[coulsoni]

I'm right now in the middle of installing the factory auxiliary driving lamps/lights to my '04 Cooper (USA/Canada type: 63 12 0 144 132). The instructions that come with them and that can be downloaded off the net are not very detailed. This aside I decided to attempt the install.
The kit comes with a wiring harness that in part has to be attached to 2 of the wires on the head unit wiring harness (one GR/RT and the other VL/BL)...this is where my problem lies. I was supposed to attach the wires with the enclosed set of 2 contact mini-binders - this I found impossible as the wiring harness to the back of the head unit is a bit short - there simply isn't enough slack to allow you to splice the cables, once you've cut them that is! I tried several times without success and in the end have had to make do with simply twisting the wires together and taping them with insulating tape (I am sure this won't last with the bumpy roads in my home town). Has anyone else installed this kit and if so do you have any advice on connecting the cables - I wondered if soldering would work? or is there a better way to attach the wires than suggested by the manufacturers?
A second problem I found is that I also have to route another cable (labelled G) from the head unit area to the BC1 control unit. I have no idea (again poor instructions) on how to get the wire to that part of the car (under the carpet?) or more importantly what to do with the '5 contact mini-binder' when I get there. Part of the install instructions state that I should connect the cable 'G' to a single cable GE/GN in colour, but if that is the case why do they give you the 5 contact connector? I am worried that I will mess up the install and worse damage my Mini's electrical system. Any help would be much appreciated. Thanks

[Wobert]

The first question I can't help you on as I've not done a US install.

The second one regarding cable G I can help with as this appears to be common with the UK install.

The BC1 unit is in the passenger footwell behind the trim panel that goes between the floor and the underside of the dash, and along the sill. It's held in by clip connectors

Once this panel is removed you will see the BC1 unit on the vertical under the dash.

Undo the bolt and swing the BC1 unit upwards, this will give enough slack to undo the multipin connector. The connector undoes by means of a lever integrated into the connector. Once the connector is free from the BC1 you should see that the outer shroud will come off. The shroud procts the wires going into the connector. The UK instructions call for cable G with a connector pin already on it to go into pin 41. The connector has the pin numbers identified, just count them along. Once the pin is in the connector, reassemble as a reverse of disassembly.

I routed the cable under the carpet......

Hope this helps....

Having re-read question 1, have you tried shrouded flat crimp connectors...???

Robert

[coulsoni]

Hi Robert,
Many thanks this is a great help. Re the crimp connectors I had one in my garage so managed to use one of these, if when I finish the install of the lights and all works I will then dissasemble the radio/centre consule and re-connect the wires with these things (problem is they are still very short - might need to add extra lengths to each). One last query, if you've done a recent install, is, is it vital to use a 4.2mm drill bit to fit the threaded rivets that support the lights (not the pop rivets that hold the brackets). I've had no luck in getting the correct metric sized drill bits here over the pond!. Thanks.

[Wobert]

I used a 4.5mm drill......the pop rivets will expand (within reason) to fill the hole.

Imperial equivalents are 5/32 or 11/64.

Good Luck

Robert

[coulsoni]

Thanks again,
Cheers, Ian