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I bought a new 04 cap from the dealer recently and had this problem. I put the old cap back on and the problem went away! These caps can be pressure tested apparently. Also check for cross threading: a common problem from what I've heard.
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James now has: 2008 987S 6 speed
Crashed: 2010 987.2 pdk in speed yellow! 
Sold to a cool racer chick: 2004 986 S
YouTube channel: the PORSCHE as seen by NewArt
www.youtube.com/channel/UCohdrH2xHTklM1thxk0KKOQ?
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