MINI Cooper S R56 High Pressure Fuel Pump (HPFF)

If you have been reading our wwws and Facebook page, you know well the issue w the BMW High Pressure Fuel Pump (HPFF) associated w the 135/335/535 N54 turbo motors. This was not a small issue, this issue of the failure of the HPFF affected 10’s of thousands of BMW owners, from 2007 thru 2010. BMW went thru four iterations of this fuel pump before they found the right long term solution.

Now we have the same issue rearing its head with the newer MINI Cooper S turbo motors (MINI Cooper S cars from 2007 thru 2009, 2010 and newer seem to be OK and may have the newer designed HPFF). These motors also have two fuel pumps (one in the main fuel tank, and a second high pressure fuel pump on the side of the motor). The main fuel pump in the fuel tank runs at the normal type of fuel pressure (output of about 5 bar), but the secondary pump, the HPFF, runs at 50bar at idle, and runs at 120bar at wide open throttle. The newer MINI Cooper S turbo motor is also a direct injected motor, which is why it requires the HPFF unit on the side of the motor.

So, what is the issue? The HPFF dies. But, it doesn’t just die all at once. It prolongs the issue, confusing the owner. Some have been reported to die all at once, with some having the pump die while driving the car on the freeway, and this is a scary event. But most have a series of events that gives some hints that the HPFF is starting to have issues (although most owners don’t know that these symptoms are signs of the HPFF dying). The car will start having some surging when driving. Then it will have difficulty starting when cold. Finally, it will run, but feel like a diesel truck, and when you get to this stage, the “check engine light” (CEL) will also come on for “massive misfires”.

Is this a KNOWN issue? You bet. So much so that MINI has issued another letter to customers talking about this issue and saying they will take care of it WHEN IT HAPPENS. But not until it happens….oh my.

Here is the text of the letter from MINI USA –

MINI USA has become aware of a potential problem that could affect durability of the high-pressure fuel pumps in select 2007, 2008, and 2009 model year MINI vehicles equipped with the N14 turbocharged engines. The Service Engine Soon lamp may illuminate on affected vehicles, and drivers may experience reduced engine performance.
While we estimate that only a small percentage of vehicles will develop a problem, MINI USA will demonstrate the confidence we have in our product by extending the warranty for the high-pressure fuel pump to 10 years or 120,000 miles from the original in-service date, whichever comes first.
The emissions warranty extension for this component applies to your vehicle, and is transferable to any subsequent purchaser of your car.
All terms and conditions of the Federal Emissions Defect Warranty, the Federal Emissions Performance Warranty, and the California Emissions Warranty apply to the extended warranty. Warranty coverage for all other parts is not affected. Warranty terms and conditions can be found in your Service and Warranty Information booklet.
In the event that your vehicle’s high-pressure fuel pump exhibits the conditions outlined above, please contact your nearest authorized MINI dealer to schedule an appointment. Your MINI dealer has received a service information bulletin informing them of this warranty extension.
Please be assured that we at MINI are totally committed to the highest standards of product excellence and ownership experience, and we are determined to provide a level of service that exceeds your expectations.

BRR

We just had a car w this exact HPFF failure, and we did the repair. Now, we’re seeing if MINI USA will cover the expense for the customer. Stay tuned.