Z-man

I had a non-Porsche gas cap that was leaking a little: I found this out on the autocross course.

Now I've replaced it with the red Porsche OEM gas cap, and it still leaks!

Can I double up the gasket in the gas cap? Anyone else have this issue? (My friend's 964 has the same problem: leaking gas cap). Could I have an issue with the filler tube?

Help!
-Z.

Luis de Prat

What do you mean by leak? Are you losing fuel? In any case it's possible the O-ring around the base may be too brittle even if it's new. Someone on the E-Mail lists had this problem. Lube it with some WD-40 for a better seal.

If you're just getting a fuel smell in the cabin after sitting overnight that goes away at start up, you may have a saturated emissions canister, like I think I do. I have one on order at the dealer and will be replacing it soon.

Z-man

Luis:
There are streaks of gas on the side of my car after autocross and track work, so I am definately spilling gas out of the filler cap. (There is no gas in the 'overflow tube'.)

I'll try the WD-40, but I am not sure that will solve my problem...

-Z.

threesticks1

I have seen instances of the filler neck not being flat and not allowing the seal in the gas cap to seal. One owner drove away with the gas pump still in the filler neck ahd bent it out of round, again not allowing the cap to seal.

Hope that this helps.

Konstantin

just screw the cap 2 times instead of one till you hear two clikcs. then it will be ok. I had the same problem and it is solved.

Konstantin

Skip

An upgrade to the 944 cap is the late model 911(993) gas cap. It has a much better seal, but no lock apparatus. Part# 993.201.271.00 (is actually less expensive than the 944 cap)

<img src="http://www.paragon-products.com/images/911_gascap.jpg" alt=" - " />

Good Luck!

P944forScott

My car is MUCH older than yours Z-man but I had the same problem. Turned out the lower lip of aluminum filler that you screw the gas cap into was slightly bent down from years of hanging the gas pump nozzle on it. It is very tricky to bend it back into place, someone suggested using a large pair of pliers but when I attempted that it looked like I might crush the lip of the filler. I ended up using a very large, very dull, screwdriver, lots of rags around the gas filler opening to avoid scratching the paint. Then gently but firmly pried up on the lower lip and smacked on the end of the screw driver with my hand to push the bottom lip of the filler back up into round.

I also though of trying a piece of PVC pipe the same size as the gas filler but the screw driver trick worked so I never designed the tool.

That is if that is even the problem!

DerSchlechtSpecht

Z, I had the exact same problem early April! Fuel all over my right rear quarter panel at an Auto X. I ended up getting a generic Stant gas cap and all is now well.

Christian

MHT

you mentioned your friends 964, there is an updated filler neck for those cars to fix a leaking condition. There is a TSB about the problem, bulletin #9401, that describes the problem and the remedy.

Mark

944Play

</font><blockquote><font size="1" face="Verdana,Tahoma,Helvetica">quote:</font><hr /><font size="2" face="Verdana,Tahoma,Helvetica">Originally posted by P944forScott:
It is very tricky to bend it back into place, someone suggested using a large pair of pliers but when I attempted that it looked like I might crush the lip of the filler.</font><hr /></blockquote><font size="2" face="Verdana,Tahoma,Helvetica">I used pliers with rags to cushion the jaws and bent the edge back into round. Also, I flipped over the seal ring. ISTR that the seal ring is a dealer-only part, due to its weird U-shaped cross section (944.201.553.00?).

Z-man

Guys:
Thanks for the comments, suggestions. I will see if the filler is out of round, and if so, I'll try to carefully bend it back to shape.

A little more history: I actually have three filler caps: the original cap failed inspection: it failed the pressure test they do here in NJ. So I bought a generic one that I suppose worked fine until I started driving my car harder at autocross. So I bought a Porsche replacement cap like Skip showed, but with the hole for the lock/tumbler. (Paid $25.00 for it: I think that's an ok price). Anyway, at the last DE I attended, there were streaks of gas on the side of my car, even with the new Porsche cap.

(Side note: there was that one time when the gas station attendant dropped the gas pump off my filler: maybe that's when it got bent a little! Stupid Jersey law: I can't pump my own gas! )

So, I'll see if it's out of round, and I may also double up the gasket on the gas cap, since I have three gas caps for my Porsche now! <img border="0" title="" alt="[Eek!]" src="eek.gif" /> We'll see what happens at autocross this Saturday!

Thanks again,
-Z.

Luis de Prat

</font><blockquote><font size="1" face="Verdana,Tahoma,Helvetica">quote:</font><hr /><font size="2" face="Verdana,Tahoma,Helvetica">Originally posted by Z-man:
<strong>Stupid Jersey law: I can't pump my own gas! )</strong></font><hr /></blockquote><font size="2" face="Verdana,Tahoma,Helvetica">Really? I've been through NJ several times and never noticed this at the fuel stations on the NJ Turnpike.

Z-man

Yes: it is a law: there are no "Self-Serve" gas stations in NJ. However, many people still pump their own gas, myself included. (Newsflash: Zoltan breaks the law!!!!!!)

-Z.

Mighty Shilling

that's a dumb law. it's not hard to pump your own gas. the Jersey Govt must think that you guys are a bunch of retards or something. either that, or that you are all a bunch of theives.

fpena944

What upsets me at times is when they forget to put the "Check your oil?" flap back up over the gas cap!

Then I'm driving around with my flap flapping in the wind like an idiot.

I also have issues with my gas cap as it seems to seal but sits a little too high. So it almost seems like the gas filler door is partly open but it is not.