2024 Jeep Wrangler P04B5 Fuel Door Stuck Open TSB

Symptoms

Owners of affected 2024 Jeep Wrangler and Grand Cherokee vehicles may notice the "Malfunction Indicator Lamp (MIL)-On" or "Check Engine Lamp (CEL)-On" illuminating on the dashboard. This indicates that the Powertrain Control Module (PCM) has detected a fault within the system.

Fault Codes / DTCs

When the MIL or CEL illuminates, a scan tool will likely reveal the following Diagnostic Trouble Code (DTC) stored in the Powertrain Control Module (PCM):

• P04B5: FUEL FILL DOOR STUCK OPEN

Diagnosis / Trigger Conditions

The Powertrain Control Module (PCM) triggers the P04B5 code when it detects that the fuel fill door is not closing correctly. Before any repair, technicians are advised to record all DTCs and Wi-Tech Freeze Frame Data, then save a Vehicle Scan Report.

It's important to note that the diagnostic system for the fuel door requires specific driving conditions to re-enable and complete its check. Anytime the fuel door is opened, the vehicle must be driven more than 16 miles to re-enable the diagnostic. After 16 miles have been accumulated, the vehicle must be driven above 25 mph for more than 5 minutes for the diagnostic to complete.

Repair Procedure Summary

Manufacturer communication S2414000001 outlines the diagnostic and repair steps for the "Jeep Wrangler P04B5" fault, depending on whether the DTC is stored or active.

If DTC P04B5 is STORED: If the P04B5 code is stored but not currently active, the Malfunction Indicator Lamp (MIL) will typically turn off after three "Good Trips." A "Good Trip" is defined by specific driving conditions:

1. First Trip: Drive more than 16 miles, then maintain a speed no less than 25 mph for more than 5 minutes.
2. Second Trip: After a key cycle, drive above 25 mph for more than 5 minutes.
3. Third Trip: After another key cycle, drive above 25 mph for more than 5 minutes.

The MIL should extinguish at the start of the Fourth Trip if these conditions are met. Technicians should check the "Good Trip Counter" using a scan tool under the Environmental Data of the DTC to assess the current status.

If DTC P04B5 is ACTIVE: If the P04B5 code is currently active, indicating an ongoing issue, the following steps should be performed:

1. Inspect the Fuel Door Area: Check if the fuel cap tether is blocking the fuel door from closing properly. Technicians should look for impact marks on the tether where the fuel door plunger tappet might have been forced closed against it. Figure 1 in the communication illustrates a "Tether blocking fuel door tappet from closing properly."

   • If the tether is blocking the fuel door: Verify that the fuel door plunger tappet is present on the door (as shown in Figure 2, which depicts a "Fuel Door with Plunger Tappet Missing") and reposition the tether. After repositioning, clear the DTC with a scan tool. It is crucial to inform the customer about the proper positioning of the tether to prevent future occurrences.
   • If the tether is NOT blocking the fuel door: Check if the fuel door is opening and closing properly. If not, inspect the plunger tappet and solenoid for proper alignment or damage. Figure 3 shows how to "Check the tappet for looseness or damage" and "Check the solenoid for looseness or damage."

2. Component Replacement and Circuit Check: If issues are found with the plunger tappet and/or solenoid, replace the fuel door plunger tappet and/or the entire fuel door housing as necessary. Additionally, check the (G66) Fuel Door Status Signal Circuit for any short to ground using service diagnostics.

3. Final Verification: After any repairs or repositioning, clear the code with the scan tool. Then, perform the same three-trip ride evaluation described for stored DTCs to verify that the P04B5 code does not repeat.

Important Warnings

This manufacturer communication, S2414000001, serves as a record of past experiences and does not authorize warranty repairs. It does not provide definitive conclusions about vehicle issues but offers guidance based on similar reported conditions. Owners should be aware that this document does not guarantee a specific repair outcome or warranty coverage.

Owner Action

If your 2024 Jeep Wrangler is displaying a "Check Engine Lamp (CEL)-On" or "Malfunction Indicator Lamp (MIL)-On" with the DTC P04B5, it is recommended to have your vehicle inspected by a qualified service technician. They can accurately diagnose the cause of the "FUEL FILL DOOR STUCK OPEN" code and perform the necessary repairs or adjustments as outlined in manufacturer communication S2414000001.

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Source: NHTSA ID: 10255959