NHTSA Complaint #10483585 — 2007 MINI COOPER

WHILE DRIVING IN TRAFFIC, THE ENGINE SEIZED AND STOPPED ABRUPTLY DUE TO THE FAILURE OF THE OIL SUCTION PUMP. THE PUMP FAILED INTERNALLY AND DUE TO THE DESIGN THAT TIED IT DIRECTLY TO THE OVERHEAD CAM, IT CAUSED THE CAMSHAFT TO SEIZE, STRETCHED AND BROKE THE BOLT CONNECTING THE TIMING GEAR AND CHAIN TO THE CAMSHAFT, WHICH THE FELL INTO THE LOWER ENGINE AREA AND CAUSED FURTHER ENGINE DAMAGE. FORTUNATELY, THIS PARTICULAR INCIDENT OCCURRED IN A RELATIVELY SLOW TRAFFIC SITUATION AND THE CAR WAS SHIFTED TO NEUTRAL AND PUSHED OFF TO THE SIDE. DAMAGE TO THE ENGINE WAS SUBSTANTIAL AND CONSISTENT WITH MULTIPLE OTHER REPORTS OF SIMILAR FAILURES. THIS IS A MAJOR DESIGN FLAW (IN MY OPINION AS AN ENGINEER) IN THAT THE SHEAR POINT BEING ON THE CAMSHAFT INSTEAD OF THE PUMP CAUSES INSTANTANEOUS ENGINE FAILURE WITHOUT WARNING AND COULD LEAD TO A SERIOUS CRASH OR INJURY. IN ADDITION TO THIS FAILURE, THERE WAS DAMAGE TO THE OIL SYSTEM THAT MAY HAVE TRIGGERED THIS PUMP FAILURE. MINI HAD ALLEGEDLY PERFORMED SOME 'VALVE CLEANING' APPROXIMATELY 6,000 MILES PRIOR TO THIS INCIDENT, HOWEVER THERE WAS NO EVIDENCE OF ANY SUCH 'CLEANING' WHEN THE ENGINE WAS OPENED. I HAVE EXTENSIVE PHOTOS OF THIS ENGINE AS IT WAS DISASSEMBLED, SHOWING THE PUMP, BOLT AND OTHER PARTS AND WILL BE HAPPY TO SHARE THOSE. *TR