Replacing Fuel Door Actuator

[vljbbeach]

Are there any articles out there on how to replace the Fuel Door Actuator?
2003 Porsche 996 Carrera 4 Cabriolet.
I had done a search but to no avail. Did I miss something?
Help would greatly be appreciated.
Thank You in Advance.
Vin

[JFP in PA]

Originally Posted by vljbbeach

Are there any articles out there on how to replace the Fuel Door Actuator?
2003 Porsche 996 Carrera 4 Cabriolet.
I had done a search but to no avail. Did I miss something?
Help would greatly be appreciated.
Thank You in Advance.
Vin

Get a Bentley manual for the 996, fully covered on pages 50-2 and 50-3, with photos and diagrams.

[LarryHughes]

I'm going to make a leap of faith here and assume that folks searching this forum are looking for practical advice on the how-to rather than a bibliography.

The task is fairly straightforward but requires some time and a lot of patience. I just replaced the actuator and it took me a good 4 hours. BTW, the Bentley manual is different than my installation ('01 996) and they describe "electrical connector" on the vapor canister but they are all fuel vapor hoses.

Remove right front wheel.
Remove inner fender liner. Now the fun begins!
Remove the 3 fuel vapor lines connected to the canister. These use 'squeeze and pull' connectors but the space they are in is not meant for human hands. It took me 1 1/2 hours just to get these 3 connectors off.
Now remove the nut on the stud to the right of the canister that holds it in place.
At this point, there are only 2 rubber grommets on the back side of the canister (door hinge side) holding the canister in place. You will swear you've missed a bolt or something. It just take a lot of force to pull the plastic studs out of grungy old rubber biscuits. I used a flat pry bar and gently forced it off. Lube the biscuits and studs with liquid dish soap and it will make reassembly much easier. Now brace yourself for even MORE fun!
The actuator (< $40 at Pelican) is buried above where the canister was. Apparently this was the single part around which the 996 is assembled. To remove it, you will need a T15 Torx that is very short (1") in length so you can worm it in there. The 2 screws need not be completely removed as the bracket that holds them is slotted at the top. (So there was at least one maintenance oriented designer at Porsche who apparently was subsequently fired.) You would be wise to replace the T15 screws in your replacement unit with hex head screws to simplify reassembly. In any case, you will need that T15 driver to get the old one off.
Remember to replace the plastic cable emergency release when replacing the actuator. Fish the cable through the door jamb where it rests in a slot and hole arrangement.
Now replace the centering grommet from the fuel flap access. As these tend to fall out and get lost with some frequency, I put a dab of trim adhesive on mine.
Put the electrical connector back on the actuator and test.
Replace the fender liner and the wheel.
Check the ground for excess parts and toast yourself with a cold brew if there are none. You deserve it!

Oh. And do consider the Bentley Manual. I have one and use it as a reference frequently. But I find that the folks on this forum have some valuable input.