How to change an Alternator for a 2004 Mini Cooper?

Answer 1

Question: how to change an alternator for a mini cooper? I'm an auto tech, over 40 years experience. I found this question by looking for the answer. So, Alldata says you need to remove the Intake manifold to replace this alternator. In my case it's the R50, standard Mini. not an S. flat rate time is 1.6 hrs to remove the intake manifold. flat rate time for Alternator is also 1.6 hrs. which doesn't make sense. so, I'm looking online for other perspectives, since it looks like it's possible to remove alternator by removing upper radiator hose, removing front motor mount and lifting the engine. We will see. and, may be almost the same amount of time. but my (possible) way would save having to order and wait for intake manifold gasket and o-Rings. plus it looks like, from the drawings, that I'll need to remove the front motor mount and lift the engine up anyway, just to remove the intake manifold. anyone have any experience on this? thanks update: found online; Online for S, may work for r50. Here's the two options spelled out... Option #1 - Chadtoolio's method. 1. Remove front bumper cover 1. Raise vehicle & support 2. Remove splash shield under engine. 3 bolts, 2 screws 3. Remove screws holding bumper cover to Modular Front End (MFE) 4. Remove plastic rivets securing bumper to lower spoiler 5. Remove bolts securing bumper cover to position adjustment bracket 6. Detach bumper cover clips from bumper carrier 7. Disconnect fog lights, turn signals, & outside temperature sensor 8. Lift off bumper cover 2. Remove Front bumper carrier 1. Pull out electrical harness for outside temperature sensor 2. Remove fasteners securing front bumper carrier to front frame supports 3. Remove nuts from crush stand tubes 4. Lift out bumper carrier (watch for cables or hoses to be snagged) 3. pull 4 clips out of RH Rad. core support to fender liner. 1. Detach both front wheel housing liners from MFE 4. Disconnect horn wire on RH side, 5. Disconnect CVT radiator & cap lines 1. Remove screw holding CVT radiator to radiator 2. slide left to disengage 3. disconnect & plug CVT radiator lines 6. Remove front crush tubes 7. Remove bolt mounting each tube to the MFE 8. pull Rad. core support out to gain access. 1. Install two 100 mm (4 inch) m8 bolts to support the MFE 2. slide MFE forward 9. Disconnect battery 10. Remove alt belt 1. ??? 11. Remove alternator 1. Remove 3 bolts for alternator, one plug in connector at alt. and 10mm nut for B positive wire on Alt. When reinstalling, don't forget to do the following... 1. Replace radiator hose clamp 2. top off CVT fluid 3. top off & bleed cooling system Option #2 - Bentley Service Manual method. 1. Raise vehicle & support 2. Disconnect battery 3. Remove fuel tank vent valve 1. disconnect vent hoses via quick fit connectors 2. straighten retaining tab 3. slide vent valve off bracket 4. remove electrical harness connector 4. Remove splash shield under engine 3 bolts, 2 screws 5. Remove Right font wheel 6. Remove Right front wheel housing liner 7. Remove alt belt 1. Use special tool 11 8 390 to release drive belt tension 2. Use lock pin (special tool 11 8 280) to lock drive belt tensioner 3. lift off drive belt 8. Remove Intake Manifold 1. Remove air filter housing 1. Detach air duct from air filter housing 2. detach wire harness 3. Remove air filter housing mounting screws 4. Detach crankcase breather hose 5. Lift air filter housing 2. remove throttle valve assembly 1. Loosen & remove air duct clamp at throttle assembly 2. detach air duct 3. disconnect electric harness connector 4. detach fuel vent line 5. loosen & remove 4 throttle assembly mounting screws 6. lift off throttle assembly 3. Remove brake booster vacuum line 1. Press brake booster vacuum line locking ring downward to detach from manifold 2. remove hose from PCV valve 4. Remove fuel rail cover 1. Squeeze locking tabs to detach rear of cover 2. tilt and pull cover forward until plastic clips detach from fuel rail (careful, they break easily) 5. Detach electrical harness connector from intake air temp/MAP sensor 6. Detach electrical harness connector from knock sensor 7. Disconnect top fuel vent line and unclip at fuel rail 8. Detach Fuel Rail from top of engine 1. disconnect fuel injector electrical harness connector 2. disconnect harness connector 3. remove cover from harness loom and swing harness out of way to left side of engine 4. working at fuel rail, unclip hoses and ducts. Cut wire tires as needed 5. disconnect vacuum line at base of fuel pressure regulator 6. remove 2 fuel rail mounting bolts 9. Remove fuel rail together with fuel injectors from intake manifold 1. unclip fuel line from engine vibrations damper bracket 2. carefully fold hose to right & rear of engine. Protect fuel rail & injectors in a clean plastic bag 10. Remove oil dipstick 11. Remove intake manifold mounting bolts in sequence working outside to inside 12. Unclip coolant line below manifold 13. lift manifold 9. Remove alternator 1. Remove 3 bolts for alternator, one plug in connector at alt. and 10mm nut for B positive wire on Alt. When reinstalling, don't forget to do the following... 1. replace intake manifold profile gaskets 2. torque manifold to cylinder head to 26 Nm 3. Coat fuel injector sealing o-rings with anti seize agent 4. torque fuel rail to intake manifold to 25 Nm 5. Replace sealing ring between throttle valve assembly and intake manifold 6. torque throttle valve assembly to intake manifold to 9 Nm 7. torque air filter housing to body 7-10 Nm 8. Replace air duct clamp