Removing and installing fuel tank (US version Natural Vacuum Leak Detection) (Cooper)

Preliminary work needed: 

• Extract FUEL  from fuel tank.
• Remove left and right UNDERBODY PLANKING .
• Remove EXHAUST SYSTEM .
• Remove heat shield.
• Remove rear left WHEEL ARCH TRIM .
• Remove REAR SEAT .
• Detach parking brake BOWDEN CABLE on left of center.

Removal: 

Release plastic nuts (1) and remove service cap (2).

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Disconnect plug connection (1).

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Attention! 

To unlock/lock or disconnect/connect the fuel line with a quick connector, no tool  must be used.

To unlock snap fastener (1) on the fuel line, follow the instructions given below.

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Press in locks (1) and (2) in the arrow direction.

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Disconnect fuel lines (1) and (2) in the arrow direction.

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Press the snap fastener towards the delivery unit. Then press locks (1) and (2) in the arrow direction and detach the snap fastener in the arrow direction.

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Detach parking brake Bowden cable from holders (1).

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Unlock and disconnect snap fasteners (1).

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Detach tank vent line from holders (1).

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Release hose clamp (1) and detach filling hose (2) from fuel tank.

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Unlock and disconnect snap fastener (1).

Detach fuel filler neck vent pipe from holders (2).

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Attention! 

Support fuel tank over a wide area with a suitable workshop jack and secure against falling down!

Release screw and nut (1) and remove luggage strap.

Release nuts (2) and lower fuel tank.

Attention! 

While the fuel tank is being lowered, the fuel filler neck vent pipe must be led from the wheel well through the body aperture!

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Preparation for the installation: 

• Remount CARBON CANISTER  (US version).
• Remount DELIVERY UNIT .

Installation: 

Attention! 

While the fuel tank is being raised, the fuel filler neck vent pipe must be led into the wheel well through the body aperture!

Raise fuel tank and position and screw in nuts (2).

Tightening torque 16 11 2AZ .

Fit luggage strap and position and tighten screw and nut (1).

Tightening torque 16 11 4AZ .

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Position snap fastener (1) and lock.

Hook the fuel filler neck vent pipe into holders (2).

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Mount the fuel filler hose (2) on the fuel tank.

Parts  : Hose clamp

Tighten hose clamp (1).

Tightening torque 16 11 3AZ .

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Hook the venting line into holders (1).

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Position snap fasteners (1) and lock.

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Hook the parking brake Bowden cable into holders (1).

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Attention! 

To unlock/lock or disconnect/connect the fuel line with a quick connector, no tool  must be used.

Procedure for installing a new fuel line: 

When installing a new fuel line, ensure that lock (1) protrudes.

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Insert fuel line (2) into fuel line (1).

Slide fuel line (2) into fuel line (1) by clicking the first lock (white).

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Lock the red lock (1) in the arrow direction.

Lock (1) can be locked only if the fuel lines are connected correctly.

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Check to ensure that snap fastener (1) locks in place correctly.

The snap fastener must engage audibly and perceptibly.

A traction check is not permitted!

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Procedure for installing a previous fuel line: 

When installing a fuel line that has already been installed, the red lock (1) is already pressed down.

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Slide fuel line (2) into fuel line (1) in the arrow direction until the two locks lock audibly.

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Check to ensure that snap fastener (1) locks in place correctly.

The snap fastener must engage audibly and perceptibly.

A traction check is not permitted!

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Locking tabs (1) and (2) must be locked in place.

Position the snap fastener in the arrow direction and lock it in place.

Attention! 

Check the locking mechanisms of the snap fastener for damages and replace if necessary!

Check that the snap fastener locks in place correctly.

The snap fastener must engage audibly and perceptibly.

A traction check  is not permitted!

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Connect plug connection (1).

Check gasket (2) and replace if necessary.

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Fit service cap (2) and position and tighten plastic nuts (1).

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Required follow-up work: 

• Install left and right UNDERBODY PLANKING .
• Install EXHAUST SYSTEM .
• Fit heat shield.
• Fit rear left WHEEL ARCH PANEL .
• Install REAR SEAT .
• Connect parking brake BOWDEN CABLE at center and on left.

Attention! 

After installation of fuel tank/prior to first engine start-up: 

• Check resistance between metal filler bowl and wheel hub.
• Measured value:  about 0.65 Ω.
• Fill fuel tank with at least 5 liters of fuel.