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1996 850 - How to fix gas tank lid locking mechanism

Help, Advice and DIY Tutorials on Volvo's P80 platform cars -- Volvo's 1990s "bread and butter" cars -- powered by the ubiquitous and durable Volvo inline 5-cylinder engine.

1992 - 1997 850, including 850 R, 850 T-5R, 850 T-5, 850 GLT
1997 - 2000 S70, S70 AWD
1997 - 2000 V70, V70 AWD
1997 - 2000 V70-XC
1997 - 2004 C70

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Sommerfeldt
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1996 850 - How to fix gas tank lid locking mechanism

Post by Sommerfeldt »

Hey!

Since I bought my "new" 850, a 1996 T5, the projects and small-to-medium issues have piled on little by little, and I try to take them on one by one... Today, the problem of the "door", "hatch", lid, whatever, that you open before screwing out the filler cap not locking along with the other doors.

Some of you might not have the locking mechanism at all - apparently it was an option on US cars, but all the 850s I've seen over here has this. So - how to remove and fix the lid locking mechanism:

1: Remove trim/interior panel on passenger side of trunk area. What you need to access is the area behind the wheel well, where there's a covered opening in the panel above the vent. Take off the soundproofing cover, if it's still there.

2: Remove this screw:
IMG_0329.JPG
IMG_0329.JPG (124.84 KiB) Viewed 921 times
and the clip holding the emergency opening wire. Don't worry, nothing's falling down anywhere.

3: Remove these 2 screws - they're all T15 or T20, iirc:
IMG_0331.JPG
IMG_0331.JPG (116.24 KiB) Viewed 921 times
Once all 3 screws and the clip are removed, pull out the entire locking mechanism. Remove the electrical connection.

Once you've got the whole thing out, it's much easier to see what the issue might be. It's a simple setup, so usually, it just needs some good blobs of litium grease and some WD-40 to the motor.

There are 5 screws on the assembly. Take off the 2 on the "cover" first, and then open the mechanism by removing the 3 remaining screws, which are T10s. Open the mechanism up. You'll see this:
IMG_0328.JPG
IMG_0328.JPG (67.28 KiB) Viewed 921 times
Pretty basic stuff. Grease everything if all is working, replace motor if you must, etc.
Putting everything back together is a simple reversal of the steps.

When you're putting this back in the car, connect power and check functionality before anything else. Then, fix the interior screw first, leaving some slack for movement. Then, find the two exterior screws, and line the locking mechanism up by putting the screws back in. You can aim the screws at the holes, and stuff's tight enough in there for the screws to reach in w/o the assembly disappearing.

:)

- S
2018 S90 T8 Inscription - glossy black with amber interior and dark as night rear windows.
[Gone] '96 855 T5 - R bumper and spoiler, Koni Yellows & blue H&R springs all 'round.
[Sold] '97 S70 T5
[Gone] '95 855 T5-R - one of the black ones... sadly stolen and wrecked.

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dosbricks
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Post by dosbricks »

Nice writeup. Nice to have a contributor from one of the countries I've always most wanted to visit.
'98 S70, 230k, purchased new in '98
'96 855 GLT, 163k, purchased lightly used in '99
Onceuponatime RIP '69 Shelby GT500 w/7.0 liter

Sommerfeldt
Posts: 1148
Joined: 29 July 2008
Year and Model: 2018 S90 T8
Location: Oslo Area, Norway
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Post by Sommerfeldt »

Thank you, sir!

Come on over - we're friendly, for the most part. But beef up your beer budget! It's expensive. :D

- G
2018 S90 T8 Inscription - glossy black with amber interior and dark as night rear windows.
[Gone] '96 855 T5 - R bumper and spoiler, Koni Yellows & blue H&R springs all 'round.
[Sold] '97 S70 T5
[Gone] '95 855 T5-R - one of the black ones... sadly stolen and wrecked.

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misha
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Year and Model: '97 850 2.5 20v
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Post by misha »

If you didn't cleaned black dirt marks from little brushes on the rotor it will get stuck again.
Been there:
https://www.matthewsvolvosite.com/forums ... =1&t=31961

:wink:
'97 850 2.5 20v / fully equipped / Motronic 4.4 from the factory / upgraded with S,V,C,XC70 instrument cluster / polar white wagon
History of Volvos in the family:
'71 144 S
'73 144 De Luxe
'78 244 DL
'78 244 DL
'79 244 GLE
'85 340 GLS

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MrAl
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Post by MrAl »

Hi,

Mine is the 1998 v70 and is similar, although i am not sure about the two external screws...i'd have to check.

Yes nice writeup, thanks.
I’ve been driving a Volvo long before anyone ever paid me to drive one.
That's probably because I've been driving one since 2015 and nobody has offered to pay me yet.
1998 v70, non turbo, FWD, base model, on the road from April 2nd, 2015 to July 26, 2023.

Sommerfeldt
Posts: 1148
Joined: 29 July 2008
Year and Model: 2018 S90 T8
Location: Oslo Area, Norway
Has thanked: 55 times
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Post by Sommerfeldt »

misha wrote:If you didn't cleaned black dirt marks from little brushes on the rotor it will get stuck again.
Been there:
https://www.matthewsvolvosite.com/forums ... =1&t=31961

:wink:
Yup - also, if you're not into fiddling around inside the tiny motor, a replacement is about $2 for this kind of thing. Mine is stamped "Made in China", so I'm thinking it's not exactly a specialty item. :D

I saw that post of yours, and opened the motor up, but mine didn't have the black stuff on the brushes, so I closed it all up, greased everything and it seems to be working like a charm now. :)

- S
2018 S90 T8 Inscription - glossy black with amber interior and dark as night rear windows.
[Gone] '96 855 T5 - R bumper and spoiler, Koni Yellows & blue H&R springs all 'round.
[Sold] '97 S70 T5
[Gone] '95 855 T5-R - one of the black ones... sadly stolen and wrecked.

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