02 Boxster S Vacuum Line Mystery

[ymg183]

Asking for help with a small mystery in my 02 Boxter S's vacuum lines. Near the vacuum accumulator tank, there is a 3-way junction in the vacuum line. One line coming from the junction goes directly to the vacuum accumulator tank, one seems to come from the vacuum source (wherever that may be) and the third is a short 3-4" piece of vacuum hose that is cut off and ends without a plug or a place to connect to and lies open on the top of the engine case below the intake manifold. I can reach it with a hooked wire to manipulate it, but there is no fitting nearby to which it should be attached. What to do??

The engine runs well apparently, although a recent check on a scanner threw a possible O2 sensor code. It has been explained to me that the code might be misleading and that the real cause could be related to some aspect of the fuel management system but not necessarily in the O2 sensor itself.

Any help in identifying what this short piece of hose should be connected to, or what should be done with it, would be greatly appreciated.

Thanks in advance.

[tcora]

Working totally from memory here, the vacuum source is the intake manifold. That short stub of tubing you see should attach to a fitting on the intake somewhere.

[ymg183]

Thanks Tom. I will look for the vacuum source connection fitting again and get back to the forum. It needs to be within reach of that third short piece of tubing. It's possible that the connection point is out of sight under or behind the many engine components near the passenger-side intake manifold.

[ymg183]

OK.

After some more research, I have discovered that the unconnected end of the mystery piece of vacuum hose lies at the base of the Secondary Air Injector, way underneath the passenger side intake manifold. According to details in other posts on this forum, the vacuum hose going to the Secondary Air Injector attaches to it at its top, that is, immediately under the intake manifold. It appears that the hose is long enough to reach that connection point, but how to manipulate it and connect it in that hard-to-reach position without having to remove the cross pipes and intake manifold??

Has anyone faced this problem before and is there a solution short of intake manifold removal to permit access??

Any and all suggestions gratefully appreciated.

[flmont]

I have/had vacuum issue's just ask google for the vacuum diagram for the 02 boxster and it shows all the connections required, it may go to your resonance tube flap door inside the 2 nd intake tube.

[Brian in Tucson]

http://forums.pelicanparts.com/boxster-cayman-forum/597995-air-intake-vacuum-line-routing.html

[ymg183]

Thanks Brian and flmont. According to diagrams of the vacuum hose routing, this short section of vacuum hose should go to the small u-shaped rubber hose connection at the top of the Secondary Air Injector right under the intake manifold. It appears that the only way to access that part without removing the intake manifold is to remove the alternator.

My prolonged efforts (4-5 hours) to remove the alternator have failed so far, but I will try again. I have loosened the seized slide bushing at the back of the alternator and have moved the alternator itself, but rotating it counterclockwise out of its mounting just is not working. I will do a search on this and other forums to see if there is something that I am missing. So, thanks again for the input.

[tcora]

Agreed that removing the alternator is a bear. Pulling the crossover tube in the intake manifold is really much simpler. A couple of hose clamps and a little fiddling and the job is done.