🏷️ Basic Information

Make:

Austin Mini / Morris Mini / Rover Mini

Model:

Mini (all variants)

Production Years:

1959-2002

Internal Project Name:

ADO 28

👋 Introduction

Target Audience:

Mini owners undertaking DIY maintenance, repairs, and performance tuning. Also valuable for professional mechanics working on classic Minis.

Advantage:

Covers an exceptionally long production run and multiple variants, including dedicated performance information, differentiating it from more generic manuals.

Performance Bible:

Includes a dedicated section on 'hotting up' and performance modifications, a significant draw for enthusiasts.

Comprehensiveness:

A-to-Z coverage for a vast range of models and technical aspects.

📋 Manual Details

Vehicle Variants:

Sedan, Countryman, Traveller, Cooper, Cooper S, 1275 GT, Clubman, Estate, Van

Engine Variants Detailed:

All specified engine displacements, including specific tuning for Cooper and Cooper S models.

Estimated Pages:

Varies by specific sub-model and year, but comprehensive coverage implies hundreds of pages.

Type:

Comprehensive Workshop Manual

Language:

English

Format:

PDF

📖 Manual Coverage

Engine:

Engine overhaul, tuning, diagnostics, lubrication, cooling, fuel systems (carburettor and early injection), ignition systems

Transmission:

Gearbox overhaul, clutch, final drive, drive shafts

Chassis And Suspension:

Hydrolastic/Hydragas suspension, telescopic dampers, suspension arms, steering assembly, wheel bearings

Brakes:

Hydraulic system, disc and drum brake overhauls, master cylinder, wheel cylinders, brake adjustments

Electrical:

Wiring diagrams, lighting, ignition, charging system, starter motor, instrumentation, accessory circuits

Bodywork:

Body shell construction, panel replacement, doors, windows, trim, sealing

Cooling System:

Radiator, fan, hoses, thermostat, water pump, and coolant circulation.

Fuel Delivery:

Fuel pumps (mechanical or electric), fuel lines, filters, and tank.

Maintenance:

Routine servicing, oil changes, filter replacements, spark plug checks, brake adjustments, fluid level checks, lubrication points

Repair:

Complete engine rebuild, gearbox rebuild, suspension component replacement, brake system repair, electrical fault diagnosis and repair

Troubleshooting:

Diagnostic charts for common problems, symptom-based fault finding

Performance Enhancement:

Tuning for increased power (hotting up), carburetor tuning, camshaft upgrades, exhaust modifications, ignition timing adjustments

Wheel Alignment:

Specifications for camber, caster, and toe-in, crucial for handling and tire wear.

Body Panel Alignment:

Guidelines for fitting and aligning doors, bonnets, and boot lids for proper shut lines.

Depth:

Comprehensive, covering everything from basic maintenance to full engine and gearbox rebuilds, including performance modifications.

Diagnostic Charts:

Inclusion of detailed diagnostic flowcharts for troubleshooting common electrical and mechanical issues.

📊 Manual Specifications

PDF Quality:

High-resolution, searchable text, enabling easy navigation and printing.

Printability:

Designed for easy printing of individual pages or sections.

Binding:

N/A (Digital PDF)

Paper Type:

N/A (Digital PDF)

⚙️ Engine Specifications

Engine Sizes Covered:

848cc, 970cc, 997cc, 998cc, 1071cc, 1275cc

Performance Tuning:

Details for tuning carburetors (e.g., SU, Weber), ignition timing, camshaft selection, and exhaust systems for increased power output.

Carburetion:

Extensive coverage of single and twin SU carburetors, Stromberg CD, and early Lucas fuel injection systems where applicable.

Valve Clearance Specifications:

Specific valve clearance settings for each engine variant (e.g., intake/exhaust for 998cc Cooper: 0.012 inches cold).

Typical Compression Ratios:

Varies by engine; e.g., 8.3:1 for 848cc, 8.5:1 for 998cc, 9.75:1 for 1275cc Cooper S.

Block Material:

Cast iron engine block with wet liners.

🔧 Transmission

Gearbox Type:

4-speed manual transaxle (remote or rod change).

Automatic Transmission:

Some later models offered a 3-speed automatic transmission, coverage likely included.

Gear Ratios:

Specific gear ratios for different models and performance applications will be detailed.

Gearbox Oil Type:

Typically SAE 20W-50 or SAE 80 EP gear oil, depending on specific gearbox and era. Manual will specify exact requirements.

📐 Dimensions

Wheelbase:

Approximately 2096 mm (84.4 inches) for most standard saloons.

Overall Length:

Approximately 3054 mm (120.2 inches) for standard saloons.

Overall Width:

Approximately 1372 mm (54 inches).

Wheel Bolt Pattern:

4 x 101.6 mm (4 x 4 inches).

Kerb Weight:

Typically around 600-700 kg depending on variant.

🛡️ Safety Features

Crash Test Performance:

Early models had minimal safety features. Later models incorporated improvements like collapsible steering columns and seat belts. Manual will detail structural repairs and safety system checks.

Braking System:

Front disc brakes (often 7.5-inch on Cooper/S models) and rear drum brakes. Later models may have servo assistance. Details on adjustment and maintenance are key.

Seatbelts:

Installation and adjustment procedures for seat belts.

💡 Technology Features

Radio Options:

Early models featured basic AM radios; later models had improved radio/cassette units. Manual will cover electrical connections.

Advanced Features:

Minimal advanced driver assistance systems, focus is on mechanical and electrical systems.

Lighting System:

Coverage of headlamps, tail lamps, indicators, and interior lighting circuits, including diagnostic procedures for faults.

🔧 Maintenance

Oil Change Interval:

Typically every 3,000-5,000 miles or annually, depending on usage and oil type.

Grease Points:

Regular greasing of suspension kingpins, track rod ends, and other chassis points is critical.

Engine Oil Type:

SAE 20W-50 or SAE 20W-50 (with a zinc additive for flat tappet engines) is commonly recommended for A-series engines.

Coolant Type:

Ethylene glycol-based antifreeze mixed with water (typically 50/50). Manual will specify concentration and type.

Brake Fluid Type:

DOT 3 or DOT 4 brake fluid. Manual will specify.

Hydrolastic Fluid:

Specific Hydrolastic fluid (often a mixture of water and a special additive). Manual will detail procedure for topping up and 'topping up' (re-adjusting).

Common Wear Items:

Suspension cones/dampers, gearbox synchromesh, clutch components, engine mounts, exhaust system, rust in common areas (wheel arches, sills, floor pans).

Engine Problems:

Oil leaks from crankshaft seals, gearbox oil leaks, potential for bearing wear if lubrication is neglected.

Carburetor Tuning:

Detailed guidance on synchronizing twin SU carburetors and setting correct jet drop for optimal performance and economy.

📚 Vehicle History

Designer:

Sir Alec Issigonis.

Key Development Stages:

Initial ADO 28, introduction of Cooper and Cooper S variants, Hydrolastic suspension, rubber cone suspension, fuel injection, hatchback variants, significant interior and exterior styling updates across its 43-year production run.

Manufacturing Locations:

Principally Longbridge, Birmingham, UK, but also licensed production in several other countries.

Total Production Numbers:

Over 5.3 million units produced globally.

🏆 Awards & Recognition

Design Awards:

The Mini's design has been widely acclaimed as a masterpiece of compact car engineering, influencing automotive design globally.