41 63 003 Replace cover bowl

Special tools required:

00 9 321

Necessary preliminary tasks

Remove FLAP FOR FUEL FILLER NECK .

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.

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

Fig 2: Identifying Rubber Collar And Cover Bowl

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Lift out retaining strap (1).

Pierce markings (2) with a small screwdriver.

Fig 3: Identifying Rubber Collar, Pierce Markings And Cover Bowl

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

Fig 4: Turning Cover Approx. 90°

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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 = approx. 10 mm

Fig 5: Releasing Cover Bowl Catch

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Keep cover bowl tensioned with pliers (1).

Unlock catches individually with screwdriver (2).

Unlock catches in following order:

Top left
Bottom left
Top right
Bottom right

Move screwdriver in opposite direction at both lower catches.

Fig 6: Releasing Cover Bowl Catch Individually Using Screwdriver

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Close hinge arm (1).

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

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

Fig 7: Twisting Out Cover Bowl

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Installing cover bowl

Remove rubber collar (1) from new part.

NOTE: When replacing rubber collar: Remove wheel arch cover .

Fig 8: Identifying Cover Bowl Rubber Collar

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

Fig 9: Identifying Left/Right Of Cover And Locks

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Check protective cap (3) for correct seating.

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

Fig 10: Identifying Protective Cap, Catches And Ejector

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

Fig 11: Fitting Cable In Rubber Collar Groove

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Install cover bowl (1).

Thread ends of cable (2) outwards.

Cover bowl must snap into place 4 times.

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

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

Fig 12: Pulling Ends Of Cable

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Slowly pull out cable ends (2).

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

Fig 13: Pressing Rubber Cup Into Groove Using Special Tool (00 9 321)

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Carefully check cover bowl (2) in area of latches for proper 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 collar (1) is correctly seated (watertightness).

Fig 14: Identifying Rubber Collar And Cover Bowl

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4163003 Replace cover bowl