Out of the blue - it won't start!

[Thumper]

Well, I received advice from several sources and got some great advice from the local chapter of the PCA here in the DFW area. First thing I did was change out the fuel pump relay....same problem, then I bought a new Optima 34R and installation plate from Zims in Bedford, TX.....same problem, so I narrowed it down to a defective fuel pump. I ordered one online at a great price and had it overnighted to me. Then I spent last evening removing the defective pump and installing the new pump.

IT IS ALIVE!!!!!! :dance: :dance: :dance:

Took it for a quick test spin and all is well.

On a side note, I took my 98 GMC ext. cab Z71 pickup to Kansas last weekend to attend my brother's graduation from his Master's program at Friend's University. After a stop in Edmond, OK for fuel, the fuel pump went out on the GMC too!!!! What is up with my luck???? My nephew drove down from Wichita and towed me to Wichita (thanks again Tony!) and I took the bed off of the truck and replaced the fuel pump on it. I was surprised to find out that the fuel pump for my truck cost $125 more than the one for the Porsche. But at least it worked and I was able to leave Kansas once again. One other thing happened in Edmond, OK. I was inside the gas station purchasing some munchies and a frosty cold beverage when I looked outside and saw a guy running to my truck to shut off the fuel. Apparently the auto-shutoff of the pump wasn't working and I had fuel gushing out of the filler neck. Thank goodness that he shut off the pump when he did, as my gas total was $80 when I went out to check on it. There was also a HUGE gas spill on the ground (around 10 gallons I estimated). Right after that is when I discovered that my fuel pump had decided that it's life was over.

Oh well, not to ramble on too much more...but both vehicles are now repaired and operational. My wallet is very empty, but my piece of mind has been restored.

[Thumper]

I almost forgot. Replacing a fuel pump in a Boxster is not a difficult task. Once you take the battery and battery tray out, you can get pretty easy access to the top of the tank. The retaining ring is a pain to remove, but the rest is very straight foward. You just have to be careful removing the sending unit to get to the pump. The pump locks in place with a simple twist (make sure that the rounded side is facing the front of the car.....). I also discovered that premium fuel will begin to burn skin pretty quickly. I figured that I saved $600+ doing the job myself and I further bonded with my Little Red Bast!@d.

[98Boxster98]

Thumper - How'd you get the retaining ring off? A strap wrench? The Porsche manual references a special tool VW 3217.

[Thumper]

No fancy tools for me. I used the largest channellock wrench I could find at Home Depot. It fit over the top and without squeezing the retaining ring, I was able to catch the tabs on the side of the retaining ring with the sides of the channellock jaws and twist counterclockwise. Once it's broken loose, it spins off rather easily. Porsche does put a dab of silicone sealer on the ring and sending unit to "lock" the ring into place. It helps to remove the dab of sealer before attempting to break the ring loose.

If the channellock's hadn't worked, my next attempt would've been a strap wrench. It's pretty tight quarters, but the retaining ring isn't really torqued down very tight. Worst case, I could've broken off the ring and just bought a new one, as it's plastic (I'm amazed at the amount of plastic Porsche uses).

[peterjg]

Hi Thumper , my porshe 2003 2.7 just stopped and the mechanic has advised fuel pump, I have been quoted stating the fule pump is one with the tank and by removing the Tank and bottom supension they will replace it , this sounds sus as you have advised that its just a batery removal and the pump is separate , any suggestions , im thinking a second opinion. thanks

[Thumper]

Absolutely get a second opinion. Replacing a fuel pump has nothing to do with any suspension components. Just pull the battery, the battery tray (four nuts), disconnect the electrical connector to the fuel pump/sending unit, unscrew the large ring at the top of the tank, pull out the sending unit and there is the fuel pump. A quarter turn counter clockwise and lift out the pump. Other than having to stick your arm into a fuel tank full of fuel, it couldn't be any simpler.

Replacement is the reverse of disassembly. Sounds as if someone was trying to take you for much more than what it should cost for replacement. I'm surprised that they didn't tell you that your muffler bearings were going out as well.

[peterjg]

thanks thumper, second opinion helped and i got a third , new people servicing the car now , you were a great help regards Peterjg