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1997 960 gas smell and leak on fillup 900

Small hands help!!

When I changed the hose I first thought that I could do the job entirely from the top. I soon discovered that I needed to be under the car to see the small hose connection. I put a jackstand under the right rear jack point and was able to see the access hatch and hose connection. I used a torx bit on a ratchet with extensions to remove the screws to the valve that hangs down in the way on the right side. I disconnected the small hoses surrounding the fuel filler hose.
I disconnected the hoses from the valve and set it aside.
I disconnected the fuel filler hose from the fuel sending unit.
Using a combination of offset screwdriver and flexible driver, I disconnected the fuel filler hose from the fuel filler tube.

I then discovered that I couldn't unscrew the clamp to the small hose and thought that I might be able to cut it off. As a last attempt before cutting, I tugged on the small hose and it easily came off. If I had to do it again, I would tug on the small hose before disconnecting anything else.

Installing the new hose wasn't the easiest thing in the world. The large section
of hose fits tightly. Fit the hose over the fuel sending connection. Leave it loose so that you can twist it into position to slip over the fuel filler tube.
I had to wiggle and push and finally got the hose to fully cover the fuel filler tube.

When replacing the valve, attach the hoses before tightening the screws. There isn't clearance to attach the hose at the front of the access hatch if you tighten the valve bracket first.

I would consider using a different type of clamp for the small hose. Something easier to tighten and loosen. When I was attempting to attach the small hose and clamp the first time, I discovered that the body dips down and gets in the way of the clamp. A thinner clamp would be good.


Hope this helps,
Michael Diamante
93 964 95K






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