Replacing Scion Tc Fuel Filler Door: Step-By-Step Guide

If the fuel filler door of your Scion tC is damaged or not working properly, you may need to replace it. The fuel filler door is a small, square door on the side of your vehicle that covers the gas cap. There are several reasons why your fuel filler door may not be opening, including a broken fuel door release, exterior damage near the fuel door, or a damaged fuel door hinge. If your fuel filler door won't open, you can get it inspected and repaired by a certified mechanic. The cost of this service can vary depending on your location and the model year of your Scion tC, but it typically ranges from around $100 to $130. You can also attempt to fix the problem yourself by purchasing a replacement fuel filler door online, which typically costs around $80 to $120.

Fixing a broken switch

If the switch to open the fuel filler door from inside your Scion tC is broken, you can try to manually open the fuel door. One way to do this is by removing the trunk lid and fuel door opener cover to access the cable end. You can then use pliers to manually pull the wire and release the fuel door. Alternatively, you can peel back the side trunk liner to access the cable where it hooks up to the latch device, then squeeze the clips to remove it and open the fuel door.

To fix or replace the broken switch, you will need to replace the entire pull cable sleeve and cable. This appears to be a substantial job, requiring the removal of the rear seat, front and rear door sill moldings, center pillar cover trim, pull carpet back, left gusset cover, spare tire lid, left trunk side panel, and rear trim panel. You can refer to a shop manual for guidance if you plan to do this yourself.

Another option is to cut the cable just in front of the plastic box where the fuel cap and trunk wires split. Then, tie the front end of the new cable to the old one and wrap it with tape. Next, open the lever end of the cable and remove the plastic door sills on the driver's side. Pull the old cable out from the front of the car, assisting around the door sills if necessary. Finally, fasten the front end of the new cable, replace the old cable in the trunk, and hook it up before replacing the plastic door sills.

If your fuel door is stuck due to a faulty hinge or spring, you may be able to resolve the issue by lubricating the hinge or spring. In some cases, physical damage, such as a snapped or loose spring, may require replacement.

Drilling out rivets

To replace a fuel filler door on a Scion tC, you will need to remove the existing door. This can be done by drilling out the two rivets that hold the hinge in place. Here is a step-by-step guide on how to drill out rivets:

Step 1: Gather Your Tools

You will need a drill and a drill bit that is appropriate for the size and material of the rivets. A drill bit that is slightly smaller than the rivet's diameter will help ensure that you do not damage the surrounding area. You may also want to wear safety goggles and gloves to protect yourself from any debris.

Step 2: Position the Drill Bit

Place the tip of the drill bit at the centre of the rivet head. Ensure that the drill is perpendicular to the surface to achieve a straight and clean hole.

Step 3: Drill Slowly and with Control

Start drilling at a slow speed to ensure that you do not slip off the centre. Increase the speed gradually as you cut through the rivet. Use firm and steady pressure to maintain control.

Step 4: Drill Through the Rivet

Continue drilling until you have completely penetrated the rivet. You may need to apply more pressure as you get closer to the rivet's core. Be cautious not to drill too deeply, as you do not want to damage the surface beneath.

Step 5: Remove the Remnants

Once the rivet head has been drilled off, the rivet stem can be pushed out from the backside. If needed, use a chisel and hammer to carefully remove any remaining pieces.

By following these steps, you can successfully drill out the rivets holding the fuel filler door in place, allowing you to replace it with a new one. Remember to take your time and work carefully to avoid any damage to your vehicle.

Replacing the hinge

To replace the hinge of your Scion tC's fuel filler door, you will first need to remove the old hinge. This can be done by carefully drilling out the two black rivets that hold the hinge in place. Make sure to wear eye protection and work gloves to catch any metal shavings.

Once the rivets have been removed, the old hinge should come off easily. If necessary, use a flathead screwdriver to gently pry it off. Be careful not to scratch or damage the surrounding paintwork.

To install the new hinge, line it up with the holes left by the old rivets. You can then use a pop rivet gun to secure the new hinge in place. Again, make sure to wear eye protection when using the rivet gun.

Finally, test the new hinge to ensure it is secure and functioning correctly. Open and close the fuel filler door several times to make sure it moves smoothly and latches properly.

If you are having trouble with the fuel filler door not opening or closing properly, it could be due to a frozen or broken cable pulley system. In this case, you may need to repair or replace the cable before installing the new hinge.

Opening a stuck fuel door

If your fuel door is stuck, there are a few things you can try to open it. Firstly, check if it is frozen shut, especially if you live in a cold climate. You can try using a hairdryer on a mild setting to thaw any ice that might be preventing the door from opening. If this doesn't work, you can try using hot water from a gas station or microwave to melt the ice.

Another common reason for a stuck fuel door is a broken or faulty release mechanism. If the cable, spring, or latch is damaged, the door may not open properly. In this case, you can try using a flat object like a credit card or a screwdriver to pry the door open. Insert the object opposite the hinge and pry the door open, you may need someone to help you by holding the release lever inside the car.

If the fuel door is stuck due to dirty hinges or worn-out springs, you can try lubricating the hinges with grease. This may help the door open more smoothly. Additionally, you can try bending the catch on the fuel door inward slightly so that the latch doesn't have to open as far to release it. Just be careful not to bend it too far, or the door may not close properly.

If none of these solutions work, you may need to remove the fuel door by drilling out any rivets or screws holding it in place. You can then purchase a replacement door from a dealership.

Replacing the fuel door

The fuel door on your Scion tC is an important part of your vehicle that you might not think about until it stops working. If your fuel door won't open, you can't refuel your car, so it's important to get it fixed as soon as possible.

Common Causes of a Stuck Fuel Door:

Before attempting to replace your fuel door, it's a good idea to diagnose the problem. There are several common reasons why your fuel door might not be opening:

• Broken fuel door release: If your vehicle has a fuel door release (usually a lever inside the car or a button on the keys), it may be broken, resulting in a stuck fuel door.
• Exterior damage: Recent exterior damage to your vehicle could have impacted the fuel door or its hinge, preventing it from opening.
• Damaged fuel door hinge: The hinge on the fuel door may be stuck, or the pin and bushings may be too loose or too stiff, causing the door to malfunction.

Steps to Replace the Fuel Door:

• Purchase a Replacement Fuel Door: You can buy a new fuel door online or from a Scion dealership. Make sure to select a fuel door that is compatible with your specific Scion tC model.
• Access the Fuel Door Mechanism: Depending on your Scion tC model, you may need to remove the rear left interior panel to access the fuel door mechanism. This may involve removing a tray and cover.
• Remove the Old Fuel Door: The fuel door is typically attached with rivets. You will need to drill out the rivets carefully to detach the old fuel door. Be cautious not to damage any surrounding components.
• Install the New Fuel Door: Align the new fuel door with the hinge and secure it in place using the appropriate fasteners. Ensure that the door opens and closes smoothly.
• Test the Fuel Door: Once the new fuel door is installed, test it by opening and closing it several times to ensure it functions correctly.

By following these steps, you can replace the fuel door on your Scion tC, restoring your ability to refuel your vehicle. Remember to consult a professional mechanic if you encounter any issues or complications during the replacement process.

Frequently asked questions