🔧 Tucson - Fuel Cap Replacement

The fuel cap seals the fuel tank so fuel vapors stay contained and the emissions system can run its self-checks. Replacing it is one of the easiest repairs on your Tucson and can help fix an evaporative emissions leak code or a “check fuel cap” warning.

Difficulty Level: Beginner | Estimated Time: 2-5 minutes

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⚠️ Safety & Precautions

• ⚠️ Work in a well-ventilated area and keep flames, cigarettes, sparks, and hot tools away from the fuel filler area.
• ⚠️ Turn the engine OFF before opening the fuel door.
• ⚠️ Do not overfill the tank after replacing the cap; stop when the pump clicks off the first time.
• ⚠️ Battery disconnect is not required for this repair.

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🔧 Required Tools

You'll need the following tools for this repair:

• Nitrile gloves
• Safety glasses

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🔩 Required Parts

HowToo sells all the parts you need for this repair:

• Fuel cap - Qty: 1

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📋 Before You Begin

• 🅿️ Park your Tucson on level ground and set the parking brake.
• 🔑 Turn the ignition OFF and remove the key.
• 🧤 Put on nitrile gloves and safety glasses.
• ⛽ Open the fuel door using the fuel door release.

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🔨 Step-by-Step Instructions

Follow these steps in order:

Step 1: Remove The Old Fuel Cap

• Use your hand to turn the old fuel cap counterclockwise until it releases from the filler neck.
• If the cap has a tether strap, use your hand to unclip the tether from the fuel door or filler area.
• Set the old cap aside away from the open filler neck.
• Keep dirt away from the opening.

Step 2: Inspect The Filler Neck Seal Area

• Use your gloved hand to check the metal filler neck where the fuel cap seal touches.
• Look for dirt, rust buildup, dents, or debris that could stop the new cap from sealing.
• If needed, wipe the sealing surface with a clean dry cloth.
• Do not use sharp tools near the filler neck.

Step 3: Install The New Fuel Cap

• Use your hand to place the new fuel cap squarely onto the filler neck.
• Turn the cap clockwise until it clicks several times.
• The clicking sound means the cap has reached its built-in tightening limit.
• No torque wrench is used for this cap; tighten by hand only until it clicks.

Step 4: Reattach The Tether If Equipped

• Use your hand to clip the new fuel cap tether onto the fuel door or filler area if your replacement cap includes one.
• Make sure the tether does not get pinched when the fuel door closes.

Step 5: Close The Fuel Door

• Use your hand to close the fuel door until it latches flush with the body.
• Confirm the door sits even and does not press hard against the new cap.

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✅ After Repair

• ✅ Start your Tucson and confirm there is no fuel smell around the fuel door area.
• ✅ If the check engine light was on for an EVAP leak, it may take several drive cycles to turn off by itself.
• ✅ You can use an OBD-II scan tool to clear the code sooner, but the emissions monitor still needs normal driving to retest.
• ✅ If the warning returns, inspect the filler neck sealing surface and confirm the cap is the correct replacement for your Tucson.

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💰 DIY vs Shop Cost

Shop Cost: $45-$110 (parts + labor)

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

You Save: $35-$75 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.