MINI2

Beau · Apr 22nd, 2002, 09:51 AM

I got my new Cooper 3 weeks ago. The fuse cover (on the inside left kick panel, next to the clutch) will not stay on. As a matter of fact, I don't see how it can. There are 2 big grey fuses on the bottom right corner of the block and they stick up above the level of the opening. When I try to put the cover on, all the little tabs will not snap in, because the cover is deformed by those big grey fuses. I called the dealer & they said no one else had complained (and of course to bring it in & they would fix it).
Any one here heard of or experienced this? Or have an idea on fixing it?
Thanks!

monsta · Apr 22nd, 2002, 09:53 AM

Sounds like the fuses aren't fitted properly or they are the wrong ones.

The panel on my fusebox fits very easily with no problems.

Daddu · Apr 22nd, 2002, 10:21 AM

[quote]Originally posted by monsta
The panel on my fusebox fits very easily with no problems.

Could it be because your's is chrome?

monsta · Apr 22nd, 2002, 10:40 AM

Quote:

Originally posted by Daddu
Could it be because your's is chrome?

If only....

MiNiGuY · Apr 22nd, 2002, 01:10 PM

Hi,
If you remove the two (or3) big block fuses you will notice that they have plastic lugs on the top. It is possible to cut these lugs off with a junior hacksaw without damaging the fuses. When you replace them you should find that the fuse cover now fits on ok. Of course if your'e not confident then best to take the car to the dealer to be safe. Its just a suggestion, hope you find it useful.

pdubyab · Apr 22nd, 2002, 01:15 PM

Beau, my UK Nov/01 built Cooper has a similar problem to yours. As you say, the lid can't clip in place properly because the fuses are in the way. Maybe the fuses in question relate to optional equipment - hence the "mine's ok" replies above and the fact that others I've driven have been fine. I'll try and check what these fuses are for and post again later

Red & White Cooper 2 · Apr 22nd, 2002, 01:24 PM

My December 01 build Cooper has this problem, though the cover will stay on - it just bows outwards. Looks like a hopeless piece of design.

Beau · Apr 22nd, 2002, 04:13 PM

Miniguy, you wrote " It is possible to cut these lugs off with a junior hacksaw without damaging the fuses.". Yikes! Does that mean you did (or know someone who did) this?

I just took it down to the dealer. The mechanic looked at it and didn't have a fix. I think he's going to ask BMW. He said he'd seen it a lot on the Cooper Ss, which mine is not.

Thanks!

MiNiGuY · Apr 22nd, 2002, 07:45 PM

Hi,
Your dealer won't have seen a lot of cooper S's and as the car has not been on general sale yet they certainly will not have been correcting fusebox cover problems for customers!!.
My previous suggestion is a solution 9 out of 10 cases.
Sometimes and only sometimes, the fusebox's lower anchorage point has been fixed incorrectly. That would need BMW rectification (ie- your dealer).
If the cover on your fusebox stays on but protrudes slightly, then the fuse suggestion I gave should do it (but as I said, don't do it if you are not at least a confidant and somewhat expierienced home mechanic).
If it's a large gap and a struggle to keep the cover from falling off then its probably the lower anchorage point on the fuse box, or incorrect 'lower Inner A post finisher' fitment.
This would also need BMW rectification unless you intend to totally wreck your warranty!! as its a big job to do properly.
Patience is a virtue, and its best to let your dealer sort it out really.
In answer to your question,

All the best.

nickheatheruk · Apr 23rd, 2002, 03:40 AM

Hi Beau,

my Nov 2001 Cooper has exactly the same problem. The fuse box cover won't close flush against the passenger footwell side, due to the offending fuse(s) underneath sitting proud of the cover seating rim. I'm yet to take it back to my dealer. On closer inspection, it appears that BMW have changed sourcing of the offending fuse(s), since production started. If you look you'll see that the actual fuse has an additional plastic moulding on top of it to help removal - this is causing the problem. It should just be a case of getting the dealer to source the original specification fuse.

MiNiGuY · Apr 23rd, 2002, 10:27 AM

the plastic bits nickheather is talking about are the ones you can cut off.

Beau · Apr 23rd, 2002, 10:24 PM

Ok good deal --
I cut the little 'handle' off the top of the big fuse.
That made it a little better.
Then I took my mini sawz-all and removed the lower right corner of the block. Geez that was close -- I can see a bit of metal mere millimeters or less from where I sawed.
But now the cover closes. It's still not closely firmly & flatly but I think it will stay.
It's a great fix until BMW comes up with a better one.

Thanks for everyone's help!

MiNiGuY · Apr 24th, 2002, 07:30 AM

You've got guts, i'll say that!! My heart stopped just reading your post!!!
Snipping the fuse down is one thing but it sounds like you started hacksawing your whole car man!!
As you've done it now you may as well try this to get the couple extra mm it sounds like you need.
The panel that the fusebox cover is fitted into is Called the lower A post finisher. If you pull on it you will notice that you will get a few more mm space between it and the fusebox before it pops out from under the door seal. Get as much space as you can doing this, and you will then be able to keep the finisher in place by wedging a small rubber block or similar out of sight between the top of the A post and the bottom of the dashboard. Make it a tight fit to prevent squeeks and hold the finisher secure.
Reckon that should do it.

!!!

MiNiGuY · Apr 24th, 2002, 07:40 AM

P.s,
No hacksaws required on that one. Put em away!! - think warranty.

Beau · Apr 24th, 2002, 07:45 AM

LOL

I've never been one to think I couldn't do something.
"How hard can that be?"

ADO15 · Apr 26th, 2002, 02:25 PM

Quote:

Originally posted by MiNiGuY
P.s,
No hacksaws required on that one. Put em away!! - think warranty.

MiniGuy/Ashley,

Now it's clear to me that you do infact work for MINI / BMW... Mind if I ask what you do?

(I'll settle for a work on the factory, sell cars or work with administration etc. - if you're reluctant to share such (private) information.)

BruceK · May 26th, 2002, 12:38 AM

This thread has a very good picture of the problem.

http://www.mini2.com/forum/showthrea...&threadid=8356

MINI needs to go back to the original sized fuses or develop a new cover to fit the bigger fuses.

karmuze · May 26th, 2002, 12:19 PM

This is not a serious enough problem to warrant a redesign of the cover or even a replacement of the relays with a lower profile case, IMO. Two minutes with a file will easily and permanently fix this problem.

I am disappointed that they left the factory that way, since the worker putting on the cover clearly knew there was an interference fit at that point. The short term solution should have been to remove the pull tab at the factory and go back to the relay supplier for relay covers without the tab for the next order of parts. A breakdown of the vaunted BMW quality control program--KISS this

.

lightbody · Feb 24th, 2003, 03:05 PM

What a great thread. This (and the other thread mentioned) have answered the question i was about to post about my badly fitting fuse cover on my Oct01 Cooper! 2 big fuses/relays are in the way and stopping the door shutting properly. I only had a proper look at finally this weekend!

Apr 22nd, 2002, 09:51 AM	#1
Beau MINI2 Regular Join Date: Apr 2002 Location: Richmond, Va Local Time: 08:42 PM Posts: 134 Offline	Fuse block cover I got my new Cooper 3 weeks ago. The fuse cover (on the inside left kick panel, next to the clutch) will not stay on. As a matter of fact, I don't see how it can. There are 2 big grey fuses on the bottom right corner of the block and they stick up above the level of the opening. When I try to put the cover on, all the little tabs will not snap in, because the cover is deformed by those big grey fuses. I called the dealer & they said no one else had complained (and of course to bring it in & they would fix it). Any one here heard of or experienced this? Or have an idea on fixing it? Thanks!

Apr 22nd, 2002, 09:53 AM	#2 (permalink)
monsta MINI2 Global Moderator Join Date: Jul 2001 Location: Brighton Local Time: 09:42 PM Posts: 4,669 Offline	Sounds like the fuses aren't fitted properly or they are the wrong ones. The panel on my fusebox fits very easily with no problems. the MINI has gone...

Apr 22nd, 2002, 10:40 AM	#4 (permalink)
monsta MINI2 Global Moderator Join Date: Jul 2001 Location: Brighton Local Time: 09:42 PM Posts: 4,669 Offline	Quote: Originally posted by Daddu Could it be because your's is chrome? If only.... the MINI has gone...

Apr 22nd, 2002, 01:10 PM	#5 (permalink)
MiNiGuY MINI2 Master Join Date: Apr 2002 Local Time: 09:42 PM Posts: 808 Offline	FUSE PANEL Hi, If you remove the two (or3) big block fuses you will notice that they have plastic lugs on the top. It is possible to cut these lugs off with a junior hacksaw without damaging the fuses. When you replace them you should find that the fuse cover now fits on ok. Of course if your'e not confident then best to take the car to the dealer to be safe. Its just a suggestion, hope you find it useful.

Apr 22nd, 2002, 07:45 PM	#9 (permalink)
MiNiGuY MINI2 Master Join Date: Apr 2002 Local Time: 09:42 PM Posts: 808 Offline	Reply to Beau Hi, Your dealer won't have seen a lot of cooper S's and as the car has not been on general sale yet they certainly will not have been correcting fusebox cover problems for customers!!. My previous suggestion is a solution 9 out of 10 cases. Sometimes and only sometimes, the fusebox's lower anchorage point has been fixed incorrectly. That would need BMW rectification (ie- your dealer). If the cover on your fusebox stays on but protrudes slightly, then the fuse suggestion I gave should do it (but as I said, don't do it if you are not at least a confidant and somewhat expierienced home mechanic). If it's a large gap and a struggle to keep the cover from falling off then its probably the lower anchorage point on the fuse box, or incorrect 'lower Inner A post finisher' fitment. This would also need BMW rectification unless you intend to totally wreck your warranty!! as its a big job to do properly. Patience is a virtue, and its best to let your dealer sort it out really. In answer to your question, All the best.

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Apr 22nd, 2002, 10:21 AM	#3 (permalink)
Daddu MINI2 Senior Join Date: Mar 2002 Location: 2nd Star to the right, and on till morning! Local Time: 04:42 PM Posts: 580 Offline	[quote]Originally posted by monsta The panel on my fusebox fits very easily with no problems. Could it be because your's is chrome?

Apr 22nd, 2002, 01:15 PM	#6 (permalink)
pdubyab MINI2 Regular Join Date: Apr 2002 Local Time: 09:42 PM Posts: 189 Offline	Beau, my UK Nov/01 built Cooper has a similar problem to yours. As you say, the lid can't clip in place properly because the fuses are in the way. Maybe the fuses in question relate to optional equipment - hence the "mine's ok" replies above and the fact that others I've driven have been fine. I'll try and check what these fuses are for and post again later

Apr 22nd, 2002, 01:24 PM	#7 (permalink)
Red & White Cooper 2 MINI2 Senior Join Date: Dec 2001 Local Time: 08:42 PM Posts: 372 Offline	My December 01 build Cooper has this problem, though the cover will stay on - it just bows outwards. Looks like a hopeless piece of design.

Apr 22nd, 2002, 04:13 PM	#8 (permalink)
Beau MINI2 Regular Join Date: Apr 2002 Location: Richmond, Va Local Time: 08:42 PM Posts: 134 Offline	Miniguy, you wrote " It is possible to cut these lugs off with a junior hacksaw without damaging the fuses.". Yikes! Does that mean you did (or know someone who did) this? I just took it down to the dealer. The mechanic looked at it and didn't have a fix. I think he's going to ask BMW. He said he'd seen it a lot on the Cooper Ss, which mine is not. Thanks!

Apr 23rd, 2002, 03:40 AM	#10 (permalink)
nickheatheruk MINI2 Regular Join Date: Apr 2002 Local Time: 08:42 PM Posts: 62 Offline	Hi Beau, my Nov 2001 Cooper has exactly the same problem. The fuse box cover won't close flush against the passenger footwell side, due to the offending fuse(s) underneath sitting proud of the cover seating rim. I'm yet to take it back to my dealer. On closer inspection, it appears that BMW have changed sourcing of the offending fuse(s), since production started. If you look you'll see that the actual fuse has an additional plastic moulding on top of it to help removal - this is causing the problem. It should just be a case of getting the dealer to source the original specification fuse.

Apr 23rd, 2002, 10:27 AM	#11 (permalink)
MiNiGuY MINI2 Master Join Date: Apr 2002 Local Time: 09:42 PM Posts: 808 Offline	fuses the plastic bits nickheather is talking about are the ones you can cut off.

Apr 23rd, 2002, 10:24 PM	#12 (permalink)
Beau MINI2 Regular Join Date: Apr 2002 Location: Richmond, Va Local Time: 08:42 PM Posts: 134 Offline	Ok good deal -- I cut the little 'handle' off the top of the big fuse. That made it a little better. Then I took my mini sawz-all and removed the lower right corner of the block. Geez that was close -- I can see a bit of metal mere millimeters or less from where I sawed. But now the cover closes. It's still not closely firmly & flatly but I think it will stay. It's a great fix until BMW comes up with a better one. Thanks for everyone's help!

Apr 24th, 2002, 07:30 AM	#13 (permalink)
MiNiGuY MINI2 Master Join Date: Apr 2002 Local Time: 09:42 PM Posts: 808 Offline	cover You've got guts, i'll say that!! My heart stopped just reading your post!!! Snipping the fuse down is one thing but it sounds like you started hacksawing your whole car man!! As you've done it now you may as well try this to get the couple extra mm it sounds like you need. The panel that the fusebox cover is fitted into is Called the lower A post finisher. If you pull on it you will notice that you will get a few more mm space between it and the fusebox before it pops out from under the door seal. Get as much space as you can doing this, and you will then be able to keep the finisher in place by wedging a small rubber block or similar out of sight between the top of the A post and the bottom of the dashboard. Make it a tight fit to prevent squeeks and hold the finisher secure. Reckon that should do it. !!!

Apr 24th, 2002, 07:40 AM	#14 (permalink)
MiNiGuY MINI2 Master Join Date: Apr 2002 Local Time: 09:42 PM Posts: 808 Offline	P.s P.s, No hacksaws required on that one. Put em away!! - think warranty.

Apr 24th, 2002, 07:45 AM	#15 (permalink)
Beau MINI2 Regular Join Date: Apr 2002 Location: Richmond, Va Local Time: 08:42 PM Posts: 134 Offline	LOL I've never been one to think I couldn't do something. "How hard can that be?"

Apr 26th, 2002, 02:25 PM	#16 (permalink)
ADO15 MINI2 Regular Join Date: Nov 2001 Local Time: 08:42 PM Posts: 232 Offline	Re: P.s Quote: Originally posted by MiNiGuY P.s, No hacksaws required on that one. Put em away!! - think warranty. MiniGuy/Ashley, Now it's clear to me that you do infact work for MINI / BMW... Mind if I ask what you do? (I'll settle for a work on the factory, sell cars or work with administration etc. - if you're reluctant to share such (private) information.) "Life begins @ 7,000 rpm's"

May 26th, 2002, 12:38 AM	#17 (permalink)
BruceK Moderator & Sponsor Join Date: Mar 2001 Location: San Antonio, Texas Local Time: 02:42 PM Posts: 3,759 Offline	This thread has a very good picture of the problem. http://www.mini2.com/forum/showthrea...&threadid=8356 MINI needs to go back to the original sized fuses or develop a new cover to fit the bigger fuses. + 2002 MINI Cooper S - Dark Silver / White roof, Sport, Premium, Lapis blue leather + 1965 Mini Traveller - Tartan Red / White roof, 1275, Cooper S discs, fully restored/renewed

May 26th, 2002, 12:19 PM	#18 (permalink)
karmuze MINI2 Regular Join Date: Feb 2002 Location: colorado Local Time: 08:42 PM Posts: 259 Offline	This is not a serious enough problem to warrant a redesign of the cover or even a replacement of the relays with a lower profile case, IMO. Two minutes with a file will easily and permanently fix this problem. I am disappointed that they left the factory that way, since the worker putting on the cover clearly knew there was an interference fit at that point. The short term solution should have been to remove the pull tab at the factory and go back to the relay supplier for relay covers without the tab for the next order of parts. A breakdown of the vaunted BMW quality control program--KISS this .

Feb 24th, 2003, 03:05 PM	#19 (permalink)
lightbody MINI2 Master Join Date: Nov 2001 Location: Glasgow, Scotland Local Time: 09:42 PM Posts: 897 Offline	What a great thread. This (and the other thread mentioned) have answered the question i was about to post about my badly fitting fuse cover on my Oct01 Cooper! 2 big fuses/relays are in the way and stopping the door shutting properly. I only had a proper look at finally this weekend! Rob Lightbody - http://www.roblightbody.com 2004 Red/Black Cooper replaced a 2001 BRG/White Cooper

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