HI all, there is a little history here so let me be detailed.

in 2017 I had a "GUY" Clone a new key to my 2006 R53 (6 speed manual), during this process they remove the EWS and READ the board to generate a new cloned KEY, they state the EWS is in no way modified or written to.
Well, that caused the EWS to FAIL and no longer recognize ANY key original or new.... I had to Get a new EWS and sync it to the car and my original key worked again... I left it at that

Now fast forward to 2025, I again contracted a different "BMW Key Specialist" and informed them of my previous experience with my EWS, they stated they were experienced in the matter and would perform the JOB without problems.
Well, what do you know, IT HAPPENED AGAIN! This time these have been more detailed in finding the problem. It seems the EWS is reading BOTH keys but the starter relay inside the EWS is not getting power.
If we jump the starter relay output to starter, directly from the EWS the car starts up perfectly with both keys.

We have discarded the possibility of the clutch switch being faulty by installing a new one just in case. Tech states that the Starter Relay in the EWS it's not just activating, its actually NOT getting power (need to confirm this)

Any ideas where I should start to diagnose this, I don't want to just throw a new EWS and have that not be the answer (and losing the cloned key), even though this was the solution last time, the tech assures me it's not the culprit this time
Edit: I was assured by the tech that he tested my EWS on another MINI and it worked just fine

A new dealer key for this model here is about $600
I could always have my ECM programmed/altered to bypass all EWS functions, but at the moment I'm not sure If I have other issues.

Any ideas or leads to diagnose this will be much appreciated,

Thanks, in advanced.

 

I will try the steps shown here to test the starter/switch activation WITHOUT the EWS to discard the faulty EWS possibility,
IF this CRANKS then it's the EWS, if it don't then it must be elsewhere.

 

One of the few good sources of info.

https://www.rpmmotorsport.net/collec...rpm-motorsport

 

Hopefully you didn't just eliminate the clutch switch? You also have to "jump" the terminals to bypass the Hall effect (magnetic) switch in order to start the car. Was that done?

 

The Clutch switch is in place and connected, sorry about my misleading statement saying I discarded the Clutch Switch, I meant to say we have discarded the clutch switch from a possible faulty switch culprit, (I will edit original post to clarify this.)

I'm taking over the diagnostics now, so I'm currently looking up the Clutch Switch Diagram, I will assume I need to jump Pin#3 & pin#4 (or press clutch pedal ) following the diagram below? (pin#2 goes to DME) I will also assume pin#8 in the EWS is expecting a 12v signal, and Pin#3 in Clutch Switch should be live 12v?

I have reviewed most of wiring diagrams and have a better Idea of sources to verify, including fuse box, ignition switch, Clutch Switch and EWS inputs. Hopefully these can narrow down the culprit.

 

Thanks, this would be the last resort, but great to have the resources ready!

 

Jumping the pins is only necessary if you want to bypass the clutch switch. Since you just installed a new switch I doubt that's your problem.

Suggestion: member "adriancl" is an automotive engineer and remote tunes many other members' MINIs on this forum, including mine. It's possible he might be able to help diagnose your problem remotely.

 

UPDATE:
Bypassing the EWS Harness (as in video) I got CRANK at starter when key turned, so I will assume the Ignition Switch is good and Power is also good on wiring.

Using a Foxwell (BMW/MINI) 530 Scanner (Diagnostics section) I was able to read the live data from the EWS, I found 2 areas of concern.
The BAD:
1. it states "Stater Blocked by P/N" this usually means the EWS is not synced with the ECU/DME.
2. Clutch switch live data stays in "Driving Mode" even when pressed, but this could be a result of "Not synced State".
The GOOD:
3. Key live data is recognized as OK, rolling code is OK, EWS also identifies Ignition ON/OFF, (key is passing all security)

on further diagnostics, when using the Foxwell Scanner (Service section):
4. when I try to read the DME service section I get NO connection.
5. when I try to enter the EWS service section I also get NO Connection,
6. All other service sections communicate seem to work correctly.

Odd I can read EWS live data but not access the service area of the EWS,
On a WEB search, someone had this EXACT problem, and while the EWS did not show clutch switch operation, the same live data from the DME did show the clutch switch operation, he was able to sync the EWS using INPA eliminating the "Blocked Starte by P/N" code from the EWS. (I can't read the DME live data)
I believe what I have here is a problem in communicating to the DME from the OBD Connector therefore not being able to Sync the EWS from Scanner. I will try to use INPA for more info. (K+CDAN USB Cable)

This is making some sense, in 2017 my solution was to order a new EWS from BMW, it probably synced since it was a dealer part maybe pre synced?
Maybe a solution would be to test my DME and EWS on another vehicle see if I can get communication (identifying a wiring problem) or use a donor DME (just to test communication) on my Mini (identifying a DME problem)?

For the moment I guess I will have to "JUMP" the starter signal manually from the EWS harness to start the vehicle.

Will UPDATE with INPA results.

 

Thanks, this WILL come in handy once my Laptop and INPA/INSTA/NCS/WFP is up and running.