🔧 XT4 - Fuel Cap Replacement

Replacing the fuel cap is a quick job, but it matters because a worn or incorrect cap can cause an EVAP leak (fuel vapor leak) and trigger a check engine light. On your XT4, it’s simply a remove-and-replace part—no special programming needed.

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

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⚠️ Safety & Precautions

• ⚠️ Work outside or in a well-ventilated area—fuel vapors are flammable.
• ⚠️ Keep sparks, cigarettes, and open flames away from the fuel door.
• ⚠️ If the engine was just running, let things cool a few minutes before opening the fuel door.
• ⚠️ No battery disconnect is 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 filler cap (OEM-style, tethered) - 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 area if possible.
• Wipe dirt away from the fuel door 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

• Use your hand to open the fuel door on the driver side rear quarter panel.
• If it’s dark, use a flashlight to clearly see the cap and sealing area.

Step 2: Remove the old fuel cap

• Put on nitrile gloves.
• Turn the cap counterclockwise until it comes free, then pull it straight out.
• If you hear a small hiss, that’s normal.

Step 3: Inspect and clean the sealing surfaces

• Use a clean shop towel to wipe the cap sealing surface on the filler neck (the round area the cap gasket seals against).
• Check the old cap’s rubber gasket (seal). If it’s cracked, flattened, or missing, that can cause an EVAP leak.

Step 4: Install the new fuel cap

• Insert the new cap straight into the filler neck.
• Turn it clockwise until it is fully tight.
• If your replacement cap is the “click” type, keep turning until you feel/hear it click.

Step 5: Close the fuel door

• Close the fuel door firmly with your hand until it’s fully latched.

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✅ After Repair

• Start your XT4 and make sure there’s no fuel smell around the fuel door.
• If you had a check engine light for an EVAP small leak, it may take a few drive cycles to clear on its own after the cap is replaced.
• If the light stays on, the EVAP system may have another leak (hose, purge valve, vent valve), and it may need a scan for codes.

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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.