Special Tool for Fuel Pump removal

[moosport]

Anyone remove the fuel pump without using the special VW tool 3217?

My fuel gauge is stuck at full. It a simple procedure to perform but I want to make sure I do not need the special tool to remove the union nuts. The manual also recommend replacing the union nuts too.

[ericinboca]

The special tool is to remove the locking collar, right? I changed the fuel pump on my '04 986S without it. I very carefully used a rubber mallet and a screwdriver (one with a big blade) to tap the collar in the correct rotational direction until it was loose enough to remove with my hands. It did not damage the collar.

I replaced the rubber seal under the collar, but I don't remember anything on union nuts. I think I replaced the collar too, though. Just don't remember clearly about replacing the collar. Too many gas fumes:)

It was a simple job.

[moosport]

what is the part no for the rubber seal? Did you torque it to 52 in/lb without the tool?

[1schoir]

what is the part no for the rubber seal? Did you torque it to 52 in/lb without the tool?

The sealing ring for the gas tank on a 986 Boxster is listed as part # 321 919 133 for a 1997.

For some reason, the parts list also shows that same part number, listed separately, for 1998 on.

And now, that part # has been superseded by part # 1J0919133A.

Regards, Maurice.

Edited October 25, 2010 by 1schoir

[Schnell Gelb]

The "special tool" to remove and replace the lock ring above the fuel sender on top of the fuel tank - yes a blunt chisel and hammer may work but ...

Make sure you cut the gob of clear silicone that stops the ring rotating.

Consider buying a universal tool to remove the lock ring.I bought one for less than $20 on line.

If you didn't buy a replacement seal for the sender make sure the old one is in perfect condition  wash it and when dry spray with some silicone lube in case it rotates when you tighten the ring.Using some rubber-compatible lube on the underside of the ring may be a good idea. The ring needs to be tightened firmly but not so much that the seal puckers so the idea is that the lube may help achieve that

If you have any trouble rotating the fuel pump to dislodge it from the cam locks, a generic strap wrench (like for an oil filter) works well. You only need to rotate it a few degrees to free it.

While you are in there - check both drain holes near the fire wall for debris and consider putting some filter mesh in them to prevent debris from plugging them.

If you have trouble seating the sender it is probable that the rubber seal lip is hung up on the metal lip of the tank. The sealing ring will not thread correctly if this happens. With a headlight you may be able to see the protruding lip .More likely you can feel it with your finger tip

Beware of the very cheap pumps on Amazon. You'll notice that none of the reputable Porsche enthusiast vendors carry those unknown asian brands.

Hope this helps

Edited November 6, 2022 by Schnell Gelb