🔧 Regal - Fuel Cap Replacement

Replacing the fuel cap is a quick job that helps prevent fuel vapor leaks and can stop an EVAP-related check engine light if the old cap seal is cracked or the ratcheting clicks no longer work.

You’ll remove the old cap, inspect the filler neck seal surface, and install a new cap until it clicks.

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

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⚠️ Safety & Precautions

• ⛽ Work outdoors or in a well-ventilated area; fuel vapors are flammable.
• Do not smoke or use open flames/sparks near the fuel door.
• Shut the engine off and keep the key fob away from the car while working near fuel vapors.
• Open the cap slowly to release any tank pressure.
• 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 - Qty: 1

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📋 Before You Begin

• Park on level ground and shift to Park.
• Turn the engine off and wait 30 seconds.
• Unlock the car; on the Regal the fuel door may stay locked when the doors are locked.
• Assumption: fuel door is push-to-open.

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🔨 Step-by-Step Instructions

Follow these steps in order:

Step 1: Open the fuel door

• Use your hand to press on the rear edge of the fuel door until it pops open.
• If it won’t open, use the key fob to unlock the doors again, then press the fuel door.
• Use a flashlight if you need better visibility.

Step 2: Remove the old fuel cap

• Put on nitrile gloves and safety glasses.
• Turn the cap counterclockwise slowly to release any pressure, then continue turning until it comes off.
• If your cap is tethered (attached with a strap), let it hang without twisting the strap.

Step 3: Inspect and clean the sealing area

• Use a flashlight to look at the filler neck opening (where the cap seals).
• Use a clean shop towel to wipe off dust, sand, or fuel residue from the sealing surface.
• Check the old cap’s rubber seal; cracks/flat spots are a common reason for leaks.

Step 4: Install the new fuel cap

• Place the new cap on the filler neck and turn it clockwise by hand.
• Tighten until you hear/feel it ratchet and click: tighten until 1–3 clicks.
• Do not use tools to tighten the cap.

Step 5: Close the fuel door

• Push the fuel door closed with your hand until it latches.
• Use a clean shop towel to wipe any spilled fuel from the paint, if needed.

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✅ After Repair

• Start the engine and confirm there’s no “Check Gas Cap” message (if equipped).
• If the check engine light was on for an EVAP leak, it may take a few drive cycles to turn off on its own after installing a good cap.
• If the light stays on after several normal trips, the issue may be elsewhere in the EVAP system (not just the cap).

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💰 DIY vs Shop Cost

Shop Cost: $40-$120 (parts + labor/diagnostic)

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

You Save: $28-$85 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.