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41 63 003 Replace cover bowl

Necessary preliminary tasks: 

IMPORTANT: Deformation of the sheet metal flanges in the side wall and the wheel arch results in permanent vehicle leakage. Carry out removal/installation with great care.

The following new parts are required:

Fig 1: Identifying Cover Bowl
G10142144Courtesy of BMW OF NORTH AMERICA, INC.

Removal: 

Press sealing cup (1) through to the outside.

Fig 2: Pressing Sealing Cup
G11172497Courtesy of BMW OF NORTH AMERICA, INC.

Release screws (1) and (2) and slacken fuel filler pipe (3).

Installation note: 

Replace plastic nut.

Fig 3: Identifying Fuel Filler Pipe And Screws
G11172498Courtesy of BMW OF NORTH AMERICA, INC.

Attach plastic adhesive tape (1) to side panel.

At the position shown, drill a Ø 10 mm hole in the cover bowl.

Fig 4: Attaching Plastic Adhesive Tape To Side Panel
G11172499Courtesy of BMW OF NORTH AMERICA, INC.

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

Pierce markings (2) with a small screwdriver.

Fig 5: Identifying Retaining Strap
G11172500Courtesy of BMW OF NORTH AMERICA, INC.

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

Fig 6: Checking Cover Bowl Latch Mechanism Depth
G04752418Courtesy of BMW OF NORTH AMERICA, INC.

Insert a hook (1) into the drilled hole and hold the covert bowl slightly drawn.

Unlock latch mechanisms individually with screwdriver (1) in direction of arrow.

Unlock catches in following order:

  1. Top left
  2. Bottom left
  3. Top right
  4. Bottom right
Fig 7: Inserting Hook Into Drilled Hole
G11172502Courtesy of BMW OF NORTH AMERICA, INC.

Move screwdriver in opposite direction at both lower catches.

Press fuel filler pipe to rear.

Carefully twist out the cover bowl in direction of arrow.

IMPORTANT: Do not damage sheet metal flange of side wall.
Watch the cables for the actuator drive.
Fig 8: Twisting Out Cover Bowl
G11172503Courtesy of BMW OF NORTH AMERICA, INC.

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

Release cowl pull for emergency release at separation point (2).

Fig 9: Identifying Actuator Drive Plug Connection
G11172504Courtesy of BMW OF NORTH AMERICA, INC.

Loosen controller drive (1) in the direction of the arrow to remove it.

Fig 10: Loosening Controller Drive
G11172505Courtesy of BMW OF NORTH AMERICA, INC.

Installation: 

Following parts of cover housing not be damaged or missing:

  1. Marks
  2. Latch mechanisms, top/bottom
  3. Spring
  4. Catch
  5. Lock
Fig 11: Identifying Cover Housing Related Parts
G11172506Courtesy of BMW OF NORTH AMERICA, INC.

Insert controller drive (1) in the direction of the arrow and lock in place.

NOTE: Make sure the servo drive for fuel filler flap is correctly installed!
Fig 12: Inserting Controller Drive
G11172507Courtesy of BMW OF NORTH AMERICA, INC.

Clean contact surface  (1) on body and ground connection at fuel filler pipe.

The ground connection must be guaranteed.

Fig 13: Identifying Body Contact Surface
G11172508Courtesy of BMW OF NORTH AMERICA, INC.

Connect plug connection (1) for the controller drive.

Connect cowl pull for emergency release at separation point (2).

NOTE: Check function of controller drive before installation of cover bowl!
Fig 14: Identifying Actuator Drive Plug Connection
G11172504Courtesy of BMW OF NORTH AMERICA, INC.

Systematic view.

Turn sealing sleeve in area of hinge inwards and hold.

Fig 15: Locating Hinge Sealing Sleeve In Area
G04752421Courtesy of BMW OF NORTH AMERICA, INC.

Carefully insert cover bowl up to the position shown and place sealing cup over fuel filler pipe.

Press fuel filler pipe to rear when doing this.

Fig 16: Identifying Cover Bowl
G11172511Courtesy of BMW OF NORTH AMERICA, INC.

Install cover bowl and lid.

IMPORTANT: Do not damage sheet metal flange of side wall.
Cover bowl must audibly snap into place 4 times.
There must be no visible gap between sealing lip and side panel in area (1).
Fig 17: Identifying Sealing Lip And Side Panel In Area
G11172512Courtesy of BMW OF NORTH AMERICA, INC.

Check seat of fuel filler pipe (3) for correct installation position and correct if necessary.

Tighten nuts (1) and (2).

Installation note: 

Replace plastic nut.

Tightening torque 16 11 2AZ .

Fig 18: Identifying Fuel Filler Pipe And Screws
G11172498Courtesy of BMW OF NORTH AMERICA, INC.

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

Fig 19: Pulling Sealing Lip Over Sheet Metal Flange Of Wheel Arch
G04752422Courtesy of BMW OF NORTH AMERICA, INC.

Check that sealing lip is correctly seated.

NOTE: Shown without fuel filler pipe for clarity.

Systematic diagram.

Fig 20: Locating Fuel Filler Pipe Sealing Lip
G04752417Courtesy of BMW OF NORTH AMERICA, INC.
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