Cayenne S 2007-2010 (957) High Pressure Fuel Pump (HPFP) Replacement DIY - Dorkiphus.net
Navigation » Dorkiphus.net > Technical & Track Disussions > Porsche Technical Discussions » Cayenne S 2007-2010 (957) High Pressure Fuel Pump (HPFP) Replacement DIY

Porsche Technical Discussions Porsche related technical discussions and questions go here.

Reply
 
Thread Tools Display Modes
  #1  
Old 11-12-2014, 12:15 AM
987kmns's Avatar
987kmns 987kmns is offline
 
Join Date: Jul 2012
Location: Annandale, VA
Posts: 293
987kmns has five HoF threads987kmns has five HoF threads987kmns has five HoF threads987kmns has five HoF threads987kmns has five HoF threads
Hall of Fame Cayenne S 2007-2010 (957) High Pressure Fuel Pump (HPFP) Replacement DIY

My 2008 Cayenne S with 96,000 miles has been exhibiting fuel system issues. The problems started with long crank intervals and continued with loss of power, rough running, and eventually going into limp mode. Using my Durametric tool and the "actual values" menu I determined that the issues pointed to the HPFP. I compared the "fuel high pressure set point" and "fuel high pressure actual value" measurements and noticed that (1) at idle the car will require about 40 bar while the system was generating around 5.5 bar and that (2) the actual pressure value was unable to follow the set point value as throttle was applied. At full throttle the car will require about 120 bar, while my car was struggling to put out 20 to 30 bar. Also worth noting is that the low pressure fuel system (2 in-tank pumps) is supposed to supply a nominal pressure of about 5.5 bar. In other words, my high pressure system eventually failed completely and the car was simply running (poorly) on the low pressure system alone. Others here have had similar symptoms leading to the replacement of the HPFP. Following is a DIY replacement of the HPFP. I took the DIY route because Porsche will charge about 4 to 5 hours of labor for this job, which is actually reasonably simple for a DIYer. I sourced a remanufactured HPFP with an updated PN from Suncoast Porsche. There is a $90 core for the old pump and the total cost was around $850 after returning the core.
__________________
Mihnea

2007 Cayman S Track Car
2004 911 GT3
2016 Cayenne S
2017 Macan S

2008 Cayenne S - Sold
2011 Boxster S - Sold
2007 Boxster S - Sold
2001 Boxster S - Sold
Reply With Quote
  #2  
Old 11-12-2014, 12:29 AM
987kmns's Avatar
987kmns 987kmns is offline
 
Join Date: Jul 2012
Location: Annandale, VA
Posts: 293
987kmns has five HoF threads987kmns has five HoF threads987kmns has five HoF threads987kmns has five HoF threads987kmns has five HoF threads
Default

Here are some step-by-step DIY instructions:

Remove the driver's side and rear engine bay cowling. Twist the plastic fasteners 90 degrees and they will pop out. Use a T25 torx to remove the two torx screws securing the rear cowling piece to the side pieces. Here is the engine bay with the cowling removed.

Name:  IMG_3243.jpg
Views: 10541
Size:  900.3 KB

The pump is located on the back of the driver's side engine head.

Name:  IMG_3244.jpg
Views: 8112
Size:  482.8 KB

There is a triangular metal shield behind the pump that needs to be removed first. It is number 16 in the diagram below. It's held in place by three 10mm bolts, number 17 in the diagram.

Name:  HPFP Diagram.png
Views: 8011
Size:  47.8 KB

The photo shows what you can actually see, looking at the engine. Indicated are some items that will make life easier if removed.
Name:  IMG_3245.jpg
Views: 8495
Size:  591.0 KB

Here is the shield, finally removed.

Name:  IMG_3247.jpg
Views: 7878
Size:  547.3 KB

I then removed one of the torx bolts for the engine hoist hook and zip tied it out of the way to give myself more room.

Name:  IMG_3250.jpg
Views: 8512
Size:  567.9 KB

Next, it's time to undo the high pressure fuel line going to the fuel rail.

Name:  IMG_3252.jpg
Views: 8564
Size:  662.9 KB

Now, remove the three bolts securing the pump to the block. Two of them are really long (labeled number 14 in the diagram above) and one is short (labeled number 13 in the diagram above). Leave number 15 alone as it does not go through the pump housing. All three are 10mm. Here is what the long ones look like.

Name:  IMG_3248.jpg
Views: 7723
Size:  889.4 KB

It's time to remove the pump. Jiggle it back until it comes out of the block. I don't have a picture of the electrical connector, but once the pump is free of the block, turn the pump until you can see the connector and undo it. You'll have to lift on a tab to free the connector. The low pressure fuel hose feeding the pump is flexible and can be removed after the pump is out. Here is the removed pump.

Name:  IMG_3253.jpg
Views: 9644
Size:  988.7 KB

And the low pressure line free.

Name:  IMG_3254.jpg
Views: 7786
Size:  875.4 KB

This is how all the parts are laid out. The three shield bolts screw into the top of the long pump bolts, which are threaded at the top.

Name:  IMG_3262.jpg
Views: 9604
Size:  1.04 MB

Prior to reassembly, it is important to determine whether the HPFP "clutch" has fallen off the end of the camshaft or not. The diagram below will help clarify the design. Number 5 in the diagram is the "clutch" while number 6 is a plastic stopper that is supposed to keep the clutch attached to the camshaft.

Name:  Camshaft Diagram.png
Views: 7944
Size:  147.0 KB
Name:  Camshaft PNs.png
Views: 7452
Size:  16.0 KB

In my case, the plastic stopper had fallen apart and allowed the clutch to fall off and down into one of the underbody linings. I failed to notice this during the disassembly process and proceeded to install the new pump without the clutch. Unfortunately, the camshaft will not drive the pump without the clutch, so I had to redo the entire procedure, but first I had to purchase a new stopper.

Name:  IMG_3272.jpg
Views: 7643
Size:  487.7 KB

Here is the stopper and clutch together, as they should be attached to the camshaft.

Name:  IMG_3273.jpg
Views: 7797
Size:  574.7 KB

FOR NEXT STEPS PLEASE GO TO PAGE 4, POST #40.
__________________
Mihnea

2007 Cayman S Track Car
2004 911 GT3
2016 Cayenne S
2017 Macan S

2008 Cayenne S - Sold
2011 Boxster S - Sold
2007 Boxster S - Sold
2001 Boxster S - Sold

Last edited by 987kmns; 01-30-2018 at 09:31 PM. Reason: Editing photos.
Reply With Quote
  #3  
Old 11-12-2014, 08:28 AM
ausgeflippt951's Avatar
ausgeflippt951 ausgeflippt951 is offline
Shock Whisperer
 
Join Date: Mar 2012
Location: Atlanta, GA
Posts: 3,261
ausgeflippt951 has one HoF thread
Default

Great writeup, as always.
__________________
Collin M.
I wear a cowboy hat.

'86 951: lucky number 13...rare 6.0L edition.
'06 M3: hers.
Reply With Quote
  #4  
Old 11-12-2014, 08:46 AM
N0tt0N's Avatar
N0tt0N N0tt0N is offline
 
Join Date: Sep 2013
Location: DC
Posts: 4,741
N0tt0N has five HoF threadsN0tt0N has five HoF threadsN0tt0N has five HoF threadsN0tt0N has five HoF threadsN0tt0N has five HoF threads
Default

Nice job! Thanks for sharing!
__________________
Martin
2011 Cayman S (Gone) - Hardtop Blechster
2006 Cayman S (DD)
2016 Mazda CX-5 (Her DD)
2002 Boxster S (Gone) - Ragtop Blechster - Pura Patina!

Dorkiphus: I buy it for the articles
Reply With Quote
  #5  
Old 11-12-2014, 09:23 AM
BlackTalon's Avatar
BlackTalon BlackTalon is offline
Make Dorki Great Again
 
Join Date: Dec 2002
Location: Alexandria, Virginia
Posts: 14,792
BlackTalon
Default

Nominated for HOF
__________________
David D.
'87 Targa

- 2021 quickly disappearing...
Reply With Quote
  #6  
Old 11-12-2014, 09:42 AM
Dr K's Avatar
Dr K Dr K is offline
Colorado's finest
 
Join Date: Apr 2005
Location: Montgomery County, MD
Posts: 16,150
Dr K has two HoF threadsDr K has two HoF threads
Default

Excellent write-up, photos, and labeling!

HOF?-->Thanks, Jazz.
__________________
Peter (not "Pete") K.

2016 Cayman S
1999 Miata ("SM") race car
2016 Toyota Highlander--tow vehicle/wife's DD
2017 VW GTI SE (DD)

Gone and missed:
1992 Miata ("SSM") race car
2009 911 C2S Coupe
2004 Toyota Prius - sold to son's girlfriend
2006 Dodge Durango
2003 Acura MDX
86 Black 911 Coupe race car
86 Gold 911 Targa
82 WineRedMetallic 911 Targa

Last edited by Dr K; 11-12-2014 at 02:15 PM. Reason: HOF granted!
Reply With Quote
  #7  
Old 01-16-2015, 11:20 PM
personalt personalt is offline
 
Join Date: Jan 2015
Location: nj
Posts: 1
personalt
Default

can you tell me what value you read to get the high pressure value. I have a 2009 base and dont see any values about the fuel pump pressure.

Quote:
Originally Posted by 987kmns View Post
My 2008 Cayenne S with 96,000 miles has been exhibiting fuel system issues. The problems started with long crank intervals and continued with loss of power, rough running, and eventually going into limp mode. Using my Durametric tool and the "actual values" menu I determined that the issues pointed to the HPFP. I compared the "fuel high pressure set point" and "fuel high pressure actual value" measurements and noticed that (1) at idle the car will require about 40 bar while the system was generating around 5.5 bar and that (2) the actual pressure value was unable to follow the set point value as throttle was applied. At full throttle the car will require about 120 bar, while my car was struggling to put out 20 to 30 bar. Also worth noting is that the low pressure fuel system (2 in-tank pumps) is supposed to supply a nominal pressure of about 5.5 bar. In other words, my high pressure system eventually failed completely and the car was simply running (poorly) on the low pressure system alone. Others here have had similar symptoms leading to the replacement of the HPFP. Following is a DIY replacement of the HPFP. I took the DIY route because Porsche will charge about 4 to 5 hours of labor for this job, which is actually reasonably simple for a DIYer. I sourced a remanufactured HPFP with an updated PN from Suncoast Porsche. There is a $90 core for the old pump and the total cost was around $850 after returning the core.
Reply With Quote
  #8  
Old 01-16-2015, 11:52 PM
87turbolook911's Avatar
87turbolook911 87turbolook911 is offline
 
Join Date: Feb 2003
Location: Clarksville, MD
Posts: 2,702
87turbolook911
Default

Subscribed
__________________
Vu
It's not just the cars...It's the people!
Reply With Quote
  #9  
Old 01-17-2015, 09:35 AM
Vicegrip's Avatar
Vicegrip Vicegrip is offline
Porkchop & SGB for prez!
 
Join Date: Jan 2003
Location: The other Woodstock.
Posts: 13,238
Vicegrip has seven HoF threadsVicegrip has seven HoF threadsVicegrip has seven HoF threadsVicegrip has seven HoF threadsVicegrip has seven HoF threadsVicegrip has seven HoF threads
Default

Thanks for the great writeup. Based on what I have been hearing it looks like this repair will not be uncommon.
__________________
http://vimeo.com/29896988

“Those that can make you believe in absurdities can make you commit atrocities.” Voltaire.

"There is grandeur in this view of life...." Darwin.

The mountains are calling and I must go.

“The earth has music for those who listen”
Shakespeare.

You Matter.
(Until you multiply yourself times the speed of light squared. Then you Energy)

“We’ve got lots of theories, we just don’t have the evidence’.
Reply With Quote
  #10  
Old 01-17-2015, 10:25 PM
987kmns's Avatar
987kmns 987kmns is offline
 
Join Date: Jul 2012
Location: Annandale, VA
Posts: 293
987kmns has five HoF threads987kmns has five HoF threads987kmns has five HoF threads987kmns has five HoF threads987kmns has five HoF threads
Default

Quote:
Originally Posted by personalt View Post
can you tell me what value you read to get the high pressure value. I have a 2009 base and dont see any values about the fuel pump pressure.
I used my Durametric tool to connect to the DME and clicked on the "Actual Values" menu under the Engine Management tab. If you scroll through the list (there are lots and lots of different sensor readings) you will see both "Fuel high pressure set point" and "Fuel high pressure actual value". Check the selection box next to these values and they'll be displayed at the bottom of the screen. The setpoint is what the DME is requesting from the pump and the actual value is what is being delivered.
__________________
Mihnea

2007 Cayman S Track Car
2004 911 GT3
2016 Cayenne S
2017 Macan S

2008 Cayenne S - Sold
2011 Boxster S - Sold
2007 Boxster S - Sold
2001 Boxster S - Sold
Reply With Quote
Reply

Thread Tools
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off

Forum Jump