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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.
Instrument cluster completely dark and gauges not moving.
How to save $5000 in 3 easy steps.
2002 Boxster S
Here is my story, the problem AND THE SOLUTION.
I have a 2002 Boxster S which was sitting for approximately 6 months unused. As you might expect the battery was dead when I went to use it. It was easy to jump with a portable jumper starter. The car started right up and it was easy to drive. However, when I stopped to get gas, the dashboard instrument cluster went crazy and all the idiot lights came on. Even though I had driven the car for about a half-hour the battery was dead, so being prepared, I use my portable jumper starter. The car started up fine, however all the idiots lights stayed on. The instrument cluster otherwise worked. Drove home, left the doors slightly open so that I would not get locked out, and open the hood so I could get to the battery, then turned off the car. Shortly thereafter drove to get a battery, but now all the idiot lights were on and the instrument cluster was completely dark. Gauges were not moving. Nothing! The battery was replaced while the car was off. After restarting with a new battery, the gauges were not moving, the instrument cluster was dark and now only the check engine/oil pressure idiot light was on. Drove home and turned the car off. However, the check engine/oil pressure idiot light stayed on, even though the car was off. I asked my local mechanic who recommended, "Just take it to Porsche". So I called the Porsche dealer, who could not take the car for a week, but figured it needed a new instrument cluster and after diagnosing fees and the all the other fees and costs would be a few thousand dollars. So, I decided to search the web. I did not find an example exactly like mine, but after my research it seemed that the main computer might have been confused by too many low-voltage signals since the battery was weak. I was sure there had been no overvoltage situations or sparks. I had little to lose, so I thought I'd try the following which worked!
Tools needed: 10 mm socket wrench and portable jumper starter.
Disconnect the negative (black) cable from the battery using a 10 mm socket wrench.
Reconnect the negative (black) cable to the battery using a 10 mm socket wrench.
If needed use the portable jumper starter to start the car.
Smile and save $5000.
The instrument cluster is working perfectly and all the idiot lights are off, even the radio works! Hope this helps someone else!
I have a 2003 Boxster base model (2.7) with auto. Current showing code P0600 and DTE 61. Had a few different Porsche mechanics look at the issue and have not found a solution. Cleaned the electrical connection at the transmission and verified the ground connections at the tiptronic control module. Had the DME, tiptronic module and immobilizer checked and they were found to be working.
Does the Can-bus connection between the DME and the tiptronic module extend to the immobilizer or other modules? All I could find is information up to the 2001 model year.
Looking for a reason why the DME Is not communicating with the tiptronic and how to test the Can-bus circuit. Is there a wiring schematic available for the 2003/2004 boxster?
By Angel Martin
I need to replace the ATF wiring harness in my 2002 986 w/tiptronic due to a defective temperature sensor that forms part of it. I have been unable to find any information as to what it entails and / or how it can be replaced. Appreciate any insight.
By Branko Ljubetic
Hi. Im new in this forum, and i registered search for help, so thanks in advance.
I bought a 97 boxster tiptronic, with no issues at all. Scanned, everything was ok. Then i started to read about the model, and i was concerned about de IMS, so i replaced it with parts from Pelican. I took the oportunity to drain the torque converter and replace fluid (filters gaskets also) on the tiptronic transmission. Then my mechanic built everything, and the lights on the gear and lever on the panel were blinking. Also cant use "manual mode" nor the 5th gear. He checked everything, but the problem are still there.
Searched on the interenet, seems to be something called "limited driving programme" where the transmision limits itself in event of a failure. On the internet also i found most of time is related with transmision servicing, but i changed all fluid (torque converter including).
I used the recomended ATF by manual (pentosin) and changed filter, gaskets from ZF (the transmission manufacturer).
Sadly, i live on a small city in Northern Chile, almost 2000km from a Porsche authorized mechanic in capital, Santiago, so its not an option to take the car there.
My mechanic here is a really honest guy, but he seems to not understand this transmission. I dont know what to do, but ill scan the car in a few hours.
Any advice will be hughely appreciated guys. Thanks a lot.