41 63 003 Replacing Cover Bowl

Necessary preliminary tasks:

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.

The following new body parts are required:

(1) Cover bowl

Fig 1: Identifying Cover Bowl
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MINI COOPER S:

Unclip tank cap and remove.

Fig 2: Identifying Unclip Tank Cap

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MINI COOPER S:

Installation:

Catches (1) must not be damaged.

Fig 3: Identifying Catches

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

Tightening torque, see 16 11 1AZ

Installation:

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

Fig 4: Identifying Nuts On Fuel Filler Pipe With Ground Cable

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NOTE: Illustrations shows fuel filler pipe removed.

Release rubber seal from sheet metal flange.

Fig 5: Locating Rubber Seal

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

Fig 6: Identifying Sleeve Turn Positions Approx. 45°

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

Remove cover (2).

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

Fig 7: Pressing Retaining Strap

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

Fig 8: Inserting Screwdriver To Depth

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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 9: Identifying Lever Out Cover Bowl In Area

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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 10: Turning Cover Bowl

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Installation:

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

Fig 11: Pulling Sealing Lip

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Installation:

Illustrations shows fuel filler pipe removed.

Check that sealing lip is correctly seated.

Fig 12: Locating Rubber Seal

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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 13: Identifying Sealing Lip & Side Panel

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