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High Pressure Fuel Sensor Replacement
 
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Pelican Technical Article:

High Pressure Fuel Sensor Replacement

Steve Vernon

Time:

30 minutes30 mins

Tab:

$150

Talent:

*

Tools:

24mm wrench

Applicable Models:

Porsche 955 Cayenne GTS (2008-10)
Porsche 955 Cayenne S (2008-10)
Porsche 955 Cayenne Turbo (2008-10)
Porsche 955 Cayenne Turbo S (2009-10)
Porsche 970 Panamera 4S (2010-14)
Porsche 970 Panamera GTS (2013-14)
Porsche 970 Panamera S (2010-14)
Porsche 970 Panamera Turbo (2010-14)
Porsche 970 Panamera Turbo Executive (2014)
Porsche 970 Panamera Turbo S (2012-14)
Porsche 970 Panamera Turbo S Executive (2014)

Parts Required:

Sensor

Hot Tip:

Work in a well-ventilated area

Performance Gain:

Proper working engine

Complementary Modification:

Replace intake manifold gaskets

The direct injection motor in the Porsche Cayenne uses incredibly high fuel pressures in the fuel rail and injectors. This pressure can vary between 580 psi or 40 bar and 1740 psi or 120 bar depending whether the motor is at idle or wide open throttle. The maintenance of this pressure is critical to the proper performance of the engine. If your engine is taking longer to start up and cranking more than usual and/or if you have a check engine light with a high pressure fuel sensor code there is a good chance your high pressure fuel sensor is going bad.

Replacement of the sensor is simple, quick and easy once you get access to it. You will need to remove the intake manifold before you can replace the high-pressure fuel sensor so please see our article on engine cover removal and the article on intake manifold removal before starting this job.

The fuel rail and high pressure sensor is located under the intake manifold so it must be removed first.
Figure 1

The fuel rail and high pressure sensor is located under the intake manifold so it must be removed first. Please see our article on intake manifold removal for additional information.

With the manifold removed you can see the fuel rail (red arrow), the line from the high-pressure pump (yellow arrow) and the high-pressure sensor (green arrow).
Figure 2

With the manifold removed you can see the fuel rail (red arrow), the line from the high-pressure pump (yellow arrow) and the high-pressure sensor (green arrow).

Disconnect the wiring from the sensor by squeezing the tab and pulling the harness off (red arrow).
Figure 3

Disconnect the wiring from the sensor by squeezing the tab and pulling the harness off (red arrow).

The high-pressure pump attached to the left camshaft provides the high pressure for the system.
Figure 4

The high-pressure pump attached to the left camshaft provides the high pressure for the system. The system does not stay under high pressure once the motor is turned off but there will still be some fuel in it so be prepared with a rag to catch it and dispose of it properly. Make sure the engine is cold and that you are in a well-ventilated area. Use a 24mm wrench and remove the old sensor.

There is no way to tell by looking at the sensor whether it is failing or not so you just need to replace it.
Figure 5

There is no way to tell by looking at the sensor whether it is failing or not so you just need to replace it. There is also no O-ring or gasket so make sure all the mounting surfaces are clean. Installation is the reverse of removal.





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Comments and Suggestions:
Rick Comments: Replace highg fuel pressure sensor on a 2009 Porsche Cayenne 3.6
March 8, 2016
  Followup from the Pelican Staff: Applicable Models:


Porsche 955 Cayenne GTS (2008-10)
Porsche 955 Cayenne S (2008-10)
Porsche 955 Cayenne Turbo (2008-10)
Porsche 955 Cayenne Turbo S (2009-10)
Porsche 970 Panamera 4S (2010-14)
Porsche 970 Panamera GTS (2013-14)
Porsche 970 Panamera S (2010-14)
Porsche 970 Panamera Turbo (2010-14)
Porsche 970 Panamera Turbo Executive (2014)
Porsche 970 Panamera Turbo S (2012-14)
Porsche 970 Panamera Turbo S Executive (2014) - Nick at Pelican Parts
 

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