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Old 09-08-2017, 07:06 AM   #1
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Progress report

I was back in the engine compartment a couple of days ago and found the check valve that plugs into the rubber inlet manifold was not very tight, no barbs on it to hold things in place. I had found this one disconnected a week ago and it is the main vacuum source.

I bought some barbed 3/16 brass fittings and and inserted that into the hole and used high temp silicon tubing to connect it to the "Y" fitting. Also put in a barbed fitting going into the "Y". I plan to work my way through the vacuum lines and put in these better materials in place of the rubber that is deteriorating.

high quality silicon tubing is so much better than the rubber that Porsche used.

No SAI codes for a day or so, so I am going to run the route and try to get in for a smog test today or tomorrow.

Last edited by boxfix; 09-08-2017 at 07:10 AM.
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Old 09-08-2017, 07:26 AM   #2
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Vacuum leaks are hard. I chased one in my 01S for a year. Replaced lines and valves to no avail. It turned out that the reservoir itself had a small crack. CEL has been off ever since.
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Old 09-08-2017, 07:53 PM   #3
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Did 100miles today. No sai codes for first 40 and then they came back.

gotta cure this.

More work.....I have an idea.
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Old 09-26-2017, 07:10 PM   #4
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Well an update.....I was in New England for a while so I have been away from this Boxster project.

I did go 450 miles and go a P0491 and 0492 code. Today I found that the vacuum reservoir was leaking and replaced that. Luckily I had ordered one just in case....they are only $22.

I bench tested the new one and it would hold vacuum.

Plugged the same test rig into the installed reservoir and it would not hold vacuum.

After idling about 10 minutes EVERYTHING but SAI monitors reset. That is pretty cool without driving the car. Will put some miles on it tomorrow.

Also replaced the driver's door window regulator finally and the window works well.......the old one was really fouled up.

Good day.
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Old 09-27-2017, 08:20 PM   #5
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I put 87 miles on the Boxster today and the SAI has not yet reset.

I did more testing on the vacuum system with the new reservoir installed.

I am getting 18" of HG at my 1000 feet or elevation. This appears to be a good reading. I tried this before with the leaking reservoir in there and I was getting like 9 "hg.

I wish I had done this test days and miles ago.

You can get a vacuum gauge for $13 from Harbor freight, and a hand vacuum pump for $25 or so.

I used the hand pump to test the reservoir and the good one would hold 15" hg.

Bad one would not hold any vacuum. I kept the reservoir in place and reached in there with 2 long needle nose pliers to remove the hose on the old reservoir. then I put the hand pump with a long piece of silicone tubing hooked to the old reservoir. Sure enough it would hold no vacuum.

I put on connector on the "Y" fitting and use a long piece of hose to hook the new reservoir into the system.

I disconnected a vacuum line on solenoid for the Triptronic and installed the test vacuum gauge there. I go 17"HG which climbed to over 18" when the car warmed up. That was at 830 idle RPM.

So I feel I have fixed the vacuum leaks. I assume I would not have this much vacuum if I had a leak of any size.

I have replaced every bit of vacuum tubing I can reach with 4mm ID silicon tubing and brass barbed connectors.
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Old 10-02-2017, 05:21 PM   #6
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finally got all the monitors to reset yesterday. Passed CA smog today.

Replacing the vacuum reservoir was the last step. It too 200 miles or so for all the monitors to go PASS on the Durametric.

Lesson learned......put a vacuum gauge on the system and make sure you have 15 to 20 " Hg. Then you are in the ball park.

suspect all connections and hoses and REALLY suspect the reservoir......and it only costs $21. Test it with a hand vacuum pump.
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