The only problem so far with my S...

[ficcion]

This fuse box does not accept it's cover completely (cover not shown). It's as if the two large green/white fuses (or whatever they are) protrude to far to allow the cover to attach into slots.

Any thoughts or similar experiences?

[BruceK]

Quote:

Originally posted by ficcion
This fuse box does not accept it's cover completely (cover not shown). It's as if the two large green/white fuses (or whatever they are) protrude to far to allow the cover to attach into slots.

Any thoughts or similar experiences?

Have a look at this thread for a discussion on this very problem:

http://www.mini2.com/forum/showthrea...&threadid=6649

Seems like a new cover should be designed.

[ficcion]

Thanks for the re-direction to that other post. Sounds like a relatively chronic problem.

Will talk to my dealer soon. No hack saws for me a this point and time.

[Sealevel]

ficcion--I have three of those fuses stacked in that corner, it must be related to options as someone speculated in the thread BruceK recommended. I've spotted something not mentioned in that thread. Looking at my cover, which fits just fine, I see that a section of the "lip" that sticks out on the inside of the cover has been cut out in that corner, flush to the surface of the cover. It's very apparent that if this wasn't done, the lip will make contact with the lower fuse and prevent the cover from fitting properly. Take a look at yours & see if any of this makes sense, since we may not have the same kind of cover (my build date was 4/19). It doesn't look like a complete redesign of the cover would have been necessary, the lip is very thin and you could trim it with an exacto knife or an industrial razor blade. Messing around with the fuse itself wouldn't be necessary. If what I've described is not what you see, contact your dealer for a "new issue" cover like mine.

[karmuze]

Quote:

Originally posted by ficcion
It's as if the two large green/white fuses (or whatever they are) protrude to far to allow the cover to attach into slots

"Whatever they are', are (did anyone see a seel in here?) relays. The fuses are the red, green, yellow,and blue thingies in front of those. Relays are used to remotely switch high current devices such as headlights, wiper motors, starter, AC fans, etc. so that the wire to the dashboard/steering column switches for those devices doesn't have to carry 30 amps of current.

Those relays could be turn signal, window motor, or sunroof relays. All the light relays (and fuses) are likely in the fuse box to the right of the battery in the engine compartment. It appears that there is space for 4 relays in that area--since Sealevel has 3, the additional relay could be for the sunroof which is optional.

The solution to the problem, which has already been mentioned, is to grind off the pull tab on the lower relay only, since the next one up appears to barely clear the cover. You could do that with a bench grinder or hand file (I wouldn't recommend a hacksaw-hard to control depth of cut), or ask your dealer to fix, if he's not too far away, and you are concerned about warranty issues.

[MiNiGuY]

The fusebox cover IS of adequate design although I agree with the person who suggested a relay/fuse change.
1 or 2 in a couple of thousand rolls off the line with the problem discussed here which is a very minor and simple to rectify fitment 'fault'. It's nothing more. It is usually picked up in quality checks and rectified at the factory and takes a couple of minutes to 'fix'.
People with the problem need not worry that there's something major wrong or that their car is built badly.

It's unfortunate but apparent that some cars have got through unnoticed,(although you can also instigate the problem yourself by kicking the A post finisher) but the problem is very minor and a dealer should be able to rectify it there and then.

The picture above is typical. Perhaps I should also mention that this fault is nothing to do with the fusebox at all. The fault in the picture is mainly due to incorrect fitment of the 'lower inner A post finisher' (the big grey panel).
You can see a gap between the footrest and the finisher. That gap is too big as the finisher should be pretty flush to the footrest. If it's not, the finisher doesn't clear the fuses properly just like in the picture.

A dealer should rectify the problem effectively and in little time or you can read my posts and do it yourself.

If your car has no gap between footrest and finisher, and the fuses still stick out, it could be fuse box fitment (1 car in a gazillion), so that's gonna take the dealer a bit longer.

I hope you get your fuse covers sorted soon with little fuss.

[ficcion]

Took it in to my dealer and guess what they did?

They put some spacers in to move plastic covering out and CLIPPED off the extensions on the relays.

Guess the "do it yourself" method is a winner.

Fits now.

[MiNiGuY]

They nicked my idea!!
Actually they were probably given it!!

[ficcion]

Good show MiniGuy! (my best attempt at some English jargon)

We appreciate all your insider...I mean well informed information.