IllustrationDriverside headlight assembly flickers everytime when you turn the key to position 1 with selector on off or auto. Flickers multiple times but doesn'tturn on unless I cycle the key on off until headlight does. This annoyance would reoccur the very next morning. Passenger headlight assembly doesn't have any issues.
2002 Mini Cooper
Owner reports · Recalls · Investigations
More warning signs than most Cooper years
Owner complaints for the 2002 Mini Cooper are substantially higher than the model-year median of 40.5.
About this comparison →How this year compares
Owner complaints by model year
Compare all Cooper years →Counts vary with age, sales and reporting. They are not failure rates.
What owners reported most
All reported categories
Tap a category to read its complaints. One report may name several components.
When problems were reported
Mileage at the reported incident
400–25K
2725–50K
3850–75K
1975–100K
31100–150K
2150K+
157 reports with mileage · 30 unknown
NHTSA’s mileage field refers to the reported incident, not necessarily the filing date. This shows report counts, not the likelihood of a failure.
What to inspect
Issues worth paying extra attention to based on owner reports.
- Steering. Review the 61 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Power Train. Review the 43 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Visibility. Review the 29 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
NHTSA owner reports · September 18, 2026 snapshot.
4 crash reports8 fire reports5 injury reports
What owners actually said
187 reportsI purchased the vehicle used with airbag light showing on the speedometer gauge cluster. Searched with vin for recalls but showed 0 unrepaired recalls. Tried clearing the light with my Launch CREADER BMW V2 scan tool. Light flashes a few times and goes away but immediately appears on the speedometer gauge cluster. This would hap…
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I purchased the vehicle used with airbag light showing on the speedometer gauge cluster. Searched with vin for recalls but showed 0 unrepaired recalls. Tried clearing the light with my Launch CREADER BMW V2 scan tool. Light flashes a few times and goes away but immediately appears on the speedometer gauge cluster. This would happen everytime. Wires are intact with no signs of damages to all 3 wire connectors under the seat.
Unoccupied passenger side airbags; all front & backseat bags deployed after passenger side tires hit pothole on road. Pieces of interior, including decorative plastic, interior light covers were projected across cabin & hit me. I had no idea what had happened. Car shut off shortly after incident. It was night, I was sitting in m…
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Unoccupied passenger side airbags; all front & backseat bags deployed after passenger side tires hit pothole on road. Pieces of interior, including decorative plastic, interior light covers were projected across cabin & hit me. I had no idea what had happened. Car shut off shortly after incident. It was night, I was sitting in middle of my lane, unable to start Mini. Good samaritans helped push it into parking lot while waiting for assistance. After 15 minutes, car started and was driven home. I had slight injuries from being hit by hard material projectiled across cabin. Very thankful I was the only occupant because if a passenger had been in the seat, they would have most definitely sustained injuries. I had to cut the airbags out in order to have clear lines of sight before driving the following day. I’m fearful that the drivers side air bags may do this as well. I have owned this vehicle since 2004. Not aware of history prior to 2004;(accidents, original airbags?). only know it came from a Dealer in CA. (Possibly “Friendship” may be name of town or dealership). I have not had repairs made yet. I don’t drive this vehicle daily. There are no police reports since there was no need. No insurance claims since 2002 model. There were no malfunctions with the warning light prior to incident. However, the following day when I drove, the airbag indicator light came on for passenger side. I did not find a recall but not sure if I would for a 22 year old vehicle.
MY MINI COOPER NEEDS RECALL WORK DONE. I AM IN BILLINGS, MT AND 392 MILES FROM THE CLOSEST CERTIFIED PLACE TO GET IT REPAIRED. I CAN'T TRAVEL THAT FAR IN A 2002 VEHICLE WITH HIGH MILES DURING A PANDEMIC. I AM A SENIOR CITIZEN AND HAVE ISSUES THAT DO NOT ALLOW ME TO TRAVEL THAT FAR. I AM STUCK WITH A VEHICLE THAT MAY HAVE A POTEN…
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MY MINI COOPER NEEDS RECALL WORK DONE. I AM IN BILLINGS, MT AND 392 MILES FROM THE CLOSEST CERTIFIED PLACE TO GET IT REPAIRED. I CAN'T TRAVEL THAT FAR IN A 2002 VEHICLE WITH HIGH MILES DURING A PANDEMIC. I AM A SENIOR CITIZEN AND HAVE ISSUES THAT DO NOT ALLOW ME TO TRAVEL THAT FAR. I AM STUCK WITH A VEHICLE THAT MAY HAVE A POTENTIAL STEERING ISSUE WITH NO WAY TO RESOLVE IT. I NOW CAN'T SELL THIS VEHICLE EITHER BECAUSE IT WOULD BE MORALLY WRONG TO PASS THIS PROBLEM ON TO A NEW OWNER. I CAN'T AFFORD THIS KIND OF SAFETY AND FINANCIAL PROBLEM. I NEED HELP TO GET THIS WORK DONE AND MINI COOPER CALLED ME AFTER MY INQUIRY AND SAID I AM BASICALLY OUT OF LUCK. THEY HAVE NO RESOLUTION FOR ME OR ANY OTHER MINI COOPER OWNERS THAT LIVE IN RURAL STATES AND ARE NOT NEAR A CERTIFIED DEALERSHIP. I NEED THIS REPAIRED AND AM HOPING YOU CAN HELP ME AND ALL THE OTHER MINI COOPER OWNERS IN THIS DANGEROUS SITUATION. THE NUMBER THE MINI REPRESENTATIVE CALLED ME FROM WAS 800-831-1117.
SO I BOUGHT A 2002 MINI COOPER LESS THAN A YEAR AGO AND IT CURRENTLY HAS 74K MILES AND ATTEMPTING TO PULL INTO A PARKING SPOT AT THE GROCERY MY STEERING GOES COMPLETELY OUT WHILE I WAS TRYING TO TURN INTO MY SPOT AND RIPPED OFF A BLACK MOLDING THAT GOES OVER THE FRONT PASSENGER WHEEL AND A SIGNIFICANT DING AND SCRATCH.
TL* THE CONTACT OWNS A 2002 MINI COOPER. WHILE DRIVING APPROXIMATELY 50 MPH, THE STEERING WHEEL SEIZED AND THE POWER STEERING WARNING INDICATOR ILLUMINATED. THE VEHICLE WAS ABLE TO COAST TO THE SIDE OF THE ROAD. THE CONTACT POWERED OFF AND RESTARTED THE VEHICLE, AND WAS ABLE TO DRIVE NORMALLY. THE CONTACT, A CERTIFIED MECHANIC, …
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TL* THE CONTACT OWNS A 2002 MINI COOPER. WHILE DRIVING APPROXIMATELY 50 MPH, THE STEERING WHEEL SEIZED AND THE POWER STEERING WARNING INDICATOR ILLUMINATED. THE VEHICLE WAS ABLE TO COAST TO THE SIDE OF THE ROAD. THE CONTACT POWERED OFF AND RESTARTED THE VEHICLE, AND WAS ABLE TO DRIVE NORMALLY. THE CONTACT, A CERTIFIED MECHANIC, DIAGNOSED THAT THE STEERING PUMP FAILED AND NEEDED TO BE REPLACED. THE VEHICLE WAS NOT TAKEN TO A DEALER. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS CONTACTED AND DID NOT OFFER ASSISTANCE. THE APPROXIMATE FAILURE MILEAGE WAS 120,000.
TL* THE CONTACT OWNS A 2002 MINI COOPER. THE CONTACT STATED THAT WATER WAS ENTERING THE VEHICLE FROM THE SUN ROOF, WHICH CAUSED THE COMPUTER IN THE VEHICLE TO GET MOIST AND NOT OPERATE. THE VEHICLE WAS TAKEN TO A DEALER WHERE IT WAS DIAGNOSED THAT THE SUN ROOF RUBBER CONNECTOR NEEDED TO BE REPAIRED. THE VEHICLE WAS REPAIRED; HOW…
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TL* THE CONTACT OWNS A 2002 MINI COOPER. THE CONTACT STATED THAT WATER WAS ENTERING THE VEHICLE FROM THE SUN ROOF, WHICH CAUSED THE COMPUTER IN THE VEHICLE TO GET MOIST AND NOT OPERATE. THE VEHICLE WAS TAKEN TO A DEALER WHERE IT WAS DIAGNOSED THAT THE SUN ROOF RUBBER CONNECTOR NEEDED TO BE REPAIRED. THE VEHICLE WAS REPAIRED; HOWEVER, THE FAILURE RECURRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 118,000.
TL* THE CONTACT OWNS A 2002 MINI COOPER. WHILE DRIVING 15 MPH OUT OF A PARKING LOT, THE VEHICLE MADE A LEFT TURN AND THE GEAR SHIFTER FAILED. IN ADDITION, THE GEAR SHIFTER CABLE DETACHED. THE VEHICLE WAS TOWED TO THE CONTACT'S RESIDENCE. THE FAILURE RECURRED TWICE. THE VEHICLE WAS NOT DIAGNOSED NOR REPAIRED. THE VIN WAS NOT INCL…
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TL* THE CONTACT OWNS A 2002 MINI COOPER. WHILE DRIVING 15 MPH OUT OF A PARKING LOT, THE VEHICLE MADE A LEFT TURN AND THE GEAR SHIFTER FAILED. IN ADDITION, THE GEAR SHIFTER CABLE DETACHED. THE VEHICLE WAS TOWED TO THE CONTACT'S RESIDENCE. THE FAILURE RECURRED TWICE. THE VEHICLE WAS NOT DIAGNOSED NOR REPAIRED. THE VIN WAS NOT INCLUDED IN NHTSA CAMPAIGN NUMBER: 02V201000 (POWER TRAIN). THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS UNKNOWN.
THE DASH LOW TIRE AIR LIGHT SUDDENLY CAME ON; IT COMES ON AFTER DRIVING FOR ABOUT 5 MINUETS. I'VE CHECKED ALL TIRES AND THEY ARE IN COMPLIANCE. I SEE THAT ON-LINE BLOGS THIS IS A MAJOR ISSUE
ABS DASH LIGHT AND BREAK LIGHT SUDDENLY CAME ON. IN ADDITION TO THE AIR BAG LIGHT THAT SUDDENLY CAME ON, THE DEALER SAID THE COMPUTER MODULE FOR THE ABS WILL COST $1,000 (IN ADDITION TO THE AIRBAG MODULE OF $1.000). I SEE ON INTERNET BLOGS AND NHTSA THAT THIS IS A COMMON INCIDENT TOTAL AIR BAG AND ABS COST WILL BE $2,000
Official recalls
315V660000 · Steering:electric Power Assist System
Oct 15, 2015
BMW of North America, LLC (BMW) is recalling certain model year 2002-2005 MINI Cooper and Cooper S vehicles and 2005 Cooper and Cooper S Convertible vehicles. The affected vehicles may experience temporary or permanent loss of the electro-hydraulic steering assistance.
Consequence & remedy
Consequence: If the vehicle experiences a loss of power steering assist, extra steering effort will be required at lower speeds, potentially increasing the risk of a vehicle crash.
Remedy: MINI will notify owners, and dealers will inspect the electro-hydraulic power steering system, replacing the components and wiring, as necessary, free of charge. Interim notices were mailed to owners on December 10, 2015. Owners will receive a second notice when remedy parts become available. Owners may contact MINI customer service at 1-866-825-1525.
05V470000 · Equipment:other:labels
Oct 12, 2005
CERTAIN PASSENGER VEHICLES FAIL TO CONFORM TO THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 110, 'TIRE SELECTION AND RIMS.' THE STANDARD REQUIRES THAT THE RELATIONSHIP BETWEEN THE TIRE SIZE AND MAXIMUM TIRE PRESSURE BE INDICATED ON THE VEHICLE'S TIRE INFORMATION LABEL. THIS RELATIONSHIP IS NOT PRESENT.
Consequence & remedy
Consequence: TOO LOW OR TOO HIGH TIRE PRESSURE CAN CAUSE PREMATURE WEAR AND/OR TIRE DAMAGE, AND COULD LEAD TO UNFAVORABLE DRIVING CONDITIONS.
Remedy: OWNERS WILL BE PROVIDED WITH NEW TIRE INFORMATION PLACARDS AND INSTALLATION INSTRUCTIONS. AT THE CUSTOMER'S OPTION, A DEALER CAN PERFORM THE INSTALLATION FOR THEM. THE RECALL BEGAN ON NOVEMBER 30, 2005. OWNERS MAY CONTACT MINI AT 1-866-275-6464.
02V201000 · Power Train:manual Transmission:floor Shift Assembly
Jul 25, 2002
ON CERTAIN PASSENGER VEHICLES EQUIPPED WITH MANUAL TRANSMISSIONS, THE TRANSMISSION SHIFT CABLE CONNECTS THE GEARSHIFT LEVER IN THE VEHICLE INTERIOR TO THE SHIFT LINKAGE ON THE TRANSMISSION. IT IS POSSIBLE FOR THE SHIFT CABLE TO DETACH FROM THE TRANSMISSION SHIFT LINKAGE WHILE THE DRIVER IS ATTEMPTING TO CHANGE GEARS. IF THE CABLE DETACHES FROM THE SHIFT LINKAGE, GEAR CHANGES WILL NO LONGER BE POSSIBLE AND THE TRANSMISSION WILL REMAIN IN THE LAST GEAR SELECTED.
Consequence & remedy
Consequence: IF SHIFT CABLE DETACHMENT OCCURS AND THE TRANSMISSION REMAINS IN ANY FORWARD GEAR, THE VEHICLE CAN STILL BE DRIVEN IN THAT GEAR ONLY. HOWEVER, IF THE TRANSMISSION MOVES INTO NEUTRAL AND REMAINS THERE, THE ABILITY TO ACCELERATE OR MAINTAIN SPEED WILL BE LOST, INCREASING THE RISK OF A CRASH.
Remedy: DEALERS WILL INSPECT THE SHIFT CABLE AND, IF NECESSARY, INSTALL A RETAINING CLIP OVER THE END OF THE SHIFT CABLE TO PREVENT IT FROM DETACHING FROM THE TRANSMISSION. OWNER NOTIFICATION BEGAN AUGUST 6, 2002. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT BMW AT 1-866-ASK-MINI (1-866-275-6464).
Model-level recall history does not show whether a particular VIN is affected or has received a repair. Check a VIN with NHTSA ↗
NHTSA investigations
5EA11005 · Loss Of Power Steering Assist
Opened May 4, 2011 · Closed Jan 5, 2016
Status: closed (inferred from source dates) · Steering; Steering:electric Power Assist System; Steering:hydraulic Power Assist System; Steering:hydraulic Power Assist:pump
The Office of Defects Investigation (ODI) originally opened the investigation of loss of power steering assist in model year (MY) 2004 and 2005 Mini Cooper as Preliminary Evaluation PE10-038.The investigation was upgraded to Engineering Analysis EA11-005 in May, 2011.During EA11-005 the scope was expanded to include MY 2002 and 2003 vehicles that use the same steering system.The subject vehicles now include MY 2002, the first year BMW sold MINI in the U.S., through mid-MY 2005 covering approximately 109,000 vehicles.The subject vehicles use an electrically driven pump to provide hydraulic pressure to a conventional rack-and-pinion steering gear.A pump, the electric motor, and an electronic control unit (ECU) are housed in a single component BMW calls a Power Pack.The investigation focused on contaminant-induced failure of the ECU resulting in a loss of assist without warning.When assist is lost mechanical steering is retained however increased steering effort is required to keep the vehicle on an intended path.Some consumers reported that restarting the vehicle (cycling the ignition switch) would often reinstate the steering assist.Additionally, and by design, assist can also reinstate during the drive cycle in limited circumstances.The unexpected loss of assist, and/or possibly the reinstatement of assist while driving, may contribute to a loss of vehicle control in certain driving situations.During MY 2005 production BMW introduced a revised Power Pack design (the ECU incorporated a conformal coating of the circuit board) which resulted in a significant reduction in failures.ODI identified 20 reports describing crashes consistent with a loss of power assist event possibly caused by a failure of the Power Pack.Two reports alleged an injury however both were minor in nature and did not require emergency treatment (a subsequent doctor's visit occurred in one case).Ten of these reports described low speed crashes with minimal, or in most cases no property or vehicle damage (e.g., striking a movable barrier in a parking lot).Additionally 27 other reports alleged or indicated that a crash occurred due to a Power Pack failure however in reviewing these reports, ODI either 1) was unable to confirm that a crash actually occurred (8 reports), or 2) determined that the crash circumstances (e.g., adverse road/weather conditions) or cause (e.g., the crash was caused by steering linkage failure) were not attributable to a Power Pack failure (19 reports).Throughout the investigation BMW maintained that loss of assist in the subject vehicles did not constitute a safety related defect, noting that the subject vehicles are smaller, light weight vehicles that can be reasonably controlled when assist is lost.In May 2013 BMW launched a 13 year/150,000 mile extended warranty coverage utilizing the redesigned Power Pack as a replacement part.ODI continued its investigation.In July 2014 BMW provided ODI a status of the ongoing extended warranty program, and in May 2015 ODI requested an update of complaint data.Following a review of the provided data, ODI informed BMW of its assessment that loss of steering assist failures were not adequately resolved by an extended warranty program.On October 12, 2015 BMW notified NHTSA that it would conduct a safety recall (15V-660) on approximately 86,000 subject vehicles not previously remedied with the new design Power Pack through regular or extended warranty programs.The recall covers MY 2002-2005 MINI Cooper, MY 2002-2005 MINI Cooper S, and MY 2005 MINI Cooper/Cooper S convertibles manufactured through Feb 9, 2005.Vehicles produced after this date are not included si
Additional source detail variants (4)
Steering
The Office of Defects Investigation (ODI) originally opened the investigation of loss of power steering assist in model year (MY) 2004 and 2005 Mini Cooper as Preliminary Evaluation PE10-038.The investigation was upgraded to Engineering Analysis EA11-005 in May, 2011.During EA11-005 the scope was expanded to include MY 2002 and 2003 vehicles that use the same steering system.The subject vehicles now include MY 2002, the first year BMW sold MINI in the U.S., through mid-MY 2005 covering approximately 109,000 vehicles.The subject vehicles use an electrically driven pump to provide hydraulic pressure to a conventional rack-and-pinion steering gear.A pump, the electric motor, and an electronic control unit (ECU) are housed in a single component BMW calls a Power Pack.The investigation focused on contaminant-induced failure of the ECU resulting in a loss of assist without warning.When assist is lost mechanical steering is retained however increased steering effort is required to keep the vehicle on an intended path.Some consumers reported that restarting the vehicle (cycling the ignition switch) would often reinstate the steering assist.Additionally, and by design, assist can also reinstate during the drive cycle in limited circumstances.The unexpected loss of assist, and/or possibly the reinstatement of assist while driving, may contribute to a loss of vehicle control in certain driving situations.During MY 2005 production BMW introduced a revised Power Pack design (the ECU incorporated a conformal coating of the circuit board) which resulted in a significant reduction in failures.ODI identified 20 reports describing crashes consistent with a loss of power assist event possibly caused by a failure of the Power Pack.Two reports alleged an injury however both were minor in nature and did not require emergency treatment (a subsequent doctor's visit occurred in one case).Ten of these reports described low speed crashes with minimal, or in most cases no property or vehicle damage (e.g., striking a movable barrier in a parking lot).Additionally 27 other reports alleged or indicated that a crash occurred due to a Power Pack failure however in reviewing these reports, ODI either 1) was unable to confirm that a crash actually occurred (8 reports), or 2) determined that the crash circumstances (e.g., adverse road/weather conditions) or cause (e.g., the crash was caused by steering linkage failure) were not attributable to a Power Pack failure (19 reports).Throughout the investigation BMW maintained that loss of assist in the subject vehicles did not constitute a safety related defect, noting that the subject vehicles are smaller, light weight vehicles that can be reasonably controlled when assist is lost.In May 2013 BMW launched a 13 year/150,000 mile extended warranty coverage utilizing the redesigned Power Pack as a replacement part.ODI continued its investigation.In July 2014 BMW provided ODI a status of the ongoing extended warranty program, and in May 2015 ODI requested an update of complaint data.Following a review of the provided data, ODI informed BMW of its assessment that loss of steering assist failures were not adequately resolved by an extended warranty program.On October 12, 2015 BMW notified NHTSA that it would conduct a safety recall (15V-660) on approximately 86,000 subject vehicles not previously remedied with the new design Power Pack through regular or extended warranty programs.The recall covers MY 2002-2005 MINI Cooper, MY 2002-2005 MINI Cooper S, and MY 2005 MINI Cooper/Cooper S convertibles manufactured through Feb 9, 2005.Vehicles produced after this date are not included si
Steering:electric Power Assist System
The Office of Defects Investigation (ODI) originally opened the investigation of loss of power steering assist in model year (MY) 2004 and 2005 Mini Cooper as Preliminary Evaluation PE10-038.The investigation was upgraded to Engineering Analysis EA11-005 in May, 2011.During EA11-005 the scope was expanded to include MY 2002 and 2003 vehicles that use the same steering system.The subject vehicles now include MY 2002, the first year BMW sold MINI in the U.S., through mid-MY 2005 covering approximately 109,000 vehicles.The subject vehicles use an electrically driven pump to provide hydraulic pressure to a conventional rack-and-pinion steering gear.A pump, the electric motor, and an electronic control unit (ECU) are housed in a single component BMW calls a Power Pack.The investigation focused on contaminant-induced failure of the ECU resulting in a loss of assist without warning.When assist is lost mechanical steering is retained however increased steering effort is required to keep the vehicle on an intended path.Some consumers reported that restarting the vehicle (cycling the ignition switch) would often reinstate the steering assist.Additionally, and by design, assist can also reinstate during the drive cycle in limited circumstances.The unexpected loss of assist, and/or possibly the reinstatement of assist while driving, may contribute to a loss of vehicle control in certain driving situations.During MY 2005 production BMW introduced a revised Power Pack design (the ECU incorporated a conformal coating of the circuit board) which resulted in a significant reduction in failures.ODI identified 20 reports describing crashes consistent with a loss of power assist event possibly caused by a failure of the Power Pack.Two reports alleged an injury however both were minor in nature and did not require emergency treatment (a subsequent doctor's visit occurred in one case).Ten of these reports described low speed crashes with minimal, or in most cases no property or vehicle damage (e.g., striking a movable barrier in a parking lot).Additionally 27 other reports alleged or indicated that a crash occurred due to a Power Pack failure however in reviewing these reports, ODI either 1) was unable to confirm that a crash actually occurred (8 reports), or 2) determined that the crash circumstances (e.g., adverse road/weather conditions) or cause (e.g., the crash was caused by steering linkage failure) were not attributable to a Power Pack failure (19 reports).Throughout the investigation BMW maintained that loss of assist in the subject vehicles did not constitute a safety related defect, noting that the subject vehicles are smaller, light weight vehicles that can be reasonably controlled when assist is lost.In May 2013 BMW launched a 13 year/150,000 mile extended warranty coverage utilizing the redesigned Power Pack as a replacement part.ODI continued its investigation.In July 2014 BMW provided ODI a status of the ongoing extended warranty program, and in May 2015 ODI requested an update of complaint data.Following a review of the provided data, ODI informed BMW of its assessment that loss of steering assist failures were not adequately resolved by an extended warranty program.On October 12, 2015 BMW notified NHTSA that it would conduct a safety recall (15V-660) on approximately 86,000 subject vehicles not previously remedied with the new design Power Pack through regular or extended warranty programs.The recall covers MY 2002-2005 MINI Cooper, MY 2002-2005 MINI Cooper S, and MY 2005 MINI Cooper/Cooper S convertibles manufactured through Feb 9, 2005.Vehicles produced after this date are not included si
Steering:hydraulic Power Assist:pump
The Office of Defects Investigation (ODI) originally opened the investigation of loss of power steering assist in model year (MY) 2004 and 2005 Mini Cooper as Preliminary Evaluation PE10-038.The investigation was upgraded to Engineering Analysis EA11-005 in May, 2011.During EA11-005 the scope was expanded to include MY 2002 and 2003 vehicles that use the same steering system.The subject vehicles now include MY 2002, the first year BMW sold MINI in the U.S., through mid-MY 2005 covering approximately 109,000 vehicles.The subject vehicles use an electrically driven pump to provide hydraulic pressure to a conventional rack-and-pinion steering gear.A pump, the electric motor, and an electronic control unit (ECU) are housed in a single component BMW calls a Power Pack.The investigation focused on contaminant-induced failure of the ECU resulting in a loss of assist without warning.When assist is lost mechanical steering is retained however increased steering effort is required to keep the vehicle on an intended path.Some consumers reported that restarting the vehicle (cycling the ignition switch) would often reinstate the steering assist.Additionally, and by design, assist can also reinstate during the drive cycle in limited circumstances.The unexpected loss of assist, and/or possibly the reinstatement of assist while driving, may contribute to a loss of vehicle control in certain driving situations.During MY 2005 production BMW introduced a revised Power Pack design (the ECU incorporated a conformal coating of the circuit board) which resulted in a significant reduction in failures.ODI identified 20 reports describing crashes consistent with a loss of power assist event possibly caused by a failure of the Power Pack.Two reports alleged an injury however both were minor in nature and did not require emergency treatment (a subsequent doctor's visit occurred in one case).Ten of these reports described low speed crashes with minimal, or in most cases no property or vehicle damage (e.g., striking a movable barrier in a parking lot).Additionally 27 other reports alleged or indicated that a crash occurred due to a Power Pack failure however in reviewing these reports, ODI either 1) was unable to confirm that a crash actually occurred (8 reports), or 2) determined that the crash circumstances (e.g., adverse road/weather conditions) or cause (e.g., the crash was caused by steering linkage failure) were not attributable to a Power Pack failure (19 reports).Throughout the investigation BMW maintained that loss of assist in the subject vehicles did not constitute a safety related defect, noting that the subject vehicles are smaller, light weight vehicles that can be reasonably controlled when assist is lost.In May 2013 BMW launched a 13 year/150,000 mile extended warranty coverage utilizing the redesigned Power Pack as a replacement part.ODI continued its investigation.In July 2014 BMW provided ODI a status of the ongoing extended warranty program, and in May 2015 ODI requested an update of complaint data.Following a review of the provided data, ODI informed BMW of its assessment that loss of steering assist failures were not adequately resolved by an extended warranty program.On October 12, 2015 BMW notified NHTSA that it would conduct a safety recall (15V-660) on approximately 86,000 subject vehicles not previously remedied with the new design Power Pack through regular or extended warranty programs.The recall covers MY 2002-2005 MINI Cooper, MY 2002-2005 MINI Cooper S, and MY 2005 MINI Cooper/Cooper S convertibles manufactured through Feb 9, 2005.Vehicles produced after this date are not included si
Steering:hydraulic Power Assist System
The Office of Defects Investigation (ODI) originally opened the investigation of loss of power steering assist in model year (MY) 2004 and 2005 Mini Cooper as Preliminary Evaluation PE10-038.The investigation was upgraded to Engineering Analysis EA11-005 in May, 2011.During EA11-005 the scope was expanded to include MY 2002 and 2003 vehicles that use the same steering system.The subject vehicles now include MY 2002, the first year BMW sold MINI in the U.S., through mid-MY 2005 covering approximately 109,000 vehicles.The subject vehicles use an electrically driven pump to provide hydraulic pressure to a conventional rack-and-pinion steering gear.A pump, the electric motor, and an electronic control unit (ECU) are housed in a single component BMW calls a Power Pack.The investigation focused on contaminant-induced failure of the ECU resulting in a loss of assist without warning.When assist is lost mechanical steering is retained however increased steering effort is required to keep the vehicle on an intended path.Some consumers reported that restarting the vehicle (cycling the ignition switch) would often reinstate the steering assist.Additionally, and by design, assist can also reinstate during the drive cycle in limited circumstances.The unexpected loss of assist, and/or possibly the reinstatement of assist while driving, may contribute to a loss of vehicle control in certain driving situations.During MY 2005 production BMW introduced a revised Power Pack design (the ECU incorporated a conformal coating of the circuit board) which resulted in a significant reduction in failures.ODI identified 20 reports describing crashes consistent with a loss of power assist event possibly caused by a failure of the Power Pack.Two reports alleged an injury however both were minor in nature and did not require emergency treatment (a subsequent doctor's visit occurred in one case).Ten of these reports described low speed crashes with minimal, or in most cases no property or vehicle damage (e.g., striking a movable barrier in a parking lot).Additionally 27 other reports alleged or indicated that a crash occurred due to a Power Pack failure however in reviewing these reports, ODI either 1) was unable to confirm that a crash actually occurred (8 reports), or 2) determined that the crash circumstances (e.g., adverse road/weather conditions) or cause (e.g., the crash was caused by steering linkage failure) were not attributable to a Power Pack failure (19 reports).Throughout the investigation BMW maintained that loss of assist in the subject vehicles did not constitute a safety related defect, noting that the subject vehicles are smaller, light weight vehicles that can be reasonably controlled when assist is lost.In May 2013 BMW launched a 13 year/150,000 mile extended warranty coverage utilizing the redesigned Power Pack as a replacement part.ODI continued its investigation.In July 2014 BMW provided ODI a status of the ongoing extended warranty program, and in May 2015 ODI requested an update of complaint data.Following a review of the provided data, ODI informed BMW of its assessment that loss of steering assist failures were not adequately resolved by an extended warranty program.On October 12, 2015 BMW notified NHTSA that it would conduct a safety recall (15V-660) on approximately 86,000 subject vehicles not previously remedied with the new design Power Pack through regular or extended warranty programs.The recall covers MY 2002-2005 MINI Cooper, MY 2002-2005 MINI Cooper S, and MY 2005 MINI Cooper/Cooper S convertibles manufactured through Feb 9, 2005.Vehicles produced after this date are not included si
EA07011 · Engine Compartment Fire
Opened Aug 14, 2007 · Closed Aug 13, 2008
Status: closed (inferred from source dates) · Steering:electric Power Assist System; Steering:hydraulic Power Assist System; Steering:hydraulic Power Assist:hose, Piping, And Connections; Steering:hydraulic Power Assist:pump
THE OFFICE OF DEFECTS INVESTIGATION (ODI) ANALYZED CONSUMER COMPLAINTS TO BMW OF NORTH AMERICA, LLC (BMW)AND TO ODI THAT ALLEGED FAILURES OF THE ELECTROHYDRAULIC POWER STEERING (EHPS) USED IN MODEL YEAR 2002 THROUGH 2003 MINI COOPER VEHICLES.THE ANALYSIS DETERMINED THAT 43 OF THE 52 (83%) REPORTS WERE RELATED TO ALLEGATIONS OF POWER STEERING LOSS AND 9 (17%) WERE RELATED TO ALLEGATIONS OF ENGINE COMPARTMENT FIRES. ALTHOUGH SOME OF THE REPORTS ALLEGING FIRES NOTE SMALL FLAMES WERE VISIBLE IN THE ENGINE COMPARTMENT, ANALYSIS OF THE DAMAGE CAUSED BY THESE FAILURES INDICATES THAT EVEN THE MOST SEVERE INCIDENTS WERE LIMITED TO LOCALIZED THERMAL DAMAGE TO THE EHPS ELECTRICAL CONNECTIONS AND WIRING INSULATION.NONE OF THE COMPLAINTS ALLEGING LOSS OF POWER ASSISTED STEERING INDICATED THAT THE INCREASED EFFORT RESULTED IN A CRASH OR LOSS OF VEHICLE CONTROL. A SAFETY-RELATED DEFECT TREND HAS NOT BEEN IDENTIFIED AT THIS TIME AND FURTHER USE OF AGENCY RESOURCES DOES NOT APPEAR TO BE WARRANTED. ACCORDINGLY, THIS INVESTIGATION IS CLOSED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT A SAFETY-RELATED DEFECT DOES NOT EXIST. THE AGENCY WILL MONITOR THIS ISSUE AND RESERVES THE RIGHT TO TAKE FURTHER ACTION IF WARRANTED BY CIRCUMSTANCES.SEE DOCUMENT FILE FOR ADDITIONAL INFORMATION REGARDING THIS RESUME.
Additional source detail variants (4)
Steering:electric Power Assist System
THE OFFICE OF DEFECTS INVESTIGATION (ODI) ANALYZED CONSUMER COMPLAINTS TO BMW OF NORTH AMERICA, LLC (BMW)AND TO ODI THAT ALLEGED FAILURES OF THE ELECTROHYDRAULIC POWER STEERING (EHPS) USED IN MODEL YEAR 2002 THROUGH 2003 MINI COOPER VEHICLES.THE ANALYSIS DETERMINED THAT 43 OF THE 52 (83%) REPORTS WERE RELATED TO ALLEGATIONS OF POWER STEERING LOSS AND 9 (17%) WERE RELATED TO ALLEGATIONS OF ENGINE COMPARTMENT FIRES. ALTHOUGH SOME OF THE REPORTS ALLEGING FIRES NOTE SMALL FLAMES WERE VISIBLE IN THE ENGINE COMPARTMENT, ANALYSIS OF THE DAMAGE CAUSED BY THESE FAILURES INDICATES THAT EVEN THE MOST SEVERE INCIDENTS WERE LIMITED TO LOCALIZED THERMAL DAMAGE TO THE EHPS ELECTRICAL CONNECTIONS AND WIRING INSULATION.NONE OF THE COMPLAINTS ALLEGING LOSS OF POWER ASSISTED STEERING INDICATED THAT THE INCREASED EFFORT RESULTED IN A CRASH OR LOSS OF VEHICLE CONTROL. A SAFETY-RELATED DEFECT TREND HAS NOT BEEN IDENTIFIED AT THIS TIME AND FURTHER USE OF AGENCY RESOURCES DOES NOT APPEAR TO BE WARRANTED. ACCORDINGLY, THIS INVESTIGATION IS CLOSED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT A SAFETY-RELATED DEFECT DOES NOT EXIST. THE AGENCY WILL MONITOR THIS ISSUE AND RESERVES THE RIGHT TO TAKE FURTHER ACTION IF WARRANTED BY CIRCUMSTANCES.SEE DOCUMENT FILE FOR ADDITIONAL INFORMATION REGARDING THIS RESUME.
Steering:hydraulic Power Assist:hose, Piping, And Connections
THE OFFICE OF DEFECTS INVESTIGATION (ODI) ANALYZED CONSUMER COMPLAINTS TO BMW OF NORTH AMERICA, LLC (BMW)AND TO ODI THAT ALLEGED FAILURES OF THE ELECTROHYDRAULIC POWER STEERING (EHPS) USED IN MODEL YEAR 2002 THROUGH 2003 MINI COOPER VEHICLES.THE ANALYSIS DETERMINED THAT 43 OF THE 52 (83%) REPORTS WERE RELATED TO ALLEGATIONS OF POWER STEERING LOSS AND 9 (17%) WERE RELATED TO ALLEGATIONS OF ENGINE COMPARTMENT FIRES. ALTHOUGH SOME OF THE REPORTS ALLEGING FIRES NOTE SMALL FLAMES WERE VISIBLE IN THE ENGINE COMPARTMENT, ANALYSIS OF THE DAMAGE CAUSED BY THESE FAILURES INDICATES THAT EVEN THE MOST SEVERE INCIDENTS WERE LIMITED TO LOCALIZED THERMAL DAMAGE TO THE EHPS ELECTRICAL CONNECTIONS AND WIRING INSULATION.NONE OF THE COMPLAINTS ALLEGING LOSS OF POWER ASSISTED STEERING INDICATED THAT THE INCREASED EFFORT RESULTED IN A CRASH OR LOSS OF VEHICLE CONTROL. A SAFETY-RELATED DEFECT TREND HAS NOT BEEN IDENTIFIED AT THIS TIME AND FURTHER USE OF AGENCY RESOURCES DOES NOT APPEAR TO BE WARRANTED. ACCORDINGLY, THIS INVESTIGATION IS CLOSED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT A SAFETY-RELATED DEFECT DOES NOT EXIST. THE AGENCY WILL MONITOR THIS ISSUE AND RESERVES THE RIGHT TO TAKE FURTHER ACTION IF WARRANTED BY CIRCUMSTANCES.SEE DOCUMENT FILE FOR ADDITIONAL INFORMATION REGARDING THIS RESUME.
Steering:hydraulic Power Assist:pump
THE OFFICE OF DEFECTS INVESTIGATION (ODI) ANALYZED CONSUMER COMPLAINTS TO BMW OF NORTH AMERICA, LLC (BMW)AND TO ODI THAT ALLEGED FAILURES OF THE ELECTROHYDRAULIC POWER STEERING (EHPS) USED IN MODEL YEAR 2002 THROUGH 2003 MINI COOPER VEHICLES.THE ANALYSIS DETERMINED THAT 43 OF THE 52 (83%) REPORTS WERE RELATED TO ALLEGATIONS OF POWER STEERING LOSS AND 9 (17%) WERE RELATED TO ALLEGATIONS OF ENGINE COMPARTMENT FIRES. ALTHOUGH SOME OF THE REPORTS ALLEGING FIRES NOTE SMALL FLAMES WERE VISIBLE IN THE ENGINE COMPARTMENT, ANALYSIS OF THE DAMAGE CAUSED BY THESE FAILURES INDICATES THAT EVEN THE MOST SEVERE INCIDENTS WERE LIMITED TO LOCALIZED THERMAL DAMAGE TO THE EHPS ELECTRICAL CONNECTIONS AND WIRING INSULATION.NONE OF THE COMPLAINTS ALLEGING LOSS OF POWER ASSISTED STEERING INDICATED THAT THE INCREASED EFFORT RESULTED IN A CRASH OR LOSS OF VEHICLE CONTROL. A SAFETY-RELATED DEFECT TREND HAS NOT BEEN IDENTIFIED AT THIS TIME AND FURTHER USE OF AGENCY RESOURCES DOES NOT APPEAR TO BE WARRANTED. ACCORDINGLY, THIS INVESTIGATION IS CLOSED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT A SAFETY-RELATED DEFECT DOES NOT EXIST. THE AGENCY WILL MONITOR THIS ISSUE AND RESERVES THE RIGHT TO TAKE FURTHER ACTION IF WARRANTED BY CIRCUMSTANCES.SEE DOCUMENT FILE FOR ADDITIONAL INFORMATION REGARDING THIS RESUME.
Steering:hydraulic Power Assist System
THE OFFICE OF DEFECTS INVESTIGATION (ODI) ANALYZED CONSUMER COMPLAINTS TO BMW OF NORTH AMERICA, LLC (BMW)AND TO ODI THAT ALLEGED FAILURES OF THE ELECTROHYDRAULIC POWER STEERING (EHPS) USED IN MODEL YEAR 2002 THROUGH 2003 MINI COOPER VEHICLES.THE ANALYSIS DETERMINED THAT 43 OF THE 52 (83%) REPORTS WERE RELATED TO ALLEGATIONS OF POWER STEERING LOSS AND 9 (17%) WERE RELATED TO ALLEGATIONS OF ENGINE COMPARTMENT FIRES. ALTHOUGH SOME OF THE REPORTS ALLEGING FIRES NOTE SMALL FLAMES WERE VISIBLE IN THE ENGINE COMPARTMENT, ANALYSIS OF THE DAMAGE CAUSED BY THESE FAILURES INDICATES THAT EVEN THE MOST SEVERE INCIDENTS WERE LIMITED TO LOCALIZED THERMAL DAMAGE TO THE EHPS ELECTRICAL CONNECTIONS AND WIRING INSULATION.NONE OF THE COMPLAINTS ALLEGING LOSS OF POWER ASSISTED STEERING INDICATED THAT THE INCREASED EFFORT RESULTED IN A CRASH OR LOSS OF VEHICLE CONTROL. A SAFETY-RELATED DEFECT TREND HAS NOT BEEN IDENTIFIED AT THIS TIME AND FURTHER USE OF AGENCY RESOURCES DOES NOT APPEAR TO BE WARRANTED. ACCORDINGLY, THIS INVESTIGATION IS CLOSED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT A SAFETY-RELATED DEFECT DOES NOT EXIST. THE AGENCY WILL MONITOR THIS ISSUE AND RESERVES THE RIGHT TO TAKE FURTHER ACTION IF WARRANTED BY CIRCUMSTANCES.SEE DOCUMENT FILE FOR ADDITIONAL INFORMATION REGARDING THIS RESUME.
PE07022 · Engine Compartment Fire
Opened Apr 19, 2007 · Closed Aug 15, 2007
Status: closed (inferred from source dates) · Steering:electric Power Assist System; Steering:hydraulic Power Assist System; Steering:hydraulic Power Assist:hose, Piping, And Connections; Steering:hydraulic Power Assist:pump
IN RESPONSE TO AN INFORMATION REQUEST (IR) LETTER SENT BY THE OFFICE OF DEFECTS INVESTIGATION (ODI), BMW STATED THAT THE CAUSE OF THE ALLEGED DEFECT IS AN INSUFFICIENT SEAL OF THE GROUND CABLE OF THE POWER STEERING PUMP AT ITS ATTACHMENT TO THE CHASSIS.WATER INGRESS CAN OCCUR AND THE WATER CAN TRAVEL ALONG THE POWER STEERING PUMP POWER CABLE AND COME IN CONTACT WITH THE POWER STEERING PUMP POWER CABLE CONNECTOR.THE CONNECTOR CAN THEN CORRODE AND A HIGH THERMAL LOAD CONDITION CAN OCCUR.ACCORDING TO BMW, THIS ULTIMATELY COULD RESULT IN A LOCALIZED SMOLDERING CONDITION THAT DOES NOT PROPAGATE. TO CORRECT THE WATER INGRESS ISSUE, BMW IMPLEMENTED CHANGES TO THE WIRE ROUTING, THE POWER STEERINGPUMP CONNECTOR AND THE GROUND EYELET CONNECTION BETWEEN FEBRUARY AND JULY OF 2002. IN A REVIEW OF WARRANTY CLAIM DATA SENT BY BMW, 67 PERCENT OF THE VEHICLES NOTED IN WARRANTY CLAIMS HAD PRODUCTION DATES AFTER AUGUST 1, 2002. ADDITIONALLY, ODI NOTED EIGHT REPORTS OF CONSUMERS WITNESSING FLAMES COMING FROM THE ENGINE COMPARTMENT.THIS PRELIMINARY EVALUATION HAS BEEN UPGRADED TO AN ENGINEERING ANALYSIS (EA07-011) TO FURTHER ASSESS THE SCOPE, FREQUENCY ANDPOTENTIAL SAFETY CONSEQUENCES ASSOCIATED WITH THE ALLEGED DEFECT.
Additional source detail variants (4)
Steering:electric Power Assist System
IN RESPONSE TO AN INFORMATION REQUEST (IR) LETTER SENT BY THE OFFICE OF DEFECTS INVESTIGATION (ODI), BMW STATED THAT THE CAUSE OF THE ALLEGED DEFECT IS AN INSUFFICIENT SEAL OF THE GROUND CABLE OF THE POWER STEERING PUMP AT ITS ATTACHMENT TO THE CHASSIS.WATER INGRESS CAN OCCUR AND THE WATER CAN TRAVEL ALONG THE POWER STEERING PUMP POWER CABLE AND COME IN CONTACT WITH THE POWER STEERING PUMP POWER CABLE CONNECTOR.THE CONNECTOR CAN THEN CORRODE AND A HIGH THERMAL LOAD CONDITION CAN OCCUR.ACCORDING TO BMW, THIS ULTIMATELY COULD RESULT IN A LOCALIZED SMOLDERING CONDITION THAT DOES NOT PROPAGATE. TO CORRECT THE WATER INGRESS ISSUE, BMW IMPLEMENTED CHANGES TO THE WIRE ROUTING, THE POWER STEERINGPUMP CONNECTOR AND THE GROUND EYELET CONNECTION BETWEEN FEBRUARY AND JULY OF 2002. IN A REVIEW OF WARRANTY CLAIM DATA SENT BY BMW, 67 PERCENT OF THE VEHICLES NOTED IN WARRANTY CLAIMS HAD PRODUCTION DATES AFTER AUGUST 1, 2002. ADDITIONALLY, ODI NOTED EIGHT REPORTS OF CONSUMERS WITNESSING FLAMES COMING FROM THE ENGINE COMPARTMENT.THIS PRELIMINARY EVALUATION HAS BEEN UPGRADED TO AN ENGINEERING ANALYSIS (EA07-011) TO FURTHER ASSESS THE SCOPE, FREQUENCY ANDPOTENTIAL SAFETY CONSEQUENCES ASSOCIATED WITH THE ALLEGED DEFECT.
Steering:hydraulic Power Assist:hose, Piping, And Connections
IN RESPONSE TO AN INFORMATION REQUEST (IR) LETTER SENT BY THE OFFICE OF DEFECTS INVESTIGATION (ODI), BMW STATED THAT THE CAUSE OF THE ALLEGED DEFECT IS AN INSUFFICIENT SEAL OF THE GROUND CABLE OF THE POWER STEERING PUMP AT ITS ATTACHMENT TO THE CHASSIS.WATER INGRESS CAN OCCUR AND THE WATER CAN TRAVEL ALONG THE POWER STEERING PUMP POWER CABLE AND COME IN CONTACT WITH THE POWER STEERING PUMP POWER CABLE CONNECTOR.THE CONNECTOR CAN THEN CORRODE AND A HIGH THERMAL LOAD CONDITION CAN OCCUR.ACCORDING TO BMW, THIS ULTIMATELY COULD RESULT IN A LOCALIZED SMOLDERING CONDITION THAT DOES NOT PROPAGATE. TO CORRECT THE WATER INGRESS ISSUE, BMW IMPLEMENTED CHANGES TO THE WIRE ROUTING, THE POWER STEERINGPUMP CONNECTOR AND THE GROUND EYELET CONNECTION BETWEEN FEBRUARY AND JULY OF 2002. IN A REVIEW OF WARRANTY CLAIM DATA SENT BY BMW, 67 PERCENT OF THE VEHICLES NOTED IN WARRANTY CLAIMS HAD PRODUCTION DATES AFTER AUGUST 1, 2002. ADDITIONALLY, ODI NOTED EIGHT REPORTS OF CONSUMERS WITNESSING FLAMES COMING FROM THE ENGINE COMPARTMENT.THIS PRELIMINARY EVALUATION HAS BEEN UPGRADED TO AN ENGINEERING ANALYSIS (EA07-011) TO FURTHER ASSESS THE SCOPE, FREQUENCY ANDPOTENTIAL SAFETY CONSEQUENCES ASSOCIATED WITH THE ALLEGED DEFECT.
Steering:hydraulic Power Assist:pump
IN RESPONSE TO AN INFORMATION REQUEST (IR) LETTER SENT BY THE OFFICE OF DEFECTS INVESTIGATION (ODI), BMW STATED THAT THE CAUSE OF THE ALLEGED DEFECT IS AN INSUFFICIENT SEAL OF THE GROUND CABLE OF THE POWER STEERING PUMP AT ITS ATTACHMENT TO THE CHASSIS.WATER INGRESS CAN OCCUR AND THE WATER CAN TRAVEL ALONG THE POWER STEERING PUMP POWER CABLE AND COME IN CONTACT WITH THE POWER STEERING PUMP POWER CABLE CONNECTOR.THE CONNECTOR CAN THEN CORRODE AND A HIGH THERMAL LOAD CONDITION CAN OCCUR.ACCORDING TO BMW, THIS ULTIMATELY COULD RESULT IN A LOCALIZED SMOLDERING CONDITION THAT DOES NOT PROPAGATE. TO CORRECT THE WATER INGRESS ISSUE, BMW IMPLEMENTED CHANGES TO THE WIRE ROUTING, THE POWER STEERINGPUMP CONNECTOR AND THE GROUND EYELET CONNECTION BETWEEN FEBRUARY AND JULY OF 2002. IN A REVIEW OF WARRANTY CLAIM DATA SENT BY BMW, 67 PERCENT OF THE VEHICLES NOTED IN WARRANTY CLAIMS HAD PRODUCTION DATES AFTER AUGUST 1, 2002. ADDITIONALLY, ODI NOTED EIGHT REPORTS OF CONSUMERS WITNESSING FLAMES COMING FROM THE ENGINE COMPARTMENT.THIS PRELIMINARY EVALUATION HAS BEEN UPGRADED TO AN ENGINEERING ANALYSIS (EA07-011) TO FURTHER ASSESS THE SCOPE, FREQUENCY ANDPOTENTIAL SAFETY CONSEQUENCES ASSOCIATED WITH THE ALLEGED DEFECT.
Steering:hydraulic Power Assist System
IN RESPONSE TO AN INFORMATION REQUEST (IR) LETTER SENT BY THE OFFICE OF DEFECTS INVESTIGATION (ODI), BMW STATED THAT THE CAUSE OF THE ALLEGED DEFECT IS AN INSUFFICIENT SEAL OF THE GROUND CABLE OF THE POWER STEERING PUMP AT ITS ATTACHMENT TO THE CHASSIS.WATER INGRESS CAN OCCUR AND THE WATER CAN TRAVEL ALONG THE POWER STEERING PUMP POWER CABLE AND COME IN CONTACT WITH THE POWER STEERING PUMP POWER CABLE CONNECTOR.THE CONNECTOR CAN THEN CORRODE AND A HIGH THERMAL LOAD CONDITION CAN OCCUR.ACCORDING TO BMW, THIS ULTIMATELY COULD RESULT IN A LOCALIZED SMOLDERING CONDITION THAT DOES NOT PROPAGATE. TO CORRECT THE WATER INGRESS ISSUE, BMW IMPLEMENTED CHANGES TO THE WIRE ROUTING, THE POWER STEERINGPUMP CONNECTOR AND THE GROUND EYELET CONNECTION BETWEEN FEBRUARY AND JULY OF 2002. IN A REVIEW OF WARRANTY CLAIM DATA SENT BY BMW, 67 PERCENT OF THE VEHICLES NOTED IN WARRANTY CLAIMS HAD PRODUCTION DATES AFTER AUGUST 1, 2002. ADDITIONALLY, ODI NOTED EIGHT REPORTS OF CONSUMERS WITNESSING FLAMES COMING FROM THE ENGINE COMPARTMENT.THIS PRELIMINARY EVALUATION HAS BEEN UPGRADED TO AN ENGINEERING ANALYSIS (EA07-011) TO FURTHER ASSESS THE SCOPE, FREQUENCY ANDPOTENTIAL SAFETY CONSEQUENCES ASSOCIATED WITH THE ALLEGED DEFECT.
PE05053 · Air Bag Warning Lamp Illumination
Opened Sep 27, 2005 · Closed Mar 1, 2006
Status: closed (inferred from source dates) · Air Bags; Air Bags:side/window
IN MARCH 2006, BMW REISSUED A SERVICE BULLETIN FIRST ISSUED IN SEPTEMBER 2003, TO MINI DEALERS REGARDING THE REPAIR PROCEDURE FOR IMPROPER WIRE CRIMPS IN APPROXIMATELY 31,500 MODEL YEAR 2002 AND 2003 MINI COOPER VEHICLES PRODUCED UP TO JANUARY 2003.THE NEW SERVICE BULLETIN STATES THAT THE WARRANTY COVERAGE FOR THE ISSUE (I.E., AIR BAG WARNING LAMP ILLUMINATION WITH FAULT CODE FOR HIGH RESISTANCE IN SIDE AIR BAG/SEAT BELT PRETENSIONER CIRCUIT) IS EXTENDED TO 10 YEARS OR 150,000 MILES, WHICHEVER OCCURS FIRST.BMW PLANS TO SEND LETTERS TO OWNERS DURING MARCH 2006.THE SUBJECT WIRE CRIMPS ARE LOCATED UNDER THE FRONT SEATS AND ARE PART OF THE MAIN WIRING HARNESS THAT INTERFACE WITH THE UNDER-SEAT WIRING HARNESS CONNECTORS FOR SIDE AIR BAG AND SEAT BELT PRETENSIONER MODULES.BMW STATED THAT, ALTHOUGH THE SUBJECT CRIMPS WERE IMPROPERLY MANUFACTURED, THE CRIMP CONNECTION IS STILL SUFFICIENT FOR THE RESTRAINT SYSTEM TO DEPLOY WHEN NEEDED.ACCORDING TO BMW, THE ELECTRICAL RESISTANCE LEVELS IN THE SUBJECT VEHICLES CAN EXCEED THE THRESHOLD THAT ILLUMINATES THE AIR BAG WARNING LAMP, BUT THEY DO NOT EXCEED A MUCH HIGHER LIMIT IN WHICH DEPLOYMENT OF THE RESTRAINTS MAY NO LONGER OCCUR.ODI BELIEVES THAT THERE IS LACK OF EVIDENCE AT THIS TIME TO CONCLUDE THAT THE RESTRAINT SYSTEMS MAY NOT DEPLOY WITH THE HIGH RESISTANCE CONDITION.THE AGENCY BELIEVES THAT FURTHER EXPENDITURE OF AGENCY RESOURCES DOES NOT APPEAR TO BE WARRANTED AT THIS TIME.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT NO SAFETY-RELATED DEFECT EXISTS.THE AGENCY WILL MONITOR THE ISSUE AND RESERVES THE RIGHT TO TAKE FUTURE ACTION IF WARRANTED BY THE CIRCUMSTANCES.
Additional source detail variants (2)
Air Bags
IN MARCH 2006, BMW REISSUED A SERVICE BULLETIN FIRST ISSUED IN SEPTEMBER 2003, TO MINI DEALERS REGARDING THE REPAIR PROCEDURE FOR IMPROPER WIRE CRIMPS IN APPROXIMATELY 31,500 MODEL YEAR 2002 AND 2003 MINI COOPER VEHICLES PRODUCED UP TO JANUARY 2003.THE NEW SERVICE BULLETIN STATES THAT THE WARRANTY COVERAGE FOR THE ISSUE (I.E., AIR BAG WARNING LAMP ILLUMINATION WITH FAULT CODE FOR HIGH RESISTANCE IN SIDE AIR BAG/SEAT BELT PRETENSIONER CIRCUIT) IS EXTENDED TO 10 YEARS OR 150,000 MILES, WHICHEVER OCCURS FIRST.BMW PLANS TO SEND LETTERS TO OWNERS DURING MARCH 2006.THE SUBJECT WIRE CRIMPS ARE LOCATED UNDER THE FRONT SEATS AND ARE PART OF THE MAIN WIRING HARNESS THAT INTERFACE WITH THE UNDER-SEAT WIRING HARNESS CONNECTORS FOR SIDE AIR BAG AND SEAT BELT PRETENSIONER MODULES.BMW STATED THAT, ALTHOUGH THE SUBJECT CRIMPS WERE IMPROPERLY MANUFACTURED, THE CRIMP CONNECTION IS STILL SUFFICIENT FOR THE RESTRAINT SYSTEM TO DEPLOY WHEN NEEDED.ACCORDING TO BMW, THE ELECTRICAL RESISTANCE LEVELS IN THE SUBJECT VEHICLES CAN EXCEED THE THRESHOLD THAT ILLUMINATES THE AIR BAG WARNING LAMP, BUT THEY DO NOT EXCEED A MUCH HIGHER LIMIT IN WHICH DEPLOYMENT OF THE RESTRAINTS MAY NO LONGER OCCUR.ODI BELIEVES THAT THERE IS LACK OF EVIDENCE AT THIS TIME TO CONCLUDE THAT THE RESTRAINT SYSTEMS MAY NOT DEPLOY WITH THE HIGH RESISTANCE CONDITION.THE AGENCY BELIEVES THAT FURTHER EXPENDITURE OF AGENCY RESOURCES DOES NOT APPEAR TO BE WARRANTED AT THIS TIME.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT NO SAFETY-RELATED DEFECT EXISTS.THE AGENCY WILL MONITOR THE ISSUE AND RESERVES THE RIGHT TO TAKE FUTURE ACTION IF WARRANTED BY THE CIRCUMSTANCES.
Air Bags:side/window
IN MARCH 2006, BMW REISSUED A SERVICE BULLETIN FIRST ISSUED IN SEPTEMBER 2003, TO MINI DEALERS REGARDING THE REPAIR PROCEDURE FOR IMPROPER WIRE CRIMPS IN APPROXIMATELY 31,500 MODEL YEAR 2002 AND 2003 MINI COOPER VEHICLES PRODUCED UP TO JANUARY 2003.THE NEW SERVICE BULLETIN STATES THAT THE WARRANTY COVERAGE FOR THE ISSUE (I.E., AIR BAG WARNING LAMP ILLUMINATION WITH FAULT CODE FOR HIGH RESISTANCE IN SIDE AIR BAG/SEAT BELT PRETENSIONER CIRCUIT) IS EXTENDED TO 10 YEARS OR 150,000 MILES, WHICHEVER OCCURS FIRST.BMW PLANS TO SEND LETTERS TO OWNERS DURING MARCH 2006.THE SUBJECT WIRE CRIMPS ARE LOCATED UNDER THE FRONT SEATS AND ARE PART OF THE MAIN WIRING HARNESS THAT INTERFACE WITH THE UNDER-SEAT WIRING HARNESS CONNECTORS FOR SIDE AIR BAG AND SEAT BELT PRETENSIONER MODULES.BMW STATED THAT, ALTHOUGH THE SUBJECT CRIMPS WERE IMPROPERLY MANUFACTURED, THE CRIMP CONNECTION IS STILL SUFFICIENT FOR THE RESTRAINT SYSTEM TO DEPLOY WHEN NEEDED.ACCORDING TO BMW, THE ELECTRICAL RESISTANCE LEVELS IN THE SUBJECT VEHICLES CAN EXCEED THE THRESHOLD THAT ILLUMINATES THE AIR BAG WARNING LAMP, BUT THEY DO NOT EXCEED A MUCH HIGHER LIMIT IN WHICH DEPLOYMENT OF THE RESTRAINTS MAY NO LONGER OCCUR.ODI BELIEVES THAT THERE IS LACK OF EVIDENCE AT THIS TIME TO CONCLUDE THAT THE RESTRAINT SYSTEMS MAY NOT DEPLOY WITH THE HIGH RESISTANCE CONDITION.THE AGENCY BELIEVES THAT FURTHER EXPENDITURE OF AGENCY RESOURCES DOES NOT APPEAR TO BE WARRANTED AT THIS TIME.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT NO SAFETY-RELATED DEFECT EXISTS.THE AGENCY WILL MONITOR THE ISSUE AND RESERVES THE RIGHT TO TAKE FUTURE ACTION IF WARRANTED BY THE CIRCUMSTANCES.
DP05006 · Air Bag Warning Lamp Illumination
Opened Sep 19, 2005 · Closed Oct 6, 2005
Status: closed (inferred from source dates) · Air Bags; Air Bags:side/window
ODI HAS GRANTED THE PETITION AND HAS OPENED A PRELIMINARY EVALUATION (PE05-053) ON ILLUMINATION OF AIR BAG WARNING LAMP ON MODEL YEAR 2002 AND 2003 MINI COOPER VEHICLES.
Additional source detail variants (2)
Air Bags
ODI HAS GRANTED THE PETITION AND HAS OPENED A PRELIMINARY EVALUATION (PE05-053) ON ILLUMINATION OF AIR BAG WARNING LAMP ON MODEL YEAR 2002 AND 2003 MINI COOPER VEHICLES.
Air Bags:side/window
ODI HAS GRANTED THE PETITION AND HAS OPENED A PRELIMINARY EVALUATION (PE05-053) ON ILLUMINATION OF AIR BAG WARNING LAMP ON MODEL YEAR 2002 AND 2003 MINI COOPER VEHICLES.