Fuel Tank - Difficulty Filling
Boxster3/99 2015
Binder - 2, Fuel & Exhaust
Fuel Tank Hose Modification
Date: 8-12-99
Vehicle Type:
Boxster
Model Year:
As of 1997 (V)
Concern:
1. Difficulty filling fuel tank.
2. Running out of fuel due to incorrect fuel gauge reading.
Information:
1. Difficulty filling the fuel tank can occur if the flexible fuel hoses in the fuel tank obstruct the inner flap of the fuel filler neck.
2. Incorrect fuel gauge readings can also be caused by the flexible fuel hoses in the fuel tank, should they interfere with the travel of the fuel sending unit arm and/or float.
When addressing complaints of "difficulty fueling" or "running out of fuel", the routing of the flexible fuel hoses in the fuel tank must be modified.
Warning!
There is danger of fire and injury when working with fuel! Always observe all general safety regulations for working on the fuel system! Wear protective gloves!
Work Procedure:
Performing fuel hose modification.
- Mark the position of the fuel sender union nut before removing. Remove union nut and fuel sending unit.
- Ensure the inner filler neck flap moves freely. Affix the two flexible hoses in the fuel tank exactly as shown in Figure 1, using two tiestraps.
- Install fuel sending unit and union nut. Ensure the arrow on the fuel sending unit is perfectly aligned with the middle mark on the fuel tank. Tighten union nut one additional rib further than its previously installed position. (Use the markings made previously for reference.) See the Boxster Technical Manual, page 20-7.
Working Time:
Labor Operation Time Description
20 15 19 99 * 70 TU Remove and install fuel level sensor. Perform fuel hose modification
* State: "Fuel Tank Hose Modification" in claim drop-down box.
Literature:
Boxster Technical Manual, Group 2, sections:
20 66 19 - Removing and installing fuel pump, pages 20-5 - 20-9
20 15 01 - Calibrating fuel level sensor system, page 20-9