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Ozzie

I had a problem with bad fuel smell after filling the tank.
I knew it had to be cracked lines around the tank and after reading the Haynes manual I figured there had to be an easier way than removing the exhaust and transmission before lowering the tank.
I didn't want the tank out, I only wanted access to the fuel lines.
This is my story.

I have a 1984 NA euro with automatic transmission.

First I studied the Pet diagram to understand what and where the fuel lines are.
I had to replace hoses 2, 18, 23, 24, 6, 8 & 22.
These are slightly different depending on model and country and environmental laws.
Hose 2 in some countries goes to a carbon canister.

When the tank was nearly empty I removed the pump fuel line and drained it into a fuel can.
I then let it "air " out for a few days to get rid of any dangerous vapour and reduce risk of explosion.
Other methods are to fill the tank with water (but increase weight) or nitrogen which I dont have.
Besides I wasn't in a hurry.

I removed the carpet and liner in the rear and lowered the seat.

I removed the cover for the fuel lines and started removing them.
I noticed an access hole on the left hand side.

I removed that and I disconnected the battery and fuel sender.
I disconnected the rear exhaust bracket attached to the transmission, undone the straps and lowered the tank about 4 inches/100mm.

I had to gain access for the hose connection on the LHS and with a pair of tin snips carefully cut a hole above the appropriate area.

I removed and replaced the hose in this area and the one going out the back
I also cut a section out for access to hose 22.

I refitted the tank, exhaust and fuel lines under the car.
Using some thin aluminium sheet and 3m sealant I fashioned covers for these access holes and painted them.

Replaced the remainder of the lines.

Refiited everything removed earlier and cleaned up.
This was definitely easier than removing the transmission and exhaust.
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Porsche 924 1984 (UK import) NA
Its AUTO and its BLACK
Montego Black on black/red
Engineer of Electro/Mechanical Systems Maintenance

macBdog · Posted: Thu Jan 19, 2006 2:54 pm Post subject:

So this fixed the problem completely? Great guide!
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1979 931 with a 350 chev
1973 911E with EFI

Ozzie · Posted: Thu Jan 19, 2006 7:53 pm Post subject:

I think I have to change the lines near the accumulator but the smell is almost completely gone when I fill up.
I am going over the entire fuel lines and replacing them as I go.
These were the hardest to get to.

*the first pic with the carpet removed is actually the finished product on that side but looked exactly the same.
_________________
Porsche 924 1984 (UK import) NA
Its AUTO and its BLACK
Montego Black on black/red
Engineer of Electro/Mechanical Systems Maintenance

Zuffen · Posted: Sun Feb 12, 2006 2:16 pm Post subject:

Item number 5 is the main culprit as it is plastic and cracks, I would like to see someone willing to replace that piece and give the fuel system a try and see if the smell goes away
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Bob Dodd - 924turbo@cox.net
931 1982, 944 1982 euro, 924S 1988SE, 93 968 tip 06 Silver Cayenne S, 06 Black Cayenne S

I have Way too many cars, parts for the 931,944 and 951

Ozzie · Posted: Sun Feb 12, 2006 2:20 pm Post subject:

I checked mine and it was OK. Otherwise it would have been one long hose.
_________________
Porsche 924 1984 (UK import) NA
Its AUTO and its BLACK
Montego Black on black/red
Engineer of Electro/Mechanical Systems Maintenance

Zuffen · Posted: Sun Feb 12, 2006 3:01 pm Post subject:

did you happen to locate the fuel leak then?
_________________
Bob Dodd - 924turbo@cox.net
931 1982, 944 1982 euro, 924S 1988SE, 93 968 tip 06 Silver Cayenne S, 06 Black Cayenne S

I have Way too many cars, parts for the 931,944 and 951

Ozzie · Posted: Sun Feb 12, 2006 3:08 pm Post subject:

Hoses 22,23 & 24 were discoloured so I suspect it was them.
I fill up completely and just get a faint smell now and not for very long.
_________________
Porsche 924 1984 (UK import) NA
Its AUTO and its BLACK
Montego Black on black/red
Engineer of Electro/Mechanical Systems Maintenance

Eagle924S · Posted: Tue Nov 28, 2006 12:10 pm Post subject:

What did you use to cut through the metal to get to the hoses?
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87 924S

Ozzie · Posted: Tue Nov 28, 2006 12:53 pm Post subject:

Tin snips.
http://en.wikipedia.org/wiki/Tin_snips
_________________
Porsche 924 1984 (UK import) NA
Its AUTO and its BLACK
Montego Black on black/red
Engineer of Electro/Mechanical Systems Maintenance

joecitizennn · Joined: 12 Sep 2005 Posts: 2096 Location: no mans land

Ozzie, if I am planning to replace my tank hoses, what sizes do I need to get and in what lengths? That way I can have my parts when I start rather than running to town after the car is torn apart.

Ozzie · Posted: Thu Mar 13, 2008 12:38 pm Post subject:

I forget as it was so long ago.
I know the big one across the top of the tank was an unusual size.
As I have/had 7 cars in my yard at one time, different makes, I usually carry most sizes in the shed. I had to get that one special though.
The rest were 8, 10 or 12mm
_________________
Porsche 924 1984 (UK import) NA
Its AUTO and its BLACK
Montego Black on black/red
Engineer of Electro/Mechanical Systems Maintenance

PieszczoH · Joined: 03 Dec 2009 Posts: 66 Location: Warsaw Poland

Size of filling up hose is 50mm inner diameter and You need about 25cm of it.
lenght should be checked becouse there were at least two lenghts of it.