41 63 003 Replace Cover Bowl

Special tools required: 

• 00 9 321

Necessary preliminary tasks: 

• 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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Release rubber collar (1) from cover bowl (2) by pressing inward.

Fig 2: Identifying Rubber Collar And Cover Bowl

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Remove ejector (1) in direction of arrow.

Fig 3: Removing Ejector

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

Pierce markings (2) with a small screwdriver.

Fig 4: Identifying Retaining Strap And Areas For Markings

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

Dimension "a" = approx. 10 mm

Fig 5: Inserting Screwdriver To Unlock 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 6: Unlocking Catches With Screwdriver And Pliers

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

Fig 7: Pulling Locking Pin

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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 8: Removing Cover Bowl

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

Fig 9: Identifying Actuator Drive Plug Connection

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Use a suitable tool to unlock the tabs (1) on the front and back.

Remove actuator drive (3) from cover pot (2).

Fig 10: Identifying Actuator Drive, Cover Pot And Tabs

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Release the actuator drive (2) by simultaneously turning and pressing the locking pin (1).

Installation note: 

Make sure the setting for the actuator drive (2) for the fuel filler flap is correct. It must be possible to lock or unlock the fuel filler flap completely.

Fig 11: Identifying Actuator Drive And Locking Pin

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Installing the cover bowl: 

Remove rubber collar (1) from new part.

Install and check the function of the actuator drive at the new part.

Fig 12: Identifying Rubber Collar

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Graphic similar.

Check protective cap (3) for correct seating.

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

Fig 13: Identifying Catches, Ejector And Protective Cap

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

Fig 14: Identifying Long 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 15: Pulling Rubber Collar Over Cover Bowl

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Slowly pull out cable ends (2).

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

Fig 16: Pressing Rubber Collar Into Groove Using Special Tool (00 9 321)

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Carefully check cover bowl (2) in area of latch mechanisms for proper seating.

There must be no discernible gap between the sealing lip of the cover bowl and the side wall in the area. (watertightness).

Make sure rubber collar (1) is correctly seated (watertightness).

Perform function check of the lock/unlocking of the fuel filler cap.

Fig 17: Identifying Rubber Collar And Cover Bowl

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