2003 C4S

Had a strong fuel smell in the cabin, pulled the access cover to see top of fuel tank and saw puddled fuel. Started car and saw spraying out of the bottom of the pressure line at 2 o'clock in the photo. If I push down on this fitting I can move it down toward the tank 1/4" or so at which point if I hold it there the leaking stops or at least reduces greatly. There are also numerous hairline cracks in the sending unit. Did hours of forum searches and it seems rare that the coupler itself is the problem, more often it is the sending unit. My question is should this coupling have that much play? Is this possibly just a bad sending unit or does it seem more likely it is a bad connector? Thanks in advance.

 

Anybody willing to pop those 4 nut of their access panel and see if their fitting has that much up and down play? Mine's a C4 not sure if accessing it on a C2 is more difficult? Just trying to get more info before I order unneeded parts.
Thanks

 

Is there an O ring in it?

 

I have not tried the porsche fuel system but every other quick disco i have worked on has about a 1/4" of play. Im pretty sure there is a replacable o-ring or clip in there that will solve your issue.

 

At almost 20 years old, any and all rubber or plastic pieces will need replacing.

 

Lately I've been sensing a strong gasoline smell too. I'll have to check this.

 

I think Bill is right. Pinch that hose connector and pull up. I'll bet you will find an O-ring. A little trip to the hardware store for a new O-ring might just fix you right up.

 

does the return line connector have any play ?

 

Sorry about the delay in responding had a dog emergency over ht e last 24 hours. There is a tiny o ring but it will be a little tricky to pull out of there as the whole thing is facing downward and there's not a lot of play in the hose/fitting to get it to point towards you. Because there seemed to be a lot of threads regarding cracked and leaking sending units I ordered one from OEM Exotic auto for $199 along with the seal. As mine was cracked I figured I might as well order a new one even if it turns out not to be the problem. I'm guessing there are threads regarding replacement and that it has to be way easier than the AOS I had to do on this car. As far as I know this year doesn't have a return line but the vent line seems to have the same type of connector and I was especially airheaded that day and didn't think to check that one until yesterday. Yes it does seem to have the same amount of play. I will definitely try the a new oring if the sending unit doesn't solve the problem, is there a material that will work better than others in contact with gasoline? If neither work I guess it is buying this fuel line 996-201-261-05, lowering the tank a bit and trying to snake it through. There was a thread somewhere regarding someone having to do this and now I'm wondering if they tried replacing the oring first? Thanks for the replies I will definitely report back with the first results.

 

I replaced my pump last summer .It is not too bad a job Hopefully you don't have a full tank because it needs to be empty .The hardest part is the new seal takes a bit of trial and error to get a technique .On the oring I don't think I would go the hardware store route .As a last resort I think you can find a similar fitting and use that oring .

 

It looks like your parts may be # 1 & 2 in this drawing http://www.autoatlanta.com/porsche-p...section=201-05

 

Any update on this? Was the fuel smell apparent when the frunk was open? I'm getting a fuel smell in the cabin after the car warms up, but I popped the frunk lid and there was no smell there.

 

Part arrived today, will try to get it in tomorrow. I don't remember the smell being overwhelming in the frunk, very noticeable in the cabin though. That part number 99620126103 maybe has been replaced by 99620126105. Hopefully the sending unit will fix it we'll see. Right now I'm dealing with a broken water pump bolt in my Audi, fingers crossed or this one is on it's way to the junkyard...

 

Good luck! I have a feeling that this might be my problem too.

 

So I just went out and put in the new sending unit and Voila! no leak, no spray, all good. Took 15 minutes tops to swap out. As I was putting the access cover back on I could hear what sounded like draining in the tank, then it took a little bit of cranking for it to startup the second time, I'm guessing this will go away as air gets out of the system. Looking at it it seemed like it had to have been the connection but it wasn't. Thanks for all the help.