The other day our S80's fuel door broke. On P2 Volvos there is an electric solenoid that locks the fuel door closed. If the door doesn't shut properly, the solenoid will still 'lock', but the door will be free to flap around in the wind like a Maple Leafs flag on your window.
To fix a fuel door on a P2 Volvo, you'll need the following part: Volvo 31265160.
I believe that the fuel door on a Volvo 740/940/S90, and S70/V70/C70 will install in a very similar fashion.
Fuel door hinge, original Volvo.
I highly recommend an original Volvo part for durability. I previously installed a lesser brand, and it did not hold up beyond a few months of use. So here's what you need to do:
1. Punch out the plastic rivets
1. Punch out plastic rivets
Use a punch, or a small screwdriver and punch out the old plastic rivets. Make sure you push them in far enough. You'll know when you've done it properly when the fuel door hinge comes off with little effort. You should not need to pry it off. If you do, you just need to punch the rivets in more.
2. Remove the hinge from the door
2. Remove the hinge from the door
Removing the hinge from the door can be difficult, I used a flathead screwdriver and placed it between the metal rod and the hinge connection, prying away at the plastic. As a testament to the strength of OEM plastic, it took me a while to free the hinge from the door. With the lesser quality brand, the hinge simply snapped off. Don't be afraid of mutilating the old hinge. Afterall, you are throwing it out. Most importantly, don't damage your fuel door!
3. Install the hinge on the door
3. Install door hinge on door
This step is surprisingly difficult. You have to snap the plastic hinge onto the metal rod by pushing it in. It sounds simple, but requires quite a bit of finger strength to do so. Video gamers may do well with this step. It is almost impossible to install it backwards, but make sure the plastic rivets are sticking out towards the fuel door and the metal spring is between the hinge and the door on the inside. Then, snap the spring into the hinge, being careful not to put too much pressure on one spring mount so as not to break it.
4. Install the hinge onto the car
4. Press in rivets.
Take your hinge and place it into the holes. It should slide right in with little to no effort. Then, press/punch in the rivets using any tool that has a good fit on top of the plastic rivet and is larger than the rivet to prevent an accident of punching the rivet through the hole completely. I recommend a round file with a flat tip. You could also use an appropriate screwdriver.
*Note, don't get ahead of yourself and let the punch slip off the rivet, denting your car body!
There you have it. After no more than 30 minutes, you'll have a fully functioning fuel door. Lets see how long this one holds up.
Fuel door installed
About the Author: Tim Wong
Tim is a Canadian from Windsor, which means he has plans to use his Volvo as an emergency space heater. He is a mechanical engineer by day and backyard mechanic by night. His mantra in life is to never break another bolt.
