Boxstertips Porsche Boxster Gas Cap Replacement 986 987

Porsche Boxster Gas Cap Replacement 986 987

The replacement of the Porsche Boxster gas cap is very simple and straightforward.

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986 987 996 997 gas Fuel Cap and Clip GENUINE oem pertrol tank filler cover
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986 987 996 997 gas Fuel Cap and Clip GENUINE oem pertrol tank filler cover
  • Genuine part
  • Fuel Cap
  • Part Number 996 201 241 03
  • INCLUDED: (1) 999 507 499 40 clip

Reasons for Replacing Porsche Boxster Gas Cap

With age and use, the Porsche Boxster Gas Cap can experience wear or cracking. This results in an uneven seal to the gas tank and EVAP canister.

CEL (Check Engine Light)

Boxstertips - Porsche Boxster CEL Error
Boxstertips – Porsche Boxster CEL Error

If you are driving your Porsche Boxster and experience a CEL light, you need to read the CEL code quickly.

WARNING: If CEL light is flashing you need to pull over and have your Boxster towed.
Never drive your car with a flashing CEL!

You need to make use a good OBD2 Code Reader and obtain the CEL code.

Reading the CEL Code

To read the CEL code on your Porsche Boxster, you simply turn the car off, install the OBD II reader plug into the receptacle (under the dash, show below.) Once installed, move the key to the ACC position and do not start the car.

Follow the instruction on your OBD reader and obtain the CEL code.

Boxstertips - Porsche Boxster OBD II Port Location
Boxstertips – Porsche Boxster OBD II Port Location

If your CEL error is related to your EVAP system, you should reset the CEL code, check the gas cap for proper closure and drive your Boxster to determine if the CEL error is a persistent problem (reoccurs).

Common Boxster CEL Code(s) for Gas Cap Replacement

P0440 CEL Error Code

  1. Missing fuel cap
  2. Defective or damaged fuel cap
  3. Distorted or damaged Fuel Tank Filler Neck
  4. Torn or punctured Evaporative system hose(s)
  5. Defective Fuel Tank Sending Unit gasket or seal
  6. Split or damaged Carbon Canister
  7. Defective Evaporative Vent Valve and/or Evaporative Purge Valve
  8. Defective or damaged fuel tank

P0441 CEL Error Code

  1. Missing fuel cap
  2. Stuck open or closed purge valve
  3. Defective or damaged fuel cap
  4. Distorted, damaged, or cracked Fuel Tank Filler Neck
  5. Torn or punctured Evaporative system hose(s)
  6. Defective Fuel Tank Sending Unit gasket or seal
  7. Split or damaged Carbon Canister
  8. Defective Evaporative Vent Valve
  9. Defective or damaged fuel tank

P0442 CEL Error Code

  1. Defective or damaged fuel cap
  2. Distorted or damaged Fuel Tank Filler Neck
  3. Small tear or puncture in the Evaporative system hose(s) and/or Carbon Canister
  4. Defective Fuel Tank Sending Unit gasket or seal
  5. Small split in a seam of the Carbon Canister
  6. Defective Evaporative Vent Valve and/or Evaporative Purge Valve
  7. Damaged or Defective Fuel Tank
  8. Defective Fuel Tank Pressure Sensor
  9. Defective Leak Detection Pump
  10. Slightly loose and/or worn clamps or hardened O-rings anywhere in the EVAP system

P0455 CEL Error Code

  1. Missing fuel cap
  2. Defective or damaged fuel cap
  3. Distorted or damaged Fuel Tank Filler Neck
  4. Torn or punctured Evaporative system hose(s)
  5. Defective Fuel Tank Sending Unit gasket or seal
  6. Split or damaged Carbon Canister
  7. Defective Evaporative Vent Valve and/or Evaporative Purge Valve
  8. Damaged or Defective fuel tank
  9. Defective Fuel Tank Pressure Sensor

P0456 CEL Error Code

  1. Missing fuel cap
  2. Defective or damaged fuel cap
  3. Distorted or damaged Fuel Tank Filler Neck
  4. Torn or punctured Evaporative system hose(s)
  5. Defective Fuel Tank Sending Unit gasket or seal
  6. Split or damaged Carbon Canister
  7. Defective Evaporative Vent Valve and/or Evaporative Purge Valve
  8. Damaged or Defective fuel tank
  9. Defective Fuel Tank Pressure Sensor

If you experience any of these CEL error codes that are repeatable after you have checked your gas cap for a proper seal. Examine your gas cap thoroughly for any cracking, wear, or damage. If any of these conditions are evident, then it is an easy repair to simply replace your Porsche Boxster gas cap.

How to Replace Porsche Boxster Gas Cap

The hardest part of replacing your Porsche Boxster gas cap is the removal of the plastic rivet.

Boxstertips - Porsche Boxster Gas Cap Replacement 986 987 - Plastic Rivet
Boxstertips – Porsche Boxster Gas Cap Replacement 986 987 – Plastic Rivet
  1. Locate the Porsche Plastic rivet that holds the gas cap plastic strap in place.
  2. Use a punch tool or small finishing nail to lightly push the plastic center dowel of the plastic rivet through the rivet enclosure. Be careful to catch the center plastic dowel as it pushes free.
  3. Lightly pry the plastic rivet housing out of position with your fingernail.
  4. Ensure that no damage comes to the rivet.
  5. Install the new Porsche gas cap into place using the plastic rivet housing and push the small plastic center down into place.
  6. This fully secures the new Porsche gas cap.
  7. Install the Porsche gas cap into the gas tank opening and turn it firmly 3-5 clicks to ensure a proper seal.

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Last update on 2021-12-01 / Affiliate links / Images from Amazon Product Advertising API