Manifold/header/muffler/tail Pipe problems of the 2003 Mini Cooper S

Two problems related to manifold/header/muffler/tail pipe have been reported for the 2003 Mini Cooper S. The most recently reported issues are listed below. Please also check out the statistics and reliability analysis of the 2003 Mini Cooper S based on all problems reported for the 2003 Cooper S.

1 Manifold/header/muffler/tail Pipe problem

Failure Date: 12/05/2008

I purchased my '03 Mini copper s with 49k from a Honda in mechanicsburg, PA dealer in August. In December, I purchased tires and then went to a self-service carwash afterward. When I got home and before I put it in the garage, I took out the hose and washed off the wheels and under the car. During the process there was white smoke, which I thought was steam from the water hitting the manifold. I put the car in the garage and later when my wife came home she commented on the smoke and mist in the garage (it was quite cold that night. ) the next day when I pulled the car out, the steering was very stiff and I only drove it out the driveway and on the road before I realized the power steering was completely out. I drove it about 15 miles to the dealer after checking fuses and determining that the problem was beyond my mechanical skills. The power steering pump, fan and harness were replaced along with the battery (shorted out). Insurance adjusters from hondacare (extended warranty), state farm insurance company (my comprehensive insurance) and the dealership determined that the power steering pump had caught fire. Their conjecture was that I had put out the fire with the hose when I sprayed under the car. Honda care paid $1999 from extended warranty for the power steering pump, battery, power steering harness and fan. A total of $2700 additional from state farm comprehensive insurance (hondacare extended warranty would not cover harness, towing and diagnostic work from the Mini dealer in maryland, etc because they were the result of damage caused by the power steering pump fire); state farm insurance was exceptional and covered the difference with comprehensive covered. The parts are not available at this time but I was told that there are reports including pictures from adjusters at hondacare and from state farm insurance.

2 Manifold/header/muffler/tail Pipe problem

Failure Date: 12/02/2007

While driving the car to the dealership for service I heard a loud noise and felt a shutter, then a loss of power and smoke to the rear of the car. I turned motor off and coasted to the side of the road to make sure everything was ok. Once stopped, I tried to restart the car. Saw more smoke and sparks from the tail pipe. I then sat and started to call a tow truck, when I noticed flames coming from the hood scoop. I popped the hood and upon opening it, noticed a fire at the front of the motor, directly in front of the supercharger. I was unable to put out the flame, so I call 911 and the fire department was on site to put out the fire in a few minutes, but by then the entire engine compartment was engulfed in flames. Allstate called it a total loss.


Other Engine And Engine Cooling related problems of the 2003 Mini Cooper S



Safety Ratings of Cooper S Cars
Cooper S Service Bulletins
Cooper S Safety Recalls
Cooper S Defect Investigations