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2005 Mini R53 Works
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Discussion Starter #1
as mentioned in my "who are you" topic, I recently acquired a 2005 Mini R53 JCW. Since I got the Mini I started working on some well-known issues and give the Mini a bit of TLC .





The Mini equipped with new interior filter, spark plugs, Pipercross air filter and vacuum hoses fixed and checked. The Mini was getting better and better.

Until I suddenly heard a rattle in 5 km grow into a huge rattle in my engine. Conclusion Mini specialist, connecting rod bearing is out. what to do now ? Decided to refurbish the Mini together with the specialist and immediately tackle some pain points.

First started a search for a good engine. My R53 is a JCW ex works. In consultation decided to transfer the head to another bottom block. You will notice here in the Netherlands that there are now fewer parts for a 15-year-old Mini, but a good bottom block has been found.

schedule:

Disassemble the engine and have the head pressurized, flattened and fitted with new valve seals. And while it is still on the workbench equipped with a Newman PH1 camshaft.



The Mini has run 109 thousand kilometers, so immediately provided the compressor with new oil.

A whole mountain of new parts has now been ordered:
OEM piston rings;
CR4600XP STDX King Racing connecting rod bearings;
new valve seals;
new gaskets;
new rubbers for all sensors etc;
new water pump
compresssor service kit from the UK;

also decided to replace all ball joints and wishbone rubbers (powerflex PU), everything goes loose anyway.

clutch was replaced 1000km ago so it can still be used for a while.

Donor bottom block disassembled and there were almost new standard connecting rod bearings in it.

Pistons are provided with a layer of carbon:



Look neat after cleaning:





Also cleaned some other parts



14/5000


to be continued

Ron
 

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Not hanging about, great work Ron.

Very wise to throw ball joint and bush replacement into the mix too whilst everything is out.
 

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2005 Mini R53 Works
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Discussion Starter #3
We are now on schedule with regard to the supply of parts.



You keep ordering, you see rubbers every time that cost almost nothing, but which you can now replace. Anyway, only bring 4 new rubber seals for the injectors. You now have them in your hands.

Gr Ron
 

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I can say that I usually do the same, replace parts that have not yet failed but if I'm taking them away while doing something else, why not to replace it?
 

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2005 Mini R53 Works
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Discussion Starter #5
If you are realistic, you know you can run into things with a 15 year old JCW. It is a light hothatch with relatively decent power. So it has also been driving quite firmly for 15 years. I am a petrol head and I think the Mini R53 is a brilliant hothatch. I had already started to give the Mini some TLC, but the broken connecting rod bearing made me choose what to do. Or to the demolition or get it right. I can do a lot myself, but a change of engine with building another engine was just too exciting for me. I will now do that together with a Mini specialist. My goal is to get the JCW relatively bullitproof. I can do a new wheel bearing, defect steering pump, drive shafts, brakes, stabilizers and coilover at home by myself. it is therefore also useful to buy a Mini R53 with a budget next to it to absorb setbacks, and not from your last cents.

If I really wanted to drive problem-free, with warranty, I would have bought a Fiesta ST or something like that.

Ron
 

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2005 Mini R53 Works
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Discussion Starter #6
Today we got to work:
















Corsa with trunk with parts to take home. (have to get some toothbrushes from all the neighbors) in the coming days try to get the parts a bit presentable again. Head to a company this week to have it tested, level it and then rebuild the engine with another short block on Friday. Putting it in on Saturda...........


Ron
 

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you're going to skim it regardless?
 

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2005 Mini R53 Works
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Discussion Starter #9
The donor short block will be fitted with new King Racing CR4600XP STDX con rod bearings, new piston rings (OEM), cylinders will be honed (no oversized) crankshaft is still new and perfect (measured). Pistons I made fresh again and are still perfect. All gaskets of the short block are replaced including all o-rings of the sensors and the crankshaft gaskets. The clutch was replaced 1000km ago, including the auxiliary clutch cylinder. Both are still new. Flywheel also appeared to be renewed.

Head is also refreshed and immediately fitted with a Newman PH1 camshaft. there too, of course, all new gaskets and o-rings for the sensors. Injectors are also getting new o-rings. New timing chain and new multi-belt tensioner with rollers.

Compressor is serviced and equipped with new Meyle water pump and gaskets. Ordered a service kit in the UK for the compressor, which I also have.

subframe is fitted with new ball joints, PU wishbone rubbers and new steering ball joints.

Then the Mini should be able to handle it again. Had already equipped the Mini with new spark plugs, a Pipercross air filter in the JCW airbox and Castrol 10W40 oil is used.

I do it together with a Mini specialist, which saves a lot of man hours in terms of costs. And there is one who has an idea of what to do with the huge bunch of wires and vacuum hoses when placing the engine.

gr Ron
 

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2005 Mini R53 Works
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Discussion Starter #10
what a caked mess after 15 years ........



After some initial cleaning attempts





Tomorrow fill the compressor with new oil.

Coincidentally also ran into a set of chairs with side-mounts and rails for the Mini. Are no longer made by Corbeau and this is the XL version.



Also found a handout on this forum on how to mount these XL chairs directly onto the original rails. Don't let them stand.



The head of the block is completely tackled, surfaces, pressure testing, control valve guides, removing carbon and valves ground. Will not be ready this week, so the built-in engine will be a week later. In the meantime build up the short block, subframe fitted with new ball joints, steering arms and new PU wishbone rubbers.

Gr Ron
 

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2005 Mini R53 Works
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Discussion Starter #12
The past few days addressed some parts of the Mini. Supercharger provided with new oil. There was more than enough oil on the side of the pulley. Not a drop of oil came out on the side of the water pump. Supercharger ran smoothly, no noise. Could not shake sharps or iron residues from the supercharger as well. I mount it again with fresh oil, next spring I am looking for a used facelift supercharger. Let's see if I can overhaul it myself, or at least provide it with new oil seals. After cleaning, I made the parts a bit tidy. In the coming days, build the short block and tackle the subframe

 

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did you remove the PTO cover? I hope so if no oil came out....
 

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2005 Mini R53 Works
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Discussion Starter #14
No, I didn’t I don't like this supercharger with disappearing oil. It's not my way rebuilding, screwing it back on like that.

Ron
 

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2005 Mini R53 Works
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Discussion Starter #16
Opened the supercharger today. Didn't disappoint me, it didn't run very long without oil.







But I didn’t like the leaking seals. Once they leak, it will only get worse. Found a company specializing in superchargers. Went along with the supercharger.The Eaton M45 is basically indestructible. BMW itself designed the attachments for the water pump side and the pulley side. the seals that have to seal the chamber with the rotor are much too weak. A kind of vacuum is created in the rotor chamber that, as the seal gets older, sucks the oil into the chamber along the seal rings. My supercharger is fitted with new, modified seals, fresh oil and the bearings are checked. The gears were still new. Rotors also looked neat.



Pick up on Monday and install with the engine next week. gr Ron
 

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Discussion Starter #17
The Mini's resurrection is progressing steadily. On the instructions of the specialist, I try to make it something reliable. Placing the pistons was a # @% job, it just takes a lot of time, putting everything neatly on NM also requires good concentration.

To start with the faillure of the previous short block, had to see how the piston nozzles were placed exactly



This connecting rod bearing is quite broken .............. no idea what the rest looked like.

Cylinders honed.



Assemble bottom block, new connecting rod bearings mounted (everything checked 15 times) tighten everything on the correct NM, new o-rings and gaskets



Clutch was really brand new



It's starting to look like an engine again



PU rubbers in the wishbones and new steering knuckles. (We install new steering arms and outer steering knuckles under the car)






After a 1 minute course in press operation, the PU buses were in it in minutes per side.

Pressing

Next week, place the head, place the compressor, engine in the Mini, subframe underneath. Gr Ron
 

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2005 Mini R53 Works
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Discussion Starter #18
I always get happy when an engine's weaknesses are properly addressed and modified:





Connection water pump has also been renewed with the seals (and 1 bearing) under the gears.






That's the benefit of 15 years of misery with the Mini R53, a lot of modified stuff has been developed for it. It's just quite labor intensive to get that stuff in ......

Gr Ron
 

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2005 Mini R53 Works
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Discussion Starter #20
Two questions, If I’m correct BKL stands for a Getrag with LSD ?
If so, does it need special gearbox-oil ?



gr Ron
 
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