I just got my car back after having the windshield replaced and to have a mystery A/C problem investigated. The service manager had some interesting observations I thought might interest people.

MINI investigated the windshield problem and traced it to the factory. The installation machine was installing the windshield slightly out of alignment. Because of the curve of the windshield the installation has to be very precise. Any misalignment will cause undue stress and cause cracks. They are very diligent about alignment and (this dealership) has not had any problems after the initial replacement.

They could not find anything wrong with the computer diagnostics, so had no answer as to why the A/C quit, then worked (but with the check engine light light), and then worked as it should without the light, all within 1 hour. Haven't had any problem since that time.

I was asking about the stumble I experienced starting off from a dead stop. Some customers last winter got relief by switching to regular gas. There is speculation that the MINI is very sensitive to fuel mixtures, and the alcohol added to winter blends may be a source of the stumble problem. The premium fuels get a greater proportion of alcohol, and the stumble may have been reduced by using a lower octane blend.

I have notice less of a stumble this last week, and maybe it is due to changes in the blends for summer gas being introduced.

If so, it might explain why BMW is having so much difficulty coming up with a software patch to fix this problem since they are trying to hit a moving target: seasonal changes in fuel mixtures, and regional variation in mixtures.

Could knowledgeable people comment on the credibility of this theory?

 

That could be.... my Cooper has trouble starting cold all the time, but the S has only started developing the problem since the temperature has risen above 40 degrees or so. Who knows.

 

First of all, thank you very much for your informative post, nuvolari!
This is what makes MCO such a great site!

My 2 c worth on your remarks are inserted after your remarks below:


>>I just got my car back after having the windshield replaced and to have a mystery A/C problem investigated. The service manager had some interesting observations I thought might interest people.
>>
>>MINI investigated the windshield problem and traced it to the factory. The installation machine was installing the windshield slightly out of alignment. Because of the curve of the windshield the installation has to be very precise. Any misalignment will cause undue stress and cause cracks. They are very diligent about alignment and (this dealership) has not had any problems after the initial replacement.
>>

I don't really buy this: misalignment at the factory may have been one problem, but I don't think it's the only one. Supposedly the misalignment was rectified at a certain date, and stress cracks should not have appeared after that production date. Yet, some people with v ery recent production dates have reported stress cracks. The issue there has become one of deciding whether these were stress cracks or chip-induced cracks. In many cases, MINI appears to assert that they must be chip induced cracks because they happened after the installation change date, yet owners have claimed that some of these cracks have appeared with the car sitting in the garage! So, I am not convinced. The other issue is that the glass is too soft and chips too readily. As a result, 2 things could happen: 1) stress cracks could happen but appear to be chip related because there are so many chips on most windshields after some time, and so the likelihood is that a stress crack will find a nearby weak spot = chip hole, and appear to be a chip crack when it is not, or 2) chips weaken the windshield in stress spots, resulting in a crack that would not have appeared without the chips. Mind you, this is a speculation.
However, to my knowledge MINI has not at all addressed the issue of glass that is too soft!!!!!
Plus, cracked windshields are still being reported, and I don't think at a rate that has dropped, but we will have to keep an eye on this one!



>>They could not find anything wrong with the computer diagnostics, so had no answer as to why the A/C quit, then worked (but with the check engine light light), and then worked as it should without the light, all within 1 hour. Haven't had any problem since that time.
>>

I would guess the Microsoft syndrome. I have had 2 instances where the Auto AC controls went completely dead: none of the controls worked, but then all was fine after a reboot (turn car off and on again). That was a long time ago and has not happened in last 2 months.

>>I was asking about the stumble I experienced starting off from a dead stop. Some customers last winter got relief by switching to regular gas. There is speculation that the MINI is very sensitive to fuel mixtures, and the alcohol added to winter blends may be a source of the stumble problem. The premium fuels get a greater proportion of alcohol, and the stumble may have been reduced by using a lower octane blend.
>>
>>I have notice less of a stumble this last week, and maybe it is due to changes in the blends for summer gas being introduced.
>>
>>If so, it might explain why BMW is having so much difficulty coming up with a software patch to fix this problem since they are trying to hit a moving target: seasonal changes in fuel mixtures, and regional variation in mixtures.
>>
>>Could knowledgeable people comment on the credibility of this theory?
>>

I would agree that it is plausible that the stumble is in part related to or affected by fuel issues, but maybe other factors as well. I have an 03 MCS, and have experienced a bit of a stumble occasionally, but not ei=ough to cause me to get a software update until I know for sure that an update will fix it. It does not bother me that much and I don't want to make it worse. My old subaru had a much more substantial stumble, so this one seems mild by comparison. Other parameters that might affect the stumble could include:
temperature and humidity, elevation, and certainly type of fuel. This could explain why symptoms differ so much for different drivers, and then it would be very difficult to indentify the source of the problem and find a solution.

As someone else posted separately to MINI USA, regarding a lot of these issues it would be great, helpful and immensely reassuring if MINI USA would keep us a little better informed about these issues. Personally, I would not perceive it as negative in any way if MINI USA posted a message stating e.g.: we realize the stumbling is still an issue, and the windscreen is still an issue. We are continuing to work on a solution, and here is the reason it is taking so long: regional and seasonal fuel differences make it hard to... etc... In other words, keep us more informed, please, and not just with: we're working on it, but with detaiuls as to why it is taking so long!

Cheers,
Markus

 

MG-BGT says, (edited):

>>I don't really buy this: misalignment at the factory may have been one problem, but I don't think it's the only one. Supposedly the misalignment was rectified at a certain date, and stress cracks should not have appeared after that production date. Yet, some people with v ery recent production dates have reported stress cracks.

I failed to mention that my car is from Canada, and was one of the "launch edition" MINIs. It was brought in to the States in May, 2002. I bought it in January, 2003. After patiently waiting for some sucker to buy it for six months at some gouging price the Phoenix, AZ dealer apparently dropped the price to some more reasonable number by the time I bought it from a Tacoma, WA broker. The cracks were very small on two diagonal corners. It made sense to me, given the pattern and tiny size of the cracks and that it was a very early build, that it was caused by stress.

>>I would guess the Microsoft syndrome. I have had 2 instances where the Auto AC controls went completely dead: none of the controls worked, but then all was fine after a reboot (turn car off and on again). That was a long time ago and has not happened in last 2 months.

Well at least I won't panic next time. The service manager said they had customers report a similar problem but could not reproduce it. She said, if possible bring it in when that happens, stop outside the garage and LEAVE THE ENGINE RUNNING. They may be able to capture some information that way.

>>As someone else posted separately to MINI USA, regarding a lot of these issues it would be great, helpful and immensely reassuring if MINI USA would keep us a little better informed about these issues. Personally, I would not perceive it as negative in any way if MINI USA posted a message stating e.g.: we realize the stumbling is still an issue, and the windscreen is still an issue. We are continuing to work on a solution, and here is the reason it is taking so long: regional and seasonal fuel differences make it hard to... etc... In other words, keep us more informed, please, and not just with: we're working on it, but with detaiuls as to why it is taking so long!
>>
>>Cheers,
>>Markus

I agree. What is the latest buzzword about business on the news this last year? "Transparency?" Companies that acknowledge problems and communicate their plans to address those problems diffuse negative reactions and establish trust with their customers. Companies that stonewall and cover up problems are hurt by falling sales and stock prices.