Placing 2nd Gen MINIs into Service Mode
There are times when access to parts located on the front of the R56 engine, or service procedures, require the radiator support to be pulled forward. Examples include, cylinder head removal, transmission removal, turbo removal, auxiliary pump service, intercooler input tube replacement, and easier exhaust downtube access.
Removing the bumper cover and bumper is the first step in enabling service mode. Directions for disconnecting the front bumper cover and bumper on 2nd generation MINIs can be found in Chad Miller's article R56 ALTA Positive Steering Response System (PSRS).
Tools to enable service mode: modular extensions, 10mm & 13mm sockets, ratchets, needle nose pliers, flat blade screwdriver.
An OEM tool for hanging and extending the front end on frame rail studs.
Extension tools designed for first generation MINIs are used in this article. The extension tools for the second generation are longer. The R56 tools are on the right in the photo below.
The turbo hoses and intake manifold hose need to be unclasped and separated. Thankfully MINI used captured screw type hose clamps that can be loosened with a screw driver or socket, unlike spring hose clamps on the early mode. Remove the bolt on the coolant overflow reservoir, and pull the reservoir upward. To disconnect the fresh air intake tube, pinch the tube at the radiator support to unclip.
Remove the cover from the hood release cable juncture box on the right side yolk arm, and disconnect the cable end coming from the cabin.
Unclip the wheel trim from the body skin, squeeze the retaining clip barbs with needle nose pliers and press from the inside, and unscrew the 10mm bolt holding the radiator support to the end of the body skin.
Disconnect the head lamp connectors on each side. Note the intake manifold hose at the upper right of the photo has been separated from the intercooler out tube.
Unbolt the fasteners on the tabs extending rearward from the head lamps, the two bolts on each end of the yolk, and unclip the sensor connector from the intake manifold tube (intercooler out tube).
From below the vehicle, unclip the AC compressor connector.
Disconnect Xenon washer connectors if you have them, including any other connectors in the area.
The front is now ready to pull forward while supported on modular extension tools. Proceed slowly looking for tucked wires offering resistance, and any missed connectors.
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