AudiOn19s

This started after a track day about a month ago. The flap is clearly not opening to allow gasoline into the car at a rapid rate. I can pump about .40 at a time before I get the automated shutdown on the pump and have to wait for the gas to bleed into the tank slowly.

I read a few threads about this in the past and it seems common on the newer cars where the flap is electronically controlled and the fuse blows, however from what I can gather the '99's didn't have that electronic system for the valve in the filler neck.

There were old posts stating something about tubes around the filler neck getting twised causing the emergency flap to be stuck closed but everyone that spoke of it stated it was a dealer fix. I've yet to find anything I can't do on a car other than internal transmission work and would like to give it a shot at fixing this myself...I just need some guidance on how to go about it. I"m guessing I need to pull the inner fender lining to get at whatever I'm looking for...beyond that I'm clucless and need some help.

Andy

ivangene

This is wierd, I have had that happen before. Really pissed me off but I never suspected the car, always the pump. I have changed stations and it stopped, ,but I have had it happen again at "other" stations. My first thought would be to fill up somewhere else to see if the problem is car or pump...... I will watch this thread for other ideas and solutions.
Ed

AudiOn19s

I tried 3 other places. All the same issue. I can tell the flapper is stuck because each time it starts to fill you can hear it fill up the filler neck.....then slowly drain down into the tank. Really annoying. I too was hoping it was the pump I was using but no luck.

Forgot to mention. When this happens in newer cars it's the E6 fuse that I was referring to earlier. Mine is fine.

Andy

smshirk

There is a fuel level sensor. I did a quick look up in manual and that was first place it led me.

smshirk

Bad news, recalibration requires the PTS2. Even if you replace it, the manual says it must be recalibrated using tester

redridge

have you tried to fill it really slow?

ivangene

http://www.youtube.com/watch?v=ySKTfNZ7CQE

any relationship

smshirk

priceless

AudiOn19s

even as slow as I could get the pump to run it'd still shut off after you pump about .40 worth. I managed to get 1/2 tank in it eventually...took me about 10 mintues.

I'll try to dig up the old threads again...they seemed to have it figured out what the issue was but no indication on how to fix as everyone eventually took it to the dealer.

Andy

gota911

Andy,

I don't know if this will help you or not, but I hope so. Let me know if there is anything else from the 996 PET that may help you.

ivangene

great info Tim!! You are a good man

(even if you drive a piece of sh*t) LOL

anyone suspect any of those parts? hard to tell, but breather hoses and valve #21 might cause higher preasure making the nozzle shut off? or is the a splash back that makes it stop. so maybe the #11 pipe is obstructed or has more to it than meat the eye (ie.... insides), what is #25? breather too?

Man I didn't know the fuel pump was stuck in that dark and stinky hole!!! That should be fun if ever needed to be done.

cdodkin

From the 986 FAQ

Gas Tank Won't Fill

Diagnostic: When you try to fill the gas tank, only about 1/10th of a gallon will go into the tank before the auto-shutoff triggers in the gas pump.

Cause: Tubes behind the flapper in the gas tank have slipped.

Details: There is a one way flapper type valve at the junction of the filler neck and the tank. This is to allow gas in but not out. There are tubes in the tank behind the valve that can slip down preventing the flapper valve from opening allowing only the filler neck to fill up then slowly seeps by the valve.

Take to your dealer with less than 1/2 tank of gas. The fix is to have the dealer secure the tubes up and out of the way of the flapper valve.

Time in Shop: Several hours.

Repair Instructions: Requires dealer repair.

Notes: None.

wross996tt

There is a TSB (Fuel Tank Hose Modification 5/99 2015)...It effects:

1. Difficulty filling fuel tank.
2. Running out of fuel due to incorrect fuel gauge reading.

AudiOn19s

Great info guys. Exactly what I'm looking for.

Now I'm only left guessing / asking. How do I access that area? Do I need to do it from under the car and pull the lower pannels...or is it done through the fender well by removing the inner fender lining?

Thanks Gents.

Andy

Paul 996

Andy,

It is all done via the filler neck hole and the wheel well (so the liner comes off). Remove the hex bolts and the filler neck detaches by turning it Clockwise 45 degrees and pulling out. Battery disconnected of course.


I'll post a diagram in a little bit.