A vehicle fuel door assembly includes a cover comprising a plurality of alignment features fixedly disposed relative to the cover, the plurality of alignment features formed of an elastically deformable material. The assembly also includes a hinge comprising a plurality of alignment elements fixedly disposed relative to the hinge, each of the alignment features interferingly, deformably and matingly engageable with a respective alignment element, the alignment features elastically deforming to an elastically averaged final configuration that aligns the cover relative to the hinge in six planar orthogonal directions by averaging the elastic deformation of the respective alignment features.