99911

This is a job I have been putting off doing on my '99 Carrera Cab. As it turned out, it was pretty easy to do. Unfortunately I didn't take any pictures, so you will have to settle for the narrative: I was in a bit of a hurry, and I'm somewhat format impaired and don't know how to get the pictures small enough to be able to attach. Sorry for that, but here goes with the directions. Someone with really small hands might be able to do this without removing the reservoir - not me. Tools: Phillip #2 screwdriver T-25 torx driver Small prying tool Small flat head screwdriver 10mm socket 13mm socket 19mm socket Floor jack and jack stand Torque wrench Parts: Pump - Part #996 628 172 00 Grommet - Part # 431955465B This job involves access from two directions: under the left front fender; and, under the left side cowl cover under the trunk lid. 1. With the parking brake engaged and right rear wheel chucked, loosen the left front wheel lugs (19 mm socket) then jack up the left side using the rear left side jacking point and put a jack stand under the left front jacking point. 2. Remove the left front wheel and set aside. 3. Remove the left front wheel housing liner. The liner is secured by a combination of plastic nuts, expansion rivets and phillip head screws. The plastic nuts take a 10mm socket. I used a flat head screw driver to pry the expansion rivet heads up and then a pair of dikes to get behind the head of the rivet and pull it straight out. The phillip head screws and an expansion rivet attach the liner to the front bumper. Once all the fasteners are removed, the liner comes out pretty easily. 4. With the liner out, you can now see the reservoir up behind the fender, between the wheel well and the driver's door. Disconnect the hose from the top where it connects to a nipple on the filler neck bracket and pull it down to let the reservoir drain. If the reservoir is full, it holds about two gallons, and at about 8 pounds per gallon, draining it just makes the job easier. The empty reservoir is considerably lighter and easier to work with, particularly since you have to do a bit of gymnastics to get it out and disconnected. 5. Once the reservoir is drained, open the front compartment lid and remove the left side cowl cover in order to expose the filler neck. This requires the T-25 torx bit for the screw and your fingers for the other fastener (not sure what that one's called). Once the filler neck is exposed, you'll see a small plastic tab on the top of the neck where the filler neck passes into the bracket through which it goes to enter the reservoir. Gently lift the snap tab while you pull straight out on the neck and it will come out of the grommet in the side of the reservoir. This requires a little finesse, but again, should come out pretty easily. 6. With the filler neck removed, the reservoir comes out by removing the 13mm bolt securing the reservoir to the fender area on the front inboard side of the reservoir. There is only one and it's pretty hard to miss. With the 13mm bolt removed, the reservoir comes out straight forward. Don't pull too far, because you still have to disconnect the wire connectors to the tank gauge switch and the connection to the pump motor. I used a small flat head to pry the snap up slightly and then pull up on the connectors. 7. With the reservoir out from behind the fender, it is simply a matter of pulling off the old pump motor and replacing it with the new one. I went ahead and replaced the small grommet that receives the pump on the reservoir while I was at it. It just pulls out and then you press the new one in - just be sure it seats properly. 8. Once the new pump is in place, just reverse the order of the process to put it all back together. Make sure the electrical connections are on all the way (the pump connection will only go on one way). On the back of the reservoir are two stubs with rubber grommets that go into two receiver holes. The two stubs push straight in to those two holes. I put a little Ruglide on the grommets and they popped right in to their receivers. When the tab on the reservoir is lined up with the hole for the 13mm bolt you'll know you have it fully seated and lined up correctly. I also added small hose clamps to the hose where it attaches to the pump and also to the bracket. I don't know the torque setting for the bolt securing the reservoir. I snugged it enough to keep it tight without damaging the plastic of the reservoir. The plastic nuts securing the liner similarly should not be over tightened as they look like they could strip out pretty easily. The correct torque for the wheel lugs is 96 foot pounds. My 911 is my daily driver, so it's nice to be able to clean the windshield on the fly again! (Or is that the fly on the windshield?)