🔧 Cherokee - Fuel Cap Replacement

On your Cherokee, many trims use a capless fuel system (no screw-on cap). If yours does have a screw-on cap, replacement is a quick swap to prevent EVAP leaks and a check-engine light.

Difficulty Level: Beginner | Estimated Time: 0.1-0.3 hours

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⚠️ Safety & Precautions

• ⚠️ Work outside or in a well-ventilated area
• ⚠️ No smoking, sparks, or open flames near the fuel door
• ⚠️ Turn the engine OFF and remove the key/fob from the vehicle
• ⚠️ If you smell strong fuel odor after replacement, stop and re-check the seal
• Battery disconnect is not required

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🔧 Required Tools

You'll need the following tools for this repair:

• Nitrile gloves
• Clean shop towel
• Flashlight

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🔩 Required Parts

HowToo sells all the parts you need for this repair:

• Fuel filler cap - Qty: 1
• Fuel cap tether - Qty: 1

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📋 Before You Begin

• Park on level ground and shift to P.
• Turn the engine OFF and let any fuel vapors settle for a minute.
• Open the fuel door and use a flashlight to check what you have: a screw-on cap or a capless spring-loaded flap.

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🔨 Step-by-Step Instructions

Follow these steps in order:

Step 1: Open the fuel door

• Press the fuel door to open it, then hold it open by hand.
• Use a flashlight to confirm the style:
• If you see a cap you can grab and twist, follow Steps 2–5 (Screw-on Cap).
• If you only see a metal/plastic flap you push the fuel nozzle through, skip to Step 6 (Capless System).

Step 2: Remove the screw-on fuel cap

• Wear nitrile gloves.
• Turn the cap counterclockwise until it comes off.
• Tip: Turn slowly to avoid splashback.

Step 3: Inspect and clean the sealing surface

• Use a clean shop towel to wipe the filler neck where the cap seals.
• Look at the cap’s rubber seal. If it’s cracked/flattened, that can cause EVAP leaks.

Step 4: Transfer or attach the tether

• If your cap uses a tether (the strap that keeps the cap from getting lost), move it to the new cap if needed.
• If it snaps in, push it on by hand until fully seated.

Step 5: Install the new screw-on fuel cap

• Thread the new cap on by hand and turn it clockwise.
• Tighten until it’s snug and you feel/hear it finish tightening.
• Torque: Not service-torqued (hand-tight only).

Step 6: If you have a capless fuel system (no cap present)

• If there is no removable cap, your Cherokee does not use a replaceable fuel cap.
• Use a flashlight to check the capless flap area for dirt or damage.
• Use a clean shop towel to gently wipe around the opening (do not force anything into the flap).
• If you’re getting a check-engine light for an EVAP leak, the common fixes are not a “cap,” but inspection/replacement of the capless filler neck seal or related EVAP components.

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✅ After Repair

• Close the fuel door and make sure it latches flush.
• Start the engine and check for a fuel smell near the fuel door area.
• If you replaced a cap because of a check-engine light, it may take a few drive cycles to clear on its own, or you can clear it with a scan tool.

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💰 DIY vs Shop Cost

Shop Cost: $30-$90 (parts + labor)

DIY Cost: $10-$35 (parts only)

You Save: $20-$55 by doing it yourself!

Shop labor rates vary but typically run $100-$150/hour. This repair takes a shop approximately 0.1-0.3 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.