After a few days of searching the World Wide Web i still couldn't find a retrofit guide to putting an S Fuel cap onto a MINI Cooper!!! (GRRR). So here is my straight forward guide
for anyone who wants rid of their standard filler cap.
1. Jack up your passenger side rear wheel and remove
2. Ensure that your front wheels have been 'Chock'ed' to stop it rolling forward
3. Within the wheel Arch remove the two standard plastic retaining screws that you can see directly infront of you, unscrew and pull out
4. Within the wheel Arch remove the black plastic nut with a 10mm socket that is at the 12 o clock position holding the lining (Youll need to bob your head in the arch to see)
5. Peel back the lining onto itself and wedge behind the disk brake, (Youll not damage the brake or the lining!)
6. Pop your head inside the arch now the lining is removed from view and you should see this retaining bolt holding the fuel pipe secure:
http://desmond.imageshack.us/Himg585...pg&res=landing
7. Remove or Loosen the bolt with the 10mm socket (I found it easier to fully remove)
8. Open your standard fuel flap and use a screw driver or stanley blade to cut around the soft rubber thats tight against the fuel neck (I used a screw driver)
http://desmond.imageshack.us/Himg835...pg&res=landing
9. After cutting fully remove the soft rubber away from the standard filler cap (there should now be a gap between the hard plastic and the bodywork)
10. Within the gap youve now created get your fingers between the bodywork and hard plastic and pull towards your body (Its not instant and may take a few attempts)
11. HOPEFULLY! You will now be left with something that looks like this:
http://desmond.imageshack.us/Himg706...pg&res=landing
12. Twist off the gromet from your old fuel cap (This is what helps the actuator locate the hole to lock your cap when the car is locked)
http://desmond.imageshack.us/Himg404...pg&res=landing
13.Take your new 'S' cap (Without the painted insert) and push back into the location. I found it easier to place the hinge at 12 o clock and then turn to the left 9 o clock
14. While doing so, push the rubber gromet and actuator pin back together (IF YOU FIND THIS TOO TRICKY SEE STEP 23)
15. Prise the new rubber seal back over the filler neck with a screwdriver
16. Once it looks like its in position firmly push towards the car so the filler cap seats itself within the body work.
17. Open the new chrome fuel flap and slide your colour coded surround over the top (Its clear which way it goes as it has the cut out for the actuator pin assembly)
18. Push the colour surround into place, it should simply 'click'
19. Now you need to put back the Bolt from STEP 7 tightly
20. Re locate the inner wheel arch lining to normal position and put back bolt from STEP 4 and retaining screws from STEP 3
21. Put your wheel back on (PLEASE TIGHTEN YOUR WHEEL NUTS!! ;) )
22. Clean the bodywork area you have been working on and stand back and marvel at how brilliant you are!!:
http://desmond.imageshack.us/Himg834...pg&res=landing
23.EXTRA STEP (If like me you couldnt locate the actuator pin and gromet together!! :wall: )
24. Remove the Chrome surround from your back left light cluster
25. Remove the x3 torx screws holding the light in place
26. Uncouple the light from the wiring (the big green connector block)
27. Shine a torch into the recess of bodywork and youll see the actuator pin and the newly fitted fuel cap
28. Bend the Pin so it now fits into the fuel cap hole
29. Test that the car locks + fuel flap!!
30. Refit the light - JOB DONE!! :D
