Fuel Door: Service and Repair

41 63 003 Replace Cover Bowl







Necessary preliminary work:
- Remove flap for fuel filler neck
- Remove front wheel arch cover (rear section)







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 (refer to Electronic Parts Catalogue):
- (1) Filler bowl







Slacken nut (1).
Press out gasket (2).

Installation note:
Make sure gasket (2) is correctly seated..







Installation note:
Clean contact surface on body and earth cable on fuel filler pipe.

Ground connection must be guaranteed.







Unscrew nuts (1).







Release emergency release (1) from bracket.







Press retaining strap (1) inwards and remove.
Remove cover (2).
Remove rubber pad (3).







Release latch mechanisms (1) and remove ejector (2).

Installation note:
Catches (1) on ejector (2) must not be damaged.

Check protective cap (3) for correct seating.







NOTE: For purposes of clarity, picture shows cover bowl removed.

Insert screwdriver in bore hole to specified dimension a and unlock cover bowl latch mechanism.
Dimension a = 8 mm







Hold cover bowl under tension.
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.







Close hinge arm (1).

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

Carefully twist out cover bowl (2) at first at rear in direction of arrow from side panel and remove.
Remove sealing sleeve from fuel filler pipe.







Unlock connector (1) and remove.
Unclip cable (2).
Release screw (3).







Release screws (1) and remove actuator drive (2) for fuel filler cap.

Installation note:
Make sure actuator drive (2) for fuel filler flap is installed correctly.

Check central locking system before installation of cover bowl.







Installation note:
Following parts on cover bowl (6) must not be damaged or missing:
1. Rubber pad
2. Latch mechanisms, top/bottom
3. Spring
4. Catch
5. Guide







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







Installation note:
Illustrations shows fuel filler pipe removed.

Check that sealing lip is correctly seated. (watertightness).