Vehicles emit non-methane hydrocarbons (NMHCs) from a number of sources, including missing, worn or improperly tightened fuel caps. Inspection and maintenance programs and the On-Board Diagnostic (OBD) system will detect some of these deficiencies, however, even properly tightened caps will emit NMHCs due to permeation, diffusion, cracks and gaps in seals, and failures of pressure-relief mechanisms. These emissions have not been previously quantified. In this study, in-use emissions from fuel caps were measured in 213 tests on vehicles of varying age and condition over several seasons, including cold and warm temperatures. Diffusion/permeation models are presented to complement the experimental work. NMHC emissions from fuel caps were detected from all vehicles, of which benzene constituted 2.5%. Emissions averaged 2.0mgh−1 (median=0.5mgh−1), and the distribution of emission rates was highly skewed by a small number of vehicles with much higher emissions, e.g., the 90th, 95th and maximum percentile values were 2.7, 5.0, and 62.7mgh−1, respectively. Emission rates increased substantially if the fuel cap was loose, in hot weather, and with vehicle age and mileage. Overall, emissions from properly functioning caps are small relative to running and refueling losses, though they may be significant if the gas cap is defective or loose. Further reductions in emissions may be achieved by using new low-torque cap designs, improved elastomers, properly tightening fuel caps, and replacing old caps.