Procedures A to E
A. Installation and Routing Diagram for Supplemental Harness
B. Supplemental Wiring Harness Connection Overview
C. Installing Mounting Brackets
1. Insert mounting bracket (c) and (d) through the grill (bottom fin) and align them centrally using spacing dimension A = 192.5 mm
1a. For vehicles with Sports Package:
If the vehicle is equipped with sport package trim, the grill must first be modified to allow the installation of the mounting bracket through the grill.
Use the auxiliary driving light templates (Not to Scale) for MINI Cooper P/N 01 00 0 150 961.
Cut out both sport grill templates (1 & 2) for installing the RH and LH mounting bracket, then cut out the opening on each template through which the mounting bracket is to be inserted.
Apply RH template (1) and LH template (2) to grill as shown in illustration S63 02 U34.
Carefully remove the area of the grill through which the mounting bracket is to be inserted using a Dremel(R) Tool or equivalent rotary tool with cutting bit.
2. Mark the holes for rivets using the mounting brackets (c) and (d), center punch the holes and drill (drill bit diameter 4.0 mm or 5/32").
Note:
Insure that the brackets are tight against the interior panel of the hood, without any gaps.
3. Prior to drilling any holes cover the engine compartment to protect it from any metal filings.
4. When drilling the bottom holes, also drill through the grill.
5. Drill the top holes and insure that the exterior skin is not damaged.
6. Treat all of the holes with the standard anti corrosion measures.
7. Insert mounting brackets (c) and (d), secure them using rivets (m).
8. Prior to tightening the rivets raise the hood to avoid riveting the grill.
9. Tighten the rivets (m) using a rivet gun.
IMPORTANT:
For cars with a combination of Xenon Light (SA 522) and High Pressure Washing System (SA 502), the gas pressure dampers for the hood (P/N 51 23 7 064 485), must be installed for safety reasons.
D. Installing the Light Switch for the Auxiliary Driving Lights
1. Remove the driver's side knee bolster.
2. Use the auxiliary driving light templates for MINI Cooper P/N 01 00 0 150 961.
Cut out the entire knee bolster switch template (2) and then cut out the switch location on the template.
3. See Figure S63 02 U32 (Not to scale). Position the template (2) on knee bolster (1) as shown so that the top edge and left edge of the template are properly positioned adjacent to the edges of the bolster.
4. Mark switch cutout area.
5. Carefully cut opening using a Dremel(R) Tool or equivalent rotary tool with cutting bit). It will also be necessary to remove interfering material located on the inside panel to allow free access to switch opening.
6. Smooth the edges of the opening using a file and make sure that the switch fits correctly.
7. Make certain that the springs of the switch snap in behind the edges of the opening. Due to the thickness of the panel, it may be necessary to cut off about 3 mm of each spring end so that the springs snap into position once the switch is inserted in position.
E. Installing the Supplemental Wiring Harness
1. Disconnect the battery. (Refer to TIS 61 21 010).
2. Displace passenger side entrance cover strip for access to Body Control Module (BC1).
3. Remove Radio (Refer to TIS 65 11 030)
4. Locate grommet (1) on firewall and use an awl to puncture a hole in the grommet.
5. Route supplemental harness from interior driver's area through hole in grommet so that items B, C, D, E, and J of wire harness protrude through hole into engine compartment area so that junction of item J (RT wire) extends 4" (10 cm) beyond the hole in the grommet on the firewall.
NOTE:
When routing the wire harness from inside the vehicle to the engine compartment insure that the wires don't get pinched. Secure wire harness in place with cable ties.
6. Remove nut from ground stud (1) located next to the inertia switch. Place the ring terminals of supplemental harness BR wires (D) and (E) onto the ground stud and secure in place by reinstalling the ground nut.
7. Slightly loosen (do not remove) the screws (1) that secure the inertia switch (2) in place.
8. Slide the fuse holder mounting bracket (e) behind the inertia switch (2) and re-tighten the screws.
9. Route branches (B) and (C) through rubber seal opening (1) and along hood hinge (2). Insert push fasteners with cable ties (0) in vacant holes along hood hinge. Make sure that a portion of the harness with the fabric sleeve is inserted in the wing area of the hood, in a loop shape before securing harness in place with cable ties.
10. Route branches (B) and (C) through the longitudinal opening (1) in the respective mounting bracket (c) and (d) and secure in place using cable ties (n).
IMPORTANT:
For cars with a combination of Xenon Lights (SA 522) and High Pressure Washing System (SA 502), a different reinforced hood damper (P/N 51 23 7 064 485) must be installed for safety reasons.
11. Drill a 6 mm diameter hole (2) in the plastic trim (3), level with the B+ connector (1) in the main fuse box.
12. Connect ring cable lug (L) from the 20" (50 cm) long heavy gauge RT wire to the B+ connector (1) of the main fuse box. Feed the other end of the heavy gauge RT wire through the hole (2) in the plastic trim (3) and route it to the inertia switch area.
13. Use a Dremel(R) or equivalent rotary tool with a grinding bit to place a grove (4) in plastic cover (5) of the main fuse box.
14. Cut the fuse holder rubber grommet (h) and run the two RT wires (J) and (K) through the grommet (h).
15. Strip the ends of the two RT wires (J) and (K) and crimp on the blade connectors (q).
Note:
The blade receptacles (q) are different sizes and must be placed onto the appropriate sized wire.
16. Insert RT wires (J) and (K) completely into a fuse slot location in the fuse holder (f).
17. Once the wires are fully inserted into the base of the fuse holder (f), push the four-position fuse location piece (1) inwards to set the secondary lock until an audible "click" is heard securing the secondary lock in place (2).
18. Insert 15 Amp fuse (i) into the fuse holder (f) and install the fuse holder cover (9).
19. Attach the fuse holder securing clip (r) to the fuse holder (f). Attach the fuse holder (f) to the fuse holder mounting bracket (e in step 8) by turning it 1/4 turn until it locks into place with the fuse holder cover (9) facing up.
20. Insert relay (w) into the relay base connector (H) of the supplemental wiring harness. Secure the relay to the main wiring harness (2) located on the left side of the driver's footwell area with a cable tie (1).
21. Route the two wires (F) GR/RT and VI/BL of the supplemental harness through the open areas for the radio.
22. Connect the GR/RT wire from the supplemental harness to the GR/RT wire going to pin 14 (58G) of the radio (1) using a quick connect (aa).
23. Connect the VI/BL wire from the supplemental harness to the VI/BL wire going to pin 16 (R) of the radio (1) using a quick connect (aa).
24. Install switch (y) into the switch cutout (previously made into the knee bolster.
25. Route supplemental harness branch (I) to knee bolster and connect to the switch (y).
26. Reinstall the knee bolster.
27. Route wire (G) GE/GN of the supplemental harness to the passenger's footwell area.
28. Disconnect the green connector X322 (1) from the Body Control Module (2) located on the right side of passenger's footwell area.
29. Connect wire (G) GE/GN to the yellow/green wire going to X322 (1) pin 15 of BC1 (2) using a quick connect (z).