986 Forum - The Community for Porsche Boxster & Cayman Owners - View Single Post - Okay, this is weird! Fuel tank rejects fuel.

thom4782 · 08-01-2015, 06:21 PM

There are two symptoms. They may be related to a single problem or you might have two problems.

The fuel smell suggests a leak somewhere in the EVAP system. It could be a crack in the top of the tank gauge to a worn o-ring in the fuel cap or any of the hoses connecting things to the charcoal canister. Is the fuel smell always present or just when you fill the tank completely. In my case, it was there when the tank was between full and half full. This turn out to be the tank gauge.

The hard to fuel problem can have several causes. As one poster mentioned there is a TSB associated with a hose slipping inside the tank. Or it could be a plugged carbon canister. In could be literally anything that keeps the fuel system from venting as the tank fills with liquid. BTW: There is a shut off valve associated with the carbon filter. And sometimes, it can be just the pressure in the hose from the pump. If it's high like it is at some stations, air can't vent quickly enough and the pump handle clicks off. In my car, I both re-tied the hoses in the tank according to the TSB (actually the shop did it) and I replaced the carbon canister on my 14 year old DD. I did these at different time and the slow filling problem got better with each fix. Now its fixed completely

Hope these ideas help

08-01-2015, 06:21 PM	#6
thom4782 Registered User Join Date: Sep 2010 Location: Foster City CA Posts: 1,099	There are two symptoms. They may be related to a single problem or you might have two problems. The fuel smell suggests a leak somewhere in the EVAP system. It could be a crack in the top of the tank gauge to a worn o-ring in the fuel cap or any of the hoses connecting things to the charcoal canister. Is the fuel smell always present or just when you fill the tank completely. In my case, it was there when the tank was between full and half full. This turn out to be the tank gauge. The hard to fuel problem can have several causes. As one poster mentioned there is a TSB associated with a hose slipping inside the tank. Or it could be a plugged carbon canister. In could be literally anything that keeps the fuel system from venting as the tank fills with liquid. BTW: There is a shut off valve associated with the carbon filter. And sometimes, it can be just the pressure in the hose from the pump. If it's high like it is at some stations, air can't vent quickly enough and the pump handle clicks off. In my car, I both re-tied the hoses in the tank according to the TSB (actually the shop did it) and I replaced the carbon canister on my 14 year old DD. I did these at different time and the slow filling problem got better with each fix. Now its fixed completely Hope these ideas help Last edited by thom4782; 08-01-2015 at 06:29 PM.