Fuel Pump Suction Strainer – Removing, Cleaning, and Replacing

Overview

This procedure guides you through removing, cleaning, and replacing the fuel pump suction strainer on your Porsche 944 S / S2 with a 16v engine. The strainer, located on the suction side of the fuel pump in the fuel tank, can clog over time, causing low fuel pressure or reduced pump capacity. Cleaning or replacing it can resolve these issues and may fix fuel tank leaks caused by a failed strainer seal. This is a great step to try before replacing the fuel pump itself.

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Tools Required

• Floor jack
• Jack stands
• Containers for draining fuel (enough for up to 20 gallons / 76 liters)
• 17mm (11/16 inch) deep socket and ratchet or 17mm wrench
• Flat-tip screwdriver
• Hose clamp (to pinch fuel line)
• Catch rags
• Small probe (for cleaning debris)
• Low-pressure air source (max 10 psig / 0.7 bar)

Parts Required

• Fuel pump suction strainer – 928 201 081 04
• Strainer O-ring seal – 928 201 187 02
• Moly grease (small amount for lubricating the O-ring)

Step-by-Step Procedure

Step 1: Check Fuel Level and Prepare Containers

Look at your fuel gauge to estimate how much fuel is in the tank. If the gauge isn’t working or seems off, assume the tank is full and have enough clean containers ready to hold up to 20 gallons (76 liters) of fuel. You’ll reuse this fuel later, so keep the containers covered and clean.

Step 2: Disconnect the Battery

Disconnect the negative lead from the battery to ensure safety while working near fuel components.

Step 3: Raise the Vehicle

Use a floor jack to lift the rear of the Porsche 944 S / S2. Once raised, place jack stands under the vehicle for secure support.

Step 4: Remove Fuel Pump Cover (If Equipped)

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

Step 5: Pinch the Fuel Line

Find the rubber fuel line running from the fuel tank to the fuel pump’s suction side. Use a hose clamp to pinch this line shut, preventing fuel from flowing out during the next steps.

Step 6: Disconnect the Fuel Line from the Pump

With a flat-tip screwdriver, loosen the hose clamp at the fuel pump suction. Disconnect the hose from the pump, placing a container underneath to catch any fuel that drains from the line or pump. Keep catch rags handy to mop up spills.

Step 7: Drain the Fuel Tank

Position a container under the fuel line, then loosen the hose clamp to let the fuel drain from the tank. When the container fills up, pinch the line again with the hose clamp, swap in an empty container, and repeat until the tank is fully drained.

Step 8: Remove the Fuel Line from the Tank Outlet

Once the tank is drained, loosen the hose clamp at the fuel tank outlet with a flat-tip screwdriver and remove the hose from the tank outlet nozzle.

Step 9: Remove the Strainer Assembly

The tank outlet has a hex head on the nozzle. Use a 17mm (11/16 inch) deep socket and ratchet or a 17mm wrench to turn it counterclockwise. Remove the nozzle and strainer assembly, keeping a container underneath to catch a small amount of leftover fuel that will drain out.

Step 10: Inspect and Clean the Strainer

Check the strainer for debris on the screen. If it’s clogged, backflush it with fuel or carburetor/choke cleaner through the nozzle. You can also use low-pressure air (max 10 psig / 0.7 bar) to loosen debris. If there’s buildup at the base, gently clean it with a small probe—be careful not to puncture the screen. Replace the strainer if you find any holes.

Step 11: Install a New O-Ring

Place a new O-ring seal (928 201 187 02) on the strainer. Apply a thin layer of moly grease to the seal to prevent damage during installation.

Step 12: Reinstall the Strainer

Install the strainer assembly back into the tank outlet. Tighten it clockwise with a 17mm (11/16 inch) wrench or deep socket until secure.

Step 13: Reconnect the Fuel Lines

Attach the fuel line to the strainer nozzle and the fuel pump. Tighten both hose clamps securely with a flat-tip screwdriver.

Step 14: Refill the Tank and Check for Leaks

Pour the drained fuel back into the tank using your clean containers. Inspect the strainer assembly and fuel lines for any leaks.

Step 15: Reinstall the Fuel Pump Cover (If Equipped)

If your S / S2 had a fuel pump cover, secure it back in place with the strap and the 13mm bolt, tightening it with a 13mm wrench.

Step 16: Lower the Vehicle

Carefully remove the jack stands and lower the vehicle back to the ground using the floor jack.

Post Procedure Checklist

• Check the strainer assembly and fuel lines for leaks after refilling the tank.
• Ensure the fuel pump cover (if equipped) is securely fastened.
• Reconnect the battery negative lead and confirm the vehicle starts without issues.
• Monitor fuel pressure or pump performance to verify the issue is resolved.

Sources

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