Auxiliary Cabin Heater Fuel Hose/Line: Service and Repair
Removing And Installing Fuel Line
Preliminary work
1. Remove exhaust system.
2. Remove left catalytic converter.
3. Release center bearing of cardan shaft.
4. Remove cross member.
5. Remove front left wheel housing liner.
6. Remove underbody cover.
Removing fuel line
Removing fuel line - fuel pump to wheel housing connection point
NOTE: The direction of travel is identified by an arrow with the designation x.
1. Release the plug -arrows A- and pull off -arrow B-.
2. Unscrew fastening screw -arrows 1-.
3. Unscrew the fastening nuts -arrows 2- and remove the cover.
4. Release the line holder -arrow A-, open it -arrow B- and unclip the fuel line -arrow C-.
NOTE: Before disconnecting the fuel line, it is essential to observe the safety instructions.
5. Release the clamp lugs -arrow A- on the fuel pump and on the connection point in the wheel housing -arrow B-.
6. Pull out the line on both ends of the connections -arrows C-.
7. Press out the line with the rubber grommet -arrow A- inwards -arrow B-.
8. Remove the fuel line first to the rear -arrow C-, and then downward -arrows D-. If necessary, twist the fuel line slightly when removing it.
Removing fuel line - fuel pump to tank
WARNING:
Danger of injury due to falling components.
- Please observe general warning notes and working regulations.
1. Undo fastening screws -3- and pull cover down and away-arrow-.
2. Loosen the fastening screws -Arrow 4- - do not unscrew them completely - and lower the tank on the right side arrow -arrow-.
3. Lift front edge of right rear seat -Arrow A-, pull out to the front -Arrow B- and fold forward -Arrow C-.
4. Cut out the floor carpeting along the perforation and fold forward -Arrow A-.
5. Undo the fastening screws -Arrows 5- and take out the bracket with the seat-belt buckle -Arrow B-.
6. Unscrew the fastening nuts -Arrows 6- and remove the cover -Arrow C-.
DANGER: Danger of fire and poisoning when working on fuel-carrying components.
- Before disconnecting the fuel line, it is essential to observe the safety instructions in.
7. Press in the locking mechanism -Arrow A- and pull off the fuel line from the connection -Arrow B-.
8. Remove line from bracket -Arrow C-.
NOTE: The direction of travel is shown by an arrow with the designation "x".
9. Release hose clamp -Arrow A- and pull off line from fuel pump -Arrow B-.
NOTE: The direction of travel is shown by an arrow with the designation "x".
10. Unclip the line from the rear line holder -Arrow A- and pull down and away from along the tank -Arrow B-.
11. Open the front holder -Arrow C- and remove line downward -Arrow D-.
12. Remove line to the rear -Arrow E-.
Removing fuel line - wheel housing connection to heater
1. Release the clamp -Arrow A- and pull out the fuel line from the housing -Arrow B-.
2. Pull out fuel line from the clip -Arrow C-.
Installing fuel line
Installing fuel line - fuel pump to wheel housing connection point
NOTE: Before installing the fuel line, apply a suitable rubber lubricant (tyre mounting paste) on the wheel housing side of the rubber sleeve.
1. Slide the fuel line from below along the transmission -Arrows Band guide it outward through the wheel housing. If necessary, twist the fuel line slightly when installing it.
2. Press rubber sleeve into wheel housing -Arrow C- until it is felt to engage in the body.
3. Insert fuel line in the wheel housing into the fuel hose -Arrow A and fasten with a new hose clamp -Arrow B-.
4. Push fuel line with fuel hose onto the fuel pump -Arrow C- and fasten with a new hose clamp -Arrow B-.
5. Press fuel line into holder -Arrow A-.
6. Close holder -Arrow B- until locking tabs are felt to engage -C-.
7. Install the cover and screw down using fastening screws -Arrow 1- and fastening nuts -Arrows 2-. Tightening torque: 1.5 ftlb. Tightening torque: 3.5 ftlb.
Installing fuel line - fuel pump to tank
NOTE: The direction of travel is shown by an arrow with the designation "x".
1. Push the line through forwards -Arrow A-, connect to the fuel pump -Arrow B- and fasten with a new hose clamp-C-.
2. Press line into holder and close the holder -Arrow D- until the locking tab can be felt to engage.
3. Push the line through up along the tank -Arrow E- and press into holder -Arrow F- until it can be felt to engage.
4. Push line onto tank connection-Arrow A- until retaining clip -Arrow B- is felt to engage.
5. Press fuel line into the holder -Arrow C- until it is felt to engage.
6. Install cover -Arrow A- and screw down with the fastening nuts -Arrows 6-. Tightening torque: 6.5 ftlb.
7. Fold back floor carpeting -Arrow B-.
8. Install bracket with seat-belt buckle -Arrow C- and and screw down using fastening screws -5-. Tightening torque: 37 ftlb.
9. Fold back rear seat -Arrow A-, press front edge downwards -Arrow B- and push to rear -Arrow C-.
10. Press fuel tank upward -arrow- and tighten the fastening screws -Arrows 4-. Tightening torque: 24 ftlb.
11. Secure cover with fastening screws -Arrows 3-. Tightening torque: 1.5 ftlb.
12. Fill the fuel line.
Installing fuel line - wheel housing connection to heater
1. Push fuel line onto the adapter -Arrow A- and fasten with a new clamp -Arrow B-.
2. Press fuel line into retaining clip -Arrows C-.
NOTE: The direction of travel is shown by an arrow with the designation "x".
3. Push on connector -Arrow A- until the locking tabs-Arrows B- are felt to engage.
Filling the fuel line
NOTE: The fuel line of the auxiliary heater can only be filled using the Porsche System Tester.
1. Connect the Porsche System Tester to the vehicle and start the System Tester. Switch on ignition. .>>" Continue.
2. Select vehicle type using the cursor keys.
3. Using the .? |" key, move from the vehicle type to the control modules.
4. Select Auxiliary heater using the cursor keys and press the .>>" key.
5. Select Coding using the cursor keys and press the .>>" key.
6. Select Filling using the cursor keys and press the .>>" key. The fuel pump is activated for 50 seconds and fills the fuel line.
Subsequent work
1. Install cross member.
2. Fasten cardan shaft center bearing support.
3. Install left catalytic converter.
4. Install exhaust system.
5. Install underbody cover.
6. Install front left wheel housing liner.