Removing and installing/replacing intermediate levers (B36 engine) (Cooper base)

Special tools required: 

• 2 359 088
• 11 6 480
• 11 4 480
• 2 359 089

Preliminary work needed: 

• Remove INTAKE PLENUM .
• Remove CYLINDER HEAD COVER .
• Remove FRONT RIGHT WHEEL ARCH COVER .

Removal: 

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Fix intake camshaft with an open-end wrench (1).

Release screw (2).

Remove sensor wheel (3).

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Slowly adjust eccentric shaft (1) to minimum stroke via servomotor using 4 mm Allen wrench (2).

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Position special tool 2 359 088 on torsion spring (1).

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Both torsion springs (1) on the left and right must be positioned in the lateral guide of special tool 2 359 088.

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Preload return spring with lever (1) on special tool 2 359 088 in arrow direction.

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Lock special tool 2 359 088 with catch on lever (1).

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Carefully lift special tool 2 359 088.

Feed special tool 2 359 088 with torsion spring (1) out of cylinder head (2).

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Secure stand (2) for clamping lever in vice.

Position clamping lever (1) with torsion spring in stand (2).

Carefully unlock and slowly open clamping lever (1).

Remove torsion spring.

Set down all torsion springs neatly in special tool 11 4 480.

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Release screw (1) of gate (2).

Place all gates (2) in neat order in special tool 11 4 480.

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Remove all intermediate levers (1).

Place all intermediate levers (1) in neat order in special tool 11 4 480.

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Installation: 

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Installation note: 

All intermediate levers are classified.

All intermediate levers must be reinstalled in the same positions in an engine which has already been in use.

Intermediate levers are classified from 1 to 5.

Only one classification may be fitted per engine.

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Insert all intermediate levers (1).

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Installation note: 

All contact surfaces (1) of gates must be clean and free from oil and grease. If necessary, clean contact surfaces (1).

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Mount gate (2) neatly.

Tighten screw (1) hand-tight.

Check that intermediate levers are in correct installation position.

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Position special tool 2 359 089 on the cylinder head.

Pre-tension the gate with the lever (3).

Abut the screw (1) in the area (2).

Make sure that the special tool 2 359 089 does not rotate during this process.

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Secure the gate with the lever (1) in the arrow direction.

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Press the special tool 2 359 089 onto the cylinder head.

Tighten the screw (1) at the same time.

Tightening torque 11 37 1AZ .

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Clamp special tool (2) in vice.

Engage torsion spring (3) in clamping lever (1).

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Both torsion springs (1) on the left and right must be positioned in the lateral guide of special tool 2 359 088.

Ensure correct engagement of clamping lever.

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Lift clamping lever (1) with torsion spring out of stand (2).

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Insert special tool 2 359 088 with torsion spring (1) into cylinder head (2).

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Engage torsion spring (2) in intermediate lever (1).

Check that all rocker arms (3) are in correct installation position.

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Clamping lever (1) must be lying flat on cylinder head.

Carefully unlock clamping lever (1).

Check torsion spring on intermediate lever to ensure correct installation position.

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Ensure correct position of torsion spring in recess on cylinder head.

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Fix intake camshaft with an open-end wrench (1).

Position sensor wheel (3).

Tighten down screw (2).

Tightening torque 11 31 2AZ .

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Required follow-up work: 

• Install FRONT RIGHT WHEEL ARCH COVER .
• Install CYLINDER HEAD COVER .
• Install INTAKE PLENUM .