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Water Pump Replacement
 
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Pelican Technical Article:

Water Pump Replacement

Jared Fenton

Time:

3 hours3 hrs

Tab:

$200 to $350

Talent:

****

Tools:

Evacuation pump, E10 Torx socket, T40 Torx socket, screwdrivers

Applicable Models:

Porsche 955 Cayenne S (2003-08)
Porsche 955 Cayenne Turbo (2003-08)

Parts Required:

New water pump, coolant

Hot Tip:

Suck out the coolant prior to removing water pump

Performance Gain:

Proper cooling

Complementary Modification:

Replace thermostat

The water pump in your Cayenne can fail at around 100,000 miles. A water pump failing usually manifests itself in a few different ways. One is an engine that overheats at idle, but cools normally at higher RPMs. Another failure mode is seeing some coolant weeping from the pump housing itself. This is usually indicative of a failing front seal on the pump. Other times, the bearing in the water pump will be noisy, indicating a pending failure.

If you notice any of these with your vehicle, don't waste time, replace the pump as soon as possible. You risk blowing the head gaskets on the car if the car is left to overheat. In this article, I'll go over the steps involved with changing the water pump on your Cayenne. Note that in this article, the intake manifold has been removed from the engine. The procedure is the same with the intake manifold installed.

Shown here is a new water pump and gasket for your Porsche Cayenne.
Figure 1

Shown here is a new water pump and gasket for your Porsche Cayenne.

You'll need to drain off enough coolant from the engine so that it doesn't come dumping out when you remove the water pump.
Figure 2

You'll need to drain off enough coolant from the engine so that it doesn't come dumping out when you remove the water pump. There are two options here, you can drain all the coolant, or siphon it out to be re-used if the coolant is still in good shape. Shown here is the drain plug on the radiator (green arrow). Have a container large enough to catch all the old fluid once you open the valve. Keep in mind it will spray out rather forcefully and you'll probably end up getting some all over you. See our article on Coolant Flush and Replacement for information regarding accessing the drain plug.

The other option is removing the coolant if it is to be re-used.
Figure 3

The other option is removing the coolant if it is to be re-used. Most auto parts stores sell coolant testers for around $10. It's well worth using one to check the condition before hand. The Porsche approved coolant is expensive. Shown here is a simple aftermarket fuel pump available at most auto parts stores. In this case, I have stepped down the lines going to the pump to 1/4" OD plastic tubing. This will allow you to place the tube into the engine to suck out all the coolant. The other end of the tubing goes into a 5 gallon plastic container. Make sure this container is very clean if you plan to re-use the old coolant.

Begin sucking out the coolant at the expansion tank at the left rear of the engine compartment.
Figure 4

Begin sucking out the coolant at the expansion tank at the left rear of the engine compartment. Place the tube down in thee tank as far as you can, activate the pump and let it drain until no coolant remains.

Now move to the wiring harness holder directly above the water pump at the front of the engine (green arrow).
Figure 5

Now move to the wiring harness holder directly above the water pump at the front of the engine (green arrow). Pull the holder up and off the water pump. This will allow you to access the upper mounting bolts and also the hose clamps for the upper radiator hoses.

Loosen and slide back the hose clamps on each upper radiator hose (green arrows).
Figure 6

Loosen and slide back the hose clamps on each upper radiator hose (green arrows).

Use a screwdriver to carefully pull each radiator hose up enough to slip the hose from the pump inside and push it down as far as possible.
Figure 7

Use a screwdriver to carefully pull each radiator hose up enough to slip the hose from the pump inside and push it down as far as possible. The idea here is to get as much coolant out of the engine as you can.

Now remove each radiator hose and stick the hose down into the thermostat housing.
Figure 8

Now remove each radiator hose and stick the hose down into the thermostat housing. Note that these steps may take some time depending on the strength of the pump.

Now we can begin removing the pump.
Figure 9

Now we can begin removing the pump. With the serpentine belt in place, loosen and remove the three T40 Torx bolts (green arrows) holding the water pump pulley to the pump.

Release tension on the serpentine belt and pull the belt up and over the front of the pulley (see our article on serpentine belt replacement for more information).
Figure 10

Release tension on the serpentine belt and pull the belt up and over the front of the pulley (see our article on serpentine belt replacement for more information).Once the belt is removed, use a screwdriver behind the pulley (green arrow) to carefully pry the pulley off. Use caution as it is easy to damage the plastic pulley.

Now remove the eight E10 Torx bolts holding the water pump to the engine (green arrows).
Figure 11

Now remove the eight E10 Torx bolts holding the water pump to the engine (green arrows). Be prepared for some coolant to possibly spill out from behind as you remove the pump. It's helpful to have a large drip tray under the engine.

Remove the old gasket from the engine.
Figure 12

Remove the old gasket from the engine.

Check that the two dowel pins are still in the engine (green arrows) and check that the mounting surface for the pump is clean.
Figure 13

Check that the two dowel pins are still in the engine (green arrows) and check that the mounting surface for the pump is clean.

Place the new water pump gasket over the dowel pins (green arrows) as shown here.
Figure 14

Place the new water pump gasket over the dowel pins (green arrows) as shown here.

Check the mounting surface of the pulley for cracks or damage.
Figure 15

Check the mounting surface of the pulley for cracks or damage. If there are any, replace the pulley

Now install the new pump and torque the mounting bolts to 10Nm (7.
Figure 16

Now install the new pump and torque the mounting bolts to 10Nm (7.5 ft/lbs.)

Once the pump is installed, reattach the radiator hoses.
Figure 17

Once the pump is installed, reattach the radiator hoses. You will now need to bleed the cooling system of air. This is done by using a vacuum siphon type attachment such as Airlift. The idea here is to draw a vacuum in the cooling system, then use the vacuum to draw the new coolant into the engine. Follow the manufacturers instructions for each type of bleeder.

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Comments and Suggestions:
Val Comments: Ok thanks but I got Porsche Cayenne 2006 V6 3.2 engine how to change my water pump I can't find where is she
December 9, 2016
B Comments: Are there any guides for the 2011 cayenne v6
March 7, 2016
  Followup from the Pelican Staff: We don't currently have that tech article. If we get a chance to perform the procedure, we will be sure to document it.

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
 
Philip Comments: Is there a difference or recommendation for either a metal or composite impeller in the water pump construction?
November 18, 2015
  Followup from the Pelican Staff: I prefer metal if you can get an OE one. Other than that, OE for me. - Nick at Pelican Parts  
Nikko Comments: Do you have to remove the front fender in order to replace this pump?
October 22, 2015
  Followup from the Pelican Staff: Not that I am aware of. - Nick at Pelican Parts  
Mike Comments: Can you show a picture and or describe where the aux electric water pump is located on 04 Cayenne S.
March 19, 2015
  Followup from the Pelican Staff: You must remove the driver wheel and driver side inner fender liner, and you will see it. Sorry I could not find any photos! - Casey at Pelican Parts  

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