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Starter Replacement
 
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Pelican Technical Article:

Starter Replacement

Jared Fenton

Time:

5 hours5 hrs

Tab:

$250

Tools:

10mm, 13mm socket, E14 driver

Applicable Models:

Porsche 955 Cayenne (2004-10)
Porsche 955 Cayenne GTS (2008-10)
Porsche 955 Cayenne S (2003-10)
Porsche 955 Cayenne Turbo (2003-10)
Porsche 955 Cayenne Turbo S (2006-10)

Parts Required:

New starter

Hot Tip:

Use a magnetic socket to hold lower starter bolt.

Performance Gain:

Smooth cranking engine

Complementary Modification:

Replace Thermostat

The starter motor will wear out over time. It's just a fact of life. Typically, a failing starter will take longer and longer to crank, despite having a full battery. It can also develop a grinding noise, indicating that the bearings in the starter are failing. A failing starter can also trigger a diagnostic trouble code. If possible, use the factory Porsche diagnostic scanner or Durametric to check that there is not a problem with the electronic immobilizer system.

The most important thing to do before anything else is to remove the negative lead near the front driver's seat. This disconnects the entire electrical system on the vehicle and prevents you from damaging both the vehicle AND yourself.

Unfortunately, the starter is located under the intake manifold and some of the main coolant tubes. Please refer to our articles on Intake Manifold Removal and Thermostat Replacement. You'll also need to siphon out a good amount of coolant from the engine. Please see our article on Water Pump Removal for more information.

Replacing the starter itself from the engine is relatively straightforward. Remove the electrical connections and then remove the two bolts holding the starter to the engine block. The lower bolt can be a bit of a pain to access, as it sits underneath the main body of the starter. You'll want to use a universal joint and also a 3/8" drive extension to remove it.

Once the engine is clean, lower the starter into position and press it back up against the mounting flange. You should feel it slightly pop into place. Now thread the upper bolt through the starter and into the flange. Don't tighten it down just yet. You'll now need to slide the lower bolt into position. I have a socket with a magnet inside to hold the bolt while to route it under the starter. Another trick is to put a bit of heavy grease inside the socket. This will hold the bolt until you slide it in. Once both bolts are in, torque them to between 45/53Nm (33/39 ft/lbs.).

Shown here is the starter motor for the Porsche Cayenne.
Figure 1

Shown here is the starter motor for the Porsche Cayenne. In this article I'll go over the steps involved with replacing the starter.

The first step in replacing the starter is to disconnect the battery.
Figure 2

The first step in replacing the starter is to disconnect the battery. The main lead going to the starter motor is always live. The disconnect point is located under the left side carpet, near the seat. You'll see a slit in the carpet, pull it up and you'll see the 13mm acorn nut holding the ground lead to the frame (green arrow). Remove the nut and pull the lead up off the post.

I like to pull the ground lead up through the slit in the carpet to prevent the cable from touching any bare metal.
Figure 3

I like to pull the ground lead up through the slit in the carpet to prevent the cable from touching any bare metal.

Shown here is the starter, located in the center of the engine block.
Figure 4

Shown here is the starter, located in the center of the engine block.

The first step is to remove the 10mm nut (yellow arrow) and the 13mm nut (blue arrow) holding the electrical leads to the starter solenoid.
Figure 5

The first step is to remove the 10mm nut (yellow arrow) and the 13mm nut (blue arrow) holding the electrical leads to the starter solenoid. One removed, pull the leads up off the posts and position them out of the way. Next , remove the two E14 Torx bolts holding the starter motor to the engine block. The lower bolt can be a challenge to reach. I like to use a universal joint and a 3/8" drive extension to reach the bolt, just slide it under the starter until the socket is on the bolt.

Now that the starter is removed, check the area underneath (green arrow) for any water or coolant.
Figure 6

Now that the starter is removed, check the area underneath (green arrow) for any water or coolant. Take the time to vacuum out anything that may be below. Over time, water can accumulate under the starter and possibly leak inside, causing problems.

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Comments and Suggestions:
ben Comments: Does anyone have a list of the torque specs for all of the fasteners that need to be removed along the way to get at the starter?
September 7, 2016
  Followup from the Pelican Staff: I don’t have that info.

I would grab a repair manual. It will have the procedure, special tools and torque specs.

Give our parts specialists a call at 1-888-280-7799. - Nick at Pelican Parts
 
Eric Comments: I have a 2008 S with the same problem as Kel-Tec, dealer did a current draw test and it was very high. Bad starter. I held off on replacing it and now that I found the instructions here I feel comfortable changing it myself.
May 26, 2016
  Followup from the Pelican Staff: Thanks for the feedback. Glad we could help.
- Nick at Pelican Parts
 
Eddie Comments: Thanks guys, we were just about to remove the water pipes
April 13, 2016
  Followup from the Pelican Staff: Thanks for the feedback. Glad we could help.
- Nick at Pelican Parts
 
Mark Comments: Kel-Tec-Innovations.. I am very interested in what you discovered. I am having the same issue that you describe with my 2009 S. Please share any results. Thanks,
Mark mbrink44@yahoo.com
March 26, 2016
  Followup from the Pelican Staff: Use my comment to kel-tec, monitor the signal I mentioned, we can get this figured out. - Nick at Pelican Parts  
lou Comments: This is the one of the best web sites of all time. yes can't put everything on it but you can learn a lot of cars just reviewing free stuff. I wish i could buy of this in a book for my cayenne
January 30, 2016
  Followup from the Pelican Staff: Thanks for the feedback. Glad we could help.
- Nick at Pelican Parts
 
Kel-Tec-Innovations Comments: I have a 2008 Cayenne S 4.8L. I'm not sure if its a starter problem or ignition switch or something else. Battery is full and new. When I go to crank the motor the starter will crank then stop. I release the key and turn it again and the engine starts.

Happens often where when I crank it would stop and I would have to release the key and turn the key again. Starts the second time 90% of the time.

I want to make sure before I pull the starter out and put a new starter it. A mechanic's guess was the starter brushes are going. What do you think?
January 30, 2016
  Followup from the Pelican Staff: Hard to say, i would lean toward the key or start signal circuit. Monitor the signal and voltage to the starter when the problem is present. That is the only way to be sure. - Nick at Pelican Parts  
mikeydowntown Comments: Couple of comments or those with 957 2008-10 after having just finished the replacement mine is a 2008 S:
a per fuel rail removal, there are no fuel pressure relief valves nor need to relieve pressure on the 957 as long as engine has been off for a few hours, though they still drop plenty of fuel once disconnected so be ready for that.
b the starter comes out easily with no need to remove coolant tube on the 957, though use plenty of caution when removing starter bolts that you don't crack the coolant tube, which would be quite easy to do.
c don't forget to reinstall the plastic cowling over the starter connectors after you put in the new one.
d beware the little hose at the back on the manifold as it's a pain to reconnect and might be overlooked. I almost missed it since it popped off on removal and was difficult to spot.
e use a bit of electrical contact cleaner on your connections - I was throwing some fault codes P2123 & P2128 initially after putting everything back together and was only able to clear them once I'd taken the air intake back apart and cleaned/reseated some of the sensor contacts.
f you may get a check engine light and other warnings I got one also for "Light Fault" however these cleared themselves after driving a bit and restarting the vehicle.
December 28, 2015
  Followup from the Pelican Staff: Thanks for sharing your installation process and experience. These type of comments add so much to the Pelican tech community.
- Nick at Pelican Parts
 
Sponge Comments: To get the starter out without having to remove the water pipes you need to pull the starter back slightly, tip up the back slightly then rotate clockwise so the left flange is above the metal of the engine... then come back and up with the back of the starter. Takes a while, but can be done.
November 8, 2015
  Followup from the Pelican Staff: Thanks for the additional info and feedback. We appreciate it.
- Nick at Pelican Parts
 
abloke2 Comments: if you have the patience to try like i did you can change the starter without removing the water pipes
June 25, 2015
  Followup from the Pelican Staff: You can get it out without removing the coolant pipe next to it. - Nick at Pelican Parts  

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