Katerina Swanson
Replacing the cap on a fuel cell is a relatively straightforward process. The first step is to park your vehicle on a flat, hard surface and secure it. Next, you'll need to locate and open the fuel door to access the fuel filler cap. Once you've done that, you can check the cap for any exterior damage and remove it from the fuel filler neck. You may need to clean the parts and reassemble the cap before replacing it. It is recommended that you purchase an original manufactured equipment (OEM) fuel filler cap that is fitted for your vehicle.
| Characteristics | Values |
|---|---|
| Step 1 | Park your vehicle on a flat, hard surface. Make sure that the transmission is in park mode (for automatics) or in 1st gear (for manuals). |
| Step 2 | Secure the vehicle. Place wheel chocks around the front tires that will remain on the ground since the rear of the vehicle will be lifted up. Engage the parking brake to prevent the rear tires from moving. |
| Step 3 | Open the fuel door to gain access to the fuel filler cap. |
| Step 4 | Check the fuel filler cap for any exterior damage. Remove the fuel filler cap from the fuel filler neck and remove the cable from the fuel door. Look at the threads on the cap to see if they are stripped. |
| Step 5 | Hook up the cable to the fuel door. Use a combustible gas detector to verify that there are no fuel vapours leaking from the fuel filler cap. |
| Step 6 | Drive the vehicle. During the test drive, go over different terrain like bumps to allow the fuel to slosh around inside the fuel tank. This will cause the fuel to bubble up and create mass amounts of vapour. |
| Step 7 | Check for warning lights. Monitor the dash for the engine light to appear. If the engine light comes on even after replacing the fuel filler cap, you may need to get the fuel system checked for possible electrical issues. |
| General advice | When replacing a fuel filler cap, it is recommended that you purchase only original manufactured equipment (OEM). The OEM fuel filler cap is fitted and made for the vehicle. |
| Check your car manual to find specs for the fuel tank cap and its gasket and check with a supply store to get the right type of cap gasket for your car. Select a suitable gas cap gasket. Do not try to substitute it with another type, even if it looks similar. | |
| If cleaning or replacing the gasket doesn’t work, there might be an issue with the cap itself. You may be able to repair your old cap. However, it will depend on the design and make of your vehicle. | |
| You may find a lot of orange sticky fuel residues on the parts. Wash them with lacquer thinner to remove the residue. Dry the parts after cleaning and washing. Reassemble the cap inside portion. Insert the top and the bottom portions. Keep pressure on the lower part when rolling its edge over the top to properly position the o-rings. Replace the gasket if it is cut, squeezed, or damaged. The gasket becomes hard with time. Many times, the old gasket can work by applying some lubricating grease on its face. However, it will work only for a short time. |
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What You'll Learn
How to prepare your vehicle for replacing the fuel cap
To prepare your vehicle for replacing the fuel cap, park your vehicle on a flat, hard surface and ensure the transmission is in park mode (for automatics) or in 1st gear (for manuals). Secure the vehicle by placing wheel chocks around the front tires and engaging the parking brake to prevent the rear tires from moving.
Open the fuel door to access the fuel filler cap. Check the cap for any exterior damage, including stripped threads. If the cap is damaged, remove it from the fuel filler neck and disconnect the cable from the fuel door.
Before replacing the cap, it is recommended to purchase an original manufactured equipment (OEM) fuel filler cap that is specifically fitted for your vehicle. You can refer to your car manual to find the specifications for the fuel tank cap and its gasket.
If you are repairing the cap rather than replacing it, you may need to clean the parts. Use lacquer thinner to remove any sticky fuel residues, then dry the parts before reassembling.
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How to check for damage to the fuel cap
The fuel cap is an important part of the car, as it protects the fuel tank from dust and moisture, and maintains the safety of the car and the level of fuel consumption. If the fuel cap is damaged, it can cause vacuum leaks, which will illuminate the check fuel cap light.
To check for damage to the fuel cap, first, look at the underside of the fuel cap. There should be a rubber seal and a gasket. If the rubber seal has rolled over or been removed, or the gasket is broken, this can cause vacuum leaks. If the rubber seal or gasket looks damaged, the fuel cap should be replaced.
If the rubber seal and gasket look intact, reinstall the fuel filler cap onto the fuel filler neck and tighten the cap securely. After reinstalling the cap, start the engine, and drive the car for a few minutes. If the check fuel cap light is still on, the fuel cap may not have been affixed onto the fuel tank filler tube properly, or the fuel cap may be missing. If the fuel cap is not on the fuel tank at all, the fuel cannot be pressurised, and the fuel and fuel tank cannot be protected from contamination.
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How to remove the fuel cap
To remove the fuel cap, you will first need to park your vehicle on a flat, hard surface. Make sure that the transmission is in park mode (for automatics) or in 1st gear (for manuals). Secure the vehicle by placing wheel chocks around the front tires and engaging the parking brake.
Next, open the fuel door to access the fuel filler cap. Check the cap for any exterior damage, including stripped threads. If the cap is damaged, you will need to replace it with an original manufactured equipment (OEM) fuel filler cap.
To remove the fuel filler cap, simply pull it straight out of the fuel filler neck. You may need to twist it slightly to release it from the threads. Once the cap is removed, you can also check the gasket for any signs of damage or wear. If the gasket is cut, squeezed, or damaged, it will need to be replaced.
When removing the fuel cap, it is important to use caution and be aware of any fuel vapors that may be present. Always use a combustible gas detector to verify that there are no fuel vapors leaking from the fuel filler cap before proceeding.
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How to clean the fuel cap
To clean the fuel cap, you will need to open the fuel door to gain access to the fuel filler cap. Once you have located the fuel filler cap, check for any exterior damage. Remove the cap from the fuel filler neck and remove the cable from the fuel door. You may find orange sticky fuel residue on the parts. Wash them with lacquer thinner to remove the residue. Dry the parts after cleaning and washing. Reassemble the cap inside portion. Insert the top and the bottom portions. Keep pressure on the lower part when rolling its edge over the top to properly position the o-rings. Replace the gasket if it is cut, squeezed, or damaged. The gasket becomes hard with time. Many times, the old gasket can work by applying some lubricating grease on its face. However, it will only work for a short time. If cleaning or replacing the gasket doesn’t work, there might be an issue with the cap itself. You may be able to repair your old cap. However, it will depend on the design and make of your vehicle. Find the orientation marks on the top of the cap.
Before you begin, it is recommended that you park your vehicle on a flat, hard surface. Make sure that the transmission is in park mode (for automatics) or in 1st gear (for manuals). Secure the vehicle by placing wheel chocks around the front tires that will remain on the ground since the rear of the vehicle will be lifted up. Engage the parking brake to prevent the rear tires from moving.
After cleaning the fuel cap, hook up the cable to the fuel door. Use a combustible gas detector to verify that there are no fuel vapours leaking from the fuel filler cap. Drive the vehicle over different terrain, such as bumps, to allow the fuel to slosh around inside the fuel tank. This will cause the fuel to bubble up and create mass amounts of vapour. Monitor the dash for any warning lights. If the engine light comes on even after replacing the fuel filler cap, you may need to get the fuel system checked for possible electrical issues.
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How to test the fuel cap after replacement
To test the fuel cap after replacement, first, open the fuel door to access the fuel filler cap. Check the fuel filler cap for any exterior damage. Remove the cap from the fuel filler neck and remove the cable from the fuel door. Look at the threads on the cap to see if they are stripped.
Next, hook up the cable to the fuel door and use a combustible gas detector to verify that there are no fuel vapours leaking from the fuel filler cap.
Then, drive the vehicle over different terrain, such as bumps, to allow the fuel to slosh around inside the tank. This will cause the fuel to bubble up and create large amounts of vapour. Monitor the dashboard for any warning lights. If the engine light comes on, you may need to get the fuel system checked for possible electrical issues.
You can also test the fuel cap by taking the neck off and blowing into the tank end, with the cap end in a bucket of water. When vacuum is applied to the inner part of the cap, it should make a slight whining noise. When pressure is applied, the valve should close clean and tight to stop the airflow.
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Frequently asked questions
Park your vehicle on a flat, hard surface and secure it. Locate the fuel filler cap, open the fuel door, and check for any exterior damage. Remove the cap from the fuel filler neck and remove the cable from the fuel door. You may need to wash the parts with lacquer thinner to remove any sticky fuel residue. Dry the parts, then reassemble the cap inside portion.
It is recommended that you purchase an original manufactured equipment (OEM) fuel filler cap. Check your car manual to find the specs for the fuel tank cap and its gasket, and check with a supply store to get the right type of cap gasket for your car.
If the gasket is cut, squeezed, or damaged, you should replace it. You can try applying some lubricating grease to the face of the old gasket, but this will only work for a short time.
Use a combustible gas detector to verify that there are no fuel vapours leaking from the fuel filler cap. Then, take the vehicle for a test drive, going over different terrain like bumps to allow the fuel to slosh around inside the tank. Monitor the dash for any warning lights. If the engine light comes on, you may need to get the fuel system checked for possible electrical issues.
