Fuel Door Release Actuator Replacement Cost Estimate

A problem with a manual fuel door release actuator that will not open or close properly can usually be detected in the feel of the release lever. If the lever is significantly lose, the cause could be a broken cable. If the lever does not move, or moves with too much effort, the cable or release pin could be dirty or corroded. A technician will actuate the lever and sense if the cable or actuator is faulty. If the vehicle has an electric actuator, the technician will determine if the problem is with the switch or the actuator by testing for power (voltage) at the switch and at the actuator. In the case of an actuator that operates with the central locking system, a scan of the Body Control Module may be necessary.

The general replacement procedure for most fuel door release actuators is similar, however, access to the actuator (and attachment methods) can differ quite a bit. On some vehicles, the boot around the fuel filler neck (where the fuel is added) is removed and the actuator is installed through the fuel access. On other vehicles, it is necessary to remove trim components inside the trunk or in the wheelhouse for access. Electric actuators have a wire plug that needs to be disconnected. Manual actuators sometimes require that the entire cable system be replaced together as a unit with the actuator.

Because it can be difficult to open the fuel door to add fuel should the actuator fail, RepairPal recommends having the problem diagnosed and repaired as soon as symptoms begin. Most vehicles that have locking fuel doors also have some form of manual release in the trunk, but the release can be inconvenient to access, especially at a gas station.

Care should be exercised any time work is being performed around the fuel system. Although the fuel filler neck is designed to keep vapors from moving freely, accidents can still happen.

Replacement of a fuel door release actuator can be done by someone with intermediate DIY experience. With vehicles where an electric actuator is tied into the central locking system, a diagnostic scan and computer reset may be required.