41 63 003 Replace cover bowl

Special tools required:

00 9 321

Necessary preliminary tasks:

Remove FLAP FOR FUEL FILLER NECK
Remove SERVODRIVE FOR FUEL FILLER FLAP

NOTE: Carry over schematic diagram to the relevant vehicle type.

IMPORTANT: Deformation of the sheet metal flanges in the side panel and the wheel arch results in permanent vehicle leakage. Carry out removal/installation with great care.

Following new body parts are required (refer to OVERVIEW OF CONSUMABLES ):

(1) Filler bowl
(2) Butyl tape 4 x 1.5 mm (not shown)

Fig 1: Identifying Filler Bowl
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Release rubber collar (1) from cover bowl (2) by pressing inward.

NOTE: Rubber collar (1) remains attached to vehicle.

Fig 2: Identifying Rubber Collar From Cover Bowl

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Press retaining strap (1) inwards and remove.

Pierce cover bowl at markings (2) with a small screwdriver.

Fig 3: Identifying Retaining Strap And Cover Bowl Mark

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NOTE: For purposes of clarity, picture shows cover bowl removed.

Insert screwdriver to a depth of max. 5 mm and unlock cover bowl latch mechanism.

Fig 4: Identifying Cover Bowl Distance

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Keep cover bowl tensioned with pliers (2).

Unlock catches individually with screwdriver (1).

IMPORTANT: Cover bowl can be bonded with butyl tape. If necessary, heat side wall with hot air blower to max. 80 °C.

Unlock catches in following order:

Top left
Bottom left
Top right
Bottom right

Fig 5: Removing Catches
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Move screwdriver in opposite direction at both lower catches.

Close hinge arm (1).

IMPORTANT: Do not damage sheet metal flange of side wall.

Carefully twist out cover bowl (2) at first at rear in direction of arrow from side panel and remove.

Fig 6: Twisting Out Cover Bowl

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Preparation of new part:

Remove rubber collar (1) from new part.

Fig 7: Identifying Rubber Collar

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Apply butyl tape in area (1) along edge. Butyl tape must not project over the sheet metal edge.

Fig 8: Identifying Butyl Tape Area

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Installation note:

Fit approx. 0.5 m long cable (1) in groove on rubber collar (2).

Fig 9: Identifying Cable In Groove On Rubber Collar

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Installation note:

Install cover bowl (1).

Thread ends of cable (2) outwards.

Align bottom rubber cup (3) with recess (see arrow).

Pull rubber collar (3) over the cover bowl by pulling the ends of cables (2).

Fig 10: Pulling Rubber Collar Over Cover Bowl

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Installation note:

Slowly pull out cable ends (2).

Press rubber cup (1) into groove with special tool 00 9 321 .

Fig 11: Pressing Rubber Cup

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Installation note:

Cover bowl (2) must snap into place 4 times.

After installing, carefully check cover bowl at clips for secure seating.

There must be no discernible gap between the sealing lip of the cover bowl and the side wall in the area.

Make sure rubber collar (1) is correctly seated (watertightness).

Fig 12: Identifying Rubber Collar From Cover Bowl

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Installation note:

Catches (1) on ejector (2) must not be damaged.

Check protective cap (3) for correct seating.

(Watertightness!)

Fig 13: Identifying Catches On Ejector

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