Toyota 4Runner 1996-2002: How to Replace Fuel Door

This is a great introduction to at-home auto repair for the first timer.

By Jennifer Heuertz - January 20, 2016

This article applies to the Toyota 4Runner (1996-2002).

You might need to remove your fuel door to work on the fuel filler neck, or maybe you want to replace it with something fancier than factory. Well, guess what? It could not be an easier job. If you need to remove the fuel door because the lever is no longer functioning, then we've also got your covered.

Toyota 4Runner How to Replace Fuel Door

Materials Needed

  • 10mm socket and ratcheting wrench (or Phillips head screwdriver)
  • Pry tool or flat head screwdriver (if the door is stuck)
  • Tape

Step 1 – Open the fuel door

If the fuel door won't open due to a malfunctioning cable or lever, you will need to pry it open. Use a pry tool, or flat head screwdriver (with the tip wrapped with tape to prevent scratching the paint), to pry open the door. You may need an assistant to fiddle with the lever while you try to open the door. Be careful not to force it.

Removing fuel door
Figure 1. Open the fuel door.

Step 2 – Remove bolts holding fuel door to the vehicle

Use your 10mm socket and wrench to remove the mounting bolts for the fuel filler door.

Removing fuel door
Figure 2. Remove the fuel door hinge mounting bolts.

Step 3 – R&R the fuel door

R&R is shorthand for removal and reinstallation, as used by your friendly local Toyota technicians. Remove the fuel door from the vehicle, and then reinstall the new one. The mounting hardware is painted, so make sure you reinstall the bolts in the same location on the chassis and there are no bare spots on the chassis or the fuel door.

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