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Replacing the Porsche 911 Carrera Fuel Line Vent Valve
 
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Pelican Technical Article:

Replacing the Porsche 911 Carrera Fuel Line Vent Valve

Time:

2 hrs

Tab:

$105.75

Talent:

**

Tools:

10mm Wrench or 10mm Socket with Socket Wrench

Applicable Models:

Porsche 986 Boxster (1997-04)
Porsche 986 Boxster S (2000-04)
Porsche 996 Carrera models (1999-05)
Porsche 997 Carrera models (2005-08)

Parts Required:

996-201-143-01-OEM

Hot Tip:

No smoking while performing this project, remove the fender liner and take your time.

Performance Gain:

You can put gas in your car

Complementary Modification:

Replace Fuel Door Actuator

While Porsche produces some of the cleanest running vehicles in the world, the system they designed to get these results can be difficult to understand and when it goes wrong most people just give up trying to fix it. That doesn't need to be the case, with a little patience you can solve most of the issues that come up.

Like many things on a Porsche the EVAP (Evaporative Emission Restraint System) works with a series of switches and, of course vacuum pressure. All of this is done to prevent the emission of harmful fumes from getting out into the environment. The EVAP system is designed to capture these gases and recycle them back into the engine to be burnt later.

If you are having trouble filling up your car with gas, your check engine light keeps coming on, your car will not enter a "ready state" for a smog test, or you hear a howling sound like someone is blowing across the top of a Coca-Cola bottle you may have a faulty fuel line vent valve.

This project will deal with the replacement of your fuel line vent valve. Before you begin though, take a moment and check your gas cap. Many of the issues described above can be the result of a bad seal in your gas cap and it is a lot easier and cheaper to replace or fix your gas cap. If your gas cap is good then it is probably the fuel vent valve. The valve opens when you put the filler hose in from the pump and allows you to fill the car with gas. It does this by allowing the air in the tank to be diverted to the charcoal canister. If the valve does not open it will cause a back pressure problem in the tank as there is no place for the air to escape and make room for the incoming gas. Once the fuel line vent valve opens the air/fuel vapors are diverted to the charcoal canister, where it is stored. Once the engine is running, and reaches a certain state, the charcoal canister is purged of the collected vapors by sending them back to the intake manifolds to be burnt in the engine.

There is a one way check valve on the air purge line into the canister to stop the emissions from flowing back out to the environment (see Picture 1). If the vent valve does not open you will have a very difficult time filling the car, and if the valve does not close the car will think there is a vacuum leak in the system and cause all kinds of problems starting with your CEL staring at you.

If you have a 2005 or later 997 Carrera, Porsche has redesigned the tank ventilation system and eliminated many of the components and lines including the fuel line vent valve.

This is a Picture of the passenger-side front wheel well with the fender liner removed (see Project 68 for tips on removing the fender lining): notice the large black EVAP (charcoal) canister.
Figure 1

This is a picture of the passenger-side front wheel well with the fender liner removed (see Project 68 for tips on removing the fender lining): notice the large black EVAP (charcoal) canister. The red arrow is the actual vent valve. Incoming vent line from the gas tank (yellow arrow), Line out to charcoal canister (blue arrow), one way check valve (green arrow) and where the fuel vent line enters the charcoal canister (purple arrow).

To begin, disconnect the lines (green arrows) attached at the top and bottom of the EVAP canister,
Figure 2

To begin, disconnect the lines (green arrows) attached at the top and bottom of the EVAP canister, the electrical connection, which easily unclips (red arrow), and the 10mm nut (yellow arrow) holding the canister in place. Now, to remove the unit, gently pull it forward until it comes free.

Next, disconnect the top two gas vapor lines (green arrows) on the fuel vent valve by squeezing the tabs on each line.
Figure 3

Next, disconnect the top two gas vapor lines (green arrows) on the fuel vent valve by squeezing the tabs on each line.

The fuel line vent valve is attached to the fuel neck by a metal bracket.
Figure 4

The fuel line vent valve is attached to the fuel neck by a metal bracket. To loosen it, open the gas cap door, remove the gas cap and remove the 10mm nut holding the bracket to the chassis (yellow arrow). Next, loosen the black plastic piece surrounding the fuel neck by pushing in the four clips (inset photo: three visible: red arrows) from behind it inside the fender well.

Now, from inside the wheel well, remove the remaining two 10mm nuts and subsequent electrical ground wire
Figure 5

Now, from inside the wheel well, remove the remaining two 10mm nuts and subsequent electrical ground wire (inset photo) holding the vent valve to the fuel filler neck (yellow arrows): you can also rotate the bracket for easier removal.

This picture shows the fuel line vent valve (available from PelicanParts.com) removed from the fuel filler neck.
Figure 6

This picture shows the fuel line vent valve (available from PelicanParts.com) removed from the fuel filler neck.

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Comments and Suggestions:
Alden Comments: '03 986 Boxster: Can’t get gas into tank. Disconnected both air lines to filler neck. No help. Fuel flows into the tank when the gauge equipment is removed, so filler pipe obstruction is not the problem, but venting is, even though the vent lines at the filler neck are open to the atmosphere. Within the tank and forward of the filler pipe's descending elbow is a vertical plastic pipe about 1” diameter extending from the top to about 6” down. On tank exterior, the pipe connects to a large hose that wraps ccw around the porthole about 180° to rear and disappears. It looks, like but can’t be, a heater hose. Is it my mystery vent? It has a plastic a 90° elbow located directly under LR stud for battery tray, which may be there to allow it to make the tight bend around the porthole. I have discovered no diagram showing this assembly. If this thing isn't a vent, and isn't working, what is your guess as to why I cannot refuel my car?
The filler cap on this car mechanically opens the filler vent valve when cap is unscrewed.
Directional notations are relative the vehicle.
November 10, 2016
  Followup from the Pelican Staff: The vent line leaving the tank may be restricted. Check the large plastic line for blockage. The line you found is likely it. May run to a fresh air filter. Not 1005 sure.- Nick at Pelican Parts  
Ed B Comments: It was fuse E6.

Ed
October 26, 2016
  Followup from the Pelican Staff: Thanks for the follow up. We appreciate it.
- Nick at Pelican Parts
 
Ed B Comments: I have determined that the sensor does react to the flap magnet. No lines are plugged. Does this leave valve 996 605 203 01 as the problem?

Ed
October 23, 2016
  Followup from the Pelican Staff: The valve could be at fault. if fresh air doesn't enter, fuel will not fill as it should. - Nick at Pelican Parts  
Ed B Comments: '00 Boxster S No codes. Gas fill problem. Have vent valve out. Great instructions. Valve a little sluggish but works. No "click" when filler flap opens.
Has sensor 996 613 224 01 failed? It doesn't react to metal or a magnet.
Does this sensor connect to valve 996 605 203 01?

P/N's are in MG 2, SG 01, illustration 201-00. PET
Thanks, Ed
October 22, 2016
  Followup from the Pelican Staff: I don't have PEt to cross reference.

Give The Pelican Parts parts specialists a call at 1-888-280-7799. - Nick at Pelican Parts
 
bhaggen Comments: I'm getting a P2404 on a 08 Cayenne S possibly referring to the "leak detection pump". Does this indicate a leak or an issue with the pump itself?
September 23, 2016
  Followup from the Pelican Staff: Most likely the pump. Give The Pelican Parts parts specialists a call at 1-888-280-7799. They can figure out what part or repair kit you need.
- Nick at Pelican Parts
 
Rob Comments: Hi Bob T.
My 2000 996 Carrera is hard to start immediately after refueling. There are no problems with pumping fuel into the tank and the car starts fine except the one time after refueling. Since fuel goes in fine I am assuming the fuel tank bleeder valve 99620114301 is good. I am thinking the problem is the Vapor Canister valve 99660520301. If it is stuck open raw fuel could be entering the intake and flooding the car. What do you think? Thanks Rob
August 15, 2016
  Followup from the Pelican Staff: For raw fuel to enter, your tank would either ave to be overfull or have a plugged vent. It is possible the fuel vapor is not being recovered correctly, then getting to the engine via the purge solenoid. Check if the purge solenoid is stuck open. - Nick at Pelican Parts  
Deaner Comments: Do you sell the magnetic switch that attaches to the vent valve?
July 24, 2016
  Followup from the Pelican Staff: Pelican Parts can get it. Give The Pelican Parts parts specialists a call at 1-888-280-7799. They can figure out what part or repair kit you need.
- Nick at Pelican Parts
 
Ghost11561 Comments: I have a 2004 Boxster. I'm getting a P0456 code. The gas cap is not the OEM part - could this be causing the issue? Thanks.
June 29, 2016
  Followup from the Pelican Staff: Yes, it could be the issue. - Nick at Pelican Parts  
Pete Comments: Great write up, I had the same problem as Allen and Clyde, the sensor fell out when I installed the new one and all of a sudden I could not fill my tank. Please make sure you keep the sensor in the right location, nothing holds it in and it will fall out very easily, I did not even notice the sensor on the install.
May 31, 2016
  Followup from the Pelican Staff: Thanks for the additional info and feedback. We appreciate it.
- Nick at Pelican Parts
 
jameswnw Comments: Fuel filling FIXED! the problem with this 02 996C was you could not fill tank with fuel at all! no matter how you angled the filler nozzle. There is two valves involved with venting the fuel tank when filling, the valve that was the problem here was 996.605.203.01 that lives on top of the fuel tank, when the fuel nozzle is inserted this valve and the another valve should click! they are on the same circuit.
May 6, 2016
  Followup from the Pelican Staff: Thanks for sharing your installation process and experience. These type of comments add so much to the Pelican tech community.
- Nick at Pelican Parts
 
Clyde Comments: 2000 porche Boxster s fuel vent sensor. Replace vent sensor came loose can not find location for sensor. See pic below
April 27, 2016
  Followup from the Pelican Staff: There is a small black plastic molded piece that is fitted to the filler neck. That magnetic switch pops into that black piece. It should be obvious that it fits inside of it. WITHOUT it installed, you will have the issue you are experiencing. - Nick at Pelican Parts  
Andy_996 Comments: I had a P0442 small Evaporative Leak for over a year and just reset the CEL every 200 miles. Recently, the CEL lit up after 50 mi of reset which isn't good to get a smog. I was also having a hard time filling the fuel. I figured what's to lose and replaced the Vent Valve. After 2 hours of replacement time worst part was the fender liners : and over 300 miles, it's all fixed! Thanks Pelican for a great writeup!
April 26, 2016
  Followup from the Pelican Staff: Thanks for the additional info and feedback. We appreciate it.
- Nick at Pelican Parts
 
Dantheman Comments: Okay thank you. I went ahead and ordered a fuel vent valve for the code p0455 because I was having trouble filling my tank and could hear and feel air after cap was removed. Could this be throwing other codes due to evap leak?
April 21, 2016
  Followup from the Pelican Staff: Yes, it can if stuck open. - Nick at Pelican Parts  
Dantheman Comments: Okay thank you. I went ahead and ordered a fuel vent valve because I have been having trouble filing up my car with gas and I can hear air coming out after I remove the cap. Could this be throwing multiple codes due to evap leak? Follow up from previous question.

Thank you
April 21, 2016
  Followup from the Pelican Staff: Yes, it can if stuck open. - Nick at Pelican Parts  
Junruner Comments: You mean like blowing? If yes? From where? Thanks BTW Nick! I'm grateful!
April 21, 2016
  Followup from the Pelican Staff: You will have to disconnect the lines, then use a turkey baster to push air through the lines. DO NOT use compressed air. - Nick at Pelican Parts  
Junruner Comments: Checked lines and it seems to be no visible obstructions.
April 21, 2016
  Followup from the Pelican Staff: You have to check it for airflow, visually won't do it. - Nick at Pelican Parts  
kam Comments: Hi, where is the vent valve on the 997 Turbo. The filler is not the same as the 996.
thank you.
April 20, 2016
  Followup from the Pelican Staff: I think it is part of the leak detection pump on the charcoal canister. - Nick at Pelican Parts  
dantheman Comments: I have 3 codes on my 2001 Porsche Boxster S and I am tring to figure out what needs replaced.

Codes: P0455 P0410 P1411

I have replaced the gas cap and nothing has changed. Any input would be great. Thanks
April 16, 2016
  Followup from the Pelican Staff: There is likely a leak in the evap system. You will need to seal the system and smoke test it, using en evap leak tester. - Nick at Pelican Parts  
Junruner Comments: Hello Guys!
Replaced fuel valve vent on my 1999 986.
Still have the problem while fueling my tank that takes me forever to put gas on tank.
Any suggestions?
March 22, 2016
  Followup from the Pelican Staff: Check if the vent line for the charcoal canister is blocked. - Nick at Pelican Parts  
Frank Comments: I have the same problem as Allen. I can't find the connector of that black sensor. Is it possible to have a picture as to where it should be connected. I have a 2003 Porsche Boxster. Thank you
February 27, 2016
  Followup from the Pelican Staff: I don't have a photograph to share. The sensor you are looking for, is it one you replaced it? Look for a wiring harness and trace it until you find the pigtail for the sensor. - Nick at Pelican Parts  
Frank Comments: I used to fill gas easily but not until I changed the vent valve on the filler neck. Now I can't fill up gas and the whining noise when you start the car remains but as usual it goes away after several seconds. I don't any CEL nor problem starting or driving but I can't fill up gas anymore
February 27, 2016
  Followup from the Pelican Staff: The valve may be in wrong or the line has become restricted. - Nick at Pelican Parts  
RZ1978 Comments: Hello, I am working on a 911/997 from 2005.2006, and I am with some problems to see all the parts I need to fix really well the fuel tank, and all the connections around it. Include the gas duct to change. If you have the oportunity to sent t to me some links I will apreciatte, Thkyou
November 14, 2015
  Followup from the Pelican Staff: I’m not the best with part numbers.

Give our parts specialists a call at 1-888-280-7799. They can figure out what part or repair kit you need.
- Nick at Pelican Parts
 
Blackbird Comments: I have installed aftermarked aluminum fuel cap and now has a code PO455 can it really be true that a non original cap can result in an error code?
November 2, 2015
  Followup from the Pelican Staff: Yes, I would assume that is the issue. You can test the new cap, ask a shop to test it.- Nick at Pelican Parts  
phunboy Comments: Similar to musclehedz101's post, I'm experiencing the same P0441 on my 2006 C2 cab. This 1st occurred when I filled up my tank, then I had a hard time starting the C2. Only after pushing the gas was it able to start... which still occurs every time I fill up.
The P0441 comes on after each fill up, which I reset with the OBDII tool.
What part do I need to rectify this issue? Many thanks!
August 31, 2015
  Followup from the Pelican Staff: I would try the vent valve mentioned in this article. - Nick at Pelican Parts  
JR Comments: Ok, I checked the reed switch when loose with a magnet and it works. When I rub a magnet across it I can hear the solenoid pull in and out. With the reed switch in place on the filler neck I can activate it with a magnet through the plastic vent valve and hear the solenoid. However, it will not activate when you press in the flap for the fuel nozzle.
August 28, 2015
  Followup from the Pelican Staff: is the filler neck switch sending voltage to the solenoid when closed? - Nick at Pelican Parts  
JRS Comments: I was not able to fill my car with gas, so I replaced the fuel line vent valve. This did not solve the problem. I do not hear an audible "click" when I insert a fuel nozzle into the neck. I tried to activate the sensor with a 1/2" ratchet extension inserted into the filler neck, no luck. I removed the sensor from the valve and tried activating it various pieces of metal. No luck. I unplugged the sensor, cleaned the contacts with contact cleaner, dried them and plugged it back in. There is still no audible "click" with the sensor reinstalled in the valve or hanging free. I even spent several minutes at the gas station trying different nozzle positions. Should I check the resistance across the switch with a DVM to determine if it is working? Is it digital off/on or analog? a range of readings depending on how close a nozzle is to it What exactly is this magnet activating? what makes the audible "click"?
August 28, 2015
  Followup from the Pelican Staff: Check if the vent is plugged or restricted. If the vent line is detached, does it fill normally? - Nick at Pelican Parts  
Ruben Comments: My 1999 Porsche 911 996, Check engine light went on, so i have Porsche Auto repair take a look for what code causing the check Engine light, they find out it's a Evap leak system code, The first thing i did for simple repair is change the Fuel Cap, it did not resolve the problem, Light went on again and i bring it back to the same Auto Repair, they check it again and again it's evap leak, so i have them check it, they smoke check it for leak and found no leak, so they say it's the check valve, purge valve so i have them replace it, they clear the code and in a few days, the check engine light went back again. What do you think is the problem with the Evap System leak?
July 31, 2015
  Followup from the Pelican Staff: Could be the vent solenoid not sealing during the test or a leak in a line or fitting. - Nick at Pelican Parts  
Ruben Comments: My 1999 Porsche 911 996, has a Evap leak system problem, so they smoke the System and find no leak, I was unable to fill gas so they change the Check Valve, the Purge valve, but still the check engine light still coming up after a few days. What is the problem with my Evap System?
July 31, 2015
  Followup from the Pelican Staff: Could be the vent solenoid not sealing during the test or a leak in a line or fitting. - Nick at Pelican Parts  
jeff Comments: My 2000 Porsche Boxster S will start and run but after turning it off occasionally It just turns over and doesn't fire/start or even sputter. Hours later it will fire and start like there is nothing wrong. I do hear a howling sound while driving occasionally. Replaced fuel pump relay, same deal. Would bad fuel pump or pressure regulator explain symptom?
July 19, 2015
  Followup from the Pelican Staff: Very common...99% sure you have a faulty charcoal canister purge valve (aka fuel regeneration valve?!). The purge valve is located in the engine compartment on the left side beneath the intake. Part number: 996-110-129-06-M100 - Casey at Pelican Parts  
musclehedz101 Comments: I have a 2007 997.1 C4S that is throwing a P0441 Code - "Fuel tank ventilation system: Below Limit". Here is Durametric readout.
No rough starts
No slow starts
No Whistle sounds
Tried resetting but code came back after 1-2 days.
Have a new gas cap on order as a lost cost first attempt at resolution...
Any suggestions/thoughts?
July 13, 2015
  Followup from the Pelican Staff: One very good piece of information on your Durametric readout is that the fault is not currently present. These intermittent faults can be tough to track down but just know that if the gas cap does not fix it, which it most likely will, it is the evap fuel regeneration valve which is located under the intake on the passenger side. Either part number OEM-99711012940, or OEM-99711012900 depending on the year. - Casey at Pelican Parts  
thejack Comments: Well, end of the search. I have found the source of rough idle and misfiring. The 996 110 129 05 regeneration valve fuel vapor system was not closing properly and suddenly remain stuck open allow a considerably -at idle- amount of air to go into the engine through the TB. A lean mix was triggering O2 sensors to the limit until the CEL came up, first flashing than solid. Now the engine is running smooth, performance are improved, exhaust pipe has lost it's dark color and idle is now stable at 800 rpm w or wo ac. This valve was triggering also fuel pump flow rate and relais error, O2 correction error, cylider misfire error. Hope this could help anyone else with same issue. Thanks all for support and hints. Greetings from Italy.
July 8, 2015
  Followup from the Pelican Staff: Thanks for sharing your experience. These type of comments add so much to the Pelican tech community.
- Nick at Pelican Parts
 
Andy Comments: I get the P0455 major leak combined with P0450 Tank pressure. Watching my driving habits, I reset the code - and it comes on reliably after about 30 minutes of driving while taking off from a stop. Seems to be coordinated with letting the clutch out - could it be because the pressure is dropping to the vent valve with the RPMs? Is there a recommended way to check the function of the vent valve before I replace it? Thank you for your expertise.
June 23, 2015
  Followup from the Pelican Staff: What year is your Carrera? Seems to me that you've got an evap leak somewhere. The source of the leak could be the evap canister purge valve. I would recommend using your scanner to check the fuel trim values while out on your drive. If you notice them moving all over the map rich and lean chances are you have a faulty evap canister purge valve. If they stay mostly lean I would be looking for an EVAP leak. The purge valve is located in the engine compartment on the driver side. - Casey at Pelican Parts  
thejack Comments: I do not perceive misfiring during running but I can precisely ear them on idle. Car is shaking random and misfiring is clarly audible. Bank 2 is misfiring in each cylinder -4.5.6-. Furthermore, first range of rpm, util 2000, are very shaky then the engine becomes regular. But still have no pressure in the tank. Could the venting valve stuck open let the engine breathe air from it?
June 18, 2015
  Followup from the Pelican Staff: That would cause an oxygen sensing fault. What faults does your car have and which year is your 911? - Casey at Pelican Parts  
Efren Comments: I have a CEL P0455 and found this DIY while doing a search. The cars is a 2002 986 S. I've taken the car to two shops o detect the leak. One shop is a Indioendant Porsche shop. Was not able to if d the leak. Then2nd shop is a Smog certified and they performed a smoke leak detector. They were not able o find the leak. The gas cap have been changed 3x. The second cap was after market from the smog shop just o try. After driving 6 miles the CEL came on. With the OEM it took days before it came on. I'm on my 3rd cap which is another OEM.

Could this vent line be culprit? Anyone else had this problem?
June 17, 2015
  Followup from the Pelican Staff: Usually if I can't find the leak, and the cap tests good, the EVAP canister purge valve needs replacement.
Part number: 996-110-129-06-M100
- Casey at Pelican Parts
 
thejack Comments: Hi Nick, I am experiencing some idle troubles. Just repalced the rubber hose from the venting valve 97 boxster and engine improved performance but still "random" idle problem persists. Just wondering if a stuck open venting valve could generate those idle problems. No cel light no error codes apart from bank 2 misfiring which I believe they could not be related to that. But I do not longer hear tank pressure blowing when I open the tank cap, just like there's no pressure inside. Any hint?
June 15, 2015
  Followup from the Pelican Staff: If the entire bank 2 misfiring? does it misfire only at idle or down the road as well? - Nick at Pelican Parts  
Zebravanman Comments: I have the same issue as blulude, my vent valve operates in the opposite sense to the article. When fuel cap removed vent closes and when installed the vent valve opens. Is this correct.?
I have two codes p0456 and p0450 i have replaced the charcoal cannister and the pressure sensor, the tank is not breathing when i refuel and hence cant get a full tank of fuel.

Is my vent valve bad based on it operating in the opposite sense to your article.
April 18, 2015
  Followup from the Pelican Staff: What vehicle are you working on? Those faults relate to a leak in the EVAP system, look at the gas cap seal FIRST, it should have no cracks in the rubber. - Casey at Pelican Parts  
Brian Comments: Hi Casey, I've noticed the Howl while cruising along about 30 miles an hour it comes and goes at random. About once every 15 miles for about 3 seconds.
It sounds exactly like you're blowing over the top of a coke bottle. Exactly!
April 16, 2015
  Followup from the Pelican Staff: Assuming that your fuel cap is a Genuine Porsche or equivalent...It sounds to me like the howl is being produced during the purge phase. Let me explain what needs to happen during that phase. First the canister vent (purge) valve pulses, the charcoal canister shutoff valve (aka fresh air valve) opens, and the ORVR valve remains closed. Outside air is sucked through the canister shutoff valve, through the charcoal canister, through a bunch of plastic tubes by the purge valve, allowing the intake manifold to "suck" on this evaporative emission system. That howl is a result of something not seating in the system, or possibly the canister having some strange resonance producing ability. You may want to try removing the right headlight and the right front wheel housing liner where you can see the tubes connecting the filler neck to the charcoal canister. Let the car warm up, then listen to each component closely with a mechanics stethoscope. Also listen to the purge valve... This is going to be a feather in your cap if you can figure it out. - Casey at Pelican Parts  
Brian Comments: Only problem I had was a random howling sound coming from the gas filler door area, so this weekend I installed a new vent valve on my 2003 Boxster. Didn't solve the problem.
What does stop the sound is partially plugging the hole located in front of gas filler doorsee picture. I took a piece of one of my kids nerf gun bullets which is made from sponge with same OD as the hole in the filler door and a 1/8" ID hole through the middle of it. I pushed a piece of piano wire through it to hold it in place see 2nd picture. With this in place the howling completely goes away.
Since this solves the problem would you have any idea what the problem could be? Gas cap appears to be OK. Thanks
April 13, 2015
  Followup from the Pelican Staff: Does your kid know?! Haha! That hole is for the charcoal canister vent, and leaving it plugged will eventually cause a check engine light because if the canister vent is plugged the DME will not see a change in oxygen sensor activity when purging. There are two other valves behind the passenger headlight which can cause this issue, however the purge valve is usually the culprit. This is a tough one to offer advice on without seeing the car, and hearing the howl. - Casey at Pelican Parts  
Lancair Comments: Just installed a replacement Fuel Line Vent Bleeder Valve. I did not remove the lines to the EVAP Canister Step 2 as it seemed to add no advantage to access to the top bolt on the bleeder vent. Instead I removed the bottom bolt, popped the plastic trim out of the fuel filler door and rotated the unit to release the top bolt. Use a flexible extension with a wiggle ratchet to make the turn. Saves a bunch of time.
March 22, 2015
  Followup from the Pelican Staff: Thanks for sharing your installation process and experience. These type of comments add so much to the Pelican tech community.
- Nick at Pelican Parts
 
Prashanth Comments: @Nick, I forgot to mention earlier. I have a 1998 Porsche boxster.
March 9, 2015
  Followup from the Pelican Staff: The solenoid should be on the top of the intake manifold, above the alternator. It has a round body and two wire connector. - Nick at Pelican Parts  
Prashanth Comments: Evap cannister code P0446. I am suspecting Evap Cannister Purge valve. In the following picture, it is #1. Is there any link / directions on replacing it? Where is it located? any pictures?

http://s1140.photobucket.com/user/jfpeters6056/media/P0446Systemdiagram.jpg.html
March 8, 2015
  Followup from the Pelican Staff: What vehicle are you working on? I may have information listing the location.

Purge solenoids are generally connected close to the intake manifold.


- Nick at Pelican Parts
 
Milan Comments: 2001 996. I don't get CEL but intermittent howling that usually stops when revving the motor. What part tells the vent valve to open? Isn't it supposed to happen just after fueling?
March 8, 2015
  Followup from the Pelican Staff: The DME commands it open. However, if you have excessive draw or vacuum, that issue may lie with the purge solenoid. - Nick at Pelican Parts  
1969jboy Comments: I have a 2001 911 and get an engine check light like clockwork at 3/4 and 1/4 fuel tank levels. Is this caused by a bad fuel tank vent valve? Since it is so routine it must come from a venting schedule perhaps? The fuel cap is fine. Maybe I need to replace the charcoal cannister as well? This must be a common issue. No problem fueling or starting, just the light. Mech wants to replace O2 sensors first, but the check light comes on no other time but 3/4 and 1/4 tank levels.
March 7, 2015
  Followup from the Pelican Staff: Hard to day without knowing what fault code is stored. Do you know the code number and description? - Nick at Pelican Parts  
Milan Comments: I had a CEL and howling from the vent behind the gas cap. I replaced the gas cap and fuel line vent valve but howling continues. What's next? check valve?
March 6, 2015
  Followup from the Pelican Staff: What vehicle are you working ok?

Something may be stuck open causing a constant draw of fresh air.- Nick at Pelican Parts
 
Dac Comments: What is the part number to the one way check valve, the round blue one shown above. I have replaced the bleeder valve trying to fix the filling issue and howling issue. It is still there I have found the howling tone coming from the check valve. I need part number to order. Did search did not find it.
February 25, 2015
  Followup from the Pelican Staff: I am not the best with part numbers.

Give our parts specialists a call at 1-888-280-7799 and they can help figure out which part or repair kit you need.
- Nick at Pelican Parts
 
Dac Comments: What is the part number to the one way check valve, the round blue one shown above. I have replaced the bleeder valve trying to fix the filling issue and howling issue. It is still there I have found the howling tone coming from the check valve. I need part number to order. Did search did not find it.
February 25, 2015
  Followup from the Pelican Staff: I am not the best with part numbers.

Give our parts specialists a call at 1-888-280-7799 and they can help figure out which part or repair kit you need.
- Nick at Pelican Parts
 
Timb Comments: Like Allen I canot figure out where the sensor goes after changing fuel line vent valve and I am unable to refill my tank. Perhaps you did show it in the replays but I am not seeing it. Is there an illustration somewhere that shows it?
February 17, 2015
  Followup from the Pelican Staff: See my reply here:

,Strong>GREAT! Thanks for sharing the photo. There is a small black plastic molded piece that is fitted to the filler neck. That magnetic switch pops into that black piece. It should be obvious that it fits inside of it. WITHOUT it installed, you will have the issue you are experiencing. - Nick at Pelican Parts
 
dcorday Comments: So I still have issues starting car right after filling the tank. Have to crank for a couple min. The main issue was the noise. Could it be a clogged line or something else?

2001 boxster 2.7
December 31, 2014
  Followup from the Pelican Staff: Could be a restricted vent line or orvr system - Nick at Pelican Parts  
dcorday Comments: I have just Replaced the Fuel Line Vent Bleeder Valve a couple days ago. initially it was great noise was gone but it is now back any other suggestions?
December 30, 2014
  Followup from the Pelican Staff: Didn't you have a no start issue originally? Is that resolved? I don;t recall a complaint of a noise. - Nick at Pelican Parts  
dkrahn Comments: To follow up on your comment of 11/9. If I remove the two hoses from the filler neck, fill the car with fuel and then leave them off. The car does not start. The hoses can not be misconnected, the color coding matches the figure 3 above and they have a set to them which would not allow them to get to the other connection point with out kinking. What next? Thanks for helping me run down the options.

November 14, 2014
  Followup from the Pelican Staff: At this point, all I can think, if related, is raw fuel is someone making it to the intake. Which would have to be through the purge line, only if the vent was misconnected. If that isn't it, I am out of ideas, unless of course it is not related.

When your engine doesn’t start you’ll want to check the basics. Check spark, fuel injector pulse and fuel pressure, volume and quality. Are there any fault codes? Once you figure out what is missing, it will be easier to diagnose.
- Nick at Pelican Parts
 
dkrahn Comments: To follow up on your comment of 11/8. If I remove the two hoses from the filler neck, fill the car with fuel and then re attach the hoses. The car does not start right away but it significantly better than before. I think you are on to something.
November 9, 2014
  Followup from the Pelican Staff: Hoses may be misrouted, causing raw fuel to be pulled into the engine. See if the problem goes away 100% if the hoses are left off. - Nick at Pelican Parts  
dkrahn Comments: To follow up on your comments from 11/7: The car starts fine at all other times other than after a fill up. That would seem to eliminate the basics. I have two fault codes P0440 Ventilation minor leak - I installed a new fuel cap and P0446 shutoff valve activated charcoal filter function.
November 8, 2014
  Followup from the Pelican Staff: I would think you are pulling raw fuel into the purge like when refueling. If you remove the hoses from the filler neck, does the issue still occur? - Nick at Pelican Parts  
dkrahn Comments: See my comment from Oct 5th. Magnetic switch now in place and can fill the car with fuel just fine, thanks. Now the car is hard to start after filling up. Cranks and cranks before starting.
November 7, 2014
  Followup from the Pelican Staff: You'll need to see what is going on when you try to start it. It could be a fuel issue. When your engine doesn’t start you’ll want to check the basics. Check spark, fuel injector pulse and fuel pressure, volume and quality. Are there any fault codes? Once you figure out what is missing, it will be easier to diagnose. - Nick at Pelican Parts  
debprince Comments: I ordered this part vent valve just like the pic in this article and read somewhere it was supposed to come with a new magnetic switch, which it didn't. Had the part installed and now I cannot get gas into the car could gas up fine before the install. Could be they did not put switch back ocrrectly or it's just bad. Is it possible to order the magnetic switch and if so what is the part number - 2000 Boxster 986. I can't seem to locate it on your website?
October 18, 2014
  Followup from the Pelican Staff: I believe you swap the old switch to the new part. If you need a new one, give our parts specialists a call at 1-888-280-7799 and they can help figure out which part or repair kit you need - Nick at Pelican Parts  
dkrahn Comments: Comments: I have the same problem as Allen from Dec 1 2013 above I installed a new vent valve to solve hard starting. I have the same sensor hanging by 2 wires and now can not fill with fuel. Where does the sensor go, will that solve the problem?
September 28, 2014
Followup from the Pelican Staff: Can you share a photo of the sensor or can you identify it from our tech article and point it out to me? - Nick at Pelican Parts

See the attached photo.
October 5, 2014
  Followup from the Pelican Staff: GREAT! Thanks for sharing the photo. There is a small black plastic molded piece that is fitted to the filler neck. That magnetic switch pops into that black piece. It should be obvious that it fits inside of it. WITHOUT it installed, you will have the issue you are experiencing. - Nick at Pelican Parts  
Seang Comments: I have a 2000 911 Carrera. I ordered this part from you and replaced the existing one, which had gone bad. After I was still only able to put in gas slowly and it keeps shooting back out of the filler neck, however if I push down on the button on the top of this part that the cap would normally depress when closed, I am able to put in fuel. What should I change?
September 30, 2014
  Followup from the Pelican Staff: Have you checked the vent hoses for restriction? - Nick at Pelican Parts  
dkrahn Comments: I have the same problem as AllenDec 1 2013 above I installed a new vent valve to solve hard starting. I have the same sensor hanging by 2 wires and now can not fill with fuel. Where does the sensor go, will that solve the problem?
September 28, 2014
  Followup from the Pelican Staff: Can you share a photo of the sensor or can you identify it from our tech article and point it out to me? - Nick at Pelican Parts  
iruss79 Comments: I can only fill the tank very slowly on my 2002 c4s,
what can be the problem with?
August 23, 2014
  Followup from the Pelican Staff: The vent line is likely restricted. - Nick at Pelican Parts  
Daniel Comments: I can only fill the tank very slowly on my 2003 targa. I ordered the vent valve with Pelican but received a message that it was not available. I then went to the porsche dealer and ordered it. No one has it and it was ordered from Germany. Its on back order for the past 2 months. Is there a way to unclog this vent valve with wd 40?
July 31, 2014
  Followup from the Pelican Staff: No, if the valve is faulty, you will have to replace it. - Nick at Pelican Parts  
andy Comments: we have a 2003 carrera 4s. car will not accept gas. Has a new bleeder valve on filler neck and new tank vent valve on top of fuel tank. you can hear charcoal cannister valve switch when pressing the flap in filler neck and has power at connector under battery for tank vent valve. fuel backs up in filler neck and shuts pump off. tried several pumps..
thanks....
July 24, 2014
  Followup from the Pelican Staff: Check to see if the hose for the vent is blocked. SOunds like everything else is new. - Nick at Pelican Parts  
Eric F Comments: Nick
02 C2.
Replaced fuel line vent valve after whistle on and off for a year. Never had a fueling problem.
Now car will not take gas. But will fuel from gas can.
Reviewed my work all seems OK.
Where is the mechanical connection between the valve and the filler neck?
When I insert the gas pump nozzle I am not activating the vent valve.
Please email me.
Eric@racharles.com
July 5, 2014
  Followup from the Pelican Staff: The vent on the filler neck could be plugged. That is what shuts the gas pump handle off when filling. - Nick at Pelican Parts  
Torger Comments: Hi Nick. Discovered a leak in the valve that is under the right fender toward the front of the fender not at the back where the filter and canister are. I disconnected a line and I was able to hear a leak at the vent that is in the fuel filler cavity where you insert the gas station hose. It is my understanding that this should not leak when you pull a vacuum on it and the gas filler is not inserted. What is this valve called and does pelican stock it?
June 1, 2014
  Followup from the Pelican Staff: Can you share a photo of the valve? You can try describing it to our parts specialists if a photo isn't an option. Call at 1-888-280-7799. They can help you find the right part.
- Nick at Pelican Parts
 
blee Comments: Does a 2005 Boxster S have a fuel line vent valve? I am having trouble fueling. Usually stops fueling at 3/4 full.
May 31, 2014
  Followup from the Pelican Staff: Yes, all fuel tanks have a vent. I would guess that the vent hose or solenoid is plugged. - Nick at Pelican Parts  
Torger Comments: Hi. 2004 Boxster S Code P0455 coming on. Changed gas tank cap. Cleared code but it came back on 50 miles later. No problem filling with fuel. Hear clicking when I put finger into opening of tank so valve working. Took a chance. Cleared code and took in to smog. Tech said couldn't check because Evap Emission Monitor not run by computer, indicated on his tester. Did change battery in Feb but should have run by now. Was going to check Tank vent valve but when I found it I said "yikes"! Obviously hidden under intake manifold. Also smoke tested into the gas cap opening and didn't see any leaks.. So, suggestions please! Feeling challenged!! ;-
May 29, 2014
  Followup from the Pelican Staff: The code is for the canister purge solenoid. It is located on the engine and purges the charcoal canister of vapors. Locate the valve, then test the wiring and operation. - Nick at Pelican Parts  
Prashanth Comments: P0446 on 98 boxster. Replaced Gas cap. no codes for a month. Same code came back up. Should I replace shut off valve, Fuel Line Vent Bleeder Valve or some other valve?
May 28, 2014
  Followup from the Pelican Staff: P0446 is a flow issue. It could be a restricted vent solenoid or hose or a faulty purge solenoid. You will have to run a purge test to see if the system flows. If it does not, you will hae to test the solenoids to see if they are functioning, then check for restricted or broken hoses.- Nick at Pelican Parts  
jz_1978 Comments: I have an issue where when i fill up - 2003 Carrera 4S - I get some fuel leaking and sometimes a small puddle. I can confirm I am not over filling and I've tried with various levels of inserting the pump nozzle into the filler.

Is this another likely issue with the fuel vent? The fuel can be seen inside wheel arch on chassis.
May 23, 2014
  Followup from the Pelican Staff: You likely have a broken or detached hose I would inspect the filler neck hoses and fuel sending unit assembly and hoses. - Nick at Pelican Parts  
Ashmyster79 Comments: I have 2002 3.2s recently purchased. The fuel light was on when I bought it so thought it just needed fuel. I have filled up 3 times since and the red light is on and the needle is on empty. Is this the fuel line, sender unit, pump or cluster? Or even filler cap?

May 13, 2014
  Followup from the Pelican Staff: Could be the sending unit, wiring or gauge. Hard for me to guess without testing it. I would gain access to the sending unit, then check if you can get the gauge to work by grounding and removing t ground from the wire. I would grab a repair manual. It will have the wiring diagram needed for the tests. - Nick at Pelican Parts  
TJ Comments: I have a problem starting ONLY after refueling. Car was towed 3 times in the past 60 days for the same exact problem. Each time however that it rolled back off the flatbed back at my house it started right away and no issues after the initial start. After this this technical article I ordered and replaced the vent value at the filler neck but that made no difference. I currently have codes P0446, P1128/P1130 and P0430. Any other thoughts would be helpful. It seems like the value isn't closed...right? Would that be due to a blockage in the line that would close it or something else not working i.e. purge value by the tank,etc.Very strange that all it needs is a tow and then it's as right as rain until the next fill-up.. Thanks.
April 30, 2014
  Followup from the Pelican Staff: Have to checked if there is a blockage in the vent line to the fuel tank? I would remove the line and see it is it clear. - Nick at Pelican Parts  
Allen Comments: Nick, thanks for responding. I would sure like to think I installed correctly as it seems pretty easy. The bracket is was and is lined up properly with the notch on the neck as well as the hole for the 10mm nut holding it to the bracket. Both vent tubes are secure. I have attached a pic of the "sensor" to which I referred. No idea what this is or where it goes. Still have issues with filling with gas, but the car starts easily after filling.
December 1, 2013
  Followup from the Pelican Staff: Thanks for the feedback. - Nick at Pelican Parts  
Allen Comments: I recently replaced my fuel line vent valve on my 2001 996. I did not pay attention to the location of the sensor on the fuel neck though my dad would call me a shade tree mechanic and now am having a issue putting gas in my car. What is the proper location of the end of the sensor towards the top of the fuel neck?
November 21, 2013
  Followup from the Pelican Staff: Can you share a photo of the sensor you are referring to? Did you install the vent valve properly? if it is plugged it will be hard to fill the vehicle with fuel. - Nick at Pelican Parts
blulude Comments: I have a 996 with a P0455. I was checking my fuel vent valve and the component seems to work a little differently than the way you described. Is my component faulty? With mine, with the fuel cap removed, the valve actually CLOSES and it seems like it only allows air to flow one way. With the fuel cap installed, the cap edge hits the tab and pushes the valve OPEN letting air bypass. It looks like, with the cap removed, it blocks off the fuel tank vent line so it doesn't let vapor return back into the tank to cause excessive fuel tank pressure while letting vapor move to the carbon canister to help refueling? am I right or is my valve just broken?

another question, when this part fails, I assume the plunger or something ruptures and the valve stays closed which will cause the "howling" sound. But if the valve simply ruptures, wouldn't it just be like having the fuel tank cap off? so why would it be hard to refuel if this part is bad?

Forgive me for sounding like I'm trying to question what you said but, with your help and knowledge, I was hoping to be able to clarify how this system works since it does seem a bit complicated with all these parts.
November 15, 2013
  Followup from the Pelican Staff: The part you are describing is the vent for ORVR (Onboard Refueling Vapor Recovery). That is the valve described in the tech article. These normally won't set a P0455. You have to look elsewhere for your leak. For example the evap vent solenoid or the purge solenoid. - Nick at Pelican Parts  
Charlie Comments: I've been having trouble filling my gas tank. Car runs fine. I followed your advise on replacing the filler neck vent valve and the gas cap. It didn't fix the problem. Where should I look next for the source of this trouble? 2001 Boxster -S
November 10, 2013
  Followup from the Pelican Staff: Check that the hose to the vent valve is not plugged. - Nick at Pelican Parts  
Mike Comments: Nick, just an FYI. I called your sales number and I was told that they couldn't find the part for the 997-no fuel purge/vent valve was listed. When I called Porsche the answer I got was that the hose that connects to the carbon canister now has the valve built into it so the valve is not purchased separately. In this case, you need to purchase the hose. The price quote was $120 from Porsche. The instructions above suggest that the part was eliminated which is incorrect, the part was actually integrated into the vent hose for the 997 models.
August 28, 2013
  Followup from the Pelican Staff: Thanks a bunch Mike. We'll update the article to reflect these changes. We appreciate the help.- Nick at Pelican Parts  
Mike Comments: I have this exact problem right now on my 2006 911. Car would not start after last fill up, waited 2 days and car started fine. Took the car in for service but no fault codes came up. Repair shop stated it was probably this valve. Drove the car 200 miles and check engine light has recently come on for the first time. Can you please provide the exact part numbers I need? Will the CEL go off automatically once the new part is installed? Thanks, Mike
July 31, 2013
  Followup from the Pelican Staff: The check engine light will go out after 3 monitor cycles with no fault present. Give our parts specialists a call at 1-888-280-7799. They can help you find the right part. - Nick at Pelican Parts  

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