Installing Fuel Level Sender

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 fuel level sender -2-  .

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

   Clip in plug connection -1-  at the holder.

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   Top fuel-level sensor in fuel tank

   Information 

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

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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

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

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   Tool for fuel tank flange

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

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

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   Lines

6. Push on electric plug connections -Arrows-  and check that they are fitted securely.

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   Plug connections

7. Install battery console holder.

   Tighten fastening screws -1-  .

   > Tightening torque 23 Nm (17 ftlb.) 

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   Battery console holder

8. 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 

9. 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.
10. Install battery console -1-  .

    Tighten fastening screws -2-  .

    > Tightening torque 23 Nm (17 ftlb.) 

    Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Battery console