🔧 Charger - Fuel Cap Replacement

Replacing the fuel cap is quick and helps prevent fuel vapors from leaking (which can trigger a check-engine light and reduce fuel economy). On some Chargers, the system is capless (no traditional cap), so the “cap” may actually be a capless sealing plug/insert.

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

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⚠️ Safety & Precautions

• ⚠️ Work outside or in a well-ventilated area—fuel vapors are flammable.
• ⚠️ Shut the engine off and keep sparks/flames away from the fuel door.
• ⚠️ Do not top off after the pump clicks off; it can cause EVAP faults.
• ⚠️ Battery disconnect is not required.

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🔧 Required Tools

You'll need the following tools for this repair:

• Nitrile gloves
• Clean shop towel
• Flashlight

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🔩 Required Parts

HowToo sells all the parts you need for this repair:

• Fuel cap (correct type for your Charger) - Qty: 1

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📋 Before You Begin

• Park on level ground, shift to Park, and set the parking brake.
• Wipe dirt off around the fuel filler opening using a clean 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

• Press the fuel door to pop it open (most Chargers have a push-to-open door).
• Use a flashlight to look inside and confirm whether you have a traditional screw cap or a capless flap.

Step 2: If your Charger has a traditional screw-on cap, remove it

• Turn the cap counterclockwise by hand to remove it.
• If it’s tethered (attached by a strap), let it hang—don’t pull hard on the tether.
• Wipe the sealing surface on the filler neck with a clean shop towel.

Step 3: Install the new screw-on cap

• Thread the new cap on by hand (clockwise) until it seats.
• Keep tightening until you hear/feel at least 1–3 clicks (clicking means the cap is tight enough).
• Tip: If it won’t click, back off and re-thread.

Step 4: If your Charger is capless, replace the sealing plug/insert (if equipped)

• Some capless setups use a removable sealing plug/insert at the mouth of the filler.
• Pull the old plug/insert straight out by hand, then press the new one in firmly until fully seated.
• Wipe the area with a clean shop towel before closing the door.
• Capless note: The spring-loaded flap is the “seal.”

Step 5: Close the fuel door

• Push the fuel door closed until it latches flush.

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✅ After Repair

• Start the engine and confirm the fuel door is fully closed.
• If you had a check-engine light for an EVAP leak, it may take a few drive cycles to clear on its own after installing a correct, tight cap.
• If the light stays on, the issue may be the capless flap seal, filler neck, or an EVAP leak elsewhere.

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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.