Fuel Tank Assy And Parts RUIAN SHUNCHENG TRADING CO.,LTD , https://www.sunchevmarine.com
Imagine arriving at a gas station, having already paid for your fuel, only to find that the fuel cap won’t open. Frustrating, right? It’s easy to overlook the fuel door until it becomes an inconvenience — like when it gets stuck due to a faulty component or lack of lubrication in the spring.
But don’t worry — replacing this essential part is simpler than you might think! Whether it's a broken lever, damaged cable, or faulty spring, most issues can be resolved with a bit of know-how and the right tools.
If you're experiencing trouble with your fuel cap, check your vehicle manual. Some cars have a manual override, which can help you access the fuel tank even if the system isn't working properly.
Read also: Petrol vs. Gasoline: Know the Differences (There Are More Than 5)
[Image: An orange fuel cap open]
**What Are the Problems in the Fuel Cap?**
Before jumping into replacing the fuel cap, it’s important to understand the common causes of failure:
- **Broken Lever:** In some vehicles, the fuel door is operated by a lever near the driver’s seat. If this lever breaks or separates from its mechanism, the entire assembly may need to be replaced.
- **Damaged Cable:** The cable connecting the lever to the fuel door can become loose or break over time, preventing the door from opening properly.
- **Faulty Spring:** Many fuel doors use a spring to assist in opening. Over time, this spring can stiffen or fail, making it hard to open the door. Lubrication might help, but in some cases, replacement is necessary.
- **Blown Fuse:** In electrically controlled systems, a blown fuse can prevent the fuel door from functioning correctly. Replacing the fuse usually solves the issue.
- **Damaged Wiring:** Electrical problems, such as frayed or damaged wires, can also cause the fuel door to malfunction. These should be addressed promptly.
[Image: Person loosening the screw on the fuel cap]
If you’re facing any of these issues, consult your car’s manual. It may include instructions for manually opening the fuel door in case of an emergency.
Read also: 10 Myths About Cars: Part 1
**Guidelines to Change the Fuel Cap**
Replacing a non-electric fuel cap is a straightforward task that typically requires just a few basic tools. Let’s walk through how to replace the fuel cap on a Volvo XC60 as an example.
You’ll need:
- A screwdriver
- A torque wrench
Here’s how to do it:
1. Open the fuel cap and remove the interior panel if necessary. If your car has no power, you can manually open the door using the lever in the trunk or near the pedals.
2. Use the torque wrench to loosen the left-side screw on the cover.
3. Insert the screwdriver under the fuel door to act as a lever and release the springs.
4. Once the springs are released, carefully remove the cover and fuel shield.
5. Place the new fuel cap into the same slots and gently push it into place.
6. Reinstall the inner cover and tighten the left-side bolt with the torque wrench.
7. Close the fuel door and test that it opens and closes smoothly.
For a visual guide, check out the video tutorial below.
[Embed: Video of how to change a fuel cap]
If you're unsure about the process, it’s always a good idea to take your car to a certified garage for professional assistance.
Looking for a fuel door for your vehicle? We offer more than 30,000 options across over 60 brands — so you’re sure to find the right fit for your car.