Work Procedure "A"
Service Action 091
This Work Procedure is for checking and replacing all fuel level gauge senders which have a production date of "25-10-90" or earlier AND for checking and replacing defective senders with a production date of "26-10-90" or later.
The VIN ranges are as follows:
WPOAB096_KS450061 to WP0ABO96_KS451117
WPOAB296_LS450061 to WPGAB296_LS452119
WPOBB296_LS460061 to WPOBB296_LS460729
WPOCB296_LS470061 to WPOCB296_LS472169
WPOAB296_MS410061 to WPOAB296_MS410883
WPOBB296_MS440061 to WPOBB296_MS440392
WPOCB296_MS460061 to WPOCB296_MS460899
1. Open the front trunk lid.
2. Remove the luggage compartment matting from the fuel tank and check production date on the sender.
The production date is on a sticker which is attached to the hexagon nut of the sender.
Note:
The one-part sender, Part Number 964 641 801 01, with a production date of "26-10-90" or later should not be replaced unless it is not operable. If replacement is warranted, proceed with Work Procedure "A".
Date of "25-10-90" or earlier - replace with Part Number 000 043 175 00. Date of "26-10-90" or later and inoperable - replace with 000 043 175 00. Date of "26-10-90" or later, but sender is operable - DO NOT REPLACE THIS SENDER, REFER TO WORK PROCEDURE "B".
3. Tools required. Hand driven drill 3 mm drill bit Special tool # 9277 Screwdriver
4. Caution:
a. Fuel tank must not be more than 1/4 full when replacing the fuel level gauge sender, remove excessive amount of fuel.
b. Do not use electric drill. (see point 8)
c. Observe all safety regulations when working on the fuel system.
5. Remove the plug connector from the sender.
6. Loosen the sender with the special tool # 9277 or a box wrench (50 mm).
Slowly remove the sender from the fuel tank so the fuel from the sender can drain back into the tank.
Note: An additional vent hole of 3 mm must be drilled into the sender opening of the fuel tank to avoid any fuel gauge reading deviation at "Full".
7. Block off the tank opening for the sender with a non-fraying paper or cloth.
8. Mark the position for the vent hole to be drilled. The vent hole should be at the rear (relative to the direction of travel) top end of the thread, at the point of transition between the threads and the oblique surface. The sealing surface above must not be damaged.
Caution:
BECAUSE OF FUEL VAPOR AND THE DANGER OF FIRE AND INJURY - DO NOT USE AN ELECTRIC DRILL. USE ONLY A HAND DRIVEN DRILL.
Drill the required additional 3 mm vent hole with a hand driven drill in a downward angle of approximately 45~ as shown in the above sketch.
9. Deburr the drilled vent hole if needed.
10. Remove any filings and the paper/cloth.
11. Reinstall the new fuel level gauge sender part set, Part Number 000 043 175 00. This part set includes a new sealing O-ring. Coat this O-ring lightly with lubricant and hand tighten the sender.
12. Torque the sender, using Special tool # 9277, to 25 N-m (18 ft.lbs.).
13. Fasten the electronic component with the clamp onto the sender upright, and towards to the rear.
Connect the electronic component plug to the sender and the cable harness plug to the electronic component.
14. Check the fuel gauge operation.
15. Re-install the luggage compartment matting.
16. Close the trunk lid securely.
17. Place the book, Porsche - The Fine Art of the Sports Car on the passenger seat.