Fuel pressure line from tank

[edebes]

Hello,  Have not posted for a number of years...recently rejoined due to divorce. Good to be back on the forum. I now own a Box 2004S with six speed transmission 100 K miles. Having issues with leaky connection at fuel outlet on top of tank. I recently noticed the smell on long drives since warmer weather arrived on east coast. What I am I seeing? After removing battery and tray I see the pump pressures the hose, which forces the line connector up and away from the stem slightly and the fuel sprays and collects inside the retaining ring area. A call to Porsche dealer resulted in the part ID as a front fuel pressure line. I am told by parts this runs to the fuel filter...later research today indicates 04's have no inline external fuel filter. So does this line attach at another point under car?

 

I guess the question is, how is this line installed? Does the tank need to be dropped some distance to fit line? Is it possible to remove bad snap fitting and fit on a new one. Is there instructions posted on this repair on the forum?

 

Thanks in advance!

 

Ed

[JFP in PA]

Are you sure it is the line and not the fuel tank connection itself?  Your 2004 has a fuel filter that is part of the pump assembly itself down in the tank.

[edebes]

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 Thanks for your reply.  thie stem exiting the top of the pump area where the line attaches is solid with no cracks. as I mentioned in the above post the connector seems to move when pressurized. if I put pressure  on the top of the connector, holding it in place, the leaking stops. I'm assuming the connector is bad your thoughts? 

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[JFP in PA]

Without seeing it, that sound reasonable.

[edebes]

JFP (and others) …Today I installed the new fuel pressure line to address above problem with no success. With the brand new connector snapped on the existing sending unit, gas continues to leak between the male stem and the fitting on the pressure line at modest rate as previously reported. So I thought, was it possible when the fuel pump was replaced by prior owner, the sending unit was damaged or an incorrect sending  unit was attached to the new pump as part of the repair.  The part number from current sending unit is 996 620 032 01. Called Autohaus in Lancaster, PA and they reported to me it is not an active number nor could they find as inactive (no listing). Did ebay search and in fact the part did show as a fuel pump for “02, 03, 04 Boxster”.  If the 996 620 032 01 part is the same I have in the car now, why would an ebay one work of the same type?  A-Lan also told me the correct P/N for the sending unit for my ’04 Boxster is 996 620 832 02. Can I fit this correct sending unit on the currently installed pump?

Any other ideas and advice appreciated. Thanks in advance.

[JFP in PA]

According to Porsche, the correct fuel gauge sender for your car is a 996-620-832-02 (per board sponsor Sunset Porsche).

 

Sunset Porsche listing for 2004 Boxster s fuel pump