1959-1969 Mini Workshop Manual
Manual covers the folowing models 1959 - 1969:
- 848cc
- 970cc
- 997cc
- 998cc
- 1071cc
- 1275cc
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Full list of manual chapters:
Haynes - Mini '59 to '69
Routine maintenance and servicing
Maintenance - component location
Underbonnet view of a 998 cc Mini 1000 Saloon
Underbonnet view of a 1275 cc Mini Cooper Saloon
Front underside view of a 998 cc Mini 1000 Saloon
Rear underside view of a 998 cc Mini 1000 Saloon
Maintenance procedures
Introduction
Intensive maintenance
Every 3000 miles or 3 months
Drum brake adjustment
Handbrake check and adjustment
Steering and suspension check
Underbody and fuel/brake line check
Exhaust system check
Fan belt check and renewal
Air pump drivebelt check and renewal
Clutch hydraulic check
Seats and seat belt check
Headlight beam alignment check
Every 6000 miles or 6 months
Engine/transmission oil and filter renewal
Front brake wear check
Driveshaft gaiter check
Steering and suspension lubrication inspection of the ground underneath it will
Rear brake wear check
Underbonnet check for fluid leaks and hose condition
Fuel system components, checks and lubrication
Contact breaker points check and adjustment
Distributor lubrication
Clutch return stop adjustment
Dynamo check and lubrication
Control box cleaning and inspection
Ignition timing check and adjustment
carburetor idle speed and mixture adjustment
Door, boot and bonnet check and lubrication
Bodywork, paint and exterior trim check
Road test
Every 12 000 miles or 12 months
Air cleaner element renewal
Valve clearance adjustment
Distributor cap, rotor arm and HT lead check
Spark plug renewal
Emission control equipment check
Every 24 000 miles or 24 months
Coolant renewal
Brake fluid renewal
Fuel filter renewal (fuel injection models)
Engine in-car repair procedures
General information
Compression test - description and interpretation
Top Dead Centre (TDC) for number one piston - locating
Valve clearances - adjustment
Timing chain, tensioner and sprockets - removal, inspection and refitting
Rocker shaft assembly - removal, inspection and refitting
Cylinder head (carburetor engines) - removal and refitting
Cylinder head (fuel injection engines) - removal and refitting
Crankshaft oil seals - renewal
Flywheel (manual transmission models) - removal and refitting
Torque converter (automatic transmission models) - removal and refitting
Engine/transmission mountings - renewal
Distributor driveshaft - removal and refitting
Oil pressure relief valve - removal, inspection and refitting
Oil filter housing and delivery pipe - removal and refitting
Oil cooler - removal and refitting
Engine removal and overhaul procedures
General information
Engine/transmission removal - preparation and precautions
Engine/transmission - removal and refitting
Engine/transmission (with front subframe) - removal and refitting
Engine and manual transmission - separation and reconnection
Engine and automatic transmission - separation and reconnection
Engine overhaul - preliminary information
Cylinder head - dismantling, cleaning, inspection and reassembly
Camshaft and tappets - cleaning, inspection and reassembly
Oil pump - removal, inspection and refitting
Piston/connecting rod - removal, inspection, separation and reconnection
Crankshaft - removal and inspection
Cylinder block/crankcase - cleaning and inspection
Main and big-end bearings - inspection and selection
Engine overhaul - reassembly sequence
Piston rings - refitting
Crankshaft - refitting and running clearance check
Piston/connecting rod assemblies - refitting and big- end bearing clearance check
Engine - initial start-up after overhaul and reassembly
Cooling, heating and ventilation systems
General information and precautions
Cooling system hoses - disconnection and renewal
Antifreeze - general information
Radiator - removal and refitting
Thermostat - removal, testing and refitting
Water pump - removal and refitting
Auxiliary cooling fan - general information, removal and refitting
Auxiliary cooling fan thermostatic switch - removal, testing and refitting
Heater water valve control cable - removal and refitting
Heater water valve - removal and refitting
Heater assembly - removal and refitting
Heater assembly - dismantling and reassembly
Fresh air vent assembly - removal and refitting
Fuel system - carburetor engines
General information and precautions
Air cleaner assembly - removal and refitting
Accelerator cable - removal and refitting
Accelerator pedal - removal and refitting
Choke cable - removal and refitting
Electric fuel pump - testing, removal and refitting
Mechanical fuel pump - testing, removal and refitting
Fuel gauge sender unit - removal and refitting
Fuel tank - removal and refitting
Unleaded petrol - general information and usage
carburetor - general information
carburetor - removal and refitting
carburetor (SU HS2 and HS4) - fault diagnosis and overhaul
carburetor (SU HIF44 and HIF38)) - fault diagnosis and overhaul
carburetor (SU HS2 and HS4) - idle speed and mixture adjustment
carburetor (SU HIF44 and HIF38) - idle speed and mixture adjustment
Anti-run-on valve (1990-on Cooper models) - removal and refitting
Inlet manifold - removal and refitting
Fuel system - fuel injection engines
General information and precautions
Air cleaner assembly - removal and refitting
Air cleaner air temperature control system - information, testing and component renewal
Accelerator cable - removal, refitting and adjustment
Accelerator pedal - removal and refitting
Fuel system - depressurisation
Fuel system - pressure check
Fuel tank - removal and refitting
Fuel pump - removal and refitting
Fuel gauge sender unit - removal and refitting
Unleaded petrol - general information and usage
Fuel injection system - testing and adjustment
Fuel injection system components - removal and refitting
Inlet manifold PTC heater - general information and component renewal
Inlet manifold - removal and refitting
Exhaust and emission control systems
General information
Exhaust system (models without catalytic converter) - removal and refitting
Exhaust system (models with catalytic converter) - removal and refitting
Exhaust manifold - removal and refitting
Crankcase emission control system - checking and component renewal
Evaporative emission control system - checking and component renewal
Exhaust emission control system - checking and component renewal
Exhaust emission control system - checking and component renewal
Starting and charging systems
General information and precautions
Electrical fault finding - general information
Battery - testing and charging
Battery - removal and refitting
Dynamo charging system - testing
Dynamo - removal and refitting
Dynamo brushes - renewal
Control box - adjustment
Alternator charging system - testing
Alternator - removal and refitting
Alternator brushes - renewal
Starting system - testing
Starter motor - removal and refitting
Starter motor - testing and overhaul
Drive pinion assembly (inertia type starter) - removal and refitting
Starter solenoid - removal and refitting
Ignition system
General information
Ballasted ignition system (carburetor models) - identification
Ignition system (carburetor models) - testing
Ignition system (fuel injection models) - testing
Contact breaker points - adjustment
Contact breaker points - renewal
Condenser - testing, removal and refitting
Distributor - removal and refitting
Distributor - dismantling, inspection and reassembly
Ignition coil - removal, testing and refitting
Crankshaft sensor (fuel injection models) - removal and refitting
Reluctor ring (fuel injection models) - removal and refitting
Ignition timing - checking and adjustment
Transmission-controlled ignition advance - checking and component renewal
Braking system
General information
Hydraulic system - bleeding
Hydraulic pipes and hoses - renewal
Brake drum - removal, inspection and refitting
Drum brake shoes - renewal
Drum brake wheel cylinder - removal, overhaul and refitting
Disc brake pads - renewal
Disc brake caliper - removal, overhaul and refitting
Brake disc - inspection, removal and refitting
Handbrake cable - removal and refitting
Handbrake lever - removal and refitting
Master cylinder (single circuit system) - removal, overhaul and refitting
Tandem master cylinder (dual circuit system) - identification and modifications
Tandem master cylinder (type 1) - removal, overhaul and refitting
Tandem master cylinder (type 2) - removal, overhaul and refitting
Tandem master cylinder (type 3) - removal, overhaul and refitting
Tandem master cylinder (type 4) - removal, overhaul and refitting
Pressure regulating valve (single circuit system) - removal, overhaul and refitting
Pressure reducing valve (dual circuit system) - removal and refitting
Pressure differential warning actuator (dual circuit system) - removal, overhaul and refitting
Vacuum servo unit - removal and refitting
Vacuum servo unit air filter (1989 models onward) - renewal
Brake pedal - removal and refitting
Suspension and steering
General information
Hydrolastic suspension system - principles of operation
Front swivel hub - removal and refitting
Front hub bearings - renewal
Front swivel hub balljoints - removal and refitting
Front lower suspension arm - removal and refitting
Front suspension tie-bar - removal and refitting
Front upper suspension arm - removal and refitting
Front suspension rubber cone spring - removal and refitting
Front suspension Hydrolastic displacer unit - removal and refitting
Front shock absorber (models with rubber cone suspension) - removal and refitting
Front subframe mountings - renewal
Front subframe - removal and refitting
Rear hub bearings - renewal
Rear rubber cone spring - removal and refitting
Rear Hydrolastic displacer unit - removal and refitting
Rear shock absorber (models with rubber cone suspension) - removal and refitting
Rear helper spring (models with Hydrolastic suspension) - removal and refitting
Rear radius arm - removal and refitting
Rear subframe mountings - renewal
Rear subframe - removal and refitting
Steering wheel - removal and refitting
Steering column - removal and refitting
Steering column - dismantling and reassembly
Steering tie-rod outer balljoint - removal and refitting
Steering rack rubber gaiter - removal and refitting
Rack-and-pinion steering gear - removal and refitting
Rack-and-pinion steering gear - dismantling, inspection and reassembly
Rack-and-pinion steering gear - lubrication
Wheel alignment and steering angles - general information
Bodywork and fittings
General information
Maintenance - bodywork and underframe
Maintenance - upholstery and carpets
Minor body damage - repair
Major structural damage or corrosion - general information
Front door interior trim panel (Saloon and Estate models) - removal and refitting
Doors - removal and refitting
Door hinge - removal and refitting
Front door glass - removal and refitting
Front door lock assembly - removal and refitting
Front door exterior handle (Saloon and Estate models) - removal and refitting
Front door striker plate - removal and refitting
Bonnet - removal and refitting
Bonnet lock release cable - removal and refitting
Bonnet lock - removal and refitting
Boot lid - removal and refitting
Boot lid lock - removal and refitting
Rear doors (Estate and Van models) - removal and refitting
Rear door lock (Estate and Van models) - removal and refitting
Tailgate (Pick-up models) - removal and refitting
Windscreen - removal and refitting
Rear window (Saloon and Pick-up models) - removal and refitting
Rear door window (Estate and Van models) - removal and refitting
Rear quarterlight glass (Saloon models) - removal and refitting
Rear side screen window (Estate models) - removal and refitting
Wooden facia - removal and refitting
Facia top rail cover - removal and refitting
Centre console - removal and refitting
Front grille - removal and refitting
Bodywork seam trim strips - general information
Front and rear bumpers - removal and refitting
Sunroof components - general information
Body electrical system
General information and precautions
Electrical fault finding - general information
Fuses and relays - general information
Switches - removal and refitting
Bulbs (exterior lights) - renewal
Bulbs (interior lights) - renewal
Headlight beam alignment - checking and adjusting
Dim-dip lighting system components - removal and refitting
Horn - removal, refitting and adjustment
Windscreen wiper arms - removal and refitting
Windscreen wiper motor - removal and refitting
Windscreen wiper motor - dismantling and reassembly
Windscreen wiper wheelbox - removal and refitting
Windscreen washer pump - removal and refitting
Instrument panel - removal and refitting
Instrument panel - dismantling and reassembly
Speedometer cable - removal and refitting
Radio - removal and refitting
Anti-theft alarm system components - removal and refitting
Wiring diagrams 1 to 9 inclusive
Mini 850 De Luxe Saloon, Van and Pick-up (with dynamo and toggle type switches)
Mini 850 De Luxe Saloon, Van and Pick-up (with alternator and rocker type switches) - pre 1976
Mini 1000 Special De Luxe Saloon and Cooper S Mk III (with dynamo and toggle type switches)
Mini 1000 Special De Luxe Saloon (with alternator and rocker type switches) - pre 1976
Mini Clubman Saloon and Estate (with dynamo and toggle type switches)
Mini Clubman Saloon and Estate (with alternator and rocker type switches) - pre 1976
Mini 1275 GT (with dynamo and toggle type switches)
Mini 1275 GT (with alternator and rocker type switches) - pre 1976
Mini 1000 Saloon (Canada) - pre 1977
Wiring diagrams 10 to 15 inclusive
Mini 850 Saloon, Van and Pick-up - 1976 onwards
Mini 1000 Saloon (triple instrument facia) - 1976 onwards (UK, Europe, Sweden); and Mini Special (triple instrument facia) - 1976 to 77
Mini Clubman, Estate and 1275 GT - 1976 onwards
Mini Special - 1977 to 78
Mini 1000 (Canada) - 1977 onwards
Mini Special - 1979 onwards
Wiring diagrams 16 and 17
All 1984-on carburetor models with single instrument pack
All 1984-on carburetor models with multiple instrument pack
Wiring diagram 18
1988-on carburetor models
Wiring diagrams 19 to 32 inclusive
Power distribution circuit (fuel-injected models)
Engine management circuit (fuel-injected models)
Instrument circuit (fuel-injected models)
Direction indicator and hazard warning light circuit
Wash/wipe circuit (fuel-injected models)
Auxiliary cooling fan circuit (fuel-injected models)
Radio/cassette player circuit (fuel-injected models)
Brake test circuit (fuel-injected models)
Interior light circuit (fuel-injected models)
Foglight circuit (fuel-injected models)
Heater circuit (fuel-injected models)
Automatic transmission selector illumination circuit (fuel-injected models)
Reversing light, stop-light and heated rear window circuit (fuel-injected models)
Reference
Dimensions and weights
Conversion factors
Buying spare parts
Vehicle identification
Jacking and vehicle support
Radio/cassette unit anti-theft system - precaution
Tools and working facilities
Tools and working facilities
MOT test checks
Checks carried out FROM THE DRIVER'S SEAT
Checks carried out WITH THE VEHICLE ON THE GROUND
Checks carried out WITH THE VEHICLE RAISED AND THE WHEELS FREE TO TURN
Checks carried out on YOUR VEHICLE'S EXHAUST EMISSION SYSTEM
Fault finding
Introduction
Engine
Cooling system
Fuel and exhaust systems
Clutch
Manual transmission
Automatic transmission
Driveshafts
Braking system
Suspension and steering systems
Electrical system
General repair procedures
Glossary of technical terms
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