Is fuel odor normal?

[tps22]

I've had a pretty strong fuel odor since I bought my 996 a few months ago whenever there's more than half a tank of gas, strongest when full. Had it to the dealer twice, first time they replaced the filler neck gasket, second time said it's residual from before the gasket was replaced. Replacing the gasket didn't help to a noticeable degree.

 

Now they say it's a feature of the 996 and even more so on older Porsches. Something about the gas tanks being permeable--I'm not sure I heard him right.

 

Is that normal? Or is the dealership mistaken?

[mdragon]

Hi there, where is the odor coming from? Do you smell it inside the cab?
I have owned a 2003 911 Carrera 4 for four years. I have never had a gas odor. There is sometimes a vacuum problem and I can’t get a full tank of gas dispensed, but never an odor of gasoline.
Do you have a local Indie you can go to? They might be able to help you better than the dealership. I have always found dealerships difficult to deal with especially because my car is getting on in years.
Good Luck!



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[tps22]

I do have an indy, but any problem should be covered by the dealer's 90 day warranty. But I don't trust this dealer (mislead me about the car's history and showed me records for a different car), and they strongly implied the indy I took it to for an inspection isn't trustworthy.  I suspect they're just trying to get out of any warranty work.

[356to966]

Gas smell is not normal. Hairline cracks in the nylon top of the Fuel Sending Unit are often the source. The unit is located under the battery (easy to access)and when mine cracked I had strong odor both inside the trunk and outside at the fuel filler.

[judgejon]

gas smell is not normal.  

maybe for a little while if you have some overflow when filling the gas tank.  but that disappears after a short time.

if you only notice the odor when the tank is over 1/2 full I'd wonder if there's a minute leak somewhere on the upper seams of the tank.

Or maybe the fuel filler line clamps are loose?

good luck.

 

[mdragon]

Hi there,

A few questions:

- What year is your 996?

- Is it a Carrera 4?

- Convertible?

- Where are you smelling the fuel odor?

- Is the dealership Porsche or...?

- Do do you have a Bentley Service Manual?

 

- Curious if you checked out what ‘356to996’ had to say...

“Hairline cracks in the nylon top of the Fuel Sending Unit are often the source. The unit is located under the battery (easy to access) and when mine cracked I had strong odor both inside the trunk and outside at the fuel filler.”

 

Check out your local Porsche Club of America Chapter and/or word of mouth for excellent Indie shops in your area. I have had excellent luck here in the Pacific Northwest with Chris’ German Auto. They are awesome! Chris Powell is the owner and a superb technician. You can’t go wrong by hooking up with a local shop. 

 

This site is also is a great resource and has helped me numerous times. Definitely check out suggestions from the 996 owners as they won’t steer you wrong. 

 

I just did a quick search online and there are quite a few threads regarding fuel odor issues that might help you out. Maybe you have already checked them out, don’t know. I think we need more info.

 

What I do know is that when you buy your first 996, it sometimes feels somewhat daunting...

 

Please let us know what find you out. 

 

Julie

[tps22]

13 hours ago, mdragon said:

Hi there,

A few questions:

...

Sorry for the lack of details, I was didn't want to say anything that might identify the dealer in case I was wrong about the whole situation.

 

It's a 2001 C4, purchased from my local Porsche dealer, about 63,000 miles currently.

 

The fuel smell is strongest near the fuel door, but pretty much permeates  air all around the car. 

 

Strongest with a full tank, and begins to fade away under 3/4, and is gone with less than 1/2 tank.

 

I've checked the fuel sender unit but didn't see any cracks and the smell isn't stronger when I stick my nose down there.

 

It leaked a small amount of fuel a couple times before I had a chance to get it back to the dealer to get it checked out.

 

The first time I had in to the dealer for this they replaced the filler neck gasket. Since then there haven't been any more leaks, but the smell is still there.

 

The second time they said they did a smoke test and did not detect any leaks. The mechanic suggested that it was likely just residual from when the gasket was leaking and would go away in a few weeks. It hasn't.

 

They told me that it was normal when I came in trying to resolve an issue about the car's service history and 60k service.  It had just over 60,000 miles on it when I bought it, so I made sure that the 60k service was done. I was told it was and all service was up to date, and had been performed at the dealer. They even showed me records from a 60k service, and I talked to the mechanic who said he knew the car well and it was well maintained. Turns out none that was true--they have no service history for the car and have no idea what has or has not been done. 

 

After a couple of months of being told by the salesman that the 60k had been performed and service was up to date, while getting contradicting and vague answers when I called into the service department, I went in and talked to the service manager. It was after he suggested that they might pay for half the 60k service that I mentioned the fuel odor hadn't been resolved. He told me it wasn't going to go away and was normal for old Porsches, something about the fuel tank being permeable. 

 

 So I'm not so much trying to diagnose the issue (I've been down that route, with much help from this forum), as trying to figure out how much smoke the dealer is blowing up my ***.

 

Thanks again for all the replies.

[judgejon]

Here's a possibility, though slim.

Could overflow gas have leaked out of the drain basin and/or tube that drains the gas, and collected somewhere in the body of the car instead of draining out to the ground?

Maybe there's a place that still smells even thought the spilled gas would be long dry by now?  could there be any gas-soaked insulation in there somewhere?Re the dealer issue, is there such a thing as a permeable fuel tank in any car?  

pm on the way

[dporto]

"Now they say it's a feature of the 996 and even more so on older Porsches. Something about the gas tanks being permeable--I'm not sure I heard him right.

 

Is that normal? Or is the dealership mistaken?"

 

OMG! A "Feature" ? Run away, and take the car to someone who actually knows something about cars as opposed to how to ripoff unsuspecting buyers. Seriously, at best this guy(s) is an idiot, and at worst he's a lying scumbag...

 

[wizard]

Dealership. Porsche dealership?

 

If yes, you really need to hear them right .... and then write to Porsche AG in Stuttgart.

 

A feature of the 996 !!!! Permeable gas tank !!!!

 

 

[JFP in PA]

17 hours ago, tps22 said:

Sorry for the lack of details, I was didn't want to say anything that might identify the dealer in case I was wrong about the whole situation.

 

It's a 2001 C4, purchased from my local Porsche dealer, about 63,000 miles currently.

 

The fuel smell is strongest near the fuel door, but pretty much permeates  air all around the car. 

 

Strongest with a full tank, and begins to fade away under 3/4, and is gone with less than 1/2 tank.

 

I've checked the fuel sender unit but didn't see any cracks and the smell isn't stronger when I stick my nose down there.

 

It leaked a small amount of fuel a couple times before I had a chance to get it back to the dealer to get it checked out.

 

The first time I had in to the dealer for this they replaced the filler neck gasket. Since then there haven't been any more leaks, but the smell is still there.

 

The second time they said they did a smoke test and did not detect any leaks. The mechanic suggested that it was likely just residual from when the gasket was leaking and would go away in a few weeks. It hasn't.

 

They told me that it was normal when I came in trying to resolve an issue about the car's service history and 60k service.  It had just over 60,000 miles on it when I bought it, so I made sure that the 60k service was done. I was told it was and all service was up to date, and had been performed at the dealer. They even showed me records from a 60k service, and I talked to the mechanic who said he knew the car well and it was well maintained. Turns out none that was true--they have no service history for the car and have no idea what has or has not been done. 

 

After a couple of months of being told by the salesman that the 60k had been performed and service was up to date, while getting contradicting and vague answers when I called into the service department, I went in and talked to the service manager. It was after he suggested that they might pay for half the 60k service that I mentioned the fuel odor hadn't been resolved. He told me it wasn't going to go away and was normal for old Porsches, something about the fuel tank being permeable. 

 

 So I'm not so much trying to diagnose the issue (I've been down that route, with much help from this forum), as trying to figure out how much smoke the dealer is blowing up my ***.

 

Thanks again for all the replies.

 

Just to put this to bed:  We get quite a few 996/997 through the shop on a day in, day out basis; and the ONLY ones that smell of fuel have something wrong, the rest are stink free.

[Canada-Eh]

If you get this resolved I'd like to know how as I have a 1983 928S (5 speed, excellent shape) and much like you when the gas tank is above 3/4 I also get a strong smell of fuel.  There are no leaks and the only thing that seems to matter is the level of fuel.   Below 3/4 no smell - above smell.  Needless to say, I never fill it all the way up and problem solved ;)