Caledonian Posted 29November, 2017 Report Share Posted 29November, 2017 For some time now I've been a getting petrol smell in the car after filling up, i checked all the obvious stuff Vent hoses, fuel leaks from the sender, pump and lines, but nothing? The smell usually went away after a few Km's and it seemed to go once I replaced the fuel cap o-ring/seal, but that turned out to be more of a placebo effect ? So another " While I'm in here" resulted in the tank being removed, https://www.flickr.com/gp/152710446@N03/m507wm https://www.flickr.com/gp/152710446@N03/K22g1L Which was a lot less hassle than I thought it might be: • 3 x 8mm nuts to remove the sender shield and wiring. • Fuel pump and return lines • Filler and vent hoses • 3 x tank securing clamps I already had the carpet and battery out, and then just a decent shove from underneath ( some posts indicate lifting it with a trolley jack if its stuck) mine came free without that and even the seal (foam) was still intact. On removal of the fuel sender the probable cause was located! The seal was intact and there had be no sign of fuel around it, ( I usually only have it filled to a little over 1/2 fuel) but the seal was very hard more like plastic than rubber. New Porsche seal on right: https://www.flickr.com/gp/152710446@N03/920583 The fuel filter/drain plug seal was replaced also: https://www.flickr.com/gp/152710446@N03/10huzY It was good to see inside the tank was very clean, with no signs of rust or sludge: https://www.flickr.com/gp/152710446@N03/10huzY I also wanted to check the check valve on the fuel pump, and replaced the mounts as one was hanging but a thread, new clamps, copper washers and feed hose replaced too: https://www.flickr.com/photos/152710446@N03/shares/t52K4A https://www.flickr.com/gp/152710446@N03/Ct9u9n The boot area was cleaned and a new tank seal/ foam fitted (another part sourced from Bunnings at 1/4 of the Porsche cost!) : https://www.flickr.com/photos/152710446@N03/shares/uug8P1 I had bought some new hose for the fuel vent system but it was not the correct size, so the old stuff went back on apart from the 2 under the guard on the expansion tank: https://www.flickr.com/gp/152710446@N03/950N17 On refilling the tank with the removed fuel, there was no apparent fuel smell in the car! And even more satisfying was than on the way back from the wheel alignment I topped up the tank to just over half full and still no fuel smell in the car.. YEH!!! On refilling the dry tank I noted the following: 5 liters added and fuel gauge showed right on Empty Another 20 Litres showed 1/4 full The top up at the fuel station 25 Litres showed just over 1/2 full. I also now no why my fuel light does not work. There should be a thin copper wire ( sorry forgot to take a pic) that runs down the outside of the sender body, it was missing? Hopefully this one will not be continued ? Link to comment Share on other sites More sharing options...
Zelrik911 Posted 29November, 2017 Report Share Posted 29November, 2017 Thankyou for the commentary and photos. This takes a lot of 'mystery' out of these jobs. My fuel gauge (sender?) sometimes sticks & I can see that its a fairly straightforward task to get to it. Link to comment Share on other sites More sharing options...
Mark1977 Posted 30November, 2017 Report Share Posted 30November, 2017 Great post mate, pictures sure do help understanding the work you have just done. Doing similar work on my 77 in the next few weeks. Link to comment Share on other sites More sharing options...
Caledonian Posted 30November, 2017 Author Report Share Posted 30November, 2017 Thanks for the feedback, I'm glad to hear they are of some use. i do take lots of photos (not always good ones though) of the stuff on the car I'm working on, especially has I can have quite a few days between and forget where stuff goes? Link to comment Share on other sites More sharing options...
Peter M Posted 1December, 2017 Report Share Posted 1December, 2017 While the tank is out, I also like to fish oil/wax the hollow body sections around the front and if the paint is a bit chatty around the battery to respray that as well. It is so much simpler to do all this when the tank is out. I also enjoy (yep, that's the right word!) repainting the tank to match the original colour too. Link to comment Share on other sites More sharing options...
Caledonian Posted 1December, 2017 Author Report Share Posted 1December, 2017 6 hours ago, Peter M said: While the tank is out, I also like to fish oil/wax the hollow body sections around the front and if the paint is a bit chatty around the battery to respray that as well. It is so much simpler to do all this when the tank is out. I also enjoy (yep, that's the right word!) repainting the tank to match the original colour too. For once I'm ahead of you Peter? I refer to the following pic from my A/C post: https://www.flickr.com/gp/152710446@N03/8m085i that brown stuff Is cavity wax ( not the fishy kind) I did all the box sections too but more of that in future post. I did consider giving the tank a clean up, but I wanted to get her back on the road. Last Cars and coffee of the year tomorrow ? Link to comment Share on other sites More sharing options...
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