32 Reconnect the wire to the temperature
gauge sender unit.
33 Refit the heater hose to the heater valve
then tighten the heater hose and the bypass
hose retaining clips.
34 Refer to Chapter 4C and reconnect the
exhaust front pipe and, on Cooper S models,
the inlet and exhaust manifolds.
35 Refit the radiator upper support bracket.
36 Refit the ignition coil and bracket and
reconnect the wiring.
37 Refit and secure the radiator top hose.
38 Refer to Chapter 4A and refit the
carburettor(s).
39 Refer to Section 4 and adjust the valve
clearances then refit the rocker cover, HT
leads and associated components.
40 Reconnect the battery then refill the
cooling system as described in Chapter 1. If
removed, refit the bonnet, referring to
Chapter 11 if necessary.
8 Cylinder head (fuel injection
engines) - removal and
refitting
3
Note: Observe the precautions in Section 1 of
Chapter 4B before working on any component
in the fuel system.
Removal
1 Disconnect the battery negative lead. For
improved working clearance, remove the
bonnet as described in Chapter 11.
2 Drain the cooling system as described in
Chapter 1.
3 Release the fasteners and remove the
ignition cover from the front of the engine.
4 Refer to Chapter 4B and remove the air
cleaner assembly.
5 Chock the rear wheels then jack up the
front of the car and support it on axle stands
(see “Jacking and vehicle support”).
6 Working from underneath the car, slacken
and remove the single bolt securing the
exhaust front pipe to its mounting bracket on
the transmission. Undo the three nuts
securing the front pipe to the manifold, then
disconnect it and recover the gasket.
7 Trace the wiring back from the exhaust
system lambda sensor (which is screwed into
the exhaust manifold), releasing it from any
relevant cable-ties, and disconnect its wiring
connector from the main harness.
8 Lower the car to the ground.
9 Undo the bolt and remove the retaining clip
securing the injector housing fuel pipes to the
bulkhead.
10 Bearing in mind the information contained
in Chapter 4B, Section 6 on depressurising
the fuel system, using an open-ended
spanner to retain each adapter, slacken the
union nuts and disconnect the feed and return
pipes from the throttle body assembly. Plug
each pipe and adapter, to minimise the loss of
fuel and prevent the entry of dirt into the
system.
11 Release the retaining clips and disconnect
the wiring connectors from the injector
housing, the throttle potentiometer and the
stepper motor. Free the wiring from any
relevant retaining clips, and position it clear of
the throttle body assembly.
12 Slacken the accelerator cable locknuts,
and free the outer cable from its mounting
bracket. Release the inner cable from the
throttle cam, and position the cable clear of
the throttle body.
13 On automatic transmission models,
disconnect the governor control rod from the
throttle body linkage.
14 Disconnect the two vacuum hoses from
the rear of the inlet manifold, noting their
correct fitted positions; note that the hoses
are colour-coded for identification purposes.
15 Undo the union bolt securing the brake
servo vacuum hose to the inlet manifold, and
recover the hose union sealing washers.
16 Slacken the retaining clips and disconnect
the coolant hoses from the left-hand side of
the inlet manifold.
17 Slacken the clips securing the radiator top
hose to the thermostat housing and radiator,
and remove the hose.
18 Undo the radiator upper mounting bracket
retaining bolts, and remove the bracket from
the side of the cylinder head and radiator.
19 Release the retaining clip(s), and
disconnect the two vacuum/breather hoses
from the left-hand end of the cylinder head,
and the single hose from the right-hand end of
the head (see illustrations).
20 Undo the nut securing the ignition coil to
the front of the cylinder head, then release the
coil from its mounting stud and position it
clear of the cylinder head (see illustration).
21 Make a note of the correct fitted positions
of the HT leads, and disconnect them from
the spark plugs.
22 Remove the cylinder head assembly as
described in paragraphs 13 to 18 of Section 7,
noting that it will be necessary to disconnect
the wiring connectors from the PTC heater
and coolant temperature sensor (situated on
the underside of the inlet manifold) as they
become accessible.
Preparation for refitting
23 Refer to Section 7, paragraphs 19 to 22.
Refitting
24 Refit the cylinder head as described in
Section 7, not forgetting to reconnect the PTC
heater and coolant temperature sensor wiring
connectors as the head assembly is lowered
into position on the cylinder block.
25 The remainder of the refitting process is a
direct reversal of the removal procedure,
noting the following points:
a) Ensure that all pipes/hoses are correctly
reconnected, and (where necessary) are
securely held in position by their retaining
clips.
c) Tighten all nuts and bolts to the specified
torque setting (where given).
d) Position a sealing washer on either side of
the brake servo vacuum hose union, and
tighten the union bolt securely.
e) Refill the cooling system as described in
Chapter 1
f) On completion, reconnect the battery,
and adjust the accelerator cable as
described In Chapter 4B.
9 Crankshaft oil seals -
renewal
3
Front (timing cover) oil seal
1 Remove the timing cover as described in
Section 5, paragraphs 1 to 6 and 8 to 11.
2 Thoroughly clean the timing cover with
Engine in-car repair procedures 2A•9
2A
8.19a Disconnect the two vacuum/
breather hoses from the left-hand end of
the cylinder head . . .
8.19b . . . and the single hose from the
right-hand end
8.20 Remove the nut and release the
ignition coil bracket
To Next Page
Loading...