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Installation Instructions 9/17/02

Lights M63 01 02 Product
Development

SUBJECT

Auxiliary Driving Light Installation Kit P/N 63 12 0 144 132

MODEL

MINI Cooper as of 1/02

Mini Cooper S as of 3/02

IMPORTANT:
For cars with a combination of Xenon Light (SA 522) and High Pressure Washing System
(SA 502), a different/reinforced hood damper (P/N 51 23 7 064 485), must be installed for
safety reasons.

Customers should check State and Local laws regarding proper operation and use of Auxiliary
Driving Lamps. For example, many States prohibit more than four headlamps illuminated at
the same time; other States prohibit any on-road use and require the lamps to be covered with
the Auxiliary Driving Light caps when not in use.

Auxiliary driving lamps enhance the "high beam" visibility provided by dual, quad and six-
headlamp systems and are not a fog light or a substitute for normal headlights. Therefore
these lights will only be operational in conjunction with the high beam lights.

Never use the Auxiliary Driving Lights with the covers/caps attached. This may cause damage
to the Auxiliary Driving Lights as well as to the covers/caps.

Please initial and route to the following for information before filing

X Service Manager X Warranty X Service Technicians - Initial Below

X Service Advisor Parts Mgr.
X Service Advisor Body Shop
X Shop Foreman PDI Dept.

« « FIX IT RIGHT THE FIRST TIME, ON TIME, EVERY TIME « «

 2002 BMW of North America, LLC by:

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INSTALLATION TIME

The installation time for this kit is approx. 2.5 hours, but this may vary depending on the condition of
the car and the equipment in it. The vehicle does not need to be recoded after the installation is
completed.
These instructions were developed especially for MINI vehicles and are not to be compared to any
existing instructions for vehicles other than MINI. No methods other than those specified in this
document are to be used to install the Auxiliary Driving Lights.
NOTE: Once the ignition is turned off the operation of the Auxiliary driving Lights is reset, meaning
that in order to have the auxiliary driving light illuminate in conjunction with high beam lights the
Auxiliary Driving Light switch must again be depressed to activate the lights.
PARTS INFORMATION

If a vehicle is equipped with Xenon Lights (SA 522) and High Pressure Washing System (SA 502) then
the following part is also required:
Description Qty MINI Part Number
Gas pressure hood damper 2 51 23 7 064 485
Installation template and information card
Description Qty MINI Part Number
Auxiliary Driving Lights Template 1 01 00 0 150 961
Auxiliary Driving Lights Information Card 1 99 00 0 003 854
The following parts are included in each Auxiliary Driving Light kit P/N 63 12 0 144 132:
Reference Description Qty MINI Part Number
Number
A Supplemental Wiring Harness 1 63 12 0 144 133
B Auxiliary Driving Light 2 63 12 0 137 303
W Relay 1 63 12 0 144 135
X Auxiliary Driving Light Cover 2 63 12 0 144 065
Y Auxiliary Driving Light Switch 1 63 12 0 144 134
Ac Template – Light switch cutout 1 01 29 0 147 414
----------------- Mounting Parts (Package): 63 12 0 137 304
C Mounting Bracket Right Side 1
D Mounting Bracket Left Side 1
E Mounting Bracket for Fuse Holder 1
F Fuse Holder 1
G Fuse Holder Cover 1
H Fuse Holder Rubber Grommet 1
I Fuse 1
J Grub screw with M4 Slot 2
K Blade Receptacle 2
L Ring Cable Lug 2
M Rivet 6
N Cable Tie 10
O Cable Tie – Hood 5
P Hexagonal Nut M4 2
Q Blade receptacle Fuse 2
R Fuse Holder Securing Clip 1
S Shrink tubing 2
T Blind Rivet Nut M4 2
U Immersion Cap 2
V Plastic Washer 2
z Quick Connect ( 5 Contact) 1
aa Quick Connect (2 Contact) 2
ab Connector Housing 2
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The following parts are included within each Auxiliary Driving Light kit P/N 63 12 0 144 132:
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PROCEDURE:

A. Installation and Routing Diagram for Supplemental Harness

1. Auxiliary Driving
Light
2. Fuse box
3. Main Fuse box
(vehicle)
4. Auxiliary Driving
Light Switch
5. Cable route inside
the car
6. Body Control
Module (BC1)
7. Relay
8. Ground bolt
9. Main plug of radio
10. Grommet

B. Supplemental Wiring Harness Connection Overview

Item Description Color Connection location

A Supplemental Wiring Harness
B 2 Open Wires RT Right Auxiliary Driving Light
BR
C 2 Open Wires RT Left Auxiliary Driving Light
BR
D Ring Cable Lug BR Ground Bolt
E Ring Cable Lug BR Ground Bolt
F 2 Open Wires GR/RT Connection to Radio via “Quick Connect”
VI/BL
G Open Wire GE/GN Body Control Module (BC1) X322 Pin 15
H Relay Base Socket Driver’s Footwell
I Light Switch Connector Auxiliary Driving Light Switch - Driver’s
Knee Bolster
J Open Wire RT Fuse Box
K Open Contact RT Fuse Box
L Ring Cable Lug RT Main Fuse Box
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C. Installing Mounting Brackets

1. Insert mounting bracket (c) and (d) through the
grill (bottom fin) and align them centrally using
spacing dimension A = 192.5mm

1a. For vehicles with Sports Package:

If the vehicle is equipped with sport package
trim, the grill must first be modified to allow the
installation of the mounting bracket through
the grill.
Use the auxiliary driving light templates for
MINI Cooper P/N 01 00 0 150 961.

Cut out both sport grill templates (1 & 2) for

installing the RH and LH mounting bracket,
then cut out the opening on each template
through which the mounting bracket is to be
inserted.
Apply RH template (1) and LH template (2) to
grill as shown in illustration S63 02 U34.
Carefully remove the area of the grill through
which the mounting bracket is to be inserted
using a Dremel® Tool or equivalent rotary tool
with cutting bit.

2. Mark the holes for rivets using the mounting

brackets (c) and (d), center punch the holes and
drill (drill bit diameter 4.0mm or 5/32”).
Note: Insure that the brackets are tight against
the interior panel of the hood, without any
gaps
3. Prior to drilling any holes cover the engine
compartment to protect it from any metal filings.
4. When drilling the bottom holes, also drill through
the grill.
5. Drill the top holes and insure that the exterior
skin is not damaged.
7. Treat all of the holes with the standard anti
corrosion measures.
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corrosion measures.
8. Insert mounting brackets (c) and (d), secure
them using rivets (m).
9. Prior to tightening the rivets raise the hood to
avoid riveting the grill.
10. Tighten the rivets (m) using a rivet gun.

IMPORTANT: For cars with a combination of

Xenon Light (SA 522) and High Pressure Washing
System (SA 502), the gas pressure dampers for
the hood (P/N 51 23 7 064 485), must be
installed for safety reasons.

D. Installing the Light Switch for the Auxiliary Driving Lights

1. Remove the driver’s side knee bolster.
2. Use the auxiliary driving light templates for MINI
Cooper P/N 01 00 0 150 961.
Cut out the entire knee bolster switch template
(2) and then cut out the switch location on the
template.
3. See Figure S63 02 U32. Position the template
(2) on knee bolster (1) as shown so that the top
edge and left edge of the template are properly
positioned adjacent to the edges of the bolster.
4. Mark switch cutout area.
5. Carefully cut opening using a Dremel® Tool or
equivalent rotary tool with cutting bit). It will
also be necessary to remove interfering material
located on the inside panel to allow free access
to switch opening.
6. Smooth the edges of the opening using a file
and make sure that the switch fits correctly.
7. Make certain that the springs of the switch snap
in behind the edges of the opening. Due to the
thickness of the panel, it may be necessary to
cut off about 3mm of each spring end so that
the springs snap into position once the switch is
inserted in position.
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E. Installing the Supplemental Wiring Harness

1. Disconnect the battery.
(Refer to TIS 61 21 010).
2. Displace passenger side entrance cover strip for
access to Body Control Module (BC1).
3. Remove Radio (Refer to TIS 65 11 030)
4. Locate grommet (1) on firewall and use an awl
to puncture a hole in the grommet.
5. Route supplemental harness from interior
driver’s area through hole in grommet so that
items B, C, D, E, and J of wire harness protrude
through hole into engine compartment area so
that junction of item J (RT wire) extends 4”
(10cm) beyond the hole in the grommet on the
firewall
NOTE: When routing the wire harness from
inside the vehicle to the engine compartment
insure that the wires don’t get pinched. Secure
wire harness in place with cable ties.
6. Remove nut from ground stud (1) located next
to the inertia switch. Place the ring terminals of
supplemental harness BR wires (D) and (E) onto
the ground stud and secure in place by
reinstalling the ground nut.

7. Slightly loosen (do not remove) the screws (1)

that secure the inertia switch (2) in place.
8. Slide the fuse holder mounting bracket (e)
behind the inertia switch (2) and re-tighten the
screws.
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9. Route branches (B) and (C) through rubber seal

opening (1) and along hood hinge (2). Insert
push fasteners with cable ties (O) in vacant
holes along hood hinge. Make sure that a
portion of the harness with the fabric sleeve is
inserted in the wing area of the hood, in a loop
shape before securing harness in place with
cable ties.

10. Route branches (B) and (C) through the

longitudinal opening (1) in the respective
mounting bracket (c) and (d) and secure in
place using cable ties (n).
IMPORTANT: For cars with a combination of
Xenon Lights (SA 522) and High Pressure
Washing System (SA 502), a different reinforced
hood damper (P/N 51 23 7 064 485) must be
installed for safety reasons.

11. Drill a 6mm diameter hole (2) in the plastic trim

(3), level with the B+ connector (1) in the main
fuse box.
12. Connect ring cable lug (L) from the 20” (50cm)
long heavy gauge RT wire to the B+ connector
(1) of the main fuse box. Feed the other end of
the heavy gauge RT wire through the hole (2) in
the plastic trim (3) and route it to the inertia
switch area.
13. Use a Dremel® or equivalent rotary tool with a
grinding bit to place a grove (4) in plastic cover
(5) of the main fuse box.
14. Cut the fuse holder rubber grommet (h) and run
the two RT wires (J) and (K) through the
grommet (h).
15. Strip the ends of the two RT wires (J) and (K)
and crimp on the blade connectors (q).
Note: The blade receptacles (q) are different
sizes and must be placed onto the appropriate
sized wire.
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16. Insert RT wires (J) and (K) completely into a

fuse slot location in the fuse holder (f).
17. Once the wires are fully inserted into the base
of the fuse holder (f), push the four-position
fuse location piece (1) inwards to set the
secondary lock until an audible “click” is heard
securing the secondary lock in place (2).
18. Insert 15 Amp fuse (i) into the fuse holder (f)
and install the fuse holder cover (g).
19. Attach the fuse holder securing clip (r) to the
fuse holder (f). Attach the fuse holder (f) to the
fuse holder mounting bracket (e in step 8) by
turning it1/4 turn until it locks into place with
the fuse holder cover (g) facing up.
20. Insert relay (w) into the relay base connector
(H) of the supplemental wiring harness. Secure
the relay to the main wiring harness (2) located
on the left side of the driver’s footwell area with
a cable tie (1).

21. Route the two wires (F) GR/RT and VI/BL of the
supplemental harness through the open areas
for the radio.
22. Connect the GR/RT wire from the supplemental
harness to the GR/RT wire going to pin 14 (58G)
of the radio (1) using a quick connect (aa).
23. Connect the VI/BL wire from the supplemental
harness to the VI/BL wire going to pin 16 (R) of
the radio (1) using a quick connect (aa).
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24. Install switch (y) into the switch cutout

(previously made into the knee bolster.
25. Route supplemental harness branch (I) to knee
bolster and connect to the switch (y).
26. Reinstall the knee bolster.

27. Route wire (G) GE/GN of the supplemental

harness to the passenger’s footwell area.
28. Disconnect the green connector X322 (1) from
the Body Control Module (2) located on the
right side of passenger’s footwell are a.
29. Connect wire (G) GE/GN to the yellow/green
wire going to X322 (1) pin 15 of BC1 (2) using a
quick connect (z).
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F. Mounting and Adjusting the Auxiliary Driving Lights.

1. Remove the nut (1),spring ring (2) and the
washer (3) from the light housing (b).
2. Remove the Philips screws (4) and remove the
lens housing (5)

3. Place the auxiliary driving light assembly (1) with

the base (2) and attached plastic washer (v) onto
either mounting bracket (c or d) and secure it
loosely from below with a washer (3), spring ring
(4) and a nut (5).
Note: The plastic washer (v) should be aligned
concentric with the housing base (2).

4. Pull the heat shrink tubing (s) over the wires for
branches B or C, overlap the tubing slightly with
the existing protective tubing (3). Shrink the
tubing (s) using a hot air blower/heat gun and
pull it through the hollow screw (1) and into the
driving light assembly (2)

5. Crimp the blade receptacle (k) to the red cable

and the ring cable lug (l) to the brown wire.
6. Secure the ring cable lug (l) to the lamp using a
Philips screw (1).
7. Insert the blade receptacle (k) into the bigger
opening of the connector housing (ab) until an
audible click is heard.
8. Insert the lamp cable (2) through the smaller
opening of the connector housing (ab) and fully
into the blade receptacle (k).
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9. Reinstall the lens housing (1) onto the auxiliary

driving light assembly and secure using a Philips
screw (2).
10. Repeat steps 1 through 9 for the other light
11. Reconnect the battery

12. Adjust Auxiliary Driving Lights

Adjustment w ith a headlight adjustment unit:
Adjust the lamps with a headlight adjustment unit.
Tighten the nuts (3) and Torque to 9 Nm.

Adjustment without a headlight adjustment unit:

a. Park the unweighted vehicle on a flat level
surface (1).
b. Measure the height (H) from the ground
surface (1) perpendicular to the center of the
headlight (2)
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c. Draw a line parallel to the ground (1) at a

height (H) to a wall.
d. Make two markings/crosses (2) on the line at
a distance A =540 mm and mark the center
M between the two crosses (2).
e. Position the vehicle a distance of 3 to 5 m
from the wall.
Park the vehicle so that the extension of the
longitudinal vehicle axis precisely strikes
the center (M) between the markings (2)
perpendicular to the wall. If possible make
the adjustment in darkness.
f. Adjust the headlight so that the center of the
light in the individual light beam strikes the
center of the corresponding cross (2).
g. Tighten the nut (3) and Torque to 9 Nm.

13. Reinstall the passenger and driver’s side

entrance cover strips
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G. Additional support for auxiliary Lights (Sport Package vehicle only)

For vehicles with Sports Package:
An additional support for each auxiliary light, using the blind rivet nuts (t) included in the kit should
also be installed on the support/mounting bracket.
Vehicle with a four fin grill only:
Measure 147 mm from the grill/fin vertical support
bracket (2) to the grill space area (1) and mark it.
Measure 7 mm from the top of the grill space area
(1) and mark it.

Vehicles with a three-fin grill only:

Measure 15 mm from the grill/fin horizontal support
bracket (2) and mark it.
Measure 15 mm from the vertical support bracket
(3) and mark it.

Drill the holes for the blind rivet nuts (t) (pre-drill a 3
mm hole, then enlarge to 6.1 mm hole). Deburr the
holes and insert the blind rivet nuts (t) from the
inside of the grill using blind rivet nut pliers (1).

Make certain that the drill does not move from the
point to be drilled.
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Reduce the immersion cap (u) by adjusting it several

times to the distance between the blind rivet nuts (t)
and the auxiliary light (b). Screw the grub screw (j)
from the inside into the blind rivet nut (t) until the
immersion cap (u) can be placed on it
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H. Auxiliary Driving Light Circuit Diagram

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I. Information Sheet for Auxiliary Driving Lights

(A laminated information card (P/N 99 00 003 854) which contains the following information is
available and should be provided to the customer, insert the information card into the Owner’s
Manual)

To change a lamp
Lamps and lights play a major role in vehicle safety. The appropriate level of care is therefore to be
used for handling them. If you are not familiar with this type of work have it completed by your MINI
dealer.
IMPORTANT: Do not touch the glass bulb of new lamps with your bare hands, minor impurities from
your skin can burn into the glass reduce the service life of the lamp. When replacing the bulb always
use a clean cloth, paper towel, or tissue or hold the lamp by its socket.

If you mistakenly handle the lamp with your hands, clean the lamp with rubbing alcohol (isopropyl)
using a clean paper towel, tissue or cloth.
Prior to starting any work on the electrical system, switch off the appropriate device or disconnect the
negative terminal on the battery, otherwise you may cause a short circuit. Follow the enclosed
instructions from the lamp manufacturer, to prevent injury and damage when changing a lamp.

1. Remove the Philips screw (1)

2. Remove the lens housing (2)

3. Carefully pull the lamp cable (2) out of the

connector in connector housing (1).
4. Remove the screw (3)
5. Remove the lamp and replace with a 55 W H3
lamp
6. Reinstall the screw and connector.
7. Insulation/electrical tape should be placed over
the transition between the connector housing
(1) and the lamp cable (2).
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To Change a Fuse
Do not repair burned-out fuses or replace them
with fuses of a different color or amperage
rating.

The fuse box (1) is located in the engine

compartment, at the driver’s side corner near the
bulkhead.
• The fuse is 15 A
• Carefully remove the cover on the fuse box.
• Change the fuse (15 A).
• Reinstall the cover again.
NOTE: If the fuse repeatedly burns out, have the
cause of the problem rectified by a MINI dealer.

Care and Cleaning

Observe the following for the care of the additional headlights :

• Do not rub dry and do not use any scouring or caustic cleaning products.
• Soften impurities (for example insects) with MINI shampoo and wash them off with water only.
• Thaw ice with de-icer spray – do not use an ice scraper.
• You can wash your MINI with the installed additional headlights in automatic car wash systems.

Operating the Auxiliary Driving Light Switch

Basic setting:
• Carefully remove the Auxiliary Driving Light
covers.
• Switch on ignition
• Depress the switch (1) located on the driver’s
knee bolster to place the Aux. Driving Lights into
a ready/standby mode.
• The Auxiliary Driving Lights are in a
ready/standby mode when the green indicator
light (2) on the switch is illuminated.

• The Auxiliary Driving Lights will only illuminate in conjunction with the standard high beam lamps,
which can be illuminated, by either switching on the high beams or by activation of the headlight
flasher.
• The Auxiliary Driving Lights can be deactivated at any time by depressing the switch located on
the driver’s knee bolster.
Reset mode:
Once the ignition has been turned off, the operation of the auxiliary driving lights is reset. In order to
have the auxiliary driving light illuminate in conjunction with the high beam lights, the auxiliary
driving light switch must again be depressed to activate the lights.
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IMPORTANT:
Customers should check State and Local laws regarding proper operation and use of Auxiliary
Driving Lamps. For example, many States prohibit more than four headlamps illuminated at
the same time; other States prohibit any on-road use and require the lamps to be covered with
the Auxiliary Driving Light caps when not in use.

Auxiliary driving lamps enhance the "high beam" visibility provided by dual, quad and six-
headlamp systems and are not a fog light or a substitute for normal headlights. Therefore
these lights will only be operational in conjunction with the high beam lights.

Never use the Auxiliary Driving Lights with the covers/caps attached. This may cause damage
to the Auxiliary Driving Lights as well as to the covers/caps.