Dimensions
The R56 represents a logical development of the R50 and retains in principle the distinctive MINI look. The R56 is only slightly longer and narrower than the R50. Its height remains about the same.
Scheme 114
Garage Dimensions MINI COOPER S
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Garage Dimensions MINI COOPER
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Bodyshell
The R56 is a logical further development of the R50. However, the bodyshell has been completely redeveloped in regard to vehicle structure.
The outstanding crash behavior can be attributed to the specific use of high-strength steels and, in part, aluminum components (in the door area).
Although the vehicle has short overhangs and deformation zones, crash loads are well transferred. This is due to intelligent load paths. The front end features crash cans on the front axle carrier in addition to the bumper carrier and the crash boxes.
Scheme 118
This creates a second load path which together with the engine mountings allows energy to be shunted into the floor structure. The bulkhead with appropriate cross members and the so-called ski ramps in the front area of the floor assembly stabilize the footwell.
Together with sturdy seat cross-members, the side frame and the rear carrier structure produce a rigid passenger cell. The doors with extrusion molded aluminum profiles in the shoulder area and the door diagonal reinforcers constitute, together with the A-pillar and B-pillar, the deformation zone in a side-on crash.
The solid passenger cell is a prerequisite for putting the restraint systems to the best possible use. In the R56, in addition to front airbags for the driver and front passenger, side airbags (pelvis-thorax airbags) in the front seats, belt force limiters and belt tensioners for the driver and front passenger, head-level airbags (curtain) for all seats and a steering column unit with crash elements ensure that occupants are restrained in a great variety of collision situations.
In a frontal, side or rear-end collision, in particular in the event of a rollover, the front seats with integrated pelvis-thorax side airbags offer a high degree of safety for the occupants.
In accidents at low speeds, the crash boxes prevent damage to expensive components such as the body, lights and cooling system. Energy is dissipated by the deformation of the crash boxes.
The R56 has to pass the 5-star Euro NCAP test. For this, the following developments were implemented
- highly stressable carrier structures
- extremely rigid passenger cell
- compatible design of the front end structure
- highly-efficient restraint-systems.
Corrosion Protection
The R56 bodyshell structure is designed for a high level of endurance quality with 12 years corrosion protection.
The body structure is 100% galvanized. Welded seams have been avoided and spotweld joints or adhesive bonds have been used where possible.
For example, the body-side reinforcing frame for the sliding/tilting sunroof is firmly attached to the roof structure using a structural adhesive.
Furthermore, the sliding/tilting sunroof seal is stuck to the body not clipped, so that endurance quality is guaranteed. All cavities are sealed with wax. The bodyshell is manufactured at the Oxford plant.
Protecting the body and its attachment parts from corrosion, and preventing water and dust from entering the inside of the vehicle are among the most important requirements for the complete vehicle, since if these are not fulfilled, they are noticed by every customer.
Therefore, the body is coated with anti-corrosion dipping paint, sealed with PVC and protected from corrosion by the main coat and final coat of paint.
During the sheet metal lamination, the bearing surfaces are minimized. Additionally, no water is introduced into the area.
The few sheet metal laminations in wet rooms are always sealed twice and protected with wax.
The corrosion protection and leak-tightness are checked using the following tests
- Shower test - The vehicle is "statically watertight" if the interior does not show any signs of moisture in the interior after having been showered for up to 10 minutes (e.g. in a car wash)
- Driving in dust - Dust-tightness is demonstrated if the inside of the vehicle remains free of dust after driving over a dust runway several times and after several hundred miles on poor road surfaces
- Driving through water - The vehicle is "dynamically watertight" if no water penetrates the inside of the vehicle in the following driving conditions: driving through water slowly through a tank with water up to 450 mm deep driving fast through water over an 80 mm deep aquaplaning stretch high-speed driving on a wet road.
Aerodynamics
By using continuous underbody paneling, improved air-dam lips and many improvements to detail, a drag coefficient CX of 0.33 has been achieved on the R56.
In particular, the underbody paneling (new compared to the R50) reduces power losses and plays a large part in achieving the CX objective, but also improves markedly the rear lift value, which with 0.06 can even match sports cars.
A new gutter strip on the A-pillar and aerodynamically-improved door mirrors with integrated spoiler lips keep the side windows cleaner, even in adverse weather conditions.
The whole radiator area has been sealed so that the available cooling air is ideally channeled through the air-conditioning condenser and radiator. Optimum functional efficiency (CX/cooling output) is achieved, depending on the engine, by partial cladding on the upper radiator grille.
The good CX value creates the prerequisite for very good performance, in particular Vmax and 0-100 km/h. At the same time, the improved aerodynamics provide the customer with an advantage in terms of consumption, improving it by approximately 2%.
The lift coefficients of the R56, which are in the sports car range, (CZ1 = 0.03; CZ2 = 0.06) are the basis for the outstanding dynamism of the R56 and improve driving stability even at maximum road speed.
Doors
In the R56, a new door concept has been introduced for the first time, the highly integrated interior trim support module (ITM).
This reduces the assembly work at the factory and improves ease of servicing, while on the other hand typical MINI characteristics such as the hinge concept, crash design and process technologies are retained.
Scheme 119
The individual advantages of the ITM are
- Reduction in costs and reduction in weight
- All essential electrical components are in the dry cavity
- Ease of servicing: once the cover has been taken off, all dry cavity components are accessible. The ITM does not need to be disassembled
- Improved power window connection at the upper deviating points (better force introduction and transmission)
- Simplification of the quality and logistical processes (2 main sub-modules)
- Reduction in number of individual parts through integration (e.g. acoustic insulation and side-impact support).
Scheme 120
Scheme 121
Roof Spoiler
The R56 has a roof spoiler mounted on the tailgate in all equipment specifications. The spoiler reduces the CW value and increases the output at the rear axle, which leads to better driving characteristics.
The relatively low CW value reduces fuel consumption by approximately 0.1 l/100 km/h and leads to a final speed that is higher by approximately 2 km/h. A further spoiler for visual differentiation is available as an option. The aerodynamic properties are the same.
The COOPER S also has a large "wing spoiler" with undercurrent. An additional central connection to the tailgate helps to differentiate it visually from the previous model.
Standard and optional spoilers are manufactured in one-shell construction, the COOPER spoiler is in three parts.
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Scheme 124
Outside Mirrors
The outside mirrors on the R56 have a larger field of vision in terms of height and width compared to the R50. Additionally, the mirrors are supplied with a spherical glass, which also improves the field of vision laterally. This reduces the area which is not visible (blind spot).
Scheme 125
This is achieved by the mirror glass not being uniformly spherically curved (convex glass), but instead there is more curvature in the outer area.
As a further option, a mirror with "electric fold-in" mechanism is available on the R56 once again. This mirror has its own casing. The mirror covers are available in different colored versions and in chrome.
Bumper Trim/Front End
There are three trim variants
- The MINI COOPER has a lower bonnet height and smaller air inlets compared to the MINI COOPER S
- The MINI COOPER S has its own look; the larger air inlets are due to the cooling system.
All three variants must fulfill aerodynamic requirements and at the same time provide an adequate supply of cooling air to the cooling components.
The simple assembly of the front end is made possible by large assembly panels behind which the bolt connection to the vehicle is located.
The shape of the bumper trim is designed so that it guarantees the best possible protection for pedestrians. There is also sufficient space available to allow an adequate deformation path in the event of a small amount of accident damage, without causing damage to the cooling system, lights and bonnet.
Clipped-on separate grills and front spoiler enable simple and low cost replacement in the event of damage.
Front End
A high level of system integration has allowed optimum function, design, constructed size, weight and costs to be attained. A component, such as the bulkhead, for example, assumes several functions. Directing the cooling air, a mounting for different components, lights, washer fluid holder.
Additionally, with the bulkhead, the whole car front end is stiffened. For the front end, there is a service position, which allows the whole front end to be pulled forwards approximately 10 cm without having to unfasten hoses or cables. A special tool has been approved for this purpose. This makes servicing and repairs in the engine compartment simpler.
In comparison to its predecessor, functionality has been improved using fewer components in terms of the performance of the cooling system, crash behavior, rigidity, reliability and aerodynamics. In comparison to the R50, the headlights are no longer attached to the bonnet. This makes the vehicle easier to maintain.
Panoramic Sunroof
The panoramic sunroof of the R56 is a sliding/tilting sunroof running inside with two glass covers and two roof panel headliners. A new feature is the lift function for the rear glass sunroof. The sliding/tilting sunroof control unit receives signals from other control units for the sliding/tilting sunroof functions.
It activates the sliding/tilting sunroof motor on request and monitors the motor rotation at the same time. The sliding/tilting sunroof control unit uses the K-CAN.
Scheme 126
Roof Rack
The R56 design allows a roof rack to be fitted. For this, the body structure has been stiffened at the roof mounting points so that a roof clamp support can be fitted at specified points.
The two roof racks are attached at the specified points on the roof strip using a bracket fitted to the vehicle. The roof rack is further supported on the roof surface by support feet so that a maximum roof load of 75 kg can be safely transported.
Underbody Paneling
The underbody of the R56 is supplied with aerodynamic components on the underbody. As standard, underbody paneling has been fitted which on the one hand provides a smooth underbody that reduces consumption, and on the other hand also has an anti-chip function to protect cables and other components. This has also enabled acoustic characteristics to be improved
- Aerodynamic value cX = 0.33
- Lift coefficients cZ1 = 0.03; cZ2 = 0.06
These high values improve performance and reduce consumption. Additionally, vehicle handling during reactions to load-cycle changes is also improved. Finally, the underbody paneling is designed to protect against damage, corrosion and prevent cables from being damaged.
Door Trim Panel
A newly developed detail is the main support. It consists of the armrest, door handle, loudspeaker and storage support.
Scheme 127
Center Console
Various types of hand brake console are fitted.
Scheme 128
- Basic version
- High Line (console with switch block)
- High Line with armrest
- High Line with navigation system
- High Line with navigation system and armrest.
Front Seats
Both the standard equipment seats and the sport seats are designed to provide good support and allow the occupant to sit comfortably.
Both seats have an integrated airbag located in the side cushion. The cushions have designed rupture points from which the airbags are deployed in the event of activation.
Scheme 129
Both sports and standard equipment seats are ideally available with seat heating. This seat heating has two levels. Pressing the switch once or twice adjusts it to the appropriate setting.
This is indicated by LEDs in the switches. The switches are mounted on the center console.
Scheme 130
Seat Heating Control
The seat heating can be switched on using the button in the center console in three stages for the driver and front passenger respectively.
The seat heating can be activated from terminal 15 ON. Activation of the heating mats in the seats is controlled by two seat heating modules (one each for the driver's and front passenger's seat). The seat heating modules are connected directly to the junction box. The status of the buttons for the seat heating is sent from the A/C control unit to the junction box via the K-CAN. The junction box then sends pulse width-modulated signals to the seat heating modules. The pulse width depends on the heating stage requested.
The seat heating seat module regulates the seat heating to the temperature setting specified by the junction box. The seat heating seat module determines the temperature via an NTC resistor in the seat surface heating mat.
Seat Heating Power Reduction
The energy management system in the vehicle allows the seat heating to be operated at a reduced level depending on the energy balance. The energy management system is located in the engine control system. The junction box receives the reduction request from the engine control system via the PT-CAN and transmits this request directly to the seat heating module.
The reduction stages are
- Operation of seat heating in setting 2 only
- Operation of seat heating in setting 2 at 50% only
- Seat heating OFF.
The function LEDs for the seat heating buttons are not switched off.
Components
- Button for seat heating The buttons for the seat heating are integrated in the switch block of the center console. They have a 3 stage design. At the first switch stage, the seat heating is switched on at maximum power. After pressing the button for the second time, the moderate power level is switched on. In the third switch stage, the seat heating is switched on at the lowest power. Pressing the button again switches the seat heating off. Additionally, the seat heating can be switched off from any setting by pressing the button for at least 1.2 s. The center console switch block is connected to the air conditioning control unit (IHKA/IHKR) via a ribbon cable. The A/C control unit establishes the connection to the K-CAN.
- Junction box The junction box has one control outlet for the driver's seat heating and one for the front passenger's seat heating. The signal from the junction box is pulse width-modulated. The frequency of the signal is 25 Hz.
- Seat heating module The seat heating modules contain the evaluation of the signals from the junction box. Each seat heating module has three connectors. One connector establishes the connection to the vehicle. The other two connectors are for connecting the seat heating in the seat surface and the seat backrest.
- Heating mats The seat heating consists of one heating mat in the seat backrest and one in the seat surface. The heating mats form a single circuit system. There is an NTC resistor in the seat surface heating mat for regulating the seat heating temperature. The seat heating can be activated from terminal 15
Sport Seats
The sport seats are standard on the MINI COOPER S. The MINI COOPER has sport seats as an option.
The sport seats are available in material, part leather, leather and artificial leather versions. They are bigger than the standard equipment seats and have strengthened side cushions and a thigh support. The vertically adjustable head restraints also serve to make the upper support in the seat noticeable for the driver.
The seat adjustment options are the same as on the standard equipment seat.
Even lumbar support is available as an option on the sport seat.
Scheme 131
On both the sports and standard equipment seat, an adjustment lever makes it easier to swing the seat forwards and move it in order to access the rear bench seat easier.
On the driver's side, a type of mechanical memory function has been added, which permits the seat to fall back into its mechanical starting position without having to be readjusted afterwards.
In addition, the longitudinal, backrest and, on the driver's side, the height adjustment also can be activated using a lever.
The head restraints can be adjusted without using any operating lever. They are directly adjusted mechanically.
A rotary adjuster for adjusting the lumbar support is fitted to the inside surface of the backrest.
Rear Seats
The rear seats can be folded down 50:50. The procedure for folding them down can be carried out very easily. A release lever on each seat allows the folding backrest to be locked and released.
The rear seats are equipped with ISOFIX (1) brackets.
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Luggage Compartment
The luggage compartment on the R56 has a volume of 160 liters (compared to 150 liters on the R53/R50).
With the rear seats folded down, the R56 has a luggage volume of 680 liters.
There is also an accessory outlet on the left of the luggage compartment (1 bottom).
