2010 Hardtop Non-S w/77,000 miles.

Driving home from work the other day when I had the orange temp warning light come on. 5 minutes later it turned red.

Pulled over a quickly as I could to check the coolant and there was none.

I had a water source and put several gallons on water in the fill. When the water kept going in I thought of checking the dipstick.

Crankcase was full of water

Mini, Mount Laurel, NJ wants $675.00 to pull the head to determine exactly what's wrong.
$3000.00 if it's the Gasket, $5000.00 if it's the head and $10,000 if it's a cracked block.

Needless to say, I'm getting it home to do the work my self.

Compression test and leakdown test are Okay, so says Mini ML.

My question is, How common is a cracked block .vs. a blown head gasket?

I'm hoping it's just the head gasket.

Any advice would be appreciated.

 

Wow what a horror story, finding coolant in your crankcase is crazy! Either do the work yourself or take it to a reputable shop that deals only with Coopers. I don't know where the dealer gets their prices! If you're going to pull the head you might as well perform a valve job or at the least lap your valve seals.

Sorry to head the bad news.

 

Hard to believe a compression and leakdown test would be OK. Not to mention, how did they do the test with water in the oil? At any rate, with water in the oil, the only way to determine what's going on is to pull the head..

 

I had them drain the block before they did anything. If the head failed between the oil and coolant passages, makes sense the compression is good.

I'll be picking the car up in a few days. I'm definitely going to pull the head my self.

 

Not the head gasket, head or cracked block. Freeze plug!!!!

Pulled the valve cover and found the freeze plug below the cam sprockets had blown out and was all bent up and sitting on top of the cam chain tensioner. Compression is good and the chain and sprockets look okay.

I'm thinking of getting a universal rubber compression plug and putting that in to seal the block.

Should work but how to get all the cruddy oil/water mix out of the engine? I also need to clean out the cylinders. Some of the mix leached in.

Any suggestions?

 

I wonder if Mini would cover this as a manufacturing defect.

 

Wow, I would have never guessed that. This is the first thread I've seen that a freeze plug failed. At least it seems you have a viable engine, though cleaning out the block is going to be challenge without tearing it apart. Am going to follow this thread, looking forward to what other members recommend to clean it out..

 

Here's a few pics of the hole and plug.

 

Dang, not an easy place to reach. I remember many years ago I had an old Dodge pickup truck that popped a freeze plug. Fortunately, it was on the outside of the block. I put one of those adjustable rubber/metal plugs in it's place. Lasted the life of the truck. Am not sure that would work on an internal freeze plug. Thanks for posting the pics, first for me on a mini..

 

Wow I'm speechless, never would have thought it was a freeze plug! Looks like that freeze plug ended up hitting something inside your crankcase!

I'm sure that we will never hear of this happening again, what are the odds?

 

Wow im with Systemlord.. I never would of guess that! What a crazy spot for a frost plug!

 

I'm really just glad I found out what was wrong. I was thinking Head Gasket, warped head or Cracked Block.

I'm going to try the Rubber Compression plug designed for High Temps and chemicals. If I can get it in there it should do the trick. I would love to pull the cam chain cassette but I don't want to buy the $180.00 tool.

Has anyone ever seen them for rent?

 

damn thats crazy!

 

Found the CAM tool for $108.00 so I ordered it. There's not enough room to get to the hole with the cam sprockets in the way so I need to pull at least one. I should really pull the whole chain assy to give it a good check anyway.

I may need to pull the head to get to the freeze plug hole too.
The rubber expansion plug if proving difficult to get in from the top.

I also opened up communication with Mini USA to see if they will step-up on this since it definitely is a manufacturing defect.

 

Keep us updated please.

That's BS to have that happen!!

 

Mini customer service gave me a call.

They said that the dealer needs to do the diagnosis in order for them to even consider helping. Suggested I call the local dealer and see if they would confirm the problem.

Called my local service (Mini of Mount Laurel, NJ). They won't send anyone out to have a look and will not use my pictures. Against their policy. They want me to bring the car back so they can have a look. Even if they confirm that it was the freeze plug, they cannot say if Mini USA will cover anything.

Basically I just want to know if they will cover any costs and so far, I can't even get an answer.

Since I have the tool on order, I'm pressing ahead with the repair myself.
While I'm at it I'll do the belt, cam chain & maybe the water pump.

I'll post some pictures as I go along.

 

Im just wondering...Is that rubber plug going to be okay to use in place of the frost plug? With all the work your doing wouldn't you rather just install a new frost plug?

 

Yup, I'd never trust a rubber plug there.

Plus.. With all the water that had been mixed with the oil.. I'd be wary of the crank bearings..

 

Thats my feeling about the rubber plug. It would be totally different if that frost plug was to the outside of the block but this one is directly into the chain case area. That's a no go for me. I would almost bet that rubber plug will pop out in time. Im also with you on the crank bearings. Im sure theres some damage done.

 

That's BS, there's nothing you could have done to cause that freeze plug to come out on its own, Mini USA should be upfront with you and cover it if through no fault of your own! Mini USA loves to play games by getting you to bite the bait and taking it into the dealer, then deny your request for a goodwill repair. Mini USA's policy sucks just like their customer ratings being at the bottom!

 

The rubber plug is a "NO GO".

I'm going to have to use the metal one. The machined opening is only 1/2" deep and the plug is 1 1/4". Past the 1/2" there's a blockage on top which is preventing the rubber plug from seating in all the way.

I should be able to drive a new one in after removing the motor mount and right headlight.

As far as the crank bearings. Crankcase is full of good oil now so the journal bearings are sitting in good oil. Most of the water has been removed. Time will tell on other internal damage.

 

Removed the outer plug.

 

Now that's interesting, I was wondering how you were going to reach the original plug. Thx for the update..

 

Sourced the Cam Chain Kit and some other needed parts from http://www.ecstuning.com

Sourced the Block Plugs from Advanced Auto, 36mm & 40mm.

Pics to follow.

 

After you get it back together trade it in. Atleast get an oil sample to blackstone to see if your bearings are about to be gone.