Installing Fuel-Level Sensor

Information 

Always comply with the regulations for handling ESD-sensitive components!

• Assembly work may only be carried out if the mechanic is wearing the working clothes and shoes approved by Porsche. 
• The new part must only be removed from the ESD (electrostatic discharge) protective packaging just before installation and at the position at which the part is to be installed. 
• Never touch the electric pins and plug contacts. 

Information 

• When the work is complete, check that all aids and foreign objects (e.g. cloths, tools) are removed from the engine compartment. 

1. Install bottom  fuel level sender.

   Carefully guide the bottom fuel level sender -2-  into the fuel tank and clip it into the fuel pump -1-  .

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Bottom fuel-level sensor in fuel tank

2. Remove the top -2-  fuel-level sensor.

   Carefully guide the fuel level sender -2-  into the fuel tank and position it.

   Clip in plug connection -1-  at the holder.

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Top fuel-level sensor in fuel tank

   Information 

   • Replace flange gasket on the fuel tank. 
3. Fit new sealing ring on the flange.
4. Connect connections at the flange and check that they are seated securely.

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Fuel tank flange connections

   1	Vent line
   2	Fuel line
   3	Electric connection for fuel level sender
   4	Electric connection for fuel pump

5. Insert flange and lock locking ring -1-  using> 9731/1 - lug wrench-2-  by turning it clockwise.
   IMPORTANT: High closing force for locking lugs on the locking ring!

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Tool for fuel tank flange

6. Connect fuel and vent lines -A-  and check that they are seated securely.

   Lock the fuel line -B-  (variant with lock).

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Lines

7. Connect electric plug connections -Arrows-  and check that they are seated securely.

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Plug connections

8. Install battery console holder.

   Tighten fastening screws -1-  .

   > Tightening torque 23 Nm (17 ftlb.) 

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Battery console holder

9. Fit vacuum line.

   Connect the vacuum line -A-  and check that it is seated securely.

   Clip in vacuum line -B-  .

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Vacuum line

10. Plug in electric plug connection on fuel pump control unit at the underside of the battery console and check that it is seated securely.

    Only for USA vehicles 

11. Plug in electric plug connection on temperature sensor for leakage diagnosis at the underside of the battery console and check that it is seated securely.
12. Install battery console -1-  .

    Tighten fastening screws -2-  .

    > Tightening torque 23 Nm (17 ftlb.) 

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Battery console