🔧 Fuel Cap - Replacement

The fuel cap on your XC60 is a simple service item, but a worn seal or damaged tether can trigger a check engine light and evaporative emissions leak codes. Replacing it restores a proper seal at the fuel filler neck and helps keep the fuel system sealed correctly.

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

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⚠️ Safety & Precautions

• Keep open flames, sparks, and smoking materials away from the fuel filler area.
• Do not use metal tools near the filler neck sealing surface.
• If the fuel door or cap area is dirty, wipe it clean before installing the new cap.
• No battery disconnect is required for this repair.

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🔧 Required Tools

You'll need the following tools for this repair:

• Clean microfiber cloth
• Flashlight
• Gloves
• Safety glasses

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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 switch the ignition off.
• Open the fuel door and inspect the filler neck for dirt or damage.
• If the old cap has a tether, note how it routes before removing it.

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🔨 Step-by-Step Instructions

Follow these steps in order:

Step 1: Open the fuel door

• Use the fuel door release as normal and open the fuel filler door.
• Inspect the old cap and tether for cracks, missing seal material, or a broken strap.

Step 2: Remove the old cap

• Turn the cap counterclockwise by hand until it comes free.
• If it is attached by a tether, gently unclip or unhook it without forcing the plastic tabs.

Step 3: Inspect and clean the sealing area

• Use a clean microfiber cloth to wipe the filler neck sealing surface.
• Make sure the rubber seal area is clean and dry.
• Do not use oily cleaners here.

Step 4: Install the new cap

• Align the new cap with the filler neck threads.
• Use your hand to turn the cap clockwise until it clicks or stops firmly.
• Do not over-tighten. The cap should seat snugly.

Step 5: Secure the tether

• If your new cap includes a tether, attach it to the fuel door holder the same way the original was routed.
• Make sure it does not interfere with the cap sealing flat against the filler neck.

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✅ After Repair

• Close the fuel door and confirm the cap is seated tightly.
• If the check engine light was on for an evap leak, it may take several drive cycles to clear on its own.
• If the light stays on after a few trips, a scan tool can confirm whether the leak code is gone.

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💰 DIY vs Shop Cost

Shop Cost: $60-$120 (parts + labor)

DIY Cost: $20-$45 (parts only)

You Save: $40-$75 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.