🔧 Fusion - Fuel Cap Replacement

Replacing the fuel cap on your Fusion is a very simple repair. The fuel cap seals the fuel filler neck so the evaporative emissions system can hold pressure and keep fuel vapors contained.

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

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⚠️ Safety & Precautions

• ⛽ Work in a well-ventilated area away from flames, cigarettes, heaters, or sparks.
• 🧤 Avoid touching fuel residue with bare hands; gasoline can irritate skin.
• 🚫 Do not top off the tank after the pump clicks off, because this can damage the evaporative emissions system.
• 🔋 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 cloth

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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 Fusion on level ground and shift to Park.
• 🔥 Turn the engine off and keep the key away from the ignition area.
• ⛽ If you just refueled, wait a minute before opening the filler door so vapors can settle.
• 💡 A tether is the small plastic strap that keeps the fuel cap attached to the vehicle so it does not get lost.

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🔨 Step-by-Step Instructions

Follow these steps in order:

Step 1: Open the Fuel Door

• Use your hand to press and release the rear edge of the fuel door.
• The fuel door should pop open.
• Put on nitrile gloves and safety glasses before touching the cap.

Step 2: Remove the Old Fuel Cap

• Use your hand to turn the fuel cap counterclockwise until it comes loose.
• Pull the cap straight out of the filler neck.
• If your cap has a tether, use your fingers to unclip or slide the tether end off its retaining point.
• Go slow so the tether does not snap.

Step 3: Inspect and Clean the Filler Neck

• Use a clean microfiber cloth to wipe the sealing surface around the fuel filler neck.
• Look for dirt, rust, cracks, or pieces of the old cap seal.
• Do not push dirt into the fuel opening.

Step 4: Install the New Fuel Cap

• If equipped, attach the new cap tether by hand to the original retaining point.
• Place the new fuel cap squarely into the filler neck.
• Use your hand to turn the fuel cap clockwise until it clicks.
• Keep turning until you hear at least one firm click.
• No torque wrench is used; tighten by hand only.
• Do not use pliers on the cap.

Step 5: Close the Fuel Door

• Use your hand to swing the fuel door closed.
• Press the fuel door gently until it latches flush with the body.

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✅ After Repair

• ✅ Start your Fusion and make sure there is no fuel smell around the filler door.
• 🔍 If the check engine light was on for a loose or leaking fuel cap, it may take several drive cycles to turn off on its own.
• 🛠️ If you want the light cleared immediately, use an OBD-II scan tool to clear evaporative emissions codes after confirming the cap is tight.
• 🚗 Drive normally and recheck that the cap clicks tight after the next refuel.

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💰 DIY vs Shop Cost

Shop Cost: $45-$95 (parts + labor)

DIY Cost: $15-$35 (parts only)

You Save: $30-$60 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.