Hi Rennlisters,

As a new owner of a 987.1 Cayman S, I wanted to share this guide in case it proves useful to anyone dealing with similar issues.

Symptom:

While driving with the AC on, I noticed a strong fuel odor. It was so intense during my first few weeks of ownership that I avoided using the AC and kept the windows down. During the PPI, a local indy shop identified that the smell wasn’t coming from the fuel sender unit area, where fractures along the locking ring are a common issue. Instead, further investigation revealed that the culprit was the Charcoal (Evaporative) Canister (Part Number: 99720122104). It had become so clogged with fuel that the charcoal was fully saturated.

The Good:

The problem was identified, and I initially thought it would be an easy fix.

The Bad:

Unfortunately, part number 99720122104 is no longer available from Porsche and hasn’t been superseded by a replacement. I had to source the part myself through FB Marketplace, eBay, and Craigslist, hoping to find a salvaged car. Ultimately, I found one at Montoya’s Auto Wrecking in Chula Vista, CA, which had a 2006 987 Boxster Base. I purchased the canister assembly for just under $300.

The Guide:

1. Accessing the Charcoal Canister

• Remove the plastic front housing held in place by a few Phillips screws. This step is straightforward.
• With the housing removed, look towards the passenger side (US models), where you’ll see a black box—that’s the canister.

2. Removing the Retaining Triangle

• Unscrew the two T30 screws securing the black triangular piece that locks the canister in place.
• Use a plastic pry tool to wedge between the metal tub and the top of the triangle (highlighted in red in the attached image) and pry towards you. This is a snap-fit connection.

3. Disconnecting the Fuel Lines

• This step is tricky due to limited space. Two SAE EFI Quick Connects attach to the canister: one has a two-sided release mechanism, while the other has a single-sided release.
• For the two-sided connector, press both tabs and pull down. For the single-sided connector, press the one tab and pull down.
• Working in this tight space (less than 6 inches) requires tools. Hands alone won’t suffice, even for those with smaller hands.
• I recommend using this tool
  Amazon link
  Amazon link
  , which worked well for the job.

• Start by removing the smaller grey dual-sided connector, then move to the larger blue single-sided one. Removing the smaller connector first gives you slightly more room.
• Here’s what the fuel lines look like after removal:

4. Removing and Replacing the Canister

• Remove the canister from the metal tub. Be aware of the rubber gasket between the canister and the tub. The fit is tight, so take care when removing it.
• Apply silicone grease (
  Amazon link
  Amazon link
  ) to the gasket and tub opening to make reinstallation easier. This step is optional but recommended.
• Reinstall the new (used) canister, ensuring the gasket and metal tub are properly aligned. Listen for an audible click as the canister seats into place.

5. Reattaching the Quick Connectors

• Reconnect the blue single-sided connector first, then the grey dual-sided one. Perform this step in a quiet environment to hear the click that confirms proper engagement.

6. Final Steps

• Reattach the triangular plastic piece by hooking it onto the top of the canister, snapping it into the metal tub, and reinstalling the two T30 screws (hand tight).
• Reassemble the front plastic housing with the Phillips screws.

After completing these steps, I took the car for a test drive, and the fuel smell with the AC on high was completely gone.