2002 MINI Cooper

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.

Driverside headlight assembly flickers everytime when you turn the key to position 1 with selector on off or auto. Flickers multiple times but doesn'tturn on unless I cycle the key on off until headlight does. This annoyance would reoccur the very next morning. Passenger headlight assembly doesn't have any issues.

NHTSA ID

11644969

Incident

Dec 20, 2023

I purchased the vehicle used with airbag light showing on the speedometer gauge cluster. Searched with vin for recalls but showed 0 unrepaired recalls. Tried clearing the light with my Launch CREADER BMW V2 scan tool. Light flashes a few times and goes away but immediately appears on the speedometer gauge cluster. This would happen everytime. Wires are intact with no signs of damages to all 3 wire connectors under the seat.

NHTSA ID

11644968

Incident

Dec 20, 2023

Unoccupied passenger side airbags; all front & backseat bags deployed after passenger side tires hit pothole on road. Pieces of interior, including decorative plastic, interior light covers were projected across cabin & hit me. I had no idea what had happened. Car shut off shortly after incident. It was night, I was sitting in middle of my lane, unable to start Mini. Good samaritans helped push it into parking lot while waiting for assistance. After 15 minutes, car started and was driven home. I had slight injuries from being hit by hard material projectiled across cabin. Very thankful I was the only occupant because if a passenger had been in the seat, they would have most definitely sustained injuries. I had to cut the airbags out in order to have clear lines of sight before driving the following day. I’m fearful that the drivers side air bags may do this as well. I have owned this vehicle since 2004. Not aware of history prior to 2004;(accidents, original airbags?). only know it came from a Dealer in CA. (Possibly “Friendship” may be name of town or dealership). I have not had repairs made yet. I don’t drive this vehicle daily. There are no police reports since there was no need. No insurance claims since 2002 model. There were no malfunctions with the warning light prior to incident. However, the following day when I drove, the airbag indicator light came on for passenger side. I did not find a recall but not sure if I would for a 22 year old vehicle.

NHTSA ID

11625676

Incident

Aug 27, 2024

MY MINI COOPER NEEDS RECALL WORK DONE. I AM IN BILLINGS, MT AND 392 MILES FROM THE CLOSEST CERTIFIED PLACE TO GET IT REPAIRED. I CAN'T TRAVEL THAT FAR IN A 2002 VEHICLE WITH HIGH MILES DURING A PANDEMIC. I AM A SENIOR CITIZEN AND HAVE ISSUES THAT DO NOT ALLOW ME TO TRAVEL THAT FAR. I AM STUCK WITH A VEHICLE THAT MAY HAVE A POTENTIAL STEERING ISSUE WITH NO WAY TO RESOLVE IT. I NOW CAN'T SELL THIS VEHICLE EITHER BECAUSE IT WOULD BE MORALLY WRONG TO PASS THIS PROBLEM ON TO A NEW OWNER. I CAN'T AFFORD THIS KIND OF SAFETY AND FINANCIAL PROBLEM. I NEED HELP TO GET THIS WORK DONE AND MINI COOPER CALLED ME AFTER MY INQUIRY AND SAID I AM BASICALLY OUT OF LUCK. THEY HAVE NO RESOLUTION FOR ME OR ANY OTHER MINI COOPER OWNERS THAT LIVE IN RURAL STATES AND ARE NOT NEAR A CERTIFIED DEALERSHIP. I NEED THIS REPAIRED AND AM HOPING YOU CAN HELP ME AND ALL THE OTHER MINI COOPER OWNERS IN THIS DANGEROUS SITUATION. THE NUMBER THE MINI REPRESENTATIVE CALLED ME FROM WAS 800-831-1117.

NHTSA ID

11400410

Incident

Mar 11, 2021

SO I BOUGHT A 2002 MINI COOPER LESS THAN A YEAR AGO AND IT CURRENTLY HAS 74K MILES AND ATTEMPTING TO PULL INTO A PARKING SPOT AT THE GROCERY MY STEERING GOES COMPLETELY OUT WHILE I WAS TRYING TO TURN INTO MY SPOT AND RIPPED OFF A BLACK MOLDING THAT GOES OVER THE FRONT PASSENGER WHEEL AND A SIGNIFICANT DING AND SCRATCH.

NHTSA ID

11222671

Incident

Jun 15, 2019

Mileage

75,000 mi

TL* THE CONTACT OWNS A 2002 MINI COOPER. WHILE DRIVING APPROXIMATELY 50 MPH, THE STEERING WHEEL SEIZED AND THE POWER STEERING WARNING INDICATOR ILLUMINATED. THE VEHICLE WAS ABLE TO COAST TO THE SIDE OF THE ROAD. THE CONTACT POWERED OFF AND RESTARTED THE VEHICLE, AND WAS ABLE TO DRIVE NORMALLY. THE CONTACT, A CERTIFIED MECHANIC, DIAGNOSED THAT THE STEERING PUMP FAILED AND NEEDED TO BE REPLACED. THE VEHICLE WAS NOT TAKEN TO A DEALER. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS CONTACTED AND DID NOT OFFER ASSISTANCE. THE APPROXIMATE FAILURE MILEAGE WAS 120,000.

NHTSA ID

11078341

Incident

Jan 17, 2018

Mileage

120,000 mi

TL* THE CONTACT OWNS A 2002 MINI COOPER. THE CONTACT STATED THAT WATER WAS ENTERING THE VEHICLE FROM THE SUN ROOF, WHICH CAUSED THE COMPUTER IN THE VEHICLE TO GET MOIST AND NOT OPERATE. THE VEHICLE WAS TAKEN TO A DEALER WHERE IT WAS DIAGNOSED THAT THE SUN ROOF RUBBER CONNECTOR NEEDED TO BE REPAIRED. THE VEHICLE WAS REPAIRED; HOWEVER, THE FAILURE RECURRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 118,000.

NHTSA ID

10956781

Incident

Jan 1, 2017

Mileage

118,000 mi

TL* THE CONTACT OWNS A 2002 MINI COOPER. WHILE DRIVING 15 MPH OUT OF A PARKING LOT, THE VEHICLE MADE A LEFT TURN AND THE GEAR SHIFTER FAILED. IN ADDITION, THE GEAR SHIFTER CABLE DETACHED. THE VEHICLE WAS TOWED TO THE CONTACT'S RESIDENCE. THE FAILURE RECURRED TWICE. THE VEHICLE WAS NOT DIAGNOSED NOR REPAIRED. THE VIN WAS NOT INCLUDED IN NHTSA CAMPAIGN NUMBER: 02V201000 (POWER TRAIN). THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS UNKNOWN.

NHTSA ID

10896429

Incident

Aug 16, 2016

The bar code on the vehicle identificatio nnumber (VIN) label (aka Manufacturer Compliance Label ) cannot be read.

Cavity protection applied to underside of the hood is leaking out onto the wheel arch trim and grille.

W10 ENGINE: EMS2K - COMPREHENSIVE COMPONENT OBD READINESS MONITOR NOT COMPLETED: An affected vehicle fails to pass a state Inspection and Emission (I/M) test due to the ÒComprehensive ComponentÓ OBD readiness monitor status is Ònot complete,Ó or it fails complete after performing an applicable repair.

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

MINI: FAULTY SOFTWARE FOR THE TANK VENTILATION CONTROL DISPLAYS ENGINE THROTTLE REACTION WHEN TEMPERATURE IS HIGH OUTSIDE, AND MORE OBVIOUS IF THE TANK IS ONLY PARTLY FILLED. *MA