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Old 03-04-2015, 06:39 PM   #1
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Why don't My Secondary Air Injection Components Look Like This?

My 2003 Boxster S Secondary Air Injection Components look nothing like this.



The area circled in red is of concern right now. I have a broken line and I have no idea where it goes to.



Now where the canister is I have a + type plug that connects directly to the canister then the other three connections go off to other points. The connection I have circled in red is broken off from somewhere, but I don't know where it goes to.

HELP!



Sorry the picture is so blurry. Had to use my daughters camera, that I don't know how to use lol. The batteries in my camera are dead.

Thanks!
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Old 03-04-2015, 06:49 PM   #2
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See where mine broke on my 2001 Boxster, it's item #25 in the drawing you attached.

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Old 03-04-2015, 07:08 PM   #3
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The broken line goes a different direction. #25 on my car goes to the same unit, but it's located next to the throttle body. #26 goes to my plenum distribution T rubber coupler.

Daughter just got home and I have better pictures now.




Looks more similar to a 996 secondary air injection setup at the canister.

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Last edited by KRAM36; 03-04-2015 at 07:43 PM.
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Old 03-04-2015, 08:54 PM   #4
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Automatic? Coolant shutoff valve solenoid feed, mounted up by the rear lifting eye?
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Old 03-05-2015, 01:21 AM   #5
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Maybe because you have a tiptronic transmission.


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Old 03-05-2015, 02:09 AM   #6
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Quote:
Originally Posted by MechanicalDan View Post
Automatic? Coolant shutoff valve solenoid feed, mounted up by the rear lifting eye?
It seems to be pointing to something under the plenum on that side.

Quote:
Originally Posted by Smallblock454 View Post
Maybe because you have a tiptronic transmission.


Ok, so that explains why it has the + vs the Y on part #21, but where does that tube go to?
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Old 03-05-2015, 02:35 AM   #7
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This system changed a lot over the years. Make sure you know which version you have. A forum member posted the parts diagram for the 2003 and that's the only way I found it.
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Old 03-05-2015, 04:21 AM   #8
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Got this off a Pelican vacuum hose write up.

air intake/vacuum line routing - Pelican Parts Technical BBS



Quote:
A- Fuel rail
B- Intake rubber sleeve with vacuum port (installed on the right side of throttle body)
C- Fuel pressure regulator on fuel rail
D- Air injection pump valve
E- Electronic vacuum solenoid valve for air injection pump valve
F- Vacuum reservoir
G- Four-way vacuum tee
H- Vacuum check valve (black side points toward the manifold)
I- Three-way vacuum tee (one side is plugged)
J- Electronic vacuum solenoid valve for resonance flap valve
K- Resonance flap valve
L- Intake rubber sleeve with vacuum port (installed on left side of throttle body)
It looks like it goes to E.

So where do I buy the vacuum line from?
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Old 03-05-2015, 06:38 AM   #9
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Quote:
Originally Posted by KRAM36 View Post
... So where do I buy the vacuum line from?
When I replaced my engine that tubing was so brittle, that every time I replaced one section another would break. I ended up using generic flexible vacuum tubing (rubber hose) and connected it with a few pieces of the old tubing that still had some flex without breaking.
Replace it all while you are in there, or you may be back soon.
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Old 03-05-2015, 07:11 AM   #10
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Quote:
Originally Posted by 78F350 View Post
When I replaced my engine that tubing was so brittle, that every time I replaced one section another would break. I ended up using generic flexible vacuum tubing (rubber hose) and connected it with a few pieces of the old tubing that still had some flex without breaking.
Replace it all while you are in there, or you may be back soon.
Thanks, found some on eBay.

Man I can't see that Electronic vacuum solenoid valve at all. Please someone tell me I don't have to remove the Plenum.
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Old 03-05-2015, 07:47 AM   #11
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the silver tube in the top left of the above pic travels into a sai fitting fastened to the engine on the top right of the pic. on the right side of that (ie, behind the vacuum tank in the forefront of the pic on the right side) the solenoid should be fastened to that fitting, as is shown in the pet below:

[/QUOTE]
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Old 03-05-2015, 11:13 AM   #12
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Quote:
Originally Posted by 78F350 View Post
When I replaced my engine that tubing was so brittle, that every time I replaced one section another would break. I ended up using generic flexible vacuum tubing (rubber hose) and connected it with a few pieces of the old tubing that still had some flex without breaking. Replace it all while you are in there, or you may be back soon.
+1 Excellent advice. Now, I just replace it all at once.
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Old 03-05-2015, 11:53 AM   #13
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Quote:
Originally Posted by The Radium King View Post

the silver tube in the top left of the above pic travels into a sai fitting fastened to the engine on the top right of the pic. on the right side of that (ie, behind the vacuum tank in the forefront of the pic on the right side) the solenoid should be fastened to that fitting, as is shown in the pet below:
I can see the the hose from the sai fitting fastened to the engine on the top going to the Electronic vacuum solenoid valve, but the hose disappears before I see it connect into the Electronic vacuum solenoid valve.

Removing the canister I could probably see the Electronic vacuum solenoid valve.
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Old 03-05-2015, 11:59 AM   #14
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Quote:
Originally Posted by Jager View Post
See where mine broke on my 2001 Boxster, it's item #25 in the drawing you attached.

You were right on where it attaches to. I actually have three of these Electronic vacuum solenoids valve on my car.
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Old 03-05-2015, 12:26 PM   #15
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Quote:
Originally Posted by KRAM36 View Post
I can see the the hose from the sai fitting fastened to the engine on the top going to the Electronic vacuum solenoid valve, but the hose disappears before I see it connect into the Electronic vacuum solenoid valve.

Removing the canister I could probably see the Electronic vacuum solenoid valve.
perhaps just remove the plenum and crossover tube for better access?
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Old 03-05-2015, 01:05 PM   #16
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Crossover tubes are already out and the starter is out. The canister is blocking my view and reach to it. Removing the plenum would be a pain in the rear.


.
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Last edited by KRAM36; 03-05-2015 at 01:14 PM.
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Old 03-05-2015, 04:49 PM   #17
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I had to attack it from the passenger compartment and remove the alternator... Not easy but I got there. I also loosened the plenum but did not remove it.

I have gotten better at removing and reinstalling the alternator since this job (I have done it a few times on my friends Boxsters). The trick is to spray the bracket interfaces with penetrating oil and then work the alternator up and down while applying upward pressure to get it off the bracket.
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Last edited by Jager; 03-05-2015 at 05:09 PM. Reason: Added alternator information
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Old 03-05-2015, 06:32 PM   #18
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I ended up moving the canister and right there it was.

JOB DONE!
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