Date: 111001
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.2010 Mini Cooper (R56) L4-1.6L (N12)
Page 65
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.2010 Mini Cooper (R56) L4-1.6L (N12)
Page 66
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 INFORMATION2010 Mini Cooper (R56) L4-1.6L (N12)
