Rajan Wilcox
The fuel pump is an essential component of any car, but the pumps that came with Minis in the 70s were particularly long-lasting. However, they were not immune to the junky corn-based gasoline mixtures that came onto the market. Modern fuel pumps can handle these fuels, and they are available at any car parts store. The high-pressure fuel pump (HPFP) in the Mini Cooper (2007-2013) is prone to premature failure, and Mini has extended the warranty on these to 10 years/120,000 miles. If you want to replace the fuel pump yourself, you can save several hundred dollars.
| Characteristics | Values |
|---|---|
| Steps to replace the fuel pump | Prime the pump by cranking the motor for 15 seconds at a time for three times. Start the engine (it may take several tries before the HPFP is full of fuel again). Once started, run the engine for five minutes to warm up. Check for leaks and fix. You may need to replace the fuel lines. If the engine is a N14, disconnect the battery, remove the air box and re-torque the fuel line to its final tightness. Replace the air box and reconnect the battery. |
| Cost of the pump | Starts at $750 |
| Cost of labour | Not that involved, but you can save several hundred dollars by doing it yourself |
| Type of pump | High pressure fuel pump (HPFP) |
| Type of car | Mini Cooper (2007-2013) |
| Other information | The pumps that came on Minis in the 70s lasted a long time until they were exposed to junky corn-based gasoline mixtures. Modern replacements can handle this. |
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What You'll Learn
Priming the pump
Firstly, crank the motor for 15 seconds at a time, repeating this process three times. This helps to build up pressure in the fuel system and ensures that the pump is adequately primed.
Next, attempt to start the engine. It is important to note that this may take several tries, as the high-pressure fuel pump (HPFP) needs to be refilled with fuel. Be patient and persistent during this step.
Once the engine starts, let it run for at least five minutes to allow it to warm up sufficiently. During this warm-up period, keep a close eye on the engine and listen for any unusual noises.
After the engine has warmed up, carefully check for any leaks in the fuel system. If leaks are detected, address them immediately. You may also need to replace the fuel lines at this point, depending on their condition.
If your Mini has an N14 engine, there are a few additional steps to follow. Disconnect the battery and remove the air box. Re-torque the fuel line to its final tightness, then replace the air box and reconnect the battery.
By following these steps, you can effectively prime the pump when replacing the fuel pump in a classic Mini. Remember to refer to specific guides and manuals for your Mini model, as the process may vary slightly depending on the year and specifications of your vehicle.
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Disconnecting the battery
Firstly, locate the battery in the engine bay. The negative terminal, also known as the earth terminal, is usually black and is the one you should disconnect first. Unscrew it and pull it off from the battery. It's important to disconnect the negative terminal before the positive terminal to avoid any chance of your tool slipping and touching the positive terminal to the chassis, which could cause a spark and potentially lead to an explosion.
Once the negative terminal is disconnected, you can then safely disconnect the positive terminal. Again, simply unscrew it and pull it off from the battery. With both terminals disconnected, you have successfully disconnected the battery.
It's worth noting that disconnecting the battery may affect certain functions of your Mini. For example, you may need to reset the alarm/immobiliser by pressing the "unlock" button on the key fob multiple times. Additionally, if your radio has a code, it may be lost when the battery is disconnected, so make sure you have the code written down or stored elsewhere before proceeding.
Finally, if you're planning to disconnect the battery for an extended period, consider purchasing a battery maintainer to keep it charged. This will help prevent any potential issues with the battery draining completely and ensure it's ready for use when you reconnect it.
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Removing the air box
First, disconnect and remove the battery. This is an important safety step as you will be working around the positive lead and the ECU of the car. Any contact with a wrench or screwdriver can cause damage to the car and yourself. Once the battery is disconnected, unplug the battery vent tube and lift it out of the battery box.
Next, you'll need to remove the upper airbox cover and air filter. Cut the zip tie that holds the wiring harness to the airbox. Don't worry, you will be replacing this zip tie when you reassemble everything.
Now, pull the circular electrical connector out of the holder on the side of the airbox. Disconnect the harness by twisting the harness connector until the two halves separate.
Finally, remove the two 10mm bolts holding the edge of the airbox to the chassis. Be careful not to force anything, as you don't want to damage the airbox or the surrounding components. With these bolts removed, you should be able to carefully lift and remove the airbox.
It's important to note that if your engine is an N14, you will need to re-torque the fuel line to its final tightness and reconnect the battery after replacing the air box, as mentioned in your initial query about replacing the fuel pump.
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Replacing the fuel lines
If you're replacing the fuel pump in your classic Mini, you may also need to replace the fuel lines. This is because the fuel lines are supposed to be replaced whenever they are removed to ensure proper sealing.
To replace the fuel lines, you'll need to disconnect the electrical plug on the bottom of the HPFP and pull the pump away from the motor. You'll then need to place the new pump next to the old one and align the new pump drive to be at the same angle as the old pump drive. Ensure the O-ring seal is in place on the pump housing, and rub a little oil on it to help prevent it from getting pinched.
Place a small amount of oil onto the two fuel line seals. Connect the threaded line to the pump finger-tight, then push on the other fuel line.
If you're looking to replace the hard underbody fuel lines on a 1999 Mini, it seems like they don't make them anymore, at least not in the UK. You may be able to get them, but it will likely be expensive.
If you're looking for a more modern replacement, any car parts store will have a 2-4psi electric pump. Buy two as they are inexpensive, and you will have a spare in the glove box.
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Installing an electric pump
To install an electric fuel pump in a classic Mini, you will need to buy a 2-4psi electric pump from a car parts store. It is recommended that you buy two, as they are inexpensive, so you will have a spare in the glove box.
You can then install the pump as per MadDog, although some people prefer to run the pump through a separate switch (off the ignition circuit) as an anti-theft measure.
To remove the old fuel pump, you will need to unbolt the top steady. This can take a few minutes, but it is possible to remove the fuel pump without doing this.
Once the old pump is removed, you can install the new electric pump in the same way. Be sure to prime the pump by cranking the motor for 15 seconds at a time, three times. Then, start the engine (it may take several tries) and run the engine for five minutes to warm up. Check for leaks and fix if necessary. You may also need to replace the fuel lines.
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Frequently asked questions
You can buy an electric fuel pump from any car parts store. You can install it yourself, but it is recommended to have a spare in the glove box.
The pump itself starts at $750, but you can save money by installing it yourself.
Modern Minis have a low-pressure fuel pump in the fuel tank, and a high-pressure fuel pump (HPFP) under the bonnet.
Crank the motor for 15 seconds at a time, three times. Start the engine and run it for five minutes to warm up.
If you are having issues with your Mini, it may be time to change your fuel filter.
