04 CS Starter Removal. Is it possible without pulling the coolant pipe

[sgearyman]

I just had the aluminum coolant pipes put on my 04 CS.

The starter bendix arm has now started to stick on occasion (no doubt due to leaking coolant) and I want to replace the starter.

I do NOT want to pay for all that labor again so I have decided I want to DIY this.

I am looking at HD pics of the engine with the air intake removed and the aluminum coolant pipes on.

I THINK, at least I HOPE that I can pull the starter without removing those coolant pipes.

there appears to be just barely enough room to yank that starter out between the coolant pipes and engine.

can anyone that's done a starter replacement confirm this please?? I plan on tackling this once it warms up a bit outside.

any input is appreciated.

[Loren]

Air intake and fuel distribution pipe should be all you need to remove.

[PTEC]

Yes it is 100% possible but its an extremely tight fit.

[seankrider]

I just did mine while tackling several other fixes in the neighborhood, including the water pump thermostat.

It can definitely be done with out touching the larger single aluminum pipe, so I assume you're talking about the three smaller aluminum pipes in one cast piece? It must be possible since the pipes are kinked for no good reason other than to allow access. But the access looks very difficult. I thought removing the bolts was a challenge even with pipes out of the way.

A good alternative would be to remove the cover to the thermostat housing in the front, where the three metal pipes connect. Eight bolts, and disconnect the two rubber hoses to the radiator. Also one bolt on the little metal pipe that runs into the front of the thermostat housing, which is easier to remove if you disconnect the bracket holding it to the block near the oil dipstick.

Then on the other end of the three coolant pipes, unfasten the top half of the black plastic housing and you can hinge the whole assembly upward and hang while you do the job. Probably 10 extra minutes of effort.

If you go this route, you'll also want to replace the metal seal and plastic gasket on the thermostat housing (~$10). And be prepared to catch any coolant that leaks out when you pull the rubber hoses off the front. And while you're there, no better time to do the thermostat.

[sgearyman]

Thanks to everyone for the replies! I am going to try to tackle this when it warms up a bit.

[sgearyman]

Anyone know the order and torques for the bolts on the air intake manifold?

[sgearyman]

Anyone on here actually done a starter removal?

[Stoney]

Old post I know, but did you ever manage to remove the starter without taking off the three coolant pipes?

[Ricky1]

2005 CS:

 

Just got starter replaced.  Factory Porsche Service changed me time for "disconnecting the coolant pipes under manifold for access to starter" and also charged me for "vacuum fill cooling system" and charged me for the coolant itself.

 

But maybe they could of done it without removing the coolant pipes, ie. just want to make more money off of me.  (For what its worth).  Yes, I too am curious  Sgearyman replaced the starter without removing the coolant pipes.

[clarksongli]

2005 CS:

 

Just got starter replaced.  Factory Porsche Service changed me time for "disconnecting the coolant pipes under manifold for access to starter" and also charged me for "vacuum fill cooling system" and charged me for the coolant itself.

 

But maybe they could of done it without removing the coolant pipes, ie. just want to make more money off of me.  (For what its worth).  Yes, I too am curious  Sgearyman replaced the starter without removing the coolant pipes.

literally just did this a few days ago....it does come out with all coolant pipes in.

 

after unbolting it, slide the starter back and pull the motor end up about 45 degrees.  rotate the starter clockwise and sort of jiggle and pull and turn.

[Ricky1]

Good to know... fortunately my remaining 3rd party warranty covered replacement of a starter... but not everything... eg. Charged for manifold seal, coolant refill.

CLARSONGLI, when was the last time you replaced the starter? Where did u buy yours and how much if you dont mind me asking... thanks.

Edited December 5, 2015 by Ricky1

[clarksongli]

150 bucks from rock auto.  Bosch.  Replaced it maybe a week ago?

 

Honestly, #1 cost savings.....DIY.....even the starter, which is relatively a pain, is very basic in mechanical skills.  Essentially 1 socket, 1 torx bit, and some extensions and you're good.

 

My Cayenne, total has probably cost me 3k in repairs in going on 6 years? And that includes coolant pipes, radiator fans, fuel pumps, etc.

 

#2 cost savings.....Cross Reference PNs.  Every since site you will visit will say cayenne parts don't cross with anything.....if you do some digging, you will find the cayenne shares nearly every part with some other car (touareg/Q7 mostly).  Hell did you know our radiator fans are shared with a Ford?

 

Glad you got it fixed.