41 63 003 Replace cover bowl

Necessary preliminary tasks:

Remove right REAR WHEEL .
Remove rear right WHEEL ARCH COVER .
Remove flap for fuel filler neck
Remove SERVODRIVE FOR TANK 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 ELECTRONIC PARTS CATALOGUE ):

(1) Filler bowl

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

Fig 2: Identifying Rubber Collar And Cover Bowl

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Turn cover (1) through approx. 90° and lever out in direction of arrow.

Fig 3: Removing Cover

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Press retaining strap (1) inwards and remove.

Pierce markings (2) with a small screwdriver.

Fig 4: Identifying Retaining Strap And Pierce Markings

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

Insert screwdriver to specified measurement a and unlock cover bowl catch.

Measurement a=5 mm

Fig 5: Inserting Screwdriver To Specified Measurement

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Keep cover bowl tensioned with pliers (2).

Unlock catches individually with screwdriver (1).

Unlock catches in following order:

Top left
Bottom left
Top right
Bottom right

Move screwdriver in opposite direction at both lower catches.

Fig 6: Unlocking Catches Using Screwdriver

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Close hinge arm (1).

IMPORTANT: Do not damage sheet metal flange of side panel.
Do not damage cable connector (next illustration).

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

Remove sealing sleeve from fuel filler pipe.

Fig 7: Removing Cover Bowl Hinge Arm

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Disconnect plug connection (1).

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

Fig 8: Identifying Plug Connection

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Installation note:

Open hinge arm.

Turn sealing sleeve in area of hinge inwards and hold.

Insert cover bowl and engage sealing sleeve over fuel filler pipe.

Fig 9: Opening Hinge Arm

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Installation note:

Using fitting aid (1), pull sealing lip (2) over sheet metal flange of wheel arch (3).

Fig 10: Pulling Sealing Lip Over Wheel Arch Sheet Metal Flange Using Fitting Aid

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Installation note:

Cover bowl 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 panel in the area.

Make sure rubber sleeve (1) is correctly seated in areas (2) and (3).

Fig 11: Identifying Rubber Sleeve Seated Areas

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Installation note:

Illustrations shows fuel filler pipe removed.

Check that sealing lip is correctly seated.

Fig 12: Locating Sealing Lip

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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 Ejector, Catches And Protective Cap

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Installation note:

Locks (1) on left/right of cover (2) must not be damaged.

Fig 14: Identifying Cover And Locks

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