🔧 Tucson - Fuel Cap Replacement

Replacing the fuel cap on your Tucson is a very simple repair. A worn, cracked, loose, or missing fuel cap can cause fuel vapor leaks and may trigger a check engine light for an EVAP system leak.

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

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⚠️ Safety & Precautions

• ⚠️ Park away from open flames, cigarettes, sparks, or running engines because fuel vapors are flammable.
• ⚠️ Do not overfill the tank before replacing the cap.
• ⚠️ No battery disconnect is required for this repair.
• ⚠️ If the check engine light is on, it may take several drive cycles after replacement for the vehicle to confirm the leak is fixed.

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🔧 Required Tools

You'll need the following tools for this repair:

• Safety glasses
• Nitrile gloves

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🔩 Required Parts

HowToo sells all the parts you need for this repair:

• Fuel tank cap - Qty: 1

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📋 Before You Begin

• Park your Tucson on level ground.
• Shift into Park and set the parking brake.
• Turn the engine off.
• Let the area around the fuel door cool if the vehicle has been sitting in direct heat.
• The EVAP system is the fuel vapor control system; it seals fuel vapors so they do not escape into the air.

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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 the fuel door does not pop open easily, make sure the doors are unlocked first.
• Work with the engine off.

Step 2: Remove the Old Fuel Cap

• Use your hand to turn the fuel cap counterclockwise until it comes loose.
• Pull the cap away from the filler neck.
• The filler neck is the metal tube where fuel enters the tank.
• No torque spec applies; this is a hand-tightened cap.

Step 3: Remove the Retaining Tether

• Use your fingers to unclip or slide the fuel cap tether from the fuel door or filler area.
• The tether is the small plastic strap that keeps the cap from falling away during refueling.
• If the old tether is brittle, wear nitrile gloves and remove it gently by hand.
• Do not force old plastic.

Step 4: Install the New Fuel Cap Tether

• Use your hand to attach the new fuel cap tether to the same mounting point used by the old cap.
• Make sure the tether is not twisted and does not interfere with the fuel door closing.

Step 5: 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.
• Continue turning until you hear at least one click; this confirms the cap is sealed.
• Torque to hand-tight only until the cap clicks.
• One click is enough.

Step 6: Close the Fuel Door

• Use your hand to close the fuel door firmly.
• Check that the door sits flush with the body panel.

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✅ After Repair

• Start your Tucson and confirm there is no fuel smell around the fuel door area.
• If the check engine light was caused by a loose or leaking cap, it may turn off after several normal trips.
• If the light stays on after a few days of driving, scan for EVAP-related diagnostic trouble codes.
• After each refuel, tighten the fuel cap until it clicks.

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💰 DIY vs Shop Cost

Shop Cost: $40-$90 parts + labor

DIY Cost: $15-$35 parts only

You Save: $25-$55 by doing it yourself!

Shop labor rates vary but typically run $100-$150/hour. This repair takes a shop approximately 0.2-0.3 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.