How to Repair an IPP Volvo Gas Door Hinge

Over time, the plastic hinge pin on a Volvo gas door can become fractured or break due to normal wear and tear. This can lead to a gas door that sags and fails to line up properly when closed. If the gas door does not close properly, it is more likely to pop open during a drive and can become damaged further. Spare hinge pins, such as the IPP (Import Performance Parts) hinge, can be ordered from your Volvo dealer, rockauto.com, eBay.com or your favorite part supplier (see "Resources").

Removing the Damaged Hinge Pin

• 1

  Open the gas door and push the spring clip towards the door. Gently remove the spring.

• 2

  Look inside the trunk behind the plastic shroud covering the retractable antenna. Observe which of the four plastic rivet heads securing the hinge pin remain.

• 3

  Apply a flathead screwdriver between the plastic hinge pin and the fender. Gently pry the two apart, one rivet at a time.

• 4

  Remove the soft rubber washers located at each rivet head. Keep them to use with the new hinge pin if necessary to get a good fit.

Installing the New Hinge Pin

• 1

  Test fit the new hinge pin using the hard plastic washer gasket and the old soft rubber washers. Determine how best to use the washers to get the most secure fit of the hinge pin against the fender.

• 2

  Expand the rivet heads of the outer rivets to help secure the hinge pin to the fender. Use a Phillips head screwdriver inside the trunk with one hand while holding the hinge pin firmly in place on the outside of the car with the other hand.

• 3

  Tap the plastic tabs of the center rivets into place using the handle of a screwdriver or a small hammer. The two cylindrical tabs expand the heads of the rivets, locking them into place against the fender.

• 4

  Reattach the gas door by aligning the brackets with the top and bottom of the hinge pin. The gas door is plastic and will flex slightly, providing an easier fit.

• 5

  Align the spring with the two holes in the gas door and the two notches in the hinge pin. Compress the spring gently into place.