3 Engine/transmission -
removal and refitting
3
Removal
1 Disconnect the battery negative lead.
2 Drain the cooling system and the
engine/transmission oil as described in
Chapter 1.
3 Remove the bonnet and front grille as
described in Chapter 11.
4 On models equipped with an ignition shield
mounted on the front of the engine, release
the three retaining lugs and lift off the shield.
5 On carburettor engines, refer to Chapter 4A
and remove the air cleaner assembly and
carburettor(s). On fuel injection engines,
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.
6 On fuel injection engines, remove the
engine management ECU as described in
Chapter 4B.
7 Remove the starter motor and alternator as
described in Chapter 5A.
8 Where applicable, undo and remove the
screws securing the starter solenoid to the
inner wing panel and position the solenoid
clear of the engine.
9 On models equipped with a mechanical fuel
pump, disconnect the fuel inlet hose and plug
it with a suitable bolt or metal rod to prevent
loss of fuel.
10 On fuel injection engines, undo the bolt
and remove the retaining clip securing the
injector housing fuel pipes to the bulkhead.
Bearing in mind the information contained in
Chapter 4B, Section 6, concerning
depressurisation of 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 Where applicable, disconnect the cooling
system hose from the expansion tank, which
is located by the side of the radiator. Undo the
retaining bolt and remove the expansion tank
from the engine compartment.
12 On carburettor engines, slacken the
retaining clips and remove the two heater
hoses. Also slacken the two securing screws
and withdraw the heater control cable from
the valve on the cylinder head (where
applicable). On fuel injection engines, Undo
the heater control coolant valve mounting
bolt, then slacken the retaining clips and
disconnect the coolant valve hoses from the
manifold and thermostat housing. Slacken the
clip and disconnect the heater unit hose from
its union with the bottom radiator hose
(situated directly below the coolant valve).
13 If a fresh air heater/demister blower motor
is mounted in the engine compartment,
remove this unit as described in Chapter 3.
14 Undo and remove the two nuts and bolts
on the clamp, or the three flange nuts
securing the exhaust front pipe to the
manifold. Separate the front pipe from the
manifold. Note: On Cooper S models it will be
necessary to remove the complete exhaust
system as described in Chapter 4C.
15 If the horn is mounted on the front body
panel, disconnect the electrical leads, undo
and remove the mounting bolts and withdraw
the horn.
16 From beneath the right-hand front wing
detach the heater fresh air ducting from the air
inlet. Now withdraw the air inlet from the inner
wing panel.
17 Disconnect the wiring from the following
locations, after identifying the leads or wiring
plugs for subsequent reconnection:
a) Leads to the temperature gauge
transmitter and oil pressure switch (where
fitted).
b) LT leads at the ignition coil.
c) HT leads from the spark plugs and
ignition coil, and the crankshaft sensor
wiring connector on fuel injection
engines.
d) On fuel injection engines, 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. 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.
e) Wiring connectors from the auxiliary
cooling fan switch (where fitted), which is
situated at the front bottom corner of the
radiator.
18 Spring back the distributor cap retaining
clips, or undo the two screws and remove the
cap and leads. Remove the rotor arm from the
distributor shaft.
19 On manual transmission models, release
the clutch slave cylinder return spring from the
clutch operating lever. Undo and remove the
two securing bolts and lift the slave cylinder
off the flywheel housing. Tie the cylinder out
of the way from a convenient place on the
engine bulkhead.
20 If an oil pressure gauge is fitted, slacken
the clamp screw and pull the rubber hose off
the feed pipe at the rear of the engine.
21 On fuel injection engines, release the
retaining clip and disconnect the vacuum
hose from the pipe situated just behind the
thermostat housing. 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.
22 On later models, disconnect the oil
separator breather hose from the right-hand
end of the cylinder head. Undo the two bolts
securing the separator to the flywheel housing,
and remove the separator and hose assembly
from the engine, along with its gasket.
23 Undo and remove the bolt securing the
engine tie-bar to the side of the cylinder
block. Slacken the tie-bar bulkhead mounting
and move the bar back out of the way. Note
that on later models the tie-bar retaining bolt
also retains the engine earth strap.
24 Where fitted, remove the oil cooler as
described in Part A of this Chapter.
25 On models fitted with a vacuum servo unit
mounted in the engine compartment, refer to
Chapter 9 and remove the servo and brake
master cylinder. Unscrew the two union nuts
securing the master cylinder brake pipes to
the pressure-reducing valve, and remove both
the pipes, noting their correct fitted positions.
Plug the pressure reducing valve ports, to
minimise fluid loss and prevent the entry of
dirt into the system.
26 Working under the front wheel arch undo
and remove the screw securing the upper
suspension arm rebound rubber to the
subframe and withdraw the rubber. Place a
solid wooden wedge of approximately the
same thickness in its place. Repeat this
procedure on the other side of the car.
27 Chock the rear wheels then jack up the
front of the car and support it on axle stands
(see “Jacking and vehicle support”). Remove
the front roadwheels.
28 On manual transmission models fitted
with a direct engagement gear lever, undo
and remove the retaining screws and lift off
the interior rubber boot retaining plate. Now
slide the rubber boot up the gear lever slightly.
From under the car, undo and remove the two
bolts securing the gear lever retaining plate to
the rear of the differential housing. Withdraw
the gear lever into the car and lift out the anti-
rattle spring and plunger from the gear lever
housing.
29 On manual transmission models fitted
with the early type remote control extension
housing, undo and remove the four
shouldered bolts securing the housing to the
mounting on the rear of the differential
assembly. Pull the front of the extension
housing downwards to disengage the linkage
and then support the front of the housing on a
block of wood.
30 On manual transmission models fitted
with the later rod-change type remote control
extension housing, drift out the roll pin
securing the collar of the remote control
extension rod to the selector shaft. Undo and
remove the bolt securing the fork of the
steady rod to the differential housing. Release
the extension rod and the steady rod from the
rear of the transmission.
31 On automatic transmission models,
disconnect the gear selector cable from the
transmission as described in Chapter 7B,
Section 6.
32 On early models undo and remove the
bolt securing the engine earth strap to the
flywheel/torque converter housing.
Engine removal and overhaul procedures 2B•5
2B
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