Mine went really bad this week. During the PPI the mechanic mentioned that mine was sounding loud and was most likely on the way out. It lasted for another 10 months before finally starting the agonizing death.

Starting the car in the morning and hearing the "AWWWWWWWW ZZZZZZZZZ AWWWWWWWWWWWW ZZZZZZZZZ" was a clear sign that pump is about to die.

I got the new one from Pelican parts, here.

The install and removal of the old pump are very easy. It sits in the cage with two 10mm bolts holding it down, and one 10mm nut holding it to side of the car. There is one air hose on the output end of the pump, and one electrical connector at the bottom. Pull out the pump with cage attached.

Pump itself is held to the cage with 3 10mm nuts. This where I am guessing the updated pump differs from my original pump. My original pump had 3 bolts molded in the rubber on the body, and it was attached to the cage with three nuts. The new pump I got had three holes for the bolts only, no bolts came with the pump. I just broke the rubber molded bolts from the old pump and inserted them into the holes on the new pump. Seemed to work fine.

Time for the project is about 15 minutes including clean up. By the looks of it, the entire pump is basically a high volume electric pump like the ones you see at box stores for inflation of mattresses and pool toys. Porsche tax adds the $273 to it.

Old pump with molded rubber bolts already broken off.



New pump installed in the car with molded rubber bolts holding it in from the outside.

 

The rubber covered bolts are anti-vibration mounts. See if you can unscrew the part(s) that is/are left on the old pump they may have a stud on the other side*. If so you can super glue the parts together and it will be almost as strong as the molded bond.

*Like the top row

 

You could take your old pump apart, clean the plates (fan) and grease the bearing so it's ready for next time. If that doesn't fix it at least you got to look at it's guts. KrazyK posted a DIY for this somewhere, Renntech?
found it
http://www.renntech.org/forums/tutor...-sai-easy-diy/

 

The rubber bolts on the old SAI seemed glued to the pump, twisting one is how I broke the first one . I am not sure gluing would work well, as new pump has holes in the areas where rubber bolts would be glued to, so essentially they would be only held by the small strips of glue on the outside. I might try to use some epoxy to fill the holes and the mount the rubber bolts that way.

 

does anybody has a DIY to remove the whole pump system from the engine, just complexity for no reason, especially for a car like mine which is not a daily driver.

 

If you do that, you will also need to reflash your ecu to ROW(European) mapping to compensate for the lack of SAI or you'll throw a code.

 

What did you screw the "Rubber covered bolts" into to hold the new pump to the bracket?

Do the holes in the new pump housing have threads in them?

Did you cut the "Rubber covered bolts" off of a metal disk? If so what holds the disk to the old plastic pump housing?

 

The holes on the pump have threads. The was no metal disk on the old pump, rubber was the part of the pump, or fused directly into the plastic housing. Twisting the rubber things just broke them off at the base.

 

Magnet doesn't stick to the rubber left on the old housing?

 

No, it appeared to be either glued or fused to it. I tried twisting all three off, they just broke off at their base. I suspect that my pump was the OEM pump from the 2002, so it could have been how they made them. Too late to dig for it now to do a more thorough inspection, as it is already dumped.

 

what's a sai?

 

never mind, found it.

 

Must have changed it in 2003. Mine unscrew.

 

I wanted to follow up on this and help future orangutans like myself. After searching around for the Porsche replacement rubber mounts, I took a chance and bought 3 Dorman mounts for BMW/VAG vehicles. They were a perfect fit, thread is 10MM and they thread right into our SAI pump and three SAI nuts can be re-used.

http://www.ebay.com/itm/390888102161...84.m1497.l2649