16 00 005 Draining and filling fuel tank
| IMPORTANT | Observe country-specific safety regulations. Make sure the work bay is adequately ventilated. Connect an exhaust extractor system to exhaust tailpipe. Do not allow the electric fuel pump to run dry! Carefully withdraw extraction hose so as not to damage non-return flap. The electric fuel pump must not operate without fuel! On conclusion of repair work and before starting the engine for the first time, the fuel tank must be filled via the fuel filler pipe with at least 5 liters of fuel. |
Note. Vehicles with W17 engine
Before starting the engine for the first time, if the tank has been run dry or drawn off, fill with diesel fuel and turn on ignition for approx. 1 minute. The fuel circuit is thus filled and vented, which results in the engine firing more quickly.
Drawing Off Fuel
Start engine and allow to run. The electric fuel pump runs.
The pump delivers fuel via the suction jet pump and the tank expansion line from the left to the right side of the fuel tank.
Fuel can be drawn off from the left and right tank halves through the fuel filler pipe down to a small residual amount. This residual amount is drawn off after removal of the sensors for the fuel gauge (right/left).
Feed suction hose of extractor unit into filler pipe. In so doing, turn hose slightly if necessary.
Insertion Length
90 cm.
Draw off fuel with extractor unit as far as possible.
Observe the fuel gauge in the instrument cluster while extracting fuel.
Drawing Off Residual Fuel Quantity
| IMPORTANT | Make sure vehicle interior is adequately ventilated. Catch dripping fuel in a suitable container. |
Remove (right) fuel gauge sensor. Refer to 16 14 017 REMOVING AND INSTALLING/REPLACING FUEL FILTER WITH FUEL LEVEL SENSOR .
Remove (left) fuel gauge sensor. Refer to 16 14 015 REMOVING AND INSTALLING/REPLACING FUEL PUMP WITH FUEL LEVEL SENSOR .
Draw off residual fuel quantity through installation openings.
Fuel Filling
Feed suction hose of extractor unit approx. 40 cm into fuel filler pipe.
Fill fuel from suction extractor unit.
Extracting Fuel After A Defect In The Suction Jet Pump
Completely empty left half of fuel tank via fuel filler pipe.
Remove (right) fuel gauge sensor. Refer to 16 14 017 REMOVING AND INSTALLING/REPLACING FUEL FILTER WITH FUEL LEVEL SENSOR .
Insert extractor hose through installation opening of sensor into the fuel tank. The fuel (also residual quantities) can now be drawn off.
16 00 100 Checking fuel tank and tank ventilation system for leaks
Note. For Special Tool identification, see FUEL SYSTEM - SPECIAL TOOLS - COOPER (1.6L) R50/W10 and FUEL SUPPLY SYSTEM - SPECIAL TOOLS - COOPER (1.6L) R50/W10 .
Special Tools Required
- 13 3 010
- 16 1 070
- 16 1 171
- 16 1 174
Note. The following procedure is only applicable to vehicles without the tank leak diagnosis module.
Check tank venting system if a leak is suspected.
Necessary Preliminary Tasks
- Remove rear right wheel arch trim. Refer to «51 71 041 REMOVING AND INSTALLING/REPLACING REAR LEFT OR RIGHT WHEEL ARCH LINER»(/mini/cooper-s/i-2000-2006/remont/mirrors/#body-equipment-repair-cooper-r50-cooper-s-r53-convertible-r52__51-71-041-removing-and-installingreplacing) .
Comply with the following conditions in order to obtain plausible test results
- Content of fuel tank: Maximum 90 %. Minimum 13 % (reserve telltale must not light up).
- Park the car in the workshop at least 2 hours before the test so that the fuel temperature is approximately that of the workshop temperature. (ideal fuel temperature approx. 10-20° C).
- Never refuel the vehicle directly prior to the leak test due to the strong emission of gas by the fresh fuel.
Using special tool 16 1 070, seal opening (1) on carbon canister.
Scheme 34
Remove fuel filler cap and connect special tool 16 1 174 to fuel filler neck.
Clamp special tool 16 1 174 on fuel filler neck with adjusting wheel (1).
Scheme 35
| IMPORTANT | Set pressure regulator on special tool 16 1 171 fully in "-" direction. |
Connect special tool 16 1 171 using compressed air line (1) to garage compressed air system (8-10 bar).
Connect pressure sensor (2) from Diagnosis and Information System with a measuring range of 0-3.5 bar.
| IMPORTANT | Do not connect fast-release coupling (3) of special tool 16 1 171. |
Scheme 36
Select "Measurement" function on Diagnosis and Information System (DIS).
Using pressure regulator on special tool 16 1 171, increase pressure by 0.050 bar.
Connect special tool 16 1 174 to fast-release coupling of special tool 16 1 171.
Using pressure regulator on special tool 16 1 171, reset gauge pressure in fuel tank to 0.050 bar.
| IMPORTANT | Do not under any circumstances increase pressure by more than 0.05 bar as this would result in damage to the fuel tank and venting system. |
Using special tool 13 3 010, disconnect delivery line from special tool 16 1 171 to fuel filler neck.
Allow a rest period of approx. 20 secs.
Read off and note down starting pressure value.
Wait approx. 60 secs.
Read off final pressure value and compare with starting pressure value.
Measurement evaluation
| Pressure drop between 0.008 and 0.010 bar. | Measure again. |
|---|---|
| Pressure drop in 60 secs. greater than 0.010 bar. | System leaking beyond permitted levels. Carry out leak test. |
MEASUREMENT EVALUATION
16 00 510 Conducting leak test on fuel tank and tank ventilation system
Note. For vehicles without DMTL.
Pressurize fuel tank and tank venting system. Refer to 16 00 100 CHECKING FUEL TANK AND TANK VENTILATION SYSTEM FOR LEAKS .
During the leak test with a leak detector, be sure to follow the operating instructions of the equipment manufacturer.
| IMPORTANT | Escaping fuel vapors; only work in well-ventilated rooms or use suitable exhaust extraction unit. |
Observe country-specific accident prevention and occupational safety regulations.
The leak test can be carried out with a leak detector.
Possible causes may be
Scheme 37
- Fuel filler cap leaking.
- Tank venting lines leaking (fuel tank; carbon canister; tank venting valve.
- Tank ventilation valve leaky (engine compartment).
- Tank sensor on fuel tank leaky.
16 11 030 Removing and installing fuel tank
Note. For Special Tool identification, see BRAKES - SPECIAL TOOLS - COOPER (1.6L) R50/W10 .
Special Tools Required
- 34 6 330
| IMPORTANT | After installation of fuel tank/prior to first engine start-up: Check electrical resistance between metal filler bowl and wheel hub. Measured value: approx. 0.65 ohm. Fill fuel tank with at least 5 liters of fuel. |
Necessary Preliminary Tasks
- Draw off fuel from fuel tank. Refer to «16 00 005 DRAINING AND FILLING FUEL TANK»(/mini/cooper-s/i-2000-2006/remont/fuel-system/#fuel-system-repair-cooper-w10-engine__16-00-005-draining-and-filling) .
- Remove final muffler. Refer to «18 12 030 REMOVING AND INSTALLING/REPLACING REAR MUFFLER (W10)»(/mini/cooper-s/i-2000-2006/remont/exhaust/#exhaust-system-repair-instructions-cooper-w10-engine__18-12-030-removing-and-installingreplacing) .
- Remove exhaust heat shield.
R53 Only
- Detach rear half of battery main lead.
- Remove rear storage compartment.
R50 and R53
- Remove bracket for rear storage compartment. Refer to «51 16 218 REMOVING AND INSTALLING / REPLACING REAR STORAGE COMPARTMENT HOLDER»(/mini/cooper-s/i-2000-2006/remont/mirrors/#body-equipment-repair-cooper-r50-cooper-s-r53-convertible-r52__51-16-218-removing-and-installing) .
- Disconnect parking brake Bowden cables on rear brake caliper. Refer to «34 41 120 REMOVING AND INSTALLING/REPLACING BOTH HANDBRAKE BOWDEN CABLES»(ref-203071-S03774008892005103000000) .
- Remove rear seat. Refer to «52 26 005 REMOVING AND INSTALLING OR REPLACING REAR SEAT»(/mini/cooper-s/i-2000-2006/remont/seats/#seats-repair-cooper-r50-cooper-s-r53-convertible-r52__52-26-005-removing-and-installing) .
- Remove trim panels.
- Remove rear left wheel arch trim. Refer to «51 71 041 REMOVING AND INSTALLING/REPLACING REAR LEFT OR RIGHT WHEEL ARCH LINER»(/mini/cooper-s/i-2000-2006/remont/mirrors/#body-equipment-repair-cooper-r50-cooper-s-r53-convertible-r52__51-71-041-removing-and-installingreplacing) .
- Disconnect fuel level sensor and wiring harness.
Attach special tool 34 6 330 to parking brake Bowden cable (1).
Slide special tool 34 6 330 in direction of arrow onto barbs of parking brake Bowden cable (1) until barbs are free.
Push parking brake Bowden cable towards rear.
Installation
Adjust handbrake. Refer to 34 10 014 ADJUSTING HANDBRAKE .
Scheme 38
Release hose clamp (1) and remove filler hose from fuel tank.
Installation
Tightening torque, refer to 16 11 4AZ in FUEL SUPPLY SYSTEM - TIGHTENING TORQUES - COOPER (1.6L) R50/W10 .
Remove vent hose from fuel filler pipe.
Scheme 39
Support fuel tank over a large area with a suitable jack.
Unfasten screws (1).
Installation
Tightening torque, refer to 16 11 3AZ in FUEL SUPPLY SYSTEM - TIGHTENING TORQUES - COOPER (1.6L) R50/W10 .
Scheme 40
Lower fuel tank and disconnect right vent line (1) from fuel tank.
Pull vent line through body.
Remove fuel tank.
Scheme 41
Installation
Make sure lines and wiring harness are not trapped or crushed during installation.
16 11 060 Removing and installing/replacing fuel filler pipe
| IMPORTANT | After installation of fuel tank/prior to first engine start-up: Check electrical resistance between metal filler bowl and wheel hub. Measured value: approx. 0.65ohm. Fuel tank must be filled with at least 5 liters of fuel. |
Necessary Preliminary Tasks
- Remove rear left wheel arch trim. Refer to «51 71 041 REMOVING AND INSTALLING/REPLACING REAR LEFT OR RIGHT WHEEL ARCH LINER»(/mini/cooper-s/i-2000-2006/remont/mirrors/#body-equipment-repair-cooper-r50-cooper-s-r53-convertible-r52__51-71-041-removing-and-installingreplacing) .
- Unscrew fuel filler cap from fuel filler pipe.
Note. Fuel tank must be no more than half full; if necessary, draw off fuel from fuel tank. Refer to 16 00 005 DRAINING AND FILLING FUEL TANK .
Unfasten hose clip (1).
Detach fuel hose from fuel tank.
Installation
Tightening torque, refer to 16 11 4AZ in FUEL SUPPLY SYSTEM - TIGHTENING TORQUES - COOPER (1.6L) R50/W10 .
Scheme 42
Detach quick-release fastener (1).
Disengage fuel filler pipe (2) from mounting (3).
Scheme 43
Unscrew nuts (1).
Installation
Replace nuts.
Tightening torque, refer to 16 11 1AZ in FUEL SUPPLY SYSTEM - TIGHTENING TORQUES - COOPER (1.6L) R50/W10 .
Remove fuel filler pipe (2).
Installation
Make sure grounding cable (3) is correctly fitted.
Following seals must be correctly fitted
- Vent hose to fuel filler pipe.
- Fuel filler pipe to body cutout.
Scheme 44
16 11 071 Replacing rubber sleeve (fuel hose) between fuel filler pipe and fuel tank
| IMPORTANT | After installation of fuel tank/prior to first engine start-up: Check electrical resistance between metal filler bowl and wheel hub. Measured value: approx. 0.65ohm. Fuel tank must be filled with at least 5 liters of fuel. |
Necessary Preliminary Tasks
- Remove rear left wheel arch trim. Refer to «51 71 041 REMOVING AND INSTALLING/REPLACING REAR LEFT OR RIGHT WHEEL ARCH LINER»(/mini/cooper-s/i-2000-2006/remont/mirrors/#body-equipment-repair-cooper-r50-cooper-s-r53-convertible-r52__51-71-041-removing-and-installingreplacing) .
- Unscrew fuel filler cap from fuel filler pipe.
Note. Fuel tank must be no more than half full; if necessary, draw off fuel from fuel tank. Refer to 16 00 005 DRAINING AND FILLING FUEL TANK .
Unfasten hose clips (1).
First detach rubber sleeve (3) from fuel filler pipe.
Detach rubber sleeve (3) from fuel tank.
Installation
Tightening torque, refer to 16 11 4AZ in FUEL SUPPLY SYSTEM - TIGHTENING TORQUES - COOPER (1.6L) R50/W10 .
Make sure grounding cable (2) is correctly fitted.
Scheme 45
16 12 010 Removing and installing/replacing carbon canister
Necessary Preliminary Tasks
- Remove rear right wheel arch trim. Refer to «51 71 041 REMOVING AND INSTALLING/REPLACING REAR LEFT OR RIGHT WHEEL ARCH LINER»(/mini/cooper-s/i-2000-2006/remont/mirrors/#body-equipment-repair-cooper-r50-cooper-s-r53-convertible-r52__51-71-041-removing-and-installingreplacing) .
Detach quick-release fasteners (1 and 2).
Disconnect wires.
Unscrew bolt (3).
Withdraw carbon canister (4) from mounting and remove.
Scheme 46
16 12 010 Removing and installing/replacing carbon canister (DMTL)
Necessary Preliminary Tasks
- Remove rear right wheel arch trim. Refer to «51 71 041 REMOVING AND INSTALLING/REPLACING REAR LEFT OR RIGHT WHEEL ARCH LINER»(/mini/cooper-s/i-2000-2006/remont/mirrors/#body-equipment-repair-cooper-r50-cooper-s-r53-convertible-r52__51-71-041-removing-and-installingreplacing) .
Remove hose (1).
Release nuts (2) and lower carbon canister with holder slightly.
| IMPORTANT | Lower carefully so as not to damage hoses connected to carbon canister. |
Scheme 47
Disconnect plug connection (1).
Disconnect hoses (2).
Squeeze quick-release fastener (3) together and detach line.
Remove carbon canister with holder.
Scheme 48
Remove carbon canister (1) in direction of arrow from holder.
Scheme 49
16 13 015 Removing and installing/replacing tank leakage diagnosis module (DMTL)
Necessary Preliminary Tasks
- Remove rear right wheel arch trim. Refer to «51 71 041 REMOVING AND INSTALLING/REPLACING REAR LEFT OR RIGHT WHEEL ARCH LINER»(/mini/cooper-s/i-2000-2006/remont/mirrors/#body-equipment-repair-cooper-r50-cooper-s-r53-convertible-r52__51-71-041-removing-and-installingreplacing) .
Disconnect plug connection.
Release clamps (1) and detach hoses.
Remove hose (2).
Release nuts (3) and lower DMTL with holder slightly.
| IMPORTANT | Lower carefully so as not to damage hoses connected to carbon canister. |
Scheme 50
Release screws (1) and swing out leak diagnosis pump.
Scheme 51
16 14 015 Removing and installing/replacing fuel pump with fuel level sensor
Note. For Special Tool identification, see FUEL SUPPLY SYSTEM - SPECIAL TOOLS - COOPER (1.6L) R50/W10 .
Special Tools Required
- 16 1 020
Necessary Preliminary Tasks
- Draw off fuel from fuel tank. Refer to «16 00 005 DRAINING AND FILLING FUEL TANK»(/mini/cooper-s/i-2000-2006/remont/fuel-system/#fuel-system-repair-cooper-w10-engine__16-00-005-draining-and-filling) .
- Remove rear seat. Refer to «52 26 005 REMOVING AND INSTALLING OR REPLACING REAR SEAT»(/mini/cooper-s/i-2000-2006/remont/seats/#seats-repair-cooper-r50-cooper-s-r53-convertible-r52__52-26-005-removing-and-installing) .
Push trim panel (1) forward.
Unscrew nuts (2).
Tightening torque, refer to 16 11 2AZ in FUEL SUPPLY SYSTEM - TIGHTENING TORQUES - COOPER (1.6L) R50/W10 .
Remove cover (3).
Scheme 52
Disconnect plug connection.
Scheme 53
Release screw cap with special tool 16 1 020.
Installation
Replace rubber seal.
Tightening torque, refer to 16 14 1AZ in FUEL SUPPLY SYSTEM - TIGHTENING TORQUES - COOPER (1.6L) R50/W10 .
Scheme 54
Raise unit.
Remove locking clip of line connection.
Detach lines (1) and plug (2) from sensor unit.
Carefully lift sensor unit out of tank.
Catch dripping fuel in a suitable container.
Scheme 55
Installation
When installing fuel level sensor, make sure lug (1) engages in recess (2) on tank.
Scheme 56
16 14 017 Removing and installing/replacing fuel filter with fuel level sensor
Note. For Special Tool identification, see FUEL SUPPLY SYSTEM - SPECIAL TOOLS - COOPER (1.6L) R50/W10 .
Special Tools Required
- 16 1 020
Necessary Preliminary Tasks
- Discharge fuel tank. Refer to «16 00 005 DRAINING AND FILLING FUEL TANK»(/mini/cooper-s/i-2000-2006/remont/fuel-system/#fuel-system-repair-cooper-w10-engine__16-00-005-draining-and-filling) .
- Remove rear seat. Refer to «52 26 005 REMOVING AND INSTALLING OR REPLACING REAR SEAT»(/mini/cooper-s/i-2000-2006/remont/seats/#seats-repair-cooper-r50-cooper-s-r53-convertible-r52__52-26-005-removing-and-installing) .
- Remove sensor unit (left). Refer to «16 14 015 REMOVING AND INSTALLING/REPLACING FUEL PUMP WITH FUEL LEVEL SENSOR»(/mini/cooper-s/i-2000-2006/remont/fuel-system/#fuel-system-repair-cooper-w10-engine__16-14-015-removing-and-installingreplacing) .
Push trim panel (1) forward.
Unfasten screws (2).
Installation
Tightening torque, refer to 16 11 2AZ in FUEL SUPPLY SYSTEM - TIGHTENING TORQUES - COOPER (1.6L) R50/W10 .
Remove the cover (3).
Scheme 57
Unlock and withdraw fuel hose.
Scheme 58
Release locking ring with special tool 16 1 020.
Installation
Replace rubber seal.
Tightening torque, refer to 16 14 1AZ in FUEL SUPPLY SYSTEM - TIGHTENING TORQUES - COOPER (1.6L) R50/W10 .
Scheme 59
Remove line holder from sensor unit. Lift sensor unit and lines out of fuel tank.
Scheme 60
Installation
When installing fuel filter, make sure lug (1) engages in recess (2) on tank.
Scheme 61
16 14 060 Removing and installing/replacing dust filter for tank leakage diagnosis module (DMTL)
Necessary Preliminary Tasks
- Remove rear right wheel arch trim. Refer to «51 71 041 REMOVING AND INSTALLING/REPLACING REAR LEFT OR RIGHT WHEEL ARCH LINER»(/mini/cooper-s/i-2000-2006/remont/mirrors/#body-equipment-repair-cooper-r50-cooper-s-r53-convertible-r52__51-71-041-removing-and-installingreplacing) .
Release clamp (1) and detach hose.
Release screw (2) and remove dust filter (3).
Scheme 62
16 14 080 Replacing fuel level sensor (left)
Necessary Preliminary Tasks
- Remove fuel pump. Refer to «16 14 015 REMOVING AND INSTALLING/REPLACING FUEL PUMP WITH FUEL LEVEL SENSOR»(/mini/cooper-s/i-2000-2006/remont/fuel-system/#fuel-system-repair-cooper-w10-engine__16-14-015-removing-and-installingreplacing) .
Detach lines (1) at retaining lugs (2).
Release fuel level sensor from hooks (3) and pull off downwards.
Scheme 63
16 14 084 Replacing fuel level sensor (right)
Necessary Preliminary Tasks
- Remove fuel filter. Refer to «16 14 017 REMOVING AND INSTALLING/REPLACING FUEL FILTER WITH FUEL LEVEL SENSOR»(/mini/cooper-s/i-2000-2006/remont/fuel-system/#fuel-system-repair-cooper-w10-engine__16-14-017-removing-and-installingreplacing) .
Release line from hooks (1) and (2).
Scheme 64
Remove fuel level sensor. To do so, release retaining hook and pull off sensor downwards.
Scheme 65
Release line (1) from line clips (2).
Installation
Make sure the line is correctly routed and does not obstruct the float.
Scheme 66
See also:
• FUEL SYSTEM - SPECIAL TOOLS - COOPER (1.6L) R50/W10
• FUEL SUPPLY SYSTEM - SPECIAL TOOLS - COOPER (1.6L) R50/W10
• 51 71 041 REMOVING AND INSTALLING/REPLACING REAR LEFT OR RIGHT WHEEL ARCH LINER
• BRAKES - SPECIAL TOOLS - COOPER (1.6L) R50/W10
• 18 12 030 REMOVING AND INSTALLING/REPLACING REAR MUFFLER (W10)
• 51 16 218 REMOVING AND INSTALLING / REPLACING REAR STORAGE COMPARTMENT HOLDER
• 52 26 005 REMOVING AND INSTALLING OR REPLACING REAR SEAT
• FUEL SUPPLY SYSTEM - TIGHTENING TORQUES - COOPER (1.6L) R50/W10
• 16 14 017 REMOVING AND INSTALLING/REPLACING FUEL FILTER WITH FUEL LEVEL SENSOR
• 16 14 015 REMOVING AND INSTALLING/REPLACING FUEL PUMP WITH FUEL LEVEL SENSOR
• 16 00 100 CHECKING FUEL TANK AND TANK VENTILATION SYSTEM FOR LEAKS
• 16 00 005 DRAINING AND FILLING FUEL TANK