Fuel Pump Hose Fittings

[Subman]

2002 Boxster S, 114,000 miles. Great shape, runs great, everything on the car works as original and no issues - except that the fuel gauge was inaccurate. Replaced the sending unit last week with an OEM part, along with a new seal. Perfect result...newly installed unit read accurately right out of the box.

But - after the initial startup, drove the car for a test run. Two blocks from home, engine dies. Pull the sending unit on the roadside to find the fuel line (supply) from the fuel pump had popped off the bottom of the sending unit. Reconnected - tightly, again - and drove away. Good to go, drove the car a couple of days with no issues. Fuel gauge tracks accurately, life's good.

And then - yesterday it happened again. Drove away from home and the same fitting popped loose. Same roadside result - pull the sending unit, reconnect the hose. Except this time it popped off again after no more than 30 seconds. Sigh. Tried once more, same result. The hose simply will not hold.

Fuel pump (and of course hoses) are apparently original, 17 year old parts. The clip on the QD fitting simply appears to have lost its "spring" and, despite pushing it into place firmly and getting a solid "click" when installing on the underside of the sending unit every time, it simply will not hold under pressure. No issue with the corresponding QD on the top side of the sending unit - that one holds pressure just fine, but then again it hasn't been immersed in fuel for 17 years like it's counterpart beneath.

So - new fuel pump ordered and on the way. After 17 years, probably not a bad idea to replace as a preventive measure anyway, but the failed fuel hose QD has made it mandatory. Just wanted to document the issue in case anyone else finds themselves with a similar situation. Those plastic clips on the QD's are a weak point after so many years.