Voluntary Emissions Recall Campaign 04E-A01: Reprogram DME For Tank Leakage Diagnostics (M12 01 04)

VOLUNTARY EMISSIONS RECALL CAMPAIGN 04E-A01: REPROGRAM DME FOR TANK LEAKAGE DIAGNOSTICS

SERVICE CAMPAIGN BULLETIN

SUBJECT

Voluntary Emissions Recall Campaign 04E-A01: Reprogram DME for Tank Leakage Diagnostics 

MODEL

MINI Cooper/Cooper S from start of series production through May 2004

SITUATION

Tank leakage diagnostics does not run correctly due to an error in the DME software. As a result, the Check Engine Soon light will not be illuminated in case of leakage in the evaporative system.

To minimize customer's inconvenience caused by this Recall Campaign, you may pick-up (and deliver after repair) the affected vehicle from the customer's home, or provide appropriate alternative transportation. 

Customers will be impressed when you return their cars cleaned inside and out and with a full tank of gas. Reimbursement information for the vehicle fueling and valet costs can be found in the Warranty portion of this bulletin. 

Copy of the customer notification letter is attached.

AFFECTED VEHICLES

This Recall Campaign involves MINI Cooper vehicles with W10 engines and MINI Cooper S vehicles with W11 engines which were produced from December 2001 through May 2004.

In order to determine if a specific vehicle is affected by this Recall Campaign, it will be necessary to utilize the "Service Menu" of the DCS (Dealer Communication System). Based on the response of the system, either proceed with the corrective action or take no further action.

The Chassis Number Ranges listed below are only  for informational purposes and are not to be considered as the only deciding factor.

Model	Chassis Number Range
MINI Cooper	TC30047 - TC54549
MINI Cooper CVT	TE10037 - TE19959
	TJ50000 - TJ61073
Cooper S	TD50072 - TD87027

CORRECTION

Reprogram EMS2000 engine control module (DME) using DIS/GT1 CD 38.0 or higher.

PROCEDURE

To reprogram the EMS2000 control module on all affected Cooper 5-speed and Cooper S, and also on Cooper CVT FROM 10/03 production  vehicles:

1. Connect a battery charger.
2. Connect GT1 loaded with CD 38.0, or higher.
3. Select: Coding/Programming. 
4. Select: 5 Programming,  then the right arrow.
5. Select: 1 DME Programming,  then the right arrow.
6. Select 2 Exchange Control Unit,  then the right arrow.
7. Display appears First determine and then program basic control unit,  then the right arrow.
8. Select 1 Determine basic control unit,  then the right arrow. Automatic determination will now be performed.
9. DME ESM2000 is the faulty control unit still installed in the car?,  select YES. 
10. Switch on ignition. Start automatic determination?,  select YES. 
11. Display appears with VIN. Chassis number ........ Do numbers correspond?),  Select YES. 
12. Part numbers of basic control units  are displayed, then scroll down till the end
13. At this point vehicle data is stored in the tester for the automatic identification. Scroll to the left. 
14. Select: 2 Program basic control module,  then the right arrow.
15. Follow instructions for entering the last seven characters of the VIN. Select YES. 
16. Switch on ignition,  then right arrow twice.
17. The next screen displays: The control module can be programmed X times),  then the right arrow.
18. Follow the command for mileage entry Entry correct?.  Select: YES. 
19. DME EMS2000 Start automatic programming?  Select: YES. 
20. After successful programming, message is displayed: Programming completed. 
21. IMPORTANT: at this point turn ignition off and perform battery reset (disconnect battery cable) for 30 seconds. After that, reconnect battery.
    
    
22. Recode EMS2000 control module. Select 3 Coding ZCS/FA. 
23. Select R50/R53,  then the right arrow.
24. Select 1 Recoding,  then the right arrow.
25. Select 95 MOTRONIC,  then the right arrow.
26. Selection correct?  Select YES. 
27. Motronic start automatic coding?  Select YES. 
28. After coding is completed, turn ignition off for 10 seconds and then start the engine.

To reprogram the EMS2000 control module on Cooper CVT UP TO 10/03 production and Cooper S John Cooper Works kit  vehicles:

1. Connect a battery charger.
2. Connect GT1 loaded with CD 38.0, or higher.
3. Select: Coding/Programming. 
4. Select: 5 Programming,  then the right arrow.
5. Select: 1 DME Programing,  then the right arrow.
6. Select 2 Exchange Control Unit,  then the right arrow.
7. Display appears First determine and then program basic control unit,  then the right arrow.
8. Select 1 Determine basic control unit,  then the right arrow. Automatic determination is going to be performed.
9. DME ESM2000 is the faulty control unit still installed in the car?,  select NO. 
10. On the next screen, select right arrow.
11. Enter basic control unit part number) enter: 7527610 Number correct?  Select YES. 
12. On the next screen select the right arrow.
13. Enter full VIN) Number correct?  Select YES. 
14. Enter program control unit part number) enter: 7547052 (for Cooper CVT) enter: 7547870 (for Cooper S John Cooper Works kit) Number correct?  Select YES,  then scroll down till the end, and to the left. At this point basic and programmed control unit part numbers are stored for programming.
15. Select: Program basic control module,  then the right arrow.
16. Follow instructions for entering the last seven characters of the VIN. Select YES. 
17. Switch on ignition,  then right arrow twice.
18. The next screen displays: The control module can be programmed X time),  then the right arrow.
19. Follow the command for mileage entry Entry correct?.  Select: YES. 
20. DME EMS2000 Start automatic programming)  Select: YES). 
21. After successful programming, message is displayed: Programming completed. 
22. IMPORTANT: at this point turn ignition off and perform battery reset (disconnect battery cable) for 30 seconds. After that, reconnect battery.
    
    
23. Recode EMS2000 control module. Select 3 Coding ZCS/FA. 
24. Select R50/R53,  then the right arrow.
25. Select 1 Recoding,  then the right arrow.
26. Select 95 MOTRONIC,  then the right arrow.
27. Selection correct?  Select YES. 
28. Motronic start automatic coding?  Select YES. 
29. After coding is completed, turn ignition off for 10 seconds and then start the engine.

LABEL INSTRUCTIONS

After the vehicle has been checked and corrected, obtain a label (MD 20-033) and with a ball point pen, print your dealer code (5 digits) on the Recall Completion Label (see illustration). An initial quantity of 25 labels will be sent to all MINI dealers. Peel the label from its backing and affix it to the right rear side of the hood (in the engine compartment, close to windshield) next to the Vehicle Emission Control Label.

For California centers only it is required by the California Code of Regulations that an executed orange "Vehicle Emission Recall - Proof of Correction" certificate (SD92-084, see illustration) be provided to each customer (for vehicles registered in the state of California) once the Recall on their vehicle has been completed.

WARRANTY INFORMATION

Reimbursement for this Recall Campaign will be via Campaign Entry

Defect Code:  00 12 88 01 00

RE-FUELING COST

MINI USA will provide reimbursement to have the gas tank topped off once as required, for each vehicle affected by this Recall Campaign. Attach the appropriate receipt to the work order.

Defect Code:  85 99 00 33 NA - Refuel MINI Cooper/Cooper S

Sublet:  Actual cost to top off the fuel tank

Sublet Code:  4

VALET COST

MINI USA will provide reimbursement for vehicle valet services (pick up & delivery) for each vehicle affected by this Recall Campaign. Attach the appropriate receipt to the work order.

Defect Code:  99 99 77 77 NA - Valet Service for MINI Cooper/Cooper S

Sublet:  $25.00

Sublet Code:  4

RENTAL VEHICLES

Retailers participating in the MINI Dealer Administered Customer Assistance Program may self-authorize claims for reimbursement of rental costs from independent rental agencies in certain situations.

ATTACHMENTS - CUSTOMER NOTIFICATION LETTER

MINI VOLUNTARY EMISSIONS RECALL CAMPAIGN TO UPDATE TANK LEAKAGE DIAGNOSTIC SOFTWARE. 

CAMPAIGN NUMBER: 04E-A01 

Dear MINI Owner: 

MINI USA has determined that certain 2002, 2003 and 2004 model year MINI automobiles may not fully meet the Federal Environmental Protection Agency (EPA) and the California Air Resources Board emission control requirements. In order to remedy this situation, MINI USA is conducting a Voluntary Emissions Recall Campaign. We are asking you as the owner of an affected vehicle to contact your Authorized MINI dealer at your earliest convenience to have the repair carried out.

The Problem is... 

MINI USA has determined that your MINI automobile tank leakage diagnostic system contains a software error preventing the correct detection of a possible evaporation emission leak.

What MINI USA and your Authorized MINI dealer will do... 

MINI USA will repair your vehicle free of charge for parts and labor.  Your authorized MINI dealer will update the engine control module with the latest software. The complete repair should not take more than one hour.

Your obligations are... 

At your earliest convenience, please contact your Authorized MINI dealer to schedule an appointment to have this Emissions Recall Campaign performed.

If you fail to get this free Emissions Recall Campaign performed... 

If you live in a State with a SMOG Check program, your vehicle must pass an emissions test, as required by State law. Without having this Recall performed your vehicle may be more likely to fail this test.

For vehicles registered in the State of California, the completion of emission recall repairs is required prior to vehicle registration renewal.  In addition, the State of California requires that every vehicle must pass an emissions test (SMOG Check) in two year intervals and whenever a vehicle is sold. California regulations require MINI USA to provide the Department of Motor Vehicles with a record of all vehicles which have not had the recall repair performed.

Furthermore, your Authorized MINI dealer will provide you with a Proof of Correction form after this repair is completed. Please save this form since the California Department of Motor Vehicles may require it as proof of Emissions Recall Campaign completion.

Failure to have this free repair work performed could be determined as lack of proper maintenance of your vehicle and could jeopardize your full protection under the emissions warranty provisions.

If you need help... 

Should you have any questions about this Emissions Recall Campaign that cannot be answered by your Authorize MINI dealer, please call MINI Customer Relations Department, at 1-866-ASK-MINI.

If you don't own this vehicle...

If you are no longer the owner of this vehicle, we would greatly appreciate your furnishing us with the name and address of the new owner, using the enclosed return postage-paid card.

On a personal note... 

We appreciate your confidence in our product and wish to do everything we can to retain that confidence. MINI USA, in cooperation with our Authorized MINI dealers, will strive to minimize any inconvenience to you caused by this Campaign. We ask that you join us in our desire to minimize air pollution and any adverse impact on our environment and have this Emissions Recall Campaign conducted on your vehicle.

Very truly yours,