🔧 Tucson - Fuel Cap Replacement

Replacing the fuel cap is a very simple repair on your Tucson. A worn or loose fuel cap can trigger an evaporative emissions leak warning and may turn on the check engine light.

Difficulty Level: Beginner | Estimated Time: 5-10 minutes

---

⚠️ Safety & Precautions

• ⚠️ Work in a well-ventilated area away from flames, sparks, cigarettes, or hot surfaces.
• Do not overfill the fuel tank before doing this repair.
• No battery disconnect is required for fuel cap replacement.
• If fuel vapors are strong, step away and let the area air out before continuing.

---

🔧 Required Tools

You'll need the following tools for this repair:

• Nitrile gloves
• Safety glasses
• Clean microfiber rag

---

🔩 Required Parts

HowToo sells all the parts you need for this repair:

• Fuel filler cap - Qty: 1

---

📋 Before You Begin

• Park your Tucson on level ground and shift into Park.
• Turn the engine off and remove the key.
• Open the fuel door from the outside by pressing the rear edge of the fuel door.
• Put on nitrile gloves and safety glasses.
• A fuel cap seal is the rubber ring on the cap that keeps fuel vapors from leaking out.

---

🔨 Step-by-Step Instructions

Follow these steps in order:

Step 1: Open the Fuel Door

• Use your hand to press the rear edge of the fuel door and swing it open.
• Look at the fuel cap and tether before removing it. The tether is the small plastic strap that keeps the cap attached to the vehicle.
• Take a quick photo first.

Step 2: Remove the Old Fuel Cap

• Use your hand to turn the old fuel cap counterclockwise until it comes loose.
• If the cap is hanging by a tether, use your hand to carefully unclip or slide the tether loop off its holder.
• Do not use pliers or metal tools on the fuel cap area.

Step 3: Clean the Fuel Filler Neck

• Use a clean microfiber rag to gently wipe the metal sealing surface where the cap sits.
• Remove dirt, dust, or fuel residue from the sealing area.
• Do not push dirt into the filler neck opening.

Step 4: Install the New Fuel Cap Tether

• Use your hand to attach the new fuel cap tether to the same mounting point as the old cap.
• Make sure the tether is not twisted or pinched by the fuel door.

Step 5: Install the New Fuel Cap

• Use your hand to place the new fuel cap onto the filler neck.
• Turn the cap clockwise until it clicks.
• Keep turning until you hear at least one firm click.
• Torque by hand only; do not use tools.

Step 6: Close the Fuel Door

• Use your hand to close the fuel door until it sits flush with the body.
• Make sure the tether is fully inside and not trapped outside the door.

---

✅ After Repair

• Start your Tucson and check that there is no strong fuel smell near the fuel door.
• If the check engine light was caused by a loose or leaking fuel cap, it may turn off after several normal drive cycles.
• A drive cycle means starting the vehicle cold, driving normally, and letting the emissions system run its self-check.
• If the check engine light stays on after a few days, the system should be scanned for stored trouble codes.

---

💰 DIY vs Shop Cost

Shop Cost: $40-$90 parts + labor

DIY Cost: $15-$35 parts only

You Save: $25-$55 by doing it yourself!

Shop labor rates vary but typically run $100-$150/hour. This repair takes a shop approximately 0.2-0.3 hours.

---

🎯 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.