Gasoline smell

[pfarah]

So..., I've been combating the infamous gas smell with the windows down issue since purchasing the car 2 yrs ago. I performed the fuel sender R&R upon purchase since the gas gauge was acting up and it came to me, only a couple of weeks ago, that maybe I should replace the gasket. Prior to this, several long interludes of removing the fuel filler assembly, checking fuel lines, etc, etc, etc..., I was coming to the realization that the fuel tank must come down. Well, today was the first drive with the new gasket, windows down, beautiful cloudless day, and practically no smell! I also found a crack in the gas cap o-ring so that was replaced. Testing will continue...

[mytrplseven]

Are you sure that the smell originates in the cab? I'm wondering if there's a fuel/fire potential from under the hood. Sometimes opening a window will suck engine fumes from outside cabin. I'd take a close look at those fittings and hoses.

[pfarah]

I appreciate the suggestion however; every air/fuel system component under the hood has been inspected, repaired, and or replaced over the course of my two year ownership. Even the charcoal filter was removed, checked for leaks, and reinstalled with new hoses last year. When replacing the fuel sender gasket last week, I discovered two of the allen mounting screws were fairly loose so that may have contributed to the problem.

[DannoXYZ]

On my car, I found a leak at the fuel-pump. Well, didn't need much searching as gas was dripping on the ground. Someone previously couldn't tighten the fuel-pump banjo-bolt tight enough, so they used red Loctite on the crush-washer as a sealant. Didn't work as there was still a gap.

A quick 1/4-turn of the bolt while holding the fuel-pump with channel-lok pliers took care of that.

[hobie911]

on mine the S- hose, first hose out of the cell before the pump, just rotted and fell apart.

[BoxsterGT]

There are lots of possibilities for causing a fuel smell, but one of them involves early 944s with the steel gas tank. It has a defect that was caused by incorrect forming/stamping of the tank by Porsche or their supplier. This develops over time into a stress crack. Its at the top, and shows up primarily when the tank is full or close to it.

I just keep my tank at a max of 3/4 which lessens the odor. The later plastic tanks will fit but require a great deal of effort to do properly.

I am sure someone has a simple solution to this. A search may find the answer.

Len

[pfarah]

Hence the reason to exhaust all other possibilities. I haven't filled the tank yet, possibly this weekend if the weather holds out.