This time I’m doing my own mod rebuild work, and making most of the expected first-timer Mini overhaul mistakes. I’m posting this to help others NOT make the same mistake.

Stripped the head of all attached parts and sent it to Thumper for more upgrades. Then pulled the engine / trans from the car to replace rods and pistons with CP Carrillo versions. When the head came back, I installed it BEFORE adding any of the other head-attached parts. As I assembled it, still out of the car, I saved the intake and FI for last —- no good reason, just seemed easier. Original plan was to take the injectors and rail to the dealer, pay them to change the seal, bring it home and install it on the head. DOESN’T WORK THAT WAY! Newly installed seals will expand after a few minutes, making it “impossible” (so I’m told) to install in the head.

Then, re-reading Bentley’s FI seal install process, I started looking for the special tool to change the seal. Only found one source —- Assenmacher Specialty Tools —- listed in the Bentley manual, and they don’t sell retail. Had to find a local source that would do business with AST. $300 later, it’s in the mail.

Ideally, I would have taken the bare head, with injector seal kits, to the dealer for them to install the seals. Then brought it home to finish assembly. Labor costs probably would have been comparable to tool costs, maybe less, but the frustration levels would have been minimal.

So, in about another month or two, after the engine is re-assembled, broken in, and my confidence level is back up there, I’ll have a FI Seal Set tool for sale. Anyone wanting this tool can start negotiations via PM.