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Home >> Porsche >> 2016 >> Panamera 4S >> Repair and Diagnosis (Single Page) >> Engine Mechanical >> Fuel System >> 24 - Fuel System - Electronic Ignition -- PANAMERA (970) >> WM 243001 Checking Fuel Collection Pipe For Leaks (PANAMERA Turbo, PANAMERA Turbo Executive, PANAMERA Turbo S, PANAMERA Turbo S Executive) >> Checking Fuel High-Pressure System For Leaks

Checking Fuel High-Pressure System For Leaks

WARNING: Toxic substances
  • Danger of poisoning or suffocation
  • Danger of burns to the eyes and skin

→ Ventilate the work area well.

→ Never ingest or inhale.

→ Read specific information on the Hazard Sheet.

→ Do not smoke, eat or drink in the work area.

WARNING: Highly inflammable or explosive materials
  • Danger of fire or explosion

→ Avoid contact with hot parts or sources of ignition.

→ Use suction to remove ignitable vapours.

→ Attach warning sign in a clearly visible position.

WARNING: Leaking fuel supply lines
  • Emerging fuel
  • Risk of fire

→ Perform leak test.

  1. Place a cloth under the fuel supply line (low-pressure) and open the line using two open-ended wrenches. Counter at the center piece while doing this and loosen the union nut at the engine side.

    → see Fig 1

    Fig 1: Identifying Junction Point For Lines In Engine Compartment
    G09805742Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    Fig 2: Adjusting Fuel Low-Pressure Line
    G09805743Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Information 

    • Check that the tool fittings are clean before starting the leak test. 
    • Blow out the tool fittings before assembly using gentle bursts of pressure to prevent dust and foreign bodies from getting into the high-pressure system during the leak test. 
    • Ensure that the tools for the leak test remain clean and free of dirt when stored. 
  2. Screw adapter 1318/7  → see Fig 3 from K-Jetronic Tester V.A.G. 1318 WE 1291  hand-tight onto the fuel low-pressure line → see Fig 3.
    Fig 3: Identifying Adapter (1318/7)
    G09805744Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    1. Low-pressure line on engine side
    2. Adapter 1318/7
      Fig 4: Identifying Adapter On Low-Pressure Line
      G09805745Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    NOTE: Test pressure is exceeded
    • Risk of damage to high-pressure pump

    → The test gas test pressure must be set to less than → Pressure: 10 bar  on the pressure reducer on the test gas bottle.

    WARNING: Working with compressed air
    • Risk of eye injuries
    • Risk of damaging and dirtying components

    → Wear protective goggles with side eye protection.

    → Protect the point at which the compressed air emerges with suitable material.

    → Place the point at which the compressed air emerges on suitable surfaces.

    Information 

    The use of unapproved test gases results in incorrect test results. Only approved test gases guarantee comparability with fuel high-pressure systems at pressures of up to 10 bar  .

  3. Fit test gas bottle with pressure reducer and air-spring strut filling unit VAS 6231 WE 1282  securely so that no gas can escape → see Fig 5. Set pressure reducer to max. 10 bar pressure → see Fig 6.
    Fig 5: Identifying Filling Unit (VAS 6231)
    G09805746Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    Fig 6: Identifying Test Equipment
    G09805747Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    Fig 7: Adjusting Pressure Reducer Between 7 And 9 Bar Of Test Gas Pressure
    G09805748Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  4. Air-spring strut filling unit VAS 6231 WE 1282 -2-  must then be connected to the adapter. Tighten the connection if necessary.
    Fig 8: Identifying Filling Unit On Adapter
    G09805749Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  5. Depending on the high-pressure connections that were loosened (removed fuel distribution pipe or removed high-pressure pump), complete the following steps =>
  6. If the fuel distributor pipe (high-pressure rail) was removed => 
    1. 6.1. Before screwing the fuel distributor pipe (high-pressure rail) to the engine, quickly blow out residual fuel from the high-pressure pump and high-pressure line (intake) to the high-pressure rail.
    2. 6.2. Apply a quick burst of pressure using the filling unit and blow the residual fuel through the line into a cloth or receptacle. → see Fig 9
      Fig 9: Blowing Out High-Pressure Line
      G09805750Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    3. 6.3. Drain residual fuel from the high-pressure distributor pipe before fitting it. Shake the high-pressure distributor pipe over a cloth to do this.
    4. 6.4. Fit high-pressure distributor pipe (high-pressure rail) and tighten it to the correct tightening torques. → 243019 REMOVING AND INSTALLING FUEL DISTRIBUTOR PIPE 
      NOTE: Test pressure is exceeded
      • Risk of damage to high-pressure pump

      → The test gas test pressure must be set to less than → Pressure: 10 bar  on the pressure reducer on the test gas bottle.

    5. 6.5. Use air-spring strut filling device VAS 6231 WE 1282  to apply test-gas pressure of between 7 and just under 10 bar to the completely fitted high-pressure system. The pressure is distributed slowly in the system and can increase slightly on the pressure gauge. If there is a constant drop in pressure, there is a leak in the system.
    6. 6.6. Spray all connection points in the high-pressure system with commercially available leak-locating spray. If the pressure drops even though the threaded joints are perfectly sealed, also spray the soldered joints and connecting pipes as well as the high-pressure pump and test equipment with leak-locating spray.
    7. 6.7. If there is a leak, gently sashaying  , moving and growing  air bubbles → see Fig 10 will emerge. These could be caused by a damaged seal, loose connections or incorrectly fitted union nuts, for example. The cause must be determined and corrected.
      Fig 10: Locating Air Bubbles Leaks
      G09805751Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  7. If the high-pressure pump was removed => 
    1. 7.1. Before screwing the high-pressure line (intake) to the high-pressure pump, residual fuel must be blown out of the high-pressure pump.
    2. 7.2. Apply a quick burst of pressure using the filling unit and blow the residual fuel through the connection piece into a cloth. → see Fig 11
      Fig 11: Blowing Out High-Pressure Pump
      G09805752Courtesy of PORSCHE CARS NORTH AMERICA, INC.
    3. 7.3. Screw high-pressure line correctly to the high-pressure pump. → 246319 REMOVING AND INSTALLING HIGH-PRESSURE GROUP 
      NOTE: Test pressure is exceeded
      • Risk of damage to high-pressure pump

      → The test gas test pressure must be set to less than → Pressure: 10 bar  on the pressure reducer on the test gas bottle.

    4. 7.4. Use air-spring strut filling device VAS 6231 WE 1282  to apply test-gas pressure of between 7 and just under 10 bar to the fitted high-pressure pump. The pressure is distributed slowly in the system and can increase slightly on the pressure gauge. If there is a constant drop in pressure, there is a leak in the system.
    5. 7.5. Spray all connection points for the high-pressure pump with commercially available leak-locating spray. If the pressure drops even though the threaded joints are perfectly sealed, also spray other connection points as well as the high-pressure pump and test equipment with leak-locating spray.
    6. 7.6. If there is a leak, gently sashaying  , moving and growing  air bubbles will emerge (union nut on injector is shown). These could be caused by a damaged seal, loose connections or incorrectly fitted union nuts, for example. The cause must be determined and corrected.
      Fig 12: Locating Air Bubbles Leaks
      G09805753Courtesy of PORSCHE CARS NORTH AMERICA, INC.
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