122-F6Q6Y-08
Service Bulletin Details
Public Details for: 122-F6Q6Y-08
Subject: electric fuel pump information: there is a possibility that a fuel pressure control valve with a characteristic that does notmeet the required specifications was installed in the fuel pump on the affected vehicles. If this is th
- 2018 -
Models from 2018
2018 PORSCHE 718 BOXSTER |
Service Technical Information 33/18 ENU WJ22 2 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. AfterSales Jul 6, 2018 Page 1 of 8 2 Service WJ22 ENU Technical Information 33/18 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: Jul 6, 2018 Page 2 of 8 • • 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 AfterSales Service Technical Information • • • • • 33/18 ENU WJ22 2 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. AfterSales Jul 6, 2018 Page 3 of 8 2 Service WJ22 ENU Technical Information 33/18 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 Jul 6, 2018 Page 4 of 8 Raise the vehicle on a lifting platform Workshop Manual '4X00IN Lifting the vehicle'. AfterSales Service Technical Information 33/18 ENU WJ22 2 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 AfterSales Jul 6, 2018 Page 5 of 8 2 Service WJ22 ENU Technical Information 33/18 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 Jul 6, 2018 Page 6 of 8 Install battery console Workshop Manual '508419 Removing and installing battery console'. AfterSales Service Technical Information References: 33/18 ENU WJ22 2 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' AfterSales Jul 6, 2018 Page 7 of 8 2 Service WJ22 ENU Technical Information 33/18 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. Jul 6, 2018 Page 8 of 8 AfterSales