Refilling and fuel cap

[Ashmyster79]

As some are aware I recently bought my 2002 3.2s I got it cheap so knew there would be issues. Fuel gauge is saying empty when it is not. Have filled up but still the orange light is on and pin on empty

Car garage said fuel sender unit needs replacing. I have checked the fuses all fine. However when I fill up or try too the petrol pump keeps clicking like it would if the tank is full which I know it isn't. This is tricky to judge as continuing and bypassing the clicks I could over fill although I doubt I will.

So my question is. When this happens why is that?
Also the fuel cap is pretty bad on the outside. The thread is good but think needs changing. I remember from my 350z when I took fuel cap off I would get a release of pressure which I don't get on the boxster. Is this something that should happen?

I am going to check the fuel sender connections and see if the float is stuck. Will do this before I spent £300 at the specialist to get it fixed.

Thanks for the information in advance.

[rfuerst911sc]

I have a 2002 S that I picked up in January of this year. To date every time I go to fill up I have not heard any release of pressure when removing the cap. It does sound like you have a bad sending unit but make sure the chassis ground for the sending unit is good.

[Ashmyster79]

Originally Posted by rfuerst911sc

I have a 2002 S that I picked up in January of this year. To date every time I go to fill up I have not heard any release of pressure when removing the cap. It does sound like you have a bad sending unit but make sure the chassis ground for the sending unit is good.

Thanks for the reply. So we have similar cars. So maybe I should not expect any release of pressure that's good to know.

I am going to go and look at the sender unit now see if I can spot anything obvious. Will take a pic and report back.

I am hoping it's just a loose connection. I wish.

[Ashmyster79]

Looks as though it has had a 'glue repair' previously. Guess that looks like a crack which tells me I need a new fuel sender.

Now need to decide whether to do DIY or take it to the garage

[Timco]

Bought my car in Los Angeles. When I was driving home, stopped in Mojave desert for gas. Clicked off every 2-4 seconds. Must have taken 20 min for 1/2 tank. Thought what in the hell did I get myself into.

Turned out, that pump had a very sensitive CA approved vapor recovery or sensor, and that short fill tube triggered it every time. Had the black rubber shroud that contacts the car. Since getting to UT and almost 2 years later, it hasn't done that once and I didn't change anything.

Some pumps.........

[Deserion]

Originally Posted by Ashmyster79

Looks as though it has had a 'glue repair' previously. Guess that looks like a crack which tells me I need a new fuel sender.

The glue is on there as a tamper marker to show if it's been removed prior. Mine had it on there, too.

[Ian c]

Put the nozzle in on an angle and drape the hose over the side mirror .

[Ashmyster79]

Originally Posted by Deserion

The glue is on there as a tamper marker to show if it's been removed prior. Mine had it on there, too.

I thought something like that after I wrote it. I looked at the pics of others and they had the same. Thanks for that. I will get my hands dirty again and get right inside this time.

[JBoe]

Just a thought... If you remove it you may be able to check the sending unit with a simple ohm meter. Most either use that or voltage variance via resistance. A meter would be able to show changes as you operate the float. This has worked for me on many other vehicles with similar issues. Every time, thus far, it's always been a complete replacement of the unit. I've heard some sell the parts separately, but most seem molded together.

[Ashmyster79]

So. I have had the car two months. Fuel gauge was on from day one fuel in there orange light on. Stumped and told by garage that needed new sender unit £280 all in. I been delaying it and filling up every other journey

I replaced the fuel cap still no joy but it looked a lot nicer so can't grumble. So today I parked the car on the kerb leaning towards the fuel tank. Left it for a few hours. What do you known. Voila fuel gauge working and needle straight up to 3 quarters. Well happy as was getting to the point of buying a new unit.

So I guess it was a stuck float. Worth checking this before you splash out. One less job to do or pay for

[JBoe]

That's a one I've never heard of and a new trick to my book. Thanks and congratulations.