A Simple Guide To Replacing Your Hyundai's Fuel Door

Hyundai owners have reported issues with their fuel doors, including doors that won't open when the lever is pulled, and broken or stuck actuators. Some have found temporary solutions, such as using a rolled-up towel to lift the lever, or bending the spring to increase tension. Others have had to take more drastic measures, like filing down plastic parts or replacing the entire fuel door. This has been a common issue for Hyundai Venue, Santa Cruz, Sonata, and Tucson models.

Troubleshooting a broken fuel door

Identify the Issue:

Before attempting any repairs, it's important to identify the root cause of the problem. The most common issues with fuel doors are a stuck lever, a broken cable, or a faulty lock mechanism. Try opening the fuel door using the lever or button inside your Hyundai. If it doesn't open, listen for any sounds that indicate the lock mechanism is trying to engage.

Try Basic Troubleshooting Methods:

If the fuel door doesn't open, start by trying some basic troubleshooting methods. These are simple yet effective solutions that can save you time and effort:

• Lock and Unlock the Vehicle: With the key out of the ignition, lock and unlock the vehicle a few times using your remote or key fob while holding the fuel door. This may reset the lock mechanism and allow the door to open.
• Try an Old Plastic Card: If the cable that opens the fuel door is broken, you can use an old plastic card to slide between the fuel door and the body of the car. Push hard and wiggle the card to pop the door open. This method is a quick temporary fix.
• Adjust your Seat: In some Hyundai models, adjusting the seat to a higher position has been reported to fix the issue with the fuel door not opening. While it may not work for everyone, it's worth trying as it's a simple adjustment.

Check the Spring Tension:

If the basic troubleshooting methods don't work, the issue could be related to the spring tension in the hinge assembly. Over time, the spring can lose tension, preventing the fuel door from opening. To fix this:

• Access the Spring: Remove the fuel cap and the two 10mm bolts holding the gas cap cover in place. This will allow you to access the spring in the hinge assembly.
• Adjust the Spring Tension: Bend the spring towards the bolt holes to increase the tension. Test the tension by holding the hinge, closing the lid, and releasing it. If the lid pops open, the spring tension is sufficient.

Seek Professional Help:

If none of the above methods work, it's best to consult a Hyundai dealership or a qualified mechanic. They can diagnose the issue and suggest further repairs. In some cases, it may be necessary to replace the entire fuel door assembly, especially if the problem is with the lock mechanism or a broken cable.

Remember to keep your Hyundai's maintenance records and, if it's still under warranty, contact the dealer to see if the repairs are covered. Troubleshooting a broken fuel door can be challenging, but with patience and the right approach, you can identify and fix the issue.

Removing the fuel door

To remove the fuel door of a Hyundai, you will need to first open the fuel door and take out the gas cap. Then, you will need to remove the four screws that are behind the fuel cap. Once the screws are removed, you can take out the whole assembly.

There are a few different ways to remove the fuel door itself from the assembly. One way is to detach the clips holding the fuel door in place. Another way is to press down on a clip and then slide the fuel door off. If you are having trouble removing the assembly, you may need to remove the rear wheel and the inner liner to access it.

If you are removing the fuel door because the release lever is not working, there are a few potential fixes. One solution is to bend or replace the spring that pops the fuel door open. This can be done without removing the assembly by reaching the spring with a flat-blade screwdriver and bending it. If the nub that the actuator presses on has broken off, you can glue a small piece of wood or plastic to the actuator to serve as a new nub. If the cable that opens the fuel door is stuck, you can try to unjam it by lubricating it or by using an old plastic card to slide in between the body and the door to pop it open.

Repairing the fuel door actuator

If the fuel door actuator on your Hyundai is not working, it may be permanently depressed, or the fuel door may not be locking. In some cases, the fuel door may not open at all.

The first step is to diagnose the problem. If the actuator seems permanently depressed, it is likely that the nub has broken off. Inspect the actuator to see if this is the case. If the nub is broken, you can attempt to glue it back on or fabricate a new one using a broken chopstick, as described by one Hyundai owner. Sand the chopstick down to the correct size, drill a small hole in the actuator, and glue the nub in place with Gorilla Glue. Wrap the repair with saran wrap and electrical tape to hold it in place while the glue dries.

If the nub is not broken, the problem may be with the cable that operates the actuator. Check the cable for damage or stretching, and if necessary, replace it.

If you are unable to diagnose and repair the problem yourself, a dealership or mechanic can do it for you, but this will be more expensive. The cost of replacing a fuel door actuator is typically between $181 and $194, with labour costs estimated between $49 and $62, and parts priced around $132.

To avoid problems with your fuel door actuator, be careful not to use excessive force when operating the release lever, as this can cause the cable to stretch or break prematurely. Keep the actuator pin clean and free of dirt and corrosion to prevent the solenoid from sticking and failing prematurely.

Opening a stuck fuel door

If your Hyundai's fuel door is stuck, there are a few temporary solutions you can try. Firstly, try pressing the fuel release button multiple times, as this has worked for some Hyundai owners. If your Hyundai has a fuel release lever, try pulling it while someone pushes or pries gently on the fuel door. Alternatively, you can try using a credit card or a rolled-up towel to lift the lever and place it under the door to try and pop it open.

Another method is to use a lubricant such as WD-40 or a motorcycle cable lube on the hinges to help free up the mechanism. You can also try to open the fuel door manually by sliding a credit card into the gap between the body and the door where the latch is and pushing hard to try and pop it open.

If none of these methods work, you may need to take your car to a Hyundai dealership to have them diagnose and fix the problem. Some Hyundai owners have reported that their dealerships were unable to provide a permanent solution, but your experience may vary.

Replacing the fuel door

Step 1: Purchase the Correct Parts

Before beginning the replacement process, it is important to have the correct parts on hand. This includes the fuel door itself, as well as any necessary hardware such as screws or clips. It is recommended to purchase OEM (Original Equipment Manufacturer) parts from an authorized Hyundai dealer or a reputable online source.

Step 2: Remove the Fuel Fill Door Cap

Start by opening the fuel fill door and removing the fuel cap. This will give you access to the mounting screws or clips that hold the fuel door in place.

Step 3: Loosen and Remove Mounting Hardware

Using the appropriate tool, loosen the mounting screws or detach the clips that secure the fuel door in place. Be careful not to strip the screws or break the clips during this process. You may need to apply some force to remove the clips, but be gentle to avoid damaging the surrounding bodywork.

Step 4: Remove the Fuel Fill Door

With the mounting hardware loosened or removed, you can now carefully take out the fuel fill door. It may be necessary to gently pry or pull on the door to detach it from the vehicle. Be cautious not to scratch or damage the paintwork during this step.

Step 5: Install the New Fuel Door

Take the new fuel door and position it in the opening. Ensure that it is properly aligned and seated before proceeding.

Step 6: Secure the New Fuel Door

Attach the mounting hardware (screws or clips) that holds the fuel door in place. Tighten the screws securely, but be careful not to over-tighten as this can strip the threads or damage the surrounding material. If using clips, make sure they are firmly in place and fully engaged.

Step 7: Test the Fuel Door

Once the new fuel door is installed, test it to ensure it functions correctly. Open and close the door several times to verify that it locks, unlocks, opens, and closes properly. Check that the door sits flush with the surrounding bodywork and that there are no abnormal noises or resistance when operating the door.

Additional Tips:

• It is recommended to work with a helper when replacing the fuel door, as they can assist in opening and closing the door during the testing process.
• If painting or color-matching the new fuel door is required, this should be done before installation to ensure a proper fit and finish.
• Always refer to your Hyundai's specific repair manual or seek advice from a qualified mechanic if you are unsure about any steps in the replacement process.

By following these steps, you can successfully replace the fuel door on your Hyundai, ensuring it functions correctly and maintains the vehicle's aesthetic appeal.

Frequently asked questions