Fuel sender question
Thread Starter
Three Wheelin'
Joined: Apr 2004
Posts: 1,433
Likes: 1
From: bloomington, IN
Fuel sender question
Sorry in advance if this has been covered before. I searched the archives and couldn't find the answer. I have been having issues with the fuel gauge on my 1991 C4 ( no open recalls, already checked) and decided to replace the sender, as the gauge will intermittently read full or empty. Ordered a new sender and got part #964 641 801 02. I do not have a sending unit at the top of the sender,which appears to be the cars that had the recall performed. The old sender has 4 pins, and the new one has 2. I'm guessing that this will not work. Any one know if I am correct? Again, sorry if I am beating a dead horse on this one.
If it won't work, anyone need a sender?
If it won't work, anyone need a sender?
Nordschleife Master
Joined: Sep 2004
Posts: 5,061
Likes: 2
From: not in HRM
Well I got out my 89 wiring diagrams book , 4 wires ,
#1 to gauge-green ,
#2 to central informer- brown/black ,
#3 to ground - brown ,
#4 to power ? orange .
How this could help , I know not .
#1 to gauge-green ,
#2 to central informer- brown/black ,
#3 to ground - brown ,
#4 to power ? orange .
How this could help , I know not .
RL Community Team
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Originally Posted by DAVISRILEY
Ordered a new sender and got part #964 641 801 02. I do not have a sending unit at the top of the sender,which appears to be the cars that had the recall performed.
Tank Gauge part number 964 641 801 01 doesn't use the "control unit" part. The part you received, 964 641 801 02 DOES use the "control unit" part which has a part number 964 641 081 00
Technical Guru
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From: USVI
In the dealer catalog (PET) if a part number is preceded by the letter A that means the existing stock will be used up and then the part will be NLA. Usually this means that some defect was found or an improvement was made but the old part still works and in this case the part was recalled back in 1991 so you might be SOL. In which case your alternatives are to find a POS used part at one of the Porsche junk yards or add the control unit mentioned above (964-641-081-00), clamp (N-024-507-3) and sealing o-ring (999-707-115-40). I'll include the recall/install/upgrade in the next few messages.
Technical Guru
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From: USVI
Fuel Level Gauge Sender - Replacement/Checking
9222porsche01
March 12, 1991
Model
911 Carrera 2/4
1989-91
Group
2
Number
9101
Part Identifier
2015
Subject:
Fuel Level Gauge Sender
Replacement and/or Checking
This is to notify you of a Service Action on the fuel level gauge sender for all 1989, 1990 and some 1991 model Carrera 2/4 Porsches. The VIN ranges are as follows:
The new fuel level gauge sender is a two-piece sender unit consisting of a separate sensor and a separate electronic component. The new two-piece fuel level gauge sender components parts set can be ordered under Part Number 000 043 175 00.
The new sender unit must be installed on all vehicles falling within the VIN ranges listed above and which have a single-piece fuel level gauge sender with a production date of "25-10-90" or earlier. The one-part fuel level gauge sender, Part Number 964 641 801 01, with a production date of "26-10-90" or later, need not be replaced unless it is not functioning. This production date is shown on a sticker affixed to the hexagon nut of the sender.
The fuel level gauge sender with production date "26-10-90" or later, should not be replaced if the sender is operating properly. If, however, the sender is not operating, it must be replaced with the sender components shown on page one (1). The parts set is Part Number 000 043 175 00.
Note:
In addition to this Technical Bulletin, Porsche Cars N.A., will mail a letter this week to all dealers further expanding on this Service Action. See enclosed copy.
Customer Notification
The Customer Notification will be by letter mailed 1st class during the week of March 18, 1991. This letter will also include a postage pre-paid postcard to inform Porsche Cars N.A., by the vehicle owner, of any status change, if need be. See enclosed copies.
Please perform this Service Action on all applicable customer vehicles in your dealership.
For those vehicles for which the sales information is not in our files, the notification will be addressed and mailed to the dealer who received that vehicle. If the vehicle is in dealer inventory, new or used and/or in demo use, this Service Action should be performed without delay. If the vehicle has been retailed or dealer traded, the dealer is to make the necessary arrangements to have the customer or receiving dealer contacted and this action performed.
A listing of all VIN's with owners' names and addresses in your area within the Service Action VIN ranges will be sent to you shortly.
Work Procedure
See attachments:
Please note that there are two (2) different work procedures: 1) Work Procedure "A", for the replacement of a single piece unit with a production date of 25-10-90 or earlier with a new unit; and 2) Work Procedure "B", for checking such a unit, for the production date of the senders for all vehicles within the affected ranges.
Parts Requirement
One initial shipment of parts and copies of the book, Porsche - The Fine Art of the Sports Car (Part Number PNA 000 099), to commence this Service Action will be shipped to your dealership by March 15, 1991. Additional parts and books are to be ordered on a need-to-have basis through your Porsche Cars N.A. parts Customer Service Representative at our Reno PDC.
Shown above is sender components parts set, Part Number 000 043 175 00 which consists of:
Sender 964 641 801 02
Control Unit 964 641 081 00
Clamp N 024 507 3
Sealing O-ring 999 707 115 40
This set will be discontinued at a later date; the individual parts will then be available only.
Note: With each fuel level gauge sender ordered, Part Number 000 043 175 00, to perform the 091 Service Action, the book, Part Number PNA 000 099 will also be shipped.
Time Allowance
a. 30 TU for replacement of sender, including all associated work as described in work procedure "A".
b. 20 TU for checking of sender, dated "26-10-90" or later, as described in work procedure "B".
Administrative Procedure
See attachments:
Please note that there are three (3) different administrative procedures also, "A", "B" and "C".
9222porsche01
March 12, 1991
Model
911 Carrera 2/4
1989-91
Group
2
Number
9101
Part Identifier
2015
Subject:
Fuel Level Gauge Sender
Replacement and/or Checking
This is to notify you of a Service Action on the fuel level gauge sender for all 1989, 1990 and some 1991 model Carrera 2/4 Porsches. The VIN ranges are as follows:
Code:
1989 Carrera 4 - WP0AB096_KS450061 to WP0AB096_KS451117
1990 Carrera 2/4 - WP0AB296_LS450061 to WPOAB296_LS452119
- WP0BB296_LS460061 to WP0BB296_LS460729
- WP0CB296_LS470061 to WP0CB296_LS472169
1991 Carrera 2/4 - WP0AB296_MS410061 to WP0AB296_MS410883
- WP0BB296_MS440061 to WP0BB296_MS440392
- WP0CB296_MS460061 to WP0CB296_MS460899
The new fuel level gauge sender is a two-piece sender unit consisting of a separate sensor and a separate electronic component. The new two-piece fuel level gauge sender components parts set can be ordered under Part Number 000 043 175 00.
The new sender unit must be installed on all vehicles falling within the VIN ranges listed above and which have a single-piece fuel level gauge sender with a production date of "25-10-90" or earlier. The one-part fuel level gauge sender, Part Number 964 641 801 01, with a production date of "26-10-90" or later, need not be replaced unless it is not functioning. This production date is shown on a sticker affixed to the hexagon nut of the sender.
The fuel level gauge sender with production date "26-10-90" or later, should not be replaced if the sender is operating properly. If, however, the sender is not operating, it must be replaced with the sender components shown on page one (1). The parts set is Part Number 000 043 175 00.
Note:
In addition to this Technical Bulletin, Porsche Cars N.A., will mail a letter this week to all dealers further expanding on this Service Action. See enclosed copy.
Customer Notification
The Customer Notification will be by letter mailed 1st class during the week of March 18, 1991. This letter will also include a postage pre-paid postcard to inform Porsche Cars N.A., by the vehicle owner, of any status change, if need be. See enclosed copies.
Please perform this Service Action on all applicable customer vehicles in your dealership.
For those vehicles for which the sales information is not in our files, the notification will be addressed and mailed to the dealer who received that vehicle. If the vehicle is in dealer inventory, new or used and/or in demo use, this Service Action should be performed without delay. If the vehicle has been retailed or dealer traded, the dealer is to make the necessary arrangements to have the customer or receiving dealer contacted and this action performed.
A listing of all VIN's with owners' names and addresses in your area within the Service Action VIN ranges will be sent to you shortly.
Work Procedure
See attachments:
Please note that there are two (2) different work procedures: 1) Work Procedure "A", for the replacement of a single piece unit with a production date of 25-10-90 or earlier with a new unit; and 2) Work Procedure "B", for checking such a unit, for the production date of the senders for all vehicles within the affected ranges.
Parts Requirement
One initial shipment of parts and copies of the book, Porsche - The Fine Art of the Sports Car (Part Number PNA 000 099), to commence this Service Action will be shipped to your dealership by March 15, 1991. Additional parts and books are to be ordered on a need-to-have basis through your Porsche Cars N.A. parts Customer Service Representative at our Reno PDC.
Shown above is sender components parts set, Part Number 000 043 175 00 which consists of:
Sender 964 641 801 02
Control Unit 964 641 081 00
Clamp N 024 507 3
Sealing O-ring 999 707 115 40
This set will be discontinued at a later date; the individual parts will then be available only.
Note: With each fuel level gauge sender ordered, Part Number 000 043 175 00, to perform the 091 Service Action, the book, Part Number PNA 000 099 will also be shipped.
Time Allowance
a. 30 TU for replacement of sender, including all associated work as described in work procedure "A".
b. 20 TU for checking of sender, dated "26-10-90" or later, as described in work procedure "B".
Administrative Procedure
See attachments:
Please note that there are three (3) different administrative procedures also, "A", "B" and "C".
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Technical Guru
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From: USVI
Work Procedure "A"
Service Action 091
This Work Procedure is for checking and replacing all fuel level gauge senders which have a production date of "25-10-90" or earlier AND for checking and replacing defective senders with a production date of "26-10-90" or later.
The VIN ranges are as follows:
WPOAB096_KS450061 to WP0ABO96_KS451117
WPOAB296_LS450061 to WPGAB296_LS452119
WPOBB296_LS460061 to WPOBB296_LS460729
WPOCB296_LS470061 to WPOCB296_LS472169
WPOAB296_MS410061 to WPOAB296_MS410883
WPOBB296_MS440061 to WPOBB296_MS440392
WPOCB296_MS460061 to WPOCB296_MS460899
1. Open the front trunk lid.
2. Remove the luggage compartment matting from the fuel tank and check production date on the sender.
The production date is on a sticker which is attached to the hexagon nut of the sender.
Note:
The one-part sender, Part Number 964 641 801 01, with a production date of "26-10-90" or later should not be replaced unless it is not operable. If replacement is warranted, proceed with Work Procedure "A".
Date of "25-10-90" or earlier - replace with Part Number 000 043 175 00. Date of "26-10-90" or later and inoperable - replace with 000 043 175 00. Date of "26-10-90" or later, but sender is operable - DO NOT REPLACE THIS SENDER, REFER TO WORK PROCEDURE "B".
3. Tools required. Hand driven drill 3 mm drill bit Special tool # 9277 Screwdriver
4. Caution: a. Fuel tank must not be more than 1/4 full when replacing the fuel level gauge sender, remove excessive amount of fuel.
b. Do not use electric drill. (see point 8)
c. Observe all safety regulations when working on the fuel system.
5. Remove the plug connector from the sender.
6. Loosen the sender with the special tool # 9277 or a box wrench (50 mm).
Slowly remove the sender from the fuel tank so the fuel from the sender can drain back into the tank.
Note: An additional vent hole of 3 mm must be drilled into the sender opening of the fuel tank to avoid any fuel gauge reading deviation at "Full".
7. Block off the tank opening for the sender with a non-fraying paper or cloth.
8. Mark the position for the vent hole to be drilled. The vent hole should be at the rear (relative to the direction of travel) top end of the thread, at the point of transition between the threads and the oblique surface. The sealing surface above must not be damaged.
Caution:
BECAUSE OF FUEL VAPOR AND THE DANGER OF FIRE AND INJURY - DO NOT USE AN ELECTRIC DRILL. USE ONLY A HAND DRIVEN DRILL.
Drill the required additional 3 mm vent hole with a hand driven drill in a downward angle of approximately 45~ as shown in the above sketch.
9. Deburr the drilled vent hole if needed.
10. Remove any filings and the paper/cloth.
11. Reinstall the new fuel level gauge sender part set, Part Number 000 043 175 00. This part set includes a new sealing O-ring. Coat this O-ring lightly with lubricant and hand tighten the sender.
12. Torque the sender, using Special tool # 9277, to 25 N-m (18 ft.lbs.).
13. Fasten the electronic component with the clamp onto the sender upright, and towards to the rear.
Connect the electronic component plug to the sender and the cable harness plug to the electronic component.
14. Check the fuel gauge operation.
15. Re-install the luggage compartment matting.
16. Close the trunk lid securely.
17. Place the book, Porsche - The Fine Art of the Sports Car on the passenger seat.
Service Action 091
This Work Procedure is for checking and replacing all fuel level gauge senders which have a production date of "25-10-90" or earlier AND for checking and replacing defective senders with a production date of "26-10-90" or later.
The VIN ranges are as follows:
WPOAB096_KS450061 to WP0ABO96_KS451117
WPOAB296_LS450061 to WPGAB296_LS452119
WPOBB296_LS460061 to WPOBB296_LS460729
WPOCB296_LS470061 to WPOCB296_LS472169
WPOAB296_MS410061 to WPOAB296_MS410883
WPOBB296_MS440061 to WPOBB296_MS440392
WPOCB296_MS460061 to WPOCB296_MS460899
1. Open the front trunk lid.
2. Remove the luggage compartment matting from the fuel tank and check production date on the sender.
The production date is on a sticker which is attached to the hexagon nut of the sender.
Note:
The one-part sender, Part Number 964 641 801 01, with a production date of "26-10-90" or later should not be replaced unless it is not operable. If replacement is warranted, proceed with Work Procedure "A".
Date of "25-10-90" or earlier - replace with Part Number 000 043 175 00. Date of "26-10-90" or later and inoperable - replace with 000 043 175 00. Date of "26-10-90" or later, but sender is operable - DO NOT REPLACE THIS SENDER, REFER TO WORK PROCEDURE "B".
3. Tools required. Hand driven drill 3 mm drill bit Special tool # 9277 Screwdriver
4. Caution: a. Fuel tank must not be more than 1/4 full when replacing the fuel level gauge sender, remove excessive amount of fuel.
b. Do not use electric drill. (see point 8)
c. Observe all safety regulations when working on the fuel system.
5. Remove the plug connector from the sender.
6. Loosen the sender with the special tool # 9277 or a box wrench (50 mm).
Slowly remove the sender from the fuel tank so the fuel from the sender can drain back into the tank.
Note: An additional vent hole of 3 mm must be drilled into the sender opening of the fuel tank to avoid any fuel gauge reading deviation at "Full".
7. Block off the tank opening for the sender with a non-fraying paper or cloth.
8. Mark the position for the vent hole to be drilled. The vent hole should be at the rear (relative to the direction of travel) top end of the thread, at the point of transition between the threads and the oblique surface. The sealing surface above must not be damaged.
Caution:
BECAUSE OF FUEL VAPOR AND THE DANGER OF FIRE AND INJURY - DO NOT USE AN ELECTRIC DRILL. USE ONLY A HAND DRIVEN DRILL.
Drill the required additional 3 mm vent hole with a hand driven drill in a downward angle of approximately 45~ as shown in the above sketch.
9. Deburr the drilled vent hole if needed.
10. Remove any filings and the paper/cloth.
11. Reinstall the new fuel level gauge sender part set, Part Number 000 043 175 00. This part set includes a new sealing O-ring. Coat this O-ring lightly with lubricant and hand tighten the sender.
12. Torque the sender, using Special tool # 9277, to 25 N-m (18 ft.lbs.).
13. Fasten the electronic component with the clamp onto the sender upright, and towards to the rear.
Connect the electronic component plug to the sender and the cable harness plug to the electronic component.
14. Check the fuel gauge operation.
15. Re-install the luggage compartment matting.
16. Close the trunk lid securely.
17. Place the book, Porsche - The Fine Art of the Sports Car on the passenger seat.
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Technical Guru
Rennlist Member
Rennlist Member
Joined: May 2002
Posts: 8,138
Likes: 122
From: USVI
Work Procedure "B"
Service Action 091
This Work Procedure is for checking, but not replacing, the fuel level gauge senders which have a production date of "26-10-90" or later.
The VIN ranges are the same as in Work Procedure "A", which are as follows:
1. Open the front trunk lid.
2. Remove the luggage compartment matting from the fuel tank and check production date on the sender.
The production date is on a sticker which is aftached to the hexagon nut of the sender.
Note:
The one-part sender, Part Number 964 641 801 01, with a production date of "26-10-90" or later should not be replaced unless it is inoperable. If replacement is warranted, refer to Work Procedure "A".
Date of "25-10-90" or earlier - refer to Work Procedure "A" for replacement. Date of "26-10-90" or later and defective - refer to Work Procedure "A" for replacement. Date of "26-10-90" or later, but sender is not defective - proceed with Work Procedure "B".
3. Verify proper function of the fuel gauge.
4. Re-install luggage compartment matting.
5. Close the trunk lid securely.
6. Place the book, Porsche - The Fine Art of the Sports Car on the passenger seat.
Service Action 091
This Work Procedure is for checking, but not replacing, the fuel level gauge senders which have a production date of "26-10-90" or later.
The VIN ranges are the same as in Work Procedure "A", which are as follows:
Code:
WPOABO96_KS450061 to WP0ABO96_KS451117 WPOAB296_LS450061 to WP0AB296_LS452119 WPOBB296_LS460061 to WP0BB296_LS460729 WPOCB296_LS470061 to WP0CB296_LS472169 WPOAB296_MS410061 to WP0AB296_MS410883 WPOBB296_MS440061 to WP0BB296_MS440392 WPOCB296_MS460061 to WP0CB296_MS460899
2. Remove the luggage compartment matting from the fuel tank and check production date on the sender.
The production date is on a sticker which is aftached to the hexagon nut of the sender.
Note:
The one-part sender, Part Number 964 641 801 01, with a production date of "26-10-90" or later should not be replaced unless it is inoperable. If replacement is warranted, refer to Work Procedure "A".
Date of "25-10-90" or earlier - refer to Work Procedure "A" for replacement. Date of "26-10-90" or later and defective - refer to Work Procedure "A" for replacement. Date of "26-10-90" or later, but sender is not defective - proceed with Work Procedure "B".
3. Verify proper function of the fuel gauge.
4. Re-install luggage compartment matting.
5. Close the trunk lid securely.
6. Place the book, Porsche - The Fine Art of the Sports Car on the passenger seat.
Rennlist Member
Joined: Sep 2013
Posts: 61
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Fuel tank sendingn unit
Does anyone have Porsche part 96464180101?
This part is the Fuel Tanking Sending Unit for a 1991 911. This part has the four metal prongs - not two, on the newer sending unit, which requires a fuel level control unit (96464180102).
Thanks.
This part is the Fuel Tanking Sending Unit for a 1991 911. This part has the four metal prongs - not two, on the newer sending unit, which requires a fuel level control unit (96464180102).
Thanks.
Three Wheelin'
Joined: Feb 2003
Posts: 1,782
Likes: 109
From: Cambridge/Boston, MA
Related: has anyone had trouble getting the send o-ring to seal? I replaced mine after noticing fuel leaking and staining the front of the tank just below it. The new seal has stopped the big leak, but I can still smell fuel around it.
