After receiving a new head gasket on Saturday I started preparing the assembly of the Mini engine. Back during the restoration in 2019 I tried to keep the Mini as original as possible. This included sticking to the cast iron exhaust manifold and exhaust system. In 2023 the rear rusty and broken silencers got replaced with a new RC40 system with catalyst option. Part of this was a Maniflow LCB but a couple reasons prevented me from using it.
First off was flange height difference between the Maniflow LCB and the standard HIF4 inlet. For this I created split washers in the past, but fitting those was fiddly – especially two in the middle. This time I opted to weld on a matching washer onto the exhaust manifold and file it down as required. I tested this setup on the old head and the standard think washer work perfectly with this now.
Second problem was the missing Lambda probe port. This still needs to be welded onto the Y-piece of the Maniflow – but I decided to do a test fit first. Last issue to be addressed are gaskets to the catalyst which where not available back when I ordered in 2023 – but I finally got those now.
Just before I got started put the engine back together I had a good look at the rest of the front suspension and subframe. Miffi has been my daily driver even in Winter since 2021.And clearly – salty winter roads have taken their toll. The new subframe added in 2019 is starting to rust, the front axle hubs which I just painted with Hammerit are looking crusty. The Diff covers of the overhauled gearbox I put in in 2021 are leaking oil. One of the driveshaft pods covers was loose and needs cleanup. All-in-all a number of smaller things with most of them more on the optical side of things. Even though I thought about selling the Mini this year – I cannot leave it this way.
As it doesn’t really take much to get the engine out, I decided to do the right thing and overhaul the subframe and suspension now as well. All I had to do was to remove the pin and bolt from the rod change linkage as well as the lower engine steadies. Next I removed the clutch slave cylinder including mounting bracket to get more room to wiggle. I just took off the oil filter and this worked out but usually it is better to remove the entire adapter plate as well. With the enginer on the balancer of the hoist, I also removed the engine mount plate on the radiator side. The tricky part is wiggling the engine underneath the brake servo – which I thought I might leave in (well, we will see about this)
A few more bolts are left to get the subframe out – but this is relatively easy. The big question now is: What is the best way of protecting the subframe and suspension components for the next winter seasons? Powder coating with a Zinc Based primer ? 2K Epoxy primer and Raptor Liner/MIPA Protector? Hot-Dip Galvanzing?
Fixing C6622 
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