How do you install plastic hinge for Volvo gas tank cover part number 31265160?

Answer 1

Volvo's fuel door hinge is secured to the body by four expanding rivets allowing blind installation and removal (that is to say, without requiring access to the inside of the quarter panel.) Remove the old hinge by punching out the four rivet expander pins with a long, slender punch. (The approximately 1/8" expander pins aren't easy to see as they've been driven flush with the crescent-shaped hinge. The outside two are centered about 1/4" from each end of the hinge, with two more each about 1-1/4" inboard of those, centered in the spring holders.) DANGER--DON'T use an electric drill to drill out the pins as the close proximity to the fuel filler makes this an EXTREMELY DANGEROUS risk!!! Once the old hinge is removed, carefully assemble the hinge, door, and spring BEFORE securing to the car body. Clean the area of the fuel filler and remedy any rust. With the fuel door open on the hinge, line up the hinge's rivets with their respective holes and press the hinge in place with the rivet gaskets bottomed out on the sheet metal. While a helper holds the fuel door-hinge-spring assembly firmly in place, use a 1/4" drift and hammer to carefully sink the four rivet expanders flush to the hinge. Test the security of the rivets and carefully open and close the door to check alignment and flush fit of the door to the body.