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From the S80 forum - fuel flap replacement

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Old Feb 10th, 2013, 15:52   #21
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Originally Posted by mbren30 View Post
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

Volvo V60 D3 Business Edition
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Old Apr 11th, 2013, 19:07   #22
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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.
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Old Apr 4th, 2017, 20:06   #23
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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.
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Old Jun 9th, 2017, 17:22   #24
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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?
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