Fuel Pump Suction Strainer – Removing, Cleaning, and Replacing – 2.5L NA

Overview

This procedure outlines the steps to remove, clean, and replace the fuel pump suction strainer on all Porsche 944 variants with an 8-valve engine configuration. The strainer, located on the suction side of the fuel pump, can become clogged, leading to low fuel system pressure or inadequate fuel pump capacity. Cleaning or replacing the strainer can resolve these issues and fix leaks caused by a failed strainer seal. This guide is tailored for the Porsche 944 (Pre-85.5, 1983–1985.5, and 85.5 Onwards, 1986–1988) models with the 8-valve engine.

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Tools Required

• Floor jack
• Jack stands
• 17mm (11/16 inch) deep socket and ratchet or 17mm (11/16 inch) wrench
• 13mm (1/2 inch) wrench (85.5 Onwards)
• Flat tip screwdriver
• Hose clamp
• Catch rags
• Containers for draining fuel (enough for 20 gallons / 76 liters)

Parts Required

• Fuel pump suction strainer: 928 201 081 04
• Strainer O-ring seal: 928 201 187 02
• Moly grease (for O-ring lubrication)

Step-by-Step Procedure

Step 1: Prepare to Drain the Fuel Tank

1. Check the fuel gauge to estimate the amount of fuel in the tank. If the gauge is unreliable, assume the tank is full and prepare containers to hold up to 20 gallons (76 liters) of fuel.
2. Disconnect the negative battery lead to ensure safety during the procedure.
3. Using a floor jack, raise the rear of the vehicle and secure it on jack stands for safe access to the fuel tank.

Step 2: Access the Fuel Pump and Tank

For 85.5 Onwards models:
If equipped with a fuel pump cover at the bottom of the fuel tank, remove it by unfastening the strap and removing the single bolt near the wheel well using a 13mm wrench.

4. Locate the rubber fuel line connecting the fuel tank outlet to the fuel pump suction.
5. Pinch the rubber fuel line with a hose clamp to prevent fuel from draining during the next steps.

Step 3: Disconnect the Fuel Line

6. Place a container under the fuel pump to catch any fuel that may spill.
7. Using a flat tip screwdriver, loosen the hose clamp at the fuel pump suction and disconnect the hose from the pump. Use catch rags to clean up any spilled fuel.

Step 4: Drain the Fuel Tank

8. Position a clean container under the fuel line and loosen the hose clamp to start draining the fuel from the tank.
9. When the container is full, pinch the fuel line with the hose clamp to stop the flow, replace the full container with an empty one, and repeat until the tank is fully drained. Keep containers covered to ensure the fuel remains clean for reuse.
10. Once the tank is drained, use a flat tip screwdriver to loosen the hose clamp at the fuel tank outlet and remove the hose from the tank outlet nozzle.

Step 5: Remove the Strainer Assembly

11. Place a container under the tank to catch any residual fuel (a small amount may drain when the strainer is removed).
12. Using a 17mm deep socket and ratchet or a 17mm wrench, turn the hex head of the tank outlet nozzle counter-clockwise to remove the strainer assembly.

Step 6: Inspect and Clean the Strainer

13. Inspect the strainer for debris buildup on the screen. Check the base of the strainer for any accumulated debris, carefully removing it with a small probe without damaging the screen.
14. If the strainer is clogged, clean it by backflushing with fuel or carburetor/choke cleaner through the nozzle. Alternatively, use low-pressure air (maximum 10 psig) to loosen debris from the screen.
15. Check the strainer for holes. If any are found, replace the strainer with a new one (928 201 081 04).

Step 7: Install the Strainer and Reassemble

16. Install a new O-ring seal (928 201 187 02) on the strainer and apply a thin layer of moly grease to lubricate the seal, preventing damage during installation.
17. Install the strainer assembly and tighten the nozzle using a 17mm wrench or deep socket to 20 Nm (15 ft-lbs).
18. Reattach the fuel line to the strainer nozzle and fuel pump, securing both hose clamps with a flat tip screwdriver.

Step 8: Refill and Test

19. Refill the fuel tank with the drained fuel (if clean) or fresh fuel.

For 85.5 Onwards models:
Reinstall the fuel pump cover, securing the strap and tightening the bolt with a 13mm wrench.

20. Lower the vehicle from the jack stands using the floor jack.
21. Reconnect the negative battery lead.

Post Procedure Checklist

• Check the strainer assembly and fuel lines for leaks after refilling the tank.
• Verify that the fuel pump cover (if equipped) is securely installed (85.5 Onwards).
• Ensure no tools or debris are left under the vehicle.
• Start the engine and monitor fuel system pressure to confirm the strainer is functioning correctly.

Sources

• Clark’s Garage
• Pelican Parts
• Porsche 944 Workshop Manuals
• YouTube