Failed but eventually resolved - see below.
Boxster S 2001 6 speed.
Engine starts instantly, runs smoothly but SAI pump will not run in any key position
. Bench test of pump, fuse, relay is perfect. Pump been given the Krazy K SAI Pump refurb. Thank you K !
This is a problem because I have just completed the engine rebuild and need to get Smog Test to re-register the car. The engine died 10 days after I bought it – 2 years ago !
Following are the diagnostics I did & I hope others with this problem will find them a useful reference. You just need Bentley, Durametric and a simple Multimeter.
I also hope someone way smarter than me will help and
tell me what big mistake I have made !.
It was a Failed connection - see Post 26 following
More diagnostics - basically a no power problem to the SAI pump fuse even when the engine is running or any key position:
1. The wonderful Durametric cable +laptop will operate the change-over valve for the SAI system. In a very quiet environment you can hear it cycle when commanded by Durametric. BUT it fails to operate the SAI pump when commanded in any ignition key position or when the engine is running. The SAI pump never runs so it will not complete it’s “Readiness” for the Smog Test.
I used -
Bentley Service Manual Wiring Diagram EWD 109 Diagram 12. to check the circuit as follows :
2. The OEM Maxi fuse 40 A in the trunk is perfect. The 4 pin 40A Bosch relay in position #10 bench tests perfect . Part # is 0 332 019 156 .
3. In any key position, there is no 12v power at the 40A fuse socket .There is continuity between one conductor of the fuse socket and pin 87 on relay socket.
Do the following test first
But
there is no power at pin 30 of the relay socket with KOEO, nor KOEOff,nor KOEon. So logically the problem is upstream from here ?
There should be power to the #30 socket for the SAI relay with key off ,engine off.
http://www.12voltplanet.co.uk/relay-guide.html
For the sake of completeness I also did a little more testing of downstream wiring :
4. SAI pump wiring - the brown conductor shows continuity to ground (as it should). This is the uppermost terminal on the pump when installed btw.
The red conductor to the SAI pump shows no 12v power in any key position. Neither does it show continuity to ground.
5. There is 12v power at Terminal 30 the main, big "Connecting Point" with the flip top lid in the engine bay.
So here are the upstream tests from the Maxi Fuse to find the break in continuity.
From the wiring diagram EWD 109, Diagram 12 in Bentley, the terminal A2 on the 40A SAI Pump Maxi Fuse in the trunk is supplied from the 'generator'(alternator) Terminal B1. So this is where the problem must be ??
You can not reach the back of the alternator to check this connection ! Could this be the problem? I poked my fingers in between the Intake runners and groped to find loose wires – nothing. But you can’t see in there !
This suspect connection B1 is also connected to Terminal 30 & the starter ,so I assume the connections at the back of the alternator are good also.
The alternator warning light on the instrument panel behaves normally- goes out immediately the engine runs. So surely this means all is good on the back of the alternator?
The diagram shows a mystery connection(?) between the alternator and the Maxi Fuse - “
14 X59” – is this the ignition switch ? I can’t find any explanation in Bentley of 14X59 – anyone know what it is?
This is both embarrassing and disheartening – all the equipment and some diagnostics yet a total failure to locate and rectify a simple continuity problem .
So I am hoping for some helpful advice please.
Unrelated but I’ll mention what else Durametric found:
Misfire on 1,2,3.
Camshaft retard of 2 degrees also on Bank 1. The Ahsai wire pointer mod would have prevented this minor adjustment .And of course Bank 1 on a Boxster is the worst for camshaft adjustment . I am tempted to leave it – at least until I can fix the SAI wiring problem.
Grateful for any help. Thank you.