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Pelican Technical Article:

Fuel Filter Replacement

Casey Gervig

Time:

30-45 minutes

Tab:

$40 to $50

Talent:

*

Tools:

Two 19mm wrenches, flat blade screwdriver, pocket sized flat blade screwdriver, 7mm nut driver, shop rags, flashlight

Applicable Models:

Porsche 996 Turbo, GT2, GT3 (2001-05)

Parts Required:

Fuel filter

Hot Tip:

Depressurize fuel system before opening the fuel line connections

Performance Gain:

More power

Complementary Modification:

Engine air filter replacement

Every 15,000 miles or so, you should change the fuel filter in your 911. The fuel filter protects the fuel injectors from being contaminated by impurities in the gasoline. If neglected the fuel filter could become clogged robbing your car of power and efficiency. Before working on the fuel system it is a good practice to de-pressurize the fuel system by pulling the fuel pump fuse and letting the car die out. See the fuse details in the fuse box or owner's manual.

The fuel filter is attached to the coolant reservoir on the left side of the engine compartment (green arrow).
Figure 1

The fuel filter is attached to the coolant reservoir on the left side of the engine compartment (green arrow). First, remove the air filter housing. (For instructions on how to remove the air filter housing please see our 996 Turbo article on replacing the engine air filter.)

Remove this retaining clip (red arrow) by pulling it down off of the boost plenum (green arrow).
Figure 2

Remove this retaining clip (red arrow) by pulling it down off of the boost plenum (green arrow). I have also seen that clip installed from the top. If yours is installed this way remove it by pulling it up, and then sliding it off of the boost hose (blue arrow).

Now pull (green arrow) the boost hose out of the boost plenum and hold it down to the motor mount rail (red arrow) out of the way with a bungee cord or similar.
Figure 3

Now pull (green arrow) the boost hose out of the boost plenum and hold it down to the motor mount rail (red arrow) out of the way with a bungee cord or similar.

Next, remove the intake boot (red arrow) by loosening the 7mm hose clamp screw (green arrow) with a 7mm nut driver or flat blade screwdriver and pulling the boot off of the intake plenum.
Figure 4

Next, remove the intake boot (red arrow) by loosening the 7mm hose clamp screw (green arrow) with a 7mm nut driver or flat blade screwdriver and pulling the boot off of the intake plenum.

Place a few rags below the filter to absorb the fuel that will leak after disconnecting the fuel lines.
Figure 5

Place a few rags below the filter to absorb the fuel that will leak after disconnecting the fuel lines. Now pull the filter inlet pipe (blue arrow) off of the hard metal line by squeezing the tab (red arrow) and sliding the plastic connector (green arrow) off of the hard line.

Use a screwdriver or pliers to slide the ground connector (green arrow) off of the old filter.
Figure 6

Use a screwdriver or pliers to slide the ground connector (green arrow) off of the old filter.  

Using your two 19mm wrenches, loosen the filter outlet fitting.
Figure 7

Using your two 19mm wrenches, loosen the filter outlet fitting. Use the inner (red arrow) wrench to hold the filter, and use the outer wrench (green arrow) to turn the nut on the fitting counter clockwise. If you have a strong arm, you can do this with one hand, by squeezing the two wrenches together (blue arrow). Pull the line down and out of the way. 

Now looking through the opening between the coolant tank and the intake plenum, pull up on the release tab (green arrow).
Figure 8

Now looking through the opening between the coolant tank and the intake plenum, pull up on the release tab (green arrow). This will unlock the clip and allow you to pull (in the direction of the blue arrow) the filter and mounting bracket out of the slot on the coolant reservoir. I recommend using a cap (red arrow) to slow the pouring of gasoline from the filter during the removal process.

Now pull the filter out of the engine compartment by tilting it up and over the coolant hose (green arrow).
Figure 9

Now pull the filter out of the engine compartment by tilting it up and over the coolant hose (green arrow). Make sure that the inlet connector (red arrow) does not get caught on anything on its way out of the engine compartment.

Place the new and old filters next to each other on your work surface.
Figure 10

Place the new and old filters next to each other on your work surface. Loosen the 7mm hose clamp screw and transfer the bracket from the old filter to the new filter. Note the positioning of the bracket (green arrows). Installation is the reverse of removal. Remember, that when you first start your car you will need to crank the engine a few times to fill the new filter with fuel and build fuel pressure before the car will start up and idle. Immediately check for leaks once the system is pressurized.

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