Removing and installing engine with transmission (B36 engine) (Cooper base): Notes

Special tools required:

32 1 270
13 5 160
13 5 162
00 9 030

IMPORTANT: When replacing the engine:
In all vehicles, the Digital Motor Electronics (DME) must possibly be reprogrammed/recoded after the replacement of the engine.
Read out I level of the vehicle and proceed accordingly.
It is mandatory to observe PuMA measure 62634754 .
For further information, see the appropriate BMW parts catalogue.

IMPORTANT: Insufficient motor oil can cause damage on the valve train when replacing the engine.
Ensure that you follow the REPAIR NOTES FOR CYLINDER HEAD OR ENGINE REPLACEMENT .

Recycling:

Catch and dispose of leakage fuel with auxiliary materials.

Observe country-specific waste disposal regulations.

IMPORTANT: Seal openings or lines on air conditioning with special tool 32 1 270 to prevent leakage of media and contamination.

Preliminary work needed:

Remove ACOUSTIC COVER .
REMOVE VEHICLE BATTERY .
REMOVE THE POWER DISTRIBUTION BOX WITH CONTROL UNIT SUPPORT .
Remove FRONT AXLE COMPLETELY .
Remove both output shafts. Refer to REMOVING AND INSTALLING/REPLACING LEFT OUTPUT SHAFT (COOPER) and REMOVING AND INSTALLING/REPLACING RIGHT OUTPUT SHAFT (COOPER) .
Remove STARTER MOTOR .
Drain off MOTOR OIL .
Remove CHARGE AIR COOLER .
Remove RADIATOR .

REMOVAL:

Release clamp (1).

Replace clamp (1).

Disconnect the exhaust system from the catalytic converter.

Parts : Clamp.

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Vehicles with manual transmission:

Disconnect plug connection (2) on gear sensor.

Detach cable (1) with holder from transmission.

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Vehicles with manual transmission:

NOTE: Pressure line of clutch slave cylinder remains connected.

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IMPORTANT: Slowly relieve tension on clutch slave cylinder otherwise air may be drawn in through sealing sleeve.
If possible, do not deflect push rod of clutch slave cylinder.
A deflection of the push rod caused by removal will cause easy leakage of fluid. This leakage of fluid does not mean that the clutch slave cylinder is damaged.
Exchange is therefore not necessary.

Release nuts (1) and remove clutch slave cylinder.

Unscrew nuts (1).

Disconnect positive battery terminal (2) and auxiliary terminal for jump starting (3).

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Slacken screw (1) and remove ground cable from engine block.

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Unlock and disconnect the connector (1).

Disconnect wiring harness (2) from engine wiring harness.

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Detach the wiring harness at the clips (1) from the battery tray (4).

Detach the coolant hose (2) from the battery tray (5).

Loosen screws (3).

Remove battery tray (4).

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Release coolant hose (1) and detach connecting bracket.

The intake plenum will be removed for purposes of clarity.

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Release clamp (1).

Pull hose (2) off connecting pipe (3).

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Release vacuum line (1) connection and disconnect.

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Vehicles with manual transmission:

Release fixtures on stop/holder (2).

Detach selector lever cables (3) at ball joints.

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Vehicles with automatic transmission:

Unlock and disconnect the connector (1).

Release fixtures on stop/holder (2).

Detach selector lever cable (3) at ball joint.

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Slacken screw (1) and remove ground strap (2).

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Disconnect fuel line (1).

Catch and dispose of leakage fuel.

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Seal fuel lines with special tools 13 5 160 and 13 5 162.

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Unlock coolant line (1) and detach.

Detach coolant line (1) from front end.

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Unscrew the screws (2).

Remove refrigerant lines (3).

Installation note:

Replace sealing rings.

Use special tool 00 9 030 to mount sealing rings without damaging them.

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NOTE: The stands (40/50) of table top A of the mobile table lift must be seated in the mounting points (1).

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Vehicle with manual gearbox:

Prepare MOBILE TABLE LIFT :

NOTE: Position engine assembly on table top A .
Position transmission on table top B .

Structure of table lift.

Position stand (30) with stand (40) for engine block on table top A at coordinates 5/6 and 1/7 (1).

Position the stand (30) with stand (50) for the oil sump on table top A at coordinates 5/3 and 2/3 (2).

Position stand (30) with stand (80) for transmission housing on table top B at co-ordinates 6/5 , 2/5 and 2/7 (3).

Position stand (83 30 2 357 221) for transmission housing on table top B at co-ordinates 7/3 (4).

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Vehicle with automatic transmission:

Prepare MOBILE TABLE LIFT :

NOTE: Position engine assembly on table top A .
Position transmission on table top B .

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Structure of table lift.

Position stand (30) with stand (40) for engine block on table top A at coordinates 5/5 and 2/6 (1).

Position the stand (30) with stand (50) for the oil sump on table top A at coordinates 4/2 and 2/3 (2).

Position stand (30) with stand (80) for transmission housing on table top B at co-ordinates 9/6 , 7/6 and 8/2 (3).

Position stand (83 30 2 357 221) for transmission housing on table top B at co-ordinates 6/3 (4).

IMPORTANT: Removal weight approx. 150 kg to 300 kg.
Check payload of the car, if applicable unload.
Load front footwell with sandbags if necessary, approx. 100 kg.
Note safety instructions of TABLE LIFT .

Vehicles with manual transmission:

Position table lift under the engine.

Abut all stands and screw to the table lift.

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Vehicles with manual transmission:

Screw stand (83 30 2 357 221) to the housing for the clutch slave cylinder.

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Vehicles with automatic transmission:

Position table lift under the engine.

Abut all stands and screw to the table lift.

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Vehicles with automatic transmission:

Screw stand (83 30 2 357 221) to the transmission housing with screw (1).

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Unscrew the screws (1).

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Release screw connection (1) of right engine mount.

Carefully raise the vehicle.

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Loosen transmission.

Vehicles with automatic transmission, refer to REMOVING AND INSTALLING TRANSMISSION (AISIN F21FT)
Vehicles with manual transmission, refer to REMOVING AND INSTALLING TRANSMISSION (GS6-58BG) .

Slide table top B in arrow direction and remove transmission.

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Attach workshop crane and lift engine from lifting table.

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INSTALLATION:

Vehicles with manual transmission:

Prepare MOBILE TABLE LIFT :

NOTE: Position engine assembly on table top A .
Position transmission on table top B .

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Structure of table lift.

Position stand (30) with stand (40) for engine block on table top A at coordinates 5/6 and 1/7 (1).

Position the stand (30) with stand (5) for the oil sump on table top A at coordinates 5/3 and 2/3 (2).

Position stand (30) with stand (80) for transmission housing on table top B at co-ordinates 6/5 , 2/5 and 2/7 (3).

Position stand (83 30 2 357 221) for transmission housing on table top B at co-ordinates 7/3 (4).

Vehicle with automatic transmission:

Prepare MOBILE TABLE LIFT :

NOTE: Position engine assembly on table top A .
Position transmission on table top B .

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Structure of table lift.

Position stand (30) with stand (40) for engine block on table top A at coordinates 5/5 and 2/6 (1).

Position the stand (30) with stand (50) for the oil sump on table top A at coordinates 4/2 and 2/3 (2).

Position stand (30) with stand (80) for transmission housing on table top B at co-ordinates 9/6 , 7/6 and 8/2 (3).

Position stand (83 30 2 357 221) for transmission housing on table top B at co-ordinates 6/3 (4).

Vehicles with manual transmission:

Place engine on table lift.

Mount TRANSMISSION ON ENGINE .

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Vehicles with manual transmission:

Screw stand (83 30 2 357 221) to the housing for the clutch slave cylinder.

Lower vehicle.

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Vehicles with automatic transmission:

Place engine on table lift.

Mount TRANSMISSION ON ENGINE .

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Vehicles with automatic transmission:

Screw stand (83 30 2 357 221) to the transmission housing with screw (1).

Lower vehicle.

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Position table lift with engine and transmission under the vehicle.

Carefully lower the vehicle.

Tighten screws (1) on transmission carrier.

Tightening torque 22 32 1AZ .

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Tighten screws (1) on right engine mount.

Tightening torque 22 11 1AZ .

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Join refrigerant lines (3) to compressor.

Tighten down screws (2).

Tightening torque 64 53 4AZ .

Installation note:

Replace sealing rings.

Use special tool 00 9 030 to mount sealing rings without damaging them.

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Connect and lock coolant line (1).

Route coolant line (1) correctly in the front end.

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Remove special tools 13 5 160 and 13 5 162.

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Connect fuel line (1).

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Position ground strap (2) and tighten screw (1).

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Vehicles with manual transmission:

Attach selector lever cables (3) at ball joints.

Fasten stop/holder (2) with clips.

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Vehicles with automatic transmission:

Connect the connector (1).

Attach clip at stop/holder (2).

Attach selector lever cable (3) to ball joint.

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Connect vacuum line (1).

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Connect hose (2) to connecting pipe (3).

Fasten clamp (1).

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Place coolant hose (1) on connecting bracket and lock.

The intake plenum will be removed for purposes of clarity.

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Join wiring harness (2) and engine wiring harness.

Connect the connector (1).

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Connect positive battery terminal (2) and auxiliary terminal for jump starting (3).

Tighten down nuts (1).

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Secure ground cable (2) with screw (1).

NOTE: Position ground cable correctly in holder.

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Install battery tray (4) and secure with screws (3).

Attach coolant line (2) to battery tray (4).

Secure the wiring harness to the battery tray (4) with clips (1).

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Vehicles with manual transmission:

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Carefully insert clutch slave cylinder and tighten nuts (2).

Tightening torque 21 52 1AZ .

Vehicles with manual transmission:

Connect connector (2) of neutral gear sensor.

Fasten cable (1) with holder on transmission.

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Slide the exhaust system onto the catalytic converter.

Tighten clamp (1).

Tightening torque 18 20 1AZ .

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Required reworking:

Install RADIATOR .
Install CHARGE AIR COOLER .
Install both output shafts. Refer to REMOVING AND INSTALLING/REPLACING LEFT OUTPUT SHAFT (COOPER) and REMOVING AND INSTALLING/REPLACING RIGHT OUTPUT SHAFT (COOPER) .
Install STARTER MOTOR .
Install FRONT AXLE COMPLETELY .
Top up MOTOR OIL .
Install the POWER DISTRIBUTION BOX WITH THE CONTROL UNIT SUPPORT .
Install VEHICLE BATTERY .
Install ACOUSTIC COVER .

When replacing the engine, the I level must be possibly coded and programmed.

Connect diagnosis system and follow the diagnosis instructions.
Service functions
Drive
Engine electronics
Reset VANOS adaptation values
Code and program I level if necessary