🔧 Grand Cherokee - Fuel Cap Replacement

Replacing the fuel cap is quick, but it matters because the cap seals the EVAP system (the system that traps fuel vapors). A bad cap can cause a fuel smell and can turn on the check engine light with EVAP leak codes.

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

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⚠️ Safety & Precautions

• ⚠️ Do this with the engine OFF and away from sparks, cigarettes, or open flame.
• ⚠️ If you smell strong fuel, stop and check for leaks around the filler neck area before driving.
• ⚠️ Do not top off after the pump clicks off; it can damage 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, tethered) - Qty: 1

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📋 Before You Begin

• Park on level ground and turn the ignition OFF.
• Let the area cool if you were just driving (hot exhaust + fuel vapors is not a good mix).
• Wipe dirt from around the fuel filler area using a shop towel so debris doesn’t fall into the neck.

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🔨 Step-by-Step Instructions

Follow these steps in order:

Step 1: Open the fuel door

• Press/release the fuel door and open it by hand.
• Use a flashlight to look for cracked plastic or heavy rust around the filler area.

Step 2: Remove the old fuel cap

• Turn the cap counterclockwise by hand until it comes off.
• If your cap has a tether (the little retaining strap that keeps you from losing it), let it hang freely.
• Wipe the sealing surface on the filler neck with a shop towel.

Step 3: Check the sealing surfaces

• Inspect the rubber seal (O-ring) on the cap for cracks, flat spots, or swelling.
• Inspect the filler neck lip (where the cap seal sits) for dirt buildup or damage.
• Clean and dry beats “tighten harder.”

Step 4: Install the new fuel cap

• Place the new cap onto the filler neck and turn it clockwise by hand.
• Tighten until it fully seats and clicks (most caps click when correctly tightened). Keep turning until you feel/hear the clicks, then stop.

Step 5: Close the fuel door

• Close the fuel door securely.
• Use a shop towel to wipe any fuel residue if present.

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✅ After Repair

• Start the engine and make sure there’s no fuel smell around the rear quarter.
• If the check engine light was on for an EVAP issue, it may take a few normal drive cycles to turn off on its own.
• If the light does not turn off after a few days, you may need an OBD2 scan to clear the code and/or confirm the cap was the issue.

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💰 DIY vs Shop Cost

Shop Cost: $25-$80 (parts + labor)

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

You Save: $15-$45 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.