just replaced engine in cooper d with gearbox left in - MINI Cooper Forum

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post #1 of 1 (permalink) Old May 5th, 2017, 04:03 PM Thread Starter
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just replaced engine in cooper d with gearbox left in

after having a second rate turbo charger take out my wifes cooper d clubman i ended up with the special job of removing said engine and replacing with a 40k low miles one from ukbreakers off ebay, give them their due 840 included everything except the turbo as i have bought a brand new garrett this time around,, it also had its clutch and flywheel both looked like new so another bonus as ours was getting a bit vibrate'y and pedal had pump back on it,,
so if anyone is thinking of removing their 1.6 hdi out of a mk2 without removing the gearbox as well yes it can be done but its very tight and you will need to remove front off car and the drivers side drive shaft needs to come out, then there is just enough room to swing engine out off the gear box and same with putting it back in, you will need to support gear box and jack it up a tad, i did remove the timing belt and covers and water pump alternator aircon pump cps sensor before removing as did not want to damage it all as it was going back on the new engine as they had only done a few hundred miles on the first engine..
also i put a new sump on it and oil pick up, i also cleaned inside crankcase with carb cleaner get all that carbon grime that these engine have because of dpf filter, i also put new oil feed pipe to turbo and removed the gauze filter it the banjo on the block end of pipe, (this is a must if you have and diesel hdi this filter blocks up and takes out your turbo) also with new turbo you must prime it with oil before trying to start the car, also pull off the plugs to injectors and crank car over until you can see oil in the oil filler hole, then crack off the top banjo on turbo you should have oil come out by then.. if not then you have a issue dont ever run a turbo until oil has got to it..
because it was a complete engine i also had to re encode the injectors and reset adaptions i used autocom cdp+ for this as its faster than inpa i have found.
next week i will strip the engine that came out of it and see if its rebuild-able maybe find a spares repair mini with a dead engine so not all wasted

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