Cleaning Secondary-Air Injection System
Information
The cleaning process is described for one cylinder bank. The same steps must be repeated the other way around for the second cylinder bank.
- Loosen refrigerant lines at the holder.
- 1.1. Pull valve -1- up -arrow- and off.
- 1.2. Loosen screw -2- on the holder.
- Loosen combination valves for cylinder bank 1 and 2.
→ Removing Combination Valves For Secondary Air
Information
Screw on adapter using a commercially available screw (M6 x 20). The original screw hits the blind hole and does not guarantee exact positioning of the adapter.
- Fit special tool adapter VAS 6825/5 and VAS 6825/6
.
Screw adapter -1- to cylinder bank. Tightening torque 9 Nm (6.5 ftlb.).
The adapter for cylinder bank 2 has a cut-out.
Cleaning main duct
Information
Distinguishing feature of the cleaning lances
- Main duct: Lance without scale.
- Branch duct: Lance with scale.
- Cleaning tool WE 1664
(cleaning lance) must be guided approx. 5 cm into the main duct.CAUTION: Pressurized fluid
- Danger of injury to skin and eyes
→ Keep body parts away from the stream of fluid.
→ Wear personal protective gear
Information
- Significant amount of water coming from the adapter for the cylinder bank when starting the cleaning process.
- Water coming from the adapter for the cylinder bank and the exhaust manifold during cleaning.
Collect rinse water using suitable pans or extract it at the outlet using a wet vacuum cleaner and dispose of it correctly.
Information
Improper use
- The tool must only be used for the work described here!
- The high-pressure spray coming from the nozzle produces an increased recoil force, so always keep a firm grip on the tool while using it!
Always wear appropriate gloves and goggles when using the tool!
Fit the protection cap on the nozzle before and after using the tool!
- Attach cleaning lance to high-pressure cleaner.
Activate high pressure.
- Slowly guide cleaning lance as far as it will go and back again.
Repeat this step once.
- Separate cleaning lance and high-pressure cleaner.
Deactivate high pressure.
- Pull cleaning lance out of the engine.
Cleaning branch duct
- High-pressure spray for branch duct
- Positioning aid
Information
Distinguishing feature of the cleaning lances
- Main duct: Lance without scale.
- Branch duct: Lance with scale.
- Fit positioning aid on cleaning lance.
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
- 9.1. Guide cleaning lance into positioning aid.
- 9.2. Align positioning aid on the cleaning lance.
The water outlet bores -2- and bar -1- on the positioning aid must be aligned.
- 9.3. Adjust positioning aid according to the measurement table -1-
to suit the cleaning lance -2-
.
Adjustment dimension Step 1 Step 2 Step 3 Cylinder bank 1 22.2 31.2 40.2 Cylinder bank 2 17.6 26.6 35.6 - 9.4. Tighten screws on clamping piece -3- of the positioning aid hand-tight.
- Guide cleaning lance into main duct.
- Lock positioning aid -2-
with adapter -1-
.
CAUTION: Pressurized fluid
- Danger of injury to skin and eyes
→ Keep body parts away from the stream of fluid.
→ Wear personal protective gear
Information
Improper use
- The tool must only be used for the work described here!
- The high-pressure spray coming from the nozzle produces an increased recoil force, so always keep a firm grip on the tool while using it!
Always wear appropriate gloves and goggles when using the tool!
Fit the protection cap on the nozzle before and after using the tool!
Information
- Significant amount of water coming from the adapter for the cylinder bank when starting the cleaning process.
- Water coming from the adapter for the cylinder bank and the exhaust manifold during cleaning.
Collect rinse water using suitable pans or extract it at the outlet using a wet vacuum cleaner and dispose of it correctly.
- Attach cleaning lance to high-pressure cleaner.
Activate high pressure.
- Slowly move cleaning lance back and forth.
Use the defined space for movement -1- during the cleaning process.
Information
If water is still coming from the adapter after a cleaning time of longer than 1 minute, the set dimension must be checked and the cleaning process must be repeated.
Cleaning takes at least 2 minutes for each branch duct.
- Separate cleaning lance and high-pressure cleaner.
Deactivate high pressure.
- Pull cleaning lance out of the engine.
- Repeat steps→ 9.to→ 15.
Repeat the steps for setting the adjustment dimensions Step 2 and Step 3.
- Assessment of successful cleaning
The amount of water coming from the adapter and the exhaust is an indication that the cleaning process was successful.
Characteristics of successful cleaning:
- No more water coming from the engine adapter.
- Water coming from the exhaust system or exhaust manifold only.
- Repeat the cleaning process if necessary.
- Remove special tool adapter.
- Extract water from the cylinders using a vacuum pump.
- Extract water from the exhaust manifolds using a vacuum pump.
- Start the high-voltage system.
- Turn the engine 3 times using the starter.
- Isolate the high-voltage system from the power supply.