16 11 030 Removing and installing fuel tank (US version NVLD)

WARNING: This page is about a different car, the 2017 MINI Cooper, 2016 MINI Cooper, 2015 MINI Cooper, and 2014 MINI Cooper. However, it is still accessible from the selected car via links, so may be relevant.

Necessary preliminary tasks:

Extract FUEL from fuel tank
Remove underbody panelling on left and right. See REMOVING UNDERBODY COVER and REMOVING TANK COVER .
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).

Fig 1: Plastic Nuts And Service Cap

Courtesy of BMW OF NORTH AMERICA, INC.

Disconnect plug connection (1).

Fig 2: Plug Connection And Gasket

Courtesy of BMW OF NORTH AMERICA, INC.

Unlock locking tab (1) in direction of arrow.

Operate lock (2) in direction of arrow and pull off upwards from fuel delivery line (3).

Fig 3: Unlocking Locking Tab

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Detach parking brake Bowden cable from brackets (1).

Fig 4: Parking Brake Bowden Cable Brackets

Courtesy of BMW OF NORTH AMERICA, INC.

Unlock and disconnect snap fasteners (1).

Fig 5: Snap Fasteners

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Detach tank ventilation line from brackets (1).

Fig 6: Tank Ventilation Line Brackets

Courtesy of BMW OF NORTH AMERICA, INC.

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

Fig 7: Hose Clamp And Filling Hose

Courtesy of BMW OF NORTH AMERICA, INC.

Unlock and disconnect snap fastener (1).

Detach fuel filler neck breather pipe from brackets (2).

Fig 8: Snap Fastener And Brackets

Courtesy of BMW OF NORTH AMERICA, INC.

IMPORTANT: Secure fuel tank over a wide area with a suitable workshop jack and secure against falling down.

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

Release nuts (2) and lower fuel tank.

IMPORTANT: While the fuel tank is being lowered, the fuel filler neck breather pipe must be guided from the wheel arch through the body aperture!

Fig 9: Tensioning Strap Screw And Nut With Fuel Tank Nuts

Courtesy of BMW OF NORTH AMERICA, INC.

Preparation for installation:

Remount CARBON CANISTER (US version).
Remount DELIVERY UNIT

Installation:

IMPORTANT: While the fuel tank is being raised, the fuel filler neck breather pipe must be guided through the body aperture into the wheel arch!
Raise fuel tank and position and screw in nuts (2).
Tightening torque 16 11 2AZ .
Fit tensioning strap and position and tighten

Fig 10: Tensioning Strap Screw And Nut With Fuel Tank Nuts

Courtesy of BMW OF NORTH AMERICA, INC.

screw and nut (1).

Tightening torque 16 11 4AZ

Position snap fastener (1) and lock.

Attach fuel filler neck breather pipe in the brackets (2).

Fig 11: Snap Fastener And Brackets

Courtesy of BMW OF NORTH AMERICA, INC.

Mount tire inflation hose (2) at fuel tank.

Parts: Hose clamp

Tighten hose clamp (1).

Tightening torque 16 11 3AZ .

Fig 12: Hose Clamp And Filling Hose

Courtesy of BMW OF NORTH AMERICA, INC.

Hang tank ventilation line in the brackets (1).

Fig 13: Tank Ventilation Line Brackets

Courtesy of BMW OF NORTH AMERICA, INC.

Position snap fasteners (1) and lock.

Fig 14: Snap Fasteners

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Attach parking brake Bowden cable in the brackets (1).

Fig 15: Parking Brake Bowden Cable Brackets

Courtesy of BMW OF NORTH AMERICA, INC.

Lock locking tab (1) in direction of arrow.

Position and lock fuel delivery line (2).

IMPORTANT: Make sure the snap fastener is correctly locked!
Check locks for damage and replace if necessary!

Fig 16: Locking Fuel Delivery Line

Courtesy of BMW OF NORTH AMERICA, INC.

Connect plug connection (1).

Check gasket (2) and replace if necessary.

Fig 17: Plug Connection And Gasket

Courtesy of BMW OF NORTH AMERICA, INC.

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

Fig 18: Plastic Nuts And Service Cap

Courtesy of BMW OF NORTH AMERICA, INC.

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

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