Fuel Gauge Sender: Service and Repair

Removing And Installing Fuel Level Sensor

Tools







Technical values







Preliminary work
1. Place protective covers on the vehicle.
2. Disconnect and remove the battery.
3. Remove carrier plate for battery.
3.1. Unscrew four hexagon collar nuts (M8) -1- and remove lid.







3.2. Check seal for damage and replace it if necessary.

Removing fuel-level sensor

DANGER:
Risk of fire from escaping fuel.
- Danger of fatal injury and damage to property.
- Observe basic safety instructions when working on the fuel system.
- Secure working area.

Tools:







Tool for USA version







Tool for RoW version

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

1. Disconnect safety contacts on the fuel level sensor.







1.1. USA version:
1.1.1. Release and unplug plug-in couplings of the fuel lines.
1.1.2. Release and unplug multiple connector.







1.2. RoW version:
1.2.1. Release and unplug plug-in couplings of the fuel lines.
1.2.2. Release and unplug multiple connector.

2. Unscrew cap on fuel level sensor.

INFORMATION: Mark the installation position with a paint marker before removing the fuel level sensor.

Use special tool for this, depending on the version (USA - RoW).







2.1. Figure 1: USA version:
Lug wrench P 9731
Mark original position of cap.







2.2. Figure 2: RoW version:
Union nut tool 3217
Mark original position of cap.

3. Remove fuel level sensor.







3.1. USA version:
3.1.1. Carefully pull fuel level sensor out of the fuel tank.
3.1.2. Release and unplug plug-in coupling of the fuel line -2-.
3.1.3. Release and unplug two-piece multiple connector from the fuel level sensor -1-.
3.1.4. Separate the housing halves (yellow/blue) of the multiple connector.
3.1.5. Carefully remove the fuel level sensor.
3.1.6. Replace seal.







3.2. RoW version:
3.2.1. Carefully pull fuel level sensor out of the fuel tank.
3.2.2. Release and unplug plug-in coupling for fuel line -1-.
3.2.3. Release and unplug electric plug connection from fuel level sensor -2-.
3.2.4. Carefully remove the fuel level sensor.
3.2.5. Replace seal.

Installing fuel-level sensor

INFORMATION: Replace seal for fuel level sensor.

1. Install fuel level sensor.







1.1. USA version:
1.1.1. Push new seal onto fuel level sensor.
Grease new seal lightly with Kluber Syntheso Glep (Porsche part number 000.043.204.68).
1.1.2. Insert fuel level sensor into the fuel tank.
Check that sensor mechanism has sufficient clearance.
1.1.3. Join the housing halves (yellow/blue) of the multiple connector.
1.1.4. Fit two-piece multiple connector on the fuel level sensor -1-.
Check that it is seated securely.
1.1.5. Plug-in couplings for fuel lines:
Plug in plug-in coupling -2-.
The plug-in coupling must audibly click into place.
1.1.6. Fit cap.
1.1.7. Place fuel level sensor in installation position.







1.1.8. Tighten cap.
Tighten metal cap using special tool lug wrench P 9731. - Tightening torque: 60 Nm (44 ftlb.)







1.2. RoW version:
1.2.1. Push new seal onto fuel level sensor.
Grease new seal lightly with Kluber Syntheso Glep (Porsche part number 000.043.204.68).
1.2.2. Insert fuel level sensor into the fuel tank.
Check that sensor mechanism has sufficient clearance.
1.2.3. Plug in electric plug connection -2- onto fuel level sensor.
Check that it is seated securely.
1.2.4. Plug-in couplings for fuel lines:
Plug in plug-in coupling -1-.
The plug-in coupling must audibly click into place.
1.2.5. Fit cap.
1.2.6. Place fuel level sensor in installation position.







1.2.7. Tighten cap.
Tighten plastic cap using special tool union nut tool 3217. - Tightening torque: 70 Nm (52 ftlb.).

2. Fit safety contacts on the fuel level sensor.







2.1. USA version:
2.1.1. Connect plug-in couplings for fuel lines.
The plug-in couplings must lock with an audible click. Check that they are seated securely.
2.1.2. Fit multiple connector.
Check that it is seated securely.







2.2. RoW version:
2.1.1. Connect plug-in couplings for fuel lines.
The plug-in couplings must lock with an audible click. Check that they are seated securely.
2.1.2. Fit multiple connector.
Check that it is seated securely.

Subsequent work
1. Insert carrier plate for battery and secure using four collar nuts (M8). - Tightening torque: 23 Nm (17 ftlb.)
2. Install the battery.
3. Carry out a function test and check the system for leaks.
4. Calibrate fuel level sensor system.
5. Remove protective covers.