NHTSA Complaint #10457532 — 2005 MINI COOPER S

VEHICLE FIRE 5/2/2012. CAR PARKED FOR 4 HRS. RETURNED TO CAR & DROVE IT <50 YARDS FOR ~2 MINUTES (MOVED IT FROM STREET TO PARKING LOT). TURNED IT OFF AND WENT IN STORE. RETURNED ~4 MINUTES LATER, NOTICED SMOKE/EXHAUST SMELL; PRESUMED IT WAS ADJACENT CAR. UNLOCKED CAR. CAR WOULD'T START (NO LIGHTS/ELECTRICAL AT ALL). I THEN NOTICED WHITE SMOKE COMING FROM HOOD. OPENED HOOD THEN NOTICED FLAME/FIRE INSIDE ENGINE COMPARTMENT. WENT IN STORE, GOT FIRE EXTINGUISHER AND PUT FIRE OUT. INVOICE WAS >$3500 FROM MINI DEALER. THE DEALER'S ASSESSMENT: "VERIFIED POWER STEERING PUMP HAS OVERHEATED TO THE POINT WHERE IT HAS BURNED UP INTERNALLY AS WELL AS EXTERNALLY (MELTING ALL THREE CONNECTORS AND THE WIRING LEADING TO THEM). INSPECTED POWER STEERING COOLING FAN AND VERIFIED COOLING FAN IS SEIZING UP WHICH VERY LIKELY LED TO THE OVERHEATING AND EVENTUAL FAILURE OF THE POWER STEERING PUMP. REMOVED ENGINE COMPARTMENT FUSE BOX TO EXAMINE MEGAFUSE POWERING THE POWER STEERING PUMP, FUSE IS INTACT AND DID NOT BURN UP. INSPECTED POWER STEERING PRESSURE HOSE AND IT APPEARS THE RUBBER SECTION OF THE POWER STEERING PRESSURE LINE WAS SUBJECTED TO THE HEAT/MELTING OF THE MAIN POWER CONNECTOR (IT'S IN VERY CLOSE PROXIMITY TO THE CONNECTOR) AND IT APPEARS THE HOSE HAS TAKEN A LEVEL OF DAMAGE FROM THE HEAT. RECOMMEND REPLACEMENT OF POWER STEERING PUMP, THE WIRING SECTION/CONNECTOR PIGTAIL FROM THE FUSE BOX (THIS IS THE MAIN POWER CONNECTOR), THE ENGINE WIRING HARNESS (CONTAINS TWO OTHER ELECTRICAL CONNECTORS TO THE PUMP WHICH RECEIVED EXTENSIVE DAMAGE), THE POWER STEERING FAN (LIKELY CAUSE OF FAILURE), POWER STEERING PRESSURE LINE (HIGH PRESSURE HYDRAULIC LINE WHICH HAS BEEN EXPOSED TO THE MAIN CONNECTOR MELTING AND SUBSEQUENT HEAT), AND OTHER MISCELLANEOUS ITEMS ASSOCIATED WITH THOSE COMPONENTS (O-RINGS, CRUSH RINGS, HOSE CLAMPS ECT...)" *TR