Replacing Your Mini Cooper's Fuel Cap: Step-By-Step Guide

If you're looking to replace the fuel cap on your Mini Cooper, you've come to the right place. This article will outline the steps you need to take to get the job done. It's important to note that there are different types of Mini Coopers, so the process may vary slightly depending on the model you have. The fuel cap plays a crucial role in preventing fuel evaporation and reducing air pollution, so it's essential to ensure it's in good condition and properly sealed. You can purchase a replacement fuel cap online or from an auto parts store, and the cost typically starts at around $38. Now, let's get into the steps involved in replacing your Mini Cooper's fuel cap.

Removing the stock gas lid

Step 1: Remove the gas cap lid

This step is only necessary if you are looking to replace the chrome cap on an S model Mini Cooper with a custom part. Open the door and press in with a small screwdriver to release the tab. The chrome part will then come off.

Step 2: 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. The inner fender is held in place by plastic rivets and Phillips screws. Pry out the rivets and remove the screws until you can pull the inner fender free. Next, 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.

Step 3: Remove the filler door assembly

The filler door, hinge, and underlying housing are all one assembly. There are two clips hidden behind it that click into the edge of the fender opening. You can try to use a small screwdriver to press in and release them, but it is easier to drill two tiny holes where the dimples are in the ring and insert a screwdriver there. Then, use the screwdriver to pry the rubber ring on the filler neck away from the fuel door housing.

Step 4: Prepare for the new filler door assembly

With the old filler door assembly off, you can now prepare for the new one. First, pull the filler neck partially out of the tank to allow more room to work.

Removing the inner fender and fuel filler neck

To remove the inner fender and fuel filler neck of a Mini Cooper, you will need to undo the inner plastic fender to access the inside of the fender and the fuel filler neck. First, pry out the plastic rivets and remove the Phillips screws holding the inner fender in place. Once you have removed all the screws and rivets, pull the inner fender free.

Next, you 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. It is easier to remove the wheel, but it is not necessary.

Now, to remove the filler door assembly, you will need to release two clips hidden behind it that click into the edge of the fender opening. You can try to use a small screwdriver to press in and release them, but it is easier to drill two small holes where the dimples are in the ring and insert the screwdriver there. Then, use the screwdriver to pry the rubber ring on the filler neck away from the filler door housing.

Removing the filler door assembly

To remove the filler door assembly of a Mini Cooper, you will need a long flat-head screwdriver and a Phillips screwdriver. The filler door, hinge, and underlying housing are all part of the same assembly, which is held in place by two clips that click into the edge of the fender opening.

First, remove the gas cap lid. Open the door and press in with a small screwdriver to release the tab. The chrome part should now be removable.

Next, undo the inner plastic fender to access the inside of the fender and the fuel filler neck. You can do this by prying out the plastic rivets and Phillips screws until you can pull the inner fender free. Then, 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 it should be free to manipulate the rubber seal between the inner filler door and the filler neck.

Now, to remove the filler door assembly, you can try using a small screwdriver to press in and release the clips. However, it is easier to drill two tiny holes where the dimples are in the ring and insert a screwdriver to pop the clips free. Then, use the screwdriver to pry the rubber ring on the filler neck away from the filler door housing.

Installing the new filler door assembly

With the old filler door assembly off, installing the new one is fairly easy. First, pull the filler neck partially out of the tank, for more room to work. Then, 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 much easier.

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

Tighten up the bolts and clamps on the filler neck and the fuel tank, then replace the inner fender and you are done.

Tightening bolts and clamps

Once you have the new filler door assembly in place, you will need to secure it with bolts and clamps. First, pull the filler neck partially out of the tank to give yourself more room to work with. Then, press the filler neck into the housing and work the rubber ring into the corresponding groove. You can use WD-40 or a similar lubricant to make this process easier.

Once the filler neck is in the correct position, ensure the locking latch is still in place in the fender. Press the filler housing into the fender until you hear the clips click into place. Push the lock latch back through and check that it still lines up properly. Finally, tighten the bolts and clamps on the filler neck and the fuel tank.

It is important to ensure that all the bolts and clamps are properly tightened to prevent any fuel leaks. A leaking fuel cap can allow up to 30 gallons of gasoline to evaporate over a year.

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