🔧 Kona - Fuel Cap Replacement

Replacing your Kona’s fuel cap is a quick job, but it matters because a weak seal can trigger an EVAP leak code (like P0455/P0456) and turn on the check engine light. You’ll remove the old cap, confirm the seal surface is clean, and install the correct replacement cap so it clicks tight.

Difficulty Level: Beginner | Estimated Time: 0.1-0.2 hours

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⚠️ Safety & Precautions

• ⚠️ Work with the engine OFF and away from sparks/flames.
• ⚠️ Do not top off fuel after the pump clicks off.
• ⚠️ If you smell strong fuel odor or see fuel leakage, stop and don’t drive until it’s addressed.
• ⚠️ Battery disconnect is not required.

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🔧 Required Tools

You'll need the following tools for this repair:

• Nitrile gloves
• Safety glasses
• Clean shop towel
• Flashlight

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🔩 Required Parts

HowToo sells all the parts you need for this repair:

• Fuel cap (capless-style not used on your Kona) - Qty: 1
• Fuel cap tether (if damaged, optional) - Qty: 1

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📋 Before You Begin

• Park on level ground and shift to Park.
• Turn the engine off and remove the key/fob from the vehicle.
• Open the fuel door using the exterior fuel door (push-to-open) and confirm the area is clean.

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🔨 Step-by-Step Instructions

Follow these steps in order:

Step 1: Open the fuel door and remove the old cap

• Put on nitrile gloves and safety glasses.
• Open the fuel door and turn the fuel cap counterclockwise until it releases.
• Let the cap hang by the tether (the little strap/cable that keeps it from falling).

Step 2: Inspect and clean the sealing surface

• Use a flashlight to look at the filler neck sealing surface (the round rim where the cap seals).
• Wipe the rim with a clean shop towel to remove dust or grit.
• Grit on the rim can cause EVAP leaks.

Step 3: Install the new fuel cap

• Thread the new cap on by hand, turning clockwise.
• Tighten until you hear/feel at least 1–3 clicks (the cap’s built-in clutch prevents overtightening).
• If the tether is part of the cap, make sure it’s routed the same way as the old one and doesn’t bind.

Step 4: Close up

• Close the fuel door firmly.
• Wipe any fuel residue with the clean shop towel.

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✅ After Repair

• Start your Kona and confirm there’s no fuel smell.
• If you had a check engine light from a loose/bad cap, it may take several drive cycles to turn off on its own.
• If the light stays on after a few days of normal driving, you may need a scan to confirm whether another EVAP leak exists.

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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 0.1-0.2 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.