Mini Cooper Parts Catalog Mini Cooper Accessories Catalog Mini Cooper Technical Articles Mini Cooper Tech Forums
 
  Search our site:    
View Recent Cars  |   Cart  | Project List | Order Status | Help    
Bookmark and Share

Pelican Technical Article:

Fuel Filter Replacement

Nick Czerula

Time:

3 hours3 hrs

Tab:

$300

Talent:

*****

Tools:

Strap wrench, channel locks, 10mm socket, fuel pump collar tool

Applicable Models:

R52 MINI Cooper Convertible (2007-08)
R52 MINI Cooper S Convertible (2007-08)
R56 MINI Cooper Hatchback (2007-11)
R56 MINI Cooper S Hatchback (2007-11)
R57 MINI Cooper Convertible (2009-11)
R57 MINI Cooper S Convertible (2009-11)

Parts Required:

Fuel filter, fuel filter-sealing O-rings

Hot Tip:

Clean top of fuel tank before removing pump

Performance Gain:

Repair clogged fuel filter

Complementary Modification:

Fuel pump in left side of fuel tank

The fuel supply system in a MINI R56 consists of:

  • Fuel tank
  • Fuel filler with associated breathing and venting pipes
  • High-pressure fuel pump assembly with fuel filter and fuel level senders

The fuel tank is two-lobed. There are two fuel level senders, one in each lobe on the left and right sides underneath the rear seat cushion. The right fuel tank lobe holds the fuel level sender and fuel filter, while the left tank lobe holds the fuel pump.

In tank fuel pumps have many benefits. The fuel is submerged in fuel keeping it cool, preventing vapor lock and electrical issues. The fuel pump delivers a constant flow of gasoline to the fuel rail at a regulated pressure and volume. The fuel pump draws fuel from the fuel tank and pushes it through the fuel filter, mounted outside of the fuel tank.

A dirty or restricted fuel filter can cause poor engine performance and hard starting problems. If you suspect this is your issue you should replace your fuel filter.

Replacing the fuel filter on a MINI can be done without removing the fuel tank. There are access panels under the rear seat cushion that allow servicing. It is best to replace your fuel filter with the fuel tank drained. This reduces the amount of possible spilled fuel and fuel vapors. When replacing, work in a well-ventilated area. Working outdoors is a good choice. Do not use incandescent work lights or power tools. Fuel and fuel vapors are highly combustible. To relieve fuel pressure, remove the fuel pressure test cap and activate the Schrader valve. See our tech article on fuel pump testing.

Keep in mind that when your car was serviced before, parts may have been replaced with different size fasteners used in the replacement. The sizes of the nuts and bolts we give may be different from what you have, so be prepared with different size sockets and wrenches.

Protect your eyes, hands and body from fluids, dust and debris while working on your vehicle. If you're working with the electrical system, disconnect the battery before beginning. Always catch fluids in appropriate containers and properly dispose of any fluid waste. Recycle parts, packaging and fluids when possible. Do not work on your vehicle if you feel the task is beyond your ability.

Vehicle models change and evolve, as they grow older, so the vehicle shown in our illustrations may vary slightly from yours. If something seems different, let us know and share your info to help other users. Do you have questions or want to add to the article? Leave a comment below. When leaving a comment, please leave your vehicle information.

Drain your fuel tank. Run the vehicle for about 20 seconds. This equalizes the amount of fuel in the siphon unit.

Disconnect the negative battery cable. See our tech article on battery replacing and reconnecting notes.

Remove the fuel cap, then slide an anti-static siphon hose down the fuel filler neck. Once the hose has bottomed out, pump fuel out of the fuel tank into a suitable storage container. If you are unsure of the amount of fuel in your tank, you can monitor the fuel level via the fuel level sender units. As the fuel level drops, the fuel level sender resistance drops. You can measure this across the terminals at both sender units with a digital volt / ohmmeter (DVOM). You will need a wiring diagram from a repair manual.

Working in the rear of the vehicle interior, grab the corner of the rear seat cushion and pull it up to detach the locking tabs. Remove the seat cushion from the vehicle. See our tech article on seats removing.

The fuel pump /sending unit is located in the left (green arrow) side of the fuel tank.
Figure 1

The fuel pump /sending unit is located in the left (green arrow) side of the fuel tank. The sending unit / fuel filter / siphon unit are located on the right (red arrow) side.

Once you have removed the rear seat, remove the four 10mm nuts from the access panel (red arrows).
Figure 2

Once you have removed the rear seat, remove the four 10mm nuts from the access panel (red arrows). Remove the access panel lid from the body by lifting it up. Be sure to replace the panel gasket if it is damaged (inset).

Working at the fuel filter housing, remove the fuel line by squeezing the retaining clip (red arrows) and pulling the line straight out (inset).
Figure 3

Working at the fuel filter housing, remove the fuel line by squeezing the retaining clip (red arrows) and pulling the line straight out (inset).

Next, you have to unscrew the fuel filter assembly threaded collar.
Figure 4

Next, you have to unscrew the fuel filter assembly threaded collar. There is a MINI special tool (number 16 1 022) made to do this. The tool has notches that match the teeth on the collar. However, if you do not have this tool you can use a brass punch (red arrow) and a rubber mallet. Using the brash punch and a rubber mallet, tap the threaded collar on one of the ridges counter-clockwise to loosen. Once loose, unscrew the remainder of the way by hand. If the collar is damaged during this process, you will need to replace it with a new part. Remove the collar (inset).

Slowly lift the fuel unit up slightly out of the tank enough to remove the sealing O-ring.
Figure 5

Slowly lift the fuel unit up slightly out of the tank enough to remove the sealing O-ring.

Slowly lift the fuel unit up slightly out of the tank enough to access the siphon mount.
Figure 6

Slowly lift the fuel unit up slightly out of the tank enough to access the siphon mount. Release the retainer (red arrow) and slide the siphon mount off the fuel pump unit (green arrow).

Slowly lift the fuel unit up.
Figure 7

Slowly lift the fuel unit up. Compress the sending unit (green arrow) up as you lift the assembly out of the fuel tank. Be prepared with rags and a drain pan to catch any leaking fuel. The wiring and fuel lines will keep the assembly attached to the tank, but you can remove it enough to get the filter replaced.

Place the assembly on the vehicle floor.
Figure 8

Place the assembly on the vehicle floor. Sit it on a large rag or towel. Use a strap wrench (green arrow) to counterhold the assembly while loosening the filter lid using channel locks (red arrow). Rotate the lid about 20° to unlock the tabs.

Once unlocked, gently lever the lid out of the assembly (red arrow).
Figure 9

Once unlocked, gently lever the lid out of the assembly (red arrow).

Remove the lid (red arrow).
Figure 10

Remove the lid (red arrow). Be sure to get the old sealing O-ring out of the housing (green arrow).

Remove the filter from the housing.
Figure 11

Remove the filter from the housing. The sealing O-ring will hold it in. You will have to rotate as you pull up.

Replace both filter sealing O-rings, at the lid (red arrow) and the housing (green arrow).
Figure 12

Replace both filter sealing O-rings, at the lid (red arrow) and the housing (green arrow). Be sure to clean the housing out also. Wipe it clean with a lint free cloth.

This photo shows the left side fuel unit with the level sender and integrated fuel filter.
Figure 13

This photo shows the left side fuel unit with the level sender and integrated fuel filter. To replace the fuel filter, you have to replace the entire unit.

Install the new filter, press it into place until it bottoms out.
Figure 14

Install the new filter, press it into place until it bottoms out. Install the new sealing O-ring onto the lid, and slide it into the top of the filter. Align the small retainers (red arrows) with the small holes and do the same for the large retainers (green arrow) and large holes. Press the filter lid down and rotate it until locked into place. Be sure the fuel line connection is orientated as it was before removal. See step 3 for photo. Reattach the siphon as you insert assembly into tank. Hand-tighten the threaded collar. Then use the BMW special tool 16 1 022 to tighten the threaded collar. Or tap the threaded collar tight (clockwise) with a brass punch and a rubber mallet. Connect the fuel line. Fill the fuel tank with about two gallons of fuel before attempting to start the vehicle. Once you are sure that the fuel pump is operating normally, fill the remainder of the fuel tank and check for leaks. Once done, reassemble the interior.


Bookmark and Share
Comments and Suggestions:
sharkythesharkdogg Comments: I use garbage bags held on with painters tape to cover the surrounding seat faces and side panels because sometimes the filter housing won't separate without a good bit of force. Fuel on your nice leather seats is not a good thing.
December 2, 2016
Bryson Comments: I used two oil filter pliers from harbor freight to grip the filter and turn it. Locked on securely and I was able to turn in with minimal effort.
August 18, 2016
  Followup from the Pelican Staff: Thanks for the additional info. We appreciate it.
- Nick at Pelican Parts
 

  Search our site:    

View Cart & CheckOut | Project List | Order Status |  Help    

 

[Home] [Customer Service] [Shopping Cart] [Project/Wish List]
  [Privacy Statement]  [Contact Us] [About Us] [Shipping] [Careers]

Copyright © Pelican Parts Inc. -    DMCA Registered Agent Contact Page

Page last updated: Fri 12/9/2016 02:56:38 AM