Since I bought the car a couple of codes have popped up intermittently triggering a CEL.

P0455 Tank system - major leak
P0461 Fuel level sensor

I originally replaced the gas cap as was the common "fix" for this CEL to no avail.

Symptoms are:

1. When refueling, gas will pour out of the port when full, not shutting off the gas pump.
   
2. CEL will trigger when fuel level gets < = 1/4 tank
   
3. Clear the CEL with durametric and refuel; repeat #2

I finally brought the car to the dealer to diagnose and for $150 they told me it was a $400 EVAP part that was $300 to install. I paid for the diagnosis and the part and installed it myself in 10 minutes.

Location is on the drivers side of the engine compartment. Follow the lines coming off of the oil tank:



Part number 997 110 129 91:



Location was not fun, but not $300 painful either.



Hopefully this fixed it. I'm a bit bent out of shape about the labor estimate - two hours is way overboard. Can anyone recommend a good p-car shop in the metro west, MA area?

<<<<<<<<<<<<< UPDATE >>>>>>>>>>>>>>>

nope - not fixed. popped the same CEL a couple days ago.

Symptoms are the same.


Any ideas?

Thanks!
Andrew

 

Good P-car shops in metrowest MA:

• EPE, Natick (epe.com)
• Auto Engineering, Lexington
• German Motors, North Providence
• Eurotech, Framingham

.

 

Terrible diagnosis.
Fuel vapors are supposed to shut off the gas pump when the tank gets full. I'm guessing the vapors aren't making it there (leaking out), you are overfilling the tank, and that's throwing your fuel level sensor fault.
Get a smoke machine on your fuel system and see where the leak is. It's probably somewhere along the filler neck vapor hose or at the tank itself.

 

Was the cause the evap being filled with gas? I have seen this issue on bikes when gas is overfilled and it spills off, it goes directly into the evap can and can clog it up and cause a CEL.

Also, was the cause of the gas pumps not shutting off?

Cheers.

 

Typically, a saturated carbon canister will cause gas pumps to shut off frequently during filling, prior to the tank being full.

 

Thanks so much for all the info guys. I scheduled an appointment at Auto Engineering in Lexington, MA. They even accepted this link as *backstory* for the issue.

What are my chances of returning the new vent valve to the dealer that I don't think is the issue?

 

UPDATE:

Porsche tech at Auto Engineering smoke tested the fuel system, but did not find any leaks. He's going to try replacing the check valve on top of the fuel tank. I'll post again with the results.

EVAP is annoying.

 

I agree.

 

Man-o-man, don't tell me that. My other car is having this issue........ARGH.