Engine - Rattling Noise On Cold Start Up/Short Drives
SI M11 02 07Engine
September 2012
Technical Service
This Service Information bulletin supersedes SI M11 02 07 dated May 2012.
[NEW] designates changes to this revision
SUBJECT
Rattle Noise from Engine
MODEL
R55 Cooper S with N14 engine
R56 Cooper S with N14 engine
[NEW] R57 Cooper S with N14 engine
From start of production up May 4, 2009
SITUATION
The customer complains of a rattle noise from the engine.
^ During cold start-up: most often at the 1,600-1,800 rpm range, or in some instances (elongated timing chain) from the idle speed up to 2,000 rpm.
^ The rattle noise occurs more frequently when driving short distances.
^ The noise is more prevalent when the outside temperature is approximately 15° Celsius (59° Fahrenheit) or below.
CAUSE
The complaint can be caused by one or both of the following reasons:
^ Insufficient tension of the timing chain
^ The chain tensioner has not been bled sufficiently.
PROCEDURE
Work through the following procedure in order to eliminate other possible causes:
1. If a fault is stored in the DME memory (e.g., misfiring, VANOS, etc.), then work through all relevant test plans first.
Note: When the ISTA system message displays:
Battery voltage only "XX.XX" V. Please connect charger.
Please note the displayed battery voltage reading in the repair order comments section.
2. A one-off short shrill will be heard within the first two seconds of engine operation. This is an inherent noise caused by the first regulation cycle of the engine oil pump. This is normal operation and no parts should be replaced.
3. If the noise appears to be coming from the valve cover or the vacuum pump area, refer to SI M11 02 08. To verify the source of the noise, disconnect the vacuum hose from the mechanical vacuum pump to eliminate the knocking noise. This is not a failure of the mechanical vacuum pump; do not replace any parts.
4. Ensure that the noise is not created or eliminated by depressing the clutch pedal, if equipped.
5. Disconnect the electrical connector from the tank ventilation valve. If the noise disappears when the connector is removed, reconnect to verify whether the noise returns. If the noise returns, replace the tank ventilation valve.
If all of the steps above are unsuccessful in eliminating the noise, please proceed to step 6.
6. Remove the right-hand wheel arch trim to access the crankshaft central bolt.
7. Disconnect the battery and remove the ignition coils and the spark plugs. Turn the engine in the clockwise direction by hand to move the flywheel to approximately 90 before TDC. Rotating the engine counterclockwise may cause an incorrect measurement.
8. Install the locating pin (Special Tool 11 9 590) to lock the position of the engine.
Note:
Do not remove the cylinder head cover! Do not install camshaft locking tool during this procedure. To achieve an accurate measurement, the camshafts need to rotate.
9. Remove the chain tensioner and collect the residual oil with a shop towel.
10. Fit the chain tensioner (Special Tool 11 9 340) without the seal ring and with the lock nut loose. Pretension the chain tensioner with Special Tool 00 9 250 to 0.6 Nm. Finger-tighten the lock nut on Special Tool 11 9 340.
Note:
Gently turn Special Tool 00 9 250 while applying the torque. Quickly rotating the tool will provide an inaccurate measurement result.
11. Remove the chain tensioner Special Tool 11 9 340 from the engine, with the lock nut still tight. Measure the distance (A), as described in the illustration.
12. [NEW] If distance A is less than 72 mm (and the noise can only be reproduced between 1,600-1,800 rpm), only replace the chain tensioner with P/N 11 31 7 607 551.
Discard the seal ring that was originally supplied with the new timing chain tensioner. Refer to Repair Instruction REP 11 31 090, "Installing and removing/replacing chain tensioner piston N14."
13. [NEW] If distance A is 72 mm or greater (and the noise is reproducible both at the 1,600-1,800 rpm range as well as at idle speed when cold), replace the components in the list below (refer to parts list B):
^ Guide rail
^ Tensioner rail
^ Sliding rail
^ Sprocket on the crankshaft
^ Bearing bolts for the tensioner and guide rails
If you are uncertain regarding repair attempts already made, each chain tensioner part number is stamped on the outer sleeve. It must be removed from the engine in order to read the part number.
[NEW] Install timing chain tensioner P/N 11 31 7 597 895 only!
Note:
P/N 11 31 7 607 551, Timing chain tensioner should not be installed with a new timing chain.
Refer to Repair Instruction REP 11 31 051 (Replacing timing chain N14).
Refer to the EPC for additional parts required, i.e., gaskets, seals, etc.
The incorrect crankshaft central bolt tightening torque is stated in the current release of ISTA. Disregard the torque specified in the current Repair Instructions when performing repairs that include replacing the crankshaft central bolt, P/N 11 21 7 585 184. The correct torque specification is described below.
Do not replace the hydraulic valve lifters (HVA), intake camshaft VANOS adjustment unit, or the exhaust camshaft sprocket for this type of noise. It is NOT necessary to obtain a Part Replacement Authorization (TeileClearing) for this specific issue. Refer to the Warranty section of this bulletin for more details.
14. [NEW] After completion of the repairs, reprogram the complete vehicle using the current ISTA/P version (ISTA/P 2.47.1 or higher; target integration level R056-12-07-503 or higher). The new DME calibration software includes optimized injection timing strategy, as well as an increased operating pressure, improving the injectors operation.
Note that ISTA/P will automatically reprogram and code all programmable control modules that do not have the latest software.
For information on programming and coding with ISTA/P, refer to Centernet / Aftersales Portal / Service / Workshop Technology / Vehicle Programming.
[NEW] PARTS INFORMATION
[NEW] WARRANTY INFORMATION