🔧 Fuel Cap - Replacement

Replacing the fuel cap on your Outback is a simple job. The fuel cap seals the fuel tank, and a loose or worn cap can cause fuel vapor leaks, fuel smell, or an EVAP/check engine light.

Difficulty Level: Beginner | Estimated Time: 5-10 minutes

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⚠️ Safety & Precautions

• ⚠️ Work away from flames, cigarettes, sparks, or hot equipment.
• ⚠️ Do not leave the fuel filler opening uncovered longer than needed.
• ⚠️ Wipe fuel residue carefully if present, but do not use compressed air around fuel vapors.
• ⚠️ Battery disconnect is not required for this repair.

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🔧 Required Tools

You'll need the following tools for this repair:

• Nitrile gloves
• Safety glasses
• Clean microfiber towel

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🔩 Required Parts

HowToo sells all the parts you need for this repair:

• Fuel cap - Qty: 1

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📋 Before You Begin

• Park your Outback on level ground.
• Turn the ignition fully off and remove the key.
• Make sure the fuel door area is clean so dirt does not fall into the filler neck. The filler neck is the metal opening where the fuel nozzle goes.
• If your check engine light is on because of a loose fuel cap, it may take several drive cycles to turn off after replacement.

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🔨 Step-by-Step Instructions

Follow these steps in order:

Step 1: Open the Fuel Door

• Use your hand to pull the fuel door release lever inside the vehicle.
• The fuel door release lever is located on the driver-side floor area near the seat.
• Put on safety glasses and nitrile gloves.

Step 2: Remove the Old Fuel Cap

• Use your hand to turn the old fuel cap counterclockwise.
• Stop turning once the cap is loose, then pull it straight away from the filler neck.
• If the cap has a plastic tether, remove the tether from its retaining point by hand.
• Turn slowly to avoid fuel vapor puffing out.

Step 3: Inspect the Filler Neck

• Use a clean microfiber towel to gently wipe the sealing surface around the filler neck.
• Look for dirt, rust, cracks, or damaged threads where the cap tightens.
• Do not push the towel deep into the filler neck.

Step 4: Install the New Fuel Cap

• Use your hand to place the new fuel cap squarely onto the filler neck.
• Turn the cap clockwise until it clicks.
• Subaru-style caps should be tightened until you hear several clicks, which means the cap is locked and sealed.
• No torque wrench is used for this part. Tighten by hand until the cap clicks securely.
• Do not overtighten after it clicks.

Step 5: Secure the Tether and Close the Fuel Door

• Use your hand to attach the fuel cap tether to the original retaining point if equipped.
• Use your hand to close the fuel door until it latches.
• Check that the fuel door sits flush with the body.

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✅ After Repair

• Start your Outback and confirm there is no strong fuel smell around the fuel door.
• If the check engine light was caused by the fuel cap, drive normally for a few trips so the EVAP system can retest itself. EVAP means evaporative emissions system, which checks fuel vapor sealing.
• If the check engine light stays on after several days of normal driving, a scan tool may be needed to clear or diagnose stored EVAP codes.
• After your next fuel fill-up, always tighten the cap until it clicks several times.

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💰 DIY vs Shop Cost

Shop Cost: $50-$120 parts + labor/diagnostic time

DIY Cost: $15-$35 parts only

You Save: $35-$85 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.