Car is on empty, but won't take gas

[toddwess]

Very strange . . . the guage is on E. Went to put in gas, but the nozzle keeps shutting off. If I force it open, the gas just comes out and sprays everywhere.

What might cause this. I have ruled out a clog in the pipe.

Todd

[Highlander]

Check out the info in these threads. Hopefully this will help.

Graeme

http://www.renntech.org/forums/index.php?showtopic=2317

http://www.renntech.org/forums/index.php?showtopic=5265

[toddwess]

Check out the info in these threads. Hopefully this will help.

Graeme

http://www.renntech.org/forums/index.php?showtopic=2317

http://www.renntech.org/forums/index.php?showtopic=5265

Unbelievable. It was the E6 fuse.

Before I posted, I called porsche, and they said it was the fuel vent and was going to cost an arm and a leg to replace.

The fuse cost me like 75 cents.

Thanks for the help!!

[Tool Pants]

If the fuse blew because the cell phone connector shorted to ground then you can place some tape on the end of the connector.

Porsche started doing this for model year 2003 with the 986.

[ajacpril]

Have the same 'gas wont fill' problem in my 2003 Boxster.

So far I have tried the following:

1. Multiple gas stations

2. Checked the E6 fuse, which is fine

3. Replaced the E6 fuse anyway

4. Put my finger in the filler, where the nozzle goes and heard the 'click' of the valve in the neck emits (from what I've read a bad E6 fuse will result in no 'click' sound - so that bit checks out)

I still have the same issue and am assuming it is related to the issue mentioned in TSB 03/99 2015.

Thoughts

[Cassiebox]

Have the same 'gas wont fill' problem in my 2003 Boxster.

So far I have tried the following:

1. Multiple gas stations

2. Checked the E6 fuse, which is fine

3. Replaced the E6 fuse anyway

4. Put my finger in the filler, where the nozzle goes and heard the 'click' of the valve in the neck emits (from what I've read a bad E6 fuse will result in no 'click' sound - so that bit checks out)

I still have the same issue and am assuming it is related to the issue mentioned in TSB 03/99 2015.

Thoughts

Could be since you checked the other main culprits but it might still be EVAP canister. Anyhow, since you are a contributing member you can see/read TSBs. At the top of any page, click on DIY Menu and select Current TSBs submenu. Select Boxster 986 and type in the search box: fuel tank hose modification

and you'll be able to see the TSB.

[ajacpril]

Could be since you checked the other main culprits but it might still be EVAP canister. Anyhow, since you are a contributing member you can see/read TSBs. At the top of any page, click on DIY Menu and select Current TSBs submenu. Select Boxster 986 and type in the search box: fuel tank hose modification and you'll be able to see the TSB.

Might become a weekend project.

[jmcnp]

Could be since you checked the other main culprits but it might still be EVAP canister. Anyhow, since you are a contributing member you can see/read TSBs. At the top of any page, click on DIY Menu and select Current TSBs submenu. Select Boxster 986 and type in the search box: fuel tank hose modification and you'll be able to see the TSB.

Might become a weekend project.

Amazing - I'm experiencing the exact same problem. I took a look at the TSB, and it doesn't appear too challenging. From the pictures it looks like you only need to only add some ties to the hoses to tie them back and away from the filler flap. Let me know what your experience was like with the repair.

Also - the repair manual lists a VW Specialty Tool 3217 needed to remove the fuel sender unit. The tool costs $250+ online. I read online that other repairs have used a flat head screwdriver or an oil wrench to loosen the part. Any advice on whether the specialty part is needed, or can it be removed and reinstalled without the tool. I'm concerned about ensuring that the part is tightened with the right torque.

Thanks Renntech! :renntech:

Edited April 29, 2008 by jmcnp

[jmcnp]

Could be since you checked the other main culprits but it might still be EVAP canister. Anyhow, since you are a contributing member you can see/read TSBs. At the top of any page, click on DIY Menu and select Current TSBs submenu. Select Boxster 986 and type in the search box: fuel tank hose modification and you'll be able to see the TSB.

Might become a weekend project.

Amazing - I'm experiencing the exact same problem. I took a look at the TSB, and it doesn't appear too challenging. From the pictures it looks like you only need to only add some ties to the hoses to tie them back and away from the filler flap. Let me know what your experience was like with the repair.

Also - the repair manual lists a VW Specialty Tool 3217 needed to remove the fuel sender unit. The tool costs $250+ online. I read online that other repairs have used a flat head screwdriver or an oil wrench to loosen the part. Any advice on whether the specialty part is needed, or can it be removed and reinstalled without the tool. I'm concerned about ensuring that the part is tightened with the right torque.

Thanks Renntech! :renntech:

After taking a look at the job, I went ahead and bought the specialty tool for $270 with shipping. It was worth it. I could see getting the fuel sender ring off without the tool with an oil wrench or something, but a lot of torque is needed to get the ring back on tight enough without causing some damage. The tool is basically a necessity considering the space that you need to work in. I figure I'll put the tool on EBAY for a good price after everything is fixed and get some of the money back.

The frustrating thing is that applying the TSB fix (tying back the fuel lines in the fuel tank against the fuel sender unit) didn't fix the problem. Gas won't fill more than 10th of a gallon and still takes an hour to fill. I have a 2000 Boxster, and the fuel tank doesn't seem to have a flap like the TSB describes. The entire design is different. The filler tub looks like it comes down farther into the tank (almost to the bottom of the tank) and then flares and flattens out. I looked with a mirror and felt around inside the tank and there is no flap. Does anyone know whether Porsche redesigned the tank?

Also, does anyone have any advice about next steps (e.g fixing the EVAP canister) or something else I should look into? All the easy fixes (fuses, listening for the solenoid click) checked out fine.

[ajacpril]

Late (by about a year) posting this.

I had to take the car to a shop in LA to get this looked at. My problem turned out to be that an earthing wire at the top of the tank had been chewed through by some kind of rodent and this prevented some valve from opening and thus no fill!

Edited August 12, 2009 by ajacpril

[Beelzy]

That's incredible!

Thanks for relaying that tidbit, as I live fairly close to the outer city limits and rodents abound.

:renntech:

[jmcnp]

Late (by about a year) posting this.

I had to take the car to a shop in LA to get this looked at. My problem turned out to be that an earthing wire at the top of the tank had been chewed through by some kind of rodent and this prevented some valve from opening and thus no fill!

I'm just checking in on my post after a year myself and still haven't fixed the issue. I've been getting by for the past year by a little trick that at least speeds the filling up: there is a little switch to the right of the filler tube that gets pressed when you put on & tighten the gas cap. The button must vent the tank when the gas cap is on, and by pressing the button when you fill up it seems to allow enough pressure to escape to allow the tank to fill up (still slowly though).

I press the button/switch using my key while I fill up the tank. It will only allow the gas to enter the tank at the lowest pump speed, but it at least fills up the tank in 10 minutes instead of taking over an hour.

I've literally tried everything I can to figure this out, and I believe that I've narrowed the problem down to being somewhere between the tank and the evaporation canister, and there is a valve between the tank and the evap canister. Seems like I might just have the same problem.

Any idea how your shop diagnosed that the valve wasn't working?

[mattaebersold]

Thank you for this thread. I'm having the same problems and will be checking these issues tomorrow!

[judgejon]

I had not heard of this one until it started happening to me. My indy said he's only seen this happen once before with a Boxster. All posts on point will be appreciated. I won't be doing much driving in December, but will need to solve this problem right away in January. The fill up process is ....... grrrrrr.

[judgejon]

Just for info and to bring this thread current, having tried new fuse and taping the cellphone connector, has anyone found a fix for this yet?

My car goes into the shop of my very good indy on 1/31, and I'll post up any progress or solution of the problem. Cheers to all....

[judgejon]

Late (by about a year) posting this.I had to take the car to a shop in LA to get this looked at. My problem turned out to be that an earthing wire at the top of the tank had been chewed through by some kind of rodent and this prevented some valve from opening and thus no fill!

I'm just checking in on my post after a year myself and still haven't fixed the issue. I've been getting by for the past year by a little trick that at least speeds the filling up: there is a little switch to the right of the filler tube that gets pressed when you put on & tighten the gas cap. The button must vent the tank when the gas cap is on, and by pressing the button when you fill up it seems to allow enough pressure to escape to allow the tank to fill up (still slowly though).I press the button/switch using my key while I fill up the tank. It will only allow the gas to enter the tank at the lowest pump speed, but it at least fills up the tank in 10 minutes instead of taking over an hour.I've literally tried everything I can to figure this out, and I believe that I've narrowed the problem down to being somewhere between the tank and the evaporation canister, and there is a valve between the tank and the evap canister. Seems like I might just have the same problem.Any idea how your shop diagnosed that the valve wasn't working?

I believe that this little switch, which is activated when the gas cap is screwed down, only tells the computer that the gas cap is in place and tight and allows the car to start and run smoothly without throwing the cel light.

[ajacpril]

Any idea how your shop diagnosed that the valve wasn't working?

A super late reply, but I think the process was one of trial and error. The shop finally dropped the tank as there was nothing else left to try and discovered the problem.

Have you been able to fix the problem?

Edited January 24, 2013 by ajacpril

[judgejon]

not yet, car goes into shop 1/31. I'll be sure to post up the results. I guess your problem was the valve on top of the tank...?

[judgejon]

my problem was that the fuel tank vent valve was not functioning. I could not get gas into the fuel tank. Turns out a mouse had nested in the little area around the valve and had chewed through the wires. Now fixed. My indy, Mike Renzi in Fort Bragg, CA, checked this spot first and that was that. Cheers, jl

[jmcnp]

 

 

Late (by about a year) posting this. I had to take the car to a shop in LA to get this looked at. My problem turned out to be that an earthing wire at the top of the tank had been chewed through by some kind of rodent and this prevented some valve from opening and thus no fill!

I'm just checking in on my post after a year myself and still haven't fixed the issue. I've been getting by for the past year by a little trick that at least speeds the filling up: there is a little switch to the right of the filler tube that gets pressed when you put on & tighten the gas cap. The button must vent the tank when the gas cap is on, and by pressing the button when you fill up it seems to allow enough pressure to escape to allow the tank to fill up (still slowly though). I press the button/switch using my key while I fill up the tank. It will only allow the gas to enter the tank at the lowest pump speed, but it at least fills up the tank in 10 minutes instead of taking over an hour. I've literally tried everything I can to figure this out, and I believe that I've narrowed the problem down to being somewhere between the tank and the evaporation canister, and there is a valve between the tank and the evap canister. Seems like I might just have the same problem. Any idea how your shop diagnosed that the valve wasn't working?

I believe that this little switch, which is activated when the gas cap is screwed down, only tells the computer that the gas cap is in place and tight and allows the car to start and run smoothly without throwing the cel light.

 

According to my Bentley service manual, installing the filler cap tightly opens the Operating Vacuum valve. Believe me it somehow makes a difference.  Enough of a difference for me to have lived with this problem for years now.  I just hold down the switch and the gas will go in slowly but surely (~5-10 minutes to fill up).  If I get distracted and let up on pressing the switch down, the gas immediately spurts right back out of the filler.  

 

I'm checking on this thread because time has come to sell my Boxster so I'm going to give fixing this problem this another try.  It looks like I need to look into my wiring.  I'll update with whatever happens.    

Edited July 19, 2014 by jmcnp

[Kenton]

I'm using a kraft stick, like a large popsicle stick to press the cap switch, to be able to fill mine in about 10-12 minutes

[judgejon]

As Loren would say, the search engine is your friend.  
The wire fix is simple, but getting to it is a royal pain.  It’s down in there below the battery tray. 
Good luck.