Smell of gas / fuel odor: Cracked fuel sender

[scottvd]

Fairly strong odor of raw gasoline from the front area of my Boxster, no so much inside the cabin. Did some research and found this thread from renntech and this thread from this lovely forum. Both pointed towards the fuel level sending unit being cracked or damaged. I removed the battery and sure enough found raw fuel pooling up on the top of the sending unit.

Here's a photo for reference, trying to avoid becoming the lower inset picture! Will be ordering a new sending unit and o-ring from the pelican man today!

[BYprodriver]

When my Box was 3 years old I had the seal replaced under warranty which fixed the odor.

[scottvd]

This is the culprit - when I cleaned up the pooled fuel I could see fuel leaking from the base of this hose. I did not want to move it around too much just in case it brakes off completely or makes things worse before the new parts arrive. Gonna get it home and park it until the parts arrive.

[BYprodriver]

Make sure tank is at least 1/2 full to help prevent losing fuel level calibration. Note the fuel level before you disconnect power & see if it changes when you finish. If you loose the calibration dealer will charge $100+ to recalibrate with PIWIS tool.

[woodsman]

good idea to park it. I wonder if the fitting has come loose? Read everything you can find on fuel pump replacement before doing the job as there's a little twist needed when reinstalling... then again it could just be the fitting .

[scottvd]

Job's done! A couple of tips:

1. Pop the rear boot before you start just in case you need something from there before you finish

2. There was a circa 8 second delay from when I disconnected the top fuel lines to when they began spewing forth raw fuel - so be prepared with a towel to soak that up

3. Don't forget to put the new tank gasket in BEFORE you connect the hoses and wiring harness (doh!)

Here's what the cracks looked like: