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Fuel Door

 Shop Fuel Door

If your fuel door is severely scratched, dented, or won't latch on properly, you'll have to replace it as soon as possible. Once this part becomes damaged, the simple task of filling up the gas tank becomes a hassle. Just imagine if you're in a gas station and in a hurry to fill up the tank. As soon as you try to open the fuel door, you discover that it's stuck and won't open. So before you get into a similar situation, replace that busted door as soon as you can. Fortunately, replacing this component isn't that difficult. Here are the instructions:

Tools you'll need:

  • Socket and ratchet
  • Drill and bit or screwdriver

Step 1: Remove the busted door.

Depending on your car's make and model, you either have to: drill out the rivets that attach the old door to the vehicle using a drill and the right size of bit, or use a screwdriver to remove the screws that hold the fuel door in place. When drilling out or unscrewing, make sure that you don't scratch your vehicle's body.

Step 2: Place the nuts, screws, or bolts onto the holes of the replacement door.

Jam the nuts, screws, or bolts in place, but don't tighten them down yet. You still need to adjust the door into place until the fit is just right.

Step 3: Slide the new door in place.

Once the nuts or screws are attached halfway into the holes, slide the new door in place. Adjust until it fits snugly onto the body of your vehicle.

Step 4: Attach the o-rings or nuts to secure the bolts or screws.

Fuel tank door kits usually come with o-rings you can use to secure the screws or bolts in place. These gaskets also help the screws and bolts strengthen their grip so they won't easily get loose even when exposed to moisture and extreme temperatures.

Step 5: Bolt the fuel door in place.

If everything fits, screw or bolt the fuel door until it's snugly attached to the vehicle's body. Close and open the door to see if the door is tightly attached. Look for any signs of wobbling or misalignment. If the door isn't properly aligned, remove the screws or bolts, adjust the door, and bolt it back again.

Installation tips:

  • Depending on your vehicle's make, you may have to remove and reinstall a snap ring, fuel shroud, and plastic spacers when attaching a new door. Consult your vehicle instruction manual for the exact instructions.
  • When replacing a locking door with a busted locking mechanism, you can simply remove this mechanism by poking the hole beneath it with a sharp object. Once this hole is poked, the mechanism should slide out easily. Insert the new lock into the slot until it snaps in place.
  • If you don't want to use the o-rings or gaskets included in the kit when securing the screws or bolts in place, you can just use small nuts instead. These items can be bought from any hardware store and are very easy to install.