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WJ22 - Replacing Fuel Pump (Workshop Campaign)

Important:

CRITICAL WARNING - This campaign includes steps where control unit(s) in the vehicle will be
programmed with the PIWIS Tester. The vehicle voltage must be maintained between 13.5 volts and 14.5
volts during this programming. Failure to maintain this voltage could result in damaged control unit(s).
Damage caused by inadequate voltage during programming is not a warrantable defect. The technician
must verify the actual vehicle voltage in the PIWIS Tester before starting the campaign and also document
the actual voltage on the repair order.

Model Year:

2018

Vehicle Type:

718 Boxster (982)/718 Boxster S (982)
718 Cayman (982)/718 Cayman S (982)

Subject:

Electric fuel pump

Information:

There is a possibility that a fuel pressure control valve with a characteristic that does not meet
the required specifications was installed in the fuel pump on the affected vehicles.
If this is the case, the valve will open too early and the fuel pressure will fall below the specified minimum
pressure. This can result in a reduced fuel supply and the Check Engine light may be activated.

Remedial
Action:

Replace fuel pump.

Affected
Vehicles:

Only the vehicles assigned to the campaign (see also PIWIS Vehicle information). This campaign affects
78 vehicles in North America.

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Installation
Position:

1
2

Installation position overview
– Fuel pump with connecting flange (replace)
– Fuel tank

Parts required
Parts Info:

Parts for this campaign will NOT be automatically allocated to your dealership. Parts can be
ordered as normal with no PTEC/PAV required.
Part No.

Designation
– Use

Qty.

00004330423

 Fuel pump
– Fuel low-pressure supply

1 ea.

99120173301

 Sealing ring
– Fuel tank flange

1 ea.

Required tools
Tools:

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•
•

9731/1 - Pin wrench for bayonet flange ring on the fuel tank
Torque wrench, 2 - 10 Nm (1.5 - 7.5 ftlb.), e.g. V.A.G 1783 - Torque wrench, 2-10 Nm (1.5-7.5
ftlb.) or equivalent

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•
•
•
•

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Torque wrench, 6 - 50 Nm (4.5 - 37 ftlb.), e.g. V.A.G 1331A - Torque wrench, 6-50 Nm (4.5-37
ftlb.)
Connecting line no. 18 from tool set V.A.G 1318 - K-Jetronic pressure tester (also known as
VW1318)
Suitable container for collecting fuel
9900 - PIWIS Tester 3
Battery charger with a current rating of at least 90 A, e.g. VAS 5908

Information
If the fuel tank fill level is greater than the reserve (remaining fuel range warning is not displayed in the
instrument cluster), the fuel tank must be drained completely in order to remove and install the fuel
pump.
On the affected vehicles, the fuel can be drained completely into a suitable collection container by
selecting the "Drain fuel tank" function in the DME control unit using the PIWIS Tester.
If it is not possible to drain the fuel tank completely using the PIWIS Tester, the tank can be drained using a
suitable fuel extraction unit or fuel transfer unit.
The following equipment has been tested and approved by Porsche and will also be required in this case:
•

WE1262 - Fuel transfer unit Tank Primus 100/100 S

•

P378c connecting Lines (Supersedes to VAS 5190A)

•

VAS 5190A - Fuel extractor

•

9705/3 connecting lines (or locally available equivalent tool)

Preparatory work
WARNING
Highly flammable or explosive materials
•

Danger of fire or explosion



Avoid contact with hot parts or sources of ignition.



Use suction to remove ignitable vapors.



Attach warning sign in a clearly visible position.
WARNING

Caustic fluid
•

Danger of chemical burns



Avoid contact with caustic fluid.



Wear personal protective gear.

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

Ensure that there is good ventilation.



If you do come into contact, wash off immediately with plenty of warm water and contact a doctor if
necessary.

Work Procedure: 1

Switch on ignition and read off the fuel tank fill level on the fuel-level indicator in the instrument
cluster. Then switch off the ignition.
Information
Depending on the fuel tank fill level, various steps are required for draining the fuel tank during this
campaign.
•

Fuel tank completely full (all segments of the fuel-level indicator activated): Before removing
the flange cover on the fuel tank, at least 20 liters of fuel must be pumped out using the
PIWIS Tester.

•

Fuel tank fill level greater than the reserve: Before removing the fuel pump, the fuel tank
must be drained completely using the PIWIS Tester or a suitable fuel extraction unit or fuel
transfer unit.

NOTICE
Fuel can leak out when flange cover is removed when fuel tank is full
•

Danger of fire, explosion or contact with fuel



If the fuel tank is full, approx. 20 liters of fuel must first be pumped out in order to remove the flange
cover.



For other work on the fuel tank, e.g. for removing and installing the fuel pump, the tank must be
drained to at least the reserve quantity.
2

If the fuel tank fill level is greater than the reserve (remaining fuel range warning is not displayed in
the instrument cluster), drain the fuel tank completely.
Information
On the affected vehicles, the fuel can be drained completely into a suitable collection container by
selecting the "Drain fuel tank" function in the DME control unit using the PIWIS Tester.
If it is not possible to drain the fuel tank completely using the PIWIS Tester, the tank can be drained
after removing the flange cover with fuel level sender as part of this campaign. If the fuel tank
is full, however, at least 20 liters of fuel must be pumped out using the PIWIS Tester before
removing the flange cover.
To drain the fuel tank using the PIWIS Tester, carry out the following steps.
2.1

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Raise the vehicle on a lifting platform  Workshop Manual '4X00IN Lifting the vehicle'.

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2.2

Remove cover for rear underbody  Workshop Manual '519419 Removing and installing
cover for rear underbody'.

2.3

Drain fuel using the PIWIS Tester  Workshop Manual '200317 Draining and filling fuel'.
Pay particular attention to the following:
•
•

Connect connecting line for draining fuel to the connection point  Connection point for
fuel line on rear underbody -1- for the fuel low-pressure line at the rear underbody.
As soon as the fuel is completely drained, remove the connecting line and connect the
fuel low-pressure line again.

Connection point for fuel line on
rear underbody
2.4

Install cover for rear underbody  Workshop Manual '519419 Removing and installing cover
for rear underbody'.

2.5

Lower the vehicle and remove it from the lifting platform.

3

Remove plastic cover in the luggage compartment  Workshop Manual '852219 Removing and
installing technical equipment space cover'.

4

Remove the battery  Workshop Manual '270619 Removing and installing battery'.

5

Remove battery console with control unit for fuel pump  Workshop Manual '508419 Removing and
installing battery console'.

Removing fuel pump
Work
Procedure:
NOTICE
Fuel can leak out when flange cover is removed when fuel tank is full
•

Danger of fire, explosion or contact with fuel

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

If the fuel tank is full, approx. 20 liters of fuel must first be pumped out in order to remove the flange
cover.



For other work on the fuel tank, e.g. for removing and installing the fuel pump, the tank must be
drained to at least the reserve quantity.
1

Remove fuel level sender with flange cover  Workshop Manual '201519 Removing and installing
fuel level sender'.

2

If the fuel tank was not drained completely beforehand using the PIWIS Tester, drain the fuel tank
using a fuel extraction unit or fuel transfer unit.
Information
The following fuel extraction or fuel transfer units have been tested and approved by Porsche and will
also be required in this case:
•

WE1262 - Fuel transfer unit Tank Primus 100/100 S

•

VAS 5190A - Fuel extractor

For instructions, see  Workshop Manual '200317 Draining and filling fuel'.
3

4

5

Remove fuel pump and install a new fuel pump  Workshop Manual '206619 Removing and
installing fuel pump'.
Part No.

Designation
– Use

Number or quantity

00004330423

Fuel pump
– Fuel low-pressure supply

1 ea.

Install fuel level sender with flange cover.
Always use a new sealing ring for the flange on the fuel tank.
For instructions, see  Workshop Manual '201519 Removing and installing fuel level sender'.
Part No.

Designation
– Use

Number or quantity

99120173301

Sealing ring
– Fuel tank flange

1 ea.

Fill the fuel tank  Workshop Manual '200317 Draining and filling fuel'.

Concluding work
Work Procedure: 1

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Install battery console  Workshop Manual '508419 Removing and installing battery console'.

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2

Install battery  Workshop Manual '270619 Removing and installing battery'.
Then carry out the work required after connecting the battery  Workshop Manual '2X00IN Work
instructions after disconnecting the battery'.

3

Check the fuel system for leaks.
To do this, switch on the ignition and wait until you hear the fuel pump building up pressure. Then
perform a visual inspection of the fuel system in the connecting flange area on the fuel tank.

4

Install plastic cover in the luggage compartment  Workshop Manual '852219 Removing and
installing technical equipment space cover'.

5

Enter the campaign in the Warranty and Maintenance booklet.

 Workshop Manual '2X00IN Work instructions after disconnecting the battery'
 Workshop Manual '200317 Draining and filling fuel'
 Workshop Manual '201519 Removing and installing fuel level sender'
 Workshop Manual '206619 Removing and installing fuel pump'
 Workshop Manual '270619 Removing and installing battery'
 Workshop Manual '4X00IN Lifting the vehicle'
 Workshop Manual '508419 Removing and installing battery console'
 Workshop Manual '519419 Removing and installing cover for rear underbody'
 Workshop Manual '852219 Removing and installing technical equipment space cover'

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Warranty processing
Scope 1:

Only relevant for the 911 Carrera (991)/911 Carrera S (991)/911 Carrera GTS (991).

Scope 2:

Replace fuel pump
•
•

718 Boxster (982)/718 Boxster S (982)
718 Cayman (982)/718 Cayman S (982)
Working time:
Labor time: 233 TU

Replacing fuel pump
Includes:
Raising and lowering the vehicle
Removing and installing cover for rear underbody
Connecting and disconnecting PIWIS Tester
Connecting and disconnecting battery charger
Draining and filling fuel
Removing and installing cover in luggage compartment
Removing and installing battery
Removing and installing battery console
Removing and installing fuel level sender
Parts required:
00004330423

Fuel pump

1 ea.

99120173301

Sealing ring

1 ea.

 Damage Code WJ22 066 000 2

Important Notice: Technical Bulletins issued by Porsche Cars North America, Inc. are intended only for use by professional automotive technicians who have attended Porsche service training
courses. They are written to inform those technicians of conditions that may occur on some Porsche vehicles, or to provide information that could assist in the proper servicing of a vehicle. Porsche special
tools may be necessary in order to perform certain operations identified in these bulletins. Use of tools and procedures other than those Porsche recommends in these bulletins may be detrimental to the
safe operation of your vehicle, and may endanger the people working on it. Properly trained Porsche technicians have the equipment, tools, safety instructions, and know-how to do the job properly and
safely. Part numbers listed in these bulletins are for reference only. The work procedures updated electronically in the Porsche PIWIS diagnostic and testing device take precedence and, in the event of a
discrepancy, the work procedures in the PIWIS Tester are the ones that must be followed.

© 2018 Porsche Cars North America, Inc.

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