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HOMESERVICE MANUALSMINI2008COOPER CLUBMAN (R55) L4-1.6L (N12)REPAIR AND DIAGNOSISPOWERTRAIN MANAGEMENTCOMPUTERS AND CONTROL SYSTEMSTECHNICAL SERVICE BULLETINSALL TECHNICAL SERVICE BULLETINSFUEL SYSTEM - FUEL LEVEL DISPLAY INCORRECT
2008 Mini Cooper Clubman (R55) L4-1.6L (N12)
Fuel System - Fuel Level Display Incorrect
2008 Mini Cooper Clubman (R55) L4-1.6L (N12)SECTION Fuel System - Fuel Level Display Incorrect
SI M16 01 11
Fuel Supply Systems
October 2011
Technical Service
SUBJECT
R55, R56 and R57: Fuel Level Display Incorrect
MODEL
R55 (Cooper Clubman and Cooper Clubman S) with N12, N14, N16 and N18 engine
R56 (Cooper and Cooper S) with N12, N14, N16 and N18 engine
R57 (Cooper and Cooper S Convertible) with N12, N14, N16 and N18 engine
SITUATION
The customer complains that when filling the fuel tank, the gauge never reaches the full position or the fuel gauge does not appear to update while fuel is being depleted.
CAUSE
The fuel level sensor arm interferes with the fuel level sensor signal wires or the suction jet hose assembly.
PROCEDURE
Follow the applicable test plans for the faults stored or the component symptom path. If the test plan is inconclusive, follow the procedure outlined below.
Note:
When the ISTA system message displays:
Battery voltage only "XX.XX" V. Please connect charger.
Please note the displayed battery voltage reading in the repair order comments section.
1. Remove the right fuel level sensor, refer to REP 16 14 084 - Removing and installing fuel filter with fuel level sensor.
2. Inspect the fuel level sensor arm (1) for interference with the fuel level sensor signal wire (2). If interference is present, proceed to step 3. If no interference is present, proceed to step 4.
IMPORTANT:
For the clarity of the picture, this is an inside view of a MINI tank with the front wall cut away.
3. Reroute the fuel level sensor signal wire (1), as shown with the black arrows in the illustration.
4. Check for interference between the fuel level sensor arm (1) and the suction jet hose (2). It is necessary to move the fuel level sensor arm from the minimum to maximum position to ensure no interference is present.
IMPORTANT:
For the clarity of the picture, this is an inside view of a MINI tank with the front wall cut away.
5. The suction jet hose (1) is incorrectly routed and cable-tied. The bending radius of the suction jet hose is too great.
Remove the three cable straps from the suction jet hose assembly.
6. Reroute the suction jet hose (1) so that the bending radius of the hose is further from the fuel level sensor arm travel area. Install three new cable straps (P/N 16 13 1 367 599) to secure the hoses before reinstalling the assembly into the fuel tank.
PARTS INFORMATION
WARRANTY INFORMATION
Fuel Supply Systems
October 2011
Technical Service
SUBJECT
R55, R56 and R57: Fuel Level Display Incorrect
MODEL
R55 (Cooper Clubman and Cooper Clubman S) with N12, N14, N16 and N18 engine
R56 (Cooper and Cooper S) with N12, N14, N16 and N18 engine
R57 (Cooper and Cooper S Convertible) with N12, N14, N16 and N18 engine
SITUATION
The customer complains that when filling the fuel tank, the gauge never reaches the full position or the fuel gauge does not appear to update while fuel is being depleted.
CAUSE
The fuel level sensor arm interferes with the fuel level sensor signal wires or the suction jet hose assembly.
PROCEDURE
Follow the applicable test plans for the faults stored or the component symptom path. If the test plan is inconclusive, follow the procedure outlined below.
Note:
When the ISTA system message displays:
Battery voltage only "XX.XX" V. Please connect charger.
Please note the displayed battery voltage reading in the repair order comments section.
1. Remove the right fuel level sensor, refer to REP 16 14 084 - Removing and installing fuel filter with fuel level sensor.
2. Inspect the fuel level sensor arm (1) for interference with the fuel level sensor signal wire (2). If interference is present, proceed to step 3. If no interference is present, proceed to step 4.
IMPORTANT:
For the clarity of the picture, this is an inside view of a MINI tank with the front wall cut away.
3. Reroute the fuel level sensor signal wire (1), as shown with the black arrows in the illustration.
4. Check for interference between the fuel level sensor arm (1) and the suction jet hose (2). It is necessary to move the fuel level sensor arm from the minimum to maximum position to ensure no interference is present.
IMPORTANT:
For the clarity of the picture, this is an inside view of a MINI tank with the front wall cut away.
5. The suction jet hose (1) is incorrectly routed and cable-tied. The bending radius of the suction jet hose is too great.
Remove the three cable straps from the suction jet hose assembly.
6. Reroute the suction jet hose (1) so that the bending radius of the hose is further from the fuel level sensor arm travel area. Install three new cable straps (P/N 16 13 1 367 599) to secure the hoses before reinstalling the assembly into the fuel tank.
PARTS INFORMATION
WARRANTY INFORMATION
RENDER: 1.0x
NO RELATED
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.