Fuel filter replacement/starting issue
 

Hi, all.

I replaced the fuel filter on my 2004 MC40 today and now cannot start the car. In addition to the filter, I replaced all the appropriate o-rings and seals. It turns over just fine but was emitting "clicking" noises from the fuel filter area when reassembled. Thinking that the battery may have lost power (recharged from 12.3v to 12.8v after one hour), I charged the battery since I had the doors open when working. Nada.

I've removed the fuel filter twice to examine it. Found nothing wrong (again). Now when priming the pump in ignition position 2, I'm no longer getting the clicking sounds heard earlier (immediately after the initial installation), yet it still won't start. I removed the fuel line to the filter and there is no fuel leaking from the hose when removed, i.e., doesn't seem to have line pressure?

The car is throwing NO codes. I've seen some threads with the same starting issue after filter replacement. Next step would be to remove the inspection plate over the fuel pump and check for pressure there but I would like to avoid that if possible. I didn't disconnect the neg terminal on the battery when replacing the filter. Could that have compromised the actual fuel pump in some way?

How about the fuel rail? Do I need to remove the intercooler to access it (I'm a Mini newbie)?

Anyone have a solution? I'm a competent mechanic but this is extremely frustrating (maybe it's a Mini thing)!!!

Read this carefully....
https://www.pelicanparts.com/techart...eplacement.htm

This particular paragraph:
"Take the upper cover and carefully line up the tabs on it (it can only go in one way) with the tabs on the lower filter housing. Take care to make sure the upper cover is directly seated on the filter element. If it isn't, THE CAR WON'T START. We found this out the hard way after re-assembling the fuel system. Once the upper cover is seated, rotate it clockwise until it stops. This will lock it in place."

Moving you to the Stock Problems/Issues section.

Is there gas coming out the rail?

Thanks for all the responses everyone. Minsanity had the solution.

I pulled the filter housing (yet again) and the top was not fully and correctly seated. Fixed that, primed it three times and it started right up. Thanks Minsanity!!!

Anytime, sir! Glad it's fixed.