Wachuko

I took the time to change my fuel filler neck today to avoid the fuel smell, in the trunk and outside, every time I made a hard turn. Here are the steps I did. I hope it helps!!

(Please know that there is another site from a fellow Rennlister with similar documentation and for all practical purposes this thread is not really needed. The one in John's WebSite is based on a Rennlist post but I could not find the original post here... and I wanted Rennlist to have its own I guess, so... anyway, here is the link to that one Curing the Fuel Odour Problem in the 964 Trunk
And here is mine:

If your car is experiencing fuel odor in the trunk or outside there are a few things to check I will start with the least expensive ones:

1. Check the condition of all hoses, and that all hose clamps are secured. This also includes the tube going to the carbon canister, and removing bottom cover to check fuel pump area.
2. Fuel cap seal. This seal can be purchase separately for around US$3-4.00 or you can just buy a new fuel cap.
3. Vent valve at the top of the small fuel tank on the drivers side could be craked. Part No. 964 201 175 01 (This is a US$30-40.00 part). #10 in the Diagram 1
4. Fuel filler neck... reason for this thread

Fuel cap and cap seal... Start by replacing the seal or the complete cap.






Diagram 1 - FUEL SHUT OFF VALVE - Part No. 964 201 175 01 (This is a US$30-40.00 part). #10 in the diagram




If everything else fails then it is time to change the Fuel Filler Neck. As of this writting, this part is in its 7th revision with the most recent part number being 964 201 043 07.

Edit/Correction - Please take notice:

Here are photos comparing the old and the new:









New:





Old:

Wachuko

To remove the old filler neck start by opening the bonnet/hood and removing the carpet in the left side of the car (closer to the gas cap).

This is what you will see:




You will see two hoses. Loosen the clamps. The first hose clamp requires a 7mm socket or the use of a flat screwdriver. I found the use of the socket to be faster.



Pull the hose out of the way to reach the second one. For the second hose clamp you can only use a flat screwdriver.



Once loose, pull the hose from the filler neck. Now on to the other end.

Open your fuel tank filler door (if you don’t know how to do that by now please stay away from any work on this car). Proceed to unscrew/remove gas cap.



Using large snap ring(circlip ring) pliers take out the snap ring (circlip ring) that holds the filler neck in place.





Remove the plastic washer that is under it. Please take notice of its direction. It needs to be installed back in the same way or you will cover the drain hole if installed incorrectly (squared end goes up, between the two bolts).



Snap ring (circlip ring) and plastic washer removed:



Now that the hoses are out of the way and the filler neck free… wiggle the old filler neck out… it helps to push it gently from the outside with one hand while you pull it out from the inside with the other hand.

Wachuko

Installing is, as they say, the reverse of removing…

Insert the new filler neck. Make sure as you are inserting it back in place that it comes out enough to see the groove where the snap ring goes. Notice I have not removed the plastic temporary caps at the end... those need to come out before you hook up the hoses...



Install the hoses. Tighten the clamps

Install the plastic washer (squared side up).



Install the snap ring. Screw the gas cap back in place.



Close the fuel door.



Install the carpet. Close the bonnet/hood and you are done!! If you did like me (I let the gas go very, very low before tackling this task) go to the gas station and refuel. Check for any vapor leaks (do not smoke or light a cigarette while you do this, please…)

EDIT:

Wachuko

I will update with both names to avoid confusion

All in all, less that 40 minutes (that included drinking an expresso with my father-in-law.

Wachuko

Should be the same procedure. I show same part numbers and my car is a turbo body conversion with factory parts. You should be fine following the same steps.

Wachuko

Without taking the old one off... humm... I would think you will be able to tell by the differences from looking at the opening of the old vs the new...

New:


Old:


Notice the extra two holes on the border of the new one

I bought mine from Sunset Imports ... but I can't find the invoice... it was one of those invoices I threw away before the wife got a hold of it... it had a set of 1:43 water cooled Porsche set, all the maintenance kit, valve cover (ouch), etc... I have a spreadsheet where I wrote down the cost as US$ 95.96, best to call Sunset Porsche and validate.

Wachuko

See previous post...

I have a spreadsheet where I wrote down the cost as US$ 95.96, best to check by calling Sunset Imports... when I was searching for the part it was the lowest price I could find.