41 63 003 Replacing cover bowl

WARNING: This page is about a different variant/trim than selected.

Necessary preliminary tasks:

Remove servodrive for tank filler flap . See 67 11 555 REMOVING AND INSTALLING/REPLACING SERVODRIVE FOR TANK FILLER FLAP .
Remove rear left wheel arch trim .
Remove flap for fuel filler neck. On MINI ONE and MINI COOPER models: Open flap for fuel filler neck. Insert suitable screwdriver in recess and pull off flap for fuel filler neck. On MINI COOPER S: Open flap for fuel filler neck. Lever out lock and turn flap for fuel filler neck in direction of arrow and remove.

Fig 1: Pulling Flap For Fuel Filler Neck (MINI One And MINI Cooper)

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Fig 2: Turning Flap For Fuel Filler Neck (MINI Cooper S)

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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:

Cover bowl

Fig 3: Identifying Cover Bowl

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MINI COOPER S:

Unclip tank cap and remove.

Fig 4: Identifying Tank Cap

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MINI COOPER S:

Installation:

Catches (1) must not be damaged

Fig 5: Identifying Catches

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Release nuts (1) and (2) on fuel filler pipe.

Tightening torque, 16 11 1AZ.

Installation:

Make sure ground cable (3) to connected to mounting.

Fig 6: Identifying Ground Cable, Nuts And Fuel Filler Pipe

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NOTE: Illustrations shows fuel filler pipe removed.

Release rubber seal from sheet metal flange.

Fig 7: Identifying Rubber Seal

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Turn sleeve (1) through approx. 45° and pull out in direction of arrow.

Fig 8: Identifying Sleeve Angle

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

Fig 9: Pressing Retaining Strap Inwards

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Remove cover (2).

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

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

Fig 10: Identifying Cover Bowl Catch Dimension

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Unlock catches (1) and (2) in succession.

Lever out cover bowl in area (3) with plastic wedge.

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

Fig 11: Unlocking Catches

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Carefully turn cover bowl (1) in direction of arrow and remove.

Installation:

Open hinge arm.

Insert cover bowl and engage sealing sleeve over fuel filler pipe.

Fig 12: Identifying Cover Bowl Angle

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Installation:

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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Installation:

Illustrations shows fuel filler pipe removed.

Check that sealing lip is correctly seated.

Fig 14: Locating Fuel Filler Pipe

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Installation:

Cover bowl must snap into place 3 times.

After installing, carefully check that cover bowl is securely seated.

There must be no discernible gap between sealing lip and side panel in area (1).

Fig 15: Checking For Gap Between Sealing Lip And Side Panel

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