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R60 High Pressure Fuel Pump Installation Guide

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Old 10-28-2014, 12:34 PM
G3NSM0R3S's Avatar
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High Pressure Fuel Pump Installation Guide

After replacing the Fuel Injectors, made a guide for that too Fuel Injectors , our Countryman All4 was still having issues of accelerating and cold starting from sitting over night or longer. Cleared the Check engine light computer and issue came back, Even had the message Engine malfunction, Reduced power. Even has poor acceleration when trying to pass someone or climb a incline or even from a red light/ stop sign. I researched online about possible issues like Vacuum Leaks, Battery or Altenator not supplying enough electrical output. Found another issue online that the HPFP would be the issues. So not having a OBD2 scanner that would read the R60 took it to mini for $150 test and found that the High Pressure Fuel Pump was the issue. The car has 79,303 miles on it and this repair is NOT covered under this 8yr/80,000 mile warranty or any extended factory warranty. I'm sure my issue has been on going since 75k or 77k miles. So once the part gets here I will be updating this with pictures and what not, so stay tuned.

**UPDATE**
Replaced HPFP at 79500 miles. The replacement of the High Pressure Fuel Pumps relatively easy. The only thing that needs to be removed from the engine is the air box and duct that connects to the turbo, if you have one. You will want to disconnect and the electrical connections around the HPFP to give you a better working area and so you won't damage them. You will need a 8mm socket and a 14mm line wrench to remove the HPFP to Fuel Rail aluminum pipe. You can remove this line without removing the manifold. To disconnect the hose that comes from the fuel take to the HPFP you will need to use a small flat head screw driver to push the black square that is on the hose connector towards the back of the car, to the firewall, to disengage the lock and pull the hose off the HPFP. I broke the black square and was still able to disengage the lucky using a pick by catching it on one of the groves and pushing it towards the firewall. If you do brake this connection the hose is 85+ dollars. Remove the bolts that hold the HPFP to the engine using an 8mm sock, there are 3 of them. 2 are at the front of the car and one is close to the firewall on the bottom of the HPFP. Once the bolts are removed you will need to wiggle and use a flat head to some what pry the part from the engine. Once the old HPFP is removed, please note the angle of the bar that is covered in oil. See Picture Below. This bar fits into a socket in the engine which spins and turns the HPFP. So you will need to slightly spin the bar on the new HPFP, you may want to pour some gasoline into the HPFP before you spin it to give it some lubrication while spinning it to line up with the socket inside the engine. Once the two line up start with the top bolt by screwing it down enough to hold the HPFP. Then place the bottom back bolt, the one closets to the firewall, screw that in enough then place the bottom front bolt in, closest to the front of the radiator and screw that in. Then tighten 3 bolts in a pattern, starting with the top and working your way around clockwise until tight. Then connect the aluminum pipe to the manifold and HPFP. Start screwing down the connections that is behind the Manifold first just enough so you can get the connector on the HPFP screwed in. Then tighten. Connect the hose that comes from the fuel tank to the HPFP you will hear a click, you may be able to feel it click. Now give the 8mm bolts a snug twist on each. Reconnect your electrical connections and place the air duct and box back into the engine compartment. Connect the negative terminal on the battery. Turn your car to the ON position and let the pumps pressurize for 30 seconds. Now start the car and let it idle for a few minutes while you check for leaks. If you notice leaks turn off the car and check connections. And now you are ready to MINI.

Parts Replaced:
BMW/MINI part# 13517592429
ECSTuning part# 2136420
Link: ECSTuning Link

Tools required:
Flat Screw drive
8mm socket & wrench
14mm Line Wrench
Pick

Additional Parts: (may or may not be needed)
BMW/MINI part# 13537598428
ECSTuning part# 2136423
Link: ECSTuning Link

BMW/MINI part# 13539800679
ECSTuning part# 2145179
Link: ECSTuning Link
 
Attached Thumbnails High Pressure Fuel Pump Installation Guide-highpressurefuelpump.jpg  

Last edited by G3NSM0R3S; 11-11-2014 at 07:29 AM. Reason: Added A Picture
  #2  
Old 11-07-2014, 09:07 AM
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We needed our HPFP replaced at around 40K for the same symptoms, stumble upon acceleration. It was replaced under warranty. About 10K later, it went into limp mode. That was said to be plugs and a coil pack be was not covered because the plugs had not reach the service interval??!!!??? Has been running well for the last 10K.
 
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