Recall - Reprogramming DME for EVAP Leak Diagnostics: Overview
SI M12 01 04Engine Electrical Systems
May 2005
Technical Service
This Service Information bulletin supersedes S.I. M12 01 04 dated October 2004.
PERFORM THE PROCEDURE OUTLINED IN THIS SERVICE INFORMATION ON ALL AFFECTED VEHICLES BEFORE CUSTOMER DELIVERY OR THE NEXT TIME THEY ARE IN THE SHOP FOR MAINTENANCE OR REPAIRS.
[NEW] designates changes to this revision
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 shown.
IMPORTANT NOTE:
Some of Cooper S vehicles (produced 07/02 - 07/03) affected by this Recall Campaign are also in the range of the Emission Recall Campaign 04E-03: Replace Crankcase Breather Line on MINI Cooper S (refer to service bulletin M11 01 04). Make sure that both recalls are performed during the same service visit.
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 shown are only for informational purposes and are not to be considered as the only deciding factor.
CORRECTION
Reprogram EMS2000 engine control module (DME) using DIS/GT1 CD 38.0 or higher.
PROCEDURE
[NEW] 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.
[NEW] Important:
The EMS2K part numbers after programming with CD 38.0 should be as follows:
R50 Cooper 5-speed: programmed number 7547050, basic number 7527610;
R50 Cooper CVT: programmed number 7547052, basic number 7527610;
R53 Cooper S: programmed number 7547054, basic number 7527610.
[NEW] 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.
Important:
The EMS2K part numbers afier programming with CD 38.0 should be as follows:
R50 Cooper CVT: programmed number 7547052, basic number 7527610;
R53 Cooper S with JCW kit: programmed number 7547870, basic number 7527610.
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.
Note:
Additional labels can be ordered on line at MINI TIS.
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
Disclaimer