Idiots' guide to replacing the fuel flap hinge

[Jim314]

The Volvo parts guy told me at their dealership some of the mechanics use a pair of needlenose pliers (or other suitable tool) to break off each of the four pins. These pins are then inserted into the rivets from the inside. Use a suitable tool to push them most of the way through to the outside so that they don't interfere with the plastic locking rivet going into the holes in the sheet metal. This way when the pins are pushed in to expand the rivets against the sheet metal the pins don't fly. This worked for me.

When pressing in the pins use a flat end tool which is significantly larger than the pin so that when the pin suddenly gives way the tool will not insert the pin beyond flush.

I had to use pliers to force the plastic hinge onto the metal pivot rod on the flap. Of course I used a rag to protect the paint on the flap.

[Model flyer]

Thanks for the info I thought the hinge may come with a new flap !at a cost . I was about to make a small clip /bracket to hold the spring but your post has saved a lot of hassle have ordered a new hinge . Many thanks .

[Scotty]

Imagine my surprise when mine just 'popped' off upon open the flap...

Can anybody confirm if this is the same for a '05 XC90?

Scott

[october37]

Hi, Good post.
I Just recently replaced mine, but found I didnt have to remove the spring from the flap, and also found it easier to partly press the locking pins into their holes, (but not to far), before fitting the newly hinged flap onto the car and then finally driving them fully home.

Keith, V70 2.4T

[gmm]

anyone have any pics of toolbahs fix,where the self tappers and drill holes need to be? yep you guessed it mine went a few days ago 2002 s8o

[TURRET]

Originally Posted by Fordy

Good work

When I did mine, and despite 'measuring twice' I still put the bloody hinge on the flap the wrong way round 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:

Mine got blow off the hinge in the car wash at the weekend but I have ordered a new bracket etc on e bay. My concern is that on the actual flap there are 2 small plastic pieces which I assume are retaining holes for the end the spring?
When the guys at the car wash fiddled about with it they broke the plastic of one of these (which i have superglued back on) should this not hold once my new bracket arrives, can you buy what I can only describe as a new frame (which sits inside the the actual metal flap itself) retained by about 8 or so small plates which are bent over the frame to hold the flap on.
Apologies if I am not explaining this very well but hope someone understands

[Jim314]

I think the flap as a new part comes with the frame crimped on. And the new replacement is primed, but unpainted.

You are probably correct that once force is applied, then the glue joint would come apart. Since you have the part superglued together, you could try reinforcing the joint by gluing wire or small pieces of sheet metal to hold the part together. If you have epoxy glue that would probably hold better than super glue.

You could try a salvage yard.

[CLF]

My fuel cap isn't broken but loose, it will sometimes open up just under braking, is there any way to tighten it up so it stays closed?

[Jim314]

Originally Posted by CLF

My fuel cap isn't broken but loose, it will sometimes open up just under braking, is there any way to tighten it up so it stays closed?

If the hinge is OK, then the problem is probably with the locking mechanism. The loop on the flap is held by a solenoid operated bolt behind the sheet metal. Does the fuel door lock?

If it is the hinge that is at fault, replacement is very easy.

Is the spring in place?

[CLF]

It locks, but only a few minutes after locking the car. Should it lock when the car is moving?