Starter Removal and Installation – 2.5L NA

Overview

This guide outlines the procedure for removing and installing the starter on a Porsche 944 with an 8-valve engine, covering pre-1985.5 (83-85.5) and 1985.5 onwards (86-88) variants. The starter is critical for initiating engine operation, and this procedure ensures its proper removal and replacement to maintain vehicle functionality. Follow these steps carefully to avoid electrical hazards or damage to components.

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Tools Required

• Metric socket set (including 10mm (3/8 inch) and 19mm (3/4 inch) sockets)
• Metric wrench set (including 17mm (11/16 inch) and 19mm (3/4 inch) wrenches)
• Torque wrench
• Jack stands and floor jack or ramps

Parts Required

• Starter (if replacing), 944 604 103 00 (verify compatibility with your model year)

Step-by-Step Procedure

Step 1: Prepare the Vehicle

1. Park the vehicle on a flat surface and engage the parking brake.
2. Raise the vehicle using a floor jack and secure it on jack stands, or drive it onto ramps. Jack stands provide more working space but ramps are acceptable.
3. Disconnect the positive battery lead to prevent electrical hazards. Use a 10mm (3/8 inch) wrench to loosen the terminal.

Step 2: Access the Starter

4. Remove the skid pan (belly pan) from under the engine compartment. Use a 10mm (3/8 inch) socket to remove the M6 bolts securing the pan.

For Pre-85.5 models:

Proceed to the next step, as these models typically do not have a starter heat shield.

For 85.5 Onwards models:

Loosen the two M10 heat shield retaining bolts on the clutch housing using a 17mm (11/16 inch) wrench. Do not fully remove the bolts.
Remove the small nut on the end of the starter using a 10mm (3/8 inch) wrench, then slide the heat shield off the stud on the starter and the retaining bolts.

Step 3: Remove the Starter

5. Disconnect the electrical leads from the starter. Label the leads (e.g., with tape) to ensure correct reconnection.

6. Remove the two M12 starter retaining bolts using a 19mm (3/4 inch) wrench or socket.

7. Carefully pull the starter out of the clutch housing and remove it from the vehicle.

Step 4: Install the New or Refurbished Starter

8. Position the starter in the clutch housing opening, aligning it with the mounting holes.
9. Install the two M12 retaining bolts and tighten them to 45 Nm (33 ft-lbs) using a torque wrench with a 19mm (3/4 inch) socket.
10. Clean the electrical connector posts on the starter and the connectors on the electrical leads to ensure a good connection.
11. Reconnect the electrical leads to their respective posts on the starter, ensuring they are secure.

For Pre-85.5 models:

Proceed to the next step, as these models typically do not have a starter heat shield.

For 85.5 Onwards models:

Slide the heat shield onto the negative post of the starter and the retaining bolts on the clutch housing.

Install and tighten the retaining nut on the negative post using a 10mm (3/8 inch) wrench.

Tighten the two M10 heat shield retaining bolts on the clutch housing to 20 Nm (15 ft-lbs) using a 17mm (11/16 inch) wrench.

Step 5: Finalize Installation

12. Reinstall the skid pan under the engine compartment, securing it with the M6 bolts using a 10mm (3/8 inch) socket. Tighten to 8 Nm (6 ft-lbs).
13. Reconnect the positive battery lead and tighten the terminal using a 10mm (3/8 inch) wrench.
14. Lower the vehicle from the jack stands or ramps.

Post Procedure Checklist

• Verify that all bolts and nuts are tightened to the specified torque values.
• Ensure the electrical leads are securely connected to the starter.
• Check that the battery positive lead is properly connected.
• Start the vehicle to confirm the starter engages correctly and the engine runs smoothly.
• Inspect under the vehicle for any tools or debris left behind.

Sources

• Clark’s Garage
• Pelican Parts
• Porsche 944 Workshop Manuals
• YouTube