Mini Cooper S R56 SPORT Concept
2019
Here is a short version of the events that started a new chapter in my life ...
I fell in love with this car from the moment I got in it...
My name is Martin. I really like mechanics, electronics, computers and operating systems as well as specific software that always allows me to achieve my goal. What I value most is quality, good thinking and common sense.
As a car mechanic freak (hobby), I have a lot of professional tools, knowledge and quite a lot of experience in repairing various cars.
In March 2019 I acquired a Mini Cooper S R56 2007 with 66,613 miles on the clock.
At that time, I didn't know anything about this car, only that the car was made by the British Motor Corporation from 1961 to 1971, then from 1990 to 2000 and after that it is made by BMW to this day.
The first "trip" made a very positive impression on me and I wanted to learn more about this car, since I like to check and repair vehicles.
The photos below show the car when I came to my place with it. Pay attention to the engine compartment, because this is where my attention will be focused on the beginning of the modification.
plan for modification - increase in engine power
I checked on the internet for a lot of films, forums, news groups and Mini maniacs articles.
Thinking logically (which I really like ;-), in order to increase the engine power, you need to supply more "combustion mixture" = AIR + PETROL (Fuel). There is no problem with fuel, because the car is equipped with a fuel pump in the tank and a high-pressure pump at the injectors. Standard injectors also have adequate reserves for this type of modification. What about the air then - is there is enough of it? Of course everything depends on what we want to achieve.
If the high-pressure fuel pump gives 10% more fuel after reprogramming the ECU, the air is another matter. BMW programmed the "on-board" computer in such a way so that the exact amount of fuel fully coincided with the exact ratio of air which is applied by the turbo, air ducts and filters. Logically speaking, I will enlarge all air ducts and get rid of any resistances from the air system such as dampers, valves, noise/sound generators, etc. I also replace the factory-equipped Turbo with a larger capacity JCW Turbo.
To even more effectively increase the amount of Oxygen in the air supplied to the engine, I will install a much larger Intercooler and a direct cold air intake on the cone filter. Cooler air is more dense than warmer air. Warm air can actually hold more moisture because molecules are farther apart, making more room for moisture. Cold air is dense and compact, it's "thicker," so when you breathe in you get more oxygen.
Of course, the increase in engine power is also related to its higher operating temperatures, especially at high loads, so I have to think about new silicone hoses for the entire cooling system, a new water pump and thermostat to keep everything running reliably.
intercooler
I will install a much larger Intercooler.
air ducts
I will enlarge all air ducts.
JCW TURBO
Larger capacity JCW Turbo.
modification check - General inspection of the car
One of the most important things to do before any modification is to check all the components in the car that will directly correspond to or co-operate with the increase in engine power. Because the car is already 12 years old, I have to check almost every component. To get more power, that is to force the engine to work harder, I have to be sure that all parts responsible for the correct operation of the engine will work without any problems.
I decided to replace many of the sensitive and most important components with new ones:
engine cooling system pump (new metal)
engine cooling system pump pulley
engine cooling system hoses (new silicone)
engine cooling system thermostat (109'C)
engine cambelt
engine cambelt tensioner
engine timing chain
engine timing chain rails
engine timing chain tensioner
I will do a pressure test on individual cylinders to be sure that each piston will compress properly. I decided to replace the timing chain, so that I do not have additional work later and reduce the risk of breaking it, cracking and crushing valves. I will generally check for any oil leaks from various parts in the car. Of course, I will check the entire suspension system as well.
gearbox shaft seal
Gerbox oil leak
vacuum pump seal
Engine oil leak
Crankshaft seal
Engine oil leak
cylinder valve cover
Engine oil leak
Suspension system
Anti Roll Bar bush
modification work
Any work related to the modification is given below in more or less detail in comic book form.
There are many photos and almost all of them have descriptions of the operations that were performed.
If anyone requires a detailed description of any procedure, please contact me.
This is not a guide or instruction on how to perform such a modification, but information on how I performed the entire procedure. If anyone undertakes to carry out such modifications on the basis of the information contained on my website, then he / she takes responsibility for everything and must remember that each modification will result in the loss of the remaining car warranty, if any.
I do not take responsibility for wrong operation or bad execution of modifications that are described on my website.
intake and air ducts
Replacing most of the air ducts
new seal
Replacing Crankshaft seal
cleaning all valves
For oil and cooling system
Removing whole front
For access to the parts for replacement
old small original intercooler
Will be replaced by 3 times bigger capacity
Time for Cooling System
Removing Coolant
Removing old rubber pipes
Checking for oil leaks
Silicone hoses
Replacing old rubber pipes
new thermostat
To ensure proper cooling operation
new hoses
Resistant to high temperatures
old plastic pump
Removing old cooling pump
new metal pump
Redy for installation
new belt pulley
On the new cooling pump
new belt tensioner
For new v-belt
belt tensioner
Installed
new v-belt
Installed
Vacuum pump removed
All seals will be replaced
Full regenaration
New High Temp paint coat
checking all conections
For cooling system
checking for leaks
Filling the entire system
Air suppressor - OUT
Sound generator - OUT
Air filter container - OUT
Air intake "bottom" - STAYS
bigger pipes
More Air = More Power
bigger hoses
Replacing existing Air ducts
not used - just cover
Such a waste
Old filter compartment
New filter compartment
More AIR from outside
Inlet via two separate routes
Making room for new stuff
Air filter compartment
Direct cold air intake
All conected
New intercooler
Installation
oil catch box
To reduce the oil deposit in INTAKE
intake
Cheking intake temperature
Many stone chips
Sanding
Sanding & Cleaning
Primer
8D Carbon fiber
In the meantime - wraps
external door deco
Cutting Vinyl
Nice, fresh look
Instead of gray plastic
old plastic look
Preparing parts for wraping
new carbon fiber look
I am very pleased with the results
disassembly
Disassembly of the rest
disassembly
Side "skirts"
disassembly
Rear bumper
White matte stripes
Wraping
white tyre letters
Painting by paint pen
stripes
White matte Vinyl
new exhaust system
Much bigger and first silencer cut-out
3 inches pipes
Bigger than the original
Disasembled all plastic parts
Installed new wraped parts
Ordered necessary clips
Everything is put together
Washing the bonnet
cleaning before wraping
Wraping
Wraped
new sport exhaust system
First "silencer" cut-out
exhaust installed
Beautiful deep bass
anti roll bar bushes
Bran new
anti roll bar bushes
Old one for replacement
anti roll bar bushes
New one IN and clips painted
I downloaded the car's ECU for all the data to review and check the parameters with which I can change the maps responsible for the amount of fuel - petrol and air.
Sanded first layer of clear
Clear coat sanded
Looking good
Stickers ON
Rough idle investigation
Looking for Vacuum leak
carbon deposit checking
Intake OUT to check the status of Carbon residue in the engine
Checking o2 sensors
Measuring sensor using Propan torch
cleaning o2 sensors
Cleaning all carbon residue
checking MAF sensor
Cleaning sensor with pure alcohol
Air intake cleaner
Best product for this task from my experience for little price
air intake removed
All channels and ducts will be cleaned and washed
Valves covered with carbon
Valves covered with carbon
Valves covered with carbon
Valves covered with carbon
compound for paint
Smoothing new paint places on the body
palm wax on
Palm wax stays on the body for two years
polishing
Looks like a mirror
customise tools
Metal brushes, paper towels, absorbing oil fabrics
straws in the spark plug holes
Way to check that the cylinders are up and the valves are closed
Valves are clean
After making sure that the valves are closed and the cylinders are in the upper position, I flooded the inlet of the cylinder with the liquid (Air Intake & Carburettor Cleaner) and cleaned it completely with brushes as well as paper and fabric towels.
The effect surprised me completely because I could see a completely clean engine block and beautiful clean valves during the intercourse with the endoscopic camera.
cylinders and pistons pressure test
I am undergoing one of the most important tests in terms of engine quality and performance. It is a test or rather a pressure measurement on each cylinder. If there is a very large difference between one of the cylinders or the value is below 130-150 psi, then I will have a fairly expensive disassembly of the engine and its repair. All test was superb and I was so happy about it.
pressure test equipment
knocking noise
As the pipe is much bigger - hits frame
Exhaust heat tape
and metal "cable ties" for install
exhaust pipe
I wrapped the pipe, so that it would not hit the frame and make noise
Cleaning second O2 sensor
Improved connection
Checking results
Live data from the ECU
improved backlight brightness
In whole car light system
improved backlight brightness
In whole car light system
in the sun light
After replacing resistors
in the night
After replacing resistors
change of internal panels look
Preparation for wraping
Wraped in 8D super gloss vinyl
Carbon Fibre efect
suspect timing chain
Rough idle problem still existed
not replaced
and in the service book it is noted that it was replaced
my old life motto always reminds me:
if you want something to be well done, do it yourself
Vanos off by 5'
Good tip for me that it was never done
problem
The tool cannot be mounted
chain replacing tool
Loosening Intake shaft to be able to use it
Tool installed properly
Now I can unscrew both gears.
Gears out
Now I can unscrew the crankshaft screw below
crankshaft screw
Using the biggest key I have got to do it
removing pulley
And old timing chain
install new guides
and new timing chain
intake shaft torque
20Nm + 180' of rotation
exhaustshaft torque
20Nm + 90' of rotation
crankshaft torque
50Nm + 180' of rotation
the moment of truth
With slight apprehension, I put the key in the ignition.
Because I knew that I did everything myself, and according to my motto that's only for the best, I pressed the START button without thinking.
What happened made my jaw drop...
The engine started without any problems, which made me even more convinced that if I'm searching for the highest quality of work, I can only achieve it only if I do this work myself.
after 3 months
Red Carbon Fiber Vinyl turned out not to be UV resistant
sanding whole bonnet
I removed the vinyl to prepare the surface for the primer
I had to sanded a lot of chips
Whole bonnet sanded
Primer applyed
Primer pre-sanded
Black matte
I asked the seller if it has a UV filter
carbon fibre
With UV filter
vinyl wraping
deja vu...
exquisite effect
Black Matte Carbon Fibre
White matte stripes
Applyed
new air hood
Waiting for new Air Hood
New bigger Air Intake hood
Original "grill" too blocked
Painting aluminum mesh
All done
New, more aggresive look
And more Air gets inside
New, more aggresive look
And more Air gets inside
angel eyes
I bought "angel eyes" and I mounted them on a rack I made
angel eyes
View of the light ON at night
white tire pen
After 3 months, all the paint applied with the felt-tip pen started to drain from the tire. It was quite annoying, so I decided to try something else and put/glued a white rubber on the tires.
custom template
I made a template for my tires
logo letters
I cut the letters out of the rubber
gluing letters
And glued each to the tire
small engine oil leak
As you know, I am crazy about this car, so everything must work like in a Swiss watch (without jams and any problems)
damaged thread
I have to fix damaged thread in the engine block (from previous owner) to properly align and tighten the engine valve cover
I filled the entire hole for the screw with this glue
The next day, when it dried up, I could drill in it
I drilled with a slightly smaller drill than the thread itself
I also bought new stainless steel M6 40mm screws
rust ???
Everything looked fine in the engine bay except for one element
cooling pipe
Turbo coolant tube rusted very quickly after the last cleaning
turbo cooling pipe
I have to paint it with high temperature primer and paint
now it's cool
Now it looks like new. A small detail, but I am so happy
turbo temp. cover shield
Of course I also painted the temperature shield/cover for the turbo
As winter is coming
I want to check some specific chemical for the engine
I did some tests while driving and idling - NO OIL ADDITIVE
I did some tests while driving and idling - WITH OIL ADDITIVE
After checking all the measurements and comparing them using the computer data, I found that with OIL ADDITIVE the engine, even when idling, has a 3% lower load, which does not seem to be a huge, but with modifications and tunings, the load does not add, but multiplies and this is a big difference.
rubber letters
Unfortunately, some peeled off and others became very discolored
PLASTI-DIP
I bought a white rubber paint to try
Rubber paint
The effect was very good
I am returning with modifications to the interior. It will be a long and tedious process, because I'm going to disassemble almost everything and replace the stereo with a 2DIN Android unit with a touchscreen, install a reverse camera, change the color of all buttons, indicators and clocks.
changing colour
After changing the brightness
on clocks
I wanted to change the colour
and all equipment
all buttons, clocks, indicators
odometer
Changing LED's from "orange" to BLUE
led desoldered
Changing LED's from "orange" to BLUE
new look
Changing LED's from "orange" to BLUE
Main console buttons
Main console LED's
Computer and speedometer
I even painted the "needle"
disassembly of the interior
Remake/rebuild the radio to keep the computer working
replacing main panel
Space for a 2DIN touch screen
Fun by the millimeters
Additional cabin lighting
The stereo with CD does not fit
CD OUT, it will be Android
Much more space
New longer connection tape
electronic board
Switch-On Board has the necessary plugs
sufficient space
It is enough to install new screen
Reverse camera installation
Reverse camera installation
Reverse camera installation
Reverse camera installation
reverse signal
Signal from the reverse gear lamp
finding place
Fit perfectly in place of the screw
perfect fit
Goes well with everything
Silicone glue
And tape to hold until dry
invisible
It is virtually unnoticeable
interference
I had to use electronic filters
Place for tweeter speaker
Drilling out
Sanding
Ready for speakers
Finishing installation
Almost ready
Bluetooth remote control
Drilling stering wheel covers
Looking good
Happy with the results
Working fine
continuous small engine oil leak
Machine-made thread repair did not yield a result
thread checking
Machine-made thread repair did not yield a result
damaged thread
I have to do it again
loctite
Additionally I sealed the gasket itself
metal epoxy
I give the day to dry
drilling
on slow rpm
manual
This time only a manual tap
manual work
For increased thread quality
new thread
I threaded the whole piece
new thread
I threaded the whole piece
new thread
Looking much better than before
loctite seal
Loctite silicone on each edge and crease of the seal
loctite seal
Loctite silicone on each edge and crease of the seal
give time
For cure
and then
Next day
tighten
All bolts
rubbed tape
By shocks and vibrations
rubbed tape
By shocks and vibrations
replace tape
I put new pice
new tape
In two separate places
silicone liner
High temp. layered reinforced silicone
Back to wrapping. I have to fix the lower part of the rear bumper, because last time I put white vinyl stripes on the undone two parts and I want to fix it now.
wraps
White vinyl stripes
reattached parts
For better finish
putting together
Looking very good
complete bumper
without bumper
with bumper
checking seal
Everything is dry and in perfect condition
checking seal
Everything is dry and in perfect condition
day view
Successful color change of backlight LED's
night view
Successful color change of backlight LED's
The roof lining began to creak
Rubber bands are worn out
I glued felt rings
I glued felt rings
no installation date
I have no idea how old this battery is. Works fine yet, but no install date.
I change the battery
Just in case for new electronic equipment and Touchscreen to work well
greasy terminals
I always lubricates the battery terminals well with grease
both terminals with grease
I have practiced this with batteries all my life
prevent corrision
To prevent electrical corrosion, just like on the picture above
After a year since purchasing the car and making all the modifications, I had the opportunity to go to the very center of Europe (3200 km), which was a very good test for everything I did with this car. As you can expect, nothing I changed, did or improved in the car ended up breaking and the car bravely covered the whole route with very good combustion results, despite the tuned ECU. However, I must go back to my basic motto and quote it here again:
if you want something to be well done, do it yourself
Why do I mention it here and now?
The reason is simple. This is something that I have not touched on all this time, because before delivering the car to me, the previous owner had the brake discs and pads replaced and informed me about it. Everything looked like new, in fact. I didn't care about it at all - big mistake!
After driving 1750 km (on that journey) I started to feel vibrations in the steering wheel during braking. I was able to inspect my car's braking system at my friend's garage. I quickly came to the conclusion that there were some strange pits on the brake discs and one of the pads was very strangely worn. There was nothing left but to order new discs and new pads and replace them so that I could safely return to England.
brembo discs
Nothing to add, I ordered the best quality system
brembo pads
A world-famous company that deals with brake systems
Sport discs
Brembo
ventilated discs
Brembo
sport pads
Brembo