Installation

• 1). Purchase a new fuel door hinge. Volvo dealers usually charge around $15 for the part. You can also find the hinge online at Swedish car parts websites for about $6 plus shipping.
  
  
• 2). Use a flat screwdriver to pry loose the damaged, black plastic fuel door hinge from the body of your 1990 Volvo. The hinge fastens to the vehicle by four plastic rivets. You may have to sacrifice the filler cap tether by snipping it off at the hinge. Clean out all pieces of the broken hinge from the filler cavity.
  
  
• 3). Scrutinize the layout of the new hinge assembly to understand how the parts align and assemble.
  
  
• 4). Attach the new hinge on your Volvo's fuel door before installing the unit onto the car body. Line up the rounded side of the new hinge with the metal hinge pin found on the rear of the fuel door. Vigorously snap the metal hinge pin down and into the two plastic hinge brackets without breaking them.
  
  
• 5). Complete the replacement of the new hinge onto your Volvo's fuel door by turning the fuel door's metal pin over to the left. Snap the pin into the two plastic slots found at the center of the hinge unit. Again, the hinge assembly breaks easily, so do not use excessive force.
  
  
• 6). Place the hinge's four plastic rivets over the four holes found at the right of your Volvo's gas cap. Drive the plastic rivets into the holes with a small hammer until the rivets lay even with the hinge surface. Use a nail set to tap in the center pins. Close the fuel door.