🔧 Fusion - Fuel Cap Replacement

Replacing the fuel cap on your Fusion is a quick beginner-friendly repair. A worn, loose, or leaking fuel cap can cause fuel vapor leaks and may trigger an emissions warning or check engine light.

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

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⚠️ Safety & Precautions

• ⚠️ Work in a well-ventilated area and keep flames, cigarettes, and sparks away from the fuel filler area.
• ⚠️ Turn the engine off before opening the fuel door.
• ⚠️ Do not force the cap or tether; the fuel filler area is plastic and can crack if pulled too hard.
• ⚠️ 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

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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.
• Set the parking brake.
• Turn the ignition off and keep the key away from the vehicle.
• Put on nitrile gloves and safety glasses. Nitrile gloves protect your hands from fuel residue.
• If the check engine light is on because of an EVAP leak, it may take several drive cycles to clear after the cap is replaced.

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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.
• Use your safety glasses while working near the filler area.
• Do not pry the fuel door.

Step 2: Remove the Old Fuel Cap

• Use your hand to turn the old fuel cap counterclockwise.
• Keep turning until the cap comes free from the filler neck.
• The filler neck is the round opening where fuel goes into the tank.
• No torque spec is used here; the cap is hand-tightened only.

Step 3: Remove the Fuel Cap Tether

• Use your gloved fingers to inspect the plastic tether that holds the cap to the fuel door area.
• The tether is the small plastic strap that prevents the cap from falling.
• If the tether has a slip-loop style end, use your hand to stretch the loop gently over the mounting tab.
• If the tether clips into a small hole or slot, use your fingers to squeeze the clip and pull it free.
• Gentle pressure prevents broken plastic.

Step 4: Compare the New Fuel Cap

• Use your hands to compare the new fuel cap with the old one.
• Make sure the sealing ring is present on the new cap.
• The sealing ring is the rubber gasket that seals fuel vapors inside the tank.
• Make sure the tether attachment style matches the original cap.

Step 5: Install the New Fuel Cap Tether

• Use your gloved fingers to attach the new tether to the same mounting point used by the old cap.
• If it uses a loop, stretch the loop gently over the tab until it sits flat.
• If it uses a clip, push the clip into the hole or slot until it locks in place.
• Lightly tug the tether by hand to make sure it is secure.

Step 6: 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 firm click.
• Torque to hand-tight only; stop after the cap clicks.
• Cross-threading means it starts crooked.

Step 7: Close the Fuel Door

• Use your hand to close the fuel door until it latches flush with the body.
• Do not slam it.

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✅ After Repair

• ✅ Start your Fusion and confirm there is no fuel smell around the fuel door.
• ✅ If a “Check Fuel Fill Inlet” message or check engine light was present, drive normally for a few days.
• ✅ The vehicle may need several warm-up and drive cycles before the warning clears by itself.
• ✅ If the check engine light stays on after a week, an EVAP leak code scan may be needed.

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💰 DIY vs Shop Cost

Shop Cost: $40-$100 (parts + labor)

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

You Save: $25-$65 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.