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I've got a focus here at the moment that has a strong stale smoke odour. To be fair its the worst I've had, guy must have been in a family of chain smokers. Now, I seem to remember there is a 'chemical thing' you can leave in the car overnight to get rid of the smell, anyone used it?

You do not have to give his p/x back. You just refund the full asking price the car was purchased at and keep it especially if you are able to turn a few quid out of it. If the customer is not happy just explain that it is not financially viable for your business to repair the vehicle and a refund is the only option, if he does not like it still then tell him to take it further and just wipe your hands of him.

Autosmart do a product called Odor control fogger which you spray into the vehicle. It's much cheaper than an aromatex and just as good in my opinion.

A lot of the smell will be stored in the plastic trims on the pillars which turn yellow with a constant bash from smoking, I always start there with a very heavy apc cleaner be warned the yellow gunk that comes off is about as foul as it gets.

Never tried the 'cat litter tray' Had a beautiful A3 a few weeks back, Strong stench of cigarettes. Valeting every single inch of the car to an OCD standard. Changed the pollen filter and cleaned the glass. Once it dried it was no better. Next I sprayed 5 bottles of Febreze all over the roof cloth and seats. Though I had it sorted and it smelled like new. But once the Febreze dried out, same story. Cut open onions and placed coffee granules inside the car which masked it a bit. Tried two of those vanilla odour bombs, waste of time! Brought it round to a chap who has a Ioniser machine, left it with him overnight. next day the car smelled normal again. With all the time, effort and products used, I'd have been better off buying one first off.

Interesting, I've only had a handful of minis (2009 on coopers) with no issues. They sell well with full chili packs and big wheels. I'm not surprised others have had issues seeing as they are BMW product and I get nothing but hassle with German cars. Good build quality, chocolate engines.