Installing Fuel Level Sensor - Carrera 2

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Information

Replace seal for fuel level sensor.

Install fuel level sensor.
1. 1.1. Slide new seal on sensor.
2. 1.2. Insert fuel level sensor into the fuel tank.
  Check that sensor mechanism has sufficient clearance.
3. 1.3. Connect electric plug connection.
  
  Fig 1: Connecting Electric Plug Connection
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  1. 1.3.1. Join the two housing halves (yellow/blue) -2, 3- of the multiple connector.
  2. 1.3.2. Fit two-piece multiple connector on the fuel level sensor -1- .
    Check that it is seated securely.
4. 1.4. Connect plug-in couplings for fuel lines on the fuel level sensor.
  Plug in plug-in coupling -1- .
  
  The plug-in coupling must lock with an audible click.
  
  Fig 2: Identifying Fuel Lines On Fuel Level Sensor (Underside)
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
5. 1.5. Fit and tighten relevant cap.
  1. 1.5.1. Carrera 2/RoW: Place sensor in installation position.
    Tighten plastic cap using special tool Union Nut tool 3217 .
    
    → Tightening torque: 70 Nm (52 ftlb.) .
    
    Fig 3: Tightening Plastic Cap Using Special Tool
    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  2. 1.5.2. Carrera 2/USA: Place sensor in installation position.
    Tighten metal cap using special tool Lug Wrench P 9731 .
    
    → Initial tightening: 60 Nm (44 ftlb.) .
    
    Fig 4: Tightening Metal Cap Using Special Tool
    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  3. 1.5.3. Then tighten further until the notch on the cap is between the white marking lugs on the tank flange.
    
    Fig 5: Tightening Cap Position On Fuel Level Sensor
    Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Connect plug connections on fuel level sensor.
1. 2.1. Carrera 2/USA variant:
  
  Fig 6: Connecting Plug Connections On Fuel Level Sensor
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  1. 2.1.1. Connect and lock plug-in couplings for fuel lines.
    The plug-in couplings must lock with an audible click. Check that they are seated securely.
  2. 2.1.2. Fit multiple connector.
    Check that it is seated securely.
2. 2.2. Carrera 2/RoW variant:
  
  Fig 7: Identifying Flange Of Fuel Level Sensor On Carrera 2 (RoW)
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  1. 2.2.1. Connect and lock plug-in couplings for fuel lines.
    The plug-in couplings must lock with an audible click. Check that they are seated securely.
  2. 2.2.2. Fit multiple connector.
    Check that it is seated securely.
Fit and screw on cap on fuel level sensor.
Use special tool for this, depending on the version (USA - RoW).
1. 3.1. Fig 8: Carrera 2/USA variant:
  Lug Wrench P 9731
  
  Tighten as far as the marking on the tank flange.
  
  Fig 8: Fitting Screw On Cap On Fuel Level Sensor
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. 3.2. Fig 9: Carrera 2/RoW variant:
  Union Nut Tool 3217
  
  Tighten as far as the marking on the tank flange.
  
  Fig 9: Tightening Union Nut On Tank Flange (RoW Variant)
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.