🔧 86 - Fuel Filler Cap Replacement

Replacing the fuel cap on your 86 is quick and important because the cap seals the fuel tank. A bad or missing cap can cause a fuel smell, an EVAP leak, and a check engine light.

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.
• ⚠️ If you smell strong fuel odor or see wet fuel, stop and don’t drive until it’s fixed.

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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 filler cap - Qty: 1
• Fuel filler cap tether - Qty: 1

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📋 Before You Begin

• Park your 86 on level ground.
• Set the parking brake and turn the engine off.
• Let the area cool if you’ve been driving; hot parts and fuel vapors don’t mix.

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🔨 Step-by-Step Instructions

Follow these steps in order:

Step 1: Open the fuel door

• Pull the fuel door release lever inside the cabin (near the driver seat area).
• Open the fuel door by hand.

Step 2: Remove the old fuel cap

• Turn the fuel cap counterclockwise by hand until it comes off.
• Use a shop towel to wipe the filler neck sealing surface if it’s dusty or grimy.

Step 3: Inspect the sealing surfaces

• Use a flashlight to look at the rubber seal (O-ring) on the cap and the metal filler neck lip.
• If the seal is cracked, flattened, or missing, replace the cap.
• Clean, dry sealing surfaces prevent EVAP leaks.

Step 4: Install the new fuel cap

• Place the new cap onto the filler neck.
• Turn it clockwise by hand until it clicks several times and feels fully seated.
• If your replacement cap does not “click,” tighten it firmly by hand until it stops (do not use tools).

Step 5: Reattach/verify the tether (if equipped)

• The tether is the small strap that keeps the cap from getting lost.
• If your new cap includes a tether, clip it back onto the holder inside the fuel door area.

Step 6: Close the fuel door

• Close the fuel door until it latches flush.

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✅ After Repair

• Start your 86 and confirm there is no fuel smell around the rear quarter area.
• If you had a check engine light from a loose cap, it may take a few drive cycles to clear on its own.
• If the light stays on, you’ll need an OBD2 scan to confirm the code is gone (common EVAP codes can look similar).

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💰 DIY vs Shop Cost

Shop Cost: $30-$120 (parts + labor)

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

You Save: $15-$75 by doing it yourself!

Shop labor rates vary but typically run $100-$150/hour. This repair takes a shop approximately 0.2-0.5 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.