Replacing Oil Pan In Mini Cooper S: Step-By-Step Guide

If you're looking to replace the oil pan on your Mini Cooper S 05, you've got a job ahead of you. It's not incredibly hard, but it is time-consuming and requires a lot of steps. First, you'll need to drain the oil and remove the oil pan mounting bolts. Then, you'll need to remove the old oil pan gasket and clean the surface. Next, you'll install the new oil pan gasket and oil pan, torque the mounting bolts, and replace the oil drain plug. Finally, you'll refill the engine with oil and replace the oil filter. The whole process should take around 4-16 hours, depending on your experience level. Make sure to have all the necessary tools and parts before you begin, and always refer to a repair manual for detailed instructions.

Jack up the car and drain the oil

Jacking up your Mini Cooper S 05 is a relatively straightforward process, but it requires careful attention to safety procedures. Here is a detailed guide on how to jack up the car and drain the oil:

Step 1: Safety First

Before you begin, it is crucial to prioritize your safety and that of your vehicle. Block the wheels of the car to prevent any unintended movement, and engage the parking brake. Place the car in first gear if it has a manual transmission or in "Park" if it is an automatic. Always use jack stands in pairs to support the car, and never rely solely on a floor jack. Place an emergency jack stand under the frame rails or front and rear subframe as a backup. Ensure that the car is on a level surface, and use wheel chocks to secure all four wheels. Additionally, place a few 2x4 pieces of wood in front of each wheel for extra security.

Step 2: Locate the Jacking Points

The Mini Cooper S 05 has reinforced boxed jack points near each wheel. These are designed to fit the factory jack when changing a tire. However, for all other instances, you will need to use jack stands. The best places to position your floor jack and jack stands are under the factory jack support areas. These metal cup pieces act as locators for professional-style hydraulic lifts. Place the jack under the front reinforced plate, then lower the car onto a jack stand. Repeat this process for the opposite side of the car. If you need to lift the entire car, place jack stands under both the front and rear points before lowering the vehicle.

Step 3: Stability Check

Once the car is up in the air and supported on the jack stands, perform a stability check. Gently push the car in different directions to ensure it is securely supported. If the car moves at all, adjust the jack stands until it is completely stable. You can also set up a spare jack stand or two as a precautionary measure.

Step 4: Jacking Up the Car

With the safety measures in place, you can now jack up the car. Use a floor jack with a minimum height of 80mm (3.1") to easily fit under the vehicle. Position the jack at the reinforced jacking points, centering the cup of the jack on the rectangular jacking point. Slowly raise the car until it is high enough to access the oil pan. Remember to work with a cool engine to avoid burns or scalding.

Step 5: Draining the Oil

With the car securely jacked up, locate the oil pan. Place a drain pan or container underneath the oil pan drain plug to catch the drained oil. Remove the drain plug using the appropriate tool, such as an oil filter wrench or a drain plug socket. Allow the oil to drain completely. This process may take around 10-15 minutes. During this time, you can also remove the oil filter if you plan on replacing it. Remember to have a responsible disposal plan for the used oil.

By following these steps, you can safely jack up your Mini Cooper S 05 and drain the oil, making it ready for further maintenance or repairs. Always work with a cool engine, wear protective gear, and have a thorough understanding of the process before proceeding.

Remove the oil pan mounting bolts

To remove the oil pan mounting bolts from your Mini Cooper S 05, follow these steps:

• Jack up and support your Mini securely using jack stands. It is important to ensure your vehicle is secure and stable before proceeding with any repairs.
• Place a drain pan under the oil pan. This will catch the drained engine oil.
• Remove the oil fill cap at the top of the engine. This will allow for proper drainage of the engine oil.
• Using an 8mm hex socket, remove the oil drain plug from the oil pan. Allow the oil to drain completely.
• Locate the oil pan mounting bolts. There should be sixteen 8mm bolts surrounding the oil pan.
• Start removing the mounting bolts using an 8mm socket wrench. You may need to use a socket extension and a universal joint adapter to reach some of the bolts. Take care not to strip or break the bolts.
• One of the bolts is located behind the exhaust manifold and cannot be reached with a socket wrench. Use an 8mm open-end or ratcheting box-end wrench to remove this bolt.
• With all the mounting bolts removed, carefully grasp the oil pan and lower it out of the vehicle.

It is important to work carefully and ensure that you have the correct tools and equipment before beginning this task. Always refer to a trusted repair manual or seek the assistance of a qualified mechanic if you are unsure about any steps or procedures.

Take out the old oil pan

To take out the old oil pan of your Mini Cooper S 05, follow these steps:

First, jack up and support your Mini. Place a 5-gallon drain pan under the oil pan. Remove the oil fill cap at the top of the engine to allow the oil to drain properly.

Next, using an 8mm hex socket, remove the oil drain plug from the oil pan. Allow the engine oil to drain completely. This should take around 10-15 minutes.

Now, start removing the oil pan mounting bolts. You will need an 8mm socket wrench, and for hard-to-reach bolts, use a socket extension and a universal joint adapter. There is one bolt behind the exhaust manifold that you won't be able to reach without removing the manifold. Use an 8mm open-end or ratcheting box-end wrench to remove this bolt.

With all the mounting bolts removed, carefully lower and remove the oil pan from the engine. Clean the oil pan thoroughly, removing any old oil and grime, especially from the gasket surface.

At this point, you can prepare the new oil pan and gasket for installation. However, this guide focuses on the removal process, so we won't cover the installation steps in detail.

Remember to always wear protective gear and ensure your vehicle is on a level surface and securely supported before starting any repairs.

Clean the oil pan gasket surface

To clean the oil pan gasket surface of your Mini Cooper S 05, you'll want to start by removing any old gasket residue. It's important to note that you should not use metal tools to scrape off the gasket, as your engine is likely made of soft aluminum, which can be easily damaged. Instead, opt for non-metal tools such as plastic or composite scrapers. Be cautious when using a scraper, as you only want to remove the gasket and not damage the surface of the engine.

If you find that scraping is too slow or tedious, you can try using a 3M Bristle Disc attached to a rotary tool. These discs are round heads with plastic pins that can quickly remove the gasket without damaging the metal surface. However, be cautious when using this method, as the green bristle discs are not recommended for aluminum and can cause damage if too much force is applied. It is preferable to use the white bristle discs, which are softer and approved for use on aluminum.

Once the majority of the gasket has been removed, you can use a corner of the scraper or a clean cloth to wipe away any remaining residue. Be sure to use a solvent like brake cleaner, lacquer thinner, or acetone to ensure that all oil and grime are removed before applying the new gasket. It is important that the surface is completely clean and free of oil, as this will affect the adhesion of the new sealant.

After cleaning, inspect the surface for any damage or irregularities. Use a straight edge to check for any depressions or low spots caused by the removal process. If there are any issues, you may need to have the surface milled or replaced.

Install the new oil pan and gasket

Now that you have removed the old oil pan and gasket, cleaned the crankcase-sealing surface, and applied the new sealant, it's time to install the new oil pan and gasket.

First, ensure that the new oil pan gasket is correctly positioned on the oil pan, with all the holes lining up correctly. Then, raise the oil pan into place, ensuring it is flush with the crankcase.

Next, install the fasteners finger-tight until the oil pan is secure. Do not tighten them yet. Once the oil pan is in place, tighten all the fasteners according to the manufacturer's specifications. For the Mini Cooper R56, torque the mounting bolts to 12 Nm (8.8 ft-lb).

At this point, you can reinstall the exhaust, change the engine oil filter, and fill the engine with new oil. Finally, run the engine and check for any leaks around the oil pan gasket and oil filter.

Frequently asked questions