printing from undefinedsmartexpert.free.fr/mini/doc/r50/fuel supply cooper.pdfpressure regulator is...

2002-06 ENGINE

Fuel Supply System - Repair Instructions - Cooper (1.6L/W10)

CHECKING/SETTING ENGINE/EMISSION

13 00 002 CHECKING FUNCTION OF DIGITAL MOTOR ELECTRONICS (DME)

Installation Location:

OBD socket (1) in driver's footwell.

Fig. 1: Installing OBD Socket In Driver'S Footwell Courtesy of BMW OF NORTH AMERICA, INC.

FUEL PUMP WITH DRIVE AND LINE

13 31 ... NOTES ON FUEL PRESSURE CHECK (REFERENCE PRESSURE: ENVIRONMENT)

NOTE: Connect diagnosis system.

Read fault memory.

Check stored fault messages.

Clear fault memory.

2006 MINI Cooper

2002-06 ENGINE Fuel Supply System - Repair Instructions - Cooper (1.6L/W10)

2006 MINI Cooper


Microsoft

Tuesday, February 16, 2010 11:52:39 AM © 2005 Mitchell Repair Information Company, LLC.

Microsoft

Tuesday, February 16, 2010 11:52:44 AM Page 1 © 2005 Mitchell Repair Information Company, LLC.

Feature Of This Version With Ambient Pressure:

The connection for the vacuum hose of the fuel pressure regulator is located between the throttle and the air cleaner or on the air cleaner.

Test Precondition:

The correct fuel pressure regulator is fitted.

Using the EPC, check whether the fuel pressure regulator suitable for the car is fitted:

Connect test adapter.

Description Of Operation:

The control function of the fuel pressure regulator must be guaranteed under all operating conditions. The fuel pump must always be able to generate a higher fuel pressure than the pressure regulated by the pressure regulator.

The injection rate is adjusted by means of the injection time; the injection time is controlled by the DME.

Description Of Operation: Fuel Return Line:

When the engine is at a standstill and the ignition key is in position 0, the fuel return line after the pressure regulator is at zero pressure.

Description Of Operation: Pressure Retaining Function:

The pressure regulator closes when the engine is at a standstill and the ignition key is in position 0. The fuel pressure in the delivery line is retained over an extended period.

A non-return valve closes in the fuel pump. These measures help to retain the fuel pressure in the fuel system. Extended starting times are thus avoided.

Complaint: Drive Characteristic Faults, Lack Of Power:

Run engine at idle speed and measure fuel pressure.

If The Measured Value Is Less Than The Nominal Value - 0.2 Bar:

Line cross-sections in fuel feed are constricted or fuel filter is clogged, or

Fuel pump voltage supply is not O.K.: e.g. as a result of high contact resistance (corrosion) in plug connection between wiring harness and fuel pump.

If The Measured Value Is Greater Than The Nominal Value + 0.2 Bar:

2006 MINI Cooper


Microsoft


Turn off engine stop and then observe measured value.

If measured value drops to nominal value, then line cross-sections in fuel return are constricted or clogged.

Check the fuel lines for kinks.

If no kinks are visible:

Replace return lines

If measured value remains too high, then pressure regulator is in all probability faulty.

Have a cleaning cloth ready and catch and dispose of escaping fuel.

Replace the return line but not the pressure regulator.

Complaint: Starting Problems:

Run engine briefly at idle speed and switch off.

Note down measured value while engine is stopped.

Read off measured value again after approx. 20 to 30 minutes while engine is stopped.

Special tool 13 3 010 (hose clamp) is required for the following test.

If The Measured Value Has Dropped By More Than 0.5 Bar:

Start engine and wait briefly for a stable pressure increase.

Switch off the engine and immediately pinch off the delivery line just before the pressure gauge with the special tool 13 3 010.

Note down measured value.

Read off measured value again after approx. 20 to 30 minutes while engine is stopped.

If The Measured Value Has Now Dropped By Less Than 0.5 Bar, The Following Faults Can Be Present:

Fault in delivery lines.

Fault in in-tank delivery hose.

Faulty pressure-holding non-return valve in fuel pump.

Check components. Replace faulty components.

If The Measured Value Has Dropped By More Than 0.5 Bar Again:

IMPORTANT: With less likelihood, the return line may be completely blocked. When the pressure regulator is removed, fuel could escape under pressure!

2006 MINI Cooper


Microsoft


Replace pressure regulator.

13 31 029 CHECKING FUEL PUMP DELIVERY PRESSURE

Special Tools Required:

13 1 130

13 3 063

13 5 220

13 5 221

13 5 222

Necessary Preliminary Tasks:

Switch off ignition.

Recycling:

Catch and dispose of escaping fuel.

Observe country-specific waste-disposal regulations.

Checking fuel pressure with diagnosis system:

Connect special tools 13 1 130 and 13 5 222 to pressure sensor of diagnosis system.

Checking fuel pressure with pressure gauge:

Attach special tools 13 3 063 and 13 1 130.

NOTE: All the fuel hoses and hose clips which were detached within the framework of the checks must be replaced.

Interrogate fault memory of DME control unit. Check stored fault messages. Rectify faults. Now clear the fault memory.

NOTE: For Special Tool identification, see FUEL SYSTEM - SPECIAL TOOLS - COOPER (1.6L) R50/W10 .

IMPORTANT: The fuel in the fuel lines is under pressure (approx. 3 bar)!

2006 MINI Cooper


Microsoft


Fig. 2: Identifying Pressure Gauge And Adapters Courtesy of BMW OF NORTH AMERICA, INC.

Remove cover from injection pipe.

Remove dust cap (1) from measuring valve on injection pipe.

2006 MINI Cooper


Microsoft


Fig. 3: Removing Measuring Valve Dust Cap Courtesy of BMW OF NORTH AMERICA, INC.

Prepare special tool kit 13 5 220 (consisting of 13 5 221 and 13 5 222).

Connect special tool kit 13 5 220 to pressure sensor of diagnosis system.

2006 MINI Cooper


Microsoft


Fig. 4: Identifying Adapter And Non-Return Valve Courtesy of BMW OF NORTH AMERICA, INC.

Screw non-return valve (1) onto special tool so that valve remains closed in injection pipe.

Screw special tool kit 13 5 220 onto injection pipe so that sealing ring is sealed in special tool.

2006 MINI Cooper


Microsoft


Fig. 5: Locating Special Tool Kit 13 5 220 In Injection Pipe Courtesy of BMW OF NORTH AMERICA, INC.

Start engine.

Screw in non-return valve (1) of special tool kit 13 5 220 until pressure indication appears in diagnosis system.

2006 MINI Cooper


Microsoft


Fig. 6: View Of Non-Return Valve Courtesy of BMW OF NORTH AMERICA, INC.

This could damage the measuring valve in the injection pipe.

Measuring Fuel Pressure:

Start engine.

Check fuel delivery pressure. Refer to FUEL SYSTEM - TECHNICAL DATA - COOPER (1.6L) R50/W10 .

Switch off engine.

IMPORTANT: Do not screw in non-return valve up to mechanical stop.

2006 MINI Cooper


Microsoft


Fig. 7: Checking Fuel Delivery Pressure Courtesy of BMW OF NORTH AMERICA, INC.

13 31 035 REMOVING AND INSTALLING/REPLACING FUEL FEED LINE


13 5 281

13 5 282

Recycling:



2006 MINI Cooper


Microsoft





Reduce fuel pressure in fuel feed line.

The above tasks are described in the appropriate article, refer to 13 64 541 REPLACING ALL FUEL INJECTORS.

Release fuel feed line from clips.

Unlock quick-connect coupling on fuel feed line (1) and detach from injection pipe.

Seal fuel feed line with special tool 13 5 281.

Fig. 8: Sealing Fuel Feed Line With Special Tool Courtesy of BMW OF NORTH AMERICA, INC.

IMPORTANT: When working on fuel lines, make sure no fuel drips onto the alternator. Cover alternator with suitable material.

IMPORTANT: The fuel in the fuel lines is under pressure (approx. 3 bar)!

2006 MINI Cooper


Microsoft


Remove fixtures (1) of fuel line from bulkhead and body floor.

Fig. 9: Removing Fixtures Of Fuel Line Courtesy of BMW OF NORTH AMERICA, INC.

Support chassis subframe in middle with a transmission lifter.

Release both screws (1) of resilient mounting bushes.

Tightening torque, (100 N.m.).

NOTE: Lower the chassis subframe slightly in order to remove the fuel line.

2006 MINI Cooper


Microsoft


Fig. 10: Removing Screws Of Resilient Mounting Bushes Courtesy of BMW OF NORTH AMERICA, INC.

Release upper screws (1) of chassis subframe by 5 mm.

Tightening torque, (100 N.m.).

NOTE: Do not remove screws.

2006 MINI Cooper


Microsoft


Fig. 11: Removing Upper Screws Of Chassis Subframe Courtesy of BMW OF NORTH AMERICA, INC.

Slacken all 6 rear screws of chassis subframe until chassis subframe has 10 mm clearance, see illustration.

Release right screw (1) on chassis subframe.

NOTE: The transmission lifter may have to be lowered slightly so that the chassis subframe can be moved away from the body.

2006 MINI Cooper


Microsoft


Fig. 12: Removing Right Screw On Chassis Subframe Courtesy of BMW OF NORTH AMERICA, INC.

Press lugs of quick-connect coupling (1) together and carefully detach fuel feed line (2) from quick-connect coupling.

Place special tool 13 5 282 on fuel line and detach fuel line from clips on body.

Remove fuel line.

2006 MINI Cooper


Microsoft


Fig. 13: Removing Fuel Feed Line Courtesy of BMW OF NORTH AMERICA, INC.

Catch fuel remaining in the line in a suitable container.

Then examine fuel system for leaks.

INJ. PUMP, REGULATOR, MIXTURE REGULATOR

13 51 630 REPLACING FUEL PRESSURE REGULATOR



NOTE: The heat shield on the bulkhead may have to be detached so that there is sufficient space available for removal.

2006 MINI Cooper


Microsoft


Check fuel pump delivery pressure. Refer to 13 31 029 CHECKING FUEL PUMP DELIVERY PRESSURE.

Remove injection pipe. Refer to 13 64 541 REPLACING ALL FUEL INJECTORS.

Remove retaining clip (1) of pressure regulator.

Turn pressure regulator (2) and remove.

Fig. 14: Removing Retaining Clip And Pressure Regulator Courtesy of BMW OF NORTH AMERICA, INC.

Installation:

Replace sealing rings (1) and (2) of pressure regulator.

NOTE: After removing pressure regulator, make sure filter of regulator is not left behind in housing.

2006 MINI Cooper


Microsoft


Check whether filter (3) is fitted.

Oil sealing rings slightly to facilitate installation.

Fig. 15: Installing Sealing Rings And Of Pressure Regulator Courtesy of BMW OF NORTH AMERICA, INC.

INJECTION NOZZLE AND LINES

13 31 035 REMOVING AND INSTALLING/REPLACING FUEL FEED LINE

Operation is the same as 13 31 035 REMOVING AND INSTALLING/REPLACING FUEL FEED LINE.

THROTTLE AND OPERATION

13 54 030 REMOVING AND INSTALLING/SEALING THROTTLE ASSEMBLY

2006 MINI Cooper


Microsoft



Read out fault memory of DME control unit.



Remove intake filter housing. 13 71 000 REMOVING AND INSTALLING INTAKE FILTER HOUSING.

Remove intake fitting (gaiter). Refer to 13 71 031 REPLACING INTAKE FITTING FOR INTAKE FILTER HOUSING.

Unlock line of tank venting valve on throttle valve assembly and disconnect.

Unlock plug (1) and remove.

Loosen screws (2).

Remove throttle valve assembly (3).

Tightening torque, refer to 13 54 1AZ in FUEL SYSTEM - TIGHTENING TORQUES - COOPER (1.6L) R50/W10 .

Fig. 16: View Of Throttle Valve Assembly Courtesy of BMW OF NORTH AMERICA, INC.

2006 MINI Cooper


Microsoft


Installation:

Replace sealing ring (1).

Fig. 17: Installing Sealing Ring Courtesy of BMW OF NORTH AMERICA, INC.

Replacement only:

Delete adaptation values and reset.

Connect diagnosis system:

Diagnosis.

NOTE: A faulty throttle valve causes the adaptation values stored in the DME control unit to be modified. These adaptation values must be reset after the throttle valve has been replaced.

2006 MINI Cooper


Microsoft


Model.

DME engine.

Control unit function.

DME 2000.

Component activation.

Reset adaptation values.

Electronic throttle.

Fig. 18: Identifying Diagnosis System Courtesy of BMW OF NORTH AMERICA, INC.

THROTTLE POTENTIOMETER

13 63 590 REPLACING FUEL PUMP RELAY

NOTE: Now clear the fault memory.

2006 MINI Cooper


Microsoft






Installation Location: Footwell on left.

Remove fuse box cover.

Pull fuel pump relay (1) from plug-in location in fuse box.

Fig. 19: Removing Fuel Pump Relay Courtesy of BMW OF NORTH AMERICA, INC.


2006 MINI Cooper


Microsoft


START VALVES

13 64 541 REPLACING ALL FUEL INJECTORS


13 5 220

13 5 281





R53 only: Remove intercooler.

Recycling:



W10 Only

Unlock retaining lugs (1), carefully lift cover on front side and remove.


NOTE: All illustrations show the W10 engine.

IMPORTANT: When working on fuel lines, make sure no fuel drips onto the alternator. Cover alternator with suitable material.

2006 MINI Cooper


Microsoft


Fig. 20: Identifying Retaining Lugs Courtesy of BMW OF NORTH AMERICA, INC.

Remove valve cap from injection pipe.

Connect special tool kit 13 5 220.

Connect a hose of sufficient length to special tool and attach hose in fuel tank.

Screw in non-return valve (1) of special tool 13 5 220 so that pressurized fuel flows into tank.

2006 MINI Cooper


Microsoft


Fig. 21: Locating Adapter And Connector Courtesy of BMW OF NORTH AMERICA, INC.

Place an absorbent cloth around special tool 13 5 220 and remove hose and special tool.

Reinstall valve cap.

Detach vacuum line from retaining clips (1).

2006 MINI Cooper


Microsoft


Fig. 22: View Of Vacuum Line And Retaining Clips Courtesy of BMW OF NORTH AMERICA, INC.

Detach fuel feed line (1) from clips.

Unlock quick-connect coupling on fuel feed line (1) and detach from injection pipe.

Install special tool 13 5 281.

Have an absorbent cloth ready when quick-connect coupling of fuel feed line is detached.

2006 MINI Cooper


Microsoft


Fig. 23: Locating Quick-Connect Coupling On Fuel Feed Line Courtesy of BMW OF NORTH AMERICA, INC.



Unlock cable duct on fixtures (3) and remove.

Cut through cable tie (4).

2006 MINI Cooper


Microsoft


Fig. 24: Identifying Plugs And Cable Duct On Fixtures Courtesy of BMW OF NORTH AMERICA, INC.

Detach vacuum hose from fuel control valve.

Release screws (1).

Carefully detach injection pipe (2) from intake manifold.

Tightening torque, refer to 13 64 1AZ 1AZ in FUEL SYSTEM - TIGHTENING TORQUES - COOPER (1.6L) R50/W10 .

2006 MINI Cooper


Microsoft


Fig. 25: View Of Injection Pipe On Intake Manifold Courtesy of BMW OF NORTH AMERICA, INC.

Drain injection pipe before removing fuel injectors.

Remove retaining clip (1) of fuel injector and then remove fuel injector (2).

2006 MINI Cooper


Microsoft


Fig. 26: Identifying Fuel Injector Retaining Clip Courtesy of BMW OF NORTH AMERICA, INC.

Installation:

Coat sealing rings with antiseize agent.

2006 MINI Cooper


Microsoft


Fig. 27: Locating Sealing Rings Courtesy of BMW OF NORTH AMERICA, INC.

INTAKE SILENCER

13 71 000 REMOVING AND INSTALLING INTAKE FILTER HOUSING


Switch off ignition

Release clamp (1).

Detach intake fitting from intake filter housing.


2006 MINI Cooper


Microsoft


Loosen screws (2).

Release cable holders (3 and 4).

Remove intake filter housing.

Tightening torque, refer to 13 71 1AZ in FUEL SYSTEM - TIGHTENING TORQUES - COOPER (1.6L) R50/W10 .

Fig. 28: Removing Intake Filter Housing Courtesy of BMW OF NORTH AMERICA, INC.

13 71 031 REPLACING INTAKE FITTING FOR INTAKE FILTER HOUSING


Switch off ignition

Release clip (3).

Detach vent hose (4) from intake fitting (2).

Release clamps (1).

Detach intake fitting (2) from throttle assembly and intake filter housing.

2006 MINI Cooper


Microsoft


Fig. 29: Removing Intake Fitting From Throttle Assembly Courtesy of BMW OF NORTH AMERICA, INC.

AIR CLEANER

13 72 001 REPLACING AIR CLEANER ELEMENT

Release screws (1).

Raise cover and slide in direction of arrow.

Intake pipe does not have to be removed to replace air cleaner element.

NOTE: Illustration shows intake pipe removed.

2006 MINI Cooper


Microsoft


Fig. 30: Locating Screws And Cover Courtesy of BMW OF NORTH AMERICA, INC.

Fold cover open.

Remove air cleaner element from intake filter housing.

Installation:

Clean intake filter housing.

2006 MINI Cooper


Microsoft


Fig. 31: View Of Air Cleaner Element Courtesy of BMW OF NORTH AMERICA, INC.

CARBON CANISTER VENTILATION

13 90 500 REPLACING TANK VENTING VALVE





Unlock and disconnect both lines (1).

2006 MINI Cooper


Microsoft


Fig. 32: View Of Tank Venting Valve Lines Courtesy of BMW OF NORTH AMERICA, INC.

Bend locking tongue (1) straight and slide venting valve from holder.

Unlock connector (2) and remove.

2006 MINI Cooper


Microsoft


Fig. 33: Identifying Locking Tongue On Venting Valve Courtesy of BMW OF NORTH AMERICA, INC.


2006 MINI Cooper


Microsoft


printing from undefinedsmartexpert.free.fr/mini/doc/r50/fuel supply cooper.pdfpressure regulator is...

Documents