Idiots' guide to replacing the fuel flap hinge
 

I did mine at the weekend. As it's not even mentioned in the Haynes manual, but is very easy, I took some pictures. Here's how to do it (takes 5-10 mins).

You will need:
1) Awl/small punch
2) Small Hammer
3) Crocodile nosed pliers
4) New hinge bracket (£6.11 inc VAT)

Step-by-step guide
Click on the thumbnails to see larger versions.

http://www.davesmind.net/gallery/alb...01_G.thumb.jpg Punch out the 4 pins on the existing hinge (look at the new hinge to confirm locations).

http://www.davesmind.net/gallery/alb...02_G.thumb.jpg Remove the flap & old hinge bracket and clean up the bodywork.

http://www.davesmind.net/gallery/alb...03_G.thumb.jpg Remove the spring from the flap (top first) and unclip the old hinge (doesn't matter if you break this, but take care not to bend the metal hinge spindle on the flap.

http://www.davesmind.net/gallery/alb...04_G.thumb.jpg Take new hinge bracket out of packaging. :)

http://www.davesmind.net/gallery/alb...05_G.thumb.jpg Carefully press hinge bracket onto flap (again taking care not to bend the metal hinge on the flap) and (inset) replace spring, bottom first.

http://www.davesmind.net/gallery/alb...06_G.thumb.jpg Position the bracket on the vehicle and carefully tap the top and bottom pins into position. This will hold the flap in place whilst you perform the next (and trickiest) step. Use pliers to hold the last two pins steady while you hammer them in. Once started, it can be easier to use the awl and hammer to tap them fully home.

In place of the last step, you could do as v70_cymru has and use 4x½" No.6 stainless steel self-tapper screws to secure the bracket to the car.

http://www.davesmind.net/gallery/alb...07_G.thumb.jpg Carefully (this is the bit that broke before, don't want to break the new bracket just yet!) press the spring into the clips on the bracket.


Job done! :D

I imagine it will be similar for other models.

Good work :)

When I did mine, and despite 'measuring twice' I still put the bloody hinge on the flap the wrong way round :hissyfit: And it was a real pain to unclip it again. It seems obvious in hindsight but wasn't at the time.

So here's a close up of how it should be fitted:
http://img522.imageshack.us/img522/8881/dscn0075hp6.jpg

Ha! I nearly did that too Fordy! :D

Forgot to say the hinge bracket part no is 30649879.

Cap retainer
 

Hi Ollie

I've just replaced the fuel flap hinge on my V70 using your invaluable post as a guide... it saved me a lot of time and mistakes and all went smoothly. I didn't swear once! I notice from the photos that you have the fuel cap retainer strap held under one of the lock screws instead of looped to the hook on the fuel flap where it usually is. This looks like a good idea to reduce the strain on the fuel flap... was it like that when you got it or was it an idea of yours?

Robin

Hi Robin,

Glad you found it useful! :D

I've done photos, but yet to add - "changing the dash bulbs" (although I think there's quite a bit of that on here already), and "changing the top engine mount".

My filler retainer cord was already like that, never ocurred to me that it might have been different! :omg_smile: Is yours connected to top-centre lug?

Cheers,

Cap retainer
 

Hi Oliver,

Yes, on mine the cap retainer is hooked in to the flap top centre. I assumed this is where it was meant to be. Pehaps others can comment.

I look forward to seeing your other photo essays!

Regards,
Robin

Mine was hooked on the flap....till it broke and I replaced it with a locking one :cyclops:

thank for the tips mate looks so easy to tackle now

[QUOTE=ocala;232246]Hi Oliver,

my petrol cap is hooked on the flap as well for all concerned

Had to do this job on my S60. Your posting was a great help.
Thanks