Removing 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 

Watch out for emerging fuel when disconnecting fuel lines. Place a clean cloth on the connection point, then loosen the connection.

Information 

• Replace flange gasket on the fuel tank. 

Component overview - fuel tank

Fig 1: Overview Of 90-Litre Fuel Tank Components Location

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Component overview of 90-litre fuel tank

1. Place a warning sign in a clearly visible position in the work area or on the vehicle.

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   Example of a warning sign

2. Place protective covers on the vehicle.
3. Unscrew fastening screws -2-  and remove battery console -1-  .
   1. 3.1 Disconnect electric plug connection from fuel pump control unit at the underside of the battery console.
   2. 3.2 Only for USA vehicles 

      Disconnect electric plug connection from temperature sensor for leakage diagnosis at the underside of the battery console.

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   Battery console

4. Disconnect vacuum line for the brake booster.
   1. 4.1 Release vacuum line -A-  and pull it off -B-  .
   2. 4.2 Unclip vacuum line -C-  .

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   Vacuum line

5. Remove battery console holder.
   1. 5.1 Unscrew fastening screws -1-  .
   2. 5.2 Remove holder.

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   Battery console holder

6. Release electric plug connections at the flange -a-  and disconnect them -arrow-  .

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   Plug connections

7. Release -A-  and pull off -B-  vent line.

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   Tank vent line at the flange

8. Disconnect fuel line.
   1. 8.1 Press the release or open the lock -A-  .
   2. 8.2 Release -B-  and pull off -C-  fuel line.

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   Fuel line (view with lock)

9. Remove flange for fuel tank.
   1. 9.1 Mark installation position of flange and locking ring.
   2. 9.2 Insert special tool > 9731/1 - lug wrench-2-  into the grooves on the locking ring -1-  .
   3. 9.3 Release locking ring on the flange by turning it anti-clockwise and remove it.
      IMPORTANT: High loosening force for locking lugs on the locking ring!
   4. 9.4 Lift off flange at the fuel tank.

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   Tool for fuel tank flange

10. Release connections on the flange and pull them off.

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    Fuel tank flange connections

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

11. Remove fuel-level sensor at the top -2-  .
    1. 11.1 Unclip plug connection -1-  at the holder.
    2. 11.2 Carefully guide fuel-level sensor -2-  out of the fuel tank.

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    Top fuel-level sensor in fuel tank

12. Remove fuel-level sensor at the bottom -2-  .
    1. 12.1 Unclip fuel-level sensor -2-  at the retaining lugs -1-  and carefully guide it out of the fuel tank.

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    Bottom fuel-level sensor in fuel tank

    Information 

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

    Fuel-level sensor removed: 

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    Fuel level sender

    1	Electric connecting line
    2	Plug connection for fuel filter housing
    3	Linkage with float

13. Make sure there are no tools, foreign objects or aids left in the work area.