2022-2024 Hyundai Tucson Fuel Filler Door Improperly Opening TSB

Hyundai has issued Technical Service Bulletin (TSB) 25-BE-021H to address a condition where the fuel filler door on certain 2022-2024 Hyundai Tucson and Tucson Hybrid vehicles may not open or close properly. This issue is attributed to a faulty fuel filler door release actuator. This bulletin provides instructions for dealerships to replace the affected actuator.

Symptoms

Owners of affected vehicles, including 2022-2024 Hyundai Tucson (NX4, NX4A) and Tucson Hybrid (NX4 HEV) models, may notice that their Hyundai Tucson fuel filler door does not open or close as expected. This can manifest as the door being stuck in a closed position, preventing access to the fuel cap, or failing to latch securely when closed.

Important Warnings for Owners

Hyundai emphasizes that this field action requires both a customer concern and a confirmed case of the related symptom, "FUEL FILLER DOOR IMPROPERLY OPENING OR CLOSING," prior to any repair work. If these justification requirements are not met, any submitted claims may be subject to debit for the dealership. Owners should be aware that the 5-year/60,000-mile New Vehicle Limited Warranty (NVLW) applies to the parts and repair procedure outlined in this TSB.

Diagnosis

To diagnose this issue, a technician will confirm the customer's complaint regarding the Hyundai Tucson fuel filler door not operating correctly. The confirmed symptom of an "FUEL FILLER DOOR IMPROPERLY OPENING OR CLOSING" condition will lead to the replacement of the fuel filler door release actuator.

Repair Procedure Summary

The repair outlined in TSB 25-BE-021H involves replacing the fuel filler door release actuator. The procedure includes several steps:

1. The negative battery terminal is disconnected for safety.
2. The fuel filler door is opened, and the surrounding panel (A) is carefully removed.
3. The mounting arm for the fuel filler door panel is wrapped with a clean rag to prevent damage.
4. A soap and water solution is sprayed around the edge of the fuel filler door housing to assist in its removal.
5. The fuel cap is removed.
6. Plastic trim tools are used to carefully disengage the clips (B and C) holding the fuel filler door housing in place. Technicians are advised to "Avoid tearing the gasket."
7. The fuel filler door housing is gently pulled out, and the connector (D) to the fuel filler door release actuator is disconnected.
8. Plastic trim tools are used to loosen the housing from the fuel filler neck assembly (E), and the housing is then removed.
9. Three screws are removed to detach the old fuel filler door release actuator (F) from the housing.
10. A photo of the production stamp on the original actuator is taken for documentation, or the VIN and repair date are noted if a specific camera function is not used.
11. The new fuel filler door release actuator (Part Number 815A2-P2000QQH) is installed onto the housing.
12. The connector is reconnected.
13. All parts are reinstalled in the reverse order of removal.
14. The negative battery terminal is reconnected.
15. The technician verifies that the fuel door is working properly.

Required Parts

The following part is required for this repair:

• Part Name: Actuator, Fuel Filler Door Release Actuator
• Part Number: 815A2-P2000QQH
• Causal Part Number: 81560-N9000

Warranty Information

This repair is covered under the 5-year/60,000-mile New Vehicle Limited Warranty (NVLW), provided the vehicle meets the mileage and warranty start date criteria. Dealerships should submit claims as a “Campaign” type, using Operation Code 50D154R0 for Tucson (NX4) and Tucson Hybrid (NX4 HEV), or 50D154R3 for Tucson (NX4A). The estimated operation time is 0.3 hours. Repair justification photos are required, and claims may be debited if parts are not returned or documentation is insufficient.

Source: NHTSA ID 11025596, TSB 25-BE-021H