If you’re looking for a cheap fast car, then the Mini Cooper S R53 might be the car for you, thanks to its illustrious platform for tuning. We explain how to tune your R53 Mini.
Iconic hot hatch fan? Well, you’ll probably be thinking of the Peugeot 205 GTI and Volkswagen Golf GTI from the 80s, or maybe the Citroen Saxo VTS and Renault Clio Williams of the 90s. So, what about the first-generation R53 Mini Cooper S as be your hot hatch pick of the noughties.
R53 Cooper S highlights were the sharp steering and keen chassis, plus with up to 210bhp when fitted with a John Cooper Works (JCW) tuning kit, this Mini offered giant-killing performance. In addition, it has one of the most iconic Classic Mini performance badges on the boot – Cooper S.
New Mini Old Tricks
The R50 ‘New’ Mini Cooper, launched in July 2001, offered much for hot hatch enthusiasts, being great to drive, with cheeky but sympathetic styling, quality build and impressive safety features. However, when it came to the performance, with just 120bhp, the Cooper only really deserved ‘warm’ hatch status.
Right from the start, semi-disguised prototypes were featured in magazines and on-line, and a faster MINI (than the Cooper) was always on the cards. Despite the increase in performance, BMW deliberately didn’t mess with Frank Stephenson’s clever update of the iconic original Classic Mini.
Biggest changes over the Cooper, included the functional letter box vent on the bonnet, it’s designed to feed air directly into the intercooler. At the back, there is a Classic Mini-like twin center exhaust – with two smaller Coke can-style finishers. Elsewhere, there are chunkier, chrome-less bumpers, different side skirts, and a larger rear spoiler. Inside, the most obvious change, are the more supportive sports seats.
With the standard Eaton supercharger, stronger Getrag six-speed manual, and 1.6-litre Tritech engine, the performance lived up to the iconic badge. But to get to the magic double ton figure, BMW specialists were quick to offer tuning kits, although their official response, the JCW kit was the only one not to void the official warranty.
Mini Cooper S R53 engine tuning
To increase the R53 Cooper S’s performance, you’re probably best looking at its standard Eaton M45 supercharger first. To get more horsepower, you’ll need to get it spinning faster. This can be achieved by reducing the size of the supercharger, with prices starting around $146 for a quality Alta or CravenSpeed item. Although you’ll have to factor in the cost of buying ($/£94) or renting (around $/£25 for a week) a supercharger pulley removal tool. Or, get a specialist to do it. Up to 21bhp can be gained by increasing the boost between 3-5 PSI, depending on the size of the pulley.
Making the supercharger spin faster equals more heat, so after changing the pulley, it is best to look at reducing intake and supercharger temperatures. To do this you’ll need an uprated intercooler. One OEM solution, if you can find one, is to fit the bigger intercooler from the last-of-line limited build GP. It stays cooler for longer, allowing an R53 Cooper S to hold peak power for extended periods – but it’s expensive, with second hand items priced from £1,500! Otherwise, an Airtech item costs $/£1900 for example.
The ultimate performance modification for the R53 Cooper S, is to junk the supercharger altogether and fit a turbocharger kit, from well-known specialist 1320MINI. Priced at just over $/£1527, the kit includes a Garrett GTX turbo, 1320 Pro Alloy intercooler and a Tial wastegate.
Mini Cooper S R53 exhaust tuning
After the smaller supercharger pulley, and an uprated intercooler, the next area to upgrade, is the flow of exhaust gasses – by fitting a performance exhaust – it also improves the sound! There are plenty of options to suit most budgets, but it’s probably best to start with cat back exhausts, prices start from $381. Around $686 will get you the highly regarded Milltek system. You can go even further by adding a manifold and even a de-cat pipe. These will give more horses, but add to the sound, which could be too much for road use.
Transmission
The standard six-speed manual transmission was supplied by long time BMW gearbox collaborator, Getrag. It is not known to give problems, although the gearchanges can sometimes be difficult – which are a characteristic. However, if you’re upping the power or grip of your R53 Cooper S, it’s worth upgrading your clutch material and pressure, for example by fitting an organic clutch kit, from Helix priced at $663. Or, if your Cooper S is built for torque, a 4 paddle clutch from Helix could be the solution and is priced at $/£845.
Facelift models from 2004 were offered with a limited-slip differential option, but the only R53 with it fitted as standard, is the last-of-line, limited build GP. So, fitting an aftermarket Automatic Torque Biasing (ATB) differential, after fitting other engine modifications is worthwhile. Priced from $/£726, a new clutch and flywheel should be fitted at the same time.
Late in the R53’s production life, Mini offered a proper six-speed torque converter automatic gearbox. Mainly for the American market, it was fitted with steering-wheel-mounted paddles, and is strong enough for the JCW 210bhp kit to be fitted.
Mini Cooper S R53 brake upgrades
The standard disc brake set up might be fine on the R50 Mini, but is unchanged for the R53 Cooper S, and frankly are a bit weak with extra horsepower. So, if you’re making power upgrades, increasing the braking power is a necessity.
A set of upgraded brake pads can help, but an OEM solution is a JCW upgrade. Mini’s JCW solution could be retrofitted to new and used Cooper S’s, and was standard on the JCW GP. If you can find a refurbished set you’re looking around $/£635 a caliper.
A more cost-effective OEM+ brake solution, is to fit a set of later JCW Brembo calipers, from the second-generation R56 JCW hatch. Refurbed sets start at $/£450, with a new set costing you $/£1907.
The ultimate upgrade, is a big brake kit, but this is another costly option, at over £/$1400 .
Suspension upgrades
The R53 has already built a reputation for being great to drive, but the oldest 2002 cars are now 22 years old, so before any suspension upgrades are made, we’d suggest checking the condition of the bushes, and fit upgraded aftermarket items from manufacturer, such as Powerflex, and are priced from $/£94.
Simplest and most cost effective mod is to fit a set of lowering springs, dropping the MINI by as much as 30mm, they will also improve the handling, cornering and stopping of your Cooper S. A set of lowering springs from Eibach, costs $/£298.
Another R53 Cooper S suspension upgrade, is to fit a set of coiover damper and spring kits. On top of the lowered stance, and improved cornering, coilovers offer owners the opportunity to tune the damping force to how you’d like it. Coilover prices start at about $762 for the Tein Street kit.
Perhaps the ultimate R53 MINI Cooper S suspension soloution, is air suspension. This is where the suspension struts and springs are replaced by airbags that are powered air compressor that’s usually boot-mounted. Then, the suspension height can be adjusted to personal choice via the touch of a button. However, all this adjustability comes at a cost, as the Airrex kit costs almost $/£5975.
Wheel and tyre upgrades
A simple wheel change can make a big difference to a Mini’s looks. Optimum wheel size are 17s, but the standard wheels are heavy, so it’s probably best to look at aftermarket options. Watch the curb damage, as the biggest wheels are the most susceptible, and wheel damage could also affect the suspension alignment, which in turn will impact the Mini’s entertaining handling.
For inspiration, be sure to check out our guide to the best aftermarket wheels in 2024.
R53 Mini Cooper S interior upgrades
Expect seat squeaks and rattles on the earliest cars; it’s also highly likely that side bolsters of the sports seats will be scuffed. The standard sports seats might be a decent step up from those fitted to the Cooper – but if you want to go the OEM route, your options are limited to finding secondhand OEM Sparco, or Recaro seat, these seats are costly, with the Sparco seats starting at around $/£1525. A set of bucket seats are a more cost-effective solution, with prices starting at about $/£381.
The rear seats of a Mini are only really suitable for children, but the GP proved you didn’t need them in a performance Mini. Many specialists offer a GP seat delete option, which is basically a trimmed boot floor going over where the rear seats were. These can even be made by owners. You can go even further, by fitting a half rear cage – although, these are mostly for the looks.
R53 Mini Cooper S exterior upgrades
If you want to make your R53 Cooper S stand out more, the OEM Aero body kit really toughens up the looks. However, new kits are long gone, and secondhand examples are costly. However, even a set of Aero side skirts can make a difference. Other body and wide arch kits are avialable, in varying quality and fitment – so buy with caution!
For an aftermarket rear wing, we’d recommend the GP-like Orranje G-Wing, available in carbon, like the GP original, priced at from $/£445.
Looking to buy an R53? Check out our R53 buying guide for advice.
Words: Martyn Collins.
