[johns_968]

Hi all,

Just got my car back from Darryl and he did an awesome job on the exterior paint detailing. The car looks awesome. Darryl really put his heart into it.

I am attempting to isolate and address my next issue. There is a fuel smell I get in the car. I traced this back to the trunk area and more precisely the small area where you access the fuel sender. The plastic cover was just lightly sitting on the hole and when I bent over and put my nose in the hole next to the sender I got a pretty good fuel smell there.

Previous owner told me he had some fuel gauge level issues and had the sender replaced 2 times but still has the problem. I can live with the inaccuracy of the fuel gauge for the moment but don't like the smell. I noted that the the clamp on the left hose was busted and the hose was very loose on the metal outlet. So I changed the clamp and now it is pretty tight but still getting smell. I may try to isolate the fuel gauge problem later. That is probably the gauge at this point.

There is no trace of leaking gas or wetness in that area. Just the smell.

I suspect a problem occurred during the sender replacement which is at the root of this problem. Is there a seal that needs to be replaced under that unit? Is there a procedure posted somewhere that details the replacement? I'd like to figure this out before pulling out the sender.

Can I just pull those 2 tubes off the sender without gas spilling out?

What should I use to seal that plastic cap back on the hole of the fuel sender area? Is kind of just sits there now and I think there was some sort of goop holding it in place as I see a bunch of screwdriver marks around the outside that somebody made scraping something off there.

Anyone have any hints or suggestions on this problem?

Thanks all,

Any and all suggestions welcome.

John

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[Mark]

check out these threads
http://www.968forums.com/index.php?showtopic=7752

http://www.968forums.com/index.php?showtopic=6302

http://www.968forums.com/index.php?showtopic=5709

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[johns_968]

Thanks Mark, Lots of good info there.

Looks like this is a more of a complex problem then I thought. Or at least hard to isolate. After tightening up that clamp on the sender the fuel smell has decreased and it doesn't smell any stronger if the tank is full or if I drive and make hard turns either left or right. So I don't think right now I have a problem with the filler tube.

I'd like to change the gasket on the fuel sender and just wanted to see if somebody can confirm this is the right part.

http://www.pelicanparts.com/cgi-bin/smart/...95%29%2C%20Each

Is this a difficult part to replace? Will I need any special gasket sealant or something like that before putting this all back together?

Thanks

John

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[Mark]

Links to other threads is all I am good for, hopefully someone else will respond. [img]style_emoticons/<#EMO_DIR#>/smile.gif[/img]

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[stevefx]

Sorry if this sounds simple but all I do is make sure I never fill the tank more than 3/4 full. Works for me.

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[968kid]

Hey John,
I have the same issue. Yes that's the correct part# for the gasket. Here's how I changed it out
-disconnect battery
-pull sending unit connector straight up. It has four holes with only three being used. You can see the contacts inside the holes to line up with the male plugs for re-assembly or just note position before removal.
-Mark the two hoses left and right just in case and remove. About an 1/8 cup of gas came out of the right side hose if I remember correctly.
-Unscrew black plastic ring
-slowly lift unit out of tank. It's rather long and filled with gas. Might be a good idea to have a pan/rags ready if you want to inspect/remove fully.
-You'll see the gasket on the underside of top plate.

As for my access cover, I have a 1/2" thick 10x10" piece of what looks like flame retardant material with adhesive which holds the cover in place.

Unfortunately this did not solve my issue. Max @ RS Barn pressure tested the tank system with a device he rigged and it showed no leak. But the test was quick and I wonder if a very small compromise to the system would not show up on the test but still allow enough vapors to cause the odor.

Next try for me is the filler tube.
At this rate I figure in ten years I'll have replaced just about every rubber piece on the car.

Good luck with your search

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