Fuel Supply Porsche Boxster S 986 рестайлинг

Scheme 1

SPECIAL TOOL CHART

Scheme 2

Scheme 3

1. Undo covering cap on test connection of fuel collection pipe and remove.
2. Connect pressure gauge (special tool P 378a) with connecting line (special tool 9559) and connect to test connection.
3. Actuating fuel pump with Porsche System Tester 2: The fuel pump can be actuated with the Porsche System Tester 2 or by bridging the fuel-pump relay. Via fuel-pump relay without Tester: Disconnect fuel-pump relay from the central electrical board and bridge contacts 30 and 87 (identified as 3 and 5 on the central electrical board) with a fused shop-made cable. (Scheme 3) The fuel pump must now operate or deliver fuel.
4. Nominal test values

Stationary engine 3.8 +/- 0.2 bar

Engine idling 3.3 +/- 0.2 bar

Note. The seal or sealing ring in the brass closure cap is not exchangeable. It must therefore be used only once. Tightening torque of new brass closure cap 2.5 +/- 0.5 Nm (2.0 +/-0.5 ftlb.).

Precondition

Fuel filter and electrical supply in order.

Scheme 4

Scheme 5

1. Relieve pressure in fuel tank by opening tank cap.
2. Connect Porsche System Tester 2.
3. Raise vehicle.
4. Remove rear underside panel.
5. Disconnect fuel return line. Collect residual fuel.
6. Hold fuel line in a measuring container. Actuate fuel pump with the Porsche System Tester 2 and allow fuel to flow for 30 seconds into a measuring container. Quantity supplied must be at least 850 cm3 /30 s, i.e. after 30 seconds at least 850 cm3 of fuel must be present in the measuring container.

Scheme 6

Scheme 7

Scheme 8

Scheme 9

1. Undo battery terminals and battery holder. Lift battery out by holding strap.
2. Undo battery support cover (four hexagon nuts, wrench size 13).
3. Disengage fuel line and disconnect electrical plug connection.
4. Undo union nut with VW special tool 3217.
5. Extract residual fuel. NOTE: Observe safety regulations.
6. Lift fuel gauge and disconnect electrical plug connection and fuel pipes.
7. Put on fuel-proof glove, hold the fuel pump fastened to tank floor, turn it to left (approx. 15°, bayonet lock) and remove fuel pump.

Scheme 10

Scheme 11

1. Position fuel pump; the edge of the fuel-pump housing faces the fuel tank sending unit installation-position markings.
2. Place fuel pump in this position on tank floor bayonet fixture and turn fuel pump to the right as far as the stop. Then check proper seating of fuel pump by pulling it up.
3. Insert fuel tank sending unit and turn until the marking on the sending unit matches the marking on the fuel tank.
4. Tighten union nut with special tool 3217. Tightening torque with new union nut and new sealing ring: 70 Nm (52 ftlb.).
5. Attach fuel lines and electrical plug connection. The fuel lines must audibly engage. Correct engagement must be checked with a gentle pull. The colour-coded plug (green) must be fitted to the connection identified with "V".

Calibrating fuel level sensor system

Danger!

Danger of fire and injury!

1. Observe general safety regulations on the fuel system.
2. Wear protective gloves.

Note. Calibration is necessary after replacement of the fuel tank, fuel level sensor or instrument cluster.

1. Remove battery and detach battery cover.
2. Remove fuel level sensor. Refer to «REMOVING AND INSTALLING FUEL PUMP»(/porsche/boxster-s/986-2002-2004/remont/fuel-system/#fuel-supply) .
3. Using a fuel extractor, completely drain the fuel tank through the fuel level sensor opening.
4. Reinstall the fuel level sensor and, with "ignition off', fill the tank with 12 litres of fuel.
5. Perform tank calibration with the Porsche System Tester 2.

1. Select vehicle type (911 Boxster)
2. Select control modules
3. Select instrument cluster
4. Select menu item Tank calibration
5. Confirm calibration
6. The fuel level sensor system has now been calibrated.

Note. The fuel level sensor system need not be calibrated if the battery was disconnected or a plug connection on the instrument cluster or fuel level sensor was removed. The values remain stored in the instrument cluster. A range on remaining fuel of less than 15 km is not displayed in the instrument cluster.

Removing and installing fuel return line

Scheme 12

Scheme 13

Scheme 14

1. Move convertible top to service position.
2. Detach negative terminal of battery (a/f 10 mm).
3. Place protective cover on ground.
4. Remove engine compartment lining and lid.
5. Remove rear wall lining and rear wall cover
6. Raise vehicle and remove engine underside guard.
7. Unclip fuel return line from the line holder on the body.
8. Detach the fuel return line. Press unlocking buttons and simultaneously pull off the line. Immediately seal the fuel line supports with a suitable plug.
9. Lower vehicle.
10. Remove holder for servo return line, electrical plug connection and ground strap. (Hexagon-head bolt I M6 x 12)
11. Undo return line (wrench size 17); simultaneously 7 counter (wrench size 19). Remove return line.

Installation

1. Fasten fuel return line to pressure regulator, simultaneously counter.
2. Fit holder.
3. Put on rear wall cover, rear wall lining, engine compartment lining and engine compartment lid.
4. Lift the vehicle.
5. Position fuel return line in a straight line. The plug (plug part) must audibly engage in the plug-in coupling. Then pull slightly to ensure that the connection is properly locked. Clip fuel return line onto the body.
6. Connect battery, close convertible top.
7. Start engine and carry out tightness test.
8. Fit engine underside guard.
9. Read out fault memory. Enter radio code.

Checking fuel pressure - fuel system without return line, - as of MY 2001

Scheme 15

Scheme 16

A Connecting lead 9559

B Pressure gauge P 378a

Note. The battery voltage must not fall below 12 volts during the fuel pressure check!

Scheme 17

Scheme 18

Scheme 19

1. Check the battery charging condition e.g. using a voltmeter or the Porsche System Tester. The battery voltage must not fall below 12 volts during the check. NOTE: Use the brass closure cap on the test connection of the fuel supply line only once as the seating ring cannot be replaced. To avoid possible leaks, the cap must be replaced after removal!
2. Release metal cap on test connection at fuel collection pipe and screw it off by hand (a/f 13 mm).
3. Connect connecting lead 9559 with special tool pressure gauge P 378a (a/f 17 union nut) and manually attach the fuel supply line to the test connection. Proceed as follows when the engine is not running
4. Connect Porsche System Tester PST 2 and switch on ignition.
5. Activate fuel pump relay using Porsche System Tester. To do this, select the line Drive links in the DME control unit individual search and then select Fuel pump relay. Activate by pressing F8.
6. Read value on pressure gauge. Target test values when engine not running: 3.8 +/- 0.2 bar.
7. Switch off the fuel pump relay on the System Tester by pressing F8 .
8. Switch off ignition, pull off System Tester connecting lead in the vehicle and switch off System Tester.
9. To check the engine while it is idling, connect the pressure gauge as described above and start the engine. Switch off the engine after reading the fuel pressure. Target test values engine idling: 3.8 +/- 0.2 bar.
10. Loosen the union nuts of the connecting cable 9559 for the special tool pressure gauge P 378a on the test connection and remove special tool. Collect emerging fuel, e.g. with a cloth.
11. Position new closure cap on test connection and tighten (a/f 13 mm). Tightening torque of new brass closure cap: 2.5 +/- 0.5 Nm (2.0 +/- 0.5 ftlb.)

Checking quantity delivered by fuel pump - fuel system without return line - as of MY 2001

Scheme 20

Special tool for checking fuel quantity

Scheme 21

SPECIAL TOOL - CHECKING FUEL QUANTITY

Note. The battery voltage may not fait below 12 volts during the fuel pressure check!

Scheme 22

Scheme 23

Scheme 24

1. Check the battery charging condition e.g. using a voltmeter or the Porsche System Tester. The battery voltage may not fall below 12 volts during the check.
2. Reduce fuel pump supply pressure. To do this, remove the fuse carrier cover in left footwell and pull off the fuse for the fuel supply pump (level C, 4th fuse from the left). Then actuate the starter for a couple of seconds. This procedure does not cause an entry to be made in the fault memory. Insert fuse again and fit cover.
3. Connect the Porsche Tester PST 2 in the vehicle, switch on the ignition and switch off all loads, such as the radio and air conditioning.
4. Remove rear underside panel. To do this, the rear plastic nuts on the left side cover and the centre underside panel must be loosened.
5. Disconnect rapid-action coupling on the fuel supply line by pressing in the locking lug -arrow- and pulling off the coupling. (Scheme 22) Collect emerging residual fuel.
6. Connect special tool measuring adapter 9705 to the fuel pressure line with the rapid-action coupling. (Scheme 23) Be sure that the coupling is fitted correctly (must engage audibly) by pulling the line apart!
7. Place the drainage hose in a petrol-resistant canister. Be sure that the canister does not tip over.
8. Activate the fuel pump relay using the Porsche System Tester PST 2. To do this, select the line drive links in the DME control unit individual search and then select fuel pump relay. Activate by pressing F8 until fuel emerges from the drainage hose. Deactivate the fuel pump relay by pressing F8 and pour any leaked fuel from the canister into a petrol-resistant container. Keep a stopwatch at hand for the following measurement.
9. Activate fuel pump relay again and keep active for 60 seconds. Collect emerging fuel in an available container. Deactivate the fuel pump relay after 60 seconds.
10. Transfer collected fuel to a suitable measuring container and compare with the measure value specified in the following. Target values for supplied fuel quantity: - Boxster, Boxster S: at least 2.0 litres
11. Remove special tool and attach rapid-action coupling to fuel supply line. Be sure that the coupling is fitted correctly (must engage audibly) by pulling the line apart!
12. Install rear underside panel.
13. Switch off ignition, switch off Porsche System Tester and disconnect.

Poses Online

See also:
• REMOVING AND INSTALLING FUEL PUMP