DescriptionThe Stage 4 Performance Upgrade kit
to transform you MINI! This kit blends the racing performance experience of Mini Mania with the demands of the enthusiastic MINI driver.
These kits are all about improving the flow into and out of the engine. Increased flow thru the oversized Turbocharger into the engine creates stronger combustion. The oversized Intercooler lowers the intake charge temperature for a more dense intake gases resulting in a more powerful combustion. Hi Flow Intake, Intake Plumbing, oversized downpipe, and Performance Exhaust completes this kit. All this combines for increased power to the wheels!
These kits includes components that are NOT STREET LEGAL.
Fits the following models:
2011-2016 R60 MINI Cooper S Countryman
2013-2016 R61 MINI Cooper S Paceman
You have a choice of Exhaust systems from:
- Borla - splices into the stock system downstream from the secondary catalytic converter.
- NM Engineering - splices into the stock system downstream from the secondary catalytic converter.
- Quicksilver - bolts-on at the downpipe flange which removes the secondary catalytic converter.
STAGE 4 APPLICATION CHART:
THE STAGE 4 CONCEPT
This heart of this kit is the KO3 42mm Quick Spool direct bolt-on Turbocharger. Other complementary products combine with the Turbo upgrade to extract the most out of this engine. This Turbo offers the perfect balance between performance and reliability - a direct 'bolt-on' upgrade with a noticeable increase in performance! (Kit includes the Turbo Install Kit with new oil supply line, seals, and gaskets.)
The Hi-Flow Performance Exhaust system provides a gain in horsepower combined with the right amount of aggressive tones consistent with the performance image of the MINI Cooper S. The Hi-Flow Induction system with their free flowing re-usable air filter allows the engine to develop more horsepower while providing superior protection against dirt and debris, extending the engine life. The Hi-Flow Charge Pipe increases flow by eliminating the OEM sound chamber and increasing pipe diameter over stock. The Turbo Outlet Pipe increases flow by eliminating the intake muffler. The 3 inch Hi-Flo™ CATTED Downpipe helps to minimize the backpressure and improves the Turbo's efficiency.
K03 Super 42 - 42mm Quick Spool K03 Turbo Upgrade
This Super 42 Hybrid K03 turbocharger is engineered to be the most reliable and high-performance upgrade turbo for the Turbocharged Cooper S. This can be the number 1 upgrade and designed to be a 'no tuning required' turbo that will add about ~ +30hp, and more with tuning!
- Larger 42mm compressor (compare to 37mm stock)
- Extended tip compressor wheel
- Designed for higher pressure
- Upgraded 360deg bearing
- High temperature alloy turbine housing
- Twin scroll turbine housing
- Water cooled bearing housing
This Super 42 upgrade high pressure high-flow dual scrolling turbo uses a big 42mm compressor to give you boost that starts early and last much longer than even the JCW turbo. (Boost with the stock Turbo drops off between the mid to high rpm). This turbocharger delivers outstanding response with torque and power gains across the entire power-band and the 42mm design gives you extra boost at the top end when you need it most. If you are looking for an extreme street upgrade that delivers full race performance this is the turbo for you. This Turbo will deliver great torque, spool early, and maintain boost towards red line.
The Turbocharger requires a Core Charge. This Core Charge is refunded when your used 'rebuildable' core is sent in. Different models and damages may reduce the amount of Core Charge Refund.
This kit also includes the Turbo Install Kit which includes a new Oil Supply Line and various gaskets and seals.
3.0 Inch Downpipe with CAT
Large Bore Downpipe with 3.0 inch pipe diameter produced in high quality 304 aircraft grade stainless steel. This material is anti-magnetic (other manufacturers stainless steel may not be) and is less susceptible to discoloration. This quality of stainless steel is used on all pipework and the total construction of the silencer.
Mandrel bending ensures full flow bends for better gas flow and Milltek systems are increased in bore to ensure ultimate performance without the loss of mid range torque. Includes bungs for the O2 sensors.
The Downpipe with Cat will possibly trigger a CEL due to cat effiency (the high flow cat takes longer to warm up). Use the optional O2 Sensor Spacer to eliminate CEL triggered by the P0420 error code. If you choose the Downpipe without Cat, the O2 spacer will not help - you will have the CEL.
Here are a couple reasons why the 3.0" downpipe improves performance:
- The larger downpipe provide a greater area for the exhaust gases to expand - ie a greater pressure differential. The Turbo focuses the exhaust energy into the turbine to carry as much energy as possible. As the exhaust exits the turbo and expands, the energy dissipates so the goal is to have the largest area possible for the gas to expand - or a larger downpipe.
- The inlet and outlet for the cat on the stock unit is 2.25", the inlet and outlet on this unit is 3.0". The oversized inlet and outlet greatly improves flow with significant reduction in back pressure. On an upgraded turbo, less backpressure equates to MORE HORSEPOWER. The larger the turbo, the more critical this becomes. It may not sound like much, but when you run a larger turbo - it makes a BIG difference!
Hi-Flow Performance Exhaust System
The exhaust upgrades improve flow out of the engine with less backpressure for increased performance.
These systems offer:
- Great Sounds
- Performance Increase
- Light Weight
- Quality Construction
- Great looks
- Simple Installation
Performance Intercooler Upgrade
This oversized Air-to-Air Intercoler Upgrade reduces inlet temperatures and improves performance. As the inlet temperature is reduced, the air becomes 'more dense' packing a greater number of O2 molecules, which results in a more powerful combustion. This nets more horsepower to the wheels!
Technically, the Intercooler upgrade does not 'add' horsepower, but it reduces the losses which results in a net gain at the wheels. The engine basically 'retains' the horsepower normally lost to high inlet temperatures. The difference is pronounced on warmer days where normally, the car would feel 'sluggish'. If you have warm climate or hot summers, this is a must have upgrade!
Hi-Flow Induction Kit
The 'Open-Air-Box' system gives you the abundance and unrestricted 360° of air source compared to OEM's sealed air box with flat filter and tube fed air source. During R&D, we installed temperature probes around the engine compartment and the gauge showed the inside temperature matched the ambient after vehicle speed past 20 mph. And by logging the Mass Air Flow (MAF) sensor also showed that open-air-box intake generated higher volume (gr/sec) of air going through the sensor. So when we had to choose between (a) cooler air at all speed with limited air source, vs. (b) cooler air at 20~ mph. with unlimited air source, the choice was pretty obvious.
The blue intake tube feature CNC mandrel bent aluminum pipe and finished with durable textured powder coat.
Hi-Flow Intake Charge Pipe Upgrade
The MINI Cooper S engine utilizes a turbocharger to pressurize the intake tract to force feed the engine air to produce power. As such, a weak point has been identified that impairs the efficiency of this system.
The Hi-Flow Charge Pipe Upgrade replaces the factory necked-down hose between the intercooler and throttle body (cold-side) with a new larger diameter CNC mandrel bent pipe and silicone couplers that will not expand under boost. The system eliminates OEM sound chamber which, in result, helps to increase turbo response as well as mid-range and top-end power.
Turbo Outlet Pipe
The R56 MINI Cooper S engine utilizes a turbocharger to pressurize the intake tract to force feed the engine air to produce power. The factory set-up uses an 'intake muffler' with reduced diameter and baffling that prevents 'smooth' airflow.
The Premium Hi-Flow Turbo Outlet Pipe eliminates the intake muffler and replaces the factory rubber hose between the turbocharger and intercooler (hot-side) with a new CNC mandrel bent pipe and silicone couplers that will not expand under boost.
This kit includes the Turbo Oil Supply line to avoid potential future turbo issues.
Over time, the turbo and turbo supply line builds a fine layer of 'coked' or cooked oil on the internal surfaces. When you remove the supply line from the turbo, this disrupts the continuity of the coked layer with great potential of some of the coking to flake free. These coked oil particles can easily clog the fine journals that feed oil to the turbo bearings. Once the the oil flow is compromised, it is only a matter of time for cascading failures that can damage the turbo and catalytic converter!
We STRONGLY recommend you change the motor oil more frequently than the factory recommendation. Anecdotal evidence suggests Turbo's with more frequent oil changes have fewer issues. We suggest 5000-7500 mile oil change interval.
For additional protection, take a look at the Turbo Oil Supply Line Thermal Wrap.
Manufacturer Limited Warranty covers all turbochargers to be free of defects in materials and workmanship for normal use and service up to 1 year (2 years if the oil line is replaced) after retail purchase. Manufacturer reserves the right to examine any part returned for warranty claim to determine whether a defect in materials or workmanship exists in such product. Manufacturer liability is limited to repairing, replacing or crediting towards other product, and credits will not exceed the invoice total for the parts.
Labor and storage charges are not products of the manufacturer and, therefore, will not be reimbursed for any reason. Final determination of the condition and suitability of the parts for uses contemplated by the buyer and is a sole responsibility of the buyer. Manufacturer will not be liable for any damage or injury to persons or property that might be claimed as a result of improper installation or misuse of any part subjected to this warranty. No warranty claim or refund, will be given until the item is in our possession and we have processed it which can take up to 20days.
If you are adding this kit because your Turbo has failed, it is the responsibility of the installer/owner to fix or resolve any and all problems that cause the original part/item to fail and can cause the new part/item to fail. Since we do not troubleshoot we take no responsibility for incorrectly diagnosing the issue that caused the initial part/item to fail. There are no warranties expressed or implied beyond those set forth above.
MANUFACTURER NOTES ON INSTALLATION:
[ ] Always replace the turbo oil supply line with the turbo. (Included in this kit)
- - - Due to excess heat round the turbocharger and particulates suspended in the turbo supply oil the oil will harden or "coke~ in the turbo and oil supply lines. If the oil supplyline is not replaced with the turbocharger the coked oil will break free from the side walls of the oil supply line and damage the turbocharger bearings. Cleaning the oil line will not help and only aggravate and increase the likelihood of the turbo failure due to coked oil breaking free form the sidewall.
[ ] Always replace the catalytic converter on mini coopers before installing a new turbo. (Included in this kit)
- - - The Catalytic converter may look clear but if any oil leaked into it some of the holes might be blocked and will cause back pressure. This starts to happen on Mini Coopers at 15k miles! Exhaust back pressure causes premature failure of the turbocharger. Turbochargers are not designed to have pressure on the exhaust side.
[ ] Always prime the turbocharger.
- - - No oil on the turbocharger bearings will cause failure of the bearings if they are dry even for a short period of time
[ ] Always flush oil after a turbocharger change
- - - Most turbochargers fail catastrophically this means that the metal and other items can end up in your oil. Always flush your oil a minimum of 3 times with new oil after an oil change.