🔧 Tucson - Fuel Cap Replacement

Replacing the fuel cap on your Tucson is a simple beginner repair. A worn, cracked, loose, or missing fuel cap can cause fuel vapor leaks and may turn on the check engine light, often with an EVAP leak code.

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

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⚠️ Safety & Precautions

• ⚠️ Work in a well-ventilated area and keep sparks, cigarettes, and open flames away from the fuel filler area.
• ⚠️ Do not replace the fuel cap while refueling or while fuel vapors are strong.
• ⚠️ Battery disconnect is not required for this repair.

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🔧 Required Tools

You'll need the following tools for this repair:

• Safety glasses
• Nitrile gloves
• Clean microfiber towel

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🔩 Required Parts

HowToo sells all the parts you need for this repair:

• Fuel filler cap - Qty: 1

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📋 Before You Begin

• Park your Tucson on level ground and shift to Park.
• Set the parking brake.
• Turn the ignition fully OFF and remove the key.
• Let the area around the fuel door air out for a minute if you recently refueled.
• Fuel cap tether means the small plastic strap that keeps the cap attached to the vehicle so it does not get lost.

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🔨 Step-by-Step Instructions

Follow these steps in order:

Step 1: Open the Fuel Door

• Use your hand to open the fuel filler door on the driver-side rear quarter panel.
• Put on safety glasses and nitrile gloves.
• Move slowly around fuel vapors.

Step 2: Remove the Old Fuel Cap

• Use your hand to turn the fuel cap counterclockwise until it comes loose.
• If the cap is tethered, let it hang from the tether while you inspect how the tether attaches.
• No torque wrench is used here; the cap is hand-tightened only.

Step 3: Remove the Fuel Cap Tether

• Use your hand to slide or unclip the fuel cap tether from the fuel door area, depending on the replacement cap style.
• If the tether uses a small push-in retainer, gently pull it free by hand.
• Do not pry against painted surfaces.
• Protect paint with the towel.

Step 4: Inspect and Clean the Filler Neck

• Use a clean microfiber towel to wipe the sealing surface on the fuel filler neck.
• The sealing surface is the round metal lip where the rubber gasket on the cap presses to stop fuel vapor from escaping.
• Look for dirt, rust flakes, or damage that could keep the new cap from sealing.

Step 5: Install the New Fuel Cap Tether

• Use your hand to attach the new fuel cap tether to the same mounting point as the old one.
• Make sure the tether does not twist or get trapped by the fuel door.

Step 6: 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.
• On your Tucson, tighten the fuel cap until you hear at least one firm click.
• Torque to hand-tight only; do not use tools.

Step 7: Close the Fuel Door

• Use your hand to close the fuel filler door until it sits flush with the body.
• Check that the tether is tucked inside and not pinched.

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✅ After Repair

• ✅ Start your Tucson and confirm there is no fuel smell around the fuel door.
• ✅ If the check engine light was on because of the old cap, it may take several drive cycles to turn off by itself.
• ✅ A drive cycle means normal driving with the engine fully warmed up, then parked and restarted later.
• ✅ If the check engine light stays on after several days of normal driving, scan for codes before replacing more parts.

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💰 DIY vs Shop Cost

Shop Cost: $45-$95 (parts + labor)

DIY Cost: $15-$35 (parts only)

You Save: $30-$60 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.

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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.