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Fuel Level Sending Unit Replacement
 
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Pelican Technical Article:

Fuel Level Sending Unit Replacement

Steve Vernon

Time:

1 hour1 hr

Tab:

$70 to $150

Talent:

**

Tools:

Large channel locks, rags

Applicable Models:

Porsche 993 Carrera (1995-98)
Porsche 993 Carrera 4 (1995-98)
Porsche 993 Carrera 4S (1996-98)
Porsche 993 Carrera S (1998)
Porsche 993 Targa (1996-98)
Porsche 993 Turbo (1996-97)

Parts Required:

Fuel level sending unit, O-ring

Hot Tip:

Good time to determine the condition of your tank

Performance Gain:

Working fuel level gauge

Complementary Modification:

Change your fuel filter

If your fuel gauge starts acting a little strange; like you just filled the tank and it didn't move the needle, or it is stuck at zero and the light is flashing, there is a good chance that your fuel level sending unit has gone or is going bad. The level sending unit is located on the top of the tank under the carpet in the front. Replacement is quick and easy, but you will be working around gasoline so make sure to take some precautions.

When working with or around gasoline here a few precautions you should take: work in a well ventilated area, working outdoors is a good choice. Do not use incandescent work lights or power tools and DO NOT smoke. Fuel and fuel vapors are highly combustible. Disconnect the negative battery cable. Also make sure that you wear gloves, as gasoline and its components are known carcinogens that can easily be absorbed through the skin. Be well grounded - don't do anything that will create static electricity. Keep all cell phones and pagers a safe distance away. Always have a proper fire extinguisher handy and know how to use it.

Before you begin the engine should be cold and it is best if the car hasn't been driven for a while.
Figure 1

Before you begin the engine should be cold and it is best if the car hasn't been driven for a while. Open the gas or fill cap to help release pressure in the system

Open the hood and pull back the carpet.
Figure 2

Open the hood and pull back the carpet. The gas tank is the large black plastic container between the two strut towers (red arrow) and the fuel level sending unit is located on the right side of it (yellow arrow).

Separate the electrical connection by simply pulling it off with your hand.
Figure 3

Separate the electrical connection by simply pulling it off with your hand.

Use a large set of pliers or channel locks and unscrew the top of the sender from the tank.
Figure 4

Use a large set of pliers or channel locks and unscrew the top of the sender from the tank.

Carefully lift the sending unit from the tank allowing the fuel to drain out the bottom of it as you lift.
Figure 5

Carefully lift the sending unit from the tank allowing the fuel to drain out the bottom of it as you lift. If your sending unit looks as bad as ours, you need to do some further investigating and may need to pull the tank and have it sent out for a flush.

Installation is the reverse of removal.
Figure 6

Installation is the reverse of removal. If you are reinstalling the old unit, Porsche recommends that you always replace the O-ring (red arrow). The new unit may have a guard on it for shipping purposes; make sure to remove it before installation.

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Page last updated: Tue 10/17/2017 03:27:11 AM