Repair Procedure

WORK PROCEDURE

Porsche 928 S4 and 928 GT Inspection and/or Replacement of Fuel Level Sending Unit Mounting Nut.

1. Open rear hatch. Remove tool panel, luggage compartment floor covering and cover plate for fuel level sending unit.





2. Inspect fuel level sending unit mounting nut. If VW-, Audi trademark and part number 113 201 375 is cast on mounting nut between reinforcements (Figure 1, Arrow C) nut is okay. Go to Step 12.

If mounting nut has no markings, nut must be replaced.

IMPORTANT:
Observe safety regulations for working on fuel system. Do not remove fuel level sending unit if the tank is full.

3. To ease installation, put new mounting nut in a container with hot water (60-70 degrees Centigrade or 140-158 degrees Fahrenheit) for approximately 8 minutes.

4. Disconnect wiring plug (Figure 1, Arrow A) from fuel level sending unit.

5. Place shop towel under fuel return line to absorb fuel spillage. Disconnect fuel return hose (Figure 1, Arrow B).





6. Remove mounting nut with special tool 9190 (Figure 2, Arrow D).

7. CAUTION: Do not touch heated mounting nut. Danger of burning hands. Take new mounting nut from hot water container using pliers or similar tool. Wipe off water from mounting nut with shop towel.

8. While still hot, install nut with special tool 9190 and torque to 35+5 N-m (26+3.6 ft.lbs.). Observe position of return fuel hose connection.

9. Connect return fuel hose (Figure 1, Arrow B). Ensure that screw of hose clamp does not contact the mounting nut or the fuel level sending unit.

10. Connect wiring plug (Figure 1, Arrow A).

11. Start engine and check for fuel leaks. If no leak, turn off engine. If a fuel leak is noticed, turn off engine and correct the leak.

12. Reinstall cover plate for fuel level sending unit, luggage compartment floor covering and tool panel. Close rear hatch.





13. Apply paint dot to fuel filler door hinge (Figure 3, Arrow E).

Required tools and supplies:

1. Screwdriver
2. Special tool 9190
3. Torque wrench
4. Water container
5. 1-2 liters hot water

Part required:
Mounting Nut Part Number 113 201 375

Spare parts are marked with the VW-, Audi trademark and part number; also, some are marked only with a "yellow" dot. Both versions are okay.