Replacing Mini Cooper Fuel Cap: Step-By-Step Guide

Changing the fuel cap on a Mini Cooper is a straightforward process that can be done at home with a few tools. The first step is to remove the gas cap lid, which can be done by opening the door and releasing the tab with a small screwdriver. The next steps involve removing the inner fender and fuel filler neck, as well as the filler door assembly, before installing the new filler door assembly. With a new filler neck, it is important to ensure the rubber ring is worked into the corresponding groove and that the locking latch is in place before securing the bolts and clamps.

Removing the stock gas lid

The first step in changing the fuel cap on your Mini Cooper is to remove the stock gas lid. If you are just looking to replace the chrome cap on an S model Mini Cooper with a custom part, this should only take about five minutes. To begin, open the door and press in with a small screwdriver to release the tab. The chrome part should then be able to be pulled off.

If you are changing from one type to another, you can skip this step. However, if you are unable to remove the cap, you may need to completely remove the filler neck. You may also need to remove the wheel and arch liner and undo the bolt holding the neck in place.

Once the stock gas lid is removed, you can move on to the next step of removing the inner fender and fuel filler neck.

Removing the inner fender and fuel filler neck

To remove the inner fender and fuel filler neck of a Mini Cooper, you will need a long flat-head screwdriver and a Phillips screwdriver. This process assumes that you are replacing the gas cap with a new one that already has a trim ring or fuel door painted to match the car.

First, you will need to undo the inner plastic fender to access the inside of the fender and the fuel filler neck. The inner fender is held in place by a series of plastic rivets and Phillips screws. Use a screwdriver to pry out the rivets and remove the screws until you can pull the inner fender free.

Next, you will need to unbolt the fuel filler neck where it attaches to the fender and where it is clamped to the tank. You do not need to remove it completely, but you will need to manipulate the rubber seal between the inner filler door and the filler neck. This step is much easier if you remove the wheel, although it is not necessary.

Once you have removed the inner fender and accessed the fuel filler neck, you can move on to removing the filler door assembly.

Removing the filler door assembly

First, ensure that you have the necessary tools, which include a long flat-head screwdriver and a Phillips screwdriver. It is also recommended to have a small drill to make the process easier.

The filler door, hinge, and the underlying housing are all part of one assembly on the Mini Cooper. To remove this assembly, you need to locate the two clips that are hidden behind it. These clips click into the edge of the fender opening. Using a small screwdriver, you can try to press in and release them. However, it is often easier to drill two tiny holes where the dimples are in the ring and then insert the screwdriver to release the clips. Be sure to drill carefully to avoid damaging any surrounding components.

Once the clips are released, use the screwdriver to gently pry the rubber ring on the filler neck away from the filler door housing. This will separate the filler neck from the door assembly. Now, you can remove the entire filler door assembly from the Mini Cooper.

It is important to note that you may need to remove the inner fender and fuel filler neck beforehand to provide better access to the filler door assembly. This can be done by removing the plastic rivets and Phillips screws holding the inner fender in place. Additionally, you may find it easier to remove the wheel, although it is not necessary.

Installing a new filler door assembly

Step 1: Remove the old filler door assembly

First, you need to remove the old filler door assembly. This can be done by pressing in with a small screwdriver and releasing the tab. The old filler door assembly will then be able to be pulled off.

Step 2: Prepare the new filler door assembly

Ensure that the new filler door assembly is painted to match the car. Most filler door assemblies will be painted with a primer and will need to be colour-matched.

Step 3: Partially pull out the filler neck

For easier access, pull the filler neck partially out of the tank.

Step 4: Press the filler neck into the housing

Press the filler neck into the housing and work the rubber ring into the corresponding groove. Spraying some WD-40 around the rubber parts will make this step easier.

Step 5: Secure the filler neck and housing

Once the filler neck is in the correct place, make sure the locking latch is still in its place in the fender. Press the filler housing into the fender until you hear the clips click.

Step 6: Reattach the locking latch

Push the lock latch back through and check that it still lines up properly.

Step 7: Tighten bolts and clamps

Finally, tighten up the bolts and clamps on the filler neck and the fuel tank.

Tips

It is recommended that you remove the wheel to make this process easier.

Tightening bolts and clamps

To tighten the bolts and clamps on the filler neck and the fuel tank of your Mini Cooper, you will need to follow a few steps.

First, you will need to remove the gas cap lid. Open the door and press in with a small screwdriver to release the tab. The chrome part should just pull off.

Next, remove the inner fender and fuel filler neck. Undo the inner plastic fender to access the inside of the fender and the fuel filler neck. Hold the inner fender in place with a series of plastic rivets and Phillips screws. Pry out the rivets and remove the screws until you can pull the inner fender free.

Once the inner fender is removed, you can access the bolts and clamps on the filler neck and fuel tank. Tighten the bolts and clamps securely, ensuring that they are properly fastened.

After tightening the bolts and clamps, you can proceed to reinstall the inner fender and any other components that were removed during the process. Ensure that all parts are securely fastened and aligned before considering your work complete.

Frequently asked questions