Fuel Pump Replacement

Overview

This guide walks you through replacing the fuel pump on your Porsche 944 S / S2 with its 16v engine. The fuel pump is a reliable component, but if it fails, it’s often due to another issue like a clogged fuel filter or a faulty fuel pressure regulator. Replacing the pump is straightforward with the right tools and steps, and doing a fuel system check afterward ensures everything works smoothly and prevents early wear on the new pump.

Pink and blue text represents links to additional resources, tools, parts, and partner websites.

Tools Required

• Metric wrench/socket set (sizes like 13mm wrench included)
• Catch rags
• Hose clamp pliers or locking pliers
• Jack stands and floor jack OR ramps

Parts Required

• Fuel pump for Porsche 944 S / S2 (16v engine) – 944 608 102 06

Step-by-Step Procedure

1. Depressurize the Fuel System

1. Locate and remove the fuel pump fuse. For the Porsche 944 S / S2, this is Fuse 34 (15A) on the Central Electric Panel under the hood, powered through the DME relay.
2. Try to start the engine. If it starts, let it run until it stalls from lack of fuel.
3. Disconnect the negative battery cable to ensure safety.

2. Lift the Vehicle

4. Raise the rear of the Porsche 944 S /S2 using a floor jack and secure it on jack stands, or drive it onto ramps for safe access to the fuel pump.

3. Remove the Fuel Pump Cover (If Equipped)

5. If your S / S2 has a fuel pump cover at the bottom of the fuel tank, unfasten it. Undo the strap holding it in place and remove the single 13mm bolt near the wheel well using a 13mm wrench.

4. Disconnect the Fuel Pump

6. Unplug the electrical leads from the fuel pump. On the S / S2, this might be a two-prong connector near the pump—just pull it apart gently.
7. Using hose clamp pliers (or locking pliers wrapped with a rag to protect the line), clamp the fuel line from the tank to the pump’s suction side.
8. Loosen the hose clamp on the suction line with pliers, then disconnect it from the pump. Have catch rags and a pan ready to catch any fuel that spills out.
9. Use the right-size metric wrench to disconnect the discharge line from the pump.
10. Loosen the clamp holding the fuel pump with pliers or a wrench, then slide the pump out of its holder.

5. Install the New Fuel Pump

11. Before installing, check that the new fuel pump (944 608 102 06) has all the correct fittings. If not, transfer fittings from the old pump.
12. Slide the new pump into the holder and tighten the clamp just enough to secure it—don’t overtighten, as it could harm the pump motor.
13. Reconnect the suction line and discharge line to the new pump, tightening the clamps securely.
14. Remove the clamp from the suction line.
15. Plug the electrical leads back into the pump.

6. Reconnect and Test

16. Reattach the negative battery cable.
17. Insert the fuel pump fuse back into Fuse 34 on the Central Electric Panel.
18. Start the engine and listen for the pump running. Check all connections for fuel leaks.

7. Finalize Installation

19. If you removed a fuel pump cover, reinstall it by securing the strap and tightening the 13mm bolt with a 13mm wrench.
20. Lower the vehicle off the jack stands or ramps safely.

Post Procedure Checklist

• Check for fuel leaks at all connections.
• Listen for the fuel pump running when the key is turned on—it should hum briefly.
• Ensure the engine starts and runs smoothly without hesitation.

Sources

• Clark’s Garage
• Pelican Parts
• Porsche 944 Workshop Manual, Volume 1
• YouTube