Idiots' guide to replacing the fuel flap hinge

[S60-D]

many thanks for this topic, my s60 d5 2002 does not lock the fuel flap, what could be wrong?

[DTaylor]

There is a delay to allow you to lock the car at a garage forecourt and buy fuel. The delay is around 10 to 15 minutes I believe.

[mattyfezf]

5 Star post, thank you very much

My flap dropped off due to a broken bracket, so I had it replaced at my local indie volvo garage for not that much... however, the lock mechanism would not enagage afterward.

I thought the solenoid/lock motor may have broken, ( as I stupidly secured the flap with blu-tac in the interim so that any passers buy would not see a big hole in the side of my car, and assumed it may have burned out due to this. )

But after testing that the lock was indeed engaging, after testing it with the flap fully open, it seemed to be working fine.

So I actually skimmed passed this post, until today.
In retrospect, I realised that when I closed the flap, it wasnt returning to its fully closed (home) position. Why? because the so called 'mechanic' had neglected to perform the final step if your guide, ie: the final photo where you gently push the metal bar into the hooks on the body side of the hinge.

Thanks to you I now have a fully functional petrol flap.

[BlackS60Stoke]

Good instruction and dealt with quickly. Had a bit of trouble getting the two pins nearest the spring, so just used some self tapper screws as suggested.

Good photos, as would not have realised how simple it was without them.

Thanks

[CW Lincs]

Brilliant, so gla dmy bro pointed me at thsi thread. I was in Yorkshire last week when I heard funny noises coming from the back of the car. Turned out the gales had blown my filler flap off and broken the hinges as I was driving along. The noice was the filler flap hanging from the filler cap tether. So, word of warning save a lot of money and make sure your tether is attached to teh flap not the car body!!

I'm going to tackle this job once I have the part. Nightmare thoughts of removing interior trim to get access fading thanks to this great thread.

[AUS T5]

Originally Posted by toolbah

Happy to help, I love a good cheap fix and beer aint cheep these days, gotta get priority's right LOL

Thanks Tollbah, I did the cheap option and stuck in a couple of self tapers, a bit big but the heads need to be wide enough to nip the spring behind them so it didn't jump out. I did initially try one in the centre but that didnt work. Also, by drilling back into the plastic hinge rather than down I avoided drilling into the metal shell, something I didn't want to do. If it breaks after a while, I can still get a new hinge. Works a treat (so far)

[chiptivo]

That is what I did, using a fine dremel drill, I made a hole in the old damaged plastic, and use a simple cable tie.

Works fine after many months.

[camster]

Thanks for this advice & images here http://www.volvoforums.org.uk/showth...t=34677&page=3

It made an apparently impossible job very straight-forward

[radgethedog]

with respect, why has this had over 15,000 views???? fuxache. fuel flap hinge - akin to lego. c'mon people

[Jim314]

It's a commonly needed repair within the capabilities of almost anyone, but most people would need some guidance. And just about anyone who has done it has his own variation. This explains the number of news.