Service - Overview: Other MINI Cooper I

Quality Certification I (QCI)

When performing a QC1, a checklist (item MD20-001) has to be competed.

CENTERNET FOR LATEST FORMS

Display Vehicle Check- Technician

1. Install antenna: the cover for the antenna is snapped over the antenna base on the roof, then the mast is fastened onto the base.
2. Remove transportation battery disconnect switch: the electronic battery main switch is held against the inner surface of the windshield by a wire retainer. The retainer is held in place by the inner mount of the driver's sun visor. Remove the retainer, switch and harness. Disconnect the harness at the base of the center console, and push the connector "pigtail" (1) behind the console trim panel.
3. Remove shipping spacers from front springs: lift the front of the vehicle to enable removal of the white plastic shipping spacers from the strut shafts.
4. Clear transportation mode.

Scheme 203

Delivery Check- MINI Motoring Advisor

1. Program Vehicle Memory Settings as per customer's preferences.
2. Radio Stations programmed if the customer is signed up for the "MINI Waiting is Fun" (MWF) program, the chosen radio stations shall be programmed into the radio.
3. Place MWF-specified MINI Music CD into CD player: If the customer is signed up for the MWF program, the chosen CD is to be placed into the CD player (if equipped).
4. Apply steering wheel wrap. Available from MINI USA Marketing Materials Order # MIS 002-02.
5. Place Smints on passenger seat: these candy mints are available from MINI USA Marketing Materials Order # MIS 003-02.

Notes

Scheme 204

Engine Oil Service

MINI Engine Oil Service (All models): The Service Interval Indicator (SII) calculates the first scheduled engine oil change at approximately 10,000 miles. Change the engine oil and oil filter while engine is at operating temperature. We recommend MINI Synthetic Motor Oil 5W-30, available under part number 07 51 0 143 829.

Note. Once the Service Interval Indicator is reset, all subsequent engine oil changes are calculated at approx. 15,000 mile intervals.

BMW Group Technical Hotline

The Technical Hotline was established to assist dealer technicians who are faced with difficult to diagnose technical problems. In our efforts to ensure that we provide the ultimate service, please conform to the following before calling the Technical Hotline

1. The technician assigned to the vehicle must have the training directly related to the specific vehicle or system
2. All available resources are reviewed, these may include but not limited to: SIBs, TIS, DCS messages, Service Round Table, etc.
3. The Shop Foreman / Lead Technician is consulted
4. The attached Check Sheet is completely filled out (please photocopy as needed)

If at this point a solution has not been reached, please contact the Technical Hotline at (800) 472-7222. When calling, you will be prompted to enter your dealer number and Social Security Number before choosing from a menu of the three separate technical groups. You will find attached a quick reference card that will assist you in making the proper choice.

Note. The Quality and Service Engineering Department should only be contacted if you need technical assistance or you are following up on a previous Technical Hotline discussion.

A contact number can be provided in the following cases

1. Normal troubleshooting which does not resolve the problem, and the Technical Hotline offers a recommendation to replace a component or a system.
2. All ZF ECVT (Electro Constantly Variable Transmission) unit replacements.

When possible the contact number should be reflected in the warranty claim comments. The Technical Hotline should not be called for the sole reason of obtaining a contact number.

Vehicle Memory

Various operating features in MINI vehicles can be customized using Vehicle Memory.

The customer must be informed about possible choices before delivery by filling out a selection sheet. One copy of the questionnaire stays with the customer, one copy goes to the sales department, and one copy to the service department. According to the customer choices, the vehicle should be customized during the QC 1. Selection changes during the ownership period are not reimbursable under warranty. The customer should not be charged for the programming. Individualizing your customer's vehicle is an important contribution to a positive customer experience.

Note. Any additional items contained in the table of all available options (attached) may also be programmed, but we recommend that they should be discussed with customers at a later date during a service consultation or upon customer request.

Using SSS, DISPlus, or GT1, select CIP to access the Vehicle Memory program

1. After a short period of time the menu screen will be displayed with a list of all detected control systems capable of Vehicle Memory configuration.
2. Using the owner's selection list, enter the system selected for customization.
3. From the system submenu select the function to be altered.
4. Make the appropriate selection (activation/deactivation). The following symbols may be displayed next to the selection choice
5. a light gray diamond symbol indicates present status
6. a factory icon indicates factory default (when present vehicle selection is different)
7. a highlighted diamond symbol indicates entered change in selection

After selecting all desired settings, make certain that encode vehicle is selected.

After a short amount of time, the selection screen will be displayed again, now showing the updated information.

Select "Print List" to have a paper record of the new settings. Place the printed list in the vehicle service file for future reference.

Sample Vehicle Memory Sheet

Vehicle Memory settings for MINI from production date 09/03 on (2004 model year)

"=" factory setting

VEHICLE MEMORY SHEET

Disclaimer

This module is intended for training purposes only. "Warrant Highlights" in no way supercedes or adds to any currently approved warranty information or policies and is not to be used as an information reference. Always consult the latest warranty publications when actual questions about specific issues arise.

The purpose of this training module is to provide the Technician with a basic understanding of warranty policies and procedures.

Although not involved in the day to day operations of submitting and reviewing warranty claims the Technician plays a pivotal role by documenting repairs. The information provided by the Technician is ultimately used for quality analysis at the factory and for BMW's suppliers. The comments provided form the basis of claim submission.

The topics covered in this module will be

1. The New Car/SAV Limited Warranty
2. Repair Order Documentation
3. Understanding MINI Warranty Coding
4. Proper Handling of Warranty Parts

The New Car Limited Warranty

(Valid only in the USA and Puerto Rico)

MINI owners, no matter where they purchase their vehicle, expect and deserve equal treatment when problems arise or service is needed for their vehicle. Prompt and courteous service will not only satisfy customers, but will enhance the MINI Dealer's image and that of the MINI organization.

The New Car Limited Warranty is designed to improve customer product satisfaction and assist MINI Dealers with building customer loyalty and promoting future sales.

The MINI Division of BMW of North America, LLC., "BMW NA", provides limited warranties against defects in material or workmanship to the first retail buyer, and each subsequent purchaser of U.S. specification vehicles distributed by the MINI Division.

The limited warranty begins on the date of first retail sale or the date the vehicle is placed in service as a demonstrator or company vehicle, whichever comes first.

The warranty period is 48 months or 50,000 miles, whichever comes first.

Note. Always discuss any questions concerning warranty procedures or eligibility with the Shop Foreman, Service Manager or Warranty Administrator, as well as referring to the Vehicle Service and Warranty Information Booklet.

Scheme 205

Note. This chart is only for the purpose of providing a general understanding. Please refer to the Service and Warranty Information Booklet applicable for the specific vehicle and model year.

Contents of the Service and Warranty Information Booklet

The Warranty booklet is designed to inform the customer as to the warranty coverage that the MINI Division offers, it is found along with the owners manual in a portfolio, typically stored in the glove box or trunk. The booklet contains information concerning explanations of the MINI Division's Limited Warranty.

Scheme 206

Modified Vehicles

The MINI Division New car Limited Warranty and Emissions Warranty provide protection to the Vehicle owner against defects in factory materials and workmanship. When a vehicle is modified in a way which alters the original engineering or operating specifications, the vehicle quality and safety may be compromised.

"Warranty does not apply to

Modification of the vehicle or installation of any performance accessories or components attached to the vehicle which alters the original engineering and/or operating specifications or which result in damage to the other original components, electrical interference, electrical short, radio static, water leaks, or wind noise."

Installation of an aftermarket part or accessory does not necessarily void the vehicle warranty. The number of possible modifications is very large and therefore a listing of all situations would be impossible. For example, a vehicle with a modified DME might still retain all warranties and may even have additional warranty coverage from the aftermarket supplier.

Damage caused by a previous repair or modification is not the responsibility of the manufacturer (MINI Division) and must be brought to the attention of the customer.

Note. When unknown, modification of a vehicle can complicate troubleshooting and result in multiple repair attempts. If there is suspicion that a component has been modified, contact the Market Team to arrange an inspection.

Common sense must prevail and in a questionable situation the Technician should ask for assistance from the Service Manager who can contact the Warranty Department.

Salvaged Vehicles

Vehicles sold for salvage or otherwise classified as "Totaled" have no warranty coverage from the MINI Division.

Recalls should always be performed where applicable if the vehicle has been reregistered for use on the road. If the recall cannot be performed due to the condition of the vehicle, that fact must be thoroughly documented on the repair order.

New versus Exchange?

Exchange parts must be used for warranty repairs if an exchange part is available from the MINI Division of BMW NA. New parts will only be reimbursed if the exchange was not available by any means (including direct shipment from Germany).

New parts must always be used to repair any new vehicle that has not been placed into demo service or sold (in-stock vehicles).

Repair Order Documentation

A properly documented Repair Order includes

1. Correct Vehicle and Customer Information
2. Proper Recording of Punch Times
3. Complaint, Cause and Correction
4. Complete Documentation of Defect
5. Diagnosis Attachments
6. Parts Information

Correct Vehicle and Customer Information

While not responsible for generating the repair order, the Technician should verify that the information is accurate and discuss any discrepancies with the client advisor. Important information includes

1. VIN
2. Mileage
3. Model Year
4. Model

Recording of Punch Times

All BMW Dealers are required to have a time control system that utilizes a three part time card and a time clock that shows the time of day, date, and month, or the ERO equivalent (Electronic Repair Order).

All repairs whether customer pay, internal or warranty must be documented with a minimum of one on and one off time punch per line item. In addition diagnosis time and work time require separate punches within each line item they are being claimed for.

Having an efficient time control system in-place is important because time records provide the necessary documentation to substantiate the time spent on all repairs (especially diagnosis or work time).

In addition, a time control system is a valuable service management tool which provides a means to measure how much time is spent on each repair and calculate the productivity and efficiency for both the workshop as a whole and the individual Technician.

Many automated reservation systems use productivity to calculate daily work schedules. Incorrect time data could result in too much or not enough work scheduled for the workshop.

Complete Documentation of Defect

The second most important role a Technician plays in the repair process after fixing the vehicle right the first time is documenting what was actually found and how the problem was resolved.

The approved method of documentation of a repair order utilizes the 3 C's

1. Complaint
2. Cause
3. Correction.

Scheme 207

Complaint

Always verify what the written complaint is on the repair order. Record any comments that may help clarification relating to the customer complaint. Numbering the repair requests helps to organize comments in the event of multiple lines.

Cause

Once the problem is diagnosed, carefully document the troubleshooting steps taken and where the root cause of the problem was found. This information is very important in properly identifying the correct defect code that will ultimately be used in processing the warranty claim.

Correction

Finally, document how the complaint was solved. List the steps that were performed. If the part replaced is a ZF or 6-speed AISIN exchange transmission, include the contact number from the Technical Hotline. If the Hotline or the Market Team was contacted and they provided repair instructions, record who, when and what they said to do. Generally the MINI Division will honor repairs performed in these cases when the vehicle is still covered under warranty.

Add-on Repairs

In the course of repairing or servicing a vehicle the technician sometimes finds other concerns that need to be addressed. These additional or so called "add-on" repairs need to be documented properly and receive shop management approval prior to beginning any requested work. In addition the customer approval should be obtained in advance of the work being done regardless if it is warranty or not.

Parts Information

Be sure to include information about the part replaced including production date, serial numbers and vendor names of both the original and replacement part. Recording such details often resolves much of the confusion that occurs when attempting to match parts to the repair order documents in the warranty parts retention area.

Scheme 208

Understanding MINI Warranty Coding

The coding of individual repair orders should only be done by trained warranty administrators, however the technician should be familiar with the MINI Division coding. Recognizing what the warranty administrator needs helps to prevent mistakes and misunderstandings.

For example: If the wheels are removed for Job #1 and Job #2 is a brake repair, it is helpful when documenting line #2 to state, "Replace brake caliper, wheels already removed".

Flat rate operations (labor codes) and the associated time allowances, as well as defect codes for claim submission are found in www.minidealernet.com under KSD.

The time allowance for work performed is expressed in flat rate units (fru). Flat rate time allowances cover the described job and also includes the time required for basic troubleshooting using proper MINI procedures and replacing the defective part.

The flat rate allowance for a specific repair also includes the time necessary to: obtain the repair order, locate and place the vehicle on the lift, obtain the necessary tools, clean and drain parts replaced and clean up after the repair.

Structure of the Flat Rate System

The Flat Rate System is divided into numerical sections that correspond generally to the Main Group Numbering System also used by the parts department.

Flat rate numbers are 7-digit and are made up of a 2-digit main group, a 2-digit subgroup and the 3-digit consecutive number.

Plus Codes "+"

Plus codes are a type of associated labor that must be used in conjunction with performing multiple main labor repairs. Only one main labor operation may be used and any other main work performed must be coded with plus code operations. This removes the overlapping administrative time that otherwise would occur when utilizing multiple main labor operations. Plus codes have always been available for most repair combinations.

Example: +11 12 599 Removing and installing cylinder head

In summary an "associate operation" removes the potential overlapping time from the technical aspect, and "plus operations" from the administrative aspect, that otherwise would have occurred if multiple main labor operations were used for the same repair visit.

Over the years BMW of North America, LLC. has requested feedback from each center on missing flat rate times or times that were insufficient. Many changes have found their way from the survey sheets submitted by BMW centers to today's flat rate times. The current KSD always incorporates the latest changes.

Specific questions concerning flat rates may be addressed to the Warranty Department at anytime. Please provide the vehicle identification number to identify the model, transmission type, and production date since these will affect the time allowance.

Note. Many times Service Information Bulletins contain warranty information. This warranty information is to be used in place of labor operations from the KSD CD ROM. Please be aware of the need to document the proper Work Package on the repair order that corresponds to the work that was performed.

Proper Handling of Warranty Parts

All parts replaced under the MINI Division's limited warranty becomes the property of the MINI Division and must be held by the parts department until notification of claim payment. MINI Division reserves the right to inspect parts replaced under warranty or have the parts returned to the MINI Division of BMW NA.

Replacing and Repackaging Removed Parts

Use care when removing warranty parts from the vehicle. Damaged or destroyed parts have no value for analysis and could result in the claim being rejected.

Replacement part boxes and original packaging should be used for returning parts. Some components, (i.e. A/C compressors, steering boxes, transmissions, CD changer etc) require special packaging or protective caps for return of the component. This helps to prevent damage to a part that may be remanufactured as well as preserve it for analysis. Certain parts without these protective shipping devices will be returned to the MINI dealer and the claim debited.

Returning Removed Parts to the Parts Department

It is very important that the Parts Department receives and sends the correct part for the warranty claim. To prevent confusion, document the vehicle chassis number, the date and the Repair order number directly on the part with tape or its packaging. Personnel in the parts department need this information when matching a part to the warranty parts tag.

If the Warranty Parts Return Center determines that

1. A part is not defective
2. The wrong part was sent
3. The part was altered from original condition
4. A part does not have the required BMW DIS/MoDiC printout attached
5. The part has been received physically damaged

A debit will be issued for the portion of the claim identifying the reason for the debit.

Note. Parts that are replaced on a customer pay repair order belong to the customer and should not be discarded unless directed by the customer.

1) "Customer ready"

(The battery main disconnect switch has been removed)

1.1) Vehicle goes into storage (back lot)

A four week charging cycle and calendar has been established for these cases.

The vehicle arrives, marked with a color-coded round sticker on the windshield. The respective color (one out-of-four possible colors) designates that the vehicle's battery must be charged in accordance with the new calendar on a four week cycle.

Also, the vehicle is received with a BATTERY LOG FORM. This form has to be completed upon receipt and subsequently has to be filed in the BATTERY CHARGE LOG (binder) under the applicable color coded section. All vehicles identified by their respective sheets in one section will have to be recharged in that week.

1.2) Vehicle goes into showroom or new vehicle display

A four week charging cycle will not suffice due to the increased current draw imposed on the battery because of frequent usage of the vehicle's electrical components (demonstrations, product familiarization, etc.).

Please fill in Section "A" of the BATTERY LOG FORM upon receipt of the vehicle. Further, the battery voltage should be monitored depending on the extent of customer traffic if the vehicle is subjected to, or is used for demonstrations. (Maximum: 1 check per day; minimum: 1 check per week.) The battery has to be recharged as frequently as necessary to ensure that the voltage never drops below 12.5V.

Please note every instance of recharging on the BATTERY LOG FORM, section "C". Please file in BATTERY LOG FORM in the BATTERY CHARGE LOG (binder) under the section "SHOWROOM" to provide for an instant overview of the charging activities on these vehicles at all times.

2) "Storage"

The battery draw has been minimized for storage purposes. (The battery main disconnect switch remains on the vehicle in the "OFF" position)

With the battery draw minimized, a 3-month charging cycle can be followed. Please use section "D" of the BATTERY LOG FORM to document every occurrence of charging.

Please fill in section "A" of the BATTERY LOG FORM upon receipt of the vehicle. The new windshield labels can be used to track these vehicles with the exception of those vehicles bearing a "yellow" label. These yellow labels have to be removed and replaced by one of the three applicable colors.

Please file the BATTERY LOG FORM in the BATTERY CHARGE LOG (binder) also under the "SHOWROOM" section.

3) Used vehicles

Used vehicles in MINI dealer inventory should be monitored and recharged according to the above principles. There is no reason why the battery maintenance should be neglected since poor reliability of a pre-owned MINI may deter a customer from buying a new one at a later date.

The above guidelines for proper battery maintenance are meant to provide maximum flexibility for every MINI dealer. Regional personnel will be happy to assist with setting up an effective charging and monitoring program.

Upon the sale of a MINI, its BATTERY LOG FORM should be removed from the BATTERY CHARGE LOG (binder) and filed in the vehicle file to be available for future reference.

Since leaving a battery in a discharged state has a detrimental effect on its service life, improper battery maintenance may result in rejected battery warranty claims.

Under certain circumstances (vehicle parked for the extensive period of time), due to electrolyte density stratification inside the battery, the internal hydrometer ("Magic Eye") may provide a false reading ("black eye") indicating insufficient charge condition. This is caused by the lower density electrolyte being positioned near the top of the battery, where hydrometer is located.

Always use an approved battery tester to evaluate battery's state of charge.

If, at anytime, battery voltage should drop below 11.6 volts and remain at this level or less for three or more days, this battery MUST BE SCRAPPED and the vehicle battery

Dispose of all batteries properly observing legal regulations.

Battery Log Form Procedures

A battery log form and binder have been developed to assist in tracking the battery maintenance of the vehicles at MINI dealers. The form is 2-sided which allows the use of a 4-week charging cycle or a 3-month cycle for those vehicles that have the battery draw minimized.

The form will be put in the glove box of each MINI and the charging cycle windshield label will be applied at the VDC. When the vehicle arrives at the MINI dealer, the form should be completed in the first section (A) which lists basic vehicle information; and the MINI dealer stock # entered on top.

The form has 3 charging cycles that can be used depending on the location of the vehicle at the MINI dealer (showroom display or storage), or vehicles that have the battery draw minimized.

For storage vehicles that do not have the battery draw minimized, Section B should be used. These vehicles follow a 4-week charging cycle, indicated by the windshield label color (white, red, green or yellow). This section of the form has 4 columns with the 4 individual colors and dates of the weeks when the vehicle must be recharged. The windshield label color indicates the column to be used for the charging cycle. The voltage should be checked and noted before charging and the form initialed after charging has been completed.

Section C has been designed for showroom vehicles and all vehicles in a "display" area. Any of these vehicles with a high rate of activity (i.e., customer demonstrations, etc.) should have the battery voltage monitored daily and if battery voltage drops below 12.5V, must be recharged and entered on the log form. As a minimum, each vehicle must be monitored once per week.

Note 1: For those MINI dealers who have established their own working battery maintenance procedure which falls within the guidelines, Section C can be used to track the charging of those vehicles.

Any storage vehicle moved to a display area then follows the daily/weekly monitoring cycle and should be tracked using Section C of the form.

Section D should be used for those vehicles with battery draw minimized to extend their battery maintenance requirements. These vehicles will follow the previous 3-month charging calendar. The columns on the form are identified by the colors white, red and green of the 3-month charging calendar designating the months the vehicles are to be charged. The windshield labels can also be used to track these vehicles with the exception of the 4th color, yellow. Therefore, the colored windshield labels will be available to reassign a vehicle (with a yellow charging cycle) to another cycle of the 3-month calendar, if necessary.

To facilitate the use of the forms and vehicle monitoring, a BATTERY CHARGE LOG binder was developed with 5 separators to file the maintenance forms by charging cycle. Four of the separators come in the colors of the charging cycles and the 5th separator will be marked SHOWROOM. As each form is received along with a new vehicle, it should then be filed in the binder in the appropriate section for easier tracking.

Each form should remain in the binder until the vehicle is sold, at which point it should be moved to the vehicle history file.

Before performing load test make sure the temperature of the electrolyte is at least 65°F. New batteries should not be load tested after initial filling of electrolyte. Check state of charge with a voltmeter.

To ensure the battery remains fully charged, start the engine before demonstrating the operations of components to the customer at the time of delivery.

Please note that the procedures outlined above are meant to be guidelines to assist MINI dealers in assuring a sufficient state of charge of vehicle batteries at all times. Following these procedures, however, will not guarantee a sufficient state of charge on all batteries since there may be exceptional cases of excessive current draw through very frequent movement of back lot vehicles, for example, which may call for more frequent recharging than otherwise necessary.