Fuel Door Locked/ Broken

Hey everyone. Glad to see all the van people in one area after I've been bouncing around the old forums for answers here and there. First time posting and I've got a question. I picked up my second Previa last weekend and realized today that the fuel door release isn't working. I realize there is a broken spring in there but how can I get the door to pop open to get at it (and also to get gas) without damaging the bodywork? I already tried stuffing a pack of cigs under the lever and opening it but it didn't work. This van is in nice shape (unlike my other one although it runs great just was someones work vehicle at one point) and I'd like to keep it that way. Thanks for the advice and a pic of the new van below.

Attachment 4835

Are you sure the cable is connected?

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Originally Posted by zak99b5

Are you sure the cable is connected?

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Thanks for the reply. I got it. Had the wife hold it while i got the door open.

I had to do the same thing on my Sequoia when the fuel door wasn't opening properly and then I just adjusted the bracket that locking latch hooks onto and now it works perfectly, I'm not sure if the Previa fuel door is set up the same way? I don't have one yet.... hehehehe:wnk:

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Originally Posted by JDM VANMAN

I had to do the same thing on my Sequoia when the fuel door wasn't opening properly and then I just adjusted the bracket that locking latch hooks onto and now it works perfectly, I'm not sure if the Previa fuel door is set up the same way? I don't have one yet.... hehehehe:wnk:

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The issue ended up being a broken spring in the fuel door. Should be able to source one at the junkyard.

Here is an easy, cheap and durable fix to a common problem - the broken fuel door spring.

This is the PO's fix on my newly purchased '92. It works currently, is even lower budget, but looks prone to unpredictable failure...

Attachment 13517


Upper left screw from inside fuel door. Conical spring (for stability) from Ace. Nippers for nipping. Don't use a too stiff spring - not much force is necessary to open the door.

Attachment 13518


Spring shortened for better length, and last coil bent tighter to hold screw. Don't worry about getting the cut coil perpendicular to the coil axis - you can actually use it to your advantage when installing in order to get the door and spring to contact nicely.

Attachment 13519

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There ... no more 30+ year old plastic bits to break.

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Stick a felt pad to the door if you're concerned about the spring scratching the paint.

Ah, the old red tape trick lol. :LOL2: Glad I have a parts van, but I think I've used that part already.

The Coil/Spring Jig seems pretty innovative. Does it create any issues with closing the cover, or it locking back into place? Our Previa also has the same problem where the gas door won't open. We've been using our phone to keep the gas tab propped up so that we can pry the cover loose. Initially, I removed the Latch that clips the cover into place, though the cover would flap around while driving.

Just make sure the spring you choose isn't very stiff. It should be quite easy to pinch it with your fingers. When mounted and not compressed, i.e. with the door open, the spring should stick out about 1/8" beyond the bodywork.