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 
• Close the central locking system with open cap

The following new body parts are required:

• (1) Cover bowl
  Fig 1: Identifying Cover Bowl

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Press sealing cup (1) through to the outside.

Fig 2: Pressing Sealing Cup

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Release nuts (1) and (2).

Installation note: 

Replace plastic nut.

Tightening torque 16 12 2AZ .

Slacken the fuel filler pipe (3).

Fig 3: Identifying Fuel Filler Pipe And Nuts

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Installation note: 

Clean contact surface  on body and ground connection (top of holder) on fuel filler pipe.

Ground connection must be guaranteed.

Remove ejector (1) in direction of arrow.

Fig 4: Removing Ejector

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Lift out the retaining strap (1) and remove the lid.

Pierce markings (2) with a small screwdriver.

Fig 5: Identifying Retaining Strap And Markings

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

Fig 6: Unlocking 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:

1. Top left
2. Bottom left
3. Top right
4. Bottom right

Move screwdriver in opposite direction at both lower catches.

Fig 7: Releasing Catches With Screwdriver

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Slightly pull the locking pin (1) forward in the direction of the arrow, if applicable.

Fig 8: Pulling Locking Pin Forward Slightly

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Close hinge arm (1).

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

Fig 9: Removing Cover Bowl

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Release wiring harness (1) at attachment points.

Release cable (2) for emergency operation of fuel filler cap.

Installation note: 

Make sure the cable for emergency operation is correctly installed.

Fig 10: Identifying Wiring Harness Attachment Points And Cable For Fuel Filler Cap Emergency Operation

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Unlock and disconnect plug connection (1) for actuator drive.

Detach release clip (2) in direction of arrow.

Press latch mechanism (3) in direction of arrow and pull off actuator drive (4) from cover bowl.

Installation note: 

Make sure the servo drive for fuel filler flap is correctly installed.

Fig 11: Pulling Off Actuator Drive From Cover Bowl

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Check function of controller drive before installation of cover bowl.

Systematic representation.

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 12: Turning Sealing Sleeve Inwards

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Installation note: 

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

Fig 13: Pulling Sealing Lip Over Sheet Metal Flange Of Wheel Arch

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Systematic representation.

Installation note: 

Illustrations shows fuel filler pipe removed.

Check that sealing lip is correctly seated.

Fig 14: Checking Sealing Lip

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Installation note: 

The following parts on cover bowl (6) must not be damaged or missing:

1. Bump stop
2. Latch mechanisms, top/bottom
3. Spring
4. Catch
5. Guide
   Fig 15: Identifying Cover Bowl With Related Parts

   Courtesy of BMW OF NORTH AMERICA, INC.

Cover bowl must audibly snap into place 4 times.

There must be no discernible gap between sealing lip and side wall in area.