Engine Controls - Various Driveability Concerns
SI M 12 08 05Engine Electrical Systems
November 2005
Technical Service
SUBJECT
Incorrect DME Programming
MODEL
Cooper with CVT up to 10/03 production
SITUATION
Customers may complain about various intermittent drivability problems, mainly, engine speed fluctuation when coasting down to a stop or when accelerating from a stop with engine fully warmed.
CAUSE
Incorrect programming numbers in the EMS2K (DME) control module.
The manual determination programming procedure for MY' 02 / '03 R50 CVT vehicles was not followed during the DME reprogramming, resulting in a wrong calibration version installed.
The correct procedure for DME programming is provided in SI M12 02 03 and M12 01 04.
CORRECTION
When diagnosing Cooper CVT drivability complaints, first verify the EMS2K Programmed and Basic Part Numbers.
For the MY '02/'03 MINI Cooper with CVT, the latest (as of CD 43) correct DME Part Numbers should be:
^ Programmed - 7547052
^ Basic - 7527610.
IMPORTANT:
If the EMS2K Programmed Part Number is found to be: 7539191, or 7542746, or 7547050, then the control module had been reprogrammed with calibration for the manual transmission vehicle, and needs to be manually reprogrammed using the procedure below.
PROCEDURE
To reprogram the EMS2K control module on Cooper CVT UP TO 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 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 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.
Important:
The EMS2K part numbers after programming with CD 38.0, or higher should be as follows:
R50 Cooper CVT: Programmed number 7547052, Basic number 7527610.