Oil Change Door - Permanent Solution

After 25,905 miles and four oil changes, the hinge crease for the oil change access door on the engine undercover was about 40% separated and ready to fall off, so I decided it was time to fix it.

I installed two aluminum slip joint hinges with stainless steel pins. The hinges are part no. SJA055144-150 available for $2.36 each plus shipping from Northeast Hinge Distributors, 800-882-0120, website: http://www.nehinge.com/product/specialty-hinges.html . The hinges are configured either right-handed (RH) or left-handed (LH). If you use either two RH or two LH hinges, you can have the pins point in the same direction which will allow the cover to be removed, which may be of interest to DIYer’s who use car ramps to change oil and have difficulty swinging the door open due to insufficient ground clearance. This is not an issue for me since I have a car lift in my garage, so I opted for a RH and a LH hinge for opposing pins that make the door more secure so it will not fall off if one or more of the plastic undercover push pins fail. I drilled 1/8†holes and fastened the hinges with 1/8†aluminum (medium length) rivets and rivet washers to prevent the rivets from pulling through the plastic undercover. The aluminum hinges operate smoothly, are feather light but strong, and should last permanently. The hinges will not corrode and the hinge pins should stay clean because they are covered by the hinge barrel. I did not lubricate the pins so as not to attract dirt. If the pins do get dirty, a squirt of brake cleaner and compressed air should clean them.

Anyone with basic tools and DIY capabilities can do this. Just remove the under engine cover (see post “Engine Under Panel removal†by Mendel Leisk) and install the hinges. It’s an easy job and you will be very pleased with the result. Also, you can empower yourself not to worry about whether and how Toyota will fix this problem and can move on to other more enjoyable aspects of life. Attached are a few pictures.

See Post#30 of this thread for a contiuous hinge installed on the upgraded TSB undercover.

 

I also am not satisfied with the small OEM Toyota push pins. They do not refasten securely after they have been removed and replaced a few times. NAPA has push pins that seem to fasten better than the OEM Toyota push pins and they cost less at $4.49 (plus tax) per six or seven pack. The smaller NAPA push pin is part number 665-3278; the larger NAPA push pin is part number 665-2388 (see attached picture).

The small OEM Toyota push pin that connects the oil change door with a tab to the undercover is one that does not refasten as good as I would like. I cured this by using the larger (665-2388) NAPA push pin in this location (see attached picture of pin with red dot). The larger NAPA push pin seems a bit too tight the first time you push it in, but after it is in and out a couple times, the plastic holes in the door and undercover stretch enough to make it a perfect fit. The larger NAPA push pin is also an exact size replacement for the larger OEM Toyota push pin.

I think the above will work until someone comes up with a better alternative to the push pins.

 

No flames. I agree totally with you that Toyota took the cheap way out when designing the oil change door. Toyota didn't need a test to know that the hinge crease was not durable and would fail very soon in the service life of the vehicle. But what does an owner do about it? I suggest a two prong approach. One, complain to Toyota; and, two, mitigate the damage to the car by fixing the problem yourself. Mitigating damage will not violate your rights should Toyota step up and replace the undercover/door under a warranty or service adjustment. It is OK and smart to fix your door before it falls off and rolls into a ditch.

I started this new thread for DIYers because I didn't want the DIY solution to create conflict with those in the other threads who only want to complain to Toyota and think that the DIY approach will undermine their efforts, which it won't.

 

vnhk-The quick release hinge looks good. Do you plan to install it? If you do, please post a report. Thanks.

 

They do look interesting. Below is a direct link to the website:

Plastic Hinges - Pinless Butt & Continuous

 

Looks good, and I like the option of being able to remove the door.