Katerina Swanson
If you're looking to replace the fuel cap on your Mini Cooper, you've come to the right place. This guide will take you through the process step-by-step, so you can get your Mini back on the road in no time. Whether you're opting for a custom part or simply replacing a damaged fuel door, we'll show you how to do it safely and efficiently. So, let's get started!
| Characteristics | Values |
|---|---|
| Model | S |
| Year | 2001-2013 |
| Chrome cap replacement time | 5 minutes |
| Steps | Open the door, press in with a small screwdriver and release the tab, then pull off the chrome part |
| Additional steps for changing one type for another | Undo the inner plastic fender, get access to the inside of the fender and the fuel filler neck, pry out the rivets and take out the screws, unbolt the fuel filler neck, manipulate the rubber seal between the inner filler door and the filler neck |
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What You'll Learn
Removing the old fuel cap
To remove the old fuel cap from your Mini Cooper, you'll need to 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 rivets and removing the Phillips screws that hold the inner fender in place. Once you've removed enough of them, you can pull the inner fender free.
Next, you'll need to unbolt the fuel filler neck where it attaches to the fender and where it's clamped to the tank. You don't need to remove it completely, but you will need to manipulate the rubber seal between the inner filler door and the filler neck.
If you're just replacing the chrome cap on an S model Mini Cooper with a custom part, you can skip the previous steps. Instead, open the door, press in with a small screwdriver, and release the tab. The chrome part should then pull off.
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Accessing the fuel filler neck
To access the fuel filler neck, you will need to undo the inner plastic fender to get access to the inside of the fender and the fuel filler neck. Holding the inner fender in place are a series of plastic rivets and Phillips screws. Pry out the rivets and take out the screws until you can pull the inner fender free.
The filler door, hinge and the underlying housing the mounts to the body are all one assembly on the Mini. You can get away with not taking the wheel off, but it is easier if you do.
Next, unbolt the fuel filler neck where it attaches to the fender, and where it is clamped to the tank. There is no need to pull it completely out, you just need it free to manipulate the rubber seal between the inner filler door and the filler neck.
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Removing the inner fender
To remove the inner fender of a Mini Cooper, you first need to undo the 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. You will need to pry out the rivets and unscrew the screws until you can pull the inner fender free.
It is also possible to remove the wheel to make this process easier, although it is not necessary.
Once the inner fender is free, you can 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 the fuel filler neck completely, but you will need to manipulate the rubber seal between the inner filler door and the filler neck.
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Unbolting the fuel filler neck
To unbolt the fuel filler neck, you first need to undo the inner plastic fender to access the inside of the fender and the fuel filler neck. Holding the inner fender in place are a series of plastic rivets and Phillips screws. Pry out the rivets and take out 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 don't need to pull it out completely, but you do need to free it so you can manipulate the rubber seal between the inner filler door and the filler neck.
The filler door, hinge and the underlying housing the mounts to the body are all one assembly on the Mini. You can get away with not taking the wheel off, but it is easier if you do.
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Removing the wheel
To replace the fuel cap on a Mini Cooper, you will need to remove the wheel. Here is a step-by-step guide:
- Loosen the lug nuts on the wheel with a lug wrench. Turn the lug wrench in a counter-clockwise direction to loosen the nuts. Do not remove the lug nuts yet, just loosen them.
- Jack up the car and place jack stands under the car for support. Make sure the car is securely supported before proceeding.
- Remove the lug nuts and take off the wheel. Set the wheel aside in a safe place.
- With the wheel removed, you will now have access to the fuel cap.
- If you are just replacing the chrome cap with a custom part, open the door, press in with a small screwdriver, and release the tab. The chrome part should just pull off.
- If you are changing one type for another, you will need to undo the inner plastic fender to access the inside of the fender and the fuel filler neck.
- Pry out the rivets and take out the screws holding the inner fender in place until you can pull it free.
- 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, just free it enough to manipulate the rubber seal between the inner filler door and the filler neck.
- Install the new fuel cap by following the above steps in reverse. Make sure all screws and bolts are tightened securely.
- Lower the car by removing the jack stands and lowering the jack.
- Tighten the lug nuts securely with the lug wrench.
Note: This process may vary slightly depending on the model year of your Mini Cooper. The above instructions are for the 2007-2013 model years. For older models (2001-2006), the process may be slightly different. Always consult a qualified mechanic if you are unsure about any steps.
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Frequently asked questions
First, 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 rivets and removing the Phillips screws. Next, unbolt the fuel filler neck where it attaches to the fender and the tank. You don't need to remove it completely, but you do need to be able to manipulate the rubber seal between the inner filler door and the filler neck.
No, but it is easier if you do.
If your fuel cap is damaged or missing, you should replace it.
If you are just replacing the chrome cap on an S model Mini Cooper with a custom part, it should only take about five minutes.
Yes, you can replace the fuel cap yourself. However, if you are unsure about any part of the process, it is always best to consult a professional.
