Removal and Replacement

16 11 030 - Removing and installing 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. 0.65 W.
- Fill fuel tank with at least 5 liters of fuel.





Necessary preliminary tasks:
- Draw off fuel from fuel tank Procedures
- Remove parking brake Bowden cables Service and Repair
- Remove rear left and right wheel arch trims Service and Repair
- Remove carbon canister
- Remove wind deflector on left and right
- Remove rear seat Removing and Installing or Replacing Rear Seat
- Disconnect line connection and plug connection at fuel level sensors
COOPER S only:
- Detach rear half of battery main lead Service and Repair.





Release hose clamp (1) and remove filler hose from fuel tank.

Installation Note:
Tightening torque 16 11 4AZ 16 11 Fuel Tank and Mounting Parts.





Detach vent hose from bracket (1).
Release hose clip (2) and detach vent line.

Installation Note:
Replace hose clip.





Disconnect quick-release fastener (1) in right wheel arch.





Important!
Support fuel tank over a large area with a suitable workshop jack.





Remove expander rivets (1).
Release screws (2) and carefully remove fuel tank.

Installation Note:
Tightening torque 16 11 3AZ 16 11 Fuel Tank and Mounting Parts.

Important!
Vent lines on left and right must be guided carefully through openings in body.





Replacement:
- Modify left and right fuel level sensors
Unfasten hose clip (1) and remove hose.

Installation Note:
Replace hose clip.

Disconnect quick-release fasteners (2), detach vent lines (3) from bracket and modify.

Installation Note:
Make sure lines and wiring harness are not trapped or crushed during installation.