41 63 003 Replacing cover bowl

Special tools required:

00 9 321

Necessary preliminary tasks:

Remove FLAP FOR FUEL FILLER NECK .
Remove SERVODRIVE FOR TANK FILLER FLAP .

NOTE: Carry over schematic representation 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 ETK) :

(1) Filler bowl

Fig 1: Identifying Filler Bowl

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Press retaining strap (1) inwards and lift out (see arrow).

Pierce cover bowl at markings (3) with a small screwdriver.

Remove cover (2).

Fig 2: Pressing Retaining Strap

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Lift rubber collar (1) over plastic tabs in areas (2).

Release rubber collar (1) from cover bowl (3) by pressing inward.

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

Fig 3: Identifying Rubber Collar And Cover Bowl

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

Fig 4: Checking Cover Bowl Catch Depth

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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 5: Removing Catches 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 6: Twisting Cover Bowl

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Installation:

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

Fig 7: Identifying Rubber Collar And Cable

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Installation:

Install cover bowl (1).

Thread ends of cable (2) outwards.

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

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

Fig 8: Locating Cover Bowl Rubber Collar

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Installation:

Slowly pull out cable ends (2).

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

Fig 9: Pressing Rubber Collar

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Installation:

Cover bowl must snap into place 4 times.

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

There must be no discernible gap between sealing lip and side panel in area (4).

Check secure fit of rubber collar (1) in areas (2).

Fig 10: Identifying Cover Bowl Rubber Collar Area

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