Adk46

I had this problem all winter. The garage is occupied by a '95 Saab, '87 928, '82 911 and a '59 Austin-Healey. Which should I check first?

Actually, I've already checked the fuel filter area of the 928. I changed the filter in early 2018. There were signs of puddling on the cover plate. I tried to tighten the connections, but not sure I moved anything. Nothing showed while I ran the fuel pump, and maybe the smell has been less intense. I might take it out for a spin today and check further.

dr bob

Around the sender area that the OP is looking at, the fuel return hose connects, and the seal under the cap may be suspect.

In one of the more interesting things-to-think-about categories, the fuel tank has a depressed section in it's roof where it fits up under the right-side "frame". There's a balancing hose between the tops of the two sections, but more importantly the right side section where the filler neck connects is somewhat taller than the top of the main section. With the tank full-full, there is liquid pressure on the tank sender seal. If there's a leak with fuel puddling on the tank, you'll seriously need to drain or otherwise get the tank level down several gallons before you think about removing the sender cap. Do that outside, after pushing the car out of the garage.

Once the tank level has been lowered, ventilate the car well then disconnect the negative battery strap at the rear apron behind the tool panel. Insulate the strap so no chance of sparks as you work on the fuel system. The return hose comes off with a screw clamp, and the electrical connections unplug to allow you to get the sender ring off and replace the seal. Several have mentioned McGyver methods for loosening and tightening the ring. The best tool I'v seen has been a modified ABS drain pipe fitting with some creative Dremel milling done on it to fit over and index to the ring. Easiest removal and lowest chance of damaging the ring when using this type of tool.

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At all times while working in this area, especially with fuel vapors present, You must do the work outside and away from the house/garage, out from under trees. Keep a couple of your favorite large fire extinguishers nearby but not in the car, and a charged garden hose similarly nearby and ready. Fuel vapors are heavier than air at normal temps, so they will escape from the car and fall to the floor, flowing around and hunting for something to ignite them. There's a reason why water heaters and furnaces are mounted on pedestals in the garage. Doing the work outside reduces the risk of the garage and house going up if the fuel is somehow ignited.

Grab an old screw-on coffee lid from the Folgers jar, and plan to cover the opening in the tank while you fiddle. The threads don't match but the fumes are less likely to concentrate there with a cover like that in place. No smoking, don't use the propane torch or hot-air gun, etc.

boca928s

I always had a smell of gas in the garage when the car was parked, but what made it really noticeable is I was away for a week and right before parking it I filled it up, I have been driving it around with this leak for a few months but never filled it up before, it was always around a half a tank full, now its full and the fuel spilled over around the sending unit.... do you think its safe to drive this way to the mechanic?

dr bob

It -may- be. Perhaps the question is "is it too unsafe to drive to the mechanic?".

If you can get the fuel level down, maybe by moving some fuel out of the tank, you'd feel a little better. Maybe grab the garden hose and wash the top of the tank immediately before driving it. Make sure the cover in the boot is over the hole and as tight as possible so fumes don't get in the car. The leak on top of the tank is pretty slow, so driving should keep the concentration below explosive level.

Got a piece of decent hose and a 5-gal fuel can? Use the hose to siphon out the 5 gals and the level will be below the sender.