This procedure covers the replacement of the fuel filler cap on a 2016-2024 Hyundai Tucson with the 2.5L I4 engine, a simple maintenance task requiring no tools.

Warnings

Parts

• Fuel filler cap × 1 — Use OEM specification

Preparation

1. Ensure vehicle is parked on level ground with engine off
2. Allow fuel system pressure to normalize if vehicle was recently driven or fueled
3. Locate fuel filler door release lever inside vehicle on driver's side floor or check for push-to-open type door

Procedure

1. 1

   Open fuel filler door
   Pull the fuel filler door release lever located on the driver's side floor near the door sill, or press the fuel door to release if equipped with push-to-open mechanism. The fuel filler door is located on the rear left side of the vehicle.
2. 2

   Remove old fuel cap
   Turn the fuel cap counterclockwise (left) until it clicks and releases from the filler neck. Listen for any hissing sound indicating pressure release. Continue turning and pull the cap straight out from the filler neck. The cap may be tethered to the filler door on some model years.
3. 3

   Inspect filler neck seal area
   Examine the fuel filler neck opening for debris, damage, or corrosion. Wipe the sealing surface clean with a lint-free cloth if any dirt or debris is present. Check that the spring-loaded filler neck door (if equipped) moves freely.
4. 4

   Install new fuel cap
   Align the new fuel cap with the filler neck opening and insert it straight into the neck. Turn clockwise (right) until you hear at least three distinct clicks, indicating proper sealing and engagement of the ratcheting mechanism. Do not over-tighten beyond the clicking point.
5. 5

   Close fuel filler door
   Push the fuel filler door closed until it latches securely. Verify it is flush with the body panel and properly seated.

Reassembly

1. No disassembly was required for this procedure

Verification

• Verify fuel cap clicks at least three times when tightened and cannot be turned further
• Confirm fuel filler door closes and latches properly
• If replacing cap due to check engine light, drive vehicle through several drive cycles (including cold starts) to allow the EVAP system to complete self-tests and clear codes
• Monitor for return of EVAP-related fault codes over the next 50-100 miles of driving

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