R56, R55, R57, R58, R59 MINI Cooper, Cooper S

R56, R55, R57, R58, R59 MINI Cooper, Cooper S
R56, R55, R57, R58, R59 MINI
Cooper, Cooper S, JCW
JCW GP2 Brake Kit Installation Instructions
Proper service and repair procedures are vital to the safe, reliable operation of all motor vehicles as well as the personal safety of those performing the repairs. Standard safety procedures and precautions (including
use of safety goggles and proper tools and equipment) should be followed at all times to eliminate the possibility of personal injury or improper service which could damage the vehicle or compromise its safety.
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MINI COOPER JCW GP2 BRAKE KIT INSTALLATION
ES#2652233
ES#2702967
INTRODUCTION
MINI Co op er GP2 Big Brake Full Up grade Kit ES#2702967
This kit offered by ECS Tuning is a complete front and rear brake upgrade for the MINI Cooper and Cooper S. Using OEM
engineered components and adding in our ECS Tuning Exact Fit front brake lines, it is a full conversion to upgrade your
brakes with the performance ability of the MINI Cooper JCW GP2 braking system. This kit is complete with everything you
need for a seamless, trouble free installation. Please see page 50 for important Anti-lock Brake System information.
MINI Co op er GP2 Big Brake Front O nly Kit ES#2652233
The MINI Cooper JCW comes standard with the same big rear brakes as the MINI Cooper GP2. This front brake only kit is
the perfect upgrade to give your MINI the performance ability of the JCW GP2 six piston caliper braking system. Using
OEM engineered components and adding in our ECS Tuning Exact Fit front brake lines, It comes complete with everything
you need for a seamless, trouble free installation.
BASIC SKILLS
REQUIRED
ADVANCED SKILLS &
EXPERIENCE REQUIRED
SOME EXPERIENCE
RECOMMENDED
PROFESSIONAL SKILLS &
SPECIALTY TOOLS REQUIRED
Installing a MINI Cooper GP2 brake upgrade kit is a weekend project that will equip your MINI Cooper with the track proven braking ability of
the JCW GP2 braking system. Even if you do not have a lot of previous brake experience, following these instructions closely should allow for a
smooth, trouble free installation. Plan accordingly based on your experience level. Before you begin, read and familiarize yourself with these
instructions and make sure you have all the required tools on hand. Thank you for purchasing the MINI JCW GP2 Big Brake Kit. We appreciate
your business!
ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281
1.800.924.5172
WWW.ECSTUNING.COM
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MINI COOPER JCW GP2 BRAKE KIT INSTALLATION
ES#2652233
ES#2702967
TABLE OF CONTENTS
Kit Contents......................................................................................................................pg.4
Required Tools and Equipment.................................................................................pg.7
Shop Supplies and Materials......................................................................................pg.7
Installation Notes...........................................................................................................pg.8
Preparation and Safety.................................................................................................pg.8
Installing the New Brake Master Cylinder.............................................................pg.9
Removing the Original Front Brakes.......................................................................pg.21
Installing the New GP2 Front Brakes.......................................................................pg.29
Removing the Original Rear Brakes.........................................................................pg.39
Installing the New GP2 Rear Brakes.........................................................................pg.43
Bleeding the Brake System.........................................................................................pg.50
Torque Specifications....................................................................................................pg.51
Brake Pad Break-In and Maintenance.....................................................................pg.51
When installing the GP2 Big Brake Kit, the GP2 master
cylinder must be installed for proper braking.
ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281
1.800.924.5172
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MINI COOPER JCW GP2 BRAKE KIT INSTALLATION
ES#2652233
ES#2702967
MINI COOPER GP2 BRAKE KIT CONTENTS
JCW GP2 6 PIston LH
Front Brake Caliper
JCW GP2 6 PIston RH
Front Brake Caliper
Front Brake Pad
Retaining Bolts
Front Brake Pad
Tension Clips
ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281
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Front Brake Caliper
Bracket Bolts
Front Brake Pad Set
Front Brake Rotors
Front Brake Pad
Warning Harness
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MINI COOPER JCW GP2 BRAKE KIT INSTALLATION
ES#2652233
ES#2702967
MINI COOPER GP2 BRAKE KIT CONTENTS
Front Brake Pad Warning
Sensor Harness Clip
LF Brake Shield
OE#34116858073
ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281
ECS Tuning Exact Fit Front
Brake Lines
GP2 Master Cylinder
RF Brake Shield
OE#34116858074
Brake Fluid
1.800.924.5172
WWW.ECSTUNING.COM
Master Cylinder Mounting
Nuts
ECS Tuning Exact Fit Rear
Brake Lines (Full kit only)
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MINI COOPER JCW GP2 BRAKE KIT INSTALLATION
ES#2652233
ES#2702967
MINI COOPER GP2 BRAKE KIT CONTENTS
Rear Brake Caliper
Bolts (Full kit only)
Rear Brake Pad Tension
Clips (Full kit only)
ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281
LH Rear Brake Caliper
Bolts (Full kit only)
Rear Pad Warning
Harness (Full kit only)
1.800.924.5172
WWW.ECSTUNING.COM
RH Rear Brake Caliper
Bolts (Full kit only)
Rear Brake Rotors
(Full kit only)
Rear Brake Caliper
Brackets (Full kit only)
Rear Brake Pads
(Full kit only)
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MINI COOPER JCW GP2 BRAKE KIT INSTALLATION
ES#2652233
ES#2702967
REQUIRED TOOLS
We recommend that you have a complete selection of tools and equipment necessary for automotive repair. Below is a list of the tools we used
to install the MINI JCW GP2 Big Brake Kit. Additional tools may be required for any issues that arise during installation such as rust, corrosion, or
broken and stripped fasteners.
• 17mm Protecta-Socket (for lug nuts)......................................................................... Available at ecstuning.com...........................................................................ES#2221243
• 3/8” Drive Torque Wrench.............................................................................................. Available at ecstuning.com...........................................................................ES#2221245
• 1/2” Drive Torque Wrench.............................................................................................. Available at ecstuning.com...........................................................................ES#2221244
• Flat and Phillips Blade Screwdriver(s)........................................................................ Available at ecstuning.com...........................................................................ES#2225921
• Torx Drivers T30, T40........................................................................................................ Available at ecstuning.com...........................................................................ES#11417
• Schwaben Wiper Arm Puller (Optional).................................................................... Available at ecstuning.com...........................................................................ES#2190252
• Drain Pan.............................................................................................................................. Available at ecstuning.com...........................................................................ES#2748892
• Impact Driver...................................................................................................................... Available at ecstuning.com...........................................................................ES#11416
• 3/8” Drive Sockets: 10mm,15mm,16mm.................................................................. Available at ecstuning.com...........................................................................ES#2763772
• 3/8” Drive Ratchet............................................................................................................. Available at ecstuning.com...........................................................................ES#2765896
• External Torx Socket: E7.................................................................................................. Available at ecstuning.com...........................................................................ES#2777804
• Torx Bit Sockets: T25, T40, T50...................................................................................... Available at ecstuning.com...........................................................................ES#11418
• Brake Fluid Catch Bottle................................................................................................. Available at ecstuning.com...........................................................................ES#4557
• 1/2” Drive Ratchet
• 1/2” Drive Sockets: 16mm
• Flare Nut Wrenches/Crows Feet: 11mm
• Caliper Hangers
• Hex Bit (Allen) Socket: 10mm
• Open End Wrenches: 10mm, 14mm, 15mm
• Angle Grinder with Cleaning Disc
SHOP SUPPLIES AND MATERIALS
• Hand Cleaner/Degreaser...................................................................................... Available at ecstuning.com..................................................................ES#2167336
• Aerosol Brake Cleaner........................................................................................... Available at your local auto parts store
• Shop Rags................................................................................................................ Available at your local auto parts store
• Aerosol Spray Lubricant/Penetrating Oil......................................................... Available at your local auto parts store
ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281
1.800.924.5172
WWW.ECSTUNING.COM
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MINI COOPER JCW GP2 BRAKE KIT INSTALLATION
ES#2652233
ES#2702967
INSTALLATION NOTES
• RH refers to the passenger side of the vehicle.
• LH refers to the driver side of the vehicle.
• Always use the proper torque specifications.
• If applicable to this installation, torque specifications will be listed throughout the document and at the end as well.
• Please read all of these instructions and familiarize yourself with the complete process before you begin.
GENERAL PREPARATION AND SAFETY INFORMATION
ECS Tuning cares about your health and safety. Please read the following safety information. This information pertains to automotive service
in general, and while it may not pertain to every job you do, please remember and share these important safety tips.
• Park your car in a safe, well lit, level area.
• Shut the engine off and remove the key from the ignition switch.
• Make sure any remote start devices are properly disabled.
• Always wear safety glasses.
• Make sure the parking brake is applied until the vehicle is safely lifted and supported.
• If using an automotive lift, be sure and utilize the factory specified lift points. Lifting a vehicle in an incorrect location can cause damage to the
suspension/running gear.
• When lifting a vehicle using a jack, always utilize the factory specified lift points. Lifting a vehicle in an incorrect location can cause damage
to the suspension/running gear. Always support the vehicle with jack stands.
• Always read and follow all safety information and warnings for the equipment you are using.
!
Never get underneath a vehicle that is supported only by a jack. Always make sure
that the vehicle is securely supported on jack stands.
ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281
1.800.924.5172
WWW.ECSTUNING.COM
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MINI COOPER JCW GP2 BRAKE KIT INSTALLATION
ES#2652233
ES#2702967
INSTALLING THE NEW BRAKE MASTER CYLINDER
Step 1:
Open the hood and remove the cowl seal by pulling it up off
the lip of the cowl panel in the direction of the arrows.
When installing the GP2 Big Brake Kit, the GP2 master
cylinder must be installed for proper braking.
NOTE
We are installing the master cylinder first so only clean, new
brake fluid will enter the system. Following these instructions
closely will eliminate any large air pockets in your braking
system and take the stress and mess out of bleeding your
brakes.
Step 2:
Pivot each wiper arm cap up, then gently pull and wiggle back
and forth and pull them off the wiper arms. The picture on
the right shows close up detail of the end of the caps.
ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281
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MINI COOPER JCW GP2 BRAKE KIT INSTALLATION
ES#2652233
ES#2702967
INSTALLING THE NEW BRAKE MASTER CYLINDER
Step 3:
15mm Wrench
Remove both wiper arm nuts.
Step 4:
Wiper Arm Puller (optional)
Remove both wiper arms. There are two ways to do this:
A: Use a wiper arm puller. This is the “correct” way to do this
and it works very well, however on the LH side, there is not
enough clearance between the hood and the wiper arm to
use a puller. Method “B” can be used in this situation and is
acceptable to use for both sides if you do not have a puller.
B: Fold the wiper arm up, then gently rock it back and forth
so the motion is being transferred to the base of the wiper
arm. This will release the base of the wiper arm from the
splines on the wiper transmission. Be patient and do not be
aggressive with this or you may damage the wiper arm pivot
or transmission.
ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281
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A
B
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MINI COOPER JCW GP2 BRAKE KIT INSTALLATION
ES#2652233
ES#2702967
INSTALLING THE NEW BRAKE MASTER CYLINDER
Step 5:
10mm Socket
Remove the three fasteners (One bolt and two nuts) from the
RH (passenger side) cowl panel.
Step 6:
First pull up on the RH cowl panel where it meets the
windshield until it is free of the channel at the base of the
windshield. Then lift the cowl panel at the front to disengage
the clips, and pull it towards the center of the car to remove it.
Work slowly to make sure the cowl panel clears the base of the
“A” pillar and hood.
ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281
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MINI COOPER JCW GP2 BRAKE KIT INSTALLATION
ES#2652233
ES#2702967
INSTALLING THE NEW BRAKE MASTER CYLINDER
Step 7:
10mm Socket
Remove the three fasteners and unclip the washer hose on
the LH cowl panel. Remove the panel in the same manner as
the RH side, first pulling up where it contacts the windshield,
then releasing the clips at the base, and finally pulling it
towards the center of the vehicle to remove it.
Step 8:
Small Flat Blade Screwdriver
Remove the brake fluid reservoir cap and screen. You may
need to use a small flat blade screwdriver to help remove the
screen.
C AUTION
Brake fluid is extremely corrosive and damaging. Be sure to
protect all surroundings with fender covers and rags, and clean
up any spills immediately.
ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281
1.800.924.5172
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MINI COOPER JCW GP2 BRAKE KIT INSTALLATION
ES#2652233
ES#2702967
INSTALLING THE NEW BRAKE MASTER CYLINDER
Step 9:
Fluid Extractor
Draw all the old fluid out of the brake fluid reservoir.
Step 10:
Depress the locking tab and pull the electrical connector off
the brake fluid reservoir.
ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281
1.800.924.5172
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MINI COOPER JCW GP2 BRAKE KIT INSTALLATION
ES#2652233
ES#2702967
INSTALLING THE NEW BRAKE MASTER CYLINDER
Step 11:
Pull the clutch cylinder supply hose off of the reservoir. Begin
by pulling back on the hose with light but constant pressure.
Gently wiggle the hose back and forth as you slowly increase
the pressure and it will come off with relative ease.
C AUTION
Even though you have removed the old fluid, you will still
experience brake fluid loss when disconnecting the clutch
supply hose and when removing the reservoir. Be sure
to place shop towels underneath the master cylinder to
absorb the spilled fluid.
Step 12:
E7 Torx Socket
Remove the reservoir retaining screw (arrow).
ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281
1.800.924.5172
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MINI COOPER JCW GP2 BRAKE KIT INSTALLATION
ES#2652233
ES#2702967
INSTALLING THE NEW BRAKE MASTER CYLINDER
Step 13:
Remove the master cylinder reservoir by pulling it straight up
using both hands and even, steady pressure. To keep brake
fluid from dripping, It is best to hold a rag underneath as you
move the reservoir to your work surface.
Step 14:
11mm Flare Nut Wrench
Disconnect the brake lines from the master cylinder. Do not
bend them in any way or try to reposition them. Once they
are disconnected, simply rest them on top of the master
cylinder.
ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281
1.800.924.5172
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MINI COOPER JCW GP2 BRAKE KIT INSTALLATION
ES#2652233
ES#2702967
INSTALLING THE NEW BRAKE MASTER CYLINDER
Step 15:
13mm Wrench
Remove both master cylinder mounting nuts.
Step 16:
Pull the master cylinder off the brake booster and remove it
from the car. Move the brake lines gently as necessary when
removing the master cylinder, but try to keep them as close to
their original position as possible.
NOTE
Stored vacuum in the brake booster will hold the master cylinder
in place. You will hear the hissing of air as you pull the cylinder
from the booster. This is normal.
ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281
1.800.924.5172
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MINI COOPER JCW GP2 BRAKE KIT INSTALLATION
ES#2652233
ES#2702967
INSTALLING THE NEW BRAKE MASTER CYLINDER
Step 17:
13mm Socket, Torque Wrench
Thoroughly clean up any spilled brake fluid, then install
the new GP2 master cylinder using the new mounting nuts
supplied with the kit. Torque the nuts to 23 Nm (17 Ft-lbs).
Step 18:
11mm Flare Nut Wrench
Connect both brake lines. Tighten them just until they are
fully seated. It is not necessary to fully tighten them at this
time.
ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281
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MINI COOPER JCW GP2 BRAKE KIT INSTALLATION
ES#2652233
ES#2702967
INSTALLING THE NEW BRAKE MASTER CYLINDER
Step 19:
Wipe the outside of the reservoir clean, then position it on
top of the master cylinder and push down with even pressure
until it is fully seated in the grommets.
TECH TIP
A small amount of clean brake fluid on the seals will act
as a lubricant and make the reservoir installation easy.
Step 20:
E7 Torx Socket
Complete the following:
Install the reservoir retaining screw.
Push the clutch supply hose back onto the reservoir.
Install the screen.
Fill the reservoir with new brake fluid.
ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281
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MINI COOPER JCW GP2 BRAKE KIT INSTALLATION
ES#2652233
ES#2702967
INSTALLING THE NEW BRAKE MASTER CYLINDER
Step 21:
Inspect the tool in the picture at right. It is a flare nut crow’s
foot on the end of a short extension. This will give you access
to loosen and tighten the flare nut fittings on the master
cylinder with the reservoir installed.
NOTE
Carefully performing the follwing procedure will bleed the
master cylinder and prevent any air from being ingested into
the ABS unit.
Step 22:
11mm Flare Nut Wrench
Make sure there are still plenty of rags underneath, then using
the tool shown above, loosen both flare nut fittings on the
master cylinder approximately two full turns. The lines should
be loose enough to feel them wiggle freely in the fittings.
Watch the fittings very closely. As gravity draws the brake
fluid through the master cylinder, you will see bubbles being
forced out between the lines and the fittings. Allow the fluid
to bleed in this manner until no more air bubbles can be seen
and fluid is running/dripping out of the fittings. (This will
generally take about 6-7 minutes).
Tighten the fittings.
ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281
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MINI COOPER JCW GP2 BRAKE KIT INSTALLATION
ES#2652233
ES#2702967
INSTALLING THE NEW BRAKE MASTER CYLINDER
Step 23:
Complete the following:
Top off the brake fluid.
Install the reservoir cap.
Use brake parts cleaner to flush away any remaining residue.
Plug in the electrical connector.
Remove all rags and perform a final wipe down.
Step 24:
Check the brake pedal “feel”. It should be firm with only
about an inch of travel. Complete the following:
Check both brake line flare fittings for leaks.
Install both cowl covers.
Install both wiper arms and torque them to 20 Nm (15 Ft-lbs).
Install the wiper arm caps and cowl seal.
ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281
1.800.924.5172
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MINI COOPER JCW GP2 BRAKE KIT INSTALLATION
ES#2652233
ES#2702967
REMOVING THE ORIGINAL FRONT BRAKES
Step 1:
17mm Protecta-Socket
Safely raise and support the vehicle and remove the front
wheels. If you are installing the complete front and rear
upgrade kit on your car, remove the rear wheels at this time as
well.
When installing the GP2 Big Brake Kit, the GP2 master
cylinder must be installed for proper braking. If
you have not installed the master cylinder, please
perform the master cylinder installation beginning
on page nine before you proceed.
Step 2:
On the LH side, pull the brake pad warning sensor harness out
of it’s retaining clip, then remove the clip off the end of the
brake hose.
NOTE
JCW brakes are shown in this example. MINI Cooper and
Cooper S brakes differ in design and appearance but you
can still follow these steps and remove the calipers in the
same manner. See the following page, 22, for reference
pictures of Cooper and Cooper S brakes.
ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281
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MINI COOPER JCW GP2 BRAKE KIT INSTALLATION
ES#2652233
ES#2702967
COOPER AND COOPER S FRONT BRAKES
Original Cooper and
Cooper S front brakes are
shown here. Instead of
a fixed caliper, they are
a floating caliper design
which consists of the
caliper, two slide pins,
and a caliper bracket.
The slide pins move back
and forth in the bracket
and the caliper is bolted
to the slide pins. Even
though you can unbolt
and remove the caliper
then remove the caliper
bracket separately, you
can leave the caliper
bracket and caliper
together and remove
them as one unit as we
have shown with the
fixed JCW caliper.
Caliper
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Caliper Bracket
Slide Pins
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MINI COOPER JCW GP2 BRAKE KIT INSTALLATION
ES#2652233
ES#2702967
REMOVING THE ORIGINAL FRONT BRAKES
Step 3:
Separate the pad warning harness from the ABS sensor wire
by unfastening the single rubber retainer and pulling the ABS
sensor wire out of the the molded clips on the pad warning
harness.
Step 4:
T30, Phillips Screwdriver
Remove the eight fender liner retainers highlighted in this
picture.
TECH TIP
Six of these fasteners are expanding rivets (see inset photo).
The center screw of each rivet only needs to be unscrewed
far enough to allow the fingers to collapse so the rivet can
be pulled out.
ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281
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MINI COOPER JCW GP2 BRAKE KIT INSTALLATION
ES#2652233
ES#2702967
REMOVING THE ORIGINAL FRONT BRAKES
Step 5:
Pull back the fender liner and locate the white electrical
connector for the brake pad warning harness.
Step 6:
Locking
Tab
Pull the connector out of it’s retaining clip and disconnect
it by depressing the locking tab and pulling the two halves
apart. Remove the original pad sensor wiring harness.
ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281
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MINI COOPER JCW GP2 BRAKE KIT INSTALLATION
ES#2652233
ES#2702967
REMOVING THE ORIGINAL FRONT BRAKES
Step 7:
T30, Phillips Screwdriver
Connect the new front brake pad warning harness connector,
route it in the same location as the old and reattach it to the
ABS sensor harness. Reinstall the fender liner.
NOTE
The end of the new harness will remain disconnected at this
time. It will be connected and secured after the new front
calipers are installed.
Step 8:
Flat Blade Screwdriver
Gently pry between the brake rotor and the brake pads on
each side of both front calipers. This will push the pistons
slightly back into the caliper, making removal easier.
ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281
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MINI COOPER JCW GP2 BRAKE KIT INSTALLATION
ES#2652233
ES#2702967
REMOVING THE ORIGINAL FRONT BRAKES
Step 9:
Pull the brake hose grommets out of their retaining brackets.
Step 10:
16mm Socket, 1/2” Ratchet
Remove both brake caliper mounting bolts on each side.
NOTE
JCW brakes are shown in this example. MINI Cooper and
Cooper S brakes will differ in appearance but the calipers
can be removed in the same manner.
ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281
1.800.924.5172
WWW.ECSTUNING.COM
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MINI COOPER JCW GP2 BRAKE KIT INSTALLATION
ES#2652233
ES#2702967
REMOVING THE ORIGINAL FRONT BRAKES
Step 11:
Caliper Hanger
Lift the brake calipers off and hang them so there is no weight
on the hoses.
NOTE
We leave the brake hoses connected until we are ready to install
the new ones because it keeps the mess to a minimum. Even
though the kit comes with new hoses, we prefer to hang the
calipers so the hose integrity is not compromised in the event
they get used on another vehicle.
Step 12:
T50, Impact Driver
Remove the brake rotor retaining screws, then pull the rotors
off each drive hub. Using an impact driver is one of the easiest
ways to loosen the rotor screws.
NOTE
If your rotor screws are broken or missing, we recommend
replacement. New rotor screws are availabe at ecstuning.com.
ES#16458
ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281
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MINI COOPER JCW GP2 BRAKE KIT INSTALLATION
ES#2652233
ES#2702967
REMOVING THE ORIGINAL FRONT BRAKES
Step 13:
T25 Torx
Remove the four screws (highlighted) on each side and then
remove the original brake shields.
Step 14:
Angle Grinder or Wire Brush
Thoroughly clean the surface of each drive hub. This will
ensure that the new rotors will be properly seated when
installed.
ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281
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MINI COOPER JCW GP2 BRAKE KIT INSTALLATION
ES#2652233
ES#2702967
INSTALLING THE NEW GP2 FRONT BRAKES
Step 1:
T25 Torx
Thoroughly clean the area underneath the original brake
shields, then install the new ones. There is a left and a right,
be sure to use the correct shield on each side.
LF Brake Shield
OE#34116858073
RF Brake Shield
OE#34116858074
Step 2:
Apply a thin layer of grease to the surface of each drive hub.
This will prevent corrosion between the rotor and drive hub.
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MINI COOPER JCW GP2 BRAKE KIT INSTALLATION
ES#2652233
ES#2702967
INSTALLING THE NEW GP2 FRONT BRAKES
Step 3:
T50 Torx, Torque Wrench
Place a new rotor into place on each drive hub and install the
new rotor screws included with the kit. Torque them to 27
Nm (20 Ft-lbs).
NOTE
Apply a small amount of anti seize to each front brake rotor
screw before installing.
Step 4:
Clean the surface of each brake rotor to remove any grease or
oil using aerosol brake parts cleaner sprayed onto a rag.
NOTE
What appears as gray paint on the rotor is a protective coating.
It is not necessary to remove this coating. It will not affect pad
break in or performance.
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30
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MINI COOPER JCW GP2 BRAKE KIT INSTALLATION
ES#2652233
ES#2702967
INSTALLING THE NEW GP2 FRONT BRAKES
Step 5:
To prepare the brake calipers for installation, begin by placing
one on a soft fender cover or towel.
NOTE
Be sure to install the correct caliper on each side. The easy way
to identify them is to hold a caliper in place over the rotor and
make sure the bleeder screw is located at the top.
Lubrication
Points
Step 6:
Apply a small amount of brake lubricant to the bare surfaces
in each brake caliper, as indicated by the arrows in the top and
bottom pictures.
Lubrication
Points
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31
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MINI COOPER JCW GP2 BRAKE KIT INSTALLATION
ES#2652233
ES#2702967
INSTALLING THE NEW GP2 FRONT BRAKES
Step 7:
Two Hammers
Install a brake pad tensioning clip into the top of each brake
caliper. The easiest way to do this is to position the clip in
place from the bottom, then rest the wooden handle of a
hammer on one side of the clip, and hit the top of the hammer
lightly with another. You will find that it will easily pop into
place.
Use a hammer handle to
pop each clip in place
Installed clip viewed
from top
Step 8:
Slide one of the new front brake pads into place in a caliper as
shown in the picture.
NOTE
All four front brake pads are the same.
ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281
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32
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MINI COOPER JCW GP2 BRAKE KIT INSTALLATION
ES#2652233
ES#2702967
INSTALLING THE NEW GP2 FRONT BRAKES
Step 9:
T40 Torx
Hold the brake pad in place and turn the caliper over. While
pressing up on the brake pad to overcome the tension on the
pad spring, insert the pad retaining bolts and thread them in
just until they are fully seated.
Step 10:
T40 Torx
Install the remaining brake pads in the same manner. The
calipers are now ready for installation on the car.
ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281
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WWW.ECSTUNING.COM
33
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MINI COOPER JCW GP2 BRAKE KIT INSTALLATION
ES#2652233
ES#2702967
INSTALLING THE NEW GP2 FRONT BRAKES
Step 11:
Slide the assembled calipers into place over each brake rotor.
Step 12:
16mm, Torque Wrench
Install the new caliper bracket bolts included with the kit and
torque them to 110 Nm (81 Ft-lbs).
ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281
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34
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MINI COOPER JCW GP2 BRAKE KIT INSTALLATION
ES#2652233
ES#2702967
INSTALLING THE NEW GP2 FRONT BRAKES
Step 13:
10mm Hex Bit Socket, Torque Wrench
Check the torque of the caliper bolts. These should come
properly torqued, but it’s better to double check them. Set
your torque wrench to 115 Nm (85 Ft-lbs) and check them on
both front calipers.
Step 14:
T40 Torx Socket, Torque Wrench
Torque all of the brake pad retainer bolts to 30 Nm (22 Ft-lbs).
ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281
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35
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MINI COOPER JCW GP2 BRAKE KIT INSTALLATION
ES#2652233
ES#2702967
INSTALLING THE NEW GP2 FRONT BRAKES
Step 15:
14mm
Install and tighten a new ECS Tuning Exact Fit Brake line into
each front caliper.
NOTE
Both ECS Tuning Exact Fit front brake lines are the same.
Step 16:
Clean the area where the original brake hose connects to
the hard line by flushing it with brake parts cleaner. This will
remove dirt and rock particles that tend to build up here and
prevent anything from falling into the new brake hose during
installation.
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Clean
this area
thoroughly
36
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MINI COOPER JCW GP2 BRAKE KIT INSTALLATION
ES#2652233
ES#2702967
INSTALLING THE NEW GP2 FRONT BRAKES
Step 17:
11mm Flare Nut Wrench
Place a drain pan underneath to catch brake fluid, then
loosen and disconnect the brake line on each side. With the
brake lines disconnected from the original hoses, you can
now remove the original calipers from the car.
Step 18:
11mm Flare Nut Wrench
Connect the new ECS Tuning Exact Fit brake lines on each side
and tighten the line fittings. Push the brake hose grommets
into their retainers.
NOTE
There is generally no specific torque specification for brake flare
fittings. As a standard rule of thumb, tighten the flare nut until it
is fully seated, then an additional 1/6 turn. These brake lines have
ISO flares. When the flare nut becomes tight, it is bottomed out,
applying a predetermined amount of pressure on the ISO flare to
create the seal. Additional tightening of the flare nut does not
increase the sealing ability of an ISO flare, it can only weaken the
threads on the nut or component.
ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281
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WWW.ECSTUNING.COM
37
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MINI COOPER JCW GP2 BRAKE KIT INSTALLATION
ES#2652233
ES#2702967
INSTALLING THE NEW GP2 FRONT BRAKES
Step 19:
LF only: Install the new brake pad warning harness clip
(included with the kit) onto the end of the ECS Tuning brake
line, then push the harness into place as shown in the picture.
Step 20:
Complete the following:
Install the pad warning harness into the cutout in the LH
front brake pad.
Follow the brake bleeding procedure on page 50. If you
are installing rear brakes, install them first then bleed all
brakes at the same time.
Reinstall and torque the wheels to 140 Nm (103 Ft-lbs).
ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281
1.800.924.5172
WWW.ECSTUNING.COM
38
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MINI COOPER JCW GP2 BRAKE KIT INSTALLATION
ES#2652233
ES#2702967
REMOVING THE ORIGINAL REAR BRAKES
Step 1:
10mm, T20 Torx
Remove the three fasteners at the rear of the RH underbody
panel. Note the location of the ABS and pad warning harness
connectors.
NOTE
The underbody panels are only installed on JCW cars and
MINI Cooper models with the aero underbody kit. On Cooper
and Cooper S models without the aero underbody kit, these
panels are not installed.
Step 2:
Side Cutters
Pull down the underbody panel slightly to access the harness
connectors, and if necessary cut any wire ties that hold them
in place.
ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281
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WWW.ECSTUNING.COM
39
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MINI COOPER JCW GP2 BRAKE KIT INSTALLATION
ES#2652233
ES#2702967
REMOVING THE ORIGINAL REAR BRAKES
Step 3:
Remove the white connector from it’s mounting clips and
disconnect it. Then separate the pad warning harness from
the ABS sensor harness and remove it from the brake pad.
Step 4:
Flat Blade Screwdriver
Lever a screwdriver in each rear caliper brake cable actuator
as shown, pull down slightly, then pull the end of each brake
cable out of the actuator.
ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281
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40
R
MINI COOPER JCW GP2 BRAKE KIT INSTALLATION
ES#2652233
ES#2702967
REMOVING THE ORIGINAL REAR BRAKES
Step 5:
Flat Blade Screwdriver
Remove the brake cable retaining clips then pull each cable
out of it’s mounting bracket.
Step 6:
13mm, 15mm, Caliper Hanger
Remove both caliper mounting bolts on each side, then lift
each caliper off and hang it out of the way.
NOTE
We leave the brake hoses connected until we are ready to install
the new ones because it keeps the mess to a minimum. Even
though the kit comes with new hoses, we prefer to hang the
calipers so the hose integrity is not compromised in the event
they get used on another vehicle.
ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281
1.800.924.5172
WWW.ECSTUNING.COM
41
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MINI COOPER JCW GP2 BRAKE KIT INSTALLATION
ES#2652233
ES#2702967
REMOVING THE ORIGINAL REAR BRAKES
Step 7:
16mm Socket, Ratchet
Pull the brake pads out of the caliper brackets, then remove
the two bolts on each side and remove the brackets.
Step 8:
T50 Torx, Impact Driver
Remove the brake rotor screw on each side, then remove both
rotors and clean the surface of the drive hub.
NOTE
If your rotor screws are broken or missing, we recommend
replacement. New rotor screws are availabe at ecstuning.com.
ES#16458
ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281
1.800.924.5172
WWW.ECSTUNING.COM
42
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MINI COOPER JCW GP2 BRAKE KIT INSTALLATION
ES#2652233
ES#2702967
INSTALLING THE NEW GP2 REAR BRAKES
Step 1:
T50 Torx, Torque Wrench
Install the new rear rotors using the new rotor screws included
with the kit and torque them to 27 Nm (20 Ft-lbs).
NOTE
Apply a small amount of anti seize to each rear brake rotor
screw before installing.
Step 2:
Prepare for caliper assembly by setting everything out on a
soft fender cover or towel.
ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281
1.800.924.5172
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43
R
MINI COOPER JCW GP2 BRAKE KIT INSTALLATION
ES#2652233
ES#2702967
INSTALLING THE NEW GP2 REAR BRAKES
Step 3:
Install all four rear brake pad tensioning clips onto the new
caliper brackets by pushing them into place.
NOTE
Both rear caliper brackets are the same.
Step 4:
Apply a small amount of grease to the ears on each rear brake
pad.
ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281
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44
R
MINI COOPER JCW GP2 BRAKE KIT INSTALLATION
ES#2652233
ES#2702967
INSTALLING THE NEW GP2 REAR BRAKES
Step 5:
Inspect the brake pads and note the difference between the
inboard and outboard pads.
Outboard pad
Inboard pad
Step 6:
Install the pads into each caliper bracket, making sure the
inboard pads are located on the same side as the slide pins.
Inboard pad
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Outboard pad
45
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MINI COOPER JCW GP2 BRAKE KIT INSTALLATION
ES#2652233
ES#2702967
INSTALLING THE NEW GP2 REAR BRAKES
Step 7:
16mm, Torque Wrench
Install a caliper bracket over each rear rotor, thread in the
bracket bolts, then torque them to 65 Nm (48 Ft-lbs).
Step 8:
Squeeze the brake pads together to seat them against the
rotors.
ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281
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46
R
MINI COOPER JCW GP2 BRAKE KIT INSTALLATION
ES#2652233
ES#2702967
INSTALLING THE NEW GP2 REAR BRAKES
Step 9:
5mm Hex Bit
Remove the sealing plug from each rear caliper.
NOTE
The left and right calipers are different. Be sure to install the
correct caliper on each side. The location of the bleeder screw
and brake cable bracket is the easiest way to identify them.
Compare the locations to the original calipers.
Step 10:
14mm Wrench
Install and tighten a new ECS Tuning Exact Fit brake line into
each rear caliper.
NOTE
Both ECS Tuning Exact Fit rear brake lines are the same.
ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281
1.800.924.5172
WWW.ECSTUNING.COM
47
R
MINI COOPER JCW GP2 BRAKE KIT INSTALLATION
ES#2652233
ES#2702967
INSTALLING THE NEW GP2 REAR BRAKES
Step 11:
Hold a caliper in place on each side and thread the new caliper
bolts into each slide pin.
Step 12:
Torque Wrench
Torque the caliper bolts to 35 Nm (26 Ft-lbs).
ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281
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48
R
MINI COOPER JCW GP2 BRAKE KIT INSTALLATION
ES#2652233
ES#2702967
INSTALLING THE NEW GP2 REAR BRAKES
Step 13:
11mm Flare Nut Wrench
Complete the following:
Disconnect the original brake hoses at each line and
remove the original calipers.
Connect and tighten new ECS Tuning Exact Fit lines.
Push each brake line grommet into it’s retainer.
Step 14:
Complete the following:
Connect the new pad warning sensor and route it in the
same location as the original.
Install the new pad warning sensor into the inboard pad.
Re install the underbody retaining nut and screws.
Follow the brake bleeding procedure on page 50.
Reinstall and torque the wheels to 140 Nm (103 Ft-lbs).
ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281
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WWW.ECSTUNING.COM
49
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MINI COOPER JCW GP2 BRAKE KIT INSTALLATION
ES#2652233
ES#2702967
BLEEDING THE BRAKE SYSTEM
Bleed the air from the brake calipers in the following order:
RH Rear
LH Rear
RH Front
LH Front
The majority of the air in the calipers can be removed by
“gravity bleeding”. Simply open each bleeder screw in the
prescribed order until fluid flows out bubble free. Check the
brake fluid level and top it off as necessary between calipers.
Once you have “gravity bled” each caliper, depress the brake
pedal a number of times to seat the pads. The pedal should
be firm with no more than approximately an inch of travel.
If the pedal feels slightly spongy or even as a final step, have
an assistant pump up and hold pressure on the brake pedal,
then open one bleeder screw until the pedal goes to the floor.
With the pedal held to the floor, tighten the bleeder screw
then repeat for the remaining calipers.
Before test driving the vehicle, check all brake line
connections for leaks and re tighten them as necessary.
ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281
1.800.924.5172
WWW.ECSTUNING.COM
ABS
MINI Cooper and Cooper S Anti-lock
Brake System information
Due to the drastic increase in caliper size and fluid volume
requirements, when upgrading the original brakes on a MINI
Cooper and Cooper S, the operation of the ABS brake system
will be affected. A JCW Big Brake Kit Flash is available for the
ABS control unit to adjust the ABS operation for this upgrade.
This JCW BBK Flash is available at your local MINI Dealership.
50
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MINI COOPER JCW GP2 BRAKE KIT INSTALLATION
ES#2652233
ES#2702967
TORQUE SPECIFICATIONS
Brake Hose to Caliper Front................................................................24 Nm (18 Ft-lbs).................................................................................................................(Page 36)
Brake Hose to Caliper Rear.................................................................24 Nm (18 Ft-lbs).................................................................................................................(Page 47)
Brake Pad Retainer Bolts Front..........................................................30 Nm (22 Ft-lbs)................................................................................................................(Page 35)
Brake Rotor Screw Front......................................................................27 Nm (20 Ft-lbs)................................................................................................................(Page 30)
Brake Rotor Screw Rear........................................................................27 Nm (20 Ft-lbs)................................................................................................................(Page 43)
Caliper Bolts (Allen Head) Front........................................................115 Nm (85 Ft-lbs)...............................................................................................................(Page 35)
Caliper Bolts Rear..................................................................................35 Nm (26 Ft-lbs)................................................................................................................(Page 48)
Caliper Bracket Bolts Front.................................................................110 Nm (81 Ft-lbs)...............................................................................................................(Page 34)
Caliper Bracket Bolts Rear...................................................................65 Nm (48 Ft-lbs)................................................................................................................(Page 46)
Master Cylinder Mounting Nuts........................................................23 Nm (17 Ft-lbs).................................................................................................................(Page 17)
Wheels Front..........................................................................................140 Nm (103 Ft-lbs)............................................................................................................(Page 38)
Wheels Rear............................................................................................140 Nm (103 Ft-lbs)............................................................................................................(Page 49)
Wiper Arms.............................................................................................20 Nm (15 Ft-lbs).................................................................................................................(Page 20)
PAD BREAK IN AND MAINTENANCE
• Be sure to read the pad break in procedure included with the pads in the kit. Performing this procedure as
specified will guarantee the correct performance and wear from your brake pads.
• To ensure even wear, consistent performance, and long life of your brake pads, it is a good idea to remove
the pads once a year and clean any rust, dirt, or debris from the brake pad and caliper. Relubricate the
contact points as shown on page.
ECS TUNING 1000 SEVILLE RD. WADSWORTH, OH 44281
1.800.924.5172
WWW.ECSTUNING.COM
51
Your MINI Cooper GP2 Brake Kit installation is complete!
These instructions are provided as a courtesy by ECS Tuning.
Proper service and repair procedures are vital to the safe, reliable operation of all motor vehicles
as well as the personal safety of those performing the repairs. Standard safety procedures and
precautions (including use of safety goggles and proper tools and equipment) should be followed at
all times to eliminate the possibility of personal injury or improper service which could damage the
vehicle or compromise its safety.
Although this material has been prepared with the intent to provide reliable information, no warranty
(express or implied) is made as to its accuracy or completeness. Neither is any liability assumed for loss or
damage resulting from reliance on this material. SPECIFICALLY, NO WARRANTY OF MERCHANTABILITY,
FITNESS FOR A PARTICULAR PURPOSE OR ANY OTHER WARRANTY IS MADE OR TO BE IMPLIED WITH
RESPECT TO THIS MATERIAL. In no event will ECS Tuning, Incorporated or its affiliates be liable for any
damages, direct or indirect, consequential or compensatory, arising out of the use of this material.
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