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 CONSUMABLES ):

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

Fig 1: Fuel Door Filler Bowl Component Location
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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: Cover Bowl Rubber Collar Component Location

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Press retaining strap (1) inwards and remove.

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

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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.

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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

Move screwdriver in opposite direction at both lower catches.

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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.

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Preparation of new part:

Remove rubber collar (1) from new part.

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

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Installation note:

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

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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).

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Installation note:

Slowly pull out cable ends (2).

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

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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).

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Installation note:

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

Check protective cap (3) for correct seating.

(Watertightness!)

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