Removing and installing, sealing/replacing rear timing case cover (B48 and B46 engine) (Cooper S and John Cooper Works)

Special tools required: 

• 11 4 470
• 2 469 803
• 11 8 815
• 11 9 182
• 11 9 184
• 11 9 181
• 2 360 215
• 11 9 183

Attention! 

Engines with surface sealant: 

The maximum  processing time of the liquid sealing compound is 10 minutes  .

Preliminary work needed: 

• Uninstall the ENGINE WITH TRANSMISSION .
• Mount ENGINE ON ASSEMBLY JIG .
• Remove FLYWHEEL .
• Remove CYLINDER HEAD . .
• Remove OIL SUMP .

REMOVAL: 

Attention! 

Magnet wheel (1) is magnetic.

Keep magnet wheel (1) in a plastic bag away from shavings.

Remove magnet wheel (1) from crankshaft.

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Unscrew the screws (1).

Remove coolant line (2).

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Unlock connector (1) and detach it off the crankshaft sensor.

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Release screws in the sequence 11 to 1  .

Loosen the timing case cover with a screwdriver (1) in the direction of the arrow.

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Loosen the timing case cover with a screwdriver (1) in the direction of the arrow.

Remove the timing case cover.

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Attention! 

Do not use any metal-cutting tools (e.g. emery cloth).

Remove seal remnants from the crankcase with special tool 11 4 470.

Check that lining sleeves (2) are correctly fitted, replace if necessary.

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INSTALLATION: 

Attention! 

Damage to the crankshaft seal.

Taping the sealing lip (inner) and oiling the crankshaft seal will destroy it.

• Do not tap the sealing lip (inner) of the crankshaft seal.
• Do not oil the crankshaft seal.
• Install the crankshaft seal dry.

Have special tool 2 469 803 ready.

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Apply sealing compound (1) on the special tool 2 469 803 as shown.

Parts  : SEALING COMPOUND 2.2 .

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When replacing the rear timing case cover: 

Apply the sealing bead (1) at the positions signaled (see illustration) on the inside of the timing case cover.

Parts: 

Sealing bead (1): SEALING COMPOUND 2.2 .

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Pre-assemble special tool 11 8 815 on crankshaft.

Mount the timing case cover with crankshaft seal (1).

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Insert bolts.

Tighten bolts in the sequence 1 to 11. 

Tightening torque: 11 14 1AZ .

When reinstalling the timing case cover: 

Support the timing case cover (1) from below.

Set the inner punch in the crankshaft seal (2).

Drive the crankshaft seal (2) outwards.

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Remove the gasket remnants from the timing case cover with the special tool 11 4 470.

Apply the sealing bead (1) at the positions signaled (see illustration) on the inside of the timing case cover.

Parts: 

Sealing bead (1): SEALING COMPOUND 2.2 .

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Mount the timing case cover without the crankshaft seal.

Insert bolts.

Tighten bolts in the sequence 1 to 11. 

Tightening torque: 11 14 1AZ .

Position special tool 11 8 815 on crankshaft.

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Attention! 

Damage to the crankshaft seal.

Taping the sealing lip (inner) and oiling the crankshaft seal will destroy it.

• Do not tap the sealing lip (inner) of the crankshaft seal.
• Do not oil the crankshaft seal.
• Install the crankshaft seal dry.

Carefully slide the crankshaft seal (1) straight off the special tool 11 8 815 using a rotational movement until the crankshaft seal is positioned parallel on the timing case cover.

Remove the special tool 11 8 815.

Secure special tool 11 9 182 with special tool 11 9 184 on the crankshaft.

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Prepare special tool 11 9 181 for installation.

Attach special tool 2 360 215 to special tool 11 9 181.

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Retract the crankshaft sealing ring with special tools 11 9 181 and 2 360 215 in conjunction with special tool 11 9 183.

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Screw in crankshaft seal with special tool 11 9 183 to stop.

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Check O-ring (1) of coolant line (2) for damage.

In case the O-ring is faulty, the coolant line (2) needs to be replaced.

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Install coolant line (2).

Tighten down screws (1).

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Connect connector (1) to crankshaft sensor and lock.

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Position magnet wheel (1) on crankshaft.

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Concluding tasks: 

• Mount the OIL PAN .
• Mount the CYLINDER HEAD .
• Mount the FLYWHEEL .
• Remove engine from ASSEMBLY JIG .
• Install ENGINE WITH TRANSMISSION .