Please Help - Need To Fix Fuel Filler Door Latch (Removing the Fuel Ev

[rockymount1]

I've just done a complete search on Renntech looking for a method to fix the latch on the fuel filler door on US Boxsters (I think this is similar to other Porsche models also). I found at least 10 other posts on this subject. In all cases, the same statement appears. Remove the right front tire and wheel liner. But I have not seen anyone say how to remove the evaporator (which must be removed to get to the latch).

I see that a couple of people state that the dealer fixed this for them. Did anyone see the dealer remove the evaporator? Is there a service manual I can buy that includes removing the evaporator? Do you really need to remove the entire fender to get at this?

My latch actuates perfectly, it is just loose in its bracket and I need to tighten the bolt that holds it in place so the plunger comes thru the hole in the fuel door.

I know this isn't necessary for the car to perform correctly, but I get bothered when I know something is off on my Porsche. :cursing:

Thanks in advance.

[Chuck Jones]

I've just done a complete search on Renntech looking for a method to fix the latch on the fuel filler door on US Boxsters (I think this is similar to other Porsche models also). I found at least 10 other posts on this subject. In all cases, the same statement appears. Remove the right front tire and wheel liner. But I have not seen anyone say how to remove the evaporator (which must be removed to get to the latch).

I see that a couple of people state that the dealer fixed this for them. Did anyone see the dealer remove the evaporator? Is there a service manual I can buy that includes removing the evaporator? Do you really need to remove the entire fender to get at this?

My latch actuates perfectly, it is just loose in its bracket and I need to tighten the bolt that holds it in place so the plunger comes thru the hole in the fuel door.

I know this isn't necessary for the car to perform correctly, but I get bothered when I know something is off on my Porsche. :cursing:

Thanks in advance.

I am interested in a response to this question also. I broke the plastic shaft that moves forward to lock the fuel door and need to install a new one. The car now gives a slight "beep" when I lock it becuse that shaft doesn't move forward and the car registers that as something left open. That plastic shaft isn't very strong....I was surprised that it was as flimsey as it was. Obviously it's there as a minor deterrant because a person could easily pry that fuel door open and break that shaft. I wonder if the alarm activates if the fuel filler door is opened when the car is locked???

[Loren]

Chuck,

Yes, the fuel door is armed as part of the alarm system.

If it fails to arm you will get a beep when you lock the car (the same beep you get if any other zone is "open").

I can check that fuel filler flap is the cause of the alarm beep with my PST2 (or Durametric software).

If that is the cause we can see how hard it is to take the evap canister out.

[Chuck Jones]

Chuck,

Yes, the fuel door is armed as part of the alarm system.

If it fails to arm you will get a beep when you lock the car (the same beep you get if any other zone is "open").

I can check that fuel filler flap is the cause of the alarm beep with my PST2 (or Durametric software).

If that is the cause we can see how hard it is to take the evap canister out.

That would be GREAT Loren....it's a bit disconcerting to have the car continually give that warning beep....if something other than the fuel door is open, I wouldn't be able to discern the difference. We'll get together....I will go ahead and order the fuel door locking shaft from Porsche. I have been unable to find anything on the process or procedure for getting in there.

[Tool Pants]

http://www.pca.org/tech/tech_qa_question.a...7-E583A6E12D96}

http://forums.pelicanparts.com/showthread....threadid=338379

Never done it. Don't know how to do it. Years ago I talked to a mechanic and about all I remember is he said something about the cannister and it being a pain. I'll have to ask him again.

[rockymount1]

Toolpants,

Thanks for the links, but in both cases it talks about getting to the latch. One even says it is easy to remove the evaporator canister (carbon canister), but neither article tells you how.

I have removed the wheel and liner (that part was easy). But the canister is a mystery. There is one bolt visible, but the canister won't budge and I'm afraid to force it.

Is there any shop manual available that covers this? When I do a Google search, I can find a link to a "Activated Carbon Canister" in Bentley's Service Manual for Boxsters (pg 24-5). If you own the manual can you tell me if this is the correct canister. I don't mind ordering the Service Manual, I just don't know whether the manual is talking about the fuel canister or the activated carbon filter that is sometimes used in the air intake for the cabin air.

[Loren]

I have not seen any description in any shop manual.

Let me have a look at Chuck Jones' car and we will try to take pics and write it up.

[RFM]

Hi

European canisters are bolt on and are equipped with a bracket and rubber bushes you have to push in ( it is difficult for my to explain in English ) I hope it's helps.

[rockymount1]

Hi

European canisters are bolt on and are equipped with a bracket and rubber bushes you have to push in ( it is difficult for my to explain in English ) I hope it's helps.

It wouldn't surprise me if the US version is similar. Once the bolt that is easy to get to is removed, the canister seems to be mounted on something that is very flexible. The rubber bushing would make sense. I just don't want to force it with out knowing.

On the European canister, is that a single bolt that attaches to the canister on the right side (from looking into the wheel well)?

[RFM]

Hi rockymount

The canister fixation contains: 1x nut and 2x rubber bush on the opposite side, you have to pull the canister to the front of the car. The tension on the rubbers is high.

[rockymount1]

Hi rockymount

The canister fixation contains: 1x nut and 2x rubber bush on the opposite side, you have to pull the canister to the front of the car. The tension on the rubbers is high.

Thanks - I think this sounds like this could be the same for US cars. I will give it a try this weekend.

Again, many thanks.

[Chuck Jones]

I have not seen any description in any shop manual.

Let me have a look at Chuck Jones' car and we will try to take pics and write it up.

[/quote

I should get my car back from the body shop this week...and if you're available Loren, we can tackle it. I'll order the shaft to have it on hand. I broke mine thinking the black ring in the door frame was the emergency release for the hood, and I yanked on it till it broke......yeah I know....read the manual. We can photograph the steps taken to get to this for your RennTech DIY's.

I enjoyed our little drive....although you took my 930 through some maneuvers I haven't tried. I did grab the door handle one time :) ...

[Loren]

:drive: Hehe... I will be offering a driving course on "How to lockup the front brakes on 930" in the near future.

Serious Chuck that car was a great buy - very rare, very fast and near concours condition.

Sure we can have a look at your fuel filler/canister issue.

[clickman]

I broke mine thinking the black ring in the door frame was the emergency release for the hood, and I yanked on it till it broke......

Way to go, Chuck, you idiot! Oh, wait, that's how I broke mine... :oops:

Looking forward to the details of the fix! Take lots of pix!

thx Norm

PS Out of curiosity, the cable release for the hood seems to go to the same area as the fuel filler. So where does it end up? Why didn't Porsche make it more accessible?? :unsure:

[Chuck Jones]

No the emergency release for the hood can sometimes be accessed thru the hole to the side light on the passenger's side if you're lucky enough to be able to see and snag it..I had to get to it when my manual cable release for the front latch froze up with groceries inside. I couldn't get to it and ended up taking the front bumper off to free up the latch. The cable is actually behind the headlight and not in the same area as the fuel filler. I ended up rerouting it so it came out by the front right radiator where I can actually find the **** thing.

Loren: I ordered the ...what Sunset calls the fuel door actuator....I order it from Sunset today...it's $30 and is actually a module and not just the plastic arm that slides forward. We can tackle that when I get the car back from the detailers. There seems to be a lot of interest in a good DIY with photos and I'd like to do one up with you for posting.

Oh...and Clickman...it's good to see that there are at least two idiots that read this forum. Nothing is stupid proof!

[clickman]

Nothing is stupid proof!

Chuck, I still blame Porsche. As with so many of their parts, without a lot of cost they could have made it just that much better. And for a car that costs this much ...

[Loren]

For folks wanting to do this...

Chuck Jones and I did the latch replacement today and Chuck shot a bunch of pictures.

I will post a DIY with pics soon.

Nothing really to hard here. The canister comes out with a little wiggling (disconnect the vent and electrical lines first).

The actuator itself is a bit tough to get to and you will need a really short T-20 Torx head to loosen the two screws. I say loosen because that is all you need to do to remove the part - it sits in two "U" shaped slots.

BTW... Chuck's alarm problem was not the actuator - he has a bad front hood microswitch (thanks to my trusty PST).

[Loren]

The DIY is here (finally)..

Replacing the Gas Door Actuator, for Carrera (996) or Boxster (986)