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S80 '98-'06 / S60 '00-'09 / V70 & XC70 '00-'07 General Forum for the P2-platform S60 / V70 / XC70 / S80 models |
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Idiots' guide to replacing the fuel flap hingeViews : 64534 Replies : 128Users Viewing This Thread : |
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Mar 27th, 2007, 02:09 | #1 |
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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. 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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Oliver Volvo S80 SE (2000) 2.4 petrol Self Mods: DVD (central flip-down screen), Parrot Bluetooth in-car kit (MK6100), Sony Xplod subwoofer, Snooper S1, LG Viewty cradle. |
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Mar 27th, 2007, 09:16 | #2 |
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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: |
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Mar 27th, 2007, 22:56 | #3 |
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Ha! I nearly did that too Fordy!
Forgot to say the hinge bracket part no is 30649879.
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Oliver Volvo S80 SE (2000) 2.4 petrol Self Mods: DVD (central flip-down screen), Parrot Bluetooth in-car kit (MK6100), Sony Xplod subwoofer, Snooper S1, LG Viewty cradle. |
Apr 5th, 2007, 13:38 | #4 |
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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 |
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Apr 24th, 2007, 22:35 | #5 |
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Hi Robin,
Glad you found it useful! 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! Is yours connected to top-centre lug? Cheers,
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Oliver Volvo S80 SE (2000) 2.4 petrol Self Mods: DVD (central flip-down screen), Parrot Bluetooth in-car kit (MK6100), Sony Xplod subwoofer, Snooper S1, LG Viewty cradle. |
Apr 28th, 2007, 05:43 | #6 |
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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 |
Apr 26th, 2010, 14:10 | #7 | |
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Quote:
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 |
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Apr 26th, 2010, 21:22 | #8 |
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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. Last edited by Jim314; Apr 26th, 2010 at 23:12. Reason: spelling correction |
Apr 27th, 2010, 08:45 | #9 |
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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?
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Apr 27th, 2010, 14:50 | #10 | |
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Quote:
If it is the hinge that is at fault, replacement is very easy. Is the spring in place? |
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