BMW Mini-Cooper 1968 Instruction manual

mk1-performance-conversions.co.uk

, !
... ~
~~;:~{;;~:?
',:,:~
Quote Part. No. AKD 4935 Bwhen ordering this
publication, which also replaces
AKD 4061 C
WORKSHOP
MANUAL
,.:.\
~LOO~ and MOKE
COUNTRYMAN and TRAVELLER
VAN and PICK-UP
COOPER and COOPER '5'
IINI'::'~a.B.DI ©THE BRITISH MOTOR CORPORATION LIMITED. 1968
The British Motor Corporation Limited
BMC S~rvice division .
Cowley, Oxford, England
Telef>hone: 78941
Telegrams: BMCSERV, Telex. Oxford
Telex: BMCSERV. Oxford 83145 and 83146 ....
Overseas Cables: BMCSERV. Telex. Oxford. England
mk1-performance-conversions.co.uk

2
INTRODUCTION
This Manual has been prepared to provide service operators with the necessary infor-
mation for the correct maintenance and repair
of the Mini and Mini-Cooper. The Manual
also serves as aready-reference book for service supervision and covers items of.procedure
for guidance
of both the fully qualified and the less-experienced mechanic.
.Where
~ Section has acapital letter and asmall letter 'a' at the top of the page i.e. Aa,
this section refers specifically to the Mini fitted with automatic transmission.
MINI. Issue 2.
mk1-performance-conversions.co.uk

CONTENTS
Section
Introduction
General
Data
General Data-Mini-Cooper
General Data-Mini-Cooper 's'
General Data-Mini Mk. II
General
Data-Mini Automatic (848-c.c.)
General
Data-Mini Automatic (998-c.c.)
I
~
Engine (synchromesh transmission)
Engine (automatic transmission)
..
A
Aa
"~
)
.' -'~:';,
M
S
R
N
L
J
K
End of Manual
Recommended Lubricants
..
Service Tools
Body
..
Electrical
Front Suspension
Steering
Rear Suspension
Drive Shafts
..
Hydraulic Dampers
Braking System
Clutch
Transmission (automatic)
Transmission (synchromesh)
Fuel System (automatic transmission)
Fuel System (synchromesh transmission)
Ignition (synchromesh transmission)
Ignition (automatic transmission)
..
Cooling System
MINI. Issue 2. 9764
t.~(A~'~t
·~~3 ... ·:.y:
_________________________ lIiIiIIiIIlIIIiIIIIIlIlIItdt •. ' •.. ·.,_ ... IIiIIiI·# .. Lii",;..'~."-iiii .. :.:.,' ... ~ .·"-ii"'·II··iI •••• ·,1
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GENERAL DATA
"ENGINE
Type
Number of cylinders
Bore
Stroke
Capacity
Firing order
Compression ratio
Capacity
of combustion chamber (valves fitted)
Valve operation
B.M.E.P
...
Torque
Compression pressure
Engine idle speed (approx.)
Oversize bore: 1
st
Max.
8MB.
4.
.. 2·478 in. (62,94 mm.).
2·687 in. (68,26 mm.).
51·7 cu. in. (848 cc.).
. .
1, 3,4,2.
., 8·3: 1.
. . 1·49 cu. in. (24,5 cc.).
.. Overhead by push-rod.
128 lb./sq. in. (9 kg./cm.2)
at 2,900 r.p.m.
.. 44 lb. ft. (6,08 kg. m.) at 2,900 r.p.m.
150 lb./sq. in. (10,5 kg./cm.2
).'
.. 500 r.p.m.
+'010 in. ('254 mm.).
+'040 in. (1,016 mm.).
•CRANKSHAFT
Main journal diameter
Minimum regr'ind diameter
Crankpin journal diameter
Crankpin minimum regrind diameter
Main bearings
Number and type
Material
Length
..
End-clearance ..
End-thrust
Running clearance
1·7505
to 1·751 in. (44,46 to 44-47 mm.).
1·7105 in. (43,45 mm.).
. . 1·6254
to 1·6259 in. (41'28 to 41·29 mm.).
1·5854 in. (40,27 mm.).
.. 3shell type.
.. Steel-backed white metal.
1·187 in. (30'16 mm.).
·0002
to ·003 in. (,051 to ·076 mm.).
.. Taken on centre main bearing.
.. ·0005 to ·002 in. (,013 to ·051 mm.).
_
"i~
';"" .... ,
I~>";
.. 5·75 in. (14,605 cm.).
- '~
Split skirt.
. . ·0006 to ·0012 in. ('015
to ·030 mm.).
·0026
to ·0032 in. ('066 to ·081 mm.).
+.010 in., +·020 in., +·030 in., +·040 in.
('254 mm., ·508 mm., ·762 mm., 1·016
mm.).;',,·-
. . Steel-backed· lead-bronze with lead-indium-plat'd
surface, or steel-backed copper-lead wi$: lelJd-
tin-plated
surface....::, .'j
·008 to ·012 in. (,203 to ·305 mm.). ,'\-~
.001 to ·0025 in. (,025 to ·063 mmij., \it 'It
\~~
Bearing side-clearance
Bearing diametrical clearance
CON.r.cTING RODS
Length between centres ..
Big-end bearings
Material
PISTONS
Type
-':, Clearances:
Bottom of skirt
Top of skirt
Oversizes
..
PISTON RINGS
Compression: Plain
Tapered
..
Width
Thickness
Fitted gap
Clearance
in groove
MINI Issue 1. 4908
Top ring.
. . Second
and third rings.
.. ·069 to ·070 in. (1,75 to 1·78 mm.).
.. ·095 to ·101 in. ~'41 to 2·56 mm.).
·007
to ·012 in.'(·178 to;·305 mm.).
·0015
to ·0035 in. (,038 to ·089 mm')'6+
'.
mk1-performance-conversions.co.uk

p
Oil control type ..
Width .l:
Thickness
Fitted gap
Clearance in groove ..
GUDGEON PIN
Type
Fit in piston
Diameter (outer)
..
GENERAL DATA-continued
.. Slotted scraper.
.. ·124 to ·125 in. (3'15 to 3·175 mm.).
·095 to ·101 in. (2,41 to 2·56 mm.).
· . ·007 to ·012 in. ('178 to ·305 mm.).
· . ·0015 to ·0035 in. (,038 to ·089 mm.).
.. Clamped in little-end.
.. Hand push-fit.
·624 in. (15'86 mm.).
:~-
VALVES AND VALVE GEAR
Valves
Seat angle: Inlet
Exhaust ..
Head diameter: Inlet ..
Exhaust
Stem diameter: Inlet
..
Exhaust
Valve lift
Valve stem to guide clearance: Inlet
Exhaust
Valve rocker clearance: Running
Timing
Timing markings
Chain pitch and number of pitches
Inlet valve: Opens
Closes
Exhaust valve: Opens ..
Closes
Valve rocker bush bore (reamed)
"VA~YE GUIDES
Length: Inlet and exhaust
Diameter: Outside: Inlet and exhaust ..
Inside: Inlet and exhaust ..
VALVE SPRINGS
Free length: Inlet and exhaust ..
Number of working coils
Pressure: Inlet and exhaust: Valve open
Valve closed
TAPPETS
Type
Diameter ..
Length
.. 45°.
.. 45°.
· . 1·093
to 1'098 in. (27,76 to 27·89 mm.).
.. 1·000 to 1·005 in. (25,40 to 25·53 mm.).
.. ·2793 to ·2798 in. (7,096 to 7·109 mm.).
· . ·2788 to ·2793 in. (7,081 to 7·096 mm.).
.. ·285 in. (7,24 mm.).
.. ·0015 to ·0025 in. (,038 to ·064 mm.).
·002 to ·003 in. (,051 to ·076 mm.).
· . ·012 in. (,305 mm.) (cold).
.. ·019 in. ('48 mm.).
.. Dimples on timing wheels, marks on flywheel.
iin. (9'525 mm.). 52.
5° B.T.D.C.
45° A.B.D.C.
.. 40° B.B.D.C.
· . 10° A.T.D.C.
.. ·5630 to ·5635 in. (14'30 tu 14·312 mm.).
.. 1·687 in. (42'86 mm.).
· . ·469 in. (11,91 mm.).
.. ·2813 to ,2818 in. (7'145 to 7·257 mm.).
· . 1·625 in. (41'27 mm.).
.. 41·
.. 70 lb. (31'8 kg.).
37·5 lb. (17'027 kg.).
.. Barrel type.
.. '812 in. (20,64 mm.).
.. 1,5 in. (38,10 mm.).
---
- -._.'.~
CAMSHAFT
Journal diameters: Front
Centre
Rear
~Data2
1'---;"'''
· . 1·6655 to 1·666 in. (42,304 to 42·316 mm.). •
· . 1·62275 to 1·62325 in. (41'218 to 41·231 mm.). .
· . 1·3725 to 1·3735 in. (3.4·862 to 34·887 mm.).
'. MINI. Issue 1. 4908
\\.
mk1-performance-conversions.co.uk

GENERAL DATA-continued
.' _End-float ..
Bearings: Type: Front
Centre and rear
Inside diameter (reamed in position)
Clearance: Front ..
Centre and rear
ENGINE LUBRICATION SYSTEM
Oil pump
Type
Relief pressure valve opens ..
Relief valve spring: Free length
Fitted length
·003 to ·007 hi. (,076 to ·178 mm.).
White-metal-lined, ste~l~backed.
Plain (running in block).
1·667 to 1·6675 in. (42,342 to 32·355 mm.).
·001 to ·002 in. (,025 to ·051 mm.).
·00125 to ·00275 in. ('0317 to ·0698 mm.).
Hobourn-Eaton or Burman.
60 Ib./sq. in. (4'2 kg./cm.2
).
.. 21£ in. (72,63 mm.).
2-s\ in. (54,77 mm.).
•-
Oil filter
Type
Capacity
Oil pressure
Normal running
Idling (minimum)
COOLING SYSTEM
Type
Thermostat setting
Cold climates ..
Hot climates
IGNITION SYSTEM
Coil
Resistance at 20° C. (68
0F.): primary winding
Distributor: Early type ..
Later type ..
Rotation of rotor arm
Contact point gap setting
Condenser capacity
Cam closed period
Cam open period
Automatic advance
Serial number ..
Full-flow.
Ipint (1,2 U .S. pints, ·57 litre).
60Jb./sq. in. (4,22 kg./cm.2 ).
151b.fsq. in. (1,05 kg./cm.2 ).
,Pressurized radiator, thermo-siphon, pump- and fan ... ·';
assisted.
82° C. (180° P.).
88° C. (188° P.).
74° C. (165° F.).
Lucas LAI2.
3·2 to3~4 ohms (cold).
.. DM2.
Lucas 25D4.
Anti-clockwise.
·014 to ·016 in. ('35 to ·40 mm.).
·18 to ·24 mF.
.. 60
0
±3°.
300 ±3°.
Centrifugal and vacuum.
.. 40768A.
1
1
I
I
)
MINI. Issue 1. 4908
Automatic advance commences*
.... :-;,.;;.". Maximum advance* ..
.i\~?~\~Vacuum advance: Commences
~ "'~\ Ends ..
Decelerating check* ..
Regular (commercial)
fuel distributor
1,250 r.p.m.
22° to 26° at 5,000 r.p~lIl .
•Static ignition timing
..
Stroboscopic ignition timing*
Premium fuel
distributor
500 r.p.m.
30° to 34° at 3,400 f.p.m.
7in. (17,7 cm.) Hg.
10° at 13 in. (33 cm.) Hg.
.. 24° to 28° at 2,500 f.p.m. 22° to 26° at 5,000 r.p.m.
21 ° to 25° at 2,000 r.p.m. 15° to 19° at 3,900 f.p.m.
14° to 18° at 1,000 r.p.m. 1° to 5° at 1,700 r.p.m.
4° to 11° at 800 r.p.m.
T.D.C. 7° B.T.D.C.
3° B .. T.D.C. at 600 r.p.m. 10° B.T.D.C. at 600, r.p.,*:.
• Crankspft, degrees and r,p:m. ",;.~-;'
t~' .General Data 3
-:?'
.~.~.
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G E N E R:A-Ld .,D A T A - con tin u e d
.. ::. -~'
Timing marks
Sparking plugs
Size
Gap
.".
Dimples on timing wheels, marks on flywheel.
Champion N5.
14 mm., iin. (19 mm.) reach.
·025 in. ('625 mm.). •
•/
-~
FUEL SYSTEM
Carburetter
Make and type
Diameter
Jet
Needle
..
S. U. Type HS2.
Lt in. (31'75 mm.).
·090 in. (2'29 mm.).
Standard EB. Rich M. Weak eG.
AIR CLEANER
Type . . Paper element.
•
'.
Borg and Beck.
7t in. (180,9 mm.).
Wound yarn.
Nil.
Brown.
".);,
,~, Issue 1. 4908
4.
Second, third, and fourth gears.
1·0 :
1.
1·412 : 1.
2·172 : 1.
3·627 : 1.
3·627 : 1.
3·765 : 1.
5·317 : 1.
8·176 : 1.
13·657 : 1.
13·657 : 1.
6/17.
7t in. (180,9 mm.).
Wound yarn.
6.
Red spot.
Nil.
.• 3·765: 1.
S.U. electric. PD.
S.U. electric. SP.
45 pints/hr. (25'5 litres/hr.).
56 pints/hr. (32 litres/hr.).
.. 2to 3Ib./sq. in. (,14 to ·21 kg.jcm.2 ).
2!- to 3Ib.jsq. in. (,17 to ·21 kg.jcm.2 ).
,~~
'·:;.~t"
.'.
GEARBOX
Number of forward speeds
Synchromesh
Ratios:
Top
Third
Second
First
Reverse
Overall ratios: Top
Third
Second
First
Reverse
Speedometer
DIFFERENTIAL
Ratio
General Data 4
CLUTCH
BMC single dry plate
Diameter
Facing material
Pressure springs
Colour
..
Damper springs
Diaphragm-spring clutch
Make
Diameter
Facing material
Damper springs
Diaphragm-spring colour code
FUEL PUMP
Make and type: Early cars
Later cars
Delivery rate:
PD type ..
SP and AUF 201 type ..
Delivery pressure: PD type
SP and
AUF 201 type
mk1-performance-conversions.co.uk

•DRIVE SHAFTS
Type
Make and type ofjoint
GENERAL DATA-continued
Solid shaft, reverse spline.
Hardy Spicer, hemispherical joint.
Rack and pinion.
21·
15! in. (40 cm.).
~: positive to 3° POSitive.]
9° 30' with vehicle in an
nin. (1'6 mm.) unladen condition.
23°
•
•
STEERING
Type
Steering-wheel
turns-lock to lock
Steering-wheel diameter
..
Camber angle
Castor angle
King pin (swivel hub) inclination
Toe-out
Lock angle: outer wheel
at 20°, inner wheel
FRONT SUSPENSION
Early models, 1959-1964
Front
Rear
Later models
Front
Rear
-Fluid capacity
Fluid pressure: Early models (unladen)
Later models (unladen)
(Car Nos. given in Section H.lO)
REAR SUSPENSION
Type
Toe-in
Camber
Radius
arm bushes (reamed bore)
HYDRAULIC DAMPERS (Rubber suspension only)
Type:
Front and rear
BRAKES
Lockheed hydraulic
Drum size
Lining dimensions:
Front or rear
Lining area:
Front or rear
Lining material
Lockheed hydraulic
Lining dimensions
Lining area total
Lining material
Type: ventilated disc
MINI. Issue 2. 14091
Rubber cone spring.
Levers
of unequal length.
Trailing radius arms.
Hydrolastic displacers.
Levers
of unequal length.
Trailing arms.
4pints (5 D.S. pints, 2·27 litres).
263 Ib.jsq. in. (18'49 kg.jcm.2 ).
282 lb.jsq. in. (19,74 kg.jcm.2 ).
Rubber cone spring.
iin. (3,18 mm.).
1°positive. .
·8125 to ·8130 in. (20,63 to 20·65 mm.).
/Tubular telescopic.
Single-leading shoe.
7in. (17,8 cm.) diameter.
6·75 in. X1·25 in. (17'14 cm. X3·17 cm.).
33·75 sq. in. (217·7 cm.2 ).
Don 202.
Two-leading-shoe.
6·75 X1·5 in. (17'4x3'18 cm.).
40·5 sq. in. (261·29 cm.2 ).
Don 202.
,,3·50Bx 10.
"f
fj
mk1-performance-conversions.co.uk

GENERAL DATA-continued
TYRES
Size:
Standard
Optional (Radial ply) ..
Pressures:
Standard-normal conditions
fully loaded
Optional (Radial ply), all conditions:
5·20-10 tubeless.
\."
145-10 tubeless.
Front 24 lb./sq. in. (1'7 kg./cm.2 ).
Rear 22 lb./sq. in. (1'55 kg./cm.2 ).
Front and rear 24Ib./sq. in. (1·7 kg./cm.2 ).
.. Front 28 lb./sq. in. (1,97 kg.jcm.2 ).
Rear 26 Ib./sq. in. (1'83 kg./cm.2 ).
.'
•
.0
.. 8 to 9lb. f1. (1 to 1·2 kg. m.).
.. 35 lb. ft. (4'8 kg. m.).
.. 20 to 24 lb. ft. (2,77 to 3·32 kg. m.).
35 to 40 lb. ft. (4·8 to 5·5 kg. m.).
. . 35 to 40 lb. ft. (4·8 to 5·5 kg. m.).
.. 70 lb. f1. (9,6 kg. m.).
.. 60 lb. ft. (8·3 kg. m.).
.. 60 lb. ft. (8,3 kg. m.) (align to next slot).
.. 26 to 28 lb. ft. (3,6 to 3·87 kg. tri.). 'h,
41 lb. ft. (5'76 kg. m.)."';.,
42 lb. ft. (S'8 kg. m.). .
MINI. Issue 2. 14091
60 lb. f1. (8'3 kg. m.).
.. 70 lb. ft. (9'6 kg. m.) (and align to next split pin hole).
18 lb. ft. (2'5 kg. m.).
40 lb. ft. (5'5 kg. m.).
.. 35 lb. ft. (4'8 kg. m.).
60 lb. ft. (8,3 kg. m.).
110 to
115 lb. ft. (15·2 to 15·9 kg. m.).
.. 25 lb. ft. (3,4 kg. m.).
25 lb. f1. (3,4 kg. m.).
6lb. ft. (,8 kg. m.).
40 to 50 lb. ft. (5'5 to 6·9 kg. m.).
2lb. ft. ('28 kg. m.).
.. 5lb. ft. ('7 kg. m.).
6lb. ft. (,8 kg. m.).
'14 lb. ft. (1,9 kg. m.).
17 lb. ft. (2,3 kg. m.).
8lb. ft. (1,1 kg. m.). ,
10 to 15 lb. ft. (1 ~4 't6"2 kg. m.).
9lb. f1. (1'2 kg. m.).
15 lb. ft. (2,1 kg. m.).
4lb. ft. ('56 kg. m.).
70 lb. ft. (9,6 kg. m.).
.. 8lb. ft. (1'1 kg. m.).
. . 6 lb. ft. (·8 kg. m.).
25 lb. ft. (3·45 kg. m.).
18 lb. ft. (2,5 kg. m.).
6lb. ft. ('8 kg. m.).
150 lb. ft. (20,7 kg. m.).
150 lb. ft. (20·7 kg. m.).
18 lb. ft. (2,5 kg. m.).
16 lb. ft. (2·2 kg. m.).
16 lb. ft. (2,2 kg. m.) ..
.. 50 lb. in. ('576 kg. m.).
30 lb. in. (,345 kg. m.).
tI ' ••
General Data 6
TORQUE WRENCH SETTINGS
Cylinder
~ead stud nuts ..
Connecting rod big-end bolts ..
Main bearing setscrews ..
Flywheel centre~bo1t
,Gudgeon pin clamp screws
Rocker shaft bracket nuts
Transmission
C3$e to crankcase
Transmission drain plug
..
'~. Cylinder side cov~r
Second type-deep pressed cover
Timing
cQver-! in .. UNF. bolts
Timing
cover-1\- in. UNF. bolts
Water pump
Water "Outlet elbow
Oil filter bowl
Oil
pump ..
Manifold to cylinder head
Rocker cover
Crankshaft pulley
nut
Transmission case studs-j in. dia. UNC.
Transmission case studs~* in. dia. UNC. ..
Transmission case stud nuts-j in. UNF.
Transmission case stud nuts--&- in. UNF.
Bottomcover set screws-! in. dia. UNC. (change speed tower)
First motion shaft
nut ..
Third motion shaft nut ..
Flywheel housing bolts and stud nuts ..
Set screw, drlving strap to flywheel
Set screw~ clutch spring housing to pressure plate
l)jstributor clamp bolt: Fixed nut type
Fixed bolt type
Final drive
Driven gear to differential cage
Nut, driving flange to differential
End cover bolts (differential housing)
Suspension and steering
Steering-column/rack pinion clamp bolt
Steering lever to hub bolts
Steering lever ball
joint nut ..
.Steering knuckle ball pin bottom nut
'Steering knuckle ball pin top nut
Steering knuckle ball pin retainer
Front hub ~ut (drive shaft) ..
Rear suspension stub axle nut
I?~Qnt suspension upper arm pivot pin nut ..
Steering-wheel nut
Road wheel nuts
mk1-performance-conversions.co.uk

Alternator
Brush·
box fixing screws
Diode heat sink fixings
Through-bolts
..
GENERAL DATA-continued
10 lb. in. ('115 kg. m.).
25 lb. in. ('288 kg. m.).
45 to 50 lb. in. ('518 to -576 kg. m.t
•
ELECTRICAL EQUIPMENT
System
Charging system
..
Battery
Capacity: BLT7A, BLTZ7A
..
BT7A, BTZ7A
Starter
motor
Dynamo ..
Maximum output
Cut-in speed
Control box
Cut-out: Cut-in voltage ..
Drop-off voltage
Reverse current
Regulator
(at 3,000 r.p.m. dynamo speed):
Open-circuit setting
at 20~ C. (680 F.)
For ambient temperatures other than 200C. (680F.) the
following allowances should bemade
to the above setting:
For every 10° C. (18° F.) above 20° C~ (68°.p.) subtract
·1 volt.
For every 10° C. (180F.) below 20° C. (68° F.) add ·1 volt.
12-volt, positive earth.
Compensated voltage control.
Lucas BLT7A, BLTZ7A, BT7A, BTZ7A.
34 amp.-hr.
at 20-hr. rate.
43 amp.-hr.
at 20·hr. rate.
Lucas M35G.
Lucas C40.
22 amps.
at 2,250 r.p.m.
1,450 r.p.m.
at 13·5 volts.
Lucas RBI06j2.
12·7
to 13·3.
8·5
to 11·0.
5·0 amps. (max.).
16·0
to 16·6 volts.
•
Alternator ..
Maximum output
Rotor windings: Resistance ..
Current
Minimum brush length
Brush spring pressure:
H in. (19,84 mm.) compressed length ..
.H in. (10,32 mm.) compressed length ..
Control unit
Type
Voltage setting at 3,000 alternator r.p.m.
Circuit resistance (max.)
Lucas 11AC (12 volts).
43 amperes.
.. 3·8±·2 ohms at 20° C. (68° F.).
3·2 amps.
at ·12 volts.'
Ain. (3,97 mm.).
.. 4 to 5oz. (113 to 142 gm.)•
7! to 8loz. (212 to 241 gm.).
Lucas 4TR.
13·9
to 14·3 volts.
·1 ohm.
Fields isolating relay Lucas 6RA.
General Data 7
~
.; .
..........•... ,.:.
.. 6ft. 8A in. (2,036 m.).
., 7ft. O-A- in. (2'138 m.).
.. 6ft. 8A in. (2,036 m.).
10 ft. 01 in. (3,05 m.).
10 ft.
9i in. (3'259 m.).
.. 10 ft. lOt in. (3,315 m.).
., 10 ft. 0in. (3,04 m.).
.. 4ft. 7t in. (1'41 m.).
4ft. 3-!- in. (1,36 m.).
., 4ft. 5in. (1'35 m.).
., 4ft. 6t in. (1'38 m.).
.. 4ft. 5-!- ~ .. 't\,' ,36 m.).
4ft. 8 4i.~42 m.).
.. Lucas 3AW.
Moke
Overall height: Saloon
Van
Traveller, Countryman, and Pick-up ..
Moke
MINI. Issue 2. 14091
Warning light control
Overall width
GENERAL DIMENSIONS
Wheelbase: Saloon
Van, Pick-up, Traveller,
and Countryman
Moke
Overall length:Saloon
.,
Van, Traveller, and Countryman
Pick-up
Moke
mk1-performance-conversions.co.uk

GENREAL DATA-continued
•
•
8cwt. (406,4 kg.).
6cwt. (304'7 kg.).
.. 333 lb. (151 kg.).
Ground clearance. .
6"3\ in. (15,63 cm.).
Moke
6!- in. (16'2 cm.).
Turning circle: Saloon
.. .. 31 ft. 7in. (9'63 m.).
Van, Pick-up, Traveller,
and Countryman 32 ft. 9in. (9,893 m.).
Moke
31 ft. (9,4 m.).
Track:
Front ., 47-& in. (1,205 m.).
Rear
45i in. (1,164 m.).
Kerbside weight: Saloon (Rubber suspension models)
.. 1,294 lb. (587 kg.).
Saloon (Hydrolastic suspension models)
.. 1,398 lb. (634,5 kg.).
Van . . 1,334 lb. (605 kg.) approx.
Traveller and
Countryman. .1,456 lb. (660 kg.) approx.
Pick-up 1,328 lb. (603 kg.) approx.
Moke
.. 1,240 lb. (562 kg.).
Maximum pedlfissible towing weight (suitable for 1in 8
gradient
in bottom gear):
Saloon
and Moke
Van, Pick-up, Traveller, and Countryman
WEIGHT OF COMPONENTS
Engine and transmission assembly
CAPACITIES
Transmission 'casing (including filter)
Cooling system ..
With heater
Fuel tank: Saloon
Van and Pick-up
Traveller and Countryman: Early models
Later models with underfloor
tank
8!- pints (10'2 V.S. pints, 4·83 litres).
51 pints (6,3 V.S. pints, 3litres).
61 pints (7,5 V.S. pints, 3·55 litres).
'\' 5!- gallons (6,6 V.S. gallons, 25 litres).
~',,~ 6gallons (7,2 V.S. gallons. 27·3 litres).
.. 6!- gallons (7'8 V.S. gallons, 29·6 litres).
6gallons (7,2 V.S. gallons, 27·3 litres).
•
•
General Data 8MINI. Issue
2. 14091
mk1-performance-conversions.co.uk

••
GENERAL DATA
(MINI-COOPER)
The following information is applicable to the Mini-Cooper and should be used in conjunction with the preceding
specification for the Mini Saloon.
•
ENGINE
Type
Number
of cylinders
Bore
Stroke
Capacity
Compression ratio: High compression
Low compression
..
B.M.E.P.: High compression
Low compression
Torque: High compression
Low compression
CRANKSHAFT
Main bearings
Material
..
Length ..
Runt;ling clearance
CONNECTING
RODS
Big-end bearings
Material
Bearing length
..
PISTONS
Type
Clearance: Bottom
of skirt (pressure face)
9F.
4.
2·458 in. (62,43 mm.).
3·20 in. (81,28 mm.).
60·87 cu. in. (997 c.c.).
9:1.
8·3 : 1.
134 lb./sq. in. (9,42 kg./cm.2) at 3,500 r.p.m.
129 lb./sq. in. (9,07 kg./cm.B) at 3,500 r.p.m.
54 lb. ft. (7,46 kg. m.) at 3,600 r.p.m.
53 lb. ft. (7'32 kg. m.) at 3,500 r.p.m.
Steel-backed copper-lead; thin wall.
1·0625 in. (26,99 mm.).
·001 to ·0027 in. (,025 to ·069 mm.).
Steel-backed copper-lead; thin wall.
·875 in. (22,22 mm.).
Solid skirt.
·0016 to ·0022 in. (,041 to ·056 mm.).
PISTON RINGS
Compression: Top
Second
and third
Width
Plain, chrome-faced.
Tapered.
·0615 to ·0625 in. (1'563 to 1·588 mm.).
,~
>fI'I'~ ""
•
VALVES AND VALVE GEAR
Valves
Head diameter: Inlet
..
Exhaust
Throat diameter: Inlet
Exhaust
Valve lift
Inlet valve: Opens
Closes
Exhaust valve: Opens
..
Closes ..
MINI. Issue 1. 4908
1·156 in. (29,4 mm.).
1'000 in. (25,40 mm.).
1·0312 in. (26'2 mm.).
·098 in. (23'06 mm.).
·312 in. (7,92 mm.).
16
0
B.T.D.c.] . h 019' (48 )I
560A B D C WIt· m.' mm' va ve
51
0B:B:D:C: r,ocker clearance (for checking
210 A.T.D.C. purposes only). ,
General Data 9
mk1-performance-conversions.co.uk

GENERAL DATA-continued
(M I NI- COO PER - con tin u e d)
•
VALVE SPRINGS
Free length: Inlet and exhaust
Number of working coils
Pressure: Inlet
and exhaust: Valve open
Valve closed
CAMSHAFT
Journal diameters:
Front
Centre
Rear
End-float ..
Bearings: Number and type
Inside diameter (reamed in position):
Front ..
Centre ..
Rear ..
ENGINE LUBRICATION SYSTEM
Oil pump
Type
Relief pressure valve operates
Relief valve spring: Free length
Fitted length
Oil pressure
Normal running
Idling (minimum)
FUEL SYSTEM
Carburetters
Make' and type
Diameter
Jet
Needle
..
Fuel pump
Make and type
Delivery
rate ..
Delivery pressure
AIR CLEANERS
Type
Later models
COOLING SYSTEM
Thermostat setting
· . 1·750 in. (44·45 mm.).
.. 41-.
90 lb. (40·8 kg.).
.. 55 lb. (24,9 kg.).
· . 1·6655
to 1·666 in. (42,304 to 42·316 mm.).
1·62275
to 1·62325 in. (41,218 to 41·231 mm.).
., 1·3725 to 1·3735 in. (34,862 to 34·887 mm.).
.. ·003 to ·007 in. (,076 to ·178 mm.).
.. 3. Steel-backed white metal.
· . 1·667
to 1·6675 in. (42,342 to 42·355 mm.).
1·6245
to 1·6255 in. (41,261 to 41·287 mm.).
.. 1·3748 to 1·3755 in. (34,914 to 34·937 mm.).
.. Hobourn-Eaton.
70 Ib./sq. in. (4·92 kg./cm.2
).
2* in. (66,28 mm.).
2"3\ in. (54,77 mm.).
.. 70 Ib./sq. in. (4·92 kg./cm.2 ).
· . 15 lb./sq. in. (1·05 kg./cm.2 ).
.. Twin S. U. Type HS2.
1!- in. (31,75 mm.).
·090 in. (2·29 mm.).
.. Standard GZ.
.. S.U. electric. Type SP.
.. 56 pts./hr. (67,2 U.S. pts./hr., 32 litres/hr.).
.. 2t to 3lb./sq. in. (,18 to ·21 kg./cm.2 ).
Oil-wetted gauze.
.. Paper elements.
.. 83° C. (180° F.).
•
•
IGNITION SYSTEM
Coil
Timing: High compression
Low compression
General Data 10
HAI2.
7° B.T.D.C. (Premium fuel). •
50 B.T.D.C. (91 to 96 octane rating fuel, Research"
Method). MINI. Issue
1. 4908
mk1-performance-conversions.co.uk

•
GENERAL DATA-continued
(M I N I - COO PER - con tin u e d)
CLUTCH
Pressure springs-eolour ..
Diaphragm spring colour code ..
.. Black enamel with white spot.
Light green.
•
GEARBOX
Ratios: Top
Third
Second
First
Reverse
Overall ratios:
Top
Third
Second
..
First
Reverse ..
1·0 : 1.
1,357:1.
1·916 : 1.
3·2 : 1.
.. 3·2: 1.
Standard
3·765 : 1.
5·11 : 1.
.. 7·213: 1.
12·05 : 1.
12'05 : 1.
A vailable alternative
3·444 : 1.
4·674 : 1.
6,598 : 1.
11·03 : 1.
11·03 : 1.
•
•
DIFFERENTIAL
Ratio
BRAKES
Front
Type
Disc diameter
Pad material
Rear
Lining material
TORQUE TIGHTENING FIGuRES
Calliper retaining bolts ..
Steering lever ball joint ..
GENERAL DIMENSIONS
Kerbside weight: Rubber suspension models ..
Hydrolastic suspension models
MINI. Issue 1. 4908
3·765 : 1 standard; 3-444 : 1 optional (available from
BMC Service only).
Disc.
7in. (177,8 mm.).
DA3.
.. Don 202.
. .
35 to 40 lb. ft. (4'84 to 5·53 kg. m.).
25 to 30 lb. ft. (3,46 to 4·15 kg. m.).
1,400 lb. (635 kg.).
1,433 lb. (650 kg.).
General Data 11
mk1-performance-conversions.co.uk

GENERAL DATA-continued
(M I NI - COO PER - con tin u e d)
The following information is applicable to the 998-c.c. engine and should be used in conjunction with the preceding
specifications. •
ENGINE
Type
Number of cylinders
Bore
Stroke
Capacity
Compression ratio: High
Low
B.M.E.P.: High compression
..
Low compression
Torque: High compression
Low compression
Compression pressures ..
Engine idle speed (approx.)
Oversize bores: 1st
2nd
CRANKSHAFT
Main bearings
Material ..
Running clearance
CONNECTING RODS
Big-end bearings
,Material
B~.aring length ..
PISTONS
Type
Clearance: Bottom of skirt (pressure face)
Oversizes: 1st
2nd
PISTON RINGS
Compression: 'top
Second and third
Width
Thickness (all rings)
.. 9FA.
.. 4.
2·543 in. (64'588 mm.).
· . 3·00 in. (76,2 mm.).
· . 60·96 cu. in. (998 c.c.).
.. 9: 1.
7·8 : 1.
142 lb.jsq. in. (10 kg.jcm.2) at 3,000 Lp.m. -
135 lb.jsq. in. (9'5 kg.jcm.2) at 3,000 r.p.m.
57 lb. ft. (7'881 kg. m.) at 3,000 r.p.m.
56 lb. ft. (7'74 kg. m.) at 2,900 r.p.m.
.. 165 lb.jsq. in. (11,6 kg.jcm.2 ).
500 r.p.m.
+·010 in. ('254 mm.).
+·020 in. (,508 mm.).
Steel-backed copper-lead
or aluminium-tin; thin wall.
·001 to ·0027 in. (,025 to ·069 mm.).
Steel-backed copper-lead or aluminium-tin; thin wall.
·875 in. (22'22 mm.).
Solid skirt.
·0005 to ·0011 in. (,013 to ·028 mm.).
+,010 in. (,254 mm.).
+·020 in. ('508 mm.).
Plain, chrome-faced.
Tapered.
·0620 to ·0625 in. (1,574 to 1'588 mm.).
· . ·106 to ·112 in. (2'692 to 2·835 mm.).
•
•
GUDGEON PIN
Type
Fit in piston
Fit in small end
Diameter ..
General Data 12
Fully floating, with circlip location.
·0001 in. ('0025 mm.) tight to ·00035 in. ('0089 mm.)
slack. •
·0002 in. ('005 mm.) slack, to size. .
·6244 in. (15,86 mm.) to ·6247 in. (15,867 mm.).
MINI. Issue 1. 4908
mk1-performance-conversions.co.uk

•
GENERAL DATA-continued
(M I NI· COO PER - con tin u e d)
VALVES AND VALVE GEAR
Valves
Throat diameter: Inlet
Exhaust
Head diameter: Inlet ..
Exhaust
Valve lift
Inlet valve: Opens
Closes
Exhaust valve: Opens ..
Closes ..
1·172 in. (29,77 mm.).
·908 in. (23,06 mm.).
1·219 in. (30,86 mm.).
1·00 in. (25,4 mm.).
·312 in. (7,92 mm.).
5° B.T.D.C.
45° A.B.D.C.
51 °B.B.D.C.
21 °A.T.D.C.
•VALVE
SPRINGS
Free length: Inner
Outer
Pressure: Inner: Valve closed
Valve open
Outer: Valve closed
Valve open
1·672 in. (42,47 mm.).
1·75 in. (44,45 mm.).
18 lb. (8'17 kg.).
30 lb. (13,6 kg.).
55! lb. (25,13 kg.).
88 lb. (39'9 kg.).
FUEL SYSTEM
Carburetter
Needle
Spring
.,
Standard GY.
Blue.
Lucas HA12.
3·1 to 3·5 ohms (cold). .'1:
Lucas 24D4.
40955A.
5° B.T.D.C. (premium fuel).
5° B.T.D.C. (91 to 96 octane[Research Method] fuen~
7° B.T.D.C. at 600 f.p.m.
500 f.p.m.
30° to 40° at 6,600 r.p.m.
3in. (7 ·62 cm.) Hg.
8in. (20,32 cm.) Hg.
30° to 34° at 6,600 f.p.m.
20° to 24° at 4,000 f.p.m.
12° to 16° at 1,800 f.p.m.
1° to 5° at 600 r.p.m.
*Crankshaft degrees and f.p.m.
IGNITION SYSTEM
Coil
Resistance
at 20° C. (68° F.) primary winding
Distributor
Serial
number ..
Static ignition timing: High compression
Low compression
Stroboscopic ignition timing* ..
Automatic advance commences*
Maximum advance*
..
Vacuum advance: Commences
Ends
Decelerating check*
..
•
•MINI. Issue
1. 4908 General
Data 13-
mk1-performance-conversions.co.uk

GENERAL DATA
(MINI-COOPER '8')
The following information is applicable to the Mini-Cooper'S' and should be used in conjunction with the preceding
specifications. •
ENGINE
Number of cylinders .. 4.
Bore (all models) . . .. 2·780 in. (70,6 mm.).
Stroke: 970 C.c. .. .. 2·4375 in. (61'91 mm.).
1071 C.c. .. .. 2·687 in. (68'26 mm.).
1275 C.c. .. .. 3·2 in. (81,33 mm.).
'Cubic capacity: 970
C.c. .. .. 59·1 cu. in. (970 c.c.).
1071 c.c. .. 63·35 cu. in. (1071 c.c.).
1275 C.C. 77·9 cu. in. (1275 c.c.).
Compression ratio: 970 c.c.
.. 10: 1.
1071 C.C. 9·0 : 1.
1275 C.C. 9·75 : 1.
Capacity of combustion chamber (valves and sparking plug •
fitted) 1·306 cu. in. (21,4 c.c.).
B.M.E.P.: 970
C.C. 1421b.jsq. in. (9'98 kg.jcm.2) at 4,500 r.p.m.
1071 C.C. . . 143 lb.jsq. in. (10'05 kg.jcm.!) at 4,500 r.p.m.
1275 C.C. 153 Ib.jsq. in. (10'76 kg.jcm.2) at 3,000 r.p.m.
Torque: 970 C.C. " 57 lb. ft. (7'88 kg. m.) at 5,000 r.p.m.
1071 C.C. 62 lb. ft. (8'58 kg. m.) at 4,500 r.p.m.
1275 C.C. 79 lb. ft. (10'92 kg. m.) at 3,000 r.p.m.
Compression pressure 190 to 200 Ib.jsq. in. (13'36 to 14'07 kg.jcm.2) at
500 r.p.m.
Engine idle speed 500 r.p.m. approx.
CRANKSHAFT
Main journal diameter
Minimum regrind diameter
Main bearings
Material
Length ..
Running clearance
,CONNECTING RODS
Little-end bore diameter
:PISTONS
Type
Clearance: Bottom of skirt (pressure face)
Top of skirt "
PISTON RINGS
Compression: Plain
Tapered ..
Width ..
Thickness
Fitting gap
Clearance in groove
Oil control type
Width ..
Thickness
Fitted gap
Clearance in groove ..
General Data 14
2·0005 to 2·0010 in. (50'81 to 50·82 mm.).
1·9805 to 1·9810 in. (50,30 to 50·31 mm.).
· . Steel-backed copper-lead; thin wall.
1'000 in. (25,4 mm.).
·001 to '0027 in. (,025 to ·068 mm.). •
· . ·8110 to ·8115 in. (20,60 to 20·61 mm.).
Solid skirt.
'0019 to ·0025 in. (,048 to ·063 mm.).
·025 to ·0283 in. (,63 to ·72 mm.).
Top ring.
.. Second and third ring.
.. ·0459 to ·0469 in. (1'16 to 1·19 mm.).
· . ·116 to ·122 in. (29'4 to 30·9 mm.).
·008 to ·013 in. (,20 to ·33 mm.).
·0015 to ·0035 in. (,04 to ·09 mm.).
·1153 to ·1563 in. (3'94 to 3·96 mm.).
.. ·116 to ·122 in. (29,4 to 30·9 mm.). •
·008 to ·013 in. ('20 to ·33 mm.).-
·0015 to '0035 in. ('04 to ·09 mm.).
MINI. Issue 1. 4908
mk1-performance-conversions.co.uk

•GUDGEON
PIN
Type
Fit in piston
Diameter (outer)
..
Fit in connecting rod
GENERAL DATA-continued
(M I N I - COO PER'S' - con tin u e d)
Pressed in connecting rod.
Hand push-fit.
·8123 to ·8125 in. (20·63 to 20·64 mm.).
·0008 to ·0015 in. (·020 to ·038 mm.) interference.
•
VALVES AND VALVE GEAR
Valves
Head diameter: Inlet
..
Exhaust
Valve lift
Stem diameter: Exhaust
Inlet
Valve rocker clearance: Standard
Competition
Timing
Inlet valve: Opens
Closes
Exhaust valve: Opens
..
Closes ..
VALVE SPRINGS
Free length: Inner
Outer
Number
of working coils: Inner
Outer
Pressure: Inner: Valve closed
..
Valve open
Outer: Valve closed
Valve open
1·401 to 1·406 in. (35·58 to 35·71 mm.).
1·214 to 1·219 in. (30·83 to 30·96 mm.).
·318 in. (8·08 mm.). nominal.
·2788 to ·2793 in. (7·08 to 7·09 mm.).
·2793 to ·2798 in. (7·09 to 7·11 mm.).
·012 in. (·30 mm.) cold.
. . ·015 in. (·38 mm.) cold.
.. ·021 in. (·53 mm.).
50 B.T.D.C. ] . h 021· ( 53 ) 1
450 AB D C WIt· Ill.· mm. va ve
51
0B:B:D:C: rocker clearance (for checking
21
0A.T.D.C. purposes only). .
1·705 in. (43·31 mm.).
1·740 in. (44·19 mm.).
.. 61-.
.. 4t·
.. 26·6 lb. (12·065 kg.).
46 lb. (20·865 kg.).
49·6 lb. (22·498 kg.).
94 lb. (42·638 kg.).
•CAMSHAFT
Journal diameter: Rear
Inside diameter (reamed in position): Rear
..
Running clearance: Rear
Bearing length: Rear
ENGINE LUBRICATION SYSTEM
Oil pressure (normal running)
..
1·37275 to 1·3735 in. (34·87 to 34·88 mm.).
1·3745 to 1·3750 in. (34·91 to 34·92 mm.).
·001 to ·00225 in. (·025 to ·057 mm.).
U±·010 in. (l9·45±·25 mm.).
60 lb./sq. in. (4·22 kg./cm.2)at 70° C. (1580 F.) oil
temperature.
•
COOLING SYSTEM
Thermostat setting
FUEL SYSTEM
Carburetter needle: 970 c.c.
1071 c.c.
1275 c.c.
MINI. Issue 1. 4908
. . 820C. (1800F.).
AN.
H6.
.. M.
General Data 1S
mk1-performance-conversions.co.uk

GENERAL DATA-continued
(MINI-COOPER 'S'-continued)
IGNITION SYSTEM
Sparking plugs
Coil
Distributor
Serial number ..
Static ignition timing: 970 C.c. ..
1071 C.c.
1275 c.c.
Stroboscopic ignition timing*: 970
C.c.
1071 C.c.
1275 C.c.
Centrifugal advance*: 970 c:c. ..
1071 C.c ...
Maximum advance*: 1275 C.c. ..
Decelerating check*: 1275 C.c. ..
CLUTCH.
Make and type: Early type
Later type
lDiameter
..
Facing material: Standard
Optional
Pressure springs (early type): Inner
Outer
Colour: Inner
Outer
Champion N9Y.
HA 12.
23D4.
40819B.
12° B.T.D.C.
3° B.T.D.C.
2° B.T.D.C.
14° B.T.D.C.
at 600 r.p.m.
5° B.T.D.C. at 600 r.p.m.
4° B.T.D.C.
at 600 r.p.m.
24°
at 1,500 r.p.m., 32° at 4,000 Lp.m.
15°
at 1,500 r.p.m., 23° at 4,000 r.p.m.
27°
to 31 ° at 7,000 Lp.m.
22°
at 4,000 r.p.m.
11 ° to 15° at 2,000 r.p.m.
14° at 1,500 r.p.m.
0°
to 2° at 600 r.p.m.
*Crankshaft_degrees and r.p.m.
BMC single dry plate.
Diaphragm spring.
7·125 in. (180'9 mm.).
Wound yarn, riveted.
Wound yam, cemented and riveted.
6.
.. 6.
Green spot.
.. White spot.
•
GEARBOX
Ratios:
Top
Third
Second
First
Reverse
..
Overall gear ratios (as applicable):
Standard gearbox
Standard
1·0 :1
1,357:1
1·916 : 1
.. 3·200: 1
3·200 : 1
Optional
1·0 :1
1·242 : 1
1·78 : 1
2,57 : 1
2·57 : 1 •
Final drive ratio
3'765
3·444
3·939
4·133
4·267
Optional gearbox
Final drive ratio
3'765
3'444
3·939
4·133
4·267
General Data 16
1st and
reverse
2nd
3rd 4th
12·05 : 1 7·21 : 1 5·11 : 1 3·765 :]
11·02 : 1 6·60 : 1 4·67 : 1 3·444 : 1
.. 12·06 : 1 7·54 : 1 5·34 : 1 3·939 : 1
13·27 : 1 7·92 : 1 5·61 : 1 4·133 : 1
13·65 : 1 8·18 : 1 5·79 : 1 4·267 :1
1st and
reverse
2nd
3rd 4th
9·66 : 1 6·70 : 1 4·68 :13·765 :1
8·84 : 1 6'13 : 1 4·28 : 1 3·444 : 1
10·12 : 1 7·02 : 1 4·89 : 1 3·939 : 1 •
10·61 : 1 7·35 : 1 5·13 : 1 4·133 : 1
10·90 : 1 7·61 : 1 5·30 : 1 4·267 : 1
MINI. Issue
1.
4908
mk1-performance-conversions.co.uk