Decision-Time :: R56 with broken engine :: What would you do?

[Mark at Pelican Parts]

Subject MINI is an '08 R56 which has experienced a particular engine failure which other owners of this vintage have also experienced. It's hard to say how prevalent the issue is but the results are catastrophic to the Prince engine.



Here's the end result of another unknown issue: Broken Exhaust Camshaft Sprocket Bolt . The sprocket and chain now reside deep down behind the timing cover, somewhere. Some folks say it's vacuum pump related.
This MINI ran great with no signs of a future issue. It has a few engine mods but nothing internal just bolt on upgrades.





So, the question is, what would you do at this point? Replace the engine? Replace with additional mods? Doing an engine swap isn't too difficult, so would you grab a buddy and do-it-yourself? Last resort would be towing to the local dealership (especially since there's no warranty) and having the work done.....but would you?





Sound-off here and let us know what decision you would make or have made if you've gone through this issue as well! We want to hear from you and stay tuned as we update the story with this MINI's future plans!

[Markbh]

I wonder what other damage occurred when the failure happened? Bet it's not pretty.

Subscribed!! Looking forward to an update.

[jameswnw]

Looks to me this engine lacked quality oil on a regular basics?

[belbuoy10]

I purchased a new Mini in 03. Built and sold by BMW but not the engines or transmissions. This was the worst car that I have ever owned in my life, by the time I was done with it I had payed for it twice in maintenance costs alone. I lost two engines and one transmission, exhaust valves burning off and dropping into the cylinders. Early engines where built in Brazil later in Sweden. My friend a BMW mechanic says he didn't think the Swedish engine where going to be much better. The BMW dealership in my area was of no help, in fact rude. Never again. I will stick with my Porsche.

[Ganzo]

Very unfortunate failure. I would pull the motor, disassemble, identify parts that need replaced and determine if it is cost effective to repair myself. I do all my own work. What's the cost of a new or used motor?
I'm on my 4th Mini. I currently have 2. I buy them for my wife and daughters. They are easy for them to drive. I prefer manual transmission, but the girls want CVTs. Don't get me started on the CVT garbage. All 4 are CVTs.
I had a 2005 eat a chunk of exhaust valve on the way home. I was able to drive it home. It took 1 1/2 hours to find the problem. $200. in parts and 2 days later it was back on the road. ____happens. It's a machine. My wife has no idea how much movey we save by doing all our own work.
I tell people Minis are the most complicated vehicle I have ever worked on. This applies to the electrical system. My other big beef is the cheap plastic that is guarenteed to break. There is too much of it. Other than that and CVTs I like the cars.

[pbehrens]

I agree with the comment regarding frequency and quality of oil changes. How often was the oil changed? Was the recommended oil used? I am a biig fan of more frequent oil changes to get the crud out.

Having just completed a transmission swap in a 2007 R56 yesterday, I agree with ripping it apart to identify the damage and then likely shopping for a used engine. There are enough Mini's out there and plenty of unfortunate accidents. I bought a 23K mile 6 speed for $1,150 plus shipping, I would simply get the matching engine and do a quick swap, but be aware there will be a plethora of fiddly bits, including single use fasteners that will require replacement. While you are in there, how does the clutch look?

[Mark at Pelican Parts]

Yes, it was inevitable as the broken engine had to come out sooner or later. The decision was made to go with a fresh, genuine factory-remanufactured unit for the subject car, which is a 2008 R56 Cooper S with auto trans.

Thank you to Andrew Handlen for the report and pictures!

Arrival, nicely packed!



The R56 on the lift and ready for surgery:



A last look at the dead engine before removal:



Getting ready to pull:



Even though the process is fairly plug and play, it was important to label plug ends and hardware:



Out she comes:





Midway through the transplant, the engine-less R56:



The biggest potential challenge, during the swapping process, was piecing things back together correctly. To prevent this from becoming an issue, lists were made for every disassembled part, then meticulously labeled/organized - bolts, screws, washers, plastic fasteners, etc., each in their own separate bags.

An obstacle, which became a puzzling challenge, was with the torque converter slipping off alignment while moving the transmission body to the new block. After troubleshooting, it was clear it wasn't properly aligned on the shaft splines during the first attempt which didn't allow it to fully seat but this was quickly remedied.

And the new engine installed:





Advice for those who may have to do a similar engine swap:

• Have at the very least 2 people including yourself for the job although 3 is better!
• Consolidate a parts list before beginning any work and remember to include bolts, clamps, etc for every part, you will be disassembling, to have on hand later as you tackle the installation; all the parts required were found in the Pelican Parts catalog
• Patience is the key, especially if you've never completed an engine swap before; take your time, work slowly and you'll limit or eliminate mistakes

To help with general steps, the Bentley manual, for the Mini Cooper S R56, was helpful at times but will not explain some things in enough depth or detail for many without prior experience with working on cars. Overall, this project was something most are capable of completing - you don't have to be an accomplished DIY'er as it's a very manageable project, especially when not rushing and remaining organized.

The car runs great now and drives great with the only existing issue stemming from what is believed to be a faulty thermostat shipped with the new block which is not allowing the ECU to read the coolant temperature and in turn not allowing the car to boost properly. An update on this issue soon to come.

Have you gone through an engine swap with your MINI? Tell us about it!

[Minifun13]

Do you need to pull off the whole front end when you just need to have the head cylinder removed? Dealership just quoted me $6k to replace it but I know most of that is labor and I've done abut 6 engine replacements myself, so I am not afraid to tackle this. I am only finding notes on the full engine though so I want to confirm.

Thank you!

[Jim Swan]

total timing chain failure look at having it fixed.
whats the latest on the replacment engine?

[MReali]

Originally Posted by pbehrens

I agree with the comment regarding frequency and quality of oil changes. How often was the oil changed? Was the recommended oil used? I am a biig fan of more frequent oil changes to get the crud out.

Having just completed a transmission swap in a 2007 R56 yesterday, I agree with ripping it apart to identify the damage and then likely shopping for a used engine. There are enough Mini's out there and plenty of unfortunate accidents. I bought a 23K mile 6 speed for $1,150 plus shipping, I would simply get the matching engine and do a quick swap, but be aware there will be a plethora of fiddly bits, including single use fasteners that will require replacement. While you are in there, how does the clutch look?

@PBehrens - I have a 2007 R56 with a fubar'd automatic transmission and I'm thinking of purchasing a low mileage used and swapping out. I can't find any info on the process or difficulty in doing so. I've heard from a local garage that the DME needs to be reflashed/reprogrammed to the new valve body - which is supposedly almost as expensive as the used tranny. I know that the post is pretty dated, but if you have any info I would appreciate it

[Jim Swan]

Had a machine shop rebuild my engine. Back on the road again, 6 bills.

[Jim Swan]

Originally Posted by Minifun13

Do you need to pull off the whole front end when you just need to have the head cylinder removed? Dealership just quoted me $6k to replace it but I know most of that is labor and I've done abut 6 engine replacements myself, so I am not afraid to tackle this. I am only finding notes on the full engine though so I want to confirm.

Thank you!

Dealer quoted me 10,000, that’s why I went with a machine shop, dealerships/BMW try to blame it on the owners when it’s well documented how the timing chain guides have failed even after multiple redesigns, lawsuits settled for the cars built up to 2 months before my build date, and that redesign fails too. Did