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R56 Low fuel pressure issue diagnose DIY

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Old Jan 4, 2022 | 03:13 PM
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GT350's Avatar
GT350
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Low fuel pressure issue diagnose DIY

Sharing some learnings from no fuel issue, I believe it can cover pretty much all the issues related to low-pressure fuel delivery. This should apply to all 2nd gen Minis.

The basic diagram of low-pressure fuel delivery:
- DME sends the signal to JBE (Junction box located at passenger footwell, a fuse box)
- 3 elements affect the electrical message to the fuel pump: main relay, 20A fuse, K96 relay soldered in JBE circuit board.
- Voltage sends to the fuel pump, fuel is pumped to the fuel filter housing within the fuel tank.
- fuel travels underneath the car to the fuel rail (non-turbo) or HPFP (turbo)

Diagnose process. Most of the time issue is caused by fuel pump, so follow Pelican fuel pump testing instruction. On fig 8, instruction says to turn the key on then measure the voltage. No voltage in my case, then crank the engine, voltage must be presented.
if 12V presents, then you can eliminate the electrical issue, and focus on the physical parts.
if 0V presents, then follow the instructions on JBE checks.

Physical parts check:
1. fuel pump - connect 12V to middle 2 pins, (white/blue wire is positive, brown wire is negative). the pump should run (you can hear the noise). You can also test the pump itself to check the pressure is sufficient by connecting the gauge like the pic (can leave the pump inside the tank, but has secure the hose connected to pump), the pressure should be around 80 psi.

2. fuel filter - the output is a female connector, I don't know how to test the pressure. In my case, an o-ring was missed to install when replacing the filter, so fuel escaped from the housing when pressurized, the fuel pumped out to fuel line has so little pressure to reach the fuel rail.

3. fuel line - check if the line underneath the car if crashed. or pressure test the line to ensure nothing blocked inside.


JBE checks
Wiring diagram. 30G relay is the main relay, F43 (N12 & N14, F46 for N16 & N18) is the fuse, K96 relay is soldered in the circuit board

pretty much the same as N16 & N18

This is how the circuit board looks like. I have no idea how to read or test it.


After K96 relay, this is the pin connects to white/blue wire to the fuel pump

white/blue wire



 
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Old Dec 28, 2023 | 06:48 PM
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Lex2008
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Dude this is awesome. Thanks for putting this together. This connection at the fuel rail is for the non-turbo car only though. There is no connection point at the fuel rail on the turbo model.
 

Last edited by Lex2008; Dec 29, 2023 at 06:19 PM.
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