Fuel Sender Replacement 101 with Pics

[Fischer_76_911S]

I am storing my dad's prized 996 convertible for the winter and decided to fix a few "bugs." I have washed & waxed it, had the convertible top replaced, and now on to the fuel sender. The gauge would not read a full tank. It is relatively simple, but I had no idea where it was even located. I am posting this here to help others if you wish to tackle the job.

Step 1: Get the car in your garage.


Step 2: Get the required cold beer and at least a screwdriver. Don't harass me on the "Sharps" as I love beer but gave up alcohol last summer.



Step 3: Figure out where the sender is located. Hmmmm, must remove panels.


Step 4: Ah ha, it is located under the battery tray. Plus, I knew I would need a hammer and said screwdriver. You will need to gently tap the outer ring to loosen and the hammer comes in quite handy to support the wiring harness from falling back into the gas tank.


As you can see below, the old fuel sender's electrical contacts are worn.


And now, the good sender for comparison:


Step 5: Reinstall all the wires and plugs, Porsche has already configured it so you can't screw up.

As a bonus, part 1, while I had everything apart, the Alpine amp had a bad ground which I sanded down and reattached. NOW, the stereo cranks it out.

Bonus, part2: The outdoor temperature display was always blank. I found on this forum that the sensor was located on the passenger side lower front grill. I found the two wires, but no sensor. I can't find this sensor and a generic thermister I had around would display a temperature, but about 40 degrees to low. I need the right resistance thermister...anyone?



Hope this helps, it is about a 1-2 beer project. I am now ordering rear brake pads as they are shot. Will have car ready and willing for my dad when he comes to pick it up

[Rrrockhound]

Good write-up! Thanks!

[eastbay]

I need to do this, how much for the part?

[Fischer_76_911S]

Originally Posted by eastbay

I need to do this, how much for the part?

I bought the part from my friends shop through his connections. Always OEM Porsche parts. Don't recall exactly, but the sender and gasket were about $220. I am happy to report that the gauge now works perfect including the low fuel light. I also bought a temp sensor from the dealer for $34 and soldered it in.

So let's see - Fuel sender $220, OD temp sensor $42 after shipping, rear brake pads $72, new top $800 installed, getting to drive my dad's car for "free"...priceless. I actually enjoy working on cars when the results are positive and I'll be reimbursed for my outlay. Come May my dad will fly down and drive away in his dream/retirement car that I'm happy to maintain to ensure many more miles of bliss.

If you have any questions just post here as I will actually get it through email. I usually never log in so it may be weeks otherwise. Good luck, it is really an easy repair