🔧 Cherokee - Fuel Cap Replacement

Replacing the fuel cap on your Cherokee is a quick job that helps prevent fuel vapors from leaking out of the tank (EVAP leak). A loose, cracked, or wrong cap can also trigger a check engine light and cause a “GASCAP”/EVAP-related warning.

Difficulty Level: Beginner | Estimated Time: 0.1-0.2 hours

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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.
• 🧊 If you just drove, let things cool down a few minutes before opening the fuel door.
• 🔋 Battery disconnect is not required.

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🔧 Required Tools

You'll need the following tools for this repair:

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

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🔩 Required Parts

HowToo sells all the parts you need for this repair:

• Fuel cap (EVAP-rated, tethered style) - Qty: 1

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📋 Before You Begin

• 🅿️ Park on level ground and shift to Park.
• Turn the engine off and remove the key/fob from the vehicle.
• Use a flashlight to look at the fuel cap area for dirt or damage.

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🔨 Step-by-Step Instructions

Follow these steps in order:

Step 1: Open the fuel door

• Press/open the fuel door (it’s the small door on the rear quarter panel).
• Put on nitrile gloves and safety glasses.

Step 2: Remove the old fuel cap

• Turn the cap counterclockwise by hand until it comes free.
• If your cap is tethered (a small strap that keeps it from falling), gently guide the cap out without yanking the tether.
• Use a flashlight to inspect the cap seal (rubber ring). If it’s cracked, flattened, or missing, that can cause an EVAP leak.

Step 3: Clean and inspect the filler neck sealing surface

• Use a clean shop towel to wipe the sealing surface where the cap touches.
• Tip: Dirt here can cause a leak.

Step 4: Install the new fuel cap

• Thread the new cap on by hand clockwise.
• Continue tightening until you hear/feel at least one click (that click is the cap’s torque limiter—meaning it’s tight enough).
• Do not use tools to tighten the cap.

Step 5: Close the fuel door

• Close the fuel door firmly.
• Wipe any fuel residue with the clean shop towel.

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✅ After Repair

• Start the engine and confirm there’s no “Check Fuel Cap” message.
• If the check engine light was on for an EVAP leak, it may take a few normal drives to turn off on its own after the cap is sealed correctly.
• If you have a scan tool, you can clear the code after installing the new cap (optional). A scan tool is a handheld device that reads/clears trouble codes.

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💰 DIY vs Shop Cost

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

DIY Cost: $12-$35 (parts only)

You Save: $18-$55 by doing it yourself!

Shop labor rates vary but typically run $100-$150/hour. This repair takes a shop approximately 0.1-0.2 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.