Gen2 HPFP Issue

[Motorhead]

Just thought that I'd flag this up since there's not much happening on this part of the forum.

When I took my CS in for its first service in October, I was informed by the OPC service rep that it would require a high pressure fuel pump replacement due to the fact that a batch of fuel pumps had been identified with "a bearing fault". I hadn't experienced any problems myself but understand that typical symptoms include sluggush start-up and, in the extreme, CEL/Reduced Engine Power warning and limp home mode (if you're lucky!). There are plenty of instances of HPFP failure being reported on various forums for 997/987 Gen2 cars (including our own 997 forum under Technical Articles).

I mention this because the OPC hadn't notified me in advance and, although my car was still under warranty (just!), pump replacement takes about 4.5 hours and the unit costs about £500, so it might be worth checking with your OPC to see whether or not you're affected as I suspect that it's not an official recall. For reference, mine's a MY10 S registered in October 2009.

Incidentally, I had to have the clutch interlock microswitch replaced too - a not uncommon problem I believe on Porsches with "proper" gearboxes..!!

Hope that's of interest.

Jeff

 

[cayman]

Mine is March 2009 and I received a call from OPC Tonbridge three weeks ago about a recall notice which I now know is the fuel pump, one of two I am told, and it's booked in to be done on Wednesday. I did a google search when hearing about this and found nothing, so does not seem to be that well publicised.

 

[Motorhead]

Good luck with that Martin. I suspect that Porsche are adopting a "need to know" policy on this. Just one further point, make sure that you check the coolant level when you've given it a run. The HPFP is driven off the front of the RH exhaust cam (just behind the driver) and is somewhat inaccessible, requiring the removal of some plumbing and a subsequent coolant top-up and bleed - hence the 4.5 hours labour required. Mine was a little low when I checked the next day. Jeff

 

[Scruff]

Reading OPC contacted me a few months ago regarding fuel pump issues. They collected my car replaced fuel pump,no charge My Cayman is May 2009 Regards Mike

 

[chrisH]

Mike, Having read your post, I called Guildford about my Cayman S (June 09) and they said mine is on their list to be done. Assume they use the same fuel pump across all the NA engines then. Maybe a chance to test drive a 991 whilst its being done. Chris

 

[cayman]

Mine was done Wednesday / Thursday and returned after a complimentary wash (always generous) shame that for the return trip it was rain and sleet and they then left it outside so looks very sad for itself. Jeff, I will check the coolent as suggested and hope that they did this before returning it. Martin

 

[Motorhead]

Time to get the bucket out Martin - though I'm not sure how long your black CS will stay clean in this weather..!! Glad you got the pump fixed. Chris - I'm sure that, with the exception of GT3 which uses the race-derived Mezger engine, all the N/A DFI 997/987 series use the same HPFP; hence the reporting of pump problems on 997s, Boxsters and Caymans. In fact, as far as I know they're basically the same engine with bore/stroke variations and bespoke intake/exhaust systems for each type. Interestingly, the 3.4 Cayman S engine uses the same bore and stroke as the original M96/01 engine used in the 996. Jeff

 

[Stevie996]

Does this apply to gen 2 boxsters also?

 

[BrianJ]

I asked my PC and they said my March 09 Cayman S is not subject to the change programme. However, they did say that Porsche keep issuing new batches of cars on which pumps should be changed.

 

[Motorhead]

ORIGINAL: Stevie996 Does this apply to gen 2 boxsters also?

You should check with your OPC Steve, but I suspect that it does. Any vehicle with the DFI engine uses the (mechanical) high pressure fuel pump in addition to the electrical supply pump in the tank. Jeff

 

[topgear253]

My CS May 09 had a 2 year service this year and they did the fuel pump at the same time. I echo what Jeff said, the coolant on mine was way low when they handed it back, it took an entire bottle to get it back which the OPC gave me. Also be wary of a smell of coolant. Mine absolutely stank of coolant inside the car with loads of drying marks all over the interior trim around the engine bay lid. I reckon they had started the engine up without the coolant cap on

 

[chrisH]

How do you check the coolant level on a Cayman after they have replaced the pump? As far as I know there are just the 2 filler tubes, whereas suppose the CS has a coolant bottle. I hope this doesn't mean another visit to the OPC incase they don't top it up to the correct level.

 

[topgear253]

I just looked in the cap and saw that the wasn't any coolant showing, and then kept filling it up until it came up to the level.

 

[chrisH]

I didn't know that the level was supposed to be up to the filler neck and will ask the OPC for a bottle of coolant as you referred to for top-up. Thanks Alex

 

[topgear253]

Just to be specific Chris, it should between the two marks looking down the neck. I found that it sometimes blew some out somewhere if it was to the top mark, but it seemed to settle around half way between the two.

 

[Motorhead]

Alex/Chris, When the OPC replenish the coolant I believe that they use a pressurised supply and bleed the system, which may account for the spillage you noticed Alex (pretty shoddy workmanship there.!). If you have to DIY, I guess that the only way is the tried and tested method: remove the filler cap (carefully), rev the engine for a minute or so and hope for the best..!! By the way, the coolant capacity is about 18 litres (19 litres for the PDK), so a slightly low coolant level isn't a major problem - unless of course you're having to top-up regularly. Jeff

 

[chrisH]

I have never checked it to be honest as I thought it was a filler, not a level to be checked, just like the oil on the Cayman. By CS you mean Cayman S not Carrera S? If they are to give me a top up bottle after changing the HPFP presumably it will be the neat antifreeze stuff to be diluted as I never heard of bottled coolant top-up.

 

[Motorhead]

ORIGINAL: chrisH I have never checked it to be honest as I thought it was a filler, not a level to be checked, just like the oil on the Cayman. By CS you mean Cayman S not Carrera S? If they are to give me a top up bottle after changing the HPFP presumably it will be the neat antifreeze stuff to be diluted as I never heard of bottled coolant top-up.

Yes Chris, I do mean the Cayman S. The smallest coolant container is 1 litre - you can use it neat but I think the standard dilution is 50%. If all's well, you should never need to top-up the coolant but it's always worth checking the level regularly just as you do the tyre pressures - it only takes a minute. Just make sure that you only check the level when the engine's cold. Although there's coolant warning light and warning message displayed if there is a problem, it may be too late if there is a catastrophic loss of coolant.! Jeff

 

[chrisH]

Jeff, Had the HPFP changed yesterday and got to see the old pump they have to send back to Germany. Its quite a major job as they have to drop the engine down one side to access it as well as drain the coolant, waiting 1 hr at least for it to cool down beforehand. I asked about top-up and they said just use water, its the old coolant they put back in anyway as e a pressure system is used to suck it out. Have yet to check level today. Worthwhile to get this recall done as otherwise its not done until the next service is carried out. For me that's not due until May 2013.

 

[Motorhead]

A good job done there Chris although, probably like yourself, I wasn't experiencing any problematic symptoms. Somewhat annoyingly, I was only informed that the pump would be changed when I took her in for the first service and had to leave her for an unscheduled overnight stay. It's an 80-mile round trip for me to the OPC, so I wasn't too pleased..!! As you say, it's quite an awkward job to do on the Cayman. I suspect that the HPFP may be more accessible on a 911 where the engine is at the rear of the vehicle but on the Cayman it's tight up against the rear bulkhead. Jeff