🔧 Encore - Fuel Cap Replacement

Replacing the fuel cap is a quick job, but it matters because a worn or incorrect cap can cause fuel vapor leaks and trigger a check engine light (EVAP leak codes). On your Encore, you’ll remove the old cap, install the correct replacement, and confirm it seals properly.

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

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⚠️ Safety & Precautions

• ⚠️ Work outside or in a well-ventilated area; fuel vapors are flammable.
• ⚠️ Keep away from sparks, cigarettes, and hot surfaces.
• ⚠️ Don’t top off the tank after the pump clicks off; it can flood the EVAP system.
• ⚠️ Battery disconnect is not required.

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🔧 Required Tools

You'll need the following tools for this repair:

• Nitrile gloves
• Shop towel
• Flashlight

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🔩 Required Parts

HowToo sells all the parts you need for this repair:

• Fuel cap (EVAP-sealing type) - Qty: 1

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📋 Before You Begin

• Park on level ground and shut the engine off.
• Wait a minute if you just drove, so heat around the filler area can cool down.
• Have your shop towel ready to wipe the filler neck sealing surface.

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🔨 Step-by-Step Instructions

Follow these steps in order:

Step 1: Open the fuel door

• Press the fuel door to pop it open (your Encore uses a push-to-open door).
• Use a flashlight if lighting is poor.

Step 2: Remove the old fuel cap

• Put on nitrile gloves.
• Turn the cap counterclockwise until it releases, then remove it by hand.
• If the cap is tethered (a small strap that keeps you from losing it), let it hang.

Step 3: Inspect and clean the sealing surfaces

• Use a shop towel to wipe the filler neck rim (the round sealing surface the cap presses against).
• Look for cracks on the old cap’s rubber seal (the soft ring that makes it airtight).
• Tip: Dirt on the rim can mimic a “bad cap.”

Step 4: Install the new fuel cap

• Align the new cap and turn it clockwise by hand.
• Keep turning until you feel/hear it click several times (this means it’s tightened to the built-in limit).
• Do not use tools to tighten the cap.

Step 5: Close the fuel door

• Press the fuel door closed until it latches.

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✅ After Repair

• Start the engine and make sure there’s no fuel smell around the filler area.
• If you had a check engine light for an EVAP leak, it may take a few drive cycles to turn off on its own after the seal is fixed.
• If the light stays on, the issue may be the filler neck, purge valve, vent valve, or EVAP lines—not just the cap.

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💰 DIY vs Shop Cost

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

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

You Save: $30-$85 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.