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Home >> Porsche >> 2016 >> Panamera Turbo >> Repair and Diagnosis >> Engine Performance >> Tune-Up >> 24 - Fuel System - Electronic Ignition 4.8L Turbo -- 970 - PANAMERA (970) >> WM, 243001 Checking Fuel Collection Pipe For Leaks >> 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.
    • Wear personal protective gear.
    • 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 vapors.
    • Attach warning sign in a clearly visible position.
    • Contain leaked media using non-flammable absorbent material and put it in a container designed for this purpose for disposal in accordance with local requirements.
    • Secure collection containers/vessels to prevent them from tipping over.
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 centre piece while doing this and loosen the union nut at the engine side. >
    G15198683Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Junction point for lines in engine compartment

    G15198684Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Fuel low-pressure line

    Information 

    • Check that the tool fittings are clean before starting the leak test. 
    • Clean the tool fittings before assembly using gentle bursts of compressed air 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  > from > V.A.G 1318 - K-Jetronic Tester  hand-tight onto the fuel low-pressure line >.
    G15198685Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Adapter 1318/7

    G15198686Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Adapter on low-pressure line

    1  Low-pressure line on engine side
    2  Adapter 1318/7

    NOTIFICATION 

    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.

    Information 

    Unapproved test gases will give incorrect test results. Only the approved test gases guarantee comparability with fuel high-pressure systems at pressures of up to 10 bar.

    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.
  3. Fit test gas bottle with pressure reducer and > VAS 6231 - Air-Spring Strut Filling Unit  securely so that no gas can escape >. Set pressure reducer to max. 10 bar pressure >.
    G15198687Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Filling unit VAS 6231

    G15198688Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Test equipment setup

    G15198689Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Adjusting pressure reducer to between 7 and 9 bar of test gas pressure

  4. > VAS 6231 - Air-Spring Strut Filling Unit-2-  must then be connected to the adapter. Tighten the connection if necessary.
    G15198690Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Filling unit on adapter

  5. Depending on the high-pressure connections that were loosened (removed fuel distributor pipe or removed high-pressure pump), complete the following steps =>
  6. If the fuel distributor pipe (high-pressure rail) was removed => 

    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.

    Apply a quick burst of pressure using the filling unit and blow the residual fuel through the line into a cloth or receptacle. >

    G15198691Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Blowing out high-pressure line

    Drain residual fuel from the high-pressure distributor pipe before fitting it. Shake the high-pressure distributor pipe over a cloth to do this.

    Fit high-pressure distributor pipe (high-pressure rail) and tighten it to the connect tightening torques.

    > 243019 REMOVING AND INSTALLING FUEL DISTRIBUTOR PIPE 

    NOTIFICATION 

    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.

    Use > VAS 6231 - Air-Spring Strut Filling Unit  to apply test-gas pressure of between 7 and just under 10 bar to 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.

    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.

    If there is a leak, gently sashaying, moving and growing  air bubbles > 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.

    G15198692Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Leaks

  7. If the high-pressure pump was removed => 

    Before screwing the high-pressure line (intake) to the high-pressure pump, residual fuel must be blown out of the high-pressure pump.

    Apply a quick burst of pressure using the filling unit and blow the residual fuel through the connection piece into a cloth. >

    G15198693Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Blowing out high-pressure pump

    Screw high-pressure line correctly to the high-pressure pump.

    > 246319 REMOVING AND INSTALLING HIGH-PRESSURE PUMP 

    NOTIFICATION 

    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.

    Use > VAS 6231 - Air-Spring Strut Filling Unit  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.

    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.

    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.

    G15198694Courtesy of PORSCHE CARS NORTH AMERICA, INC.

    Leaks

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