This article is one in a series that have been released in conjunction with Wayne's book, 101 Projects for Your Porsche 911. The book contains 240 pages of full color projects detailing everything from performance mods to changing your brake pads. With more than 650+ full-color glossy photos accompanying extensive step-by-step procedures, this book is required reading in any Porsche 911 owner's collection. See The Official Book Website for more details.
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. 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. 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.