2003 MINI Cooper S

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

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.

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.

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.

The contact owns a 2003 Mini Cooper S equipped with Falken Tires, Tire Line: Sincera SN250 A/S, Tire Size: 235/45R17, DOT Number: FMHR3120. The contact stated that while washing the vehicle, he noticed that a bubble had developed on the front driver’s side tire. The contact was concerned for his safety while driving the vehicle. The contact stated that he rotated the tire to the rear driver’s side but was concerned and uncertain if the bubble might cause a risk to his safety while driving. The vehicle had not yet been diagnosed. The vehicle was not repaired. Neither the dealer nor the manufacturer was notified of the failure. The failure mileage was approximately 101,000.

NHTSA ID

11541298

Incident

Aug 25, 2023

Mileage

101,000 mi

I WAS STARTING MY VEHICLE AND IT MADE A BAD KNOCKING NOISE THEN IT WAS LIKE CRUNCHING NOISE SO I STOPPED TURN IT OFF AND WAITED FOR A WHILE WENT BACK TO THE CAR STILL MAKING A STRANGE NOISE BUT ONCE I PUT IT IN THE DRIVE IT STOPPED MAKING NOISE DROVE DOWN THE ROAD A BIT AND TALKING ABOUT APPARENTLY SLIPS OFF OF THE CAR SO IT JUST PULLS OVER INSIDE ALL THE ALL THE WEARING LIGHTS CAME ON SO PULLED OVER APPARENTLY THIS HAPPENS QUITE OFTEN BUT THE HARMONIC BALANCER SEPARATED AND WITH SPINNING AGAINST ITSELF AND KNOCKED THE PIECES OFF OF IT AND THROUGH THE SERPENTINE BELT SO THAT NEEDS TO REPLACE NOW THAT SHOULD NOT HAPPEN IT'S ONE PIECE IS THIS ONE PIECE THIS NEEDS TO BE RECALLED FOR THESE WHATEVER CARS HAD THESE HARMONIC BALANCERS IS DANGEROUS AND IT COULD BLOW YOUR CAR UP THANK YOU

NHTSA ID

11362320

Incident

Jul 1, 2020

Mileage

140,000 mi

TL* THE CONTACT OWNS A 2003 MINI COOPER S. THE CONTACT STATED THAT ON THREE OCCASIONS, THE MAT OCCUPANCY SENSOR ON THE FRONT PASSENGER'S SEAT WAS REPLACED DUE TO THE WARNING LIGHT BEING ILLUMINATED. THE VEHICLE WAS TAKEN TO MINI OF BIRMINGHAM LOCATED AT 2001 TOM WILLIAMS WAY, BIRMINGHAM, AL 35210, 205-267-4505. THE CONTACT WAS INFORMED THAT THE MAT SENSOR NEEDED TO BE REPLACED AT A COST OF $1,200. THE CONTACT WAS ALSO INFORMED THAT THE PART MAY ALSO BE AVAILABLE AT THE LOCAL JUNKYARD. THE MAT SENSOR WAS REPLACED HOWEVER, THE FAILURE RECURRED. THE CONTACT WAS INFORMED THAT THE SEAT SHOULD BE REPLACED WHICH WAS STILL PENDING. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 79,000.

NHTSA ID

11319813

Incident

Mar 1, 2005

Mileage

79,000 mi

WE KNOW OF TWICE THAT OUR CAR'S POWER STEERING PUMP FAILED WHILE IN MOTION. AFTER BMW WAS FINALLY FORCED INTO A RECALL FOR THE POWER STEERING PUMP FAILURE AND WE RECEIVED A NOTIFICATION, WE TOOK OUR CAR TO CENTURY BMW IN GREENVILLE, SC. THE SERVICE DEPARTMENT CHECKED OUR WORK REGARDING REPLACEMENT PUMP, FAN, ETC. AND DEEMED IT 100% SATISFACTORY. WE SUBMITTED THE PAPERWORK AND INVOICE FOR THE REPAIR AND WAITED (REQUESTED . AFTER 16 WEEKS AND NO REIMBURSEMENT OR NOTIFICATION, WE CALLED AND WAS INFORMED BY THE SERVICE DEPARTMENT MANAGER THAT BMW WOULDN'T PAY US ANYTHING BECAUSE WE DIDN'T USE OEM PARTS. WHY WOULD WE KEEP REPLACING THE PUMP (THIS WAS THE 3RD PUMP THAT WE KNOW OF) WITH A DEFECTIVE ONE (BY ZF) THAT KEPT QUITTING? WE REPLACED IT WITH DORMAN (WELL-KNOWN MANUFACTURER OF QUALITY PARTS) WHICH HAD A LIFE-TIME WARRANTY (LIFE-TIME!) AND WAS MUCH CHEAPER. THE SD MANAGER EVEN SAID THAT SINCE HE'D SEEN SO MANY REPAIRS USING THAT BRAND OF POWER STEERING PUMP HE HAD RESEARCHED THEM AND FOUND NOTHING WRONG WITH THEM. BUT BMW DECIDED THEY WOULDN'T PAY FOR THIS. THERE WAS NOTHING IN THE RECALL LETTER THAT SAID OEM HAD TO BE USED OR THEY WOULDN'T REIMBURSE FOR REPAIRS. I BELIEVE BMW SAW SO MANY DORMAN PUMPS USED THEY KNEW THEY COULD SAVE A LOT OF MONEY BY REFUSING TO PAY. WE FILED A COMPLAINT WITH THE SC DEPT. OF CONSUMER AFFAIRS BUT BMW WOULDN'T ANSWER THEM SO THEY JUST DROPPED IT, LETTING BMW GET BY WITH THIS. WE WERE ONLY REQUESTING $721.04 WHICH IS LESS THAN HALF OF WHAT A REPAIR SHOP WOULD HAVE CHARGED. CAN YOU DO ANYTHING ABOUT THIS? WE FILED THE COMPLAINT WITH SC CONSUMER AFFAIRS IN DECEMBER OF 2017, TOOK THE CAR TO BMW IN MAY OF 2017 SO THIS HAS BEEN GOING ON FOR A WHILE. HAVE OTHER OWNERS HAD THIS PROBLEM? HAS A LAWSUIT BEEN STARTED AGAINST BMW?

NHTSA ID

11290482

Incident

Dec 13, 2017

Mileage

150,000 mi

POWER STEERING PUMP FAILED WHILE DRIVING

NHTSA ID

11235343

Incident

Feb 20, 2019

Mileage

115,000 mi

OCCASIONALLY THE STEERING OVER MY MINI COOPER S IS BECOMING VERY HARD. IT SEEMS LIKE THE POWER STEERING IS FAILING. THE CAR THEN CAN ONLY BE STEERED WITH A LOT OF DIFFICULTY. I CAN NO LONGER RISK TO HAVE MY DAUGHTER OR WIFE DRIVE THIS CAR. I CHECKED THE STEERING FLUID AND IT IS AT OPTIMAL LEVELS. IT USUALLY HAPPENS AT LOWER SPEED, BUT I HAVE NOT DRIVEN IT ON THE FREEWAY SINCE THIS ISSUE STARTED TO APPEAR.

NHTSA ID

11190112

Incident

Mar 8, 2019

Mileage

82,790 mi

TL* THE CONTACT OWNS A 2003 MINI COOPER S. THE CONTACT NOTICED FUEL LEAKING UNDERNEATH THE VEHICLE. THE CONTACT CHECKED UNDER THE HOOD AND DISCOVERED THAT THE FUEL FILTER HAD A LEAK. THE VEHICLE WAS TOWED TO THE CONTACT'S RESIDENCE. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED. THE VIN WAS NOT PROVIDED. THE FAILURE MILEAGE WAS APPROXIMATELY 130,000.

NHTSA ID

11096780

Incident

May 17, 2018

Mileage

130,000 mi

AFTER BATTERY WENT DEAD, REPLACED WITH NEW BATTERY AND SHORTLY AFTER AIR BAG LIGHT ILLUMINATED. HAD INDEPENDENT SHOP CLEAR CODE IN 2015 INSPECTED HARNESS FOUND NOTHING OUT OF ORDINARY. 3 DAYS LATER AIR BAG LIGHT RETURNED. NOW IN FEBRUARY 2018 HAD MINI OF TOWSON DIAGNOSE AIR BAG LIGHT THINKING THE DEALERSHIP CAN RESET AIR BAG LIGHT PROPERLY. DEALERSHIP RECOMMENDED UPGRADING WIRING HARNESS UNDER SEAT FOR 525 DOLLARS. I HAVE BEEN ON MULTIPLE FORUMS AND THIS AIR BAG LIGHT IS A COMMON PROBLEM FOR 02-03 MINIS, INCLUDING 05-06, AND 12-15 YEAR MINIS. MY CONCERN IS THAT MINI KNOWS THIS IS A DEFECTIVE PART FROM THE MANUFACTURER BUT REFUSES TO STAND BY THEIR PRODUCT EVEN WHEN IT COULD AFFECT THE SAFETY OF THE PURCHASER OF ITS VEHICLES. IN THE EVENT NHTSA RECEIVES ENOUGH COMPLAINTS TO FORCE MINI TO ISSUE A RECALL FOR THIS ISSUE, I WOULD LIKE TO BE INCLUDED AS ANOTHER DISSATISFIED CONSUMER. THANK YOU FOR YOUR TIME, GARRETT

NHTSA ID

11067115

Incident

May 15, 2015

Mileage

48,000 mi

Programming a Replacement EGS Module with ISTA/P. Programming a replacement electronic transmission control module (EGS) with ISTA/P requires the manual entry of the correct target basic and programmed part numbers. Programming concept.

NAVIGATION SYSTEM HAS MISSING OR INCORRECT ROAD MAP DATA: The route guidance is inaccurate and therefore irritating to the customer; or it is not possible to locate certain addresses, for instance:

NAVIGATION SYSTEM HAS MISSING OR INCORRECT ROAD MAP DATA: The route guidance is inaccurate and therefore irritating to the customer; or it is not possible to locate certain addresses, for instance:

This Service Information bulletin supersedes SI 32 02 14 dated August 2014. SUBJECT Installation of Right-Hand Drive Steering Spindle in Left-Hand Drive Vehicle is No Longer Required. Left-hand drive steering spindles are currently available.

MINI: DIFFERENT FAULTS ACTIVATES ENGINE MALFUNCTION AND OIL WARNING. *MA

MINI: BECAUSE OF THE DME SOFTWARE, AND A DAMAGED CLUTCH, THE DRIVETRAIN MALFUNCTION CHECK MESSAGE APPEAR. *MA