Replacing The Fuel Pump In Your 2009 Porsche Cayenne Turbo

The fuel pump in your Porsche Cayenne is not a matter of 'if' it will fail, but 'when'. The fuel pump is one of the most important components in your car, and when it fails, your car will not start. Therefore, it is important to know how to change it yourself.

The fuel pump in your Porsche Cayenne Turbo 2009 is located in the engine bay, on the driver's side, and is driven by the camshaft. It is a difficult task to replace the fuel pump as it is in a very tight location, and you will be doing most of the job by feel. However, with the right tools and safety precautions, you can replace the fuel pump yourself and save money on labour costs.

Tools Required:

- 10mm wrench

- 14mm flared nut wrench

- 17mm wrench

- Crowfoot wrenches

- Fire extinguisher

Step-by-Step Guide:

1. Remove the belly pans/plastic under trays and the plastic coil pack cover (4 torx bolts) for easier access and to prevent tools from falling into the engine bay.

2. Disconnect the battery and remove the fuel pump control unit fuse (number 13 fuse) in the engine bay fuse box to cut power to the fuel pumps.

3. Depressurise the fuel system by starting the car and letting it run until it dies, or by cranking the car a few times for a few seconds.

4. Loosen and remove the low-pressure fuel line from the pump using an 18mm and 19mm wrench. Catch the spilling fuel with a cloth.

5. Remove the three bolts holding the black metal crash panel behind the pump with a 10mm wrench.

6. Disconnect the high-pressure fuel line from the pump to the fuel rail with a 14mm flared nut wrench. Again, catch the spilling fuel.

7. Remove the two hexagon head union nuts and one mounting bolt (all three require a 10mm socket) that hold the pump to the engine.

8. Loosen the wiring harness that runs over the top of the valve cover to create more space for pump removal.

9. Gently pry the pump away from the engine block with a flat-head screwdriver and remove the electrical connector from the pump solenoid.

10. Remove the pump from the engine bay, being careful not to drop the metal coupling (Oldham coupling) that sits between the fuel pump and the camshaft.

11. Prepare the new pump by attaching the low-pressure fuel hose and tightening it to 26 foot-pounds. Ensure an 18-22mm gap between the high and low-pressure hoses.

12. Reinstall the new pump by lining up the Oldham coupling with the camshaft and securing it with the bolts.

13. Reattach the electrical connector, high-pressure fuel line, and low-pressure fuel line.

14. Reinstall the crash panel and all other components that were removed.

15. Check for fuel leaks and clear any fault codes before starting the car.

Disconnect the battery and have a fire extinguisher nearby

Disconnecting the battery is a crucial step when working on a car, especially when working with fuel. Disconnecting the battery will prevent any electrical current from reaching the fuel pump, which could cause a spark and ignite the fuel. This is a safety precaution that should always be taken when working on a car, but especially when working with flammable liquids such as fuel.

It is also important to have a fire extinguisher nearby when working on a car, and even more so when working with fuel. A fire extinguisher will help to put out any fires that may occur while working on the car. It is also a good idea to have a first aid kit nearby in case of any injuries.

When disconnecting the battery, it is important to follow the correct procedure. First, locate the battery. In most cars, the battery is located in the engine bay, usually near the front of the car. Once you have located the battery, look for the negative terminal, which is usually marked with a "-" sign. Using a wrench or socket, loosen the nut that holds the negative battery cable in place. Once the nut is loose, you can remove the cable from the terminal. Be sure to disconnect the negative terminal first, as disconnecting the positive terminal can cause sparks which could ignite any fuel vapors that may be present.

When disconnecting the battery, it is also important to take note of any wires or cables that may be connected to the battery. These wires may be for the car's security system, radio, or other electrical components. Be sure to label or mark these wires so that you can reconnect them properly when you are finished with your work.

• Always wear safety goggles and gloves when working with batteries, as battery acid can be harmful if it comes into contact with your skin or eyes.
• If you are unsure about how to disconnect your car's battery, consult the owner's manual or a trusted mechanic.
• Be sure to have a plan for how you will move or store the battery once it is disconnected, as it can be heavy and awkward to carry.
• Be careful not to drop or damage the battery, as this can cause leaks or short circuits.
• If you are disconnecting the battery to store your car for an extended period, be sure to clean the battery terminals and apply a thin layer of grease or petroleum jelly to prevent corrosion.

Remove the rear seats to access the fuel tank

To remove the rear seats of a Porsche Cayenne, follow these steps:

For 2003-2010 Cayenne models:

• Pull the rear seat cushion up from the front.
• Unbolt the rear seat backs and remove.

For 2011-2018 Cayenne models:

• Tilt the back of the seat all the way forward and then move the seat all the way forward.
• Remove the rear hardware caps with a trim removal tool.
• Use an M10 stubby to remove the rear bolts.
• Move the seat all the way to the rear and remove the front bolts in the same manner.
• Tilt the seat back and you will find an access panel in the carpet for the seat controls.
• Separate the electrical connections.
• Lift the wiring harness out from the push plug.
• Disconnect the airbag connection by sliding the top black locking clip towards the front of the vehicle and then pushing down on the back of the clip to slide the connector back and out.
• Move the seat into the back seat area to get it out of the way to remove the seat belt anchor.
• To fully remove the seat, tilt it on its side and use a trim removal tool to pry off the belt cover on the bottom side of the seat.
• Use a trim removal tool to lift up on the lock out and slide the belt back and off of the anchor on the seat.

Remove the fuel pressure regulator

To remove the fuel pressure regulator, follow these steps:

First, relieve the pressure in the fuel system by removing the fuses for the fuel pumps and running the car until it dies. Disconnect the battery and have a fire extinguisher nearby.

Next, access the fuel tank by removing the rear seats and seat belt brackets. Cut the carpet along the perforation and remove the four 10mm nuts holding the access panel to the floor.

Now, you will need to remove the fuel line connections and the electrical connection to the fuel pressure regulator. Press the tab on the side of the fuel line connections and pull the line off. For the electrical connection, press the tab and pull the connector off.

Finally, loosen and remove the retaining ring that holds the fuel pressure regulator in place. You can use Porsche's special tool T10202 or place a brass tool on the edge of the ring and use a hammer to tap it loose counter-clockwise (do not use a regular screwdriver as it may create sparks).

Be sure to work in a well-ventilated area and have a fire extinguisher nearby when performing this task, as you will be working with raw fuel.

Remove the fuel filter

To remove the fuel filter from your 2009 Porsche Cayenne Turbo, follow these steps:

• Disconnect the battery and have a fire extinguisher nearby.
• Remove the rear seats to access the fuel tank.
• Cut the carpet along the perforation using a razor blade.
• Remove the four 10mm nuts holding the access panel to the floor.
• Disconnect the electrical connector by pushing the tab in and pulling the connector off.
• Press the tab on the fuel line connector and pull it off.
• Loosen and remove the retaining ring that holds the fuel filter in the fuel tank.
• Pull the fuel filter up and out of the fuel tank, carefully moving the hose connections out of the way.

Remove the retaining rings

To remove the retaining rings, you will need to use a brass tool to tap the ring loose counter-clockwise. This is because the fuel vapours are highly flammable, so you must avoid using a tool that could cause sparks. Porsche recommends using their special tool T10202 to do this, but a brass tool will also work.

When re-installing the rings, use a screwdriver to tap the ring clockwise as tight as you can. If you have Porsche's special tool, torque the retaining ring to 140 Nm (104 ft/lbs).

Frequently asked questions