S80 S60 V70 XC70 Fuel Door Hinge Replacement

Is your fuel door hinge hanging on by a thread? Here’s how to change it yourself. The hinge is a plastic part that costs $15 at the dealer. These must break often as the parts man knew exactly what I was talking about right off the bat.

Here’s a pic of my old hinge. The top spring retention clip has already broken clear off and the bottom door retention clip has cracked. It wouldn’t have been too long before my door left the car:
This is the new Volvo hinge:

Start off by using your thumbs or a suitable tool to push the spring out of the retention clips. It really doesn’t matter if you break the clips off since you are replacing the whole hinge.

Now take a pin punch, nail, or jeweler’s screwdriver and hammer the four hinge rivet pins all the way through the rivets and into the body. You’ll have to rap the pins pretty hard to drive them through. Here are the four places where the pins are in sequence (shown by the jeweler’s screwdriver in the rivet hole:

After you punch out all the rivet pins, just pull on the fuel door and the hinge will come off the car:
Now push the hinge around to what would be the “door open” position if it were still on the car and pull the hinge off the pin in the door. It takes some force to do this. Be careful not to break the door.

Here’s a pic of the door next to the old hinge (closest to the door) and the new hinge (farthest from the door):
Now place the new hinge on the door hinge pin and force it down on the pin. It takes quite a bit of force to get it to snap into place. I’ve read that some people put the hinge on the car first and then had trouble getting the door onto the pin, so I put the hinge on the door first. I placed the door on a rag and used a screwdriver to apply downward force on the two areas where the hinge snaps on:
Image

Now place the hinge on the side of the car and make sure all the rivets drop into their holes. Use a punch, extension, screwdriver, or other suitable tool to drive all the pins in until they are flush with the surface of the hinge plastic:

Now use your thumbs to gently push the spring over and into the spring retaining clips:
It should look like this when you’re done.
You just saved a few bucks over having the dealer do it for you.

I’m going to load this into the S80 repair database. I don’t know if it applies to any other models.

S80 S60 V70 XC70 Fuel Door Hinge Replacement

Last Updated on March 26, 2022