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diceman
Newbie


Joined: 24 Sep 2018
Posts: 21



PostPosted: Sat Dec 21, 2019 10:16 pm    Post subject: Starter cable replacement - help required Reply with quote

Having suffered an alternator failure i've decided to do some routine preventative maintenance in the form of alternator, starter cable, AOS, coil packs and probably the tandem pump.

I'm just starting to refit the starter cable but have fears that one of the cables that connects at the gearbox terminal block has failed :-(

The primary connection is to the main battery cable to the front of the car but the secondary cable (the one that's potentially failed) goes up through the floor of the car around the rear seat area.

Now my questions: -
1) Should the terminal swivel on the cable here or has the crimp to wire failed?
(It won't pull off but rotates).
2) does anyone know what it goes to, if there is a part of the loom I can look up and order or if I may get away with getting my hydraulic crimpers on it?
_________________
2005 997 C2S Manual - Midnight Blue
2003 E46 M3 Manual - Silver
1991 Celica ST185 RC - Grey
 



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Luddite
Montreal


Joined: 18 Dec 2018
Posts: 539
Location: Scotland


PostPosted: Sun Dec 22, 2019 8:39 am    Post subject: Reply with quote

diceman, I have never as much as touched a 997, though have a measure of electrical experience... I suspect if that terminal acts as you typed I would be stripping back the insulation to have a look and no doubt follow that up with replacing the terminal with a new one, given you have access to a crimping tool.... If you just re-crimp it it is possible/probable that you will get away without issue.... BUT... ?

As for the crimped termination rotating.... Consider if you left that nut connecting all three lugs even fractionally loose , I suspect it would initially create a resistance when under load, that resistance would generate heat/voltage drop, that heat would cause burning, the burning would increase the resistance and cause more burning/voltage drop, the very situation you are trying to avoid with your pre-emptive maintenance..?

Good luck in your choices..
 
  
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diceman
Newbie


Joined: 24 Sep 2018
Posts: 21



PostPosted: Sun Dec 22, 2019 9:27 am    Post subject: Reply with quote

Thank you for your response.

I know you are right. It needs investigating more and fixing properly regardless of what it serves. I'd kind of hoped I could get away with it short-term; if somebody said "oh it's the power feed to the bose sub amp" I'd have left it for now and dealt with in a couple of weeks.

It's MOT time 3rd Jan so I need the car complete before then to give it a test run and clean up discs etc and it seems to be fighting me!

I'll have a look and check to see what size die sets I have for the crimper and diameter of glue lined heatshrink I have here. I doubt I'll get any delivery of bits if I need them.
_________________
2005 997 C2S Manual - Midnight Blue
2003 E46 M3 Manual - Silver
1991 Celica ST185 RC - Grey
 
  
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deMort
Dijon


Joined: 21 Mar 2015
Posts: 7721
Location: Brighton


PostPosted: Sun Dec 22, 2019 5:11 pm    Post subject: Reply with quote

1/ It sounds like the wire has broken inside the terminal .. a new terminal will be required .

2 / The feed is for the fuses / relays for the heated rear screen and the engine compartment blower fan .
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diceman
Newbie


Joined: 24 Sep 2018
Posts: 21



PostPosted: Mon Dec 23, 2019 8:53 am    Post subject: Reply with quote

That's fantastic. Many thanks deMort.

So non-critical items short-term if time stipulates I must do it in a couple of weeks. (Although I see that the fuse/relay board also serves the secondary air-pump so emissions for MOT may be compromised).

I've ordered a new terminal of hopefully the right size as the ones I have are all 10mm hole!

Big thank you for your help Smile
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2003 E46 M3 Manual - Silver
1991 Celica ST185 RC - Grey
 
  
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deMort
Dijon


Joined: 21 Mar 2015
Posts: 7721
Location: Brighton


PostPosted: Mon Dec 23, 2019 6:01 pm    Post subject: Reply with quote

The feed seems to be only the blower fan and the heated rear screen .. the secondary air pump takes its feed direct from the starter motor main feed .

The blower fan for the engine is needed though so i wouldn,t run it for too long without this working .

Secondary air is only used for fast warm up and as such has no bearing on an mot test other than if it triggers an EML .
_________________
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My Daughter's Crowdfunding has hit the target .

Thank you all so Very much .

She's not going until july 2020 though .



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diceman
Newbie


Joined: 24 Sep 2018
Posts: 21



PostPosted: Tue Dec 24, 2019 8:40 pm    Post subject: Reply with quote

Thank you deMort,
I'd assumed the air pump was a modern incarnation of EGR but I should have engaged brain as the M3 operates similar to the 997.

Anyway, I've started now so no going back! The cable had indeed sheared at the terminal. I assume it's a combination of corrosion and work hardening of the cable as there is no form cable restraint to prevent excessive movement around the entry to the terminal point. Removal of the heatshrink resulted in the terminal coming away.

New terminal purchased and arrived and I'm cleaning the cable ready for a new crimped terminal and glue lined heatshrink. Once fitted it will be coated with dielectric grease and a good dose of ACF50 shoved up it's innards.

I can't say I'm impressed with Porsche build quality so far, there was excessive corrosion on the nuts, terminals and cables on all ends of the starter cable. All parts are being replaced and I'm adding further protection over standard. I'm currently undertaking a rolling restoration of a 1991 Celica GT4 Carlos Sainz and the electrics and bolts have survived far better even though they are twice the age & miles. My 997 has never lived by the sea (a pre-purchase requirement having been bitten before!)

You've been a massive help, thank you.
_________________
2005 997 C2S Manual - Midnight Blue
2003 E46 M3 Manual - Silver
1991 Celica ST185 RC - Grey
 
  
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Luddite
Montreal


Joined: 18 Dec 2018
Posts: 539
Location: Scotland


PostPosted: Wed Dec 25, 2019 11:07 am    Post subject: Reply with quote

Diceman, first off thanks for coming back with the all important update to help others understand and resolve any similar issue...

As for your assessment of Porsche quality.... yeah a great pity... I tuned into Porsche engineering standards many years back, a time when I considered them to be no more than souped up Beetles, though when I first put a spanner to my then rusted out 912`s engine expecting the fixing to break... it unscrewed.. as did everything else I touched...Changed days it seems, and not just from that which you have typed, I have been on this forum for perhaps a year looking to update my Porsche education, and it seems to me that Porsche priorities have altered with the passage of time, whereas mine may not have moved with the times...(-:

I had the hots for a 997.1 at 911 V last Christmas which sold before I could declare interest, and having spent time on here, I am leaning towards a 3.2 Carrera, in the hope that which I admired in Porsche might be found again.... but any 3.2 is an old car now, and an old SPORTS car at that... hmm..!

Sorry, I rambled off a tad.... though at least you are a bit more in tune with the realities of the expectations you should have relative to Porsche..err..quality in terms of that which it seems might be considered as engineering basic ideals, and fortunately for you, it was your own preventative maintenance ideals that have caused you to avoid and inconvenient breakdown or worse... well done.. Thumb

DeMort…. worth his weight in gold... worship worship
 
  
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deMort
Dijon


Joined: 21 Mar 2015
Posts: 7721
Location: Brighton


PostPosted: Fri Dec 27, 2019 8:57 pm    Post subject: Reply with quote

@ diceman ..

I think when you have worked on the shear number of cars i have then you would realise these ain't so bad .. rare to get body corrosion .. only Volvo and i can say the same .

Yes these cars have issues and i realise the price is not that of a ford .. but i can only say .. after many years of many different makes .. these aint bad .

I am somewhat biased though lol .

Your problem is not one i have come across .. and i've done a few but like any car .. sods law applies .. a fairly simple fix though

I must say though .. hats off .. starter cable replacement is not the easiest job in the world . Thumb
_________________
.
My Daughter's Crowdfunding has hit the target .

Thank you all so Very much .

She's not going until july 2020 though .



Mechanic

7pm - 9pm

Indy Mechanic .
 
  
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