🔧 Flex - Fuel Cap Replacement

Replacing the fuel cap is a quick job that helps prevent fuel vapor leaks and “Check Engine” lights caused by an EVAP (fuel vapor) leak. On your Flex, it’s a simple twist-off/twist-on part, but getting the seal right matters.

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

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⚠️ Safety & Precautions

• ⚠️ Work in a well-ventilated area and keep away from sparks/flames.
• ⚠️ Turn the engine OFF before opening the fuel door.
• ⚠️ Do not top off the tank after the pump clicks off.
• 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 (OE-equivalent, tethered) - Qty: 1

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📋 Before You Begin

• Park on level ground and shift to Park.
• Shut the engine off and wait 30 seconds to let vapors settle.
• Wipe dirt around the fuel filler opening using a shop towel so debris doesn’t fall in.

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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 rear quarter panel.
• Use a flashlight to check for dirt or damage around the filler area.

Step 2: Remove the old fuel cap

• Put on nitrile gloves.
• Turn the cap counterclockwise until it releases, then pull it away from the filler neck.
• If your cap has a tether (a small retaining strap), let it hang freely.

Step 3: Inspect and clean the sealing area

• Use a shop towel to wipe the filler neck sealing surface (the smooth ring where the cap seals).
• Make sure there are no cracks, deep nicks, or stuck-on debris.
• Clean seal = no EVAP leak.

Step 4: Install the new fuel cap

• Align the new cap and turn it clockwise by hand.
• Continue turning until you feel/hear it click multiple times (typically 1–3 clicks).
• Do not use tools to tighten; hand-tight only.

Step 5: Close the fuel door

• Close the fuel door fully until it’s flush with the body.
• Use a flashlight for a quick final check that the cap sits straight.

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✅ After Repair

• Start the engine and verify there’s no fuel smell near the fuel door.
• If you had a “Check Engine” light for an EVAP leak, it may take a few normal drive cycles to turn off on its own after the cap is sealing correctly.
• If the light stays on, the issue may be a different EVAP leak (not the cap).

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💰 DIY vs Shop Cost

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

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

You Save: $25-$85 by doing it yourself!

Shop labor rates vary but typically run $100-$150/hour. This repair takes a shop approximately 0.2-0.4 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.