I had the same bad Experience in an heavy Rainy day.
I did request the Application of the remedy indicated into LSB relating to such issue, but the local Dealer refused as fuel door was still opening even if being just ajar!
At the end They performed the fix that was the relubrication of the fuel door neck!!
Now it works correctly since months.
My NX is a MY2022 J production 450h+ model.
Great car after an uncountable number of Safety recalls and SW updates, but DC-DC converter fix that for Italian Market is still Waiting for operative instructions to apply remedy!!

 

dc88 - Did they replace your outer door that’s painted colour of your car too? Did it align up better than original? Mine has terrible alignment like the image shown earlier and just last night it stopped opening so I had to use access port in back hatch to fill up with fuel. I’m hoping the replacement fits much better.

 

Hello TheCDN, the dealership didn't replace the outer gas door. It appears the issue causing my fuel door not to open might be diffrent from yours. Regardless, you should not have to use the port in back hatch to open the fuel door.

 

For 2023 NX 350 fuel door emergency release, you can access from back cargo on the driver side and right above the little side-wall net storage. Open the cover using credit card and put your hand in the hole and reach the plastic lever right above. Pull the the plastic lever and the fuel door will open.

Pull the emergency lever to release fuel door

 

that's what the $0.25 screwdriver is for.

 

Reviving an old thread. It's been very cold around here lately, wondering if this has something to do with it. The last 2 times I filled up with gas (last night and 2 weeks ago), I could not get the fuel door open. I'd press the release button and could hear a click. The door moves a bit but would not open. By the time I got back to the fuel door, the latch had reset. Appears it's not frozen stuck as it does move. So I had to have my Wife reach over from the passenger seat, press and hold the button while I opened the door with my fingernails. The car had not just been washed. Is anyone else experiencing this again? Last time I had this, took the car in and they replaced the filler door.

 

I too have had my fuel filler door latch system replaced and even afterwards it never seemed to work like all my other doors did. That is to say you pull the lever from the inside (on my previous cars) and that door flings open with authority, why, because there was a strong metal tab that acted like a spring and pushed out the door with some force. This one on the NX has nothing present to apply force to swing the door open. There is a black plastic latch assembly, not unlike you see on your front door of your home, and the dealer lubricates this extensively with a white coloured silicone grease, in the hope that the pin will retract fast enough to overcome the tension of the latch mechanism and allow the door to open up just barely beyond the closed position. My guess is the fault lies in the simple fact that the latch pin isn't retracting in the cold weather. And if it doesn't retract you can't even pull it open with a plastic pry tool to get it to open. That pin has to get out of the way to even hope to open the door. It's my understanding the initial design flaw was the force used to pull the pin was too feeble for our colder climates, and now I think they under estimated in their upgraded replacement, how much more stronger it needed to be!

It is a very feeble design at best and cold weather will most likely infringe on it's operation. I haven't had a problem with mine in this frigid weather so far but I did spray some silicone grease to the latch in November with my fingers crossed that it would stave off any issues as temp dropped. Last week I took it to a hand wash booth to spray off all the salt. I immediately wiped down the fuel door to remove any moisture when done.

I thought I would check mine just now as I plan to go get fuel today in this cold weather. My door wouldn't open either! I pushed on it around the edges, I still had some ice that had formed even though I dried it up at car wash. Driving the car home the wind / airflow must've moved the water around and it settled in crevices and edge of door. It did pop open and I put some more grease on it. It's working fine now, but it proves how feeble this assembly is especially in cold weather!

 

How did Lexus manage to pull this off?

 

Not sure what you're asking here? Practically everything to do with the fuel door except the painted metal door itself is plastic! I believe the hinge and latch assembly is accessed from the interior, needing to remove the inner left side trunk carpeted panel.

 

I was being facetious. Never heard of fuel door issues like this for any brand. This has to be a new "achievement" for Lexus.

 

It's absolutely pathetic I'd say! Just an FYI the RX and TX have endured similar issues at launch but seem to have corrected things rather quickly. I think the NX was the guinea pig for this new design. And yet even '25 MY cars I see at my dealership are still nowhere near being aligned correctly. They use to be to be the world leader in fit and finish, and set the standard for panel gap fit up of 3mm or less. Their first foray into the luxury market with the LS was the pinnacle right out of the box. I've had my door alignment (so called) repaired 3 times now and I've given up.

 

Same for me,was thinking someone tried to open it and damaged.it is misaligned,presses to right side against latch and that causes it not to open.not any grease helps.very hard to reach mechanism,u need to disassemble trunk interior parts.i think it just needs to move a bit to the left.
so problem is not a latch,misaligment causes that

 

idk it still looks misaligned how it works properly?did they change whole unit or just a latch?

 

I will also point out that I've only had the plastic hinge assembly mechanism replaced. They never want to replace the painted steel door. Now I ask you a very simple alignment question here, which one of a two piece assembly is causing the misalignment? Well it would start out as fifty fifty, could be either one. Try one and if that didn't work replace the other. Hmm, I haven't heard of anyone having their painted steel door assembly replaced. And from what I've seen online the painted door is bought already painted just as other trim pieces are. The fact that they all look like they're off centre towards the right side is a simple fix with a change to the stamping die and assembly of the steel door as it's two pieces at least. The outer surface and the inner structure which is a stiffener panel to give it rigidity.