I just found out this is a common issue, I have one of the first Minis in Los Angeles, bought March/02, everything good until last Sunday, on the way to Costco, lost spark plug #2. Drove it home, about 7 miles, called Alexander Mini, only $3,900 if the head had to be replaced, but maybe there were more options, they had to see it. After researching and watching some youtube videos, I decided to try to fix it myself. Went to NAPA, bought their save-a-thread, made by helicoil, on sale for under $28. I had to buy a spark plug and a cable, so I decided to change all of them. I went with NGK sparkies and Bosch cables. Took me about 1 hour to fix it, plus 24hrs to let the thread lock cure (per instructions). When I tested it, I noticed the car was shaking and I could hear like one of the chambers wasn't working. After 3-5 seconds later, the engine sounded normal. I'm assuming the ECU shut down #2 chamber, as I didn't had my scanner to reset the error code before testing. So far it's working fine, I think new cables and spark plugs help feeling the car stronger. Look at the cable, split in half.

 

interesting photo!

 

Check your stock coil pack for burned terminals too...very common problem.

 

Yes. And for some reason it's always #2. Once this started showing up I routinely check my plugs every 5000 miles when I change the oil. And it is hard to figure out why the plug gets ejected in the first place. Or why it seems to be always #2.

My routine is to install plugs with the head stone cold and to check them regularly. I do not believe that the brand of plugs matters. Proper installation matters.

I am glad you got this fixed reasonably. I used a Back-Tap on a friends and it is still holding after 4 years. If that didn't work helicoil was next.

Enjoy the road and keep those first R53s alive.

Rich

 

Coil terminals look OK, I need to put some dielectric. Mine is an R50, I wanted a supercharged but those were not available before May/02. Now the insulation has a hole, I don't know if it was the plug hitting or the boom-boom from the piston.

 

I had a plug jump out, it was cylinder #3. The wire was fine. A Time-Sert was used to repair the threads, the cylinder head did not have to be removed.

 

I was looking for the Time-sert, but I think it has to ordered on line. The Helicoil is something similar. I didn't remove the head either, just used lots of grease, a piece of panti-hose and a generous amount of prayers. I've removed a Cr-v head before, to replace 2 burnt valves, change the timing belt, the Cr-v has more space to work. I didn't want to remove the head this time. I think I spent about $140 total, including new cables, spark plugs and few other things.

 

I have a 2006 Cooper S with 70,000 milies and the #1 plug flew out last week. Dealer wants to charge $4600 to replace the head. Sounds like I need a second opinion. Is this a common problem with Minis. I have never heard of it before.

 

MiniFrau, Frau like in German? I didn't know but I seems it's a common problem. The kit that I bought has the tool and 4 inserts, there is some information around about the correct size that you have to get. If you can't find this information, send me an email. If you think you or somebody can do it for you, I can lend you the tool, just buy the insert. My email: Camucho@att.net