Starters Porsche Cayenne S I

DESCRIPTION & OPERATION

Starter is a brush-type, series-wound electric motor with an overrunning clutch. Field frame is enclosed by commutator end frame and drive bushing, and carries pole shoes and field coils. Digital Motor Electronics (DME) control unit controls operation of start inhibit relay and operation of magnetic switch (starter solenoid) via terminal No. B1 at starter.

PRELIMINARY INSPECTION

Verify customer complaint by operating system. Visually inspect for obvious signs of mechanical and electrical damage. Inspect for blown fuses and damaged relays. Inspect for loose or corroded connections, damaged wiring harnesses and/or switches. Check for a broken or partially broken wire inside insulation, which could cause system malfunction but prove good in a continuity/voltage check with system disconnected. Ensure any aftermarket electronic equipment is properly installed. If fault is found, repair as necessary.

ON-VEHICLE TESTING

Information not available from manufacturer.

BENCH TESTING

Information not available from manufacturer.

SERVICE PRECAUTIONS

The following precautionary measures must be taken before disconnecting or total discharge of battery or serious electrical damage can occur

1. To avoid triggering siren, on vehicles equipped with an additional alarm siren, battery must be disconnected with ignition switch turned to ON position.
2. All loads must be switched off and ignition key removed from ignition switch.
3. Never disconnect battery with engine running.
4. Ensure battery is securely connected before starting.
5. Do not use a boost charger to start engine.
6. Never start engine, unless battery is securely connected.
7. Battery terminals should be connected without force, to prevent damage to battery housing.
8. When jump starting, use jumper cables with overvoltage protection.
9. Always disconnect battery before performing any welding.
10. After installation, ensure battery is seated correctly. Other dangers exist with a loose battery such as: reduced service life due to vibration, damage to grid plates of battery, damage to battery housing from mounting elements (possible acid leak), or inadequate crash safety.

BATTERY DISCONNECT PRECAUTIONS

After disconnecting battery or replacing ECM, drive vehicle to enable ECM to relearn driveability. Inform your customer that they may experience driveability different from what they are accustomed to until ECM completes relearn function.

Ready Status

After battery is disconnected and reconnected, the "Ready Status" must be obtained following a test drive or using a Porsche System Tester (or equivalent aftermarket scan tool).

Idle Relearn

After disconnecting the power supply, the idle speed might change or fluctuate briefly until the throttle adjusting unit readapts. The mixture adaption is also lost.

To readapt the DME control unit (PCM), perform the following procedure

1. Turn ignition on, with engine off for 30 seconds. Do NOT touch accelerator pedal. This completes the adaption of the throttle adjusting unit.
2. The engine must run for several minutes before the PCM can relearn the idle speed and mixture adaption values.

Tire Pressure Monitoring

Tire pressure monitoring values will be lost after the battery is disconnected. After reconnecting the battery, drive the vehicle for a short distance. The actual tire pressures will start to display again.

Steering Angle Sensor

The steering angle sensor must be re-initialized after battery is disconnected and connected.

1. Turn steering wheel to straight ahead position.
2. Turn ignition off then on again twice (do not start the engine yet).
3. Start engine.
4. From the straight-ahead position, turn steering wheel about 20 degrees to the left and 20 degrees to the right (past the straight-ahead position).
5. Drive the vehicle straight ahead for at least one second at a speed above 2.5 MPH.
6. The stored fault code in the Porsche Stability Management (PSM) control unit should now be cleared automatically. The PSM indicator light in the instrument cluster should now go out.

Sliding Roof Electric Motor

The sliding roof limit positions are lost when battery is disconnected and connected. To restore settings, turn ignition on (engine off) and press the rocker switch upwards. The roof opens and closes completely. The limit positions are now stored in the control unit.

Power Windows

The limit positions of the power windows are deleted from the control unit when the battery is disconnected and connected.

To restore the settings, manually close each power window as far as it will go. Open it completely, and then press the rocker switch for closing the window again. The power window limit positions are now stored in the control unit.

Supply Voltage Fault Entry

A "supply voltage" entry may be stored in various electronic control units if the battery is completely discharged. This will have to erased from fault memory using a scan tool.

REMOVAL & INSTALLATION

Scheme 1

Scheme 2

Scheme 3

Scheme 4

Scheme 5

Scheme 6

Scheme 7

Scheme 8

Scheme 9

Scheme 10

Scheme 11

1. Remove throttle body cover. (Scheme 1) Disconnect Throttle Position Sensor (TPS) harness connector. Unclip TPS wire harness from retaining clip.
2. Unlock retaining bolts for throttle body. Turn right bolt 45° counterclockwise, and left bolt 45° clockwise. (Scheme 2) Using pliers, gently pull retaining bolts out, by rubber ring. Remove "Y" pipe from throttle body.
3. Separate air bellows for air flow sensors. (Scheme 3)
4. Remove vacuum hose for "Y" pipe by pressing button at vacuum connection. (Scheme 4) Disconnect vacuum hose, on rear of intake system. (Scheme 5)
5. Remove right side (passenger) engine cover. Remove bolt securing engine torque support. (Scheme 6) Loosen torque support on body and pull engine torque support upward from body bracket. (Scheme 7)
6. Remove bolts securing secondary air pump. Remove secondary air pump from holder, and place aside. (Scheme 8)
7. Remove bolts securing engine design covers. (Scheme 9) Gently remove engine design cover from cylinder Nos. 1-4 bank (passenger side). Lift design cover on side point towards intake manifold until it snaps out of mounting bosses. (Scheme 10) Lift design cover on the front edge and slide the ignition coil cover of the second cylinder out of the torque support bracket. Pull off the cover to the front. Repeat this procedure for cylinder Nos. 5-8 bank (driver side).
8. Disconnect PCV hoses from both valve covers. To do this, press the plastic ring and pull the connections. (Scheme 11) Remove the PCV hose from the retaining clip. Remove vent line between intake distributor and oil separator.
9. Disassemble line between oil mist collector and the intake manifold. (Scheme 12) Separate fuel line on plenum panel. (Scheme 13)
10. Disconnect harness connectors from fuel injectors. Remove bolts securing intake manifold, in sequence as shown. (Scheme 14) Remove intake manifold.

Scheme 12

1. Replace intake manifold gaskets.
2. Place intake manifold on engine. Install and tighten screws in 2 stages. See «TORQUE SPECIFICATIONS»(/porsche/cayenne-s/i-2002-2007/remont/starter/#starters__torque-specifications). (Scheme 15) Continue installation in reverse of removal procedure.

Scheme 13

Scheme 14

Scheme 15

1. Disconnect and isolate battery cables. See «SERVICE PRECAUTIONS»(/porsche/cayenne-s/i-2002-2007/remont/starter/#starters__service-precautions). Battery is located below driver's front seat. Remove front and rear engine guards. (Scheme 16) Open press studs (arrows) and remove heat insulation cover, for starter solenoid switch. see scheme 17
2. Pull off protective cap for battery cable terminal, on starter solenoid. Disconnect battery cable and wiring terminals from starter solenoid.
3. Remove screw securing harness holder. Turn holder slightly, and remove. Remove starter bolt from transmission side. see scheme 18 Remove bolt securing transmission oil cooler lines retainer. Gently pull retainer in a downward motion. Remove starter bolt, from engine side. Rotate starter, if necessary and remove.
4. To install, reverse removal procedure. Tighten all fasteners to specification. See «TORQUE SPECIFICATIONS»(/porsche/cayenne-s/i-2002-2007/remont/starter/#starters__torque-specifications).

Removal & Installation (4.5L V8)

Note. Starter motor for 4.5L V8 is located on top of engine, under intake manifold.

Scheme 16

1. Disconnect and isolate battery cables. See «SERVICE PRECAUTIONS»(/porsche/cayenne-s/i-2002-2007/remont/starter/#starters__service-precautions). Battery is located below driver's front seat.
2. Remove intake manifold. See «INTAKE MANIFOLD»(/porsche/cayenne-s/i-2002-2007/remont/starter/#starters).
3. Remove nuts from starter solenoid switch terminals. Remove wires, and set aside. Remove starter mounting bolts. Remove starter. see scheme 19
4. To install, reverse removal procedure. Tighten all fasteners to specification. See «TORQUE SPECIFICATIONS»(/porsche/cayenne-s/i-2002-2007/remont/starter/#starters__torque-specifications).

OVERHAUL

Information not available from manufacturer.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

WIRING DIAGRAMS

See STARTING/CHARGING SYSTEMS in appropriate SYSTEM WIRING DIAGRAMS article.

Poses Online

See also:
• DISABLING/ENABLING ELECTRONIC LEVEL CONTROL
• TORQUE SPECIFICATIONS
• SERVICE PRECAUTIONS
• INTAKE MANIFOLD