NHTSA owner reports · September 18, 2026 snapshot.
Electrical System complaints
26 reportsClear category filter115,000 miles · Dec 12, 2012
Electrical SystemSteeringFire
I PARKED MY CAR IN A PARKING GARAGE AFTER DRIVING APPROXIMATELY 20 MILES. I WALKED TO A DENTIST DOWN THE STREET FOR AN APPOINTMENT. WHILE AT THE DENTIST I GET A CALL THAT WENT TO MY VOICEMAIL THAT MY CAR (WHILE PARKED WITH THE ENGINE OFF) WAS ON FIRE AND WAS FILLING THE PARKING GARAGE WITH SMOKE. UPON RECEIVING THE MESSAGE I RUS…
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I PARKED MY CAR IN A PARKING GARAGE AFTER DRIVING APPROXIMATELY 20 MILES. I WALKED TO A DENTIST DOWN THE STREET FOR AN APPOINTMENT. WHILE AT THE DENTIST I GET A CALL THAT WENT TO MY VOICEMAIL THAT MY CAR (WHILE PARKED WITH THE ENGINE OFF) WAS ON FIRE AND WAS FILLING THE PARKING GARAGE WITH SMOKE. UPON RECEIVING THE MESSAGE I RUSHED HOME TO FIND THAT THE FIRE WAS ALREADY OUT, BUT THE SMELL OF SMOKE WAS STILL VERY STRONG. I NOTICED THAT THE INSIDE INDICATING LIGHTS OF THE CAR WERE ON AS IF THE KEY WAS IN THE IGNITION OF THE CAR. I IMMEDIATELY DISCONNECTED THE BATTERY AND INSPECTED THE CAR TO FIND THE SOURCE OF THE FIRE. UPON INSPECTION I FOUND THAT THE FLAMES HAD COME FROM BEHIND AND SLIGHTLY BELOW THE MOTOR. THERE WAS A METAL SHIELD THAT WAS BLACKENED BY THE FLAMES THAT I COULD NOT SEE AROUND SO I JACKED UP THE CAR AND REMOVED THE DRIVER SIDE WHEEL TO FURTHER INSPECT THE SOURCE OF THE FIRE. AFTER DOING SO I COULD THEN CLEARLY SEE THAT THE SOURCE OF THE FIRE WAS THE POWER STEERING PUMP DUE TO THE SURROUNDING BURN MARKS. THE TOTAL AMOUNT OF DAMAGE HAS YET TO BE ASSESSED BY MY INSURANCE COMPANY. THEY TOWED THE CAR AND ARE INSPECTING THE CAR ON DEC 13, 2012. *TR
NHTSA ODI #10488125
74,100 miles · Jun 29, 2012
Electrical SystemSteering
WHILE I WAS DRIVING MINI 2003 (ODO: 74K) ON I-90 HIGHWAY AT 70MPH, SUDDENLY THE POWER STEERING WHEEL STOPPED WORKING ON JUNE 28, 2012. I BARELY MADE TO EXIT FROM THE HIGHWAY, AND GOT HOME. NEXT DAY, THE CAR WAS SENT TO THE BMW-MINI DEALERSHIP, AND ASSESSED THE FAILURE OF POWER STEERING PUMP. THEY KNOW THIS HAPPENS FREQUENTLY …
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WHILE I WAS DRIVING MINI 2003 (ODO: 74K) ON I-90 HIGHWAY AT 70MPH, SUDDENLY THE POWER STEERING WHEEL STOPPED WORKING ON JUNE 28, 2012. I BARELY MADE TO EXIT FROM THE HIGHWAY, AND GOT HOME. NEXT DAY, THE CAR WAS SENT TO THE BMW-MINI DEALERSHIP, AND ASSESSED THE FAILURE OF POWER STEERING PUMP. THEY KNOW THIS HAPPENS FREQUENTLY WITH MINI, BUT IT WAS NOT COVERED BY MANUFACTURERS. THE ONLY OPTION WAS TO REPLACE THE PART. THE PART WAS REPLACED AND THE COST WAS $1,200. *TR
NHTSA ODI #10463634
83,567 miles · Apr 11, 2012
Electrical SystemSteeringFire
MY 2003 MINI COOPER (R50), WITH MANUAL SHIFT AND 83,567 MILES, WAS PARKED ON A CITY STREET WHEN A PASSERBY NOTICED SMOKE AND FIRE COMING OUT OF THE ENGINE AREA. THE FIRE DEPARTMENT WAS CALLED TO PUT THE FIRE OUT. THE TIME FROM THE CAR BEING PARKED UNTIL THE FLAMES WERE EXTINGUISHED IS ESTIMATED AT 10 TO 20 MINUTES. THE CAR WAS T…
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MY 2003 MINI COOPER (R50), WITH MANUAL SHIFT AND 83,567 MILES, WAS PARKED ON A CITY STREET WHEN A PASSERBY NOTICED SMOKE AND FIRE COMING OUT OF THE ENGINE AREA. THE FIRE DEPARTMENT WAS CALLED TO PUT THE FIRE OUT. THE TIME FROM THE CAR BEING PARKED UNTIL THE FLAMES WERE EXTINGUISHED IS ESTIMATED AT 10 TO 20 MINUTES. THE CAR WAS TOWED THE FOLLOWING MORNING TO A MINI DEALER SERVICE CENTER FOR DIAGNOSIS. THE DIAGNOSIS WAS THAT THE AUXILIARY POWER STEERING COOLING FAN HAD FAILED. THE OTHER ITEMS THAT ARE ESTIMATED TO NEED REPLACEMENT ARE THE POWER STEERING PUMP, ENGINE WIRING HARNESS, AUXILIARY WIRING HARNESS, POWER STEERING PUMP RESERVOIR HOSE AND POWER STEERING RETURN HOSE. AT THE TIME I WAS ON A TRIP OUT-OF-TOWN 600 MILES AWAY FROM HOME AND THE CAR IS STILL AT THE OUT-OF-TOWN DEALER. PRIOR TO THE INCIDENT NO SIGNS OF ANYTHING SUSPECT WITH THE CAR WERE NOTICED. APPROXIMATELY 1 HOUR PRIOR TO THE INCIDENT THE BONNET OF THE CAR WAS OPENED AT A MILITARY ENTRANCE GATE VEHICLE INSPECTION AND NO SIGNS OF ANY ISSUES WERE NOTICED AT THAT TIME. TO MY KNOWLEDGE THERE IS NO AFTERMARKET EQUIPMENT IN THE AFFECTED AREA. I AM THE 2ND OWNER OF THE CAR HAVING PURCHASED IT AT 35,086 MILES MID-2007 FROM A LONG-TIME FRIEND WHO WAS THE FIRST OWNER. I MAINTAIN THE CAR AND KEEP ALL MAINTENANCE RECORDS. I BELIEVE THE MANUFACTURER SHOULD BE RESPONSIBLE FOR ALL REPAIRS AND THE RETURN OF THE CAR TO MY HOME. I HAVE READ ABOUT RECALLS BY TRANSPORT CANADA FOR 2002-2005 MINI STEERING PUMPS WHICH WOULD INDICATE THIS ISSUE IS WORTHY OF INVESTIGATION FOR RECALL. THIS IS A DANGEROUS VEHICLE DEFECT. PLEASE FORMALLY INVESTIGATE THIS INCIDENT. *TR
NHTSA ODI #10454920
90,000 miles · Mar 7, 2012
Electrical SystemCrashFireInjury
CAR IMPACTED THE REAR END OF A JEEP AT LOW RATE OF SPEED (WAS BRAKING TO AVOID CRASH IN THE FRONT). UPON IMPACT THE CAR BURST INTO FLAMES. THE AIR BAG DEPLOYED. LUCKILY THE OCCUPANT OF THE VEHICLE WAS ABLE TO GET OUT OF CAR. WITHIN MINUTES THE CAR WAS TOTALLY IN FLAMES. NO ONE WAS KILLED OR SERIOUSLY INJURED BUT IF THE OCCUPANT …
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CAR IMPACTED THE REAR END OF A JEEP AT LOW RATE OF SPEED (WAS BRAKING TO AVOID CRASH IN THE FRONT). UPON IMPACT THE CAR BURST INTO FLAMES. THE AIR BAG DEPLOYED. LUCKILY THE OCCUPANT OF THE VEHICLE WAS ABLE TO GET OUT OF CAR. WITHIN MINUTES THE CAR WAS TOTALLY IN FLAMES. NO ONE WAS KILLED OR SERIOUSLY INJURED BUT IF THE OCCUPANT DID NOT GET OUT WHEN THEY DID THE OCCUPANT WOULD HAVE DIED DUE TO SMOKE OR FLAME INJURY.MY COMPLAINT IS THAT THIS LOW FRONT END IMPACT SHOULD NOT HAVE RESULTED IN IMMEDIATE FIRE AND LARGE FLAMES. I HAVE PHOTOS OF THE CAR JUST AFTER THE OCCUPANT GOT OUT OF THE VEHICLE AND ALSO PHOTOS OF THE CAR AFTER IT WAS TOWED BACK TO WRECKER YARD. *TR
NHTSA ODI #10450588
Mileage unknown · Feb 1, 2012
Air BagsElectrical System
BEGINNING IN APPROXIMATELY APRIL OF 2009, THE AIRBAG WARNING LIGHT HAS BEEN ON CONSTANTLY. ANYONE WHO IS INTELLIGENT ENOUGH TO USE ANY INTERNET SEARCH ENGINE CAN FIND HUNDREDS OF ACCOUNTS OF THE SAME ISSUE. DUE TO WHAT HAS BEEN INDEPENDENTLY VERIFIED AS A WIRING PROBLEM IN THE SEAT SENSORS, THE AIRBAG WARNING LIGHT IS ALWAYS O…
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BEGINNING IN APPROXIMATELY APRIL OF 2009, THE AIRBAG WARNING LIGHT HAS BEEN ON CONSTANTLY. ANYONE WHO IS INTELLIGENT ENOUGH TO USE ANY INTERNET SEARCH ENGINE CAN FIND HUNDREDS OF ACCOUNTS OF THE SAME ISSUE. DUE TO WHAT HAS BEEN INDEPENDENTLY VERIFIED AS A WIRING PROBLEM IN THE SEAT SENSORS, THE AIRBAG WARNING LIGHT IS ALWAYS ON AND CAN CAUSE THE CAR TO DEPLOY WITH IMPROPER FORCE. THIS IS A WIDELY KNOWN ISSUE WITH MINI OWNERS, AND SEVERAL INDEPENDENT MECHANICS HAVE ALL ATTRIBUTED THE PROBLEM TO A WIRING HARNESS UNDERNEATH THE SEAT THAT BREAKS DUE TO MOVING THE SEAT BACK AND FORTH. UNLESS I'M MISSING PAGES FROM THE MANUAL, MOVING THE SEAT BACK AND FORTH IS A NORMAL FUNCTION, AND IT SHOULD NOT BE CONSIDERED NORMAL WEAR AND TEAR IF SIMPLY MOVING THE SEAT BACK AND FORTH CAN RENDER THE AIRBAG SENSOR USELESS. MINI ACKNOWLEDGED THIS ISSUE IN 2006, AND STATED 'IN THE INTEREST OF CUSTOMER SATISFACTION, WE ARE EXTENDING THE WARRANTY COVERAGE OF THE VEHICLE FOR DEFECTS THAT MAY OCCUR, FOR THIS SPECIFIC AIR BAG WARNING LAMP ISSUE, ON YOUR VEHICLE FOR 10 YEARS / 150,000 MILES, WHICHEVER OCCURS FIRST. UNDER TERMS OF THIS WARRANTY COVERAGE, MINI WILL COVER ALL NECESSARY REPAIR COSTS RELATED TO THIS ACTION.' I HAVE BEEN TOLD THREE TIMES BY MINI THAT THIS DOES NOT APPLY TO MY CAR. THEY CANNOT PROVIDE ANY INFORMATION AS TO WHY IT DOES NOT APPLY. THEY JUST TELL ME THAT MY CAR IS NOT ELIGIBLE FOR THIS REPAIR DESPITE THE FACT THAT IT CLEARLY FITS THE BILL. THIS IS A MAJOR SAFETY ISSUE. THE WIRING IS CLEARLY DEFECTIVE, AND NOBODY SHOULD HAVE TO PAY OUT OF POCKET TO HAVE A DEFECT CORRECTED. MINI WON'T EVEN PAY TO HAVE A TECHNICIAN DIAGNOSE THE ISSUE. *TR
NHTSA ODI #10446200
121,000 miles · Nov 16, 2011
Electrical SystemSeats
UPON TURNING ON MY DRIVER'S SIDE HEATED SEAT, ONE PART OF MY BACK SEEMED TO BE GETTING EXTREMELY HOT. UPON TURNING AROUND, I SAW A SMALL HOLE HAD BEEN BURNED IN THE SEAT COVER AND WAS SMOLDERING AND SMOKING. I IMMEDIATELY TURNED OFF THE SEAT WARMER. IT TOOK MANY MINUTES TO COOL DOWN AND STOP SMOKING. THANKFULLY THE VEHICLE W…
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UPON TURNING ON MY DRIVER'S SIDE HEATED SEAT, ONE PART OF MY BACK SEEMED TO BE GETTING EXTREMELY HOT. UPON TURNING AROUND, I SAW A SMALL HOLE HAD BEEN BURNED IN THE SEAT COVER AND WAS SMOLDERING AND SMOKING. I IMMEDIATELY TURNED OFF THE SEAT WARMER. IT TOOK MANY MINUTES TO COOL DOWN AND STOP SMOKING. THANKFULLY THE VEHICLE WAS STATIONARY WHEN THIS HAPPENED. IF IT HAD BEEN IN MOTION, MY SAFETY WOULD CERTAINLY HAVE BEEN COMPRISED, AS I COULD HAVE SUSTAINED BURNS BEFORE PULLING THE CAR TO THE SIDE OF THE ROAD. THE DISTRACTION OF A BURNING SEAT IS ALSO NOT AN INSIGNIFICANT SAFETY HAZARD AS WELL. *TR
NHTSA ODI #10436074
48,000 miles · Nov 23, 2010
Electrical SystemEngine And Engine CoolingLatches/locks/linkages
MY 2003 MINI COOPER HAS ALMOST CAUGHT ON FIRE SEVERAL TIMES, REPLACED TRANSMISSION, ELECTRICAL HARNESS, POWER STEERING PUMP, A/C HOSES AND A/C SERVICE, WHEEL BEARINGS, INJECTION PLUGS ETC....... I STILL CANNOT FIND THE REAL PROBLEM WHY IS CAUSING A SHORT, IT HAS ALMOST CAUGHT ON FIRE SEVERAL TIMES, THIS CAR HAS BEEN THE MOST DAN…
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MY 2003 MINI COOPER HAS ALMOST CAUGHT ON FIRE SEVERAL TIMES, REPLACED TRANSMISSION, ELECTRICAL HARNESS, POWER STEERING PUMP, A/C HOSES AND A/C SERVICE, WHEEL BEARINGS, INJECTION PLUGS ETC....... I STILL CANNOT FIND THE REAL PROBLEM WHY IS CAUSING A SHORT, IT HAS ALMOST CAUGHT ON FIRE SEVERAL TIMES, THIS CAR HAS BEEN THE MOST DANGEROUS CAR I HAVE EVER OWN, I HAVE NEVER SPEND SO MUCH MONEY ON TRYING TO FIX ANY VEHICLE, RIGHT NOW I'M ABOUT $11,500 IN COSTS OF REPAIRS, THIS IS A CRIME TO THE CONSUMER, I HAVE BEEN READING ABOUT A CLASS ACTION LAWSUIT THAT IS IN PROGRESS, I HOPE AND PRAY THAT WE GET JUSTICE FROM THE MAKER OF MINI. *TR
NHTSA ODI #10367312
60,500 miles · Apr 3, 2009
Electrical SystemSteeringFire
SPONTANEOUS ENGINE BAY FIRE IN 2003 MINI COOPER WITH 60,000 MILES. VEHICLE WAS DRIVEN NORMALLY TO WORK, TURNED OFF, PARKED, LOCKED AND LEFT. UNATTENDED CAR CAUGHT FIRE SEVERAL MINUTES LATER. SEATTLE CITY FIRE DEPARTMENT RESPONDED TO EMERGENCY CALL, BUT FIRE SELF-EXTINGUISHED WITHIN 10 MINUTES. SOOT COVERED ENGINE BAY AND ACRID S…
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SPONTANEOUS ENGINE BAY FIRE IN 2003 MINI COOPER WITH 60,000 MILES. VEHICLE WAS DRIVEN NORMALLY TO WORK, TURNED OFF, PARKED, LOCKED AND LEFT. UNATTENDED CAR CAUGHT FIRE SEVERAL MINUTES LATER. SEATTLE CITY FIRE DEPARTMENT RESPONDED TO EMERGENCY CALL, BUT FIRE SELF-EXTINGUISHED WITHIN 10 MINUTES. SOOT COVERED ENGINE BAY AND ACRID SMOKE PERMEATED VEHICLE. INSPECTION REVEALED MELTED CONNECTION BETWEEN WIRING HARNESS AND POWER STEERING PUMP, REQUIRING REPLACEMENT OF PUMP, COOLING FAN, WIRING AND OTHER PARTS. INTERNET COMMUNITIES OF MINI OWNERS CONTAIN NUMEROUS REPORTS OF SUDDEN ENGINE BAY FIRES IN 2002 AND 2003 MINI COOPERS CAUSED BY ELECTRICAL SHORTS LINKED TO FAULTY POWER STEERING PUMPS OR FANS. FREQUENTLY THESE FIRES OCCUR AFTER THE CAR HAS BEEN SWITCHED OFF. THEY ALWAYS RESULT IN MODERATE VEHICLE DAMAGE AND MAJOR REPAIR COSTS (MINE IS ESTIMATED @ $1,600). OCCASIONALLY THEY RESULT IN TOTAL VEHICLE LOSS AND / OR ADDITIONAL PROPERTY DAMAGE. HAD THIS FIRE OCCURRED IN MY HOME GARAGE AT NIGHT THE RESULTS COULD HAVE BEEN CATASTROPHIC; IF THIS KIND OF INCIDENT (SUDDEN POWER STEERING PUMP FAILURE + ELECTRIC FIRE) WERE TO OCCUR ON A FREEWAY AT SPEED IT COULD EASILY RESULT IN FATALITIES. BMW / MINI USA HAS REPORTEDLY QUIETLY REIMBURSED INDIVIDUAL OWNERS WHO HAVE SUFFERED SPONTANEOUS FIRES, BUT HAS NOT ACKNOWLEDGED THE WIDESPREAD NATURE OF THE PROBLEM -- WHICH IS RIDICULOUS. AS I DISCOVERED WHILE RESEARCHING MY INCIDENT, IF YOU GOOGLE "MINI COOPER FIRE" OR "MINI POWER STEERING PUMP FAILURE" YOU GET A RASH OF THESE REPORTS. APPARENTLY NHTSA INVESTIGATED MINI ENGINE BAY FIRES IN 2006-2008 AND DISMISSED THE PROBLEM, ALLUDING ONLY TO THE CHANCE OF SOME "LOCALIZED SMOLDERING." THIS IS IRRESPONSIBLE -- MY MINI WAS BILLOWING ACRID BLACK SMOKE AND COULD EASILY HAVE BURNED OUT, TAKING OTHER CARS ON THE PARKING DECK WITH IT. SHOCKING THAT THIS MAJOR, DANGEROUS VEHICLE DEFECT HAS BEEN IGNORED. I AM ONE OF MANY VICTIMS. PLEASE REOPEN THIS INVESTIGATION INTO MINI FIRES. THANK YOU. *TR
NHTSA ODI #10264037
68,500 miles · Dec 1, 2008
Electrical System
BATTERY FAILURE. BATTERY HAS FAILED FOR THE THIRD TIME SINCE CAR BRAND NEW IN FEB, 2003. ON EACH OCCASION THE VEHICLE WOULD NOT START AFTER HAVING GIVEN NO WARNING. THE FIRST FAILURE WAS IN 2005 AT 26,000 MI., THE SECOND IN 2007 AT 51,000 MI., THE THIRD IN 2008 AT 68,000 MI. EACH FAILED BATTERY WAS A MANUFACTURER'S BRAND (MI…
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BATTERY FAILURE. BATTERY HAS FAILED FOR THE THIRD TIME SINCE CAR BRAND NEW IN FEB, 2003. ON EACH OCCASION THE VEHICLE WOULD NOT START AFTER HAVING GIVEN NO WARNING. THE FIRST FAILURE WAS IN 2005 AT 26,000 MI., THE SECOND IN 2007 AT 51,000 MI., THE THIRD IN 2008 AT 68,000 MI. EACH FAILED BATTERY WAS A MANUFACTURER'S BRAND (MINI). *TR
NHTSA ODI #10250256
60,000 miles · Jul 29, 2008
Electrical System
I WAS DRIVING HOME ONE DAY WHEN SEVERAL LIGHTS LIT UP IN MY CAR. I WAS SCARED BECAUSE THESE LIGHTS WERE: LOW TIRE PRESSURE, LOW BRAKE PADS, TRACTION CONTROL LIGHT, & ABS BREAK LIGHT. I PULLED OVER AND SHUT OFF THE CAR, AND WHEN I TURNED IT BACK ON, THEY STILL WERE LIT UP. I AM NOT SURE WHAT CAUSED THIS AS I WASN'T DRIVING ERRATI…
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I WAS DRIVING HOME ONE DAY WHEN SEVERAL LIGHTS LIT UP IN MY CAR. I WAS SCARED BECAUSE THESE LIGHTS WERE: LOW TIRE PRESSURE, LOW BRAKE PADS, TRACTION CONTROL LIGHT, & ABS BREAK LIGHT. I PULLED OVER AND SHUT OFF THE CAR, AND WHEN I TURNED IT BACK ON, THEY STILL WERE LIT UP. I AM NOT SURE WHAT CAUSED THIS AS I WASN'T DRIVING ERRATICALLY, JUST NORMAL. I STILL DO NOT KNOW WHY EXACTLY THEY ARE ON, HOWEVER I FIGURE IT IS SOMETHING TO DO WITH THE COMPUTER. *TR
NHTSA ODI #10236313
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.
Illustration