Jeep Cherokee Forum

Jeep Cherokee 1984-2001: How to Replace Fuel Door

Here are some tips on getting the Cherokee's fuel door to work correctly; and for those interested, how to make it look real cool.

By Jon LeSage - August 26, 2015

This article applies to the Jeep Cherokee (1984-2001).

For novice owners of a Jeep Cherokee, getting the fuel door to work correctly can become a big deal. It starts with getting the fuel door to open at the gas station, and then making sure it stays closed while driving. Some owners of Jeep Cherokees like to get the exterior “tricked out” with colorful designs, and there are simple ways your fuel door can be replaced and look cool. For owners of a Jeep Cherokee XJ, here are some steps to take.

Materials Needed

  • Missing parts (optional)
  • Custom fuel door cover (if desired)

Step 1 – Find out how the fuel door opens

For some new owners of a Cherokee (and maybe for other passengers riding along), attempting to fuel up at the gas station can become a hassle if they can’t get the fuel door to open. They may be looking inside the Jeep near the driver’s seat, but can’t find a release lever.

You’ll need to learn how to open the fuel door by hand. Some of the Cherokees can be opened by pressing on the edge of the door facing the front of the vehicle, which will leverage it open. If that doesn’t work, try pressing your thumb onto the left side. Once you feel the pressure on that side lift a little bit, press your fingertips into the right side to open the door. Another method to try is pushing on the left side of the fuel door with your fingers, and then pulling the door open on the right side with your thumb or other hand.

Figure 1. Attempting to fuel up at the gas station can become a hassle if the fuel door won't open.

Step 2 – Make sure the fuel door stays shut

Jeep Cherokee drivers can become very annoyed and concerned about their safety if the fuel door keeps flapping open while they’re driving. They find out that they can’t get the fuel door to stay shut.

As you can see from these photos of a red Cherokee, the fuel door may be missing parts. The assembly might be replaced from a parts yard or retail store. One Cherokee driver suggested to another that they take off the rubber bumper and replace it with a small magnet to keep the door fastened in place.

  • Figure 2. As you can see from these photos, the fuel door may be missing parts.
  • Figure 3. This part of the fuel door assembly was missing from the Cherokee in Figure 2.

Step 3 – Customize the cover

Some Cherokee owners love to get their jeeps customized to stand out. That might come from changing colors on the accessories or going with a metallic look.

The measurements for the fuel door covers are usually 7 1/4" in length and 5" in height. Contrasting the colors can make the Jeep stand out – such as a black cover on a yellow Cherokee XJ.

One Cherokee owner is making covers out of 16-gauge aluminum, which can be finished in the “chrome” color or can be primed and painted black. The only difference is that on the newer models, the cover is slightly curved and the older body style cover is fairly flat. The 16-gauge aluminum offers enough flexibility to adapt to the curve.

Figure 4. Cover made out of 16-gauge aluminum.

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