IllustrationTHE AIRBAG LIGHT IN THE VEHICLE GOES ON, AND THE DEALER TOLD ME THAT NOTHING WAS WRONG, NOW THE AIRBAG LIGHT IS CONSTANTLY ON. *TR
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
Air Bags complaints
26 reportsI JUST FOUND THIS WEB SITE AND AFTER READING THROUGH THE VARIOUS ISSUES OTHER PEOPLE ARE HAVING WITH THEIR MINI, I DECIDED I SHOULD ALSO GO AHEAD AND SHARE MY ISSUES AS WELL. BACK IN APRIL OF 2004, I WAS HIT ON THE FRONT PASSENGER SIDE BY A HONDA ACCORD TRAVELING ABOUT 50 MILES AN HOUR AND MY AIRBAGS FAILED TO DEPLOY. I NEVER …
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I JUST FOUND THIS WEB SITE AND AFTER READING THROUGH THE VARIOUS ISSUES OTHER PEOPLE ARE HAVING WITH THEIR MINI, I DECIDED I SHOULD ALSO GO AHEAD AND SHARE MY ISSUES AS WELL. BACK IN APRIL OF 2004, I WAS HIT ON THE FRONT PASSENGER SIDE BY A HONDA ACCORD TRAVELING ABOUT 50 MILES AN HOUR AND MY AIRBAGS FAILED TO DEPLOY. I NEVER HAD A CHECK ENGINE LIGHT OR AN AIRBAG LIGHT FOR THAT MATTER BUT IT'S A SCARY THOUGHT NOT HAVING YOUR AIRBAGS DEPLOY, ESPECIALLY AT SUCH A HIGH SPEED OF IMPACT. I USED TO BE IN LOVE WITH MINI'S BUT I HAVE BEEN SO "SOURED" BY THEM AS OF LATE WITH ALL OF THE ISSUES I HAVE BEEN HAVING. MY AUTOMATIC TRANSMISSION IS SHOT AND BECAUSE OF THAT, I CAN'T EVEN START MY CAR. *TR
AIR BAG LIGHT CAME ON AND STAYED ON. I TOOK IT TO THE DEALER, HE COULD NOT FIX THE PROBLEM. NOW I READ THAT THIS IS A COMMON PROBLEM WITH THE MINI. *TR
THIS IS A FOLLOW-ON TO INVESTIGATION PE05053 ORIGINALLY OPENED ON 09/27/2005. I TOO HAVE EXPERIENCED INTERMITTENT ILLUMINATION OF THE AIR BAG WARNING LAMP ON MY MY 2002 MINI COOPER. THE INCIDENTS OF INTERMITTENT AIRBAG WARNING LAMP ILLUMINATION STARTED ON 12 FEB 06 AND HAVE CONTINUED SINCE THAT TIME. THE LAMP ILLUMINATION IS …
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THIS IS A FOLLOW-ON TO INVESTIGATION PE05053 ORIGINALLY OPENED ON 09/27/2005. I TOO HAVE EXPERIENCED INTERMITTENT ILLUMINATION OF THE AIR BAG WARNING LAMP ON MY MY 2002 MINI COOPER. THE INCIDENTS OF INTERMITTENT AIRBAG WARNING LAMP ILLUMINATION STARTED ON 12 FEB 06 AND HAVE CONTINUED SINCE THAT TIME. THE LAMP ILLUMINATION IS INTERMITTENT AND NOT STEADY. SINCE I LIVE 220+ MILES FROM THE NEAREST BMW/MINI DEALER I HAVE NOT BROUGHT THE CAR IN FOR SERVICE OR FURTHER INVESTIGATION. NO CONSEQUENCES OTHER THAN THE MINOR ANNOYANCE OF THE ILLUMINATED LIGHT ON HAVE OCCURRED, ALTHOUGH I AM CONCERNED THAT ONE OR MORE AIRBAGS MAY NOT INFLATE IN CASE OF IMPACT OR CRASH. *JB
TWO-CAR CRASH AT AN INTERSECTION - AIRBAGS IN 2002 MINI COOPER S FAILED TO DEPLOY. CAR 1 (2002 MINI COOPER S) WAS DRIVING WEST ON TOTTEN POND RD. IN WALTHAM, MA AT APPROX. 30 MPH, APPROACHING GREEN LIGHT AT INTERSECTION OF TOTTEN POND RD/WINTER ST AND WYMAN ST. CAR 2 (2001 CHEVY VAN) WAS TRAVELING IN OPPOSITE DIRECTION ON SAME…
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TWO-CAR CRASH AT AN INTERSECTION - AIRBAGS IN 2002 MINI COOPER S FAILED TO DEPLOY. CAR 1 (2002 MINI COOPER S) WAS DRIVING WEST ON TOTTEN POND RD. IN WALTHAM, MA AT APPROX. 30 MPH, APPROACHING GREEN LIGHT AT INTERSECTION OF TOTTEN POND RD/WINTER ST AND WYMAN ST. CAR 2 (2001 CHEVY VAN) WAS TRAVELING IN OPPOSITE DIRECTION ON SAME ROAD (MPH UNKNOWN - APPROXIMATED AT 25 MPH) AND ATTEMPTED TO MAKE A LEFT HAND TURN ONTO WYMAN ST. IN FRONT OF CAR 1, STRIKING CAR 1 IN THE FRONT DRIVER'S SIDE QUARTER PANEL AND CAUSING DAMAGE TO ENTIRE DRIVER'S SIDE OF CAR1 (FRONT AND REAR QUARTER PANELS, DRIVER'S DOOR AND TIRES). I WAS THE OCCUPANT OF CAR 1 AND BECAUSE I WAS NOT WEARING A SET BELT, I WAS THROWN INTO THE DRIVER'S SIDE DOOR AND WINDOW, SHATTERING THE WINDOW COMPLETELY WITH MY HEAD AND WAS THEN THROWN INTO THE PASSENGER SEAT AFTER IMPACT. NONE OF THE SIX AIRBAGS IN THE 2002 MINI COOPER S DEPLOYED. AT A MINIMUM, FROM THE ANGLE OF THE ACCIDENT, THE DRIVER'S SIDE SEAT AIRBAG AND DRIVER'S SIDE CURTAIN AIRBAG SHOULD HAVE DEPLOYED FROM THE IMPACT. I WAS TRANSPORTED TO THE HOSPITAL BY AMBULANCE AND SUSTAINED MINOR HEAD INJURIES (MINOR CONCUSSION), MINOR CUTS TO MY HANDS AND BRUISING TO MY LEFT LEG. THE 2002 MINI COOPER S WAS UNDRIVEABLE AND WAS TOWED FROM THE SCENE OF THE CRASH. INSURANCE COMPANY CLAIM HAS BEEN FILED WITH MY INSURANCE COMPANY (LIBERTY MUTUAL) AND THE DRIVER OF CAR 2'S INSURANCE COMPANY (AMICA MUTUAL) WILL BE NOTIFIED. A POLICE REPORT IS ON FILE WITH THE WALTHAM POLICE DEPT. IN WALTHAM, MA. IT IS UNKNOWN WHAT WILL BE DONE TO CORRECT THE FAILURE, UNTIL THE INSURANCE CLAIM IS PROCESSED. *JB
AIRBAG LIGHT REMAINS LIT. WHILE STILL UNDER WARRANTY, I HAD THE DEALER (FLOW MINI, WINSTON-SALEM, NC) "RESET" IT ON AT LEAST TWO SEPARATE OCCASIONS. SERVICE EMPLOYEE TOLD ME THE LIT LIGHT WOULD NOT AFFECT AIRBAG DEPLOYMENT/SAFETY. WITHIN DAYS (MILES) OF "RESETTING" IT, THE LIGHT COMES BACK ON AND WILL NOT GO OFF WITHOUT TAKING I…
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AIRBAG LIGHT REMAINS LIT. WHILE STILL UNDER WARRANTY, I HAD THE DEALER (FLOW MINI, WINSTON-SALEM, NC) "RESET" IT ON AT LEAST TWO SEPARATE OCCASIONS. SERVICE EMPLOYEE TOLD ME THE LIT LIGHT WOULD NOT AFFECT AIRBAG DEPLOYMENT/SAFETY. WITHIN DAYS (MILES) OF "RESETTING" IT, THE LIGHT COMES BACK ON AND WILL NOT GO OFF WITHOUT TAKING IT TO THE DEALER. *JB
2002 MINI COOPER S HAS HAD A SECOND AIRBAG SYSTEM FAILURE. WHEN ELECTRONICS ASSOCIATED WITH THE AIRBAG SYSTEM DETECT A FAILURE, THE AIRBAG SYSTEM IS DISABLED UNTIL TAKEN TO THE DEALER TO HAVE FIXED. LOOKING UNDER THE SEATS TO SEE WHAT THE ISSUE COULD BE, DISCOVERED THE "FIX" PERFORMED BY THE DEALER TO FIX THE PROBLEM THE FIRST…
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2002 MINI COOPER S HAS HAD A SECOND AIRBAG SYSTEM FAILURE. WHEN ELECTRONICS ASSOCIATED WITH THE AIRBAG SYSTEM DETECT A FAILURE, THE AIRBAG SYSTEM IS DISABLED UNTIL TAKEN TO THE DEALER TO HAVE FIXED. LOOKING UNDER THE SEATS TO SEE WHAT THE ISSUE COULD BE, DISCOVERED THE "FIX" PERFORMED BY THE DEALER TO FIX THE PROBLEM THE FIRST TIME THE PROBLEM OCCURRED. THE INTIAL FIX WAS TO COMPRESS THE PLUG TOGETHER WITH "WIRETIES" - NOT TO REPLACE THE PLUGS WITH A BETTER DESIGN. BOTH THE WORKMANSHIP OF THE REPAIR OF THE AIRBAG SYSTEM AND THE SYSTEM ITSELF ARE FAULTY.
THE AIR BAG SYSTEM WARNING LIGHT HAS BEEN ON 8 TIMES IN 3 YEARS OF OWNERSHIP. (THE INCIDENT DATE I REPORT BELOW IS SIMPLY THE MOST RECENT OCCURENCE) EACH TIME REQUIRES A TRIP TO THE DEALER TO RESET THE SYSTEM. WHEN THE WARNING LIGHT IS ON THE VEHICLE'S AIRBAG SYSTEM IS DE-CTIVATED, AND THEREFORE THE SYSTEM RESET IS AN URGENT S…
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THE AIR BAG SYSTEM WARNING LIGHT HAS BEEN ON 8 TIMES IN 3 YEARS OF OWNERSHIP. (THE INCIDENT DATE I REPORT BELOW IS SIMPLY THE MOST RECENT OCCURENCE) EACH TIME REQUIRES A TRIP TO THE DEALER TO RESET THE SYSTEM. WHEN THE WARNING LIGHT IS ON THE VEHICLE'S AIRBAG SYSTEM IS DE-CTIVATED, AND THEREFORE THE SYSTEM RESET IS AN URGENT SAFETY ISSUE. OVER THE COURSE OF 3 YEARS, THE DEALER HAS REPLACED NUMEROUS SENSORS, WIRING HARNESS PIECES, AND SEVERAL OF THE AIRBAG UNITS (ESP. THE SEAT AIRBAGS). THIS IS REPORTED TO BE ONE OF THE MOST COMMON MINI COOPER FAILURES AND HAS PLAGUED THESE CARS FOR ALL MODEL YEARS IN PRODUCTION. THIS IS AN URGENT SAFETY DEFECT AND IT IS IMPORTANT THAT THE NHSTA TAKE ACTION! (SORRY I DON'T KNOW MY VIN BY MEMORY AND CAN'T ACCESS MY REGISTRATION AT THE MOMENT...IF YOU REALLY NEED THIS, SIMPLY EMAIL ME AND I'LL GLADLY PROVIDE). *AK
2002 MINI COOPER [XXX]. CAR HAS BEEN TO THE DEALER AT LEAST FOUR TIMES TO ADDRESS THE AIR BAG LIGHT BEING LIT, IN 44,000 MILES. VARIOUS HARNESSES HAVE BEEN REPLACED THREE TIMES AND THE AIR BAG SENSOR ONCE. NOW, AT 44,500 MILES, THE AIR BAG LIGHT IS ON AGAIN FOR A FIFTH TIME. I'VE BEEN TOLD BY THE DEALER THE AIR BAGS WILL NOT…
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2002 MINI COOPER [XXX]. CAR HAS BEEN TO THE DEALER AT LEAST FOUR TIMES TO ADDRESS THE AIR BAG LIGHT BEING LIT, IN 44,000 MILES. VARIOUS HARNESSES HAVE BEEN REPLACED THREE TIMES AND THE AIR BAG SENSOR ONCE. NOW, AT 44,500 MILES, THE AIR BAG LIGHT IS ON AGAIN FOR A FIFTH TIME. I'VE BEEN TOLD BY THE DEALER THE AIR BAGS WILL NOT FUNCTION WITH THE LIGHT LIT. I SUGGEST THAT MINIUSA BE FORCED TO ISSUE A RECALL ON THIS VEHICLE TO CORRECT THE PROBLEM ONCE AND FOR ALL AS IT IS A MAJOR SAFETY CONCERN WHICH THEY DO NOT APPEAR TO HAVE FULLY ISOLATED.*AK *JS INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)
AIR BAG FAILURE LIGHT. 2ND TIME IN 2 YEARS. WIRING HARNESS CONNECTOR SEPARATED WHEN THE DRIVER SIDE SEAT MOVES ALL THE WAY BACKWARD. DEALER INSTALLED LONGER HARNESS.
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.