🔧 Tucson - Fuel Cap Replacement

Replacing the fuel cap on your Tucson is a quick job that helps prevent fuel vapors from leaking and keeps the check engine light from coming on due to an EVAP leak. You’ll remove the old cap, install the correct replacement, and confirm it seals properly.

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

---

⚠️ Safety & Precautions

• ⚠️ Work with the engine OFF and away from sparks or open flames.
• ⚠️ Do not smoke while working near the fuel filler.
• ⚠️ If you smell strong fuel vapor or see wet fuel, stop and inspect for leaks before driving.
• ⚠️ Battery disconnect is not required.

---

🔧 Required Tools

You'll need the following tools for this repair:

• Nitrile gloves
• Shop towel
• Flashlight

---

🔩 Required Parts

HowToo sells all the parts you need for this repair:

• Fuel cap (OEM-style, tethered if equipped) - Qty: 1

---

📋 Before You Begin

• Park on level ground, shift to Park, and turn the engine OFF.
• Open the fuel door and let any pressure equalize for a few seconds.
• Wipe dirt around the filler neck using a shop towel so debris doesn’t fall into the opening.

---

🔨 Step-by-Step Instructions

Follow these steps in order:

Step 1: Open the fuel door

• Open the fuel door by hand.
• Use a flashlight to look around the cap area for cracked plastic or damaged paint.

Step 2: Remove the old fuel cap

• Turn the cap counterclockwise by hand until it releases.
• If your cap has a tether (the small strap that keeps it attached), gently unhook it from the cap using your fingers while wearing nitrile gloves.
• Set the old cap aside on a clean shop towel.

Step 3: Inspect the sealing surfaces

• Wipe the filler neck sealing surface with a shop towel.
• Check the rubber seal on the old cap for cracks or flattening. A bad seal can trigger a check engine light.

Step 4: Install the new fuel cap

• Place the new cap onto the filler neck and turn it clockwise by hand.
• Keep turning until it fully seats and you feel it ratchet/click into place.
• If the new cap includes a tether, attach it the same way the old one was routed so it doesn’t twist.

Step 5: Verify it seals correctly

• Give the cap a gentle clockwise turn again by hand to confirm it’s fully tightened.
• Close the fuel door.

---

✅ After Repair

• Start the engine and confirm there is no fuel smell around the fuel door.
• If you had a check engine light for an EVAP/fuel cap issue, it may take a few drive cycles to clear on its own.
• If the light stays on after a few days of normal driving, the issue may be a different EVAP leak (not the cap).

---

💰 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.

---

🎯 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.