Remove (break) the pins from the new hinge before fitting to your car. Use a sharp knife to carefully remove excess plastic (from where they were attached) from the pins. Use a loose drillbit to remove the excess plastic - surrounding the holes - by hand. Now you can hold the pins with needlepoint pliers and gently tap them a little in the holes. This will help you to fit the hinge to your car much easier.
Just got my (Genuine Volvo gas cap, spring and hinge) parts in today for my 2004 S80 2.5T... works great! No more flippy/floppy fuel door now, thanks to FCP Euro! Thank you guys!
Good vid. I just attempted to install my hing on a '07 xc90... I'm 3/4ths there. I've watched three or four of the vids on this procedure and they all fall a bit short on the detail of the punch. I know what I see and recognize the uniqueness of the particular punch used but I didn't have one. Instead I settled for a tool of the same diameter at the tip, but conical in shape as it develops full thickness. The upshot is that you can't pound enough of the pin through the hole to free up the hinge. I ended up drilling out the old pins. The removal of the old hinge from the door took quite a bit of nibbling with a good knife to remove enough hing material to allow a well placed screwdriver to pop the hinge free of the door. The pin reinstall was too much for my fat fingers to do as our friend shows us. I put the pins in from the other end and pushed them though with the punch. Easier for me. Now the hard part... My '07 xc90's fuel door hinges had rubber bushings between the body and the hinge.... or so I though. When the door popped off, they stayed stuck to the body and it wasn't till I went to reinstall did they present a problem... Then it became apparent that those bushings pulled out of the old hinge on removal, so it was much easier to position going forward... But I ended up putting 4 stainless screws in the bleeping thing cause some of the bits intended to flair out when the pins are hammered in... broke off. YMMV
What an incredibly annoying design. I could not get the pins to go in either. I even used a security torx with a center hole as a pre-punch to partially hammer in the pins. I ended up using screws as well. #10 5/8" oval head
I agree with Dave K. Everything was easy except those plastic pins. I removed them from the new hinge and reinserted with needle nose pliers. When tapping in they either broke or flared. I installed screws instead. Our friend makes it looks so easy. I had asked my VOLVO repair shop more than one time to replace this, but now I know why they didn't do it. I am no mechanic so I will stick to just grilling food for my family and friends. They say I am real good at that.
My mechanic wanted $75 for this entire transaction. Even if I got the OEM version at the Volvo dealership, it would have only been $18. I just bought an after-market part off Amazon and did this myself. So easy and it makes you feel good inside to accomplish something yourself....kind of like self-care. 😀
It helped me, the fluel door wont closed before i had to Crowl in luggage to open and close but now this fixed thanks to you ;) saves me som cash Thanks
Greetings, and thanks for this video. It seems that I can't fit the screws in the whole at all regardless of hammering in and pushing. Not sure if I missed any steps.
…but wouldn’t a better design be one that didn’t need to be replaced frequently? Just sayin’ & ‘nuff said. (This being said, good instructional video. Short, sweet and to the point.)
bad design it should have been all metal from the beginning they want you to keep replacing this shit. i replaced the hinge and now the hinge for the spring cracked since its also plastic. have to buy a new fuel door..
I found it impossible to attach the hinge clip to the door before installing the hinge on the car. The advice that you must install the hinge to the door prior to installation on the car is not true. In fact, the only way I was able to engage the hinge clips to the door bar was to have the hinge installed which allowed me to apply sufficient force to engage the clips, and the door works perfectly. Either you need super human thumb strength, or there is a trick to it. Some more details: 2004 XC70. I installed the new hinge (great advice to remove and flip the pins). I then angled in the door so that the bar on the door engaged with the clips. It still took a lot of force: angle it into position, and then pull towards you to get the clips to engage (with a satsifying click).
Great video! Is there a way to take the fuel door off without having to change the hinge? Mine is fine, but the fuel door must be removed because of a paint job..
We fixed ours today my only problem I is the n kack platic things they just broke off when I tried to nail them in. :(((( were trying to find a screw to fit them or glue it down....
If i buy a new hinge, will it have the pieces on the hinge that the pin is supposed to clip in to? Or is that supposed to be part of the fuel door itself? My pegs broke on that…
Hey. i have same prob whit my 2006 volvo s60 i have to climb in to my bagage to open fuel flap to get some gas in my car. i dont have any fuel buttom to press on in my car dont know why i dont have, maybe its electrical fuel i have. my before volvo s70 1998 Had fuel buttom in the car, but im going to try to fix this fuel hinge, Thanks for good video :D
This is a useful video but I 100% disagree with you about attaching the hinge to the door first. I followed your instructions but the weight of the door and its presence made it almost impossible to line up the pins. I also couldn't access the middle two pins because of the door. So, I removed the door from the hinge, put the hinge on to the car on its own, punched in the pins and then fitted the door and the spring. That took a few moments after several minutes following your directions and failing to get anywhere. My additional advice is BEFORE YOU START remove all four pins first by punching them backwards out of the hinge. I then fractionally enlarged the holes and filed down the end of the pins with a nail file emery board. This allowed me to press the pins in 30% of their travel on the bench first and meant they were securely located before using a drift and a small hammer to press them into place on the car. None broke.
Remove (break) the pins from the new hinge before fitting to your car. Use a sharp knife to carefully remove excess plastic (from where they were attached) from the pins. Use a loose drillbit to remove the excess plastic - surrounding the holes - by hand. Now you can hold the pins with needlepoint pliers and gently tap them a little in the holes. This will help you to fit the hinge to your car much easier.
This was the hardest part Tapping in the inserts was a no go. I opened up the holes a little bit and then used small screws to attach.
I could not get the outer pegs in for the life of me, ended up using two screws - worked perfect.
Thanks for the instructions. The hardest part is hammer the pins in without breaking it.
Just got my (Genuine Volvo gas cap, spring and hinge) parts in today for my 2004 S80 2.5T... works great!
No more flippy/floppy fuel door now, thanks to FCP Euro! Thank you guys!
Happy to help, Jared! Nobody likes a flippy floppy fuel door!
Great video, straight to the point, no needless chatter.
Gotta say, went from a 200 dollar dealership repair to a 20 dollar amazon prime part and 10 minutes of time thanks to this video. Thank you!
Good vid. I just attempted to install my hing on a '07 xc90... I'm 3/4ths there.
I've watched three or four of the vids on this procedure and they all fall a bit short on the detail of the punch. I know what I see and recognize the uniqueness of the particular punch used but I didn't have one. Instead I settled for a tool of
the same diameter at the tip, but conical in shape as it develops full thickness. The
upshot is that you can't pound enough of the pin through the hole to free up the hinge. I ended up drilling out the old pins.
The removal of the old hinge from the door took quite a bit of nibbling with a
good knife to remove enough hing material to allow a well placed screwdriver to pop the hinge free of the door.
The pin reinstall was too much for my fat fingers to do as our friend shows us. I
put the pins in from the other end and pushed them though with the
punch. Easier for me. Now the hard part... My '07 xc90's fuel door
hinges had rubber bushings between the body and the hinge.... or so I though. When the door popped off, they stayed stuck to the body and it wasn't till I went to
reinstall did they present a problem... Then it became apparent that those bushings pulled out of the old hinge on removal, so it was much easier to position going forward... But I ended up putting 4 stainless screws in the bleeping thing cause some of the bits intended to flair out when the pins are hammered in... broke off. YMMV
What an incredibly annoying design. I could not get the pins to go in either. I even used a security torx with a center hole as a pre-punch to partially hammer in the pins. I ended up using screws as well. #10 5/8" oval head
I agree with Dave K. Everything was easy except those plastic pins. I removed them from the new hinge and reinserted with needle nose pliers. When tapping in they either broke or flared. I installed screws instead. Our friend makes it looks so easy. I had asked my VOLVO repair shop more than one time to replace this, but now I know why they didn't do it. I am no mechanic so I will stick to just grilling food for my family and friends. They say I am real good at that.
It worked as shown in your video. Thanks ever so much for posting this. Did this on my 2009 XC90.
👍
Common problem, changed this recently on my S80. Simple and easy fix, great video.
Top tip: if those flimsy inserts break just use a few screws (make sure they're the right length).
Abicim Adamsin sen,s80 2003 model ve her tamirimi senin videolarinla yapabiliyorum,çok tesekkür ederim,🤗
My mechanic wanted $75 for this entire transaction. Even if I got the OEM version at the Volvo dealership, it would have only been $18. I just bought an after-market part off Amazon and did this myself. So easy and it makes you feel good inside to accomplish something yourself....kind of like self-care. 😀
Nice work! That is what it's all about.
Exactly what I needed today, saved me a lot of time and frustration. Thanks!
It helped me, the fluel door wont closed before i had to Crowl in luggage to open and close but now this fixed thanks to you ;) saves me som cash Thanks
Excellent, like all FCP 'how to' videos!
Paulo Roberto 👌
Great & easy work. Thank you for the step by step instructions
You're welcome, Paul! Happy to help.
Wish I knew how easy it is to break those little pin inserts. Very silly design in my opinion.
What foam cleaner did you use? It seem to work like a charm!
Greetings, and thanks for this video. It seems that I can't fit the screws in the whole at all regardless of hammering in and pushing. Not sure if I missed any steps.
Wow, that's some incredible design, very easily replaceable. Great thinking on the Volvo Engineering team. :)
…but wouldn’t a better design be one that didn’t need to be replaced frequently?
Just sayin’ & ‘nuff said.
(This being said, good instructional video. Short, sweet and to the point.)
bad design it should have been all metal from the beginning they want you to keep replacing this shit. i replaced the hinge and now the hinge for the spring cracked since its also plastic. have to buy a new fuel door..
I found it impossible to attach the hinge clip to the door before installing the hinge on the car. The advice that you must install the hinge to the door prior to installation on the car is not true. In fact, the only way I was able to engage the hinge clips to the door bar was to have the hinge installed which allowed me to apply sufficient force to engage the clips, and the door works perfectly. Either you need super human thumb strength, or there is a trick to it.
Some more details: 2004 XC70. I installed the new hinge (great advice to remove and flip the pins). I then angled in the door so that the bar on the door engaged with the clips. It still took a lot of force: angle it into position, and then pull towards you to get the clips to engage (with a satsifying click).
That worked for me! Thank you.
I have an S60 and up on trying to replace the hinge, the pins go flush to the hinge but the hinge keeps falling off.
Damn, that's easy. Thanks for the excellent video!
Great video! Is there a way to take the fuel door off without having to change the hinge? Mine is fine, but the fuel door must be removed because of a paint job..
Awesome thanks
great video, congratulations, I have the same problem with my 2007 Volvo S60, on which USA page can I order the part, thank you very much
We fixed ours today my only problem I is the n kack platic things they just broke off when I tried to nail them in. :(((( were trying to find a screw to fit them or glue it down....
If i buy a new hinge, will it have the pieces on the hinge that the pin is supposed to clip in to? Or is that supposed to be part of the fuel door itself? My pegs broke on that…
if the 3mm plastic plug is broken, use a 3mm screw instead of it is perfect, and no need to hit it.
Gotta change it on my S80
Where can I find a fuel door replacement for a 17' xc60
I've never seen a release button on a UK S60?!
Hey. i have same prob whit my 2006 volvo s60 i have to climb in to my bagage to open fuel flap to get some gas in my car. i dont have any fuel buttom to press on in my car dont know why i dont have, maybe its electrical fuel i have. my before volvo s70 1998 Had fuel buttom in the car, but im going to try to fix this fuel hinge, Thanks for good video :D
This is a useful video but I 100% disagree with you about attaching the hinge to the door first. I followed your instructions but the weight of the door and its presence made it almost impossible to line up the pins. I also couldn't access the middle two pins because of the door. So, I removed the door from the hinge, put the hinge on to the car on its own, punched in the pins and then fitted the door and the spring. That took a few moments after several minutes following your directions and failing to get anywhere. My additional advice is BEFORE YOU START remove all four pins first by punching them backwards out of the hinge. I then fractionally enlarged the holes and filed down the end of the pins with a nail file emery board. This allowed me to press the pins in 30% of their travel on the bench first and meant they were securely located before using a drift and a small hammer to press them into place on the car. None broke.
perfect
I just attached the spring with a screw
What about a 2015 xc70... It's a completely different set up...
Can you use the old one after removing ?
For what? It's broken, which is why you're replacing it in the first place.
dos FCP Euro ship too norway???
Get genuine...my replacement lasted 3 months. Not a fun job to do once, let alone twice. Spend the extra $$$
These ding dongs as smart as they are could have made the hinge aluminum so the tabs for the spring seat wouldnt break.
nice work but i still hate the volvo!
Worst reinstallation instructions ever!!!!!!!!!!!!!!
Why?