From the S80 forum - fuel flap replacement
 

This link was posted on the S80 forum but would apply equally well to the S60 & V70:

http://www.volvoforums.org.uk/showth...649#post271649

S60 fuel flap hinge
 

Dear Graham,
Just done mine on the 2001 model and it was basically the same but perhaps this thread was a bit complex. I did mine in the dealers car park using a swiss army knife.

The original hinge had 4 self tappers to remove and then pulled off. I kept the self tappers and re used them.

The new hinge had 4 x plasic plugs above the fitting holes. these just snap off.

The hinge can be clipped on with just finger pressure, but it is tight. I found it best to hold the hinge and flap against the car to start with to ensure they were al the right way round before attempting to click them in place.

One hinge and flap are united the hinge just presses into place and the self tappers screw in to hold it. Total time less than 5 minutes.

Interesting when I rang the dealer, expecting to have to buy a full hinge and flap assembly, they said it was a common problem and they kept the hinges in stock. They were surprised mine had lasted so long.

october37
 

Hi Binty,
As the deales said, its a common problem but I have never heard of one with self tapping screws before.
They usually have expansion plugs with push in centres (similar to the fixings in the door cards) and are very easy to replace useing a small thin screwdriver etc to push the center tapered pins through and release the plugs.
Holding the hinge firmly against the car body, a tap with a small hammer on the end of a short thin piece of wooden doweling held against each protruding pin in turn should fix the expansion plugs properly seated in their holes
Regards
Keith V70 2.4T

Mine came away (I walked into it whilst open!) at a garage near Bristol whilst on hols towing a caravan. Rang my local dealer (TMS Hinckley) and they said no probs, they're in stock and we'll fit it for free! 2 days later, they did!

Don't know if this is normally the case but it's excellent customer service seeing as I get my S80 serviced elsewhere.

Well done TMS!!

S80 fuel flap
 

Had to replace mine walked into it at filling station, just after I'd filled up.


John

Superb.
Just got my used Silver 04 S60 D5 Gtronic 50,000m fully loaded to start new career as self employed It Contractor after years of company cardom....
First fill up last night and the flap came off in my hand !

Googled it and came across your article. 5 minutes no hassle.
Brought the part from Volvo main dealer £6.56 and the friendly parts guy shared a laugh about the number of hinges they sell.....

Well done sir...

The screws (4x½" No.6 stainless steel self-tapper screws according to the link above) would be a lot easier for an unpracticed person than the plastic pins. (I wouldn't think self tapping screws would be required since the screw threads are just biting into plastic. Whatever screws one had on hand that were the right length and diameter would probably work.)

I had a little trouble punching the old pins through to release the old hinge because at first I was afraid to punch with sufficient force to eject them.

The Volvo parts guy told me that pressing on the outside without supporting the pin could cause the pin to fly and be lost. He said one way their techs get the new pins started was to break them off and pass them through the expansion fasteners from the inside out until most of the length was clear on the outside. I did this and it did work. Then I held the hinge in place and thrust the pins in flush with a plumber's faucet valve seat remover. I could use my abdomen to support my wrist to force the pins in and didn't need a hammer.

Alternative Fix
 

Quick tip, when my retaining spring broke I just placed a rare earth magnet on the flap. Holds it fine (2 years now). Have the replacement bits, but as the magnet works fine haven't bothered to fit it.

Joe

my flap on the V70 i just bought is barely staying shut, there is a wire spring thing at the hinge but its not attached , might be some broken plastic there, is it the same design as the S80? Anyone got a pic of how it should go together?

Yes its the same. Theres a tiny plastic lug, seen here between the fingertips

http://www.davesmind.net/gallery/alb...07_G.sized.jpg

There's another above it, you'll see the broken bits on your hinge. Just use a self taper screw, about 15/20mm long and leave the head proud to retain the spring.

fuel
 

Car been chucking while driving.want to know is this fuel filter or sensor?
Thank u very much for any help.

Perhaps you should install a new plastic hinge. I gather that the screw heads now secure the spring wire that was originally held by the plastic hooks. Over time the wire might wear through due to rubbing on the hard metal screws. Of course, this might take a long time and it might be cheaper and less trouble to replace the wire spring than the hinge.

Perhaps it might be best to use soft brass screws so the screws would wear in preference to the spring wire. Or perhaps a dab of silicone grease would reduce wear.

2001 V70 2.5D Fuel Flap etc
 

I replaced mine 2 years ago and now the plastic spring retainers are flying off again !!!!!

Too much plastic on cars these days, I have remounted my air filter box base with bolts, nuts and rubber washers so no more probs there !!

Bill

To be fair...they're less than £10. It's hardly a big deal for as long as they remain available. Just don't do what I did and throw the black plastic 'pins' on the floor (on gravel...) before you realise you need them...!

cheers

James

Thanks for this I would advise to get the genuine part i bought a cheap one of ebay and whilst trying to fit the flap to the hinge one side snapped and also the pins snapped whilst trying to knock them in so i ordered a genuine volvo replacement part (cost £2 more) and the flap clipped in without problem and the pins also knocked in easily and good job done in less than 10 mins

I got a genuine one from eBay for less than £10. It's cheap enough that a knock-off (didn't know they existed!) isn't worth the risk.

cheers

James

I've just bought 2 genuine ones off the bay of e (just In case I break it while fitting! If not I've got a spare) for £15.

Mine broke ages ago and I though it was about time I sorted it.

I've just replaced my fuel flap hinge. Very simple 5 minute job. The only squeaky bum bit was getting the old hinge off the flap itself without bending/snapping the spindle that it's fitted too. Then fitting it to the new hinge again trying not to snap/bend the spindle. It's quite robust though.

I can agree with that,i had a bottom twitching moment when i was trying to get the old hinge off the spindle.

Anyway,another job done:thumbs_up:

Jason

Just done mine - 54plate V70.

Existing pins pushed out ok with a small nail (end ground flat) whose diameter matched (or was slightly less than) the diameter of the pins on the new piece.

Removing the flap from the old hinge was more of a challenge. Eventually I cut away the plastic on the hinge that was preventing the bar from being released (the old hinge was sacrificial anyway) this released the bar and the flap was completely undamaged.

Holding the hinge plate tightly against the bodywork and ensuring all four clips have passed into their respective holes in the side of the vehicle, the two outer pins can carefully be tapped in flush using a small hammer.

The inner two pins were more difficult, sheltered by adjacent mouldings. So I got a 6" nail, ground the end perfectly flat. Have to hold it carefully and perpendicular to the hinge (axially in line with the pin you're going to hit) then gently tap it home. The 6" nail diameter (being larger) will automatically ensure the pin is not driven through the face of the hinge, so it can be tapped until the pin is flush with the surface.

Finally very gently depress the wire spring and let it into its two slot on the hinge plate. I advise caution here, for any sudden snap if you let go of the wire could well set you right back to square one!!! But then it will be even easier second time around - albeit another £10 out of pocket.

Hi can anyone help, i have a volvo s80 2000, drives great but engine cuts out at road junction's and traffic lights,any ideas, thanks.

I have an s60 but presume the fuel flap is the same or similar, I managed to to get the old plastic hinge bracket off and install the new one but what is the procedure/knack to getting the flap back on?