MINI 2002-05

Fuel Level Sensor & Fuel Pump

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Removal & Installation



1.6L (W10 And W11) Engines
  1. Drain the fuel tank.
  2.  
  3. Remove the back seat.
  4.  
  5. Push the trim panel forward so it is clear of the sensor cover.
  6.  
  7. Unscrew the four nuts on the cover.
  8.  
  9. Remove the cover.

    Click image to see an enlarged view

    Fig. The trim panel (1), the four retaining nuts (2) and the cover (3)

  10.  
  11. Disconnect the plug connection by pushing to the left and pulling up.

    Click image to see an enlarged view

    Fig. The plug connection removal

  12.  
  13. Release the screw cap using special tool 16 1 020.

    Click image to see an enlarged view

    Fig. Release the screw cap

  14.  
  15. Remove the locking clip from the line connection and set aside.
  16.  
  17. Detach the lines and plug from fuel level sensor unit.

    Click image to see an enlarged view

    Fig. The lines (1) and plugs (2) on the fuel level sensor

  18.  
  19. Carefully lift the sensor unit out of the tank.
  20.  
  21. Catch any dripping fuel in a suitable container (and discard safely).
  22.  

To install:

  1. Before installing the sensor, always replace the rubber seal
  2.  
  3. When installing the fuel level sensor, make sure the lug on the sensor unit lines up with and engages in the recess on the tank.
  4.  
  5. Attach the lines and plug to fuel level sensor unit.
  6.  
  7. Replace the locking clip to the line connection.
  8.  
  9. Connect the plug connection by pushing down and to the right.

    Click image to see an enlarged view

    Fig. The lug (1) on the sensor and the recess (2) on the tank

  10.  
  11. Replace the cover.
  12.  
  13. Replace the four nuts on the cover.
  14.  
  15. Replace the trim panel over the sensor cover.
  16.  
  17. Install the back seat.
  18.  
  19. Refuel the fuel tank.
  20.  

 
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