928-I smell gas when filling past 3/4 tank

[Rice Killer]

When filling up with gasoline I cannot fill past maybe the 3/4 mark. if I do I start to smell gas inside and outside the car. Does anyone know why this is happening and how it can be fixed???

[JonA]

I just went thru this with my 924. Assuming the tanks are similar, some of this may help.
Check the hose connections where the filler tube goes into the tank. Also, there probably are one or two additional vent hoses from the top of the tank that could be loose or cracked. On the 924 it is necessary to remove the tank to get to these fittings. I cut two round openings in the rear deck to get at them (much, much easier). I will put on tight covers when done to preserve the integrity of the deck. The gauge sender unit is also probably located at the top of the tank and this should have an access plate. It may need tightening or a new gasket. Finally, the tank may be rusted thru and leaking at the top like mine was (assuming that the 928 has a metal tank) I have just completed a patch and will pressure test tomorrow once the epoxy has set up. Patching is not a good option generally. The tank should be replaced and one thing to know if you look for a used tank; the salvage yards cannot ship a used tank. You have to pick it up at their yard.
Working around gasoline, vapor and liquid, is dangerous and I do not recommend that you get into this unless you know what you are doing.
Hope all this helps. Good luck.

Jon A

[car911]

Originally posted by Rice Killer:
When filling up with gasoline I cannot fill past maybe the 3/4 mark. if I do I start to smell gas inside and outside the car. Does anyone know why this is happening and how it can be fixed???

I would first pull back carpets, etc and check the fill hoses, vent tubes, etc and anything else you can get to from the top. Then check anything you can see from the bottom (which is unlikely if the leak is at the top of the tank).

Unfortunately, it is likely to be stress cracks or other damage at the top of the tank. Means removing the tank, having it boiled out, and repaired.

If this is the case, I would probably opt for repairing it versus a used tank. This way, you know the tank's condition. The cost of repair should be relatively low ($100 or less at a rad shop) and the real cost is R&R (typically remove exhaust, drop transmission, etc).

I went through all of this on my 944 recently. I was hoping for an easy answer but there was none other than removing and repairing the tank - about 5-6 hours labour plus cost of tank restoration.

If you're lucky it will be a loose hose! But be prepared for a major job. Hope this helps.

[Mrmerlin]

[QUOTE]Originally posted by Rice Killer:
Hi Bro, for the leak look at the sealing surface of the fuel inlet it may be bent where the cap seats onto it,from there I would look into the inlet hose either being a loose clamp or the hose has a hole in it,
The tank on a 928 is made of plastic, you might find out more from inside the rear interior area lift up the rug and remove the cover plate this might give you some access to the hoses, you may also try going up from the wheel well to reach the inlet hose......Stan
PS keep a fire extinguisher handy while your working on the fuel system, and work in a ventilated area, outside is preferrible

[car911]

[quote]Originally posted by Stan Kolen:

Originally posted by Rice Killer:
Hi Bro, for the leak look at the sealing surface of the fuel inlet it may be bent where the cap seats onto it,from there I would look into the inlet hose either being a loose clamp or the hose has a hole in it,
The tank on a 928 is made of plastic, you might find out more from inside the rear interior area lift up the rug and remove the cover plate this might give you some access to the hoses, you may also try going up from the wheel well to reach the inlet hose......Stan
PS keep a fire extinguisher handy while your working on the fuel system, and work in a ventilated area, outside is preferrible

Just curious - but... can plastic tanks be boiled out and repaired like metal ones? I know that some plastics can be 'welded'. Are there shops that do this kind of work???

[Jeremy Cottrell]

Can plastic tanks be repaired??

[scheistermeiste]

or does anyone know any SAFE LOW COST (oxymoronic) fuel cells?