Hello out there from recent new member. I made a post earlier about a gas leak when filling up the shark and received some great replies. I got around to pulling the tank today and you were right, it was a bear. Now for the results. I don't think either of the plastic nipple connections on the filler neck are broken. They seem to be in great shape. The reason I went ahead and pulled the tank is that fumes were filling the gurauge even when the tank was not full. Now the only thing that jumps out at me is a large stain all around the depression for the tank sending unit. it looks like gas has filled that depression on more than one occasion. After seeing some pix of a burned 928 on ebay once, this gives me chills. Do you guys think that the seal on the sending unit is bad? It's the only way I can see for the fuel to get here. Is there a way to prove the two upper connections are not leaking? I will clean them thoroughly tomorrow. I have some tank epoxy if I can find the leaks. Now for the long hose with crimped fittings that goes from the tank fuel pump over to the second pump, should it be replaced? What other things should i replace while i have the tank out? I have the removal and re-install instructions posted earlier and they were invaluable.

Thanks again for all your help
Frank Barnhill
79 Euro - lite blue metalic
foothills of NC

 

Funny, I just did this job recently, and am working on a write-up. I'd say put all new vent hose -- 15mm is the larger size, 9.5mm is the smaller size(though I used 3/8 fuel line in one spot). The leak at the sending unit is most likely just the rubber gasket. Unscrew it and look -- maybe it really gave up, or maybe some knucklehead installed it improperly. Too bad if that's the only problem -- you shouldn't have to pull the tank for that.

 

Welcome to the Pulled the Tank Klub! (PTTK) which is a PITA. The leak around the sender is the gasket -- or lack thereof. My new sender came with a gasket which was not present on the exisiting tank. I used commercial thread sealer to coat the threads of the cap, and screwed the retainer down very hand tight. I turned the tank over and filled it with my usual kerosene 5-gallon supply. No leak.

As long as you have the tank out, replace all of the rubber hoses and fittings. Pull the overflow tank too, you would be surprised wht is inside that little booger. I used stainless steel clamps on all connections.

While you are at it, clean the in tank filter. Matter of fact, since you are PTTK, clean out the tank itself. It will last another 25 years.

Cheers,

 

Dave, not everyone has a potato farm in their tank. there was nothing to be cleaned inside mine -- looked perfect in there.

 

Dave M.
Thanks for the great advice. I have all the parts on order from 928 Specialist. Tomorrow i will take the tank outside in this beautiful 70 degree weather and wash it down fully. I want it to look new. Also i thought i would buy an inner tube, slice it up and replace all the rubber. This thing is in amazingly good shape for its age. The tank looks new inside except for just a little sediment around the tank screen. Even the screen looks clean. However, i looked over at the rear axles and all four boots are busted all the way around. Well the kits are $31.00 each so i guess that will be the next job. Shame i can't do it while i have it so high in the air.

Well, thanks again to everyone for their help

Frank Barnhill
79 Euro 38K

 

Sounds like the sender cap rubber seal is dead. FWIW I recently replaced my pressure hoses, and the first line from pump/filter up to the steel line to accumuator seemed to be in excellent condition, and the engine bay pressure hose had absolutely no signs of stress at all - no cracks visible, even when bent double. This car has spent 10 years in up to 50C (120F) temps in Arabia. I suggest you replace the vent line through the chassis rail WYAIT. If the end of the return line is showing any signs of degradation, replace that too - but be aware that the genuine part only comes in unit with the WHOLE steel return line from the front, which will need the rear suspension dropped to get it into place. I just pulled the old crimped on rubber part off the steel line with one hand, and clipped on a new piece of hose with a stainless clip/clamp.
jp 83 Euro S AT 50k

 

Hi while your fixing the fuel tank open the hood and remove all of the flexible fuel lines and get new hoses crimped on, if the lines are original then you have a fire hazard waiting to happen, most hose shops can replace the lines with HI pressure fuel injection line, also has been mentioed and i am not shure if you car has this but under the right front fender is a plastic piece called a y pipe this cracks and will let gas fumes escape, look carefully for the junction, Stan

 

Thank you Stan.

You know i saw pix of a 928 a guy was selling on ebay that had burned and the front fenders were melted. It was an s4 but darn, that is a situation I want to avoid. Now the hoses look pretty good for a car this old. I was surprised because a previous 79 with low mileage was stock full of dry-rotted hoses. I never did get them all. I will look at that y-pipe before i put this thing back together.

Thanks again
Frank Barnhill
79 Euro

 

Frank,

I'm in the middle of the same project. My Fuel Tank was cracked and was leaking like a bandit! So, I'm now knee deep into it. Got a new (used) fuel tank, ordering sending unit (bad) new intank and external pumps, new hoses, rebuilt hose from pump to accumulator at classic tube, filter to hard line rubber line also being rebuilt at classic tube. Gas tank strap and cover out to powder coater later this week. Rear bumper cover off and will be repainted shortly, new accumulator and filter, and last but not least-new battery box will be welded in as my old one is toast.

I feel your pain!

 

Potatio Farm? Po -TA-TO Farm! Why I resemble that comment! It wasn't potatoes at all, not here in The Great Volunteer State of Tennessee .. No Sir! It was the State Vegetable: OKRA! Yessir, An Okra Farm!

BTW, Last night Momma was feeling a might bit frisky so she done cooked me up a big ole batch of Turnip Greens with some salt pork seasoning and a big ole bucket full of Boiled Okra with Red Tomatoes!

Put on some of the Red Eye sauce and Yee Ha! The South Will Rise Again!

When you got Okra who needs Hoodia ?

Cheers!

 

Dave... you're welcome to ALL my ok-ri,... and
my neighborhood's too.

Hairy, slim-ey, taste like dirt. My wife (Texas gal) manages
to make it palatable in jambalaya or gumbo.

One of her (TX) gal friends got my daughter at a very early
age to eat pickled okra, while I was out of town (where'd
I go wrong?).

Yes, I'm a d%@# yankee, but I drive a fine auto-machine.


G'luck, to all you fuel systems re-joo-ven-a-turs.

 

Gad -- Okra -- <shudder> it's OK as a part of something else like a stew or goulash but no way I could handle a plateful of that stuff!