🔧 Challenger - Fuel Cap Replacement

Replacing the fuel cap on your Challenger is a quick job that helps prevent fuel vapor leaks and check-engine lights related to the EVAP system. You’ll remove the old cap from the filler neck and install a new one that seals correctly.

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

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⚠️ Safety & Precautions

• ⚠️ Work in a well-ventilated area and keep away from sparks, cigarettes, or open flames.
• ⚠️ Do not replace the cap right after driving if you smell strong fuel vapors; let things cool down.
• ⚠️ No battery disconnect is 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 cap (OEM-style, sealed) - Qty: 1

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📋 Before You Begin

• Park on level ground, turn the engine off, and remove the key.
• Open the fuel door.
• Use a flashlight to check that the filler neck area is clean and dry.

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🔨 Step-by-Step Instructions

Follow these steps in order:

Step 1: Remove the old fuel cap

• Put on nitrile gloves.
• Turn the fuel cap counterclockwise until it releases, then pull it off.
• If your cap is tethered (a small strap), let it hang safely so it doesn’t scratch paint.

Step 2: Inspect and clean the sealing surface

• Use a flashlight to look at the filler neck opening (where the cap seals).
• Wipe the sealing area with a clean shop towel to remove dust or grit.
• Clean seal = fewer EVAP leak codes.

Step 3: Install the new fuel cap

• Place the new cap onto the filler neck and turn it clockwise.
• Continue tightening until you feel/hear it click (if your replacement cap is a “click type”).
• Do not over-tighten past the clicks; the seal is made by the cap’s gasket.

Step 4: Close up and verify

• Close the fuel door.
• Use a flashlight to confirm the cap sits flat and straight (not cross-threaded).

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✅ After Repair

• Start the engine and check that there’s no fuel smell around the fuel door.
• If you were replacing the cap due to a check-engine light, it may take a few drive cycles for the light to clear on its own; if it doesn’t, you’ll need an OBD2 scan to confirm the issue is resolved.
• If the cap was missing/loose, double-check it after your next fill-up.

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💰 DIY vs Shop Cost

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

DIY Cost: $15-$40 (parts only)

You Save: $15-$50 by doing it yourself!

Shop labor rates vary but typically run $100-$150/hour. This repair takes a shop approximately 0.2-0.4 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.