Finally, I think I have something worthy of reporting. The solution first, then the saga.
Replacing the starter on a
987.2
is not easy because of the lower starter bolt. The 101
Boxster
Projects book (Dempsey) recommends using a long extension (24” ) from the front of the engine (with bulkhead cover removed). It worked, but I had to remove the alternator, loosen the PS pump, and loosen the AC compressor. It was a major hassle and it stretched over 2 days.
The Solution
: As explained below, I had to go back in and install a new starter. This time I simply removed the secondary air pump and was able to replace the starter with a lot less hassle. I didn’t have to access the front bulkhead or disturb the alternator, PS Pump or AC compressor. Still, it took me about 6 hours.
The picture below shows the access with the right-side manifold removed.
The Saga
: I was experiencing intermittent starting (not turning over) that could be rectified by jiggling and/or reinserting the key. I was also throwing Secondary Air Valve codes (P0491 & 492), but that is unrelated. Finally, one morning for work the car wouldn’t turn over even though battery was fully charged. I assumed it was the ignition switch as there is a lot gripping about them on the boards. Some $365+ later, that did not solve the problem.
Next, I had battery load checked and it was fine. Next, was the starter. I spent Saturday and most of Sunday pulling the plenum, and right side manifold, removing the alternator, loosening the PS Pump and AC compressor to get the starter out. The bottom starter bolt is hard to get to. As recommended in the Boxster Project book I accessed it through the front bulkhead with a long extension. While I had it exposed, I replaced the second air valve ($105+). I took the starter to an auto parts store and it passed with flying colors. I reinstalled the old (working) starter and buttoned it up. It fired right up. I drove it Monday through Thursday with no problems, except that the Secondary Air Valve codes returned. Friday morning, it wouldn’t turn over.
I ordered a new starter ($460+, Denso) and looked at a secondary air injection pump ($1,450+, Doh!). Installed the new starter as described above by removing the air injection pump. A lot easier than the first time.
I disassembled the air injection pump and found that the filter media in the pump volute was friable, was coming apart, and seemed to have fouled the motor and impeller (sorry, no pictures as I hadn’t planned on posting). I sprayed the motor, including brushes, with electronics cleaner, and otherwise degreased all parts. I tested the motor with 12v and it spun fine. I didn’t know what to use as replacement filter media (I couldn’t tell what the original filter was). Because the air injection pump sucks in heater air off the top of the motor, I was afraid filter sponge might melt. I considered brass or stainless steel wool but ended up using lawn mower intake filter sponge. I cut it into shape and reassembled the pump. Put everything back together, and it fired right up. The engine turns over so much quicker and better with the new starter, and the Secondary Air Valve codes have not returned.
Hope this can help someone.
