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Join Date: Jul 2011
Location: Danville, California
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Coolant Cap Issue?

2000 S. Coolant cap with .04 suffix, i.e. latest model. Replaced original cap about a year ago with this new model.

Noticed that I have condensation on the underside of the trunk lid in the coolant cap area. Cap shows a bit of dampness. Tank does not appear to be cracked nor is there any coolant in and around the carpeting. Had to fill up with about a quart of water recently but do not see any major puddling of water on underside of car. Cap is torqued down as tight as it can go.

Is it normal that the cap (new model) leaks a bit? Have any of the new caps been known to be defective? Is best remedy to buy a new cap?
Old 06-19-2012, 08:23 PM
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The best remedy is to find the leak.

You can pressure test the system to see if you can get it to leak noticeably enough to trace it.
Old 06-20-2012, 04:56 AM
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I replaced my OEM cap with the latest OEM cap and it too lasted about a year before it started leaving condensation again. There are no leaks in my system it's just the cap which I'm not going to replace again, I can live with a little condensation.
Old 06-20-2012, 06:32 AM
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I suspected it was just the cap failing, which would not be shocking to me given how parts quality is declining. I may replace it with my full system drain and pump/thermostat change this year. I can test for leaks when I do the vacuum flush.
Old 06-20-2012, 07:31 AM
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Same issue here. Replaced tank and cap (.04) last year. I opened up the trunk one day and could hear a slight whistle. Definately coming from the cap. I've tried to add teflon tape to the threads but joy. I've got condensation as well and added about a quart to the tank.

Guess its time for another new cap.

Funny thing is that the .02 cap I replaced was fine. So much for being proactive!
Old 06-20-2012, 08:45 AM
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Teflon tape to the threads probably won't be as effective as sealing the very top of the filler neck to the rubber gasket on the top. Not sure how else to do that. Thicker gasket?
Old 06-20-2012, 11:12 AM
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Yeah, that's the first thing I thought of when I pulled the cap - that the rubber seal is too thin or a bit worn.
Old 06-20-2012, 01:01 PM
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I wonder if you can take that cap down to an Ace Hardware, or somewhere similar, and find a flat gasket that would mate up perfectly for the coolant cap? If anyone has any luck with this, let us know? I don't have the condensation some of you are having, but it would be good to know I have that option if mine ever does start to leak like that. Or, just buy another $20 cap. More expensive, but would be much easier to do.
Old 06-20-2012, 03:13 PM
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ya know. I think I might just try doing that. My first thought today was to try using some Amsoil Silicon Spray on the gasket or maybe flipping the gasket to get a smooth surface contact. Be interesting to see if I can find the gasket for my M3's gas cap too since it seeps a bit.
Old 06-21-2012, 09:54 AM
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Old 06-21-2012, 09:54 AM
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