This procedure covers the replacement of the fuel filler cap on a 2011-2014 Ford F-150 with 3.5L EcoBoost engine.

Warnings

Tools required

Parts

• Fuel filler cap × 1 — Use OEM Ford cap with correct pressure rating

Preparation

1. Park vehicle on level surface and turn off engine
2. Allow fuel system to cool if vehicle has been recently operated
3. Locate fuel filler door on driver side rear quarter panel

Procedure

1. 1

   Open fuel filler door
   Press on the rear edge of the fuel filler door to release the spring-loaded latch. The door will pop open outward.
2. 2

   Remove old fuel cap
   Turn the fuel cap counterclockwise approximately 1/4 to 1/2 turn until it releases from the filler neck. You may hear a brief hissing sound as pressure equalizes. Pull the cap away from the filler neck; the tether will keep it attached to the door.
3. 3

   Inspect filler neck seal
   Examine the rubber seal inside the filler neck opening for damage, debris, or contamination. Wipe clean with a lint-free cloth if needed. Check that the seal is intact and seated properly in the neck.
4. 4

   Install new fuel cap
   Align the new fuel cap with the filler neck opening and push it onto the neck. Turn clockwise until you hear at least three distinct clicks, indicating proper engagement and sealing. The cap should feel secure and not continue to rotate freely.
5. 5

   Close fuel filler door
   Push the fuel filler door closed until it latches flush with the body panel. Ensure it is fully seated and secure.

Reassembly

1. No reassembly required for this procedure

Verification

• Verify fuel cap clicks at least three times when tightened and does not rotate freely beyond the clicking point
• Confirm fuel filler door closes and latches properly
• Start vehicle and verify no check engine light for evaporative emissions (P0440, P0455, P0456 codes) appears after driving
• Check for fuel odor around filler area after installation

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