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Idiots' guide to replacing the fuel flap hinge

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Old Sep 23rd, 2008, 14:56   #21
Rufe
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the fuel flap hinges on these p2 models are every common parts, we generally keep about 10 of them on the shelf at any one time, and supply them in 10's to local independents. very easy to fit though, and pretty cheap which is something, but they are a very weak (and bad) design.

Personally for around a fiver for a new one i wouldnt bother with a second hand one. Biggest bit of advice we tell our customers is to fit the hinge to the flap first, then attach the flap to the car.

I supply them at £5.49 plus postage which is £1.14 Royal Mail 2nd Class recorded delivery (part number 31265160, which was 30649879)
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Old Jan 13th, 2009, 13:47   #22
rigormo2
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Default V70 fuel filler flap hinge

Thanks to OllieG I have just replaced broken hinge on my 2001 V70. Worked in slightly modified way to Ollie.

1. Punched out pins and removed hinge and flap to kitchen table.
2. Pressed the spring out of the hinge but left attached to the flap.
3. Removed hinge from flap (breaking the remaining bit of hinge plastic.
4. Now the hard part. Pressed the new hinge onto the flap spindle. Found this difficult on a cold day and feared breaking the new part. Warmed the plastic hinge, added a bit of vaselene to the spingle and tried again - successfully.
5. Pressed the spring into place on the new hinge.
6. Replaced the new unit into the car tapping the pins home.
WARNING: tapping the first pin (top) popped the pin straight through and was lost into bodywork. Rplaced this with a suitable bit of old broken knitting pin (never throw anything away). Pressed and/or tapped the remaining pins in - some go easier than others for some reason.

Price from Volvo dealer in Jan 2008 was £6.56 incl VAT.
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Old Jan 18th, 2009, 18:43   #23
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Thanks for the photo sequence. Removing the flap was a doddle, cutting the old one off was a bit more tricky. Followed the self tapper screw advice.

Thanks again.

Merckenzie
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Old Feb 3rd, 2009, 00:11   #24
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The photos got lost on a server that's died, here's the original post again with the photos re-linked.

Quote:
Originally Posted by OllieG View Post
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.

Punch out the 4 pins on the existing hinge (look at the new hinge to confirm locations).

Remove the flap & old hinge bracket and clean up the bodywork.

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.

Take new hinge bracket out of packaging.

Carefully press hinge bracket onto flap (again taking care not to bend the metal hinge on the flap) and (inset) replace spring, bottom first.

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.

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!

I imagine it will be similar for other models.
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Old Feb 3rd, 2009, 01:07   #25
Barnsley-Bill
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My T5 hinge is ok its the lug that locks to the car body thats broke can these be fixed or do I need a new flap ?.
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Old Mar 7th, 2009, 12:44   #26
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Thanks for a great post (I used self tappers after I broke two pins trying to pop them in - makes it much easier).

Cheers.

Col

Last edited by TheJoyOfSix; Mar 7th, 2009 at 15:16. Reason: to get smilie working
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Old Mar 29th, 2009, 12:00   #27
V70xc_Sydney
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Default Fuel Flap hinge replacement

Thanks mate for the excellent instructions as I'd just replaced my yesterday and a friend pointed me to your detailed instructions AFTER I'd done it myself. But glad I did it the same way you did and therefore not broken anything! Although I now have to replace the white "hook" that the plunger holds the flap when it is closed as that white bit is broken!
Cheers
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Old Apr 27th, 2009, 20:22   #28
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Mine broke today just as i was about to fill up ........ opened the flap and it went. Was not too sure what had happened but after a quick search on google came across this site.

Due to some excellent posts & instructions i will give it a go once i have managed to get the parts.
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Old Apr 28th, 2009, 21:29   #29
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Picked up hinge from my local Volvo dealer earlier on in the day and fitted tonight, took about 15 minutes in total.

Total cost £6.56

Found it easier to use a panel pin punch to knock the inner pins in on the replacement rather than hold with pliers.


Many thanks to those that take the time to give detailed instructions on how to carry out effective repairs and help keep costs down........... i need to with a S60 T5 that averages 19 mpg (most probably broke due to all those refuelling stops).
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Old Jul 31st, 2009, 21:11   #30
Buzz123
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Default Fuel flap hinge replacement

Thanks for the great instructions. I replaced mine today for a 2001 S60. I broke two pins and was able to get one back in. The other was impossible to get in so I used a self tapping screw. I can't believe that Volvo has this flimsy part. Thanks again.
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