Post
by EPiK » Wed Jul 11, 2018 11:37 pm
As done on my 1999 Carrera 2
I've done this job several times. The first was when the tube broke just after getting the car and RIGHT before I was leaving for Werks Reunion in FL. I pulled the now 2 piece filler tube, epoxy glued and gorilla taped it and reinstalled... ugly but it never leaked and lasted til I bought a new one and replaced it a month later. That lasted for a month until running errands one morning after work, the alternator mounting ear bracket on the engine broke, cracking the alternator and angling it so the belt cut thru my new oil filler tube. So I got to do it again.
The actual process is pretty straight forward.. disconnect the negative battery terminal. Remove the airbox. It may help to remove the throttle body depending on how large your hands are for getting to the 2 10mm bolts that hold the filler tube to the engine. Take a picture of the serpentine belt before you remove it..trust me..or at least draw a diagram for when you put it back on after.
Loosen the 10mm bolt that is holding the coolant hose fitting that always get broken and push it aside. Loosen the bolt on the alternator mounting ear (left side), and the pinch bolt (right side) that is on the upper idler pulley. Once you get the right side pinch bolt loosened a few turns, give it a few good whacks to slide the bushing in the back right ear of the alternator. Once the bushing releases the tension, pull the long bolt and idler pulley out. Tilt the alternator up and counterclockwise to pull it forward. Disconnect the plug and 13mm nut (this is the main reason you disconnected the battery..hot wire constant 12v). From there, reach around to the right behind the power steering pump and feel the base of the filler tube. If you have a shop vac, use it back here before you pull the tube off to make sure nothing dirty falls into the hole when you pull the tube off.
I used a 1/4 drive 10mm ratchet and a 10mm gear wrench to loosen and retighten the bolts for the filler tube.
Install the new o-ring on the new tube, and reinstall, making sure to snug the bolts and that the tube is fully seated in the recessed hole. Reinstall the hot wire and plug on the back of the alternator and set it back into place and tension the bolts. Install the 10mm bolt for the coolant fitting. Install the throttle body if you removed it. Install the serpentine belt. Install the airbox and MAF plug. Reconnect the battery.
Its helpful to have a telescoping magnet on hand, you will drop those 10mm bolts at least once before you get them started.
1999 Carrera 2, factory ordered LSD, GT3 wannabe and daily driver
1988 944 NA/AT to MT/Turbo project.. future Outlaw
2003 G35 coupe 6mt GT35RS.. other daily driver
2013 Durango R/T package with a 6er