Update... well kinda... it's still stalling out until it gets hot but there is a lot of clicking as it cuts out and stalls from the relays in tge passenger door?? Not sure if they are the cause or jus a by product of it stalling like it does.

 

I learned the hard way that you HAVE to use the OEM oxygen sensor. This is the one for my 2004 R50;

Amazon.com: NTK 25648 Oxygen Sensor : Automotive

Buy NTK 25648 Oxygen Sensor: Oxygen - Amazon.com ✓ FREE DELIVERY possible on eligible purchases

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The new Bosch sensor I tried kept throwing a P0130 code. Apparently it’s a known problem.

Replacing it with the sensor above instantly cured the oxygen sensor code problem.

BTW, don’t use any dielectric grease when pushing the electrical connectors together. I read this will prevent ambient air from getting to the back side of the sensor and this is how the sensor is vented.

 

Thank you! I've got a new OEM O2 sensor on the was, along with a new oil feed line. The mini is currently torn apart as there was a very large oil leak coming from the line.

 

If you don’t already have a copy, the Bentley is the best service manual out there,

2010 MINI COOPER 1.6L L4 Turbocharged DOHC Repair Manual | Shop Now at RockAuto

Literature Parts and More for Your 2010 MINI COOPER at Reliably Low Prices. Fast Online Catalog. DIY-Easy. Your Choice of Quality. Full Manufacturer Warranty.

www.rockauto.com

The Dave Graham CD is pretty good too.

RockAuto has the best price I’ve found, although someone might sell a used one on eBay or someplace.

They only look expensive until you get a quote from a shop!

 

So, for anyone interested I found the problem... really crusty intake valves! Tore the mini apart while i was in there did a clutch and oil seals and put it all back together! Seems to be running great now! Took about 20hr across 3 days so not too bad. Next step is getting stuff together to do a bigger turbo and forged bottom end!

 

Solution, media blasting. Also, use exotic full synthetic oil that will leave as little muck around as possible. Motul is pretty good in that regard (alas, pricey). I've heard that catch cans help with carbon buildup, but might create other issues. Meth injection is a cure, as far as I know, but even more costs. These are GDIs after all, it's what we have to live with