So I just bought a 2003 Cooper S, with a burnt valve and needs a new clutch. (yes, I got it cheap)

I've built more than my share of motors, mostly BMW stuff, and 2 diesel motors for my trucks (7.3 and a LB7)

Havent dug into a mini before, and need some help. Plan is to drop the motor out of the car, and go through the motor and replace all the "trouble areas" and do the clutch with everything all apart.

Question I have is, are there any good DIYs for doing the headgasket, pulling the motor, or a list of "replace while you are in there?" I searched the stickied threads, and didnt see what I was looking for, and looking for part recommendations.

So far I have:
Valeo solid flywheel conversion from Amazon ($415)
Coolant expansion tank
Thermostat housing/thermostat
oil pan gasket


Any other stuff I should look at while Im in there. Trying to go this correctly, but stock, and keep cost down. This will either be my new DD, or a flip car to make money on.

 

crank position sensor o-ring
lower control arm bushings (w/ Powerflex)
ball joints

 

Here is part 1:

And part 2:

 

appreciate the videos.. will have to watch them when I get back from deployment, or the next time I've got wifi in a liberty port.

 

I have valves if you need them

 

When I started down this path, In addition to the needed repairs, I ended up with a pulley, cam, injectors, cat back exhaust and only narrowly avoided a BVH and header... Have fun...

 

Our clutch super kits HERE have a nice list of replacement parts that you should replace while doing the clutch. Since you'll have much more room to work on everything, it may be a good idea to tackle all of these as well. You can delete out the actual clutch from the kit once you add it to the cart so that you can just purchase the other components from it for the job and still do the Valeo conversion clutch/flywheel. Let me know if you have any questions or need any help with this job.

 

Well.. one more order, and I've got pretty much everything I need.

Even found a set of GP matching seats to replace the torn driver seat. Cant wait to get back from this deployment, and get the car broken down and on the engine stand.

 

If you want to make sure this is the first and last time you're working on the engine for awhile I would say replace as many gaskets and seals as you can afford.

The crank seals both front and rear will be quick easy jobs, oil filter housing gasket, oil cooler gaskets, valve cover gasket, thermostat (a given anytime you pull the head), a timing cassette wouldn't hurt you while it's all apart, full head job (valve guide seals, hot tank, lap the valves, true the head), spark plugs, belt, possible belt tensioner, water pump, and the list could go on until you just buy a crate engine.

But the best idea would be to do a pulley kit while it's all apart and easy to get to.

We have all the gaskets and seals required for the job, even all of the supporting bits you may need while in there, all in stock and ready to ship if ordered before 3PM EST.

If you've rebuilt an LB7, a SOHC 4 cyl should be cake.

 

I pretty much did almost all of that. This car is going to get flipped, so Im not doing everything I would be doing if it was for me.

All the parts I needed, I got ordered already, but I'll look our way next time I need something.

LB7 was fun, tons of information online. Always with a new motor is the timing of everything, and I bought the bentley manual for that (have 6 of them for other BMW models/etc), so I can get it put back together correctly.

Pretty easy day though, and should be fun. First FWD vehicle I've really torn apart. Everything else has been diesel trucks and BMW RWD stuff.