Idiots' guide to replacing the fuel flap hinge

[chiptivo]

Originally Posted by Mamouth

The flap fell off my V70 today. There it was on the drive with the flap hanging on the cap retainer, haven't filled up for a week. Thank you for all the information. What I would like to know is - if you replace the pins with stainless screws is there room for pan head screws? I have had problems previously with countersunk screws splitting the plastic that they're holding. I can't quiet work out if there will be enough clearance for pan heads as the broken parts from the hinge where lost along the road somewhere.

Very odd to have this just happen on the drive..

Are you sure someone did not try and pinch your diesel / petrol??

[Mamouth]

No it's unlikely, the car's normally garaged and it happened around lunchtime. I probably didn't notice when I got out of the car an hour earlier. If it had happened on the drive I would have found the broken bits of plastic.

[Mamouth]

I replaced the hinge today. It only took about 20 minutes using OllieG's instructions, it went quiet easily. The only thing I will say is that it is surprising how much force you have to use to both remove the old pins and replace the new ones, I ended up using a 12oz hammer. I got the new pins started using PeeDeeTee's method of pushing them in with a security torx driver and then hammered the last bit in using a drift. I had considered using stainless screws and answering my own question, yes I think there is enough room for pan head screws, but the plastic pins worked fine and I think they are probably a better job. The genuine Volvo hinge cost me £8.39 online including postage.

[Zosherooney]

Our new (2nd hand) metal flap arrived today and we spent 20 mins taking out the old plakky bit and fitting the new plakky with 4 pins. Furtherest 2 apart went in fine but the two middle ones broke off (one by hand!) Ended up finding two very small screws that just fitted tight. Many thanks for the help found here (would have struggled without it). Must have been designed by a man, if I had designed it, it would not have broken in the first place !!!!!!

[ted striker]

Thanks very much for instuctions, like the chap above, the two outers went on fine, the middle two snapped thus requiring the small srcrew fix.

[ASt85]

There are several posts in this string about using small self tappers instead of the thin plastic rods - I assume plastic rods are cheaper than threaded steel............if you are a manufacturer and need to use a machine jig to put in 4 locking tabs!!!

HOWEVER as you comment "it makes you wonder" who did actually design a fool flap (spelling mistake intentional) with the ability to break easily and require replacing with an only OEM available part every couple of years.....

[newby]

I am now on my 3rd hinge in 12 months and the last one broke this morning. This hinge is very badly designed. The hinge always fails at the same place. The two small plastic clips that retain the spring snap off. Does anyone know of a more robust replacement?

[ASt85]

I'm sure that I've seen a posting about using a pair of small self tappers to hold the spring in the same place that the plastic lugs would normally secure the spring. I can't see why this wouldn't work, and, as a repair would probably last a lot longer than these joke hinges!

[A lex]

Ive just done mine this morning - I tried the self-tapper fix 1st, but it wasnt working (the spring just jumped out of the mounting points).

So, €9 later and a new hinge is on.

Very easy to do - as mentioned the only really fiddly/annoying bit is getting the two centre pins in when replacing the new hinge - crappy design and prone to going wrong!

I've no idea if its already been mentioned, but there is also an updated part number for the hinge:

31265160.

[Wayne W]

Originally Posted by OllieG

The photos got lost on a server that's died, here's the original post again with the photos re-linked.

Thanks, OllieG. When the plastic bits that hold the flap to the hinge bracket broke off today, I expected to need to get at things from inside my V70, under the liner, in order to replace the bracket. Then I found that I couldn't figure out how to get the liner apart without damage. I was preparing myself for an expensive trip to the dealer when I found your very helpful posting. Buying the part and doing the job myself is much more appealing. Thanks for the pictures! And thanks to rigormo2 for your insights.