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Fuel Level Sender Replacement
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Pelican Technical Article:

Fuel Level Sender Replacement


30 min






Socket set

Applicable Models:

Porsche 911 (1965-89)
Porsche 912 (1965-69)
Porsche 914 (1970-76)
Porsche 930 Turbo (1976-89)

Parts Required:

New gas tank sending unit and gasket

Hot Tip:

Perform the replacement in a well ventilated area

Performance Gain:

Accurate fuel gauge readings

Complementary Modification:

Inspect the gas tank for debris
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Have you ever run out of gas because your fuel tank sender wasn't working? Chances are if you have, then you have already replaced your sender, because running out of gas is indeed very irritating. However, if you've been putting it off, don't worry: it's a very easy procedure.

The fuel tank is located in the front trunk, under the trunk carpeting. Access couldn't be any easier, as the sender is located right on top of the tank. The sender itself is a long aluminum tube that has a little float that rides up and down the center.

To replace this unit, simply remove the five nuts that hold the sender down, and pull it up out of the tank. It's wise to perform this task in a well ventilated area as there is no way to avoid spilling some gas or breathing some fumes. Also, make sure that you run the tank down as low as possible before you make the replacement. Don't let the pump run dry, however, as this might damage it. You also might want to have a fire extinguisher handy just in case 'something goes wrong.'

The old sender should simply pull out of the tank. Take a small flashlight and look down the inside of the tank to see if there is any debris. Hold the flashlight a long way away from the entrance of the tank: you don't want any fuel to ignite. You might want to empty the tank and clean it out if you see a lot of junk inside.

Installation of the new sender is straightforward. Use a new gasket when installing the new sender, and make sure that you remove the safety pin from the bottom of the sending unit before you install it.

Following the installation of the new sender, if your gauge is still not reading correctly, check the connections to the gauge itself. If the connections are fine, then you will probably have to replace the gauge. For more information on replacing the gauge, see Pelican Technical Article: Oil Temperature Gauge Upgrade.

The brand new gas tank sending unit is an aluminum tube with a small float that rides up and down the center.
Figure 1

The brand new gas tank sending unit is an aluminum tube with a small float that rides up and down the center. Make sure that you remove the small retaining pin that protects the sender during transport before you install it.

Removal and installation is very straightforward.
Figure 2

Removal and installation is very straightforward. Simply unbolt the old one and attach the new one in its place. Make sure that you use a new gasket to avoid fuel odor seeping out of the top of the sender.

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Comments and Suggestions:
pampadori Comments: Thanks Nick for your reply. I found the pin. It was hidden under the yellow sticker warning me to remove the pin. Didn't think to look under the sticker until after the fact! Have a nice working fuel gauge now :
June 12, 2015
  Followup from the Pelican Staff: Thanks for the follow up. We appreciate it.
- Nick at Pelican Parts
Pampadori Comments: Saftey pin? What does this safety pin look like? I just received my new sending unit but damned if i can find this pin.
June 12, 2015
  Followup from the Pelican Staff: The float is held in place by a pin. Remove the pin, confirm the float moves up and down, then install it. - Nick at Pelican Parts  
David Barros Comments: I need the white plastic piece located at the bottom of the aluminum tube. Like a fool I removed it and threw it away because the one I took out did not have one. Anyone have a spare for sale? Thanks
August 31, 2014
  Followup from the Pelican Staff: Give our parts specialists a call at 1-888-280-7799 and they can help figure out which part or repair kit you need. - Nick at Pelican Parts  

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