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Alternator cable replacement ongoing. What''s this I''ve f

D5RSR

Well-known member
Joined
18 Aug 2014
Messages
131
Fixing/ replacing the alternator cable as I've got the hot start problem, all going ok, alternator and air con compressor out so far, but I've found a connector/ sensor dangling down. Right hand side between manifolds.
Any idea what it is and where it goes?

Thanks
 

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Thats the engine compartment temp sensor .. should fit into a C shaped hole in the right hand inlet mainifold .

Cant find a 997 picture but its here on a 996
 

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Reply

Thank-you.

Not a lot of room in there, cable nearly out, just can't work out how those 'kin clips come apart.
 
Cable out

Well the cable is out, side cutters saw the clips off.
It doesn't look too bad now I've stripped back the insulation. A bit dark on the solenoid bit. I'll Try a load test on it later this'll week, could just re-shrink it and put it back or while it's off just bang a new one in.

Seen a cable on eBay for £90, anyone seen a better price? What about starter motors? Do I swap it now while it in bits or just try the cable?

Thanks
Darren.
 

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Its the bit of the cable in the connection you cant see that causes the issue .

Lets put it this way .. that black smear looks to me like melted plastic .. so its getting pretty dam hot on cranking which would indicate its faulty .

Also look at the colour of the copper going into the crimp .. its been hot .

Its not a big job to change the starter motor so you dont have to do it now .. but if its original then it will need doing at some point .. it will spin over faster with a new one as well .


Clips ? are they cable ties ? if so then cutting is the only way to remove them .
 
Hot

Yes it is melted plastic and the copper is black indicating heat.
I'll swap it out and see how it goes.

Thanks for your input.

Darren.
 
A voltage drop test end to end on the cable under start conditions is the best way to prove what is wrong if you can get on it that is.
 
:popcorn:
Need to do this myself sometime
 
deMort said:
Thats the engine compartment temp sensor .. should fit into a C shaped hole in the right hand inlet mainifold .

Cant find a 997 picture but its here on a 996

I had this fall out of mine a year or two ago and it was dangling by the manifold and kept turning the engine compartment fan on - used to come on for ten mins after turning engine off even - until I worked out why and found this sensor hanging loose - slotted it back in its housing and constant fan running has stopped.
 
Re: Cable out

D5RSR said:
Well the cable is out, side cutters saw the clips off.
It doesn't look too bad now I've stripped back the insulation. A bit dark on the solenoid bit. I'll Try a load test on it later this'll week, could just re-shrink it and put it back or while it's off just bang a new one in.

Seen a cable on eBay for £90, anyone seen a better price? What about starter motors? Do I swap it now while it in bits or just try the cable?

Thanks
Darren.

Years ago I had the hot start issue your suffering, I changed the cable and that improved it slightly, changed the starter motor and that cured it totally.

It could be either....
 
New cable

New cable ready to go, photo of part number and those b*****d clips for reference.
 

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Aghhhh yes .. the second picture down shows the clip you undo to get the cable out of it then in the center there is a small hole .. you hook the tag in the hole and pull it then you can remove the clip ... some are actually the reverse .. you press it .

I agree though .. they can be a right pain at times .

Good job though , its not the easiest thing in the world to replace .


Just for info .. it cant be done on a tip for any one reading .. its an engine out job on those .
 
Hi Darren.

I'm looking to swap this cable out as I need to pull the alternator anyway. I've had hot start issues since owning the car.

Can you recommend a tutorial or how to guide on how to do it please?

Also does the car need to be up in the air on a 2 poster or ramps, or can it all be done from above through the engine bay?

Thanks for your advice.

Matt
 
Guide

I used this as a guide:

https://www.6speedonline.com/forums/997/289189-3-8s-how-replace-alternator-cable.html

It's accurate and well written, thanks to the author.

I managed it with the drivers rear jacked up on a stand. I could wriggle under to remove the under tray (4 torx bolts) and then get to the connection box.

It's not difficult just a bit awkward getting alternator in and out, the rear bolt of the air compressor and working out the plastic clips. I ended up breaking them off as new ones come on new cable.

Order a new serp belt while your at it (£17 for a Conti Belt off carparts4less)

Cheers
Darren.
 

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