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First Generation Faults & Fixes MINI faults and fixes 2001 - 2006

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Old May 26th, 2012, 05:33 PM
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Aircon leaking into drivers footwell. With Pictures!

Hi. We have just purchased a 2004 Mini Cooper. The car is fantastic but has one quite annoying problem. Whenever the aircon is switched on, the drivers footwell gets quite wet. I've added a couple of pictures below to show where the water is coming from. I'm guessing there shouldn't be a hole in the casing? Any ideas whether it is possible to replace this part?

Thanks all!
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Old May 26th, 2012, 10:14 PM
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There is small drain pipe for the condensation formed on the cold evaporator in the middle of the black plastic heater/aircon casing which then drains out under the car. You therefore need to block up the crack/hole shown in your photo that has been broken/formed in the side of the plastic casing, so that it once again only drains through the correct central drainage outlet.
I guess the hole was caused by an accidental impact perhaps from someones shoe/toecap!
To replace the heater casing even using secondhand parts is a big job as the whole dashboard/ heater assembly would have to come out to remove it......far easier to block up the hole by gluing/bonding on a plastic repair plate/ waterproof amalgamating tape or similar.

Diagram of heater casing:
RealOEM.com BMW R50 Cooper Actuator, heater and air condit.

No.7 here is the condensation outlet hose which sits underneath the heater housing on the centre tunnel:
RealOEM.com BMW R50 Cooper Housing parts, heater and air condit.
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Old May 27th, 2012, 05:37 PM
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Brilliant, thanks for your help. I will get a piece of thin plastic and I've got some epoxy resin in the garage somewhere which should do the job nicely!
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Old Jun 7th, 2012, 12:57 AM
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Any idea how I can find the A/C drain on a R56?
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