dozybee

944 early 1985 NA Replacing the rubber fuel filler boot. ( RH drive, UK )

This must have contributed to the humidity and rot in the interior of the car.

Remove the screw on filler cap. Replace it whenever possible for obvious reasons.
Old Boot

Metal cover

Main drain

Filler revealed

Filler rubber mounting holes

Circlip and flap

Lever out the metal ring that holds the vinyl flap.
Remove the plastic filler cover to save it from injury. Mine required a bit of fiddling to get it out.
Try not to drop bits down the filler neck.

In hindsight a very determined effort could be made to extract the boot without removing
the inside metal cover to access the rear of the boot. I was curious to see where the fuel lines
went and to check their health, so the inside cover was also removed.

The carpets were already scrapped so the other padding over the cover had to be sliced out
to access the metal cover.
2x 8mm nuts and some self tappers held the cover. It was sealed in with some tacky stuff and
required some effort to free up.The rubber filler boot could then be levered off the bodywork from
inside the car

Check and tighten the fuel hose clamps.
Make sure the inner cover is sealed on tightly. ( Leaky exhaust ?? )

Reassembly is the reverse of the above.

A smaller drain grommet is supposed to catch the water, etc., It should have a small metal pipe on it
and tees into the rear roof drainpipe.

And so the restoration goes on !

dozybee

The filler drains were rather elaborate (1985 engineering). 6mm plastic piping and some junctions solved that problem.
I also cut and stitched a new vinyl flap. The plastic filler cover hinge was scratchy so some spray on grease fixed that.
The new carpet kit has arrived so I may report on that debacle to come.

6mm junctions

Complete assembly

Tiger03447

I just rigged my fuel filler drain with a totally new hose running out the Right rear cubby onto the ground. Roof drain has it's own problems, and it runs out about the same place...jus sayin. Might now be "absolute Kosher" but it works.