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By Schnell Gelb
For the 2001 cars there is a very difficult,obscure Secondary Air Injection ( or S.A.I.) "Not Ready" problem. This is also called "Inc" or "Incomplete".
JFP has mentioned this in the past and we've had a few sagas here trying to resolve the issue but none as extreme as this one.
The car shows no MIL/ Check Engine nor any Pending Codes. You won't fail a Smog Test even in California with this problem - your car will be "Declined". Which is nonsense because you won't get a Pass smog test certificate and you'll be unable to get tags for your car. But do pay the invoice !! You will be told by the smog tech to' just drive the car'.
I have been ' just driving' mine for 2400 miles and 20 months. The SAI according to Durametric and Foxwell NT520Pro is still Not Ready or Incomplete. No codes, no pending codes.
The S.A.I. system works perfectly by any diagnosis- O2 sensor voltage ahead of Cats at start up(thanks Ahsai). air flow of SAI pump,exhaust posts in head are clean,all SAI hoses and connectors are new/upgraded.Check valve receives strong vacuum while SAI pump operates. All 4 O2 sensors are new but I am open to replacing them all. Which are the fastest responding brands? NTk, Bosch ,Denso ?
Using an emulator(for diagnostic purposes only) in the O2 sensor circuit makes no difference.
The Referee refuses to test the car insisting it goes to the Porsche dealer for repair. That is a blank check because the Dealer speculates it might need a new ECU ,a new SAI system etc. Really the dealer doesn't want to attempt obscure repairs on an old car. The old techs who understood this problem have retired.
The reflash with ROW option is eliminated because the new (DAD) smog machine will detect the abnormal code and your car will fail for 'equipment tampering"
One option is to get a reflash to stock ,hoping that there may have been some bug fixes in the latest reflash . Is this reasonable ? The ECU is a 2001 original and unmolested.
Another option is to get an Indie with PIWIS to 'force' a Ready status even temporarily and then Smog test immediately. Any recommendations in S.California ?
I have done the Drive Cycle many times. What is unclear is how to prompt the SAI to operate during light load/cruise/2900 rpm - if that is even relevant ? I can do that because I have a plugged aux vacuum line via a Tee to the Check valve and a bypass switch to manually operate the SAI pump.
This thread may be a good spot to document an effective solution to this problem. It affects very,very few 996 and 986 M96 engines so the usual Internet resources are unhelpful. Any ideas/solutions ?
Thanks for any ideas.
2000 Boxster Tiptronic with 113k mi. I recently removed the transmission to deal with another issue, but while doing so some of the brittle SAI hoses cracked and/or became disassembled. I have replaced the cracked lines (i.e. not all of the lines) and reconnected according to the following picture, with the exception that I have a Tiptronic and there is a hose that runs to a changeover valve on the transmission:
I get the typical SAI codes, P0410 (80) and P1411 (208), about every 150mi driven. Otherwise the car drives great...SAI pump is running and holding air as usual.
Presumably, I have something connected incorrectly, possibly with respect to connection to the transmission changeover valve. The one thing I notice different than before removing the transmission is that the car seems to be running cooler than before. I suspect this could be caused by the changeover valve for the transmission as I think it controls the flow of coolant to the ATF cooler (not sure about this and hoping for clarification). The other thing that I don't really suspect, is that the new hoses used do not have the small bulbed end to help with that snap-fit into the intake sleeves.
I have not found a good image showing the SAI hose routing for a 986 Tiptronic, so if anyone knows of one I would be very grateful. I have the Bentley manual which also does not show a Tiptronic-specific diagram for SAI routing.
Any other ideas or does this sound like simply incorrect hose connections?
Many thanks for your input!
So I'm having this issue that is driving me crazy. My SAI (Secondary AIr Injection) and Oxygen Sensor are not reaching "Ready Status"
A little background about my car.
2006 Boxster S 3.2L
FVD Exhaust system
GMS Headers with 200 cell cats - has all 4 O2 sensors attached.
996 throttle body and distribution hose
ECU Tuning Group tune
I had the car up in BC Canada since 2009 (although it is a US car) and had no problems passing the sniffer and obdII tests - both before and after all the mods except for the ECU tune.
I went to get my emissions testing done last week in Texas and failed due to the 2 systems being in not-ready status. I figured it might have to do with the cat delete (ROW) configured in the tune. I sent my ECU back to ETG in California and had them re-flash my ECU in order to re-enable the O2 sensors.
I cleared all codes and figured I would start fresh. I drove the car about 120 miles and attempted to follow the drive cycle mentioned in the forums but it was really tough with the roads out here. Everything is in ready status except for the SAI, and the O2 sensor. I can manually start the SAI using the Durametric system so I would believe the pump is not bad; however, I'm not
sure that I"m hearing the SAI start up when I cold start the engine.
For testing purposes I unplugged my O2 sensors from both bank1 and bank2 and they both threw fault codes which confirms that the ECU tune re-activated my sensors.
I've uploaded a few pictures with the results from a OBDII app as well as the Durametric Software to my Google Drive. I'm not quite sure how to interpret the Durametric Voltage results - especially the negative 50 V and -127V - seems quite odd.
Any help or guidance will be appreciated as I'm out of ideas.
Here’s a quick tutorial on how to fix a P0492 error code on a Boxster 986 / 987 / Carrera 996 / 997.
Error: P0492 – Porsche fault code 208 – Secondary-air system bank 2
Symptoms: no visible symptoms, except for the CEL (check-engine light) being triggered, particularly during cold engine startups with the SAI (Secondary Air Injection) pump running for the first 90 seconds.
Diagnostics: when troubleshooting the P0492 error code, I initially focused my attention on all SAI components located on top of the engine, such as the SAI pump, hoses, solenoids, vacuum hoses and reservoir, etc.
I found it easier to remove all vacuum components and work on a workbench and running individual tests, with the invaluable help of a handheld vacuum tool. I did find the vacuum reservoir had a leak, and one vacuum line was damaged (mostly brittle due to heat / time). Also tested both solenoids with a 12-V DC power supply and then replaced the damaged components with new ones. The CEL was off for a few days, but it came back on, throwing the same error code.
With great help of Ahsai on troubleshooting the O2 sensors readings during a cold startup cycle (thread here), it looked like the problem was an obstruction in one of the paths used by the SAI pump to blow cold air form the engine compartments into the catalytic converters. And because I didn’t wanted to work on my car during the cold season, I parked the project for the winter and lived with the CEL on for many months, certainly one of my joys in life ;)
Solution: When the first nice spring days finally arrived, I used the opportunity to do this and other maintenance jobs in my car, like deep cleaning after the winter season (It’s my all-year-round daily driver), two axle rebuild job, etc.
With regards to the exhaust manifolds removal procedure, where a broken bolt can quickly become a nightmare, I had already done some prep-work on all manifold bolts: driving the car until reaching running temperature, quickly jacking-up the car and loosen all exhaust bolts while still hot, thoroughly cleaned, anti-seize and remount. This method, while not everyone’s cup of tea, ended up being quite effective in my case.
And when I finally removed both exhaust manifolds, where I was originally expecting lots of carbon buildups, I instead found a soft clay-like product (oil?), which was quite easy to remove with a finger nail (through the gloves, of course ;).
I thoroughly pressure-washed all components, carefully avoiding to send the water jet directly into the exhaust valves / catalytic converters and the use of any degreasers. A 2,000 psi electric pressure-washer with a 10 degree spread nozzle can be extremely effective, particularly at short distances. Attached is a picture of the engine block after the pressure-washing job.
Finally, a grey Scotch-brite, well lubricated in oil, for mirror-like surface finishes (well, in most cases). It honestly looked amazing… too bad I forgot to take a picture… my apologies.
Finishing-up with another thorough cleanup of all exhaust bolts, a new thin layer of anti-seize and a complete car reassembly, and my P0492 error code is finally gone, hopefully for good!
I've been lurking the forum and have been struggling with some CEL codes with my 2000 Boxster S.
A little history that I have been battling with P1126 and P1133 ever since changing out the two pre-cat O2 sensors.
Then I went ahead and replaced it with a MAF and the car has been code-free for two weeks.
Now the problem is that the SAI monitor is still showing incomplete and I've done numerous cold starts.
I've read many posts in regards to this issue and saw what the "passing" graph looks like from here http://www.renntech.org/forums/topic/49155-secondary-air-test-readiness-monitor-incomplete/?p=272478
Couldn't figure why the SAI monitor never became ready status, I finally got a BT OBD2 reader. This morning, I took some reading of the voltage from the O2 sensors on a cold start.
Could someone here look at a graph and shed some light to my problem?
Should the magenta (B2S2) voltage matches the green (B1S1) sensor? Anything else looks wrong in the graph?