Mini Workshop Manual 1959-1976IntroductionContentsData ContentsGeneral DataMini MK 1&2 848cc, Mk2 998ccMini Cooper 997cc & 998ccMini Cooper 'S'MK1 (970cc, 1071cc &1275cc)Mk2 & 3 (1275cc)

Mini Automatic (848cc & 998cc)Mini 850/1000 Saloon, Van & PickupMini ClubmanMini 1275 GTMini Clubman 1100

Engine Tuning DataMK1, 2 & 850 Saloon and variantsMK2 & mini 1000, 998ccMK1 & 2 Automatic (850cc)MK2 Automatic (998cc)Mini 1000 & Clubman automaticMk1 Cooper 997ccMk1 Cooper 998ccMK1 Cooper 'S' 970cc&1071ccMini Cooper 'S' 1275cc 64onClubman 998cc1275 GTMini 1000 (CANADA)Mini Clubman (SWEDEN)Mini 850 1972-74Mini Clubman and 1000 998cc 72-741275GT 1972 onMini 850 1974onMini Clubman & 1000, 1974onMini Clubman 1098cc

MaintenanceContentsService SummaryLubrication DiagramService LubricantsRecomended Fluids, anti-freeze, capacitiesRoutine MaintenanceLubricationEngine & Gearbox (syncromesh)Engine & Gearbox (Automatic)CarburetterFront SuspensionRear SuspensionHandbrake Cable

MechanicalCooling SystemFan Belt adjustmentClutchBrake & Clutch ReservoirsAir CleanerValve Rocker Clearances

IgnitionDistributorSparking Plugs

Carburettor TuningSingleTwin

BrakesDrumDiscServo

Wheels & TyresSteeringElectricalHeadlamp AlignmentBatteryTopping upChecking Specific Gravity

Ignition

Body & General Inspection

The EngineContentsAir CleanerCarburetterExhaust PipeExhaust ManifoldRocker ShaftCylinder HeadValvesTappetsDistributor Drive shaftValve SeatsFlywheel and CutchRemovingStarter Ring

Engine & Subframe AssemblyEngine RemovalEngine MountingsTiming CoverTiming Gears & ChainFlywheel Housing & Primary GearValve TimingTransmision HousingOil Pressure relief ValveOil PumpPistons & Connecting RodsCrankshaft & Main BearingsCrankshaft & Primary GearCrankcase Closed-Circuit BreathingBreather control ValveFlywheel and ClutchOil CoolerPrimary Gear Oil SealFlywheel Retaining screw ThreadPrimary Drive gear Train (Rod change)Engine & Gearbox removal (Rod Change)The Engine - Automatic SupplementContentsLubricationOil FilterEngine removalSpliting Engine/TransmissionIdler Gear & Input gear adjustmentExhaust SystemValve TimingOil PumpCam ShaftPistons & Connecting RodsCrankshaft & Main BearingsEngine MountingsConverter Housing Oil seal replacmentConverter Output gear

The Ignition SystemContentsDistributorType 25D4Type 45D4

TimingAutomatic SuplemmentTiming

The Cooling SystemContentsRadiatorFan BeltWater PumpThermostatFrost Precautions

The Fuel SystemContentsFuel Tank (Saloon)Fuel Tank (Van, Pickup & TravellerTank Gauge UnitFuel PumpType PDType SP & AUF 201Fuel Pump Testing

CarburettorAir CleanerMokeFuel PumpFuel Tank

Cooper 'S' - Twin tanksAutomatic SupplementNegative Earth SupplementMechanical Fuel PumpTesting

The ClutchContentsOverhaul - Coil Spring typeAdjustmentsPedal MovementThrow out stopClutch Over-throw

Master cylinderSlave CylinderDiaphragm Spring typeClutch Cover alignment

Manual GearboxOverhaulDifferentialSynchronising conesRemote controlRod Change controlOverhaul - Rod change type

Automatic GearboxGeneral DescriptionPower Flow Diagrams (Mechanical)Line Pressure & Lubrication diagrams

Fault DiagnosisDiagnosis Rectification ChartChange Speed ChartFault Diagnosis info

AdjustmentsSelector Lever Cable & Transverse Rod adjustmentInhibitor SwitchKick Down

Oil Pressure & Stall Speed ChecksTransmission Unit - DismantlingValve BlockWith inbuilt engagement control & Shuttle valves

Aux Pump & GovernorForward ClutchGear TrainTop & Reverse ClutchServo Assembly1st Gear Free-wheel assemblyDifferential AssemblyLubrication Reservoir (idler gear bearing)Selector Lever mechanism

Drive ShaftsGeneral DescriptionRemovalOverhaulDrive shaft couplingUniversal Joint OverhaulOffset Sphere inboard joint typeOut boardCV Boot replacementRemovingInboard Boot replacement

The Rear SuspensionSubframe RemovalRadius Arms removalRubber Spring unitsSubframe mountingsHydrolastic suspensionDescriptionDepresurizingPressurizingDisplacer unitsPressure & wing heightsRadius ArmsSubframe RemovalHydrolastic DiagramsSchrader valve extension housing

Subframe removal - MokeRadius arms - Moke

The SteeringSteering WheelSteering ColumnSteering Rack assemblyFront wheel alignmentSteering Rack lubricationNylon tie-rod all ends

The Front SuspensionRubber spring unitsSwivel HubsSwivel Hub ball jointsRubber suspensionUpper armLower ArmSuspension struts

Hydrolastic SuspensionDisplacer units - hydrolasticUpper arms

Swivel hub outer oil seal

The Hydraulic DampersRemove & RefitPrimingRear Dampers - Moke

The Braking SystemMaster CylinderAdjustmentShoe assemblieswheel CylindersMaster CylinderPressure regulating valveIntensifierDisc Brake CaliperBleedingVacuum Servo2 leading shoe front brakesPreventative maintenanceVacuum Servo ComponentsNegative Earth carsServo Unit (Lockheed type 6)Inertia valveTandem Master cylinderPressure failure switch assemblyBleeding

The Electrical SystemWiring DiagramsSaloons (exc standard &Deluxe) to 1964Saloons (standard & Deluxe) to 1964Saloon, Van, Pickup 64-67Cooper, S, Estate & Super deluxe. 64-67Moke to 1967S-Deluxe, estate, Cooper & S. Mark 2Saloon, van & Pickup MK2Moke Mk2

BatteryDynamoStarterVoltage regulatorCut-outLampsBi-metal resistance instrumentationWindscreen WipersWiper motor - MokeWheel Boxes

Alternator service precautionsTesting Alternator Charging circuit11AC alternator - overhaulControl Unit 4TRNegative earthInstrument panel - Clubman 1275GTIndicator flasher unitStarter - Type M35J Inertia driveWindscreen Wiper Lucas Type 14w-permanent magnetAlternator Lucas type 16ACRWiring diagramsMaster keyCooper 'S' MK3850, deluxe, saloon, van, pickup With DynamoWith alternator

1000, special,deluxe saloonWith DynamoWith alternator

Clubman Saloon & estateWith DynamoWith Alternator

1275GTWith DynamoWith Alternator

Mini 1000 Saloon (Canada)

The BodyWindowsHeater assembly - recirculator typeRoof LinerDoor LocksSliding glasses - estateTilt frame & cover - pickupSpeedoChecking body alignment - with out jigWith Jig

Windscreen - MokeHeater Assembly - Fresh air typeMK2 instrumentsHeater componentsVertical alignment checkHorizontal alignment checkSubframe alignment diagramNegative earth supplementBumpersFront GrilleHeater AssemblyFacia air ventsDoor locksDoor GlassDoor HandlesDoor Glass regulatorRoof lining - saloonClubman estate

Auto seat belts - central console typeStatic beltsRear seat belts

Service ToolsOperation listIllustrations

Emission ControlService summaryEngine tuning dataSystem componentsDrive beltsAir PumpGulp ValveDiverter ValveCheck ValveAir ManifoldAir Temperature control valveThrottle DamperHot air ductFuel line filterAbsorption canisterCarburetterCylinder head assemblyWring Diagram 1975 on