Installing Fuel Level Sensor - Carrera 4

WARNING: This page does not describe the selected car, but rather 9 other vehicles, including the 2013 Porsche 911, 2012 Porsche 911, 2011 Porsche 911, 2010 Porsche 911, and 2009 Porsche 911. However, it is still accessible from the selected car via links, so may be relevant.

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 and lock the two-piece multiple connector on the fuel level sensor -1- .
4. 1.4. Connect plug-in couplings for fuel lines on the fuel level sensor.
  Fit plug-in coupling.
  
  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 variant: Place sensor in installation position.
    Tighten plastic cap using special tool union nut tool 3217 .
    
    → Tightening torque: 70 Nm (52 ftlb.) .
  2. 1.5.2. Carrera 2/USA variant: Place sensor in installation position.
    Screw on metal cap and tighten using special tool lug wrench P 9731 .
    
    → Initial tightening: 60 Nm (44 ftlb.) .
    
    Fig 3: Inserting Fuel Level Sensor On Carrera 4 (RoW)
    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 4: 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 4/USA variant:
  1. 2.1.1. Connect and lock plug connections for fuel lines -1- and vent line -2- .
    The plug-in couplings must lock with an audible click. Check that they are seated securely.
  2. 2.1.2. Fit multiple connector -3- .
  Fig 5: Connecting Plug Connections On Fuel Level Sensor
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. 2.2. Carrera 4/RoW variant:
  1. 2.2.1. Connect and lock rapid-action couplings for fuel lines -1- and vent line -2- .
    The plug-in couplings must lock with an audible click. Check that they are seated securely.
  2. 2.2.2. Fit multiple connector -3- .
Fig 6: Fitting Flange Of Fuel Level Sensor On Carrera 4 (RoW)
Courtesy of PORSCHE CARS NORTH AMERICA, INC.