2002-2006 Mini Cooper (R50) L4-1.6L (W10) Page 286

2002-2006 Mini Cooper (R50) L4-1.6L (W10) Page 286

Computers/Controls - Diagnostic Process

SI M 07 07 07

Workshop Environment Systems

September 2007

Technical Service

This Service Information bulletin supersedes S.I. M07 07 07 dated September 2007.

[NEW] designates changes to this revision

SUBJECT

Diagnosis Process

MODEL

R50, R52, R53 (Cooper, Cooper S)

R56 (Cooper, Cooper S)

SITUATION

The procedures and information contained within MINI diagnosis are to be utilized when troubleshooting MINI vehicles. This information has been

developed within MINI and component suppliers.

MINI workshop repairs on vehicles are only guaranteed if this information is observed and the operations involved in a repair are performed in

accordance with the instructions given. In the event of a warranty or goodwill claim, incorrectly performed diagnosis can lead to the delay or debit of

the claim.

PROCEDURE

Diagnosis programs are available for all electric and electromechanical vehicle systems. In addition, there are diagnosis programs for purely

mechanical systems and fault patterns (e.g., unwanted noise).

Troubleshooting with the MINI diagnosis system is necessary whenever:

a. The fault is with an electrical component.

b. The fault is in the drive-train system (engine or transmission).

c. The fault has caused a Check-Control message or warning indicator lamp to illuminate.

d. Instructed by a service information bulletin, PuMA recommendation or market team to perform diagnosis.

Overview of diagnosis procedure

1. Ensure that the MINI diagnosis system is connected to the network and transmitting FASTA data.

2. Connect to the vehicle using the proper interface and start diagnosis.

3. Perform a "Short test"

4. In the event of a specific customer complaint, select the appropriate complaint from the "Fault symptom selection" and "Transfer" to

"Accepted symptoms"

5. Work through the "DIS test plan". Notes on working through the "DIS test plan":

^ Evaluate stored faults

^ Perform relevant test modules

^ Observe current technical information

6. If the fault could not be located, work through your "Own test plan" by using the "Function selection" path. Notes on working through your

"Own test plan":

^ Use Control-module functions

^ Perform test modules

^ Observe current technical information

2002-2006 Mini Cooper (R50) L4-1.6L (W10) Page 287

7. Correct the faults and perform a function test.

8. Clear all fault memories with "Quick delete".

Diagnosis procedure

Note the following points when performing diagnosis:

1. Starting diagnosis

Always use the latest diagnostic software (including online updates) when performing any diagnosis.

The MINI diagnosis system must be connected to the workshop network so that diagnosis data can be transmitted to MINI engineering. If the GT1 is

used outside the workshop environment, the MINI diagnosis system must be reconnected to the workshop network after at most 40 diagnosis

sessions, so that the data stored in the equipment can be transmitted.

Note:

Diagnosis data recorded during troubleshooting is important information for MINI's quality processes. Moreover, the diagnosis report is

verification that diagnosis has been properly performed.

Warranty claims may be rejected if there is no diagnosis protocol (current warranty guidelines).

2. Short test

After vehicle identification, a "Short test" must be performed on all model series.

Note:

Because of the increasing degree of networking of vehicle systems, it is not enough to simply read off the fault memories of individual control

units when troubleshooting, as faults affecting several systems (e.g. bus errors) are evaluated and analyzed by more than one control unit.

3. Fault symptom selection

In the event of a specific customer complaint, first perform a "Short test" to check whether a corresponding fault symptom is available in the fault

symptom selection. This fault symptom must be selected with "Transfer".

Note:

Fault symptom selection contains known fault patterns caused by software errors, mechanical faults and faults that do not cause a fault memory

entry.

4. Working through the "DIS test plan"

Based on the faults stored in the vehicle and the selected fault symptoms, the diagnosis system will create a test plan, the so-called "DIS test plan". In

the test modules listed in the "DIS test plan", first check which test modules are directly associated with the customer complaint or the identified

malfunction. These test plans should be called up and worked through first. Once started, test plans must be completed. A test plan is only completed

when the message "Test module completed. Continue in testing schedule" is given and you return to the testing schedule with the right arrow key. If

the diagnosis user is prompted in the test module to send feedback about the test result obtained, this prompt must be followed.

A test module may only be cancelled prematurely if one of the following reasons is given:

a. Test module was selected by mistake

b. Error in test module prevents test plan from being carried out properly

Test modules that are obviously not directly associated with the customer's complaint or the malfunction identified should be ignored (please refer to

section 5. Dealing with stored faults).

The "DIS testing schedule" is completed when:

a. The cause of the fault has been identified or

b. No malfunction or component fault can be identified with the test modules listed in the testing schedule

5. Dealing with stored faults

For technical reasons, it can happen that a control unit stores a fault even though no malfunction can be detected. In addition, faults may be stored in

the vehicle whose causes have already been eliminated, during a previous repair.

For this reason, it is not uncommon for faults to be stored that are not directly associated with a customer complaint or with an identified fault

pattern, especially on high-mileage vehicles. When performing diagnosis, you should therefore use the fault memory details to check which fault

2002-2006 Mini Cooper (R50) L4-1.6L (W10) Page 288

memory entries can be ignored.

The following fault memory details are especially significant here:

^ Current fault status (fault currently present/not currently present)

^ Mileage reading (time) of last occurrence of the fault

^ Fault frequency

Replacing a component on the basis of the fault memory entry is only justified if the fault memory details clearly show that the stored fault is directly

associated with the customer complaint or the fault

pattern.

6. Drawing up and processing your "own testing schedule"

Your "own testing schedule" can be used to select test modules for checking functions and components on the basis of your own experience.

This is always advisable when the cause of the fault cannot be identified unambiguously with the "DIS testing schedule". The test modules are

selected in the "Function selection". The selection structure allows the relationship between function and component to be unambiguously identified.

The following rules apply when performing test modules:

^ Once started, test modules must be completed (please refer to section

4. Working through the DIS test plan

^ Premature cancellation is only permissible if a test plan was selected by mistake or the test plan has an error

^ If the technician is prompted in the test plan to send feedback about the test result obtained, this must be followed

Your "own testing schedule" is completed when the cause of the fault has been identified or when no function or component faults can be detected

using the test plans in the testing schedule.

7. Use of control-module functions

The "Control-module functions" provide the option of fast access to known diagnosis functions. In addition, the fault memory details stored in the

control unit can be read. Using the control-module functions is not however a substitute for performing the test modules, as the control-module

functions:

^ Do not contain detailed information or instructions

^ Do not contain all diagnosis and testing options for functions and components

8. Observing current technical information

In addition to the diagnosis programs, information about current technical problems is published through special media and systems (e.g. Service

Information bulletins, PuMA recommendations, Bonnet Boot & Wings). It is essential that such information is also taken into account when

performing vehicle diagnosis. Before replacing components, it must be checked whether any additional information is available. If the

repair/servicing actions recommended in the test plan differ from the current information, this should be noted in the remarks field on the warranty

claim.

9. Quick delete

After identifying a fault and repairing or replacing the faulty components, all faults stored in the vehicle must be cleared with the "Quick delete"

function.

Note:

As not all fault memory entries are shown by the service diagnosis programs or a summary of fault groups is given (e.g. bus faults), only the

"Quick delete" function can guarantee that all faults stored in the vehicle are cleared.

10. Reporting faults in diagnosis programs

If during diagnosis, faults are identified in the diagnosis programs or documents, these must be reported through "Diagnosis Feedback", which can

be accessed via the "Services" button while in diagnosis.

Refer to SI M07 05 06 for more information about diagnosis feedback.

Benefits for the MINI dealer organization System-based diagnosis is the most important tool available to workshop staff in the dealer organization.

Increasingly complex systems and their networking within modern MINI automobiles, make fault elimination without electronic diagnosis systems

increasingly more difficult, or even impossible. Correct diagnosis application gives the MINI dealer important competitive advantages. These are

described below:

2002-2006 Mini Cooper (R50) L4-1.6L (W10) Page 289

^ The high degree of networking between the increasing number of control units means that when faults occur, the relationship between fault cause

and effect can be no longer intuitively identified. This means that the cause and effect of a fault may be found in different vehicle components.

Diagnosis analyzes these complex relationships and supports the fast and direct search for the cause of the customer complaint.

^ Relying on experience and repair procedures practiced for years, increasingly results in unnecessary work being performed, and may even fail to

produce a lasting fault elimination. Ongoing adaptation and expansion of diagnosis means that the fault elimination in the dealers are

constantly updated on the basis of knowledge gained in the worldwide quality improvement processes for the vehicle and workshop systems. This

applies in particular to essential electric, electronic and electromechanical systems in the vehicle. In addition, purely mechanical systems are being

increasingly covered by diagnosis.

^ The complex documentation needed for processing warranty claims can result in queries and delays in reimbursement, if diagnosis is not used or

if diagnosis data is not transmitted. When performing diagnosis with the MINI diagnosis system, diagnosis data are automatically generated.

The data can be evaluated by MINI and then used to introduce new test plans or improve existing test plans aimed at continual improvement of

diagnosis.

^ Fast, direct and lasting elimination of faults is the most important basis for the reputation of a dealership and thus for long term customer loyalty.

The lower the number of unscheduled vehicle failures and the shorter vehicle down times, the more trustworthy and competent the dealer

appears in the eyes of the customer.

WARRANTY INFORMATION

^ Warranty claims may be denied:

1. If not supported by diagnostic test plans (transferred via FASTA). Be sure to include the "Diagnostic code" in the comments section of the

warranty claim.

2. If the latest diagnostic software is not used

[NEW] The exception would be for simple repairs made in the service drive while the customer is waiting. This may include bulb replacement

and/or wiper insert/blade replacement.