41 63 003 Replace cover bowl

Necessary preliminary tasks:

NOTE: Carry over schematic diagram 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:

(1) Cover bowl

Fig 1: Identifying Cover Bowl

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MINI COOPER S:

Unclip and remove fuel filler cap cover.

Fig 2: Identifying Fuel Filler Cap Cover

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MINI COOPER S:

Installation note:

Latch mechanisms (1) must not be damaged.

Fig 3: Identifying Fuel Filler Cap Cover Latch Mechanisms

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

Tightening torque 16 11 1AZ .

Installation note:

Make sure that grounding cable (3) is connected with the mounting.

Fig 4: Identifying Fuel Filler Pipe Nuts And Grounding Cable

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NOTE: Illustrations shows fuel filler pipe removed.

Remove rubber seal from sheet metal flange.

Fig 5: Locating Rubber Seal

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

Fig 6: Turning Sleeve By 45 Degrees

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Press retaining strap (1) inwards and remove (see arrow).

Remove cover (2).

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

Fig 7: Pressing Retaining Strap Inwards

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

Fig 8: Inserting Screwdriver In Cover Bowl Latch Mechanism

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Unlock latch mechanisms (1) and (2) in succession.

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

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

Fig 9: Unlocking Latch Mechanisms

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

Installation note:

Open hinge arm.

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

Fig 10: Turning Cover Bowl

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Installation note:

Sealing lip (2) has a shaped extension that serves as a fitting aid (1).

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

Fig 11: Pulling Sealing Lip Using Fitting Aid

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Installation note:

Illustrations shows fuel filler pipe removed.

Check that sealing lip is correctly seated.

Fig 12: Locating Sealing Lip

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Installation note:

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 wall in area (1).

Fig 13: Identifying Cover Bowl Side Wall Area

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