MINI 2002-05

Engine

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NOTE
Disconnecting the negative battery cable on some vehicles may interfere with the functions of the on-board computer systems and may require the computer to undergo a relearning process.

Removal & Installation



Cooper Coupe
  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Disconnect the battery and battery container.
  4.  
  5. Properly relieve the fuel system pressure.
  6.  
  7. Remove or disconnect the following:

    Front bumper cover
     
    Bumper bracket
     
    Air cleaner housing
     
    Clutch cylinder
     
    Top stabilizer bar bracket
     
    Exhaust manifold with catalytic converter
     
    Both driveshafts
     
    Auxiliary drive belts
     

  8.  
  9. Drain the cooling system.
  10.  
  11. Remove the upper engine hood support and install a special support tool, 51-2-160.
  12.  
  13. Loosen the retainers for the modular front end and insert bracing tools, 11-8-401/2, to provide access room.
  14.  
  15. Remove or disconnect the following:

    Coolant hoses
     
    Heater hoses
     
    Overflow hose
     

  16.  
  17. Release the fuel line (1), then plug the line opening.
    CAUTION
    Fuel may still be under pressure. Use caution when releasing any fuel lines. Prepare to catch fuel spillage.

  18.  
  19. Remove the starter heat shield.
  20.  
  21. Release the brake booster line connection at the booster by pressing downward on clip ring and pulling line upward.
  22.  
  23. Remove or disconnect the following:

    Plug connector from fuse box
     
    Fuse box (position aside)
     
    Grounding cable from left spring strut
     
    Circular connector (twist upper and lower halves in opposite directions)
     
    Transmission shift cables from retaining clips and ball connections
     
    Shift control housing
     
    Engine stabilizer brace
     
    Steering pump motor connector
     
    A/C compressor connector and 2 retaining bolts (position compressor aside)
     
    Both transmission brackets
     

  24.  
  25. Install a special holding tool, 11-8-352, on transmission as a lifting eye.
  26.  
  27. Install a special lifting tool, 11-8-351, on front of engine as a lifting eye.
  28.  
  29. Attach engine lifting equipment to lifting eyes.
  30.  
  31. Remove engine mount retaining nut and remove the engine.

    Click image to see an enlarged view

    Fig. Releasing the fuel line-Cooper Coupe models

  32.  

To install:

  1. Install in reverse of removal procedure.
  2.  
  3. Torque retainers to the following:

    Engine mount retaining nut: 50 ft. lbs. (68 Nm)
     
    Mount bracket to transmission bolts: 49 ft. lbs. (66 Nm)
     
    A/C compressor mounting bolts: 18 ft. lbs. (25 Nm)
     
    Engine stabilizer bar bolts: 74 ft. lbs. (100 Nm)
     
    Shift cable bracket bolt: 16 ft. lbs. (22 Nm)
     
    Ground cable at left strut: 7 ft. lbs. (9 Nm)
     

  4.  
  5. When engine is fully installed and assembled, refill transmission and cooling systems.

    Click image to see an enlarged view

    Fig. Showing location of engine stabilizer bar-Cooper Coupe models



    Click image to see an enlarged view

    Fig. Showing left transmission bracket-Cooper Coupe models



    Click image to see an enlarged view

    Fig. Showing right transmission bracket-Cooper Coupe models

  6.  

Cooper S Coupe
  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Install the intercooler protector, 11-8-480 to ensure intercooler is not damaged during engine removal and installation.
  4.  
  5. Disconnect the battery and battery container.
  6.  
  7. Properly relieve the fuel system pressure.
  8.  
  9. Remove or disconnect the following:

    Air cleaner housing
     
    Auxiliary drive belt
     

  10.  
  11. Drain the transmission.
  12.  
  13. Remove the lower engine stabilizer bar bracket bolts and remove the bracket.
  14.  
  15. Disconnect the steering pump motor connector.
  16.  
  17. Remove the crush tubes as follows:
    1. Remove the bumper and bumper carrier.
    2.  
    3. Remove the bolt securing the impact tube to the front end module.
    4.  
    5. Remove the bolts retaining the impact tube to the chassis subframe.
    6.  
    7. Remove the impact (crush) tube.
    8.  

  18.  
  19. Loosen the retainers for the modular front end and insert bracing tools, 11-8-401/2, to provide access room.
  20.  
  21. Remove or disconnect the following:

    Subframe
     
    Driveshafts
     
    Exhaust manifold
     
    Starter motor heat shield
     
    Starter motor connections
     
    Oil pressure connector
     
    Wiring harness from brackets on starter motor and cooling pipe (note routing for installation; move wiring harness aside)
     
    Reverse lamp connector from transaxle
     
    Intercooler
     
    Throttle valve
     
    Tank venting valve lower pipe from stabilizer bracket
     
    Fuel line from fuel rail (quick-disconnect fitting); plug openings
     
    Fusebox cover and connector from fusebox
     
    Grounding cable from left spring strut
     
    Circular connector (twist upper and lower halves in opposite directions)
     
    Drain cooling system
     
    Pipes from heater matrix
     
    Expansion tank pipes at heater pipe junction
     
    Upper radiator hose
     
    Top engine stabilizer bracket
     
    Clutch slave cylinder
     
    Transmission shift cables from retaining clips and ball connections and bracket
     
    A/C compressor connector and retaining bolts (position compressor aside)
     
    MAP sensor connector (near water housing)
     
    Coolant hose from water housing
     

  22.  
  23. Install a special lifting tools, 11-8-351 and 11-8-351, as a lifting eye.
  24.  
  25. Remove the supercharger inlet retaining bolt and release the hose clip.
  26.  
  27. Remove the supercharger inlet pipe to access and disconnect additional hose fittings.
  28.  
  29. Remove the brake booster pipe from the engine and the slave cylinder pipe from the transaxle (move aside).
  30.  
  31. Attach engine lifting equipment to lifting eyes.
  32.  
  33. Remove engine mount retaining nut and remove the engine.
  34.  
  35. Remove the transaxle-to-upper mount retaining bolt.
  36.  
  37. Lower and remove the engine.

    Click image to see an enlarged view

    Fig. Showing installed position of the intercooler protector-Cooper S Coupe models



    Click image to see an enlarged view

    Fig. Identifying location of engine mount retaining nut-Cooper S Coupe models



    Click image to see an enlarged view

    Fig. Identifying location of transaxle-to-upper mount retaining bolt-Cooper S Coupe models

  38.  

To install:

  1. Install in reverse of removal procedure.
  2.  
  3. Torque retainers to the following:

    Engine mount retaining nut: 50 ft. lbs. (68 Nm)
     
    Mount bracket to transmission bolts: 49 ft. lbs. (66 Nm)
     
    Coolant pipe to cylinder head: 18 ft. lbs. (25 Nm)
     
    A/C compressor mounting bolts: 18 ft. lbs. (25 Nm)
     
    Ground cable at left strut: 7 ft. lbs. (9 Nm)
     
    Starter motor to transaxle bolts: 63 ft. lbs. (85 Nm)
     
    Alternator connection on starter: 10 ft. lbs. (14 Nm)
     
    Starter motor heat shield bolts: 7 ft. lbs. (9 Nm)
     
    Crush tube to Subframe bolts: (165 Nm)
     
    Engine stabilizer bar bolts: 74 ft. lbs. (100 Nm)
     

  4.  
  5. When engine is fully installed and assembled, refill transmission and cooling systems.
  6.  

 
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