🔧 Fusion - Fuel Cap Replacement

On most Fusions, there isn’t a traditional screw-on gas cap. They use Ford’s Easy Fuel (capless) system, so “replacing the fuel cap” usually means installing a capless-compatible replacement/locking cap or fixing the capless filler if it’s damaged.

Difficulty Level: Beginner | Estimated Time: 5-15 minutes

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⚠️ Safety & Precautions

• ⚠️ Work outside or in a well-ventilated area—fuel vapors are flammable.
• ⚠️ No smoking, sparks, or open flames near the fuel door.
• ⚠️ Turn the engine off and remove the key before opening the fuel door.

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🔧 Required Tools

You'll need the following tools for this repair:

• Flashlight
• Clean shop towels
• Nitrile gloves
• Safety glasses

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🔩 Required Parts

HowToo sells all the parts you need for this repair:

• Fuel cap (Easy Fuel capless-compatible or locking cap) - Qty: 1

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📋 Before You Begin

• Park on level ground and shut the engine off.
• Open the fuel door and use a flashlight to look for dirt or damage around the filler opening.

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🔨 Step-by-Step Instructions

Follow these steps in order:

Step 1: Confirm what style you have

• Open the fuel door.
• If you see a flap system with no screw-on cap, you have Easy Fuel (capless) (most common on your Fusion).
• If you do have a screw-on cap, skip to Step 4.

Step 2: Clean the capless sealing area

• Put on nitrile gloves and safety glasses.
• Use a clean shop towel to wipe the area around the filler opening.
• Tip: Dirt here can trigger EVAP leak codes.

Step 3: Install the replacement/locking cap (capless-compatible)

• Align the new fuel cap with the filler opening.
• Press it in (or thread it on, depending on the cap design) until it’s fully seated.
• If it’s a locking style, use the key and confirm it locks/unlocks smoothly.

Step 4: If you have a traditional screw-on cap (less common)

• Twist the old cap counterclockwise by hand and remove it.
• Inspect the rubber seal (the soft ring). If it’s cracked or flattened, replace the cap.
• Install the new cap and tighten by hand until it clicks (if it’s a click-type).

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✅ After Repair

• Start the engine and check that the fuel door closes normally.
• If you had a check engine light for an EVAP leak, it may take a few drive cycles to turn off on its own.
• If the light stays on, the capless filler seal may be dirty/damaged (not the “cap”).

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💰 DIY vs Shop Cost

Shop Cost: $60-$150 (parts + labor)

DIY Cost: $15-$60 (parts only)

You Save: $45-$90 by doing it yourself!

Shop labor rates vary but typically run $100-$150/hour. This repair takes a shop approximately 0.2-0.5 hours.

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🎯 Ready to get started?

HowToo makes it easy: same-day/2-day shipping on every part, plus all the tools and specialty tools you need! Check out the parts and tools sections below to add everything to your cart.