My steering died a few weeks ago, and we decided to order the Haynes Mini book and check the fan, fuse, etc. ourselves and attempt the Power Steering Pump cleaning if needed. After waiting a week and half for the book, it finally arrived. $30.
We then discovered we needed the following:
a torque wrench ($16 from Pep Boys), extra Pentosin fluid ($22 from BMW), three self locking nuts ($2.34 ea also from BMW), and a socket set with a various sizes to get the nuts and bolts off. We also used a screwdriver to remove the hose clamp (called a circlip in the book.)
So we managed to get the fan off, fluid out, but are having trouble removing the hose pipe from the reservoir on top from the pump itself. We got the clip off, two bolts in the back, the single bolt from the supply pipe and now we are stuck.
Can someone tell us how to get the pump out?
And is it easier to get the pump out if we remove the pipe and electrical plugs first?

Thanks so much, we are totally stuck :S

 

1. I used my Mighty Vac to suck as much of the fluid from the reservoir. I couldn't get it all, but at least 90%.

2. Disconnected the low pressure hose from the reservoir (the one toward the front) and again used the Mighty Vac to suck the fluid from the hose.

3. Remove the cooling fan for the pump. (2 13mm nuts) To complete the removal you'll have to disconnect the wire connector, easy release by pushing the lever on the side.

4. Remove the 13mm nut holding the front of the pump down, roughly in between the two that held the fan in place.

5. Remove the two 13mm bolts from the backside of the pump. This is pretty much blind, unless you have some sort of mirror or freakishly small head. You have to come from the backside of the cross memeber and they are at the bottom of the steering rack. You should be able to feel them. The exhaust down pipe made one of them a little tough to get at, but not bad.

6. I used my Dremmel to slot out the hole at the front that the 13mm nut came off. The bracket for the pump was stuck under the engine mount, so I could not lift it out.

7. The high pressure hose is a solid metal tubing that is bolted to the pump with a 13mm bolt. It is a little tight, but you can get it unbolted. There is an o-ring type of press fit for this connection, which you will have to overcome to get it released. Carefully pry it apart. Some fluid will drain out.

8. Now it is just a matter of sliding and twisting the pump around until you can get the pump out. Having the low pressure hose attached made this slightly more difficult, but also made it cleaner. It is also fairly difficult to get the low pressure hose off of the pump while it is on the car.

9. Lastly you can now release the two electrical connections and the pump will be free after you cut the nylon zip ties holding the wires to the bracket.

10. The pump is connected to a bracket which will not come with a new pump, and probably should be removed before sending in to rebuild. Four 10mm nuts and to T30 Torx will separate the pump from the bracket.

11. Now just reverse this process to install.

 

THANKS
headed down to the garage now to try some of your suggestions

 

It worked!!!! Thank you!
We took off the pump and sent it to BBA.Reman (http://www.bba-reman.com/us/index.aspx) and for $200 they remanufactured it. We put it back on yesterday and the steering problem is resolved.
To recap:
1) Purchased Mini Cooper book for repairs (http://www.minicarparts.net/), it is not sold in the States per se as it is based on a right hand drive but the engine component pieces are spot on. ($23)
2) Bought Pentosin, new bolts, and hose clips (we bought regular screwdriver tighten ones from Pep Boys as the factory clips sucked and were cheesy) Cost: $30
3) Cost to ship removed pump: $20 via UPS ground. Cost to ship back from Massachusetts (BBA): $10. We added the insurance for $5 since they had a special on next day air to California from Mass.
NOTE: Pump is guaranteed for as long as I own my Mini.
4) Tools we used for the job:
10 and 13mm sockets, Phillips and flathead screwdriver, awl for
removing those horrible clips, torque wrench, star shaped screwdriver.
Notes on removal: three bolts connecting the bracket to the car, and four from the bracket to the pump.
You will need to raise your Mini pretty high to do this job. We had to use several 2 x 4s and a floor jack to get the car up high enough to put it on ramps. Standard ramps have too much of an angle and the spoiler will hit and you can't drive it up.
You will also need a large receptacle to catch all the Pentosin. An oil change plastic container will do.
This job was challenging, but it is doable. Remember to bleed your pump once you replace and refill Pentosin by turning your wheel at a stop left all the way then right several times.