2009 MINI Cooper Us TSBs

experience a sudden engine operational failure reduced or loss of power while driving and the malfunction indicator lamp (MIL) may be illuminated along with high-pressure fuel pumprelated faults stored in the Engine Control Module (DME). PROCEDURE Perform the corresponding diagnosis/vehicle test and run the test plans to completion as applicable.

INFORMATION This updated version of this bulletin now includes the addition of the model year 2009 R55, R56 and R57 MINI Cooper vehicles with the N12 engine. For the above-referenced vehicles, MINI USA, a division of BMW of North America, LLC (""MINI USA"") is extending the limited warranty for the Tank Leak Diagnostic Module (DMTL) Pump to: 10 years/120,000 miles as determined by the vehicle's original in-service date Component #1: This ""component specific"" limited warranty extension applies to defects in materials and workmanship and is subject to the applicable vehicle and coverage eligibility requirements, exclusions and limitations that apply to the MINI New Passenger Car Limited Warranty. GRUSB0116-04 This bulletin is notice of a ""limited warranty extension."" This is NOT a notice of a Recall or Service Action. There is no immediate repair required unless the MINI vehicle is currently experiencing this problem. Even though this is NOT a Recall, MINI USA will be sending VIN-specific customer notification letters in a phased release. Customer Notification Letter - VIN and Component-specific Warranty Extension Even though this is NOT a Recall, MINI USA will be sending VIN-specific customer notification letters in a phased release for the additional MY 2009 vehicles."

No customer complaint has been received. During the scheduled engine oil service, the technician notices a black rubber o-ring lying on the bottom of the engine oil filter housing. The o-ring has been dislodged from the non-return valve inside the engine oil filter housing. No subsequent engine damage occurs from the dislodged o-ring. Engine oil filter housing (1) Rubber o-ring (2) The material dimensions of the rubber o-ring are not satisfactory, allowing it to become dislodged from its installation location.

On affected vehicles, the Tank Leak Diagnostic Module (DMTL) pump can fail. Some vehicles will have the Service Engine Soon lamp illuminated, but the vehicle's drivability and engine performance will not be reduced by this DMTL pump malfunction.

The customer states that the Service Engine Soon lamp is illuminated and the following fault is stored in the DME: FC 2BF2 Rail pressure sensor, workspace: pressure too high CAUSE A DME calibration error in the fuel pressure diagnostics results in an increased sensitivity.

Certain areas of the US experience extremely cold climate conditions during the winter months, which can cause the Service Engine Soon lamp to illuminate while the engine temperature is increasing to full operating temperature. The following fault may be stored in the DME: ??FC 2D9B Knock Sensor, Signal CAUSE Unfavorable DME knock sensor diagnostic at outside ambient temperatures below -5 C

A whistling or squealing noise is heard from the engine at idle and/or at higher engine speeds. CAUSE 1. Noise is caused by the water pump. 2. Noise is caused by the friction wheel of the belt tensioner.

CAUSE The internal sealing of the oil pump volume control solenoid valve is compromised, allowing engine oil to leak from the oil pump volume control solenoid.

Certain areas of the US experience extremely cold climate conditions during the winter months, which can cause the Service Engine Soon lamp to illuminate while the engine temperature is increasing to full operating temperature. The following fault may be stored in the DME: FC 2D9B Knock Sensor, Signal While performing test plan B1214 M KNOCK SENSOR, the following error message will be displayed: ""An error has occurred during execution of a service program. Fault code: 61/3."" This error in the test plan will not allow diagnosis to continue. The test plan error will be repaired with ISTA/D 2.36.0. CAUSE A DME calibration error in the knock sensor diagnostics results in an increased sensitivity threshold to cold temperatures."

An oil leak can develop at a sealing plug located in the cylinder head, just below the vacuum pump. The sealing plug was not tightened sufficiently during production.

An oil leak can develop at a sealing plug located in the cylinder head, just below the vacuum pump. CAUSE The sealing plug was not tightened sufficiently during production.

Certain low speed, light-load driving conditions at lower outside temperatures could cause the Service Engine Soon lamp (MIL) to illuminate. The following fault would be stored in the DME: Fault 274D: Mixture adaptation, lower engine speed range (mixture too lean) CAUSE 1. Possible intake/exhaust leaks, or a faulty component as listed in the test plan 2. Unfavorable DME software

The customer states that a small engine oil leak can be seen from the underside of the engine. CAUSE The internal sealing of the oil pump volume control solenoid valve is compromised, allowing engine oil to leak from the oil pump volume control solenoid.

INFORMATION The following three criteria must to be checked, evaluated and the resulting findings documented on the repair order prior to replacing a dual-mass flywheel as defective: 1. Total rotational angle at no load condition (with applied torque less then 20 Nm) 2. Secondary plate longitudal axial play 3. Friction surface appearance changes due to thermal overload. PROCEDURE Refer to the attached "Dual-mass Flywheel Inspection" document for the complete inspection procedure. The dual-mass flywheel replacement is justified only if one or more of the following criteria are met: 1. The total rotational free-play measured at the flywheel gear ring is: Equal to or greater than 3 tooth gaps on N14/N18-equipped engines; Equal to or greater than 14 tooth gaps on B38/B46/B48-equipped engines. 2. The secondary plate total axial bearing play measured at outside diameter of the flywheel is: Equal to or greater than 3 mm on N14/N18-equipped engines; Equal to or greater than 5 mm on B38/B46/B48-equipped engines. 3. Significant discoloration in the adjoining area outside the friction ring, or a severe ablation/erosion of the friction area, is present. WARRANTY INFORMATION Warranty claims for replacing a Dual Mass Flywheel are subject to denial or debit when it is determined that the diagnostic procedures outlined above were not followed. ATTACHMENTS View PDF attachment M210114_Dual-Mass_Flywheel_Inspection.

Certain low speed, light-load driving conditions at lower outside temperatures could cause the Service Engine Soon lamp (MIL) to illuminate. The following fault would be stored in the DME: ??Fault 274D: Mixture adaptation, lower engine speed range (mixture too lean) CAUSE 1. Possible intake/exhaust leaks, or a faulty component as listed in the test plan 2. Unfavorable DME software.

The customer states that a small engine oil leak can be seen from the underside of the engine. CAUSE The internal sealing of the oil pump volume control solenoid valve is compromised, allowing engine oil to leak from the oil pump volume control solenoid. DIAGNOSTIC Below is the procedure for identifying how far the engine oil has migrated inside the engine electrical harness, when this issue occurs, if at all. The procedure must be followed very carefully so that the proper repair is identified. 1. Disconnect the oil pump volume control solenoid valve electrical connection per Repair Instructions 11 41 519 ""Removing and installing or replacing the solenoid valve (engine oil pump)."" Inspect the electrical connector; if no engine oil is found inside the electrical connector, perform the oil pump volume control valve repair procedure. If engine oil is found inside the electrical connector, proceed to diagnostic procedure step 2. 2. Remove the cover from the DME and remove all three electrical connectors from the DME. Inspect the connectors for traces of engine oil. If no engine oil is found, perform the oil pump volume control valve repair procedure and replace the engine section of the wire harness. Refer to EPC for the additional part number. If engine oil is found in the DME connector, proceed to step 3. 3. If engine oil is found in the DME electrical connector, perform the oil pump volume control valve repair procedure, replace the engine section of the wire harness and replace the DME. Refer to EPC for the additional part numbers. Do not remove the engine oil pan. Do not replace the oil pump volume control valve. Do not replace engine oil pump. OIL PUMP VOLUME CONTROL VALVE REPAIR"

The blower motor does not operate at any fan speed. The blower motor may work intermittently with the blower fan speed operating only on FULL speed. CAUSE The blower motor is faulty and causes the blower resistor to fail.

Based on Motorer feedback, MINI has determined that during the first three years of service, some vehicles may require specific additional service work to be performed. To address this issue, MINI USA, a division of BMW of North America, LLC (""MINI USA"") is providing the following Motorer-Focused Satisfaction (MFS) Program. This program's procedures have been available to you to address specific Motorers' concerns since September 1, 2014. As part of our Motorer Pledge to deliver an incredible MINI motoring experience, for the abovereferenced MINI vehicles, we developed this program to increase our Motorers' satisfaction by helping to prevent unexpected dealer service repair visits."

SUBJECT The Blower Motor is Faulty. The blower motor does not operate at any fan speed. The blower motor may work intermittently with the blower fan speed operating only on FULL speed. CAUSE The blower motor is faulty and causes the blower resistor to fail.

Tire pressure loss after replacement of the RDC/RDCi wheel electronics. Valve stems are not being replaced in conjunction of the RDC/RDCi wheel electronics replacement.

designates changes to this revision SUBJECT N16 and N18 Engine: Engine Oil Leak. The customer states that a small engine oil leak can be seen from the underside of the engine. CAUSE The internal sealing of the oil pump volume control solenoid valve is compromised, allowing engine oil to leak from the oil pump volume control solenoid. DIAGNOSTIC

INFORMATION As part of a Class Action Suit Settlement for the vehicles listed above (""Class Vehicles""), MINI USA, a division of BMW of North America, LLC, is extending the limited warranty for the engine mechanical water pump to: z Item #1: This ""component-specific"" limited warranty extension applies to defects in materials or workmanship. z This coverage is subject to the same vehicle eligibility requirements, limitations, and exclusions that apply to the MINI New Passenger Car Limited Warranty. z When it is necessary, the friction wheel is covered only when it is done in conjunction with performing an eligible and covered engine mechanical water pump repair. z This extended coverage does not apply to electric water pump. Note: This bulletin is a notice of a component-specific ""limited warranty extension as part of a Class Action Settlement. This is NOT a notice of a Recall or Service Action. There is no immediate repair required unless the MINI vehicle is currently experiencing a problem with the water pump."

BMW of North America, LLC. MINI USA, a division of BMW of North America, LLC (""MINI USA"") has entered into a nationwide settlement with the plaintiffs in the above referenced class action and the Court has granted final approval of the settlement. This DCS message provides you with the latest information about this case and the settlement. Class Allegations. The Plaintiff claimed that MINI produced and sold certain MINI Cooper Class Vehicles with defective water pumps. Class Vehicles are MINI R55, R56, R57, R58, R59, and R60 Series vehicles equipped with N12, N14, N16 or N18 engines that were sold or leased to Class Members in the US (including Puerto Rico). The Class Vehicles were produced from October 2006 through November 2012."

behavior as in Situation1.

SUPPLY, RESULTING IN OIL STARVATION AND SEIZING OF TURBOCHARGER ASSEMBLY. MODEL ALL. *PE

THE WATER PUMP DOESNT POWER UP. *RM

There are various connectivity failures with the following devices: Apple iPhones Samsung S6 and the S6 Edge. Connectivity failure examples are: Call disconnection - Call is transferred back to the handset. In some instances the call is then transferred back to the vehicle. Contact List incomplete General connection failures Apple iOS software (issue started with iOS 8.3 continues with iOS 9.x and its variants) Samsung S6 and S6 Edge device firmware

SUBJECT Bluetooth Connection Failures. There are various connectivity failures with the following devices: z Apple iPhones z Samsung S6 and the S6 Edge. Connectivity failure examples are: z Call disconnection - Call is transferred back to the handset. In some instances the call is then transferred back to the vehicle. z Contact List incomplete z General connection failures z Apple iOS software (issue started with iOS 8.3 continues with iOS 9.x and its variants) z Samsung S6 and S6 Edge device firmware

The customer is not connected to MINI Customer Relations after dialing the number displayed in the vehicle Kombi or radio. CAUSE During the Pre-Delivery Inspection (PDI), the incorrect telephone number is being written into the vehicle. INFORMATION 1. When performing the PDI test plan, it is extremely important that you select MINI if the ISID is configured for both BMW and MINI. 2. After completion of the PDI test plan, verify that the customer relations number stored in the vehicle is correct. 3. The correct customer relations phone number is 1(866) 275-6464. 4. If the number stored in the vehicle is incorrect and the correct test plan was used, contact your 3g Administrator and have him or her verify the number stored in the ISID. 5.This picture shows the correct number stored in the Combox control unit. Note: To read out telephone number:

The customer states the recirculation display goes out, even though the recirculation button was switched on. CAUSE The automatic recirculation air deactivation feature was introduced in July 2012. Note: If the customer dislikes this feature, it can be deactivated by using the following steps.

The customer states the recirculation display goes out, even though the recirculation button was switched on. CAUSE The automatic recirculation air deactivation feature was introduced in July 2012. Note: If the customer dislikes this feature, it can be deactivated by using the following steps.

INFORMATION With the release of iOS 8.0, please be aware of the important functional change noted below: Scenario: z The customer leaves the vehicle and turns the phone off. z He or she turns the phone back on. z The customer then enters the vehicle, but does not unlock the phone prior to turning the vehicle on. https://www.minitis.net/tiscode/cgi-bin/bulletin.aspx?sie_path=/tsb/bulletins/htm_store/20701.1.M840115....3/2/2015 Page 2 of 2 Result: z The phone reconnects to the Bluetooth system (normal). z However, the contact list is not transferred (not normal). z The contact list in the iDrive will be empty. z The call list in the Kombi will display only phone numbers, but no names. z The hands-free system works for accepting calls and conversing on calls started on the phone. Solution: z Prior to the customer entering the vehicle, he or she must unlock the phone at least once (passkey). With the release of Apple's new iPhone 6, 6 Plus and iOS 8.x software, there have been many questions regarding the new phone and software. The information in the attachment to this Service Information will help answer these questions. A printed copy can be given to the customer if needed. The attachment provides information on the differences between the new iPhone 6, 6 Plus and the previous versions, along with Apple software improvements in the following areas: 1. Visual comparison 2. Connectivity 3. Functionality Refer to the PDF file in the ""Attachment"" section of this bulletin for complete details. Information on the iPhone 6 is also available via the following website: www.miniusa.com/bluetooth NOTE: This SI will be updated as new information is received. "

The Navigation road map can be installed onto the head unit in the vehicle using a USB stick connected to the USB connector in the center console in the vehicle. 32GB USB stick is necessary Desired NAV road map version can be retrieved from the HDD-Update console PROCEDURE 1. Copy the desired NAV road map from the HDD-Update console onto a 32GB USB stick. Refer to the Attachment. 2. To install the desired NAV road map version into the vehicle, connect the USB stick into the USB connector. The connector is located: On R-Series MINI vehicles in the glove box: https://www.minitis.net/tiscode/cgi-bin/bulletin.aspx?sie_path=/tsb/bulletins/htm_store/26...10/5/2015 Page 2 of 2 On F-Series MINI vehicles at the center instrument panel area 3. When prompted, enter the 20-digit enabling code. 4. Start the NAV road map installation and follow the on-screen instructions. WARRANTY INFORMATION Not applicable. ATTACHMENTS View PDF attachment M651015_Attachment.

Media connected to the USB connector is not recognized by the audio system. Playback of files from the media is not possible. Message displayed on the audio system display: ""Title cannot be reproduced"" ""Is being read"" (but never plays back any audio) CAUSE Media with data files stored in more than 32 directories or 32 subdirectories within a directory. Media with a large number of files. Media exceeds total storage capacity of 32 GB."

The customer states the recirculation display goes out, even though the recirculation button was switched on. CAUSE The automatic recirculation air deactivation feature was introduced in July 2012. Note: If the customer dislikes this feature, it can be deactivated by using the following steps.

the customer; or it is not possible to locate certain addresses, for instance:

the customer; or it is not possible to locate certain addresses, for instance:

As a result, the demand on the batteries has increased. Breakdowns due to an empty battery or problems in the vehicles electrical system can have various causes, most of which are not due to the battery itself. For this reason, a battery replacement will permanently eliminate the problem only in the rarest of cases. The energy diagnosis test module helps to localize these causes. This document covers important information for the dealer on how to handle discharged battery complaints. Without performing the energy diagnosis test plan, the root cause of a discharged battery cannot be identified. In order to properly repair the vehicle the first time, it is very important that the diagnostic test plan is performed to completion; with all results taken into consideration.

When the vehicle is parked and locked (DWA active), the alarm system is triggered intermittently. One or more of the following conditions may trigger the alarm system: Sun roof in the tilted/open position, Window partially open, Excessive local noise (for example, near an airport, on a busy road, or in heavy rain) CAUSE Normal sensitivity of the interior ultrasonic sensor.

MINI electrical systems and advancements in vehicle technology have resulted in an increased demand on the vehicle battery. This SI will help the dealer handle ""discharged battery"" complaints. A discharged battery can have various causes, most unrelated to the battery. A failed battery is often the symptom and not the cause. A fully serviceable battery fails when an electrical component causes the battery to discharge; the battery becomes internally damaged and must be replaced. For more information, refer to http://www.batteryuniversity.com/parttwo-42B.htm. For this reason, replacing the battery is not usually a permanent repair. The cause of the discharged battery must be analyzed in order to guarantee a proper repair. To properly repair the vehicle the first time in the workshop, the diagnostic test plans must be performed to completion, with all results taken into consideration. The procedure below will guide the technician to properly repairing the vehicle and getting paid for a warranty claim. CAUSE Discharged battery."

INFORMATION Parts replacement will not solve the problem if one or more of the conditions described in the situation above caused the alarm to trigger. The sensitivity of the interior ultrasonic sensor cannot be reduced. If the customer wishes to park the vehicle with the sunroof tilted, the window partially open, and/or in an area with excessive local noise, the interior sensor must be switched off by using the following procedure: Press the lock button on the remote control twice in succession. The LEDs flash in short succession for approx. 2 seconds. The interior ultrasonic sensor is switched off until the vehicle is unlocked and locked the next time. NOTE: This information can be found in the Owner's Manual in the ""Controls"" section under ""Switching off the tilt alarm sensor and interior movement detector."""

MINI electrical systems and advancements in vehicle technology have resulted in an increased demand on the vehicle battery. This SI will help the dealer handle ""discharged battery"" complaints. A discharged battery can have various causes, most unrelated to the battery. A failed battery is often the symptom and not the cause. A fully serviceable battery fails when an electrical component causes the battery to discharge; the battery becomes internally damaged and must be replaced. For more information, refer to http://www.batteryuniversity.com/parttwo-42B.htm. For this reason, replacing the battery is not usually a permanent repair. The cause of the discharged battery must be analyzed in order to guarantee a proper repair. To repair the vehicle properly the first time in the workshop, the diagnostic test plans must be performed to completion, with all results taken into consideration. Without performing the energy diagnosis test plan, the root cause of the discharged battery cannot be identified. This increases the chances of a repeat repair. CAUSE Discharged battery."

MINI electrical systems and advancements in vehicle technology have resulted in an increased demand on the vehicle battery. This SI will help the dealer handle ""discharged battery"" complaints. A discharged battery can have various causes, most unrelated to the battery. A failed battery is often the symptom and not the cause. A fully serviceable battery fails when an electrical component causes the battery to discharge; the battery becomes internally damaged and must be replaced. For more information, refer to http://www.batteryuniversity.com/parttwo-42B.htm. For this reason, replacing the battery is not usually a permanent repair. The cause of the discharged battery must be analyzed in order to guarantee a proper repair. To repair the vehicle properly the first time in the workshop, the diagnostic test plans must be performed to completion, with all results taken into consideration. Without performing the energy diagnosis test plan, the root cause of the discharged battery cannot be identified. This increases the chances of a repeat repair. Discharged battery."

*PE

A noise may be heard from the front driver's seat back when the customer applies sideways pressure during cornering. CAUSE Surface corrosion on the metal seat back frame can make a squeaking noise when rubbing against the foam rubber padding of the seat back.

The CBS data calculated for the remaining distance of the front and/or rear brake pads does not agree with the actual brake pad thickness. The yellow brake lining service due indicator illuminates even though the pad thickness is greater than the minimum wear limit (approximately 3.7 mm); the brake wear sensor has not yet been activated (from a thickness of approx. 4.2 mm). In some cases, the red warning message may already be active. The CBS front/rear brake display is based on a mathematical calculation. Various influences are incorporated into this calculation (for example, vehicle speed, brake pressure, and rotor temperature). Due to changing driving characteristics and/or unfavorable environmental conditions, the calculated remaining distance may differ from actual pad thickness.

The yellow "Service Due" warning message lights up in the instrument cluster, even though the brake pad thickness is more than 4.2mm (above the thickness at which the pad sensor intervenes). The calculated remaining service life for the brake pads (front and/or rear axle) from the CBS data does not match the actual brake pad thickness. Software calculation of the brake pad wear model in the DSC.

The customer states the red or blue cap is missing from the temperature control wheel of the heat and air conditioning control panel.

The Kumho 215/40 R17 Ecsta V700 sport tire performance optimization results in vehicle operation limitations, specifically when operated in cold climates or on wet, slushy or snow-covered roads. If your MINI JCW GP owner prefers a set of tires that better fits his/her driving style and climate, these owners can swap out the factory-original equipment (OE) Kumho 215/40 R17 Ecsta V700 sport tires for a set of the following MINI approved alternate tires: ??205/45R17 84W John Cooper Works performance run-flat tires Please refer to the attached MINI Product Planning & Strategy Bulletin M-20-0313-0012, ""MINI John Cooper Works GP Unleashed,"" for more information, including the required ""choice of tire option"" agreement form."

The air conditioning compressor is excessively loud/running rough when the air conditioning system is switched on and the compressor is active. Vibration in the air conditioning suction line (low side).

CONDITIONER SYSTEM IS ON AND COMPRESSOR IS ACTIVE. MODEL 2009-2010 R55 (COOPER CLUBMAN, COOPER S CLUBMAN, R56 (COOPER, COOPER S), R7 (COOPER CONVERTIBLE, COOPER S CONVERTIBLE), R60 (COOPER COUNTRYMAN, COOPER COUNTRYMAN S, COOPER COUNTRYMAN ALL4). *PE

Rear camber cannot be adjusted properly. CAUSE Repair instructions not followed properly

Analysis of FASTA data and repeat repair visit reports indicates that there are many fault codes that are stored in the above vehicles, but they are not diagnosed to identify their root cause. Fault codes that are not diagnosed to find their root cause can lead to a repeat repair visit to the workshop by the customer. Where diagnosis (vehicle or short test) with ISTA has already started, it is important to diagnose the fault code(s) listed below (when they are stored in the vehicle) during the current workshop visit. This will help lead to a reduction in workshop repeat repair visits and higher customer satisfaction.

*RM

Extension For the above-referenced vehicles, MINI USA, a division of BMW of North America, LLC (MINI USA) is extending the limited warranty for the front passenger's OC3 seat occupancy mat (shown) to: 10 years/120,000 miles as determined by the vehicle's original in-service date.

This Service Information bulletin supersedes SI 01 11 16 dated December 2016.

The new wheel electronics are identified as Huf Generation 5. These new wheel electronics will need to be programmed using the new tool when replaced or when depressurized (0 psi) for more than 2 minutes.

The customer may complain of a ""stiff diagonal shift"" (e.g., N-R, R-N, 2-3/3-2 or 4-5/5-4). Also, in some cases, gears cannot be selected, or the selector gear does not go into the neutral position. CAUSE 1. The deflection lever circlip of the gearshift mechanism is damaged or missing. 2. Possible corrosion at the gearshift mechanism (shift cables or transmission gearshift unit)"

When driving out of a tunnel or exiting underground parking, the automatic driving light remains switched on for two minutes. Shut-off period varies based on detected situation. This is normal operational behavior.

The bonnet lock fails to operate correctly and is difficult to open or close. CAUSE Corrosion in the bonnet lock assembly

There are various connectivity failures with the iPhone using iOS 7. Some examples are listed below: z Call disconnection z Contact List incomplete z General connection failures Apple software iOS 7 and its variants

INFORMATION Because carbon deposit buildup is related to fuel quality, it is not considered a defect in the vehicle's materials or workmanship. Consequently, the use of MINI Fuel Additive as outlined in this bulletin is not covered under the terms of the MINI New Passenger Car Limited Warranty, MINI Maintenance Program, any applicable Federal, State or MINI Emissions Warranty or the MINI Next Certified Pre-Owned Limited Warranty. [ Copyright (c)2015 BMW of North America, Inc. ] https://www.minitis.net/tiscode/cgi-bin/bulletin.aspx?sie_path=/tsb/bulletins/htm_store/217...4/7/2015