A MINI (R53 Cooper S) Adventure
Discussion
tallpaul26 said:
Todays small step forward was replacing the fuel filter. The internet warns of petrol going everywhere and being blinded in the process. As this MINI has had its battery disconnected and been nose up for over a week I think the pressure in the fuel line had dissipated sufficiently to prevent hosing VPower all over myself!
A bit of fuel spillage is unavoidable when pulling out the filter itself, but plenty of paper towel caught the worst. Suffice to say it was pretty minging; well worth the effort to change!
Nice work!A bit of fuel spillage is unavoidable when pulling out the filter itself, but plenty of paper towel caught the worst. Suffice to say it was pretty minging; well worth the effort to change!
On the petrol point, I wouldn't worry too much about using V-Power. I tracked a highly modified R53 (17% pulley, cam, injectors, map) using boggo Sainsbury's 97 Super, and never once suffered any ill effects.
No photos, busy week with little time to make progress. Not being able to work on the car has given me time to overthink ‘fixing’ things.
My coolant expansion tank had failed so certainly needed fixing, but this has now precipitated the following:
- complete system drain and flush to allow red coolant to be replaced with correct G48
- rad looked a bit grotty so replaced that
- rad top hose had seen better days. New one ordered (both parts). Bottom hose too for good measure
- decided I may as well swap the thermostat and housing for good measure
- hmmm looks like bit of a weep on the hose between the ‘stat and water pump. New one of those too. May as well change the water pump and flange while I’m in the area!
My coolant expansion tank had failed so certainly needed fixing, but this has now precipitated the following:
- complete system drain and flush to allow red coolant to be replaced with correct G48
- rad looked a bit grotty so replaced that
- rad top hose had seen better days. New one ordered (both parts). Bottom hose too for good measure
- decided I may as well swap the thermostat and housing for good measure
- hmmm looks like bit of a weep on the hose between the ‘stat and water pump. New one of those too. May as well change the water pump and flange while I’m in the area!
Ok, picture time.
Firstly, the thermostat. Having removed the airbox, ECU, and MAF, the stat housing is easy to remove. But what’s this I see? Black mastic
At least it cleaned up nicely ready for the new stat and housing to go on later:
Next I tackled the water pump. I really couldn’t be arsed with taking off the supercharger, luckily it wasn’t too bad once I’d wangled the inlet pipe out of the way (new gasket going on there before reassembly).
The pump looked ok but the flange to the block was well passed it’s best. Cleaned up the mating face and both pump and flange are being replaced:
I think (hope)I’m at the point where I can stop taking it apart
got a couple of days off work next week earmarked for putting it all back together. I may even get to drive it next week!
Firstly, the thermostat. Having removed the airbox, ECU, and MAF, the stat housing is easy to remove. But what’s this I see? Black mastic
At least it cleaned up nicely ready for the new stat and housing to go on later:
Next I tackled the water pump. I really couldn’t be arsed with taking off the supercharger, luckily it wasn’t too bad once I’d wangled the inlet pipe out of the way (new gasket going on there before reassembly).
The pump looked ok but the flange to the block was well passed it’s best. Cleaned up the mating face and both pump and flange are being replaced:
I think (hope)I’m at the point where I can stop taking it apart
got a couple of days off work next week earmarked for putting it all back together. I may even get to drive it next week! C70R said:
You're doing all the right things to set yourself up for a hassle-free ownership experience. Minis, as with many older cars, have a reputation for being troublesome because people simply don't bother to do maintenance like this until stuff fails.
Cheers. I knew it would need work and I wanted a project. Luckily, it's a relatively simple car to work on but nothing is quick to do - i'm fortunate to have space to do so, if it was out on the driveway in recent weather none of this would be getting done!Thermostat, housing, water pump and flange all replaced!
The pump put up a fight and no matter what way I contorted it, the flange o-ring would not seat preventing lining up the pump head. This went on for a good while over two sittings; I’d nearly reached the point of removing the supercharger when I thought I’d try a different o-ring. When I ordered the pump and flange it wasn’t abundantly clear if they would come with 1 or both of the o-rings I’d need, so I ordered a spare just in case. As it happened, both were there so the spare remained just that. However, no amount of swearing was getting the pump to flange o-ring to seat. Having had the bright idea of trying the spare, lo and behold the pump slipped straight in!!!
Subsequently, I also lost an hour of my life sorting a snapped bolt on the AC condenser return hose fitting. Still, at least now the path is clear for refilling the coolant tomorrow and maybe (maybe) even driving it!
The pump put up a fight and no matter what way I contorted it, the flange o-ring would not seat preventing lining up the pump head. This went on for a good while over two sittings; I’d nearly reached the point of removing the supercharger when I thought I’d try a different o-ring. When I ordered the pump and flange it wasn’t abundantly clear if they would come with 1 or both of the o-rings I’d need, so I ordered a spare just in case. As it happened, both were there so the spare remained just that. However, no amount of swearing was getting the pump to flange o-ring to seat. Having had the bright idea of trying the spare, lo and behold the pump slipped straight in!!!
Subsequently, I also lost an hour of my life sorting a snapped bolt on the AC condenser return hose fitting. Still, at least now the path is clear for refilling the coolant tomorrow and maybe (maybe) even driving it!
Things that are a pain on R53’s - part 23: refitting the supercharger inlet pipe. My top tips for anyone attempting this are 1) put the new green gasket over the ‘charger inlet first. 2) completely remove the short hose between the pipe and bypass valve and soak in boiling hot water to soften the rubber.
With that done all the other myriad bits of engine went back together painlessly. All that remained was to refill with coolant and bleed it. This took forever. There are various guides online describing the need for patience, ceremonially opening and closing bleed valves and reciting ancient incantation’s. All of these and more were required.
The way to tell if you’ve had success at filling the system is whether the cabin blowers will produce hot air when the engines warm. This took forever. Just when I was convinced the heater matrix had got blocked the last of the air miraculously began pouring out of the rad top hose bleed valve and hot cabin air resulted. Hallelujah!
In other good news, I now have working power steering. Both stages of the cooling fan work too!
In bad news I still have a rattle from the left of the engine. The cheapest and simplest cause would be the timing chain tensioner. So I’ve ordered one and crossed my fingers!
With that done all the other myriad bits of engine went back together painlessly. All that remained was to refill with coolant and bleed it. This took forever. There are various guides online describing the need for patience, ceremonially opening and closing bleed valves and reciting ancient incantation’s. All of these and more were required.
The way to tell if you’ve had success at filling the system is whether the cabin blowers will produce hot air when the engines warm. This took forever. Just when I was convinced the heater matrix had got blocked the last of the air miraculously began pouring out of the rad top hose bleed valve and hot cabin air resulted. Hallelujah!
In other good news, I now have working power steering. Both stages of the cooling fan work too!
In bad news I still have a rattle from the left of the engine. The cheapest and simplest cause would be the timing chain tensioner. So I’ve ordered one and crossed my fingers!
Edited by tallpaul26 on Monday 20th March 16:51
Good luck with the tensioner. It's the single worst bolt on the entire engine, no good angle on it full stop. Realistically, you'll just have to do it from above & put up with the five or so degrees of arc available & a boat load of patience. If you have a decent ratchet with more pawls than the usual Halfords gear then reach for that one.
Edited by President Merkin on Tuesday 21st March 09:01
We’re on a roll…
Mobile AC guy returned today to gas up the system. He kindly directed me on the correct way to fit the condenser without wrecking the dryer (ie don’t leave it exposed to atmosphere for too long whilst plumbing it in nor have it plumbed without immediately gassing).
Shiny:
Now, the moment of truth. Will it hold pressure???
Boom! Not only does it hold pressure, the AC actually works very effectively! It’s fair to say both he and I were surprised at this result. We were both fully expecting there to be another leak somewhere else. Proper chuffed!
Mobile AC guy returned today to gas up the system. He kindly directed me on the correct way to fit the condenser without wrecking the dryer (ie don’t leave it exposed to atmosphere for too long whilst plumbing it in nor have it plumbed without immediately gassing).
Shiny:
Now, the moment of truth. Will it hold pressure???
Boom! Not only does it hold pressure, the AC actually works very effectively! It’s fair to say both he and I were surprised at this result. We were both fully expecting there to be another leak somewhere else. Proper chuffed!
At this point I may be talking to myself but never mind…
As the car was now back in one piece and not obviously weeping any vital fluids I decided to take it out for a shakedown. Steady stuff to start with, get it up to temperature, make sure nothing fell off or that no warning lights appeared.
All seemed well so, I headed out to an NSL section of road for further proving. Pulled nice and smoothly right through the gears, no knocks or rattles and still appeared to have its structural integrity. At this point I should have turned for home but I wanted to see how she handled and just how bad the ditch finders were so my driving turned a little spirited. Much fun was had but a meeting was looming so I turned for base. Moved from an NSL to 30 section and to a roundabout, ah no brake pedal!
Fortunately I had been engine braking for a while and the roundabout was clear so no death or destruction ensued. I was able to pump the pedal back up and nursed myself home.
A quick once over suggested no obvious leak. Possibly a bit of a whiff of cooked fluid but the reservoir was full. Not wanting to piss about with a critical safety system, I called my local Indy for a second opinion. They duly stuck it on their ramp and diagnosed a stuck rear calliper. The fluid was toast anyway so for the price of a calliper I’m not too upset. As all the callipers are a bit crusty I had half thought of a full brake refurb at some point anyway…
As the car was now back in one piece and not obviously weeping any vital fluids I decided to take it out for a shakedown. Steady stuff to start with, get it up to temperature, make sure nothing fell off or that no warning lights appeared.
All seemed well so, I headed out to an NSL section of road for further proving. Pulled nice and smoothly right through the gears, no knocks or rattles and still appeared to have its structural integrity. At this point I should have turned for home but I wanted to see how she handled and just how bad the ditch finders were so my driving turned a little spirited. Much fun was had but a meeting was looming so I turned for base. Moved from an NSL to 30 section and to a roundabout, ah no brake pedal!
Fortunately I had been engine braking for a while and the roundabout was clear so no death or destruction ensued. I was able to pump the pedal back up and nursed myself home.
A quick once over suggested no obvious leak. Possibly a bit of a whiff of cooked fluid but the reservoir was full. Not wanting to piss about with a critical safety system, I called my local Indy for a second opinion. They duly stuck it on their ramp and diagnosed a stuck rear calliper. The fluid was toast anyway so for the price of a calliper I’m not too upset. As all the callipers are a bit crusty I had half thought of a full brake refurb at some point anyway…
Definitely not talking to yourself - loving the updates.
Nice to see you’re ticking off all the default R53 issues. Stuck rear calliper is up there in the top 5 somewhere.
Wait until you have to drive miles home with no clutch pedal, on a route with traffic lights and single-track bridge crossings. Ask me how I know
Nice to see you’re ticking off all the default R53 issues. Stuck rear calliper is up there in the top 5 somewhere.
Wait until you have to drive miles home with no clutch pedal, on a route with traffic lights and single-track bridge crossings. Ask me how I know
President Merkin said:
Good luck with the tensioner. It's the single worst bolt on the entire engine, no good angle on it full stop. Realistically, you'll just have to do it from above & put up with the five or so degrees of arc available & a boat load of patience. If you have a decent ratchet with more pawls than the usual Halfords gear then reach for that one.
Youtooob suggests long breaker bar and a flexi will do it. We shall see! Edited by President Merkin on Tuesday 21st March 09:01
Strongly advise using a six point socket too, It's a bolt with little purchase in an inaccesible location & you absolutely don't want to round it off. On the brakes, this may be an opportune moment to upgrade the front calipers to R56. I think it's been mentioned before in the thread as a worthwhile change, they''re much more powerful than the stock R53 ones & bolt straight on with the addition of the newer caliper carrier bracket.
President Merkin said:
Strongly advise using a six point socket too, It's a bolt with little purchase in an inaccesible location & you absolutely don't want to round it off. On the brakes, this may be an opportune moment to upgrade the front calipers to R56. I think it's been mentioned before in the thread as a worthwhile change, they''re much more powerful than the stock R53 ones & bolt straight on with the addition of the newer caliper carrier bracket.
Cheers, I popped my phone down the back of the block to see what I was dealing with before I ordered the part. They certainly weren’t generous with the mating surface for a socket! 
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