🔧 Crosstrek - Fuel Cap Replacement

Replacing the fuel cap is a simple job: you remove the old cap and install a new one that seals correctly. A good seal helps prevent fuel vapors from escaping and can prevent an EVAP leak warning light.

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

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⚠️ Safety & Precautions

• ⚠️ Work in a well-ventilated area; fuel vapors are flammable.
• ⚠️ Keep sparks, cigarettes, and open flames away from the fuel door area.
• ⚠️ Do not replace the cap right after driving if you smell strong fuel; let things air out first.

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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 filler cap (tethered, OEM-style seal) - Qty: 1

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📋 Before You Begin

• Park on level ground and shut the engine off.
• Make sure you’re not actively fueling (no nozzle in the filler neck).
• Wipe dirt from around the filler area using a clean shop towel so debris doesn’t fall into the filler neck.

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🔨 Step-by-Step Instructions

Follow these steps in order:

Step 1: Open the fuel door

• Press the fuel door open (it’s the door on the rear quarter panel).
• Use a flashlight to check the area is clean and not cracked.

Step 2: Remove the old fuel cap

• Put on nitrile gloves.
• Turn the cap counterclockwise until it releases, then remove it.
• If the cap has a tether (a small strap), let it hang without twisting it.

Step 3: Inspect and clean the sealing surfaces

• Use a clean shop towel to wipe the filler neck sealing surface (the smooth ring where the cap seals).
• Check the new cap’s rubber seal for damage or debris.
• Tip: Dirt on the seal can trigger EVAP leak codes.

Step 4: Install the new fuel cap

• Thread the new cap on clockwise by hand.
• Keep turning until it “clicks” several times (that’s the cap’s built-in clutch that prevents overtightening).
• Make sure the tether isn’t pinched and the cap sits flat.

Step 5: Close the fuel door

• Close the fuel door firmly until it latches.

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✅ After Repair

• Start the engine and confirm there is no fuel smell around the fuel door.
• If you had a check-engine light related to an EVAP leak, it may take a few drive cycles to clear on its own after the seal is fixed.
• If the light stays on, the issue may be the EVAP system (not just the cap).

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💰 DIY vs Shop Cost

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

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

You Save: $45-$95 by doing it yourself!

Shop labor rates vary but typically run $100-$150/hour. This repair takes a shop approximately 0.2-0.4 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.