🔧 XT5 - Fuel Cap Replacement

Replacing the fuel cap is a quick job that helps your XT5 maintain proper EVAP system sealing (the system that traps fuel vapors). A worn or incorrect cap can cause a check engine light, fuel smell, or “tighten gas cap” messages.

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

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⚠️ Safety & Precautions

• ⚠️ Work in a well-ventilated area, away from sparks, cigarettes, or open flames.
• ⚠️ Turn the engine OFF before opening the fuel door.
• ⚠️ Don’t top off the tank after the pump clicks off (can damage EVAP components).
• 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 (OEM-style, tethered if equipped) - Qty: 1

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📋 Before You Begin

• Park on level ground and shift to P.
• Turn the ignition OFF and remove the key/fob from the vehicle.
• If you just drove, wait a few minutes so any tank pressure can settle.

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🔨 Step-by-Step Instructions

Follow these steps in order:

Step 1: Open the fuel door

• Use your hand to press the fuel door to release it (push-to-open style), then swing it open.
• Use a flashlight to check the area for dirt or damage.

Step 2: Remove the old fuel cap

• Use your hand (with nitrile gloves) to turn the cap counterclockwise until it comes off.
• If your cap has a strap (tether), let it hang without twisting it.
• Tip: Go slow if you hear a hiss.

Step 3: Inspect and clean the sealing area

• Use a flashlight to inspect the filler neck sealing surface (the round lip the cap seals against).
• Use a shop towel to wipe away dust or grit. Don’t push debris into the opening.

Step 4: Install the new fuel cap

• Place the new cap onto the filler neck and turn it clockwise by hand.
• Keep turning until it is fully tight; most OEM-style caps will “click” when correctly tightened (that click is a built-in clutch so you don’t overtighten).
• Tip: If it doesn’t click, keep snugging by hand.

Step 5: Close the fuel door

• Push the fuel door closed until it latches flush with the body.

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✅ After Repair

• Start your XT5 and confirm there are no fuel smells around the fuel door area.
• If you had a check engine light related to the cap/EVAP, it may take a few drive cycles to clear on its own; a scan tool can clear codes immediately.
• Re-check the cap after your next fill-up to ensure it’s still tightening/clicking normally.

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💰 DIY vs Shop Cost

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

DIY Cost: $15-$45 (parts only)

You Save: $25-$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.