Fitting a new fuel cap is a very simple procedure, but the exact instructions vary based on your model. Before installing a new one, you also need to know how to unscrew the old one.
Steps
Part 1 of 2: Install a New Cap
Standard Model
Step 1. Remove the safety wire
Take the new cap and loosen the wire by turning it clockwise.
- You shouldn't encounter any difficulties.
- Use a high-quality cap, because it is safer and ensures efficient fuel consumption; moreover, this model is equipped with a safety cable that allows it to be connected to the car.
Step 2. Connect the cable
Insert the safety pin into the hole on the inside of the fuel filler flap.
- The door that protects the cap and therefore the tank should be open. Near the hinge there is a hole to hook the cable; most vehicles are equipped with this little trick.
- Press the pin into place from top to bottom; you should feel a sharp snap as it clicks into place.
- If the machine does not have this hole, you must use a cap without a safety cable.
Step 3. Screw on the cap
Insert it into the opening of the tank and turn it clockwise until it is firmly tightened.
- The new cap should screw in exactly like the old one; keep turning it until you hear the closing "click" or the cap does not rotate further.
- Once the cable and cap are in place, the procedure is complete.
with Pressure Release and Quick Insert with Lock
Step 1. Turn the cap to the right
Insert the replacement into the tank opening and turn it clockwise until you hear three audible "clicks".
- The cap makes these sounds when the ratchets fit into the mouth of the tank; for it to be securely tightened, this "click" must occur three times.
- Remember not to insert the key into the cap during installation.
Step 2. Give it a try
Try to unscrew the cap to the left, it shouldn't move.
- It should be locked after arming; only the key can open it.
- Once the test is complete, the installation process is complete.
Push-in Metal with Lock
Step 1. Push the cap into place
Insert it directly into the tank opening until you hear an audible "click".
- Do not enter the key during the installation process.
- When the cap is engaged, the lock bars have engaged under the rim of the tank mouth and hold the cap in place.
Step 2. Don't unscrew it
Unlike other models, you don't have to twist it to tighten it and if you try to do it by applying too much force, you could damage it.
- It is still worth taking a test after entering it. Move it gently from side to side, it shouldn't move and it shouldn't slip out of the opening.
- At this point, the cap is well fitted and ready to be used.
Part 2 of 2: Remove the Old Cap
Standard Model
Step 1. Unscrew the cap
Rotate it counterclockwise until you can lift it out of the tank opening.
Set it aside. Keep it until you have installed the spare; if for some reason the new one does not fit in the mouth of the tank, you still need to be able to close it until you find a better cap
Step 2. Remove the safety wire
If it is still attached to the cap and door, you need to remove it.
- If it remains attached to the cap, you will need to locate the safety pin on the opposite end and slide it out of the hole in the fuel filler flap.
- Pull the base of the pin until it detaches from the hole near the hinge.
- After removing the cap and cable, you can install the replacement.
with pressure release and quick insertion with lock
Step 1. Enter the key
Insert it into the lock on the top of the cap.
You cannot remove the old lockable cap without first unlocking it with the key
Step 2. Turn the key to the left
Turn it counterclockwise until the cap unlocks; in general, a 90 ° rotation is sufficient, do not try to push beyond the key.
- Hold the cap steady while you tinker with the key.
- If you have a quick release cap, you can proceed directly to the next step after unlocking the lock.
- With pressure release models you have to wait for the pressure inside the tank to clear before continuing; you should hear a hissing sound as this happens. Wait several seconds until the noise subsides before moving on to the next step.
Step 3. Turn the cap further to the left
Grab the top and turn it counterclockwise.
- Do not use the key for this operation.
- Keep turning the cap until it is completely loosened; at this point, you can lift it up and set it aside. Keep it until you are sure that the replacement fits the tank opening.
Step 4. Extract the key
When the cap has been removed, you can remove the key by turning it to the right a quarter of a turn and pulling it in a straight line.
Now you can fit the new cap
Push-in Metal with Lock
Step 1. Enter the key
Insert it into the lock on the outside of the cap.
You have to use the key to unlock the old cap and pull it out
Step 2. Turn the key to the left
Rotate it a quarter turn counterclockwise.
- In this way you open the lock; as you turn the key the internal bars of the cap retract allowing you to lift it.
- Hold it steady with one hand as you unlock it.
Step 3. Lift it up
Now that it is free from the locking system, you just have to lift it from the mouth of the tank to open the tank.
- Keep the old cap until you are sure that the new one fits snugly.
- At this point you can insert the spare part.
Advice
- Make sure the new cap is identical to the old one. For example, the yellow ones are compatible with ethanol while the normal black ones are not resistant to this substance; therefore, mount a yellow one if the old one was this color. By the same token, if you have removed a regular black cap, you should buy another of the same type.
- If you used a standard stopper before, consider upgrading to a lockable one. These devices can be locked with a key making things difficult for fuel thieves who could suck it out of the tank with a siphon.
