Engine - Water Entering Air Cleaner: Overview
Boxster7a/97 2425
Binder 2 - Fuel & Exhaust.
This bulletin replaces bulletin # 7/97, dated 10-22-98.
Water in Air Cleaner Housing
8-24-01
Vehicle Type:
Boxster
Model Year:
MY 1997 (V)
Concern:
Water entering the left-hand air guide and air cleaner housing.
Situation:
Engine misfires during driving, rough running, poor starting.
Information:
Water can enter the air cleaner housing via the air guide when the vehicle is driven in unfavorable weather conditions, e.g. during rainstorms. This can cause engine misfires and rough running.
These problems do not necessarily occur during these weather conditions; they could show up later on. Please ask the customer if the vehicle was driven in these weather conditions.
Modification:
1. A gasket between the outer left air guide and the body seals out water (Figure 2, dot-dash line).
2. A deflector (Figure 1, item 1) is fitted on the air cleaner intake opening, and a water separator bowl (Item 5) is fitted on the air cleaner housing.
3. The formerly used water shield support in the flow duct has been omitted.
Introduction:
Seal on the air guide, deflector and omission of shield support. As of August 25, 1997 production, from the following Vehicle Identification Numbers (VIN):
98 OWS 62 0150
98 6WU 62 0075
Water separator bowl on air cleaner:
Beginning on the 28th of October 1997, from the following Vehicle Identification Numbers (VIN):
98 9WS 62 1166
98 6WU 62 0533
Fault Codes
Troubleshooting:
If one of the items below is applicable, replace the air flow sensor (MAF) and carry out the modifications on the air cleaner and air guide.
Fault code P0101 (DTC 115) is displayed alone or with several of the aforementioned codes in the fault memory.
If fault code P0101 (DTC 115) is not displayed, start diagnosis with the engine at operating temperature (air conditioner off, no loads switched on). Read out the values for mass air flow voltage and adaptation in the DME "Actual values" menus and compare them with the adaption limit values below.
New Information:
MAF signal voltage:
- If the value is between 0.92 V and 1.08 V, no replacement is necessary.
- If the value is 1.15 V or above, replace MAF.
NOTE:
If the MAF needs to be replaced, the air cleaner element must also be replaced.
Adaption limit values at idle speed:
- Mass air flow set point: 12-24 kg/h
- Adaptation value, range 1 (TRA/TRA2): Adaptation limit, rich limit: +0.37
- Adaptation value, range 1 (TRA/TRA2): Adaptation limit, lean limit: -0.37
New Information:
Adaption limit values at no-load engine speed of 2500 rpm:
- Mass air flow set point: 30-60 kg/n
- Adaptation value, range 2 (FRA/FRA2): Adaptation limit, rich limit: 1.25
- Adaptation value, range 2 (FRA/FRA2): Adaptation limit, lean limit: 0.75
Assessment criteria for implementation of the modification:
Air Mass:
- If value is at limit or outside of range, (signal not plausible).
- TRA/TRA2 and FRA/FRA2: If both values are approximately the same; or have reached either the lean or rich limit stop. The fault occurs symmetrically, meaning both TRA/TRA2 and/or at FRA/FRA2.
To determine, pull off the MAF electrical plug. The engine now switches to the emergency program mode, and any previous rough running of the engine should be eliminated.
Parts Information:
The parts shown are required to perform the retrofit.
Required Tools
Shop Supplies
Acetone Vacuum cleaner
Grease Plastic body wedge
Sealant Shop light
Torch
Warranty Info
Damage Code
2425 10 0002
Literature:
Boxster Technical Manual, Group 6: - Repair: 66 56 19 - Removing and installing the engine compartment vent
Boxster Technical Manual, Group 0: - DME Diagnosis On-Board Diagnostic (OBD II) manual
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