 005 REMOVING AND INSTALLING/REPLACING ECCENTRIC SHAFT (N12)
11 4 481
2008 MINI Cooper

Release screw (2) on magnet wheel (1).
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Fig. 232: Identifying Magnet Wheel And Screw

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Installation:
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Pay attention to journal and groove on intermediate shaft and magnet wheel.
Fig. 233: Identifying Magnet Wheel

IMPORTANT: Magnet wheel (1) is extremely magnetic.

After removing, protect magnet wheel (1) against metal chips by placing it in a
2008 MINI Cooper
plastic bag (2) with a seal.
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Fig. 234: Identifying Plastic Bag With Seal
Adjust eccentric shaft to minimum lift (1).

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Fig. 235: Identifying Eccentric Shaft

Release screws on all bearing caps (1).
2008 MINI Cooper
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All bearing caps are marked with numbers from (6 to 10); set down in neat order in special tool 11 4 481 .
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Fig. 237: Identifying Mark With Number On Bearing Caps

Remove intermediate shaft (1).
2008 MINI Cooper
Fig. 238: Identifying Intermediate Shaft

IMPORTANT: If one or more needle bearings are faulty, the complete eccentric shaft must be
replaced.
Magnet wheel (2) is highly magnetic. No metal chips must stick to the magnet
wheel (2), replace if necessary.
Check all needle bearings (3) of eccentric shaft (1) for ease of movement.
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Fig. 239: Identifying Eccentric Shaft, Magnet Wheel And Needle Bearings
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Bearing cap number 10 is provided with a stop.
Lubricate all bearing caps with engine oil.

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All bearing caps (1) are identified with numbers from (6 to 10).
Adjust eccentric shaft minimum lift.
2008 MINI Cooper
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Check eccentric shaft for ease of movement.
Assemble engine.
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11 37 010 REMOVING AND INSTALLING/REPLACING INTERMEDIATE LEVER (N12)

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11 4 480
11 5 571
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11 9 571
11 9 572
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11 9 573
WARNING: Danger of injury!

A special tool is essential for opening the return spring on the
intermediate lever.
IMPORTANT: Release screw with special tool only.
2008 MINI Cooper
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Fig. 241: Identifying Intermediate Lever Stop
Position special tool 11 9 571 on bearing block of balancing shaft so that it rests on intermediate shaft (see
arrow).
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If necessary, set eccentric shaft (1) to minimum lift (2).
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Fig. 242: Identifying Special Tool (11 9 571) On Bearing Block

Clamp return spring with knurled screw (1).
2008 MINI Cooper
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Make sure return spring is correctly seated on special tool 11 9 571 (see arrow).
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When special tool 11 9 571 is correctly positioned, return spring (2) can be pressed back with lever (1).
2008 MINI Cooper
Fig. 245: Identifying Return Spring With Lever

Press lever (1) in direction of arrow on special tool 11 9 571 until locking hook (2) engages on special tool 11 9
571 .
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Fig. 246: Pressing Lever With Special Tool (11 9 571)
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WARNING: Danger of injury! at return spring.

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Locking hook (1) must engage on special tool 11 9 571 (see arrow).
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Fig. 247: Locking Hook

Release screw (1).
2008 MINI Cooper
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Fig. 248: Identifying Screw
Prepare special tool 11 9 572 on a vice (1).
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Fig. 249: Identifying Special Tool (11 9 572) In Vice

Feed out special tool 11 9 571 in return spring (1).
2008 MINI Cooper
Fig. 250: Identifying Special Tool (11 9 571) On Return Spring

Set down special tool 11 9 571 on special tool 11 9 572 (see arrow).
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WARNING: Danger of injury! at return spring.
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Release locking hook (1) on special tool 11 9 571 .

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Release lever (2) in direction of arrow.

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Fig. 252: Removing Lever

Release knurled screw (1) in direction of arrow.
Remove return spring (2).
2008 MINI Cooper
Set all return springs down on special tool 11 4 480 in a tidy and orderly fashion.
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Fig. 253: Removing Return Spring
Release bolt (2).
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Release centering bolt (1).
Remove locating plate and set down on special tool 11 4 480 in a tidy and orderly fashion.
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Fig. 254: Identifying Centering Bolt

NOTE: Screw (1)

Setscrew (2)
Installation:
Observe screwing sequence
2008 MINI Cooper
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Fig. 255: Identifying Screw And Setscrew
Remove roller cam follower (3) towards top and set down on special tool 11 4 480 in a tidy and orderly fashion.
Installation:
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Uniform distribution must not be changed.
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Fig. 256: Identifying Roller Cam Follower

All roller cam followers are classified.
Values of 0 to 5 are installed.
NOTE: A uniform distribution can only be calculated with the diagnosis tester.
2008 MINI Cooper
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Fig. 257: Identifying Roller Cam
Installation:
Installation of roller cam followers.
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Position torsion spring (1) on special tool 11 9 571 (see arrows) and clamp with knurled screw.
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Fig. 258: Identifying Special Tool (11 9 571) On Torsion Spring

Press torsion spring (1) in direction of arrow and position with lever of special tool 11 9 571 .
2008 MINI Cooper
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Fig. 259: Pressing Torsion Spring
Pretension spiral-wound spring (1) with special tool 11 9 571 in direction of arrow.
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Fig. 260: Identifying Spiral-Wound Spring

WARNING: Danger of injury! at torsion spring.
Locking hook (1) must engage on special tool 11 9 571 (see arrow).
2008 MINI Cooper
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Fig. 261: Locking Hook
Insert intermediate levers (3).
Installation:
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Make sure roller cam followers (2) are in correct installation position.
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Fig. 262: Identifying Roller Cam Follower

Install guide block.
Insert setscrew (1).
Insert screw (2).
Join screws (1 and 2) to 5 Nm.
Release screws (1 and 2) back by 90°.
2008 MINI Cooper
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Fig. 263: Identifying Centering Bolt
Pretension guide block (1) with special tool 11 9 573 .
Secure setscrews of guide block (1).
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Secure screw on guide block (1).

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Fig. 264: Identifying Special Tool (11 9 573) On Guide Block

Feed in return spring (1) with special tool 11 5 571 and position.
2008 MINI Cooper
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Fig. 265: Identifying Special Tool (11 9 571) On Return Spring
Secure screw (1) of return spring.
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Fig. 266: Identifying Screw

Installation:
Insert return spring (2) in intermediate lever (1) (see arrow).
Check roller cam follow (3) again to ensure correct installation position.
2008 MINI Cooper
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Fig. 267: Identifying Return Spring, Intermediate Lever And Roller Cam Follow
Remove all special tools.
Assemble engine.
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11 37 020 REMOVING AND INSTALLING/REPLACING POSITIONING MOTOR FOR ECCENTRIC
SHAFT (N12)
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Remove acoustic cover.

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Disconnect plug connection (2) on servodrive.

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Pull off engine wiring harness at retaining clip (1) from servodrive.
Fig. 268: Identifying Plug Connection And Retaining Clip

Release screws (1).
2008 MINI Cooper
Installation:
Replace seal.
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Fig. 269: Identifying Servodrive Screws
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IMPORTANT: Risk of damage to intermediate shaft.

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Turn screwdriver (1) counterclockwise in direction of arrow and relieve tension on intermediate shaft.
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NOTE: Do not rotate shaft too far up to maximum to end stop.

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Remove servodrive.
Installation:
Insert servodrive with screwdriver (2).
Assemble engine.
2008 MINI Cooper
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Fig. 270: Inserting Servodrive With Screwdriver
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11 37 030 REMOVING AND INSTALLING/REPLACING ECCENTRIC SHAFT SENSOR (N12)
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Release screws (2).

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Fig. 271: Identifying Plug Connection

Assemble engine.
40 OIL SUPPLY
2008 MINI Cooper
11 40 000 CHECKING ENGINE OIL PRESSURE (N12)
11 7 020
11 9 560
13 3 061
13 3 063
13 6 051
13 6 054
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Disconnect plug connection (1) on oil pressure switch.
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Fig. 272: Identifying Plug Connection On Oil Pressure Switch

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Release oil pressure switch (1) with special tool 11 7 020 .
Installation:
2008 MINI Cooper
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Fig. 273: Identifying Oil Pressure Switch
Screw in special tool 11 9 560 with sealing ring on cylinder head.
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Secure pressure gauge connection 13 3 063 to special tool 11 9 560 .
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Check engine oil pressure with diagnosis tester.
Connect special tools 11 9 560 / 13 6 054 and 13 6 051 .
Check engine oil pressure with pressure gauge.
Connect special tools 11 9 560 / 13 3 063 and 13 3 061 .
Start engine and check engine oil pressure.
2008 MINI Cooper
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Assemble engine.
41 OIL PUMP WITH FILTER A

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11 41 000 REMOVING AND INSTALLING OIL PUMP (N12)

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Removing oil pan.

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Pull off cover (1) in direction of arrow.
Installation:
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Replace cover (1).
Fig. 276: Removing Cover

2008 MINI Cooper
Release screw (1).
Grip central bolt (2) to release central bolt (1).
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Fig. 277: Tightening Central Bolt
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Release screws (1).

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Assemble engine.
42 OIL FILTER AND LINES

11 42 020 REMOVING AND INSTALLING/REPLACING MAIN FLOW OIL FILTER (N12)
2008 MINI Cooper
WARNING: Danger of scalding!

Only perform these tasks on an engine that has cooled down.
Unfasten oil filter cover.

Remove exhaust manifold.
Release screws (1).
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Replace seal (1).
Fig. 280: Identifying Seal

Assemble engine.
2008 MINI Cooper
43 OIL FILLING, DIPSTICK

11 43 000 REMOVING AND INSTALLING/REPLACING GUIDE TUBE FOR DIPSTICK (N12)
Pull dipstick out of guide tube.
Release screw (2).
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Pull dipstick (1) up in direction of arrow.
Installation:
Replace O-ring.
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Fig. 281: Pulling Dipstick

Assemble engine.
Check engine oil level, top up if necessary
51 WATER PUMP WITH DRIVE

11 51 000 REMOVING AND INSTALLING/REPLACING WATER PUMP (N12)

Recycling:
2008 MINI Cooper
Catch and dispose of drained coolant.
Remove friction gear.
Release screws (1).
Installation:
Replace seal.
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Clean sealing surfaces.
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Fig. 282: Identifying Water Pump Screws

Assemble engine.
Venting instructions must be observed without fail .
53 THERMOSTAT AND CONNECT

11 53 000 REMOVING AND INSTALLING/REPLACING COOLANT THERMOSTAT (N12)
17 2 050

2008 MINI Cooper
Recycling:
Catch and dispose of drained coolant.
Drain coolant from radiator.
Release lock (1) on coolant pipe in direction of arrow.
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Fig. 283: Identifying Lock On Coolant Pipe

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Disconnect plug connection (1) on coolant thermostat.

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Fig. 284: Identifying Plug Connection On Coolant Thermostat

Detach all coolant hoses from thermostat.
2008 MINI Cooper
NOTE: Release metal hose clamps with special tool 17 2 050 .
Disconnect plug connection (1) on coolant temperature sensor.
Slacken nut (2).
Release screws (3).
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Fig. 285: Identifying Plug Connection On Coolant Temperature Sensor

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Installation:
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Replace seal (1).
Fig. 286: Identifying Seal Area

Assemble engine.
2008 MINI Cooper
Vent cooling system and check for leaks.
61 INTAKE MANIFOLD
11 61 050 REMOVING AND INSTALLING INTAKE AIR MANIFOLD (N12)
Remove suction filter housing.

Remove engine cover.
Unfasten engine wiring harness (1) on intake manifold.
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Disconnect plug connection (3) on tank vent valve.
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Fig. 287: Identifying Engine Wiring Harness On Intake Manifold

Release tank vent valve (2).
2008 MINI Cooper
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Fig. 288: Identifying Tank Vent Valve
Disconnect plug connection (1) on solenoid valve.
Release engine breathers and hold to one side.
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Slacken nut (2).

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Fig. 289: Identifying Plug Connection On Solenoid Valve

Unfasten engine wiring harness (2) on intake manifold.
2008 MINI Cooper
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Fig. 290: Identifying Engine Wiring Harness On Intake Manifold
Release cable (1) at intake manifold holder.
Release screw (2).
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Release screw (3).
Take off holder (4).

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Fig. 291: Identifying Cable And Holder

Release screw (2).
Unscrew nuts (3).
2008 MINI Cooper
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Fig. 292: Identifying Screw And Nut
Installation:
Replace all seals.
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Assemble engine.
62 EXHAUST MANIFOLD
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11 62 000 REMOVING AND INSTALLING, SEALING/REPLACING EXHAUST MANIFOLD (N12)

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Move front end into assembly position.

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Remove both lambda oxygen sensors.
Detach heat shield.
Release screws (1).
2008 MINI Cooper
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Fig. 293: Identifying Exhaust Manifold Screws
Release all nuts (1).
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Feed out exhaust manifold (1) downwards.
Installation:
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Replace all seals.

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Fig. 294: Identifying Exhaust Manifold Nut

Assemble engine.
66 VACUUM PUMP
11 66 000 REMOVING AND INSTALLING/REPLACING VACUUM PUMP (N12)
2008 MINI Cooper
Release vacuum connection to brake booster.
Release screws (1).
Pull out vacuum pump (2).
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Fig. 295: Identifying Vacuum Pump
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Installation:
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Replace sealing ring (1).

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Fig. 296: Identifying Sealing Ring

Assemble engine.
78 EMISSION CONTROL, OXYGEN

11 78 510 REMOVING AND INSTALLING/REPLACING CONTROL SENSOR (N12)
2008 MINI Cooper
11 7 020
WARNING: Scalding hazard!

Only perform these tasks after exhaust system has cooled down.
Installation:
If an oxygen sensor is to be reused, only apply a thin and uniform coat of Never Seez Compound (refer to
BMW Parts Service) to thread.
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The part of the oxygen control sensor which projects into the exhaust system branch (sensor ceramic) must not
be cleaned or come into contact with lubricant.
Disconnect plug connection for control sensor.
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Release oxygen sensor (1) with special tool 11 7 020 .
gn
NOTE: For purposes of clarity, illustration shows and description refers to the removed
ia
engine.
rd
ca
Fig. 297: Identifying Special Tool (11 7 020) On Oxygen Sensor

Assemble engine.
11 78 510 REMOVING AND INSTALLING/REPLACING LAMBDA CONTROL SENSORS (N12)
2008 MINI Cooper
11 7 020

Only perform these tasks after the exhaust system has cooled down.
Read fault memory.
Installation:
om
The part of the oxygen control sensor which projects into the exhaust system branch (sensor ceramic) must not
.c
Disconnect plug connection for lambda control sensor.
gn
Release oxygen sensor (1) with special tool 11 7 020 .

ia
rd
ca
Fig. 298: Identifying Special Tool (11 7 020) On Oxygen Sensor

Assemble engine.
11 78 610 REMOVING AND INSTALLING/REPLACING LAMBDA MONITOR SENSORS (N12)
2008 MINI Cooper
11 7 030
11 9 150

Read fault memory.
Installation:
om
The part of the oxygen monitor sensor which projects into the exhaust system branch (sensor ceramic) must not
.c
gn
Disconnect plug connection for oxygen monitor sensor.
Release monitor sensor (1) with special tools 11 7 030 and 11 9 150 .
ia

rd
ca
Fig. 299: Identifying Special Tools (11 7 030 And 11 9 150) On Monitor Sensor
Assemble engine.
11 78 610 REMOVING AND INSTALLING/REPLACING MONITOR SENSOR (N12)

2008 MINI Cooper
11 7 020
Installation:
om
The part of the oxygen monitor sensor which projects into the exhaust system branch (sensor ceramic) must not
Disconnect plug connection for monitor sensor.
.c
Release monitor sensor (1) with special tool 11 7 020 .
gn
ia
rd
ca
Fig. 300: Identifying Special Tool (11 7 020) On Monitor Sensor

Assemble engine.

Engine Cooper 2006 Al 2008

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Engine Cooper 2006 Al 2008

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2008 MINI Cooper

2007 ENGINE Engine - Repair Instructions - Cooper

Engine - Repair Instructions - Cooper

Ingesting oil or absorbing through the skin may cause poisoning!

Protective measures/rules of conduct:

Pour oil only into appropriately marked containers

Observe country-specific safety regulations

First aid measures:

Do not induce vomiting.

Contact with eyes or skin may result in injury!

Possible symptoms are:

Monday, June 25, 2012 8:54:33

Protective measures/rules of conduct:

Wear protective goggles

NOTE: Do not use solvents/thinners.

WARNING: If the engine hood/bonnet contact is pulled upwards (workshop mode),

the information "switch closed" is output. The automatic engine start-stop

Observe safety precautions when working on MSA vehicles.

MSA function is deactivated by:

Deactivate MSA by means of button (1) in passenger compartment

Fig. 1: Identifying MSA Means Of Button

Basic setting (engine hood/bonnet open)

Fig. 2: Identifying Engine Hood/Bonnet Contact Setting

Courtesy of BMW OF NORTH AMERICA, INC.

When working with diagnosis tools:

Observe instructions in diagnosis tool

NOTE: For further information on automatic engine start-stop system (MSA):

Refer to ELECTRICAL SYSTEMS .

00 SAFETY INSTRUCTIONS FOR HANDLING OIL

WARNING: Refer to 00 DANGER OF POISONING IF OIL IS INGESTED/ABSORBED

Observe country-specific waste-disposal regulations.

Measures if oil is unintentionally released:

Release screws (1).

Lift off acoustic cover in direction of arrow.

Fig. 3: Lifting Acoustic Cover

11 00 050 REMOVING AND INSTALLING ENGINE WITH TRANSMISSION (N12)

Special tools required:

Necessary preliminary tasks:

Lift engine hood into assembly position.

Attach special tool 11 0 260 to lifting eye (1) at engine end

Fig. 4: Identifying Special Tool (11 0 260) To Lifting Eye To Engine

Attach special tool 11 0 260 to lifting eye (1) at transmission end

Fig. 5: Identifying Special Tool (11 0 260) On Transmission

Courtesy of BMW OF NORTH AMERICA, INC.

Release transmission and engine mounts.

Remove engine with special tool 11 0 260 towards front.

Check function of DME.

11 00 670 SECURING ENGINE IN INSTALLATION POSITION (N12, N14)

Special tools required:

WARNING: Risk of injury!

Necessary preliminary tasks:

Remove lock bridge.

Remove front supports (1).

Fig. 8: Identifying Special Tools (00 0 490)

IMPORTANT: Do not damage Bowden cable (1)!

IMPORTANT: Avoid a change of engine position in the transverse or longitudinal direction.

Fig. 10: Identifying Special Tool (00 0 200 And 00 0 202)

WARNING: Risk of injury!

Slacken bolts (2, 3).

Tightening torque: See ENGINE - TIGHTENING TORQUES .

Fig. 12: Identifying Rubber Mounts In Bracket With Slacken Bolts

Left side only:

Remove transmission support bracket