Engine Out

There is an awful mix of metric and imperial fasteners on this Mini. Some assemblies even use both metric and imperial, for example the clutch cover is held to the transfer case with 5/16 UNC bolts, while the oil separator is held to the same casting with what look like M8 bolts.

As I was taking it apart it became clear that the engine computer has at least some control over the air conditioning -- it takes an input from the high-low pressure switch and has an output which disables the compressor. I've also noticed that if the motor is running hot then the AC stops working, I suspect the computer has a hand in this too. This sort of integration with the engine computer would no doubt require support from the factory, but obviously this support didn't extend to redesigning the air ducts or heater system. Later models used a different condenser placed in the inner wing instead against the front grill, but the separate cabin heater remained until production finished in 2000.

The cold control on the air conditioning doesn't work, it's either on or off. While tracing the air conditioning wiring I found an adjustable mechanical thermostat with a capillary tube sensor attached to the evaporator and zip tied behind the dashboard.

The air conditioner could blow cold air into the tiny glove box, but someone taped up this duct. I always wondered what the hole in the back of the glove box with silver behind it was for.

The fog lights are not part of the standard wiring loom -- the fog lights are powered by what appears to be a universal Bosch add-on loom. I doubt I'll be retaining the fog lights -- they stopped working shortly after I got the donor and I haven't really missed them, we rarely get fog in this part of New Zealand.

There is a mix of different connectors in the wiring loom, ranging from 1950's style Lucars and unsealed bullet connectors to sealed bullet connectors to at least 2 families of modern fully sealed connectors.

The 1970's fuse box containing 4 4AG glass fuses remains and is supplemented with many many unsealed inline 4AG fuse holders, including a large bundle located on engine side of the firewall.

The dashboard is made from one flat piece MDF and has some fairly complicated machining to fit into the car and to retain the eyeball fresh air vents. The padded top and bottom rails are unchanged from the 1970's. Instead of a parcel shelf, the 1990's MDF dashboard is cut to match the old profile of the top and bottom rail and bolted into the space between them.

There appears to have been an exhaust leak blowing on the back of the engine at some point.