🔧 Fuel Cap - Replacement

Your XC90 uses a sealed fuel cap to help keep fuel vapors in the tank and the evaporative emissions system working correctly. If the cap is cracked, the seal is torn, or it no longer clicks tight, replacement is the fix.

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

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⚠️ Safety & Precautions

• Work away from open flames, sparks, and cigarettes. Fuel vapors are flammable.
• Do not overtighten the new cap. Tighten until it clicks, then stop.
• If the cap was lost while refueling, inspect the filler neck for dirt 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 towel
• Flashlight
• Safety glasses
• Nitrile gloves

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🔩 Required Parts

HowToo sells all the parts you need for this repair:

• Fuel cap - Qty: 1
• Fuel cap tether clip - Qty: 1

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📋 Before You Begin

• Park on level ground and turn the engine off.
• Make sure the fuel door area is clean before opening the cap.
• If the old cap is still hanging by the tether, do not let it drag on the ground.

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🔨 Step-by-Step Instructions

Follow these steps in order:

Step 1: Open the fuel door

• Press the fuel door to release it, then swing it open.
• Use a flashlight if the area is hard to see.

Step 2: Remove the old fuel cap

• Turn the cap counterclockwise by hand until it comes free.
• If your old cap is tethered, let it hang gently without twisting the strap.
• Keep dirt away from the filler neck.

Step 3: Inspect and clean the seal area

• Use a clean microfiber towel to wipe the fuel filler neck and the cap sealing surface.
• Look for cracks, missing rubber seal material, or debris around the opening.

Step 4: Install the new fuel cap

• Align the new cap with the filler neck and turn it clockwise by hand.
• Tighten until you hear or feel it click. Do not use tools.
• If the cap has a tether clip, secure it in the same position as the original.

Step 5: Close the fuel door

• Close the fuel door firmly until it latches.
• Make sure the cap is seated squarely and the door closes without interference.

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✅ After Repair

• Start the engine and check for any fuel smell near the filler area.
• Drive normally for a few trips so the EVAP system can recheck itself.
• If a check engine light was on for the fuel cap, it may clear after several drive cycles.
• If the light stays on, the code may need to be cleared with a scan tool.

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💰 DIY vs Shop Cost

Shop Cost: $60-$140 (parts + labor)

DIY Cost: $15-$40 (parts only)

You Save: $45-$100 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.