Broken Gas Door Hinge Fix

[MrAl]

So simple answer to your first question. No there is not a manual over-ride on a 98 on P80 sedan or wagon. 850's had a thin metal wire that ran to the back of the car and could be accesses by opening a flap in the rear inner liner panel by the rear light on the RHS.

This was dropped for some inexplicable reason in 98. Probably to cut costs.

I took the rod from a 850 and adapted it for my friends 98 V70 as the lock mechanism gets cranky in cold temperatures so she needed a way to open the flap. It took me maybe an hour mostly to remove the inner panel on her V70 on the Rear RHS to give access to the latch solenoid. To remove that you have to remove 2 x T25? Torx screws on the outside of the car at the rear of the fuel flap opening. Note, when re-fitting this it is handy to have a second person as it is a long stretch on a wagon, but possibly doable on a sedan.

I bent the end of the wire at the solenoid end as the V/S70 solenoid has a thicker actuator rod than an 850. All it actually does is pull the rod rearwards when you pull on it to release. With her car, I replaced the solenoid with a known good one, lubed it and still got the same issue when cold. Checked the door switch and it was fine as well. The only 2 things left are the relay which is on a circuit board according to Dr. Abscate which operates the door locks. I now have 2 of those units if needed, or it is possibly the wiring harness between the front edge of the LHF driver's door and the A pillar. Wires in that bundle can break with age. So I also have a door wire harness as a back up. Naturally since doing this mod, the flap has worked fine but we have had limited really extended cold periods this year.

There is a plastic clip on the wire that snaps into a pre-drilled hole on the rear inner panels of the 850. That hole is also on a V70 but have not checked an S70. Problem is the clip breaks when you remove it and I can't find a replacement any longer. So I drilled a new hole and made up a simple slider bracket and screwed it onto the inner panel brace near where it would fit on an 850 to hold it in place. IT works well but been needed in over a year now but it gives piece of mind.

Option 2 is to remove the solenoid all together or the clip and run without it. It is hard to get gas out of a P80 fuel tank. Only reason to leave the latch in place is to stop jerks breaking them off.

Neil.

Hi Neil,

Thanks for the detailed reply.

So when you were working on the v70 1998 did you notice if you could get to the holes where the gas hatch door pins on? That is, the holes where the pins go through the car body. If you could get to the back of that metal then there is hope to install a better door system, even a better hinge altogether.

[MrAl]

The plastic catch on the V70 gas cap is really cheap, so if it is stuck closed you can snap it open with your fingers and replace the catch for a whopping $4.20

It is considered poor form to ask FCP for a warranty replacement on each fillup

Thanks i ordered some parts.

But you are saying you can open the door with your fingers if it gets stuck? I could not see how to operate that catch from the outside of the body because the door covers it when closed.

Also, where can i buy some of those giant red circles?

[MrAl]

...but i remember someone saying you could get to the control solenoid that releases the gas door if the electrical button on the inside of the car doesnt work for some reason. Any truth to that? Maybe that is separate from the rest of the gas door access?

Yes, I do it every time I get gas with the S70. When I bought the car the latch was broken, so the door would just flap. I got a new latch, but the release mechanism doesn't work. The interior trunk panel was already pulled away, so I'm thinking that a previous owner possibly broke the latch purposely after getting tired of reaching into the trunk.

The interior panel mostly flops back into place, so when I need to, I just pull it out enough to get my hand in, and manually pull the mechanism back.

I'll probably be doing this tonight after work, as I need gas again.

Edit: There are some plastic retainers that need to be removed to initially pull the interior panel out. Mine were already removed when I bought the car.

Hi,

Ok so were you able to get to the back side of the holes where the door pins go through the body metal?
That would be interesting.

[454cid]

Hi,

Ok so were you able to get to the back side of the holes where the door pins go through the body metal?
That would be interesting.

I've never had reason to try. I just reach in far enough to pop the door open.

[volvolugnut]

My local Ace Hardware has some removable plastic rivets with a pin that might work for attachment. They are in several sizes. I used some on the front bumper support.
volvolugnut

[scot850]

The panel work on the inside of the car and the rear fender arch prevent getting access to the holes easily. Also the fuel filler pipe and the solenoid make it more difficult. As 454cid mentions you can possibly reach in and pop the latch, but you would need to leave the inner panel off to give enough access. You are still going to be working blind and your finger tips.

To get better access you may have better luck bu removing the solenoid first. It may be possible, but I would think it was easy to access Volvo would not have gone the route they did although it does reduce the labor time to fit.

Neil.

[454cid]

I assume the solenoid needs to be in place to keep the door closed. If s person is ok with a flopping fuel door it would be far easier to remove the latch on the door itself. I prefer to have the door latched so I just reach in and manually work the solenoid.

The panel just needs to be loose, not removed.

[cn90]

Since you already took the door off, you may as well buy a new hinge from Volvo.
It is NOT that expensive.

[MrAl]

Since you already took the door off, you may as well buy a new hinge from Volvo.
It is NOT that expensive.

Yes thanks, just thinking about alternate methods.

[454cid]

Last night when I got gas, I felt around to see if I could get the the backside of the hinge from the trunk at it seems to be two layers of steel there.