🔧 Journey - Fuel Cap Replacement

Replacing the fuel cap is a quick job: you’ll remove the old cap from the filler neck and install a new one that seals correctly. A good seal is important because a loose or faulty cap can trigger an EVAP leak (often a check-engine light) and can let fuel vapors escape.

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

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⚠️ Safety & Precautions

• ⚠️ Work in a well-ventilated area away from sparks, cigarettes, or open flames.
• ⚠️ Turn the engine OFF before opening the fuel door.
• ⚠️ Do not top off the tank after the pump clicks off; it can cause EVAP issues.
• 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-sealed, tether-compatible) - Qty: 1

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📋 Before You Begin

• Park your Journey on level ground and set the parking brake.
• Shut the engine off and remove the key.
• Use a flashlight to look at the fuel filler neck area for dirt or damage.

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🔨 Step-by-Step Instructions

Follow these steps in order:

Step 1: Open the fuel door

• Open the fuel door on the driver side 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 you hear a small “whoosh,” that can be normal pressure release.
• Set the old cap aside on a clean surface or hold it with a clean shop towel.

Step 3: Inspect and clean the sealing area

• Use the flashlight to check the filler neck rim (the round sealing surface) for cracks, rust, or debris.
• Wipe the rim gently with a clean shop towel so the new cap can seal.
• Clean seal area prevents “small leak” codes.

Step 4: Transfer the tether (if equipped)

• If your old cap has a small strap/cord (called a “tether,” which keeps the cap from getting lost), move it to the new cap if the new cap doesn’t already include one.
• Most tethers clip into a small slot on the fuel door area—use your fingers and work gently to avoid breaking the clip.

Step 5: Install the new fuel cap

• Thread the new cap onto the filler neck by hand (clockwise).
• Tighten until you feel it fully seat and you hear/feel at least 1–3 clicks (cap-dependent). This is the built-in “clutch” that prevents over-tightening.
• Torque spec: Not applicable (hand-tight until it clicks).

Step 6: Close up

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

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✅ After Repair

• Start the engine and make sure you don’t see “GASCAP”/fuel-cap warnings (if your cluster displays them).
• If you replaced the cap due to a check-engine light: the EVAP monitor may take a few normal drive cycles to reset and turn the light off on its own. If the light stays on, the vehicle may need a code scan.
• At your next fill-up, confirm the cap clicks and the door closes normally.

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💰 DIY vs Shop Cost

Shop Cost: ₹800-₹2,000 (parts + labor)

DIY Cost: ₹500-₹1,500 (parts only)

You Save: ₹300-₹500 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.