Instructables
If you own a Honda Civic (or Accord) circa 2005 ('01-'05) you may eventually run into a problem with your fuel door not opening when you push the lever. This is a common issue and at least one person is trying to monopolize on it. http://fueldoorfix.com The problem is caused by wear and tare (rust / cracking plastic) at the connection point between the control lever and the cable that runs to the door-latch mechanism. This issue can be fixed in about 1.5 hours and for under $3; avoiding a trip to the dealership to replace the entire cable ($40), and paying for labor because your 3yr/36k warranty has expired. Here's how...

Overview of Steps
1) Tools/Materials
2) Open Fuel Door (so you can gas up until you fix it)
3) Remove Panel Over Driver's Seatbelt
4) Remove Panel Over Hood Lever
5) Remove Panel Over Fuel Door / Trunk Lever
6) Remove Fuel Door / Trunk Lever Assembly
7) Make Component
8) (Optional) Remove Crumbling Tension Piece
9) Install Component

 
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Step 1: You'll Need

Tools:
- Flathead screwdriver
- Phillipshead screwdriver
- 10 mm hex socket wrench
- Dremel or Hacksaw

Materials: (found at Home Depot)
- 1/2" diameter PEX pipe (5' length found in plumbing - $1.78)
- 2 x 1/4" hitch pins (2 pack found in bolts/hardware - $0.59)

Step 3: Remove Panel Over Driver's Seatbelt

This panel overlaps the panel you want out.  Remove it by tugging it up 1/2", prying away the sides that hug the frame, and swinging the bottom frontwards (towards car front).
Blacorc4 months ago

Quick question - In my attempts thus far to repair the cable, I have stripped it back a bit and snipped off some of the metal bracing inside the insulation. Would I need to adjust the size of the component you describe?

a.gasior (author)  Blacorc4 months ago

That rusty metal piece that caps the insulated part of the cable is what will ultimately provide the brace for the pins inside the plastic PEX piece that I sketched. So yes, if you change the length of that piece you'll have to adjust for that change by moving where the pin holes are on the PEX piece (probably the middle pin).

antmat5 months ago
Awesome, Awesome, awesome fix! Best and easiest out there!
Bobptoo2 years ago
I tried to get to the fuel cable but had a hard time pulling back the cover after removing the plastic fastener. So I gave up on it and went to the switch up front and dismounted it as you prescribe. I found that the plastic piece was in good shape and was able by forcing the cable forward to open my fuel door. I then lubricated the cable at the plastic area and operated it several times and it worked fine. Able to open fuel door okay. Want to thank you for all the information, a great site. BobP 04/2/2012
chinyeel2 years ago
Great post, thanks, but as I am not too mechanically inclines and needed my tank opened and fixed. I had no choice but to leave it at Honda Markham for 1.5 hrs and they scammed me for $319.15, I know, don't say it, these dealerships are real rip-off artists. Invoice states: Parts = $84.43 & Labour $220.00 plus tax.
dukale2 years ago
a.gasior,
Excellent DIY instruction as well as engineering. I have 02 Accord, and your posting worked charm, saved bundle of money, and headache. I only had to use one hitch clip, but added couple of cable tie to hold the assembly in place. Total time spent was about two hours (internet surfing, trip to hardware store, part prep, and installation).
jknaur2 years ago
Great Fix! Saved us $200. Took a little longer, didn't have a vise, so my cuts weren't as precise as they needed to be. Took a little tinkering with the Dremel to resolve. I also found it necessary to remove the old crumbling piece to make the new one fit. Couple of points for the amateurs out there like me. The new piece fits much better if you remember to put it back under the carpet. Be careful to pull the entire assembly as far forward as you can when you are tightening the bold that holds it to the side of the car. If you don't, the lever runs into the cover when you open the trunk and you have to take all the molding off to adjust it. Thanks again! This really is a great fix!
chirag.8272 years ago
Awesome... Yesterday dt: 10/02/2011, I just applied above instructions to fix the broken fuel door and it worked. It was bit tough to make component and fit cable through hitch pin but overall - I appreciate and thank you for saving my $150.
mreds13 years ago
Thanks a.gasior! This was an excellent post. The instructions couldn't have been more clear and exact. I did everything as you indicated and it was a piece of cake. I did use my table saw with the blade set to 1/8th inch to cut the slots. My total cost was about $5 and it took me about an hour. Works like a charm. Nice to know that I wasn't putting out $150+ to Honda. Cheers!
Very clear post. I have an 01 civic, and the same instructions apply. Thanks for posting this! Saved me a bunch of cash.
What a drag that I found this today in stead of a month ago.  I had the same problem and had the dealer fix it a few weeks ago.  Nice 'Ible by the way.
skatawandi4 years ago
What a great solution! Took me about 45min and about 4 dollars for parts. The best thing is, the fix appears to be permanent! I would make sure to add the zip tie holding the PEX pipe in place; it tends to slip out otherwise.
firdawsi5 years ago
What a great fix! I only wish I had a Civic to apply it to :(