Exterior & Interior

The Body Structure
The MINI COOPER body is constructed with an extremely rigid chassis to assist in the ultimate driving experience, along with superior body strength to ensure that the highest level of safety surrounds the occupants.

Body Safety
- Torsion ally rigid occupant safety cell with roof bow welded above the B post.
- Crumple zones at both the front and rear.
- Achieves crash safety requirements with respect to front, rear and side impacts.
- Body torsional rigidity of 27,000 Nm per degree. (Compare this to 10,500 Nm per degree for the E46 Convertible and 7,500 Nm/degree for the E36 Convertible.)


The Body Shell
The Body Shell is constructed of sheet steel parts, reinforced by box sectioned longitudinal members and cross beams. Three major sub assemblies come together to produce the one piece floor frame, the front end, main floor and rear end.

Cross Members

There are six cross members on all MINI COOPER floor frames. The cross members are of a transversely connected design in conjunction with the aluminum bumper armature.

- Bulkhead cross member
- Front cross member, front floor pan (for acoustic and side impact)
- Rear cross member, front floor pan (for acoustic and side impact)
- Heel board cross member (for side impact)
- Assembly cross member, luggage compartment partition combined with cross member rear axle support
- Cross member at body rear


Front Wheelhouse
The engine support legs of the front wheelhouses are of an 8 sided sectional construction and include an uninterrupted 290 mm axial crush zone and a bend initiation mechanism at the rear.
Additionally there is a crush efficient aluminum bumper armature bolted to the front engine support legs.
(There is a similar crush efficient aluminum bumper armature fitted at the rear of the vehicle).

Side Frame and Pillars
The following components add to the structural rigidity.

- Cross members.
- Front Wheelhouse.
- Side Frame and Pillars.
- Roof.

The one-piece laser welded monoxide with three gauge areas has been designed for optimum front impact, side impact, roll-over and stiffness.

Additional panels are included in the B post area to further improve the body strength, particularly in the event of side impact or rollover.

Roof
The roof panel features a front header, rear header (incorporating tailgate hinge mounting points) and a roof bow for non sunroof versions.

Sunroof versions use a reinforced ring frame as part of the sunroof unit. The roof panel is spot welded all the way along its four sides; the front, the rear and the two sides.

Front Apron Panel
The Front Apron Panel is secured by four bolts to the body bulkhead, two Torx screws into the A posts (one each side), two bolts to the body chassis longitudinal (one each side) and two screws to the front side panels (one each side).

Front Side Panel
The Front Side panel is secured to the body by two nuts to the A post and three bolts (two to the A post and one to the front apron panel.

Hood



The Hood on MINI COOPER is of a conventional hinged type, supported at both sides by a gas strut. The hood is mounted on two adjustable hinges, which are secured to the main body A post panel (two Torx screws, per hinge) and the hood (two Torx screws, per hinge). The two gas struts limit hood open travel.


Hood Latch



Opening the hood is achieved by first operating the interior release lever (located in the right hand side front footwell, regardless of drive). The releasing of the safety catch (located between the front grille and bumper) is accomplished by reaching under the hood and pressing up on the lever. The hood release cables are color coded, white on drivers side and blue on passenger side.

Hood closure is achieved by adjustable latches mounted to the chassis longitudinal (two bolts, per side) and strikers welded to the hood.

Tailgate
The tailgate fitted to MINI COOPER is of a bolted on design. The tailgate is mounted on two adjustable hinges, which are secured to the main body roof rear header panel and the upper face of the tailgate. There are two gas struts to support the tailgate and which limit tailgate open travel.


Tailgate Latch and Striker
Tailgate closure is achieved by use of a conventional latch secured to the tailgate opening lower panel, and a striker, which is secured to the tailgate.
Opening the tailgate is achieved by depressing the release switch, which is housed in the rear license plate lamp housing trim.





Tailgate Trim Upper and Side
The Tailgate Upper Trim is secured to the tailgate by four "snap fit" clips. The tailgate side trim is secured to the tailgate by two 'snap fit' clips and one screw). The screw also retains the fixture clip for the parcel shelf strap.


Tailgate Trim Lower
The Lower Tailgate Trim is secured to the tailgate by seventeen "snap fit" clips and four screws.

Doors Exterior
The doors fitted to MINI COOPER are of a conventional bolted on design. There are four nuts securing each door to its two hinges (two per hinge) with the addition of a spacer shim between the hinge and door. Between the door and body is also the door brake. The door brake is fixed to the A post by a single bolt and by two bolts to the door.

Door Mounting
The front doors are mounted on two adjustable hinges, which are welded to the main body A posts and shimmed to the front face of the front doors and secured with two nuts. Door open travel is limited by use of a single door brake on each door. Door alignment and profile can be aided by the use of selectable shims between the hinge and body Shims are supplied in either 0.5 mm or 1.00 mm thickness.


Door Striker
All MINI COOPER derivatives are fitted with a conventional door striker secured to the rear edge (B post) of the door opening, by means of Torx bolts into captive nuts in the body.

Door Latch
Door Latch is cable operated from both the inside and outside door handles.





All MINI COOPER derivatives are fitted with a conventional door latch located inside the door and secured by Torx bolts to the rear edge. Opening the door is achieved by use of either the door handle mounted to the exterior of the door or an internally mounted door release handle.


Front Bumper
The front bumper on MINI COOPER is attached directly to the bumper armature, which in turn is bolted directly onto the body chassis longitudinal. The front bumper is broken down into three parts; bumper cover, wheel arch trim (x 2) and a front spoiler.

The bumper cover is secured to the body mounted armature by six upper bumper cover clips, five lower clips to the front spoiler and a bolt at each side for alignment purposes. The wheel arch trim is secured to the bumper cover by one screw at the top, four clips to the cover and one screw to the front spoiler.

The front spoiler is secured to the bumper cover by eight clips and one screw at each end going into the wheel arch trim and is secured to the modular front end by three central bolts and two outer screws.

Front Bumper Adjustment
Adjustment is possible on the front bumper to achieve profile of the front bumper ends to the hood and wheel arch trim. The adjuster bracket can adjust the bumper in both Vertical and Horizontal planes.

Bolt (1), will enable bumper end movement in a forward and rearward direction.

Bolt (2), will enable bumper end movement in an up and down direction.

Access to these end adjuster brackets can be achieved through the front wheel arch liner.

Front Bumper Trim
The upper grill with location tags is secured to the bumper cover by means of adhesive tape. The lower grill is secured to both the bumper cover and front spoiler by ten clips. The front towing eye cover is a push fit into the bumper cover by means of an upper and lower retaining clip.

Rear Bumper
The rear bumper on MINI COOPER is attached directly to the bumper armature, which is in turn bolted directly onto the body. The rear bumper is broken down into three parts; bumper cover, wheel arch trim (x 2) and a cover spoiler. The bumper cover is secured to the body by five screws and four threaded clips (two into the rear bumper armature and two into the rear wheel arch liner).

The wheel arch trim is secured to the bumper cover by one screw to the cover spoiler and four clips to the cover (The upper edge of the trim is the outer most bumper attachment).

The cover spoiler is secured to the bumper cover by twelve clips and one screw at each end going into the wheel arch trim.

Rear Bumper Trim - (MINI COOPER S ONLY)

Workshop Hint: The rear bumper is not adjustable.

There are two grills fitted to the rear bumper cover on MINI COOPER S derivatives and each one is secured by six clips.


Park Distance Control (PDC) Sensors (x 4)
The Park Distance Control Sensors are retained in the rear bumper by three raised clips on the sensor body.


Molding Exterior

Body Molding
- Rear Quarter Glass - lower trim is secured by seven 'snap fit' clips. The clips to the body are secured by means of T studs welded to the body rear quarter panel. This trim will need to be removed if the rear quarter glass is to be removed.
- Rear Quarter Glass Trim Front - attached directly to the front edge of the rear quarter glass.
- Rear Quarter Glass Trim Rear - attached directly to the rear edge of the rear quarter glass.
- Front Door Glass - waist seal trim is clipped to the door skin flange.


Windshield Trim


The upper trim is clipped to the top edge of the windshield prior to being bonded onto the car. This trim can be removed after windshield installation and new trim installed. Removal is required for windshield replacement. The lower trim is two-piece joined together in the center by use of a joining clip. Each half is retained to the body by means of six snap fit clips and a screw into the A pillar. Both the left and right hand trim will require removal if the windshield is to be replaced. The side trim (A post trim) is secured to the main body A post by four snap fit clips and 4 screws to the A pillar. The small fillet trim is secured at the top of the external A post trim. Retention of this piece is of a snap fit design onto a body mounted nipple at the top of the A post.

Air Intake Grills
The Air Intake Grills are fitted into the front apron panel and are retained by three forward clips and three rear edge clips. Removal is achieved by releasing the front edge and sliding the grill forward to release the rear clips. A filter housed is in the grill and not replaceable separately.

Washer Jets
The washer jets are of a simple push fit into their hood locations.

Wheel Arch and Sill Trim
- The Front Wheel Arch Trim - side panel, is retained to the body mounted side panel by means of four clips.
- The Front Wheel Arch Trim - hood is secured to the hood by three clips and one plastic nut, accessed with the hood open. Removal of the trim requires pressing the clips thought the hood from the engine side.
- The Front Wheel Arch Trim - front bumper is secured to the front bumper cover by one screw at the top edge with four plastic clips. There is an additional bolt on the lower edge securing the finisher to the front bumper cover bib spoiler.
- The Rear Wheel Arch Trim is retained to the body rear quarter panel with five female clips with welded studs on the body wheel arch and one male clip into the body.
- The Sill Trim is held by a total of twenty four attachments; Eleven clips along the body sill side face, four screws along the door opening tread strip and eight threaded clips along the body sill floor face with one screw at the rear going into the rear wheel arch liner.


Interior Trim
Dashboard Assembly
The Dashboard Assembly houses the climate control air outlets, solar sensor, Hazard Warning switch, Instrument Illumination switch, Instrumentation and the IKE.

The Dashboard assembly consists of three main assemblies:
- Dashboard
- Dashboard - upper covering
- Dashboard cross car beam

Dashboard
The Dashboard is the complete assembly and is attached to the dashboard cross car beam in 9 locations. Depending on derivative, the tachometer (or speedometer) is positioned on top of the steering column and the speedometer (or tachometer) is positioned centrally in the dashboard except on models where navigation has been specified. The speedometer and tachometer are then housed in separate units on top of the steering column. Additional switches for the hazard warning lights and instrument illumination are located centrally on the dash lower assembly.


NOTE: There is and additional locating stud that is attached to the heater unit and this is accessed from the engine bay.

Dashboard Upper Covering
The Dash Upper covering is attached to the top of the Dashboard with 4 screws accessed through the remove able side panels.

Removal of the dash upper covering allows access to the passenger airbag.

Dashboard Cross Car Beam
The Dashboard Cross Car beam is attached to the body in 6 locations. Removal of the dash, upper and cross car beam can be achieved as a complete assembly without having to remove the steering wheel, dash trim (incl. speedometer pack / nav pack, heater and heater controls, switch pack, radio unit and glove box/dash shelf).

Instruments and Vents

Dash Vents
When the MINI COOPER is equipped with Automatic Temperature Control a solar sensor is installed in the top of the Dash assembly.

The dash contains four adjustable air outlets for heating/ventilation purposes. Three more fixed outlets are fitted in the dash upper cover, two for side window de-misting purposes and a central outlet for face level heating/ventilation.

Instrumentation
Depending on model and options, the MINI COOPER is fitted with various instrument cluster arrangements.


Removal of Instruments
Center Display
Removal of Center Display (whether Standard Speedometer or Navigation Display) is as follows:

- Remove trim from switches (1)
- Remove screw on the lower right side of the instrument cluster trim (2)
- Remove screws on the upper side of the instrument cluster (3)
- Remove lower edge of trim in an outward direction
- After cover is off, remove four screws from Display unit
- Disconnect connectors and remove unit


Remote Instrument Cluster
The following procedure is applicable for all remote cluster configurations
- Remove two screws at rear of instrument cluster
- Disconnect Plug
- Remove Remote Instrument Cluster


NOTE: It is easier to remove cover from the center instruments by first removing upper dash cover, dash trim directly behind steerring wheel and passenger side air bag cover.

Consoles
Front Center Console
The Front Center Console is connected to the dash by the two support tubes. Removal of these tubes allows access to the attaching points for the heater controls, switch pack and radio unit and the removal of the front console. Housed in the front console are two cup holders*, an auxiliary power socket* and switches for door mirror adjustment.

* If a smokers pack is fitted, the auxiliary power socket is replaced by a cigar lighter and one cup holder is replaced by an ashtray.


Rear Center Console
The Rear Console is a separate unit from the front console and encases the handbrake lever. Also housed in the console is a cup holder for rear passengers and switches for heated front seats and Tire Pressure Warning (RDW). Removal of the rear center console is achieved by removing the handbrake grip, releasing the handbrake boot from the console, which will reveal a single console retaining screw. After removal of the screw the console can be released from its' two front and two rear retaining clips.

Doors Interior

Interior Door Panels

Window Regulators
The Window Regulators are of a cable drive type. The window motor is fitted to the window regulator device in the door. The motor and regulator are available as separate parts for service.


Door Glass
The Door Glass on MINI COOPER is of a frameless type and adjustment is achieved for both gaps and profile to the body. There are four attaching points; two upper and two lower. The upper bolts must be loosened to adjust the lower bolts that provide the glass to opening pre-load adjustment. The threaded glass retaining washers on the regulator enable fore and aft as well as up and down movement of the glass.


Door Handles

Exterior Door Handle
The Exterior Door Handle is secured by means of two bolts accessible from inside the door and one external bolt (only on the drivers door), accessed through a grommet on the end face of the door. The two internal bolts will require door panel removal and the glass to be in the fully raised position.

Interior Door Handle
The Interior Door Handle is secured to the door by three screws. The Tweeter and door release bezel is secured to the door trim panel by six retaining clips. Removal of the door panel is necessary for interior door handle or bezel replacement.


Sunroof
The Sunroof is available as an option and consists of a twin glass front & back panel. Only the front section is moveable in a tilt/slide operation. The back is fixed. The sunroof cassette is removable/replaceable and bolts to the roof.