Porsche Boxster 1999 User manual

Technical Manual
-..8<:;~s:;~-
TechnicalInformation
Contents:
Group0
Entirevehicle-
General
WKD483 521

Foreword
Boxster
Foreword
The workshop documentation for the Boxster model has the designation "Boxster" Technical Manual
and contains Technical Information as well as instructions on Repairs.
Theintegrationof the technicalinformationpublishedin the "Boxster"TechnicalManualwith the
descriptivematter on repairsprovidesthe userwith a complexreferencework that combinesinto one
book associatedor cross-referencedmaterialof relevanceto workshopsandoriginatingfrom various
informationmedia.
The "Boxster" Technical Manual consists of 15 folders, subdivided into the following Groups
a Entire vehicle -General
a Diagnosis, part 1 (up to Repair Group 45) *1
a Diagnosis, part 2 (as of Repair Group 69) *2
1 Engine, part 1 (up to Repair Group 13) *3
1 Engine, part 2 (as of Repair Group 15) *4
2 Fuel, exhaust, engine electronics
3 Transmission, manual transmission
3 Transmission, automatic transmission
4 Running gear
5 Body
6 Body equipment, exterior
7 Body equipment, interior
8 / 9 Air conditioning / Electrics
9 Circuit diagrams, part 1 (up to and including the '99 model) *5
9 Circuit diagrams, part 2 (as of the '00 model) *6
*1 Thetwo folders with Group0 areto be regardedas one folder;i.e. file the "TechnicalInformation"
notices onlyin front of the repair descriptionsin the folder "Group0 -Diagnosis, part 1"
(up to Repair Group 45).
*2 Thesecond folder "Group0 -Diagnosis, part 2"(as of Repair Group 69) includesthe further
RepairGroupsbelongingto GroupO.
*3 Thetwo folders with Group1 are to be regardedas one folder; i.e. file the "TechnicalInformation"
notices onlyin front of the repair descriptionsin thefolder "Group1 -Engine, part I" (up to
RepairGroup 13).
*4 Thesecond folder "Group1 -Engine, part 2" (as of Repair Group 15) includesthe further Repair
Groupsbelongingto Group1.
VORW.CHP
Foreword
Printed in Germany -34, October 1999

Foreword Boxster
*5 Thetwo folders with Group9 are to be regardedas one folder;i.e. file the "TechnicalInformation"
notices onlyin front of the repairdescriptionsinthe folder "Group9 -Circuit diagrams,part 1"(up to
the '99 model).
*6 Thesecond folder "Group9 -Circuit diagrams,part 2" (as of the '00 model) includesthe further
circuit diagramsbelongingto Group9.
The "Boxster" Technical Manual has the same structure in each folder, with the following breakdown for
all Groups:
Title page, "Boxster" Technical Manual
> Foreword
Title page: "Technical Information"
> Table of Contents,Technicalinformation
> Technicalinformation
Title page: "Repair"
> RepairGroups:overview
> Table of Contents,repairs
> General/technical data
> Instructionson repairs
As can be seen from the breakdown, the published Technical Information is in the front part of each
folder -numbered according to the Groups. The Table of Contents assigned to each Group will be
periodically updated.
Followingthe TechnicalInformation,separatedbya title page,the instructionson repairs-assigned
accordingto the Groupsor brokendowninto RepairGroups-are includedin the folder.
The instructions on repairs will be extended and updated by means of supplements.
Note
Sheets that already exist in the "Boxster" Technical Manual and are updated or revised and thereby
exchanged by a supplement are designated "Replacement sheet". Revisions or technical modifications on
pages of these replacement sheets are identified for the user with a vertical bar at the margin.
Foreword
Printed in Germany -34, October 1999
VORW.CHP

Record sheet for supplements to
We ask that you file the supplement under the appropriate Repair Groups and enter them in the
table below to provide an overview.
Supplement No. Datefiled Signature
alreadyfiled
1
JI
2
3II
4II
5"
6II
7II
II
8
9II
10 II
11 II
12 "
13 I J
14
,
1
15 1/
16 II
17
18
19
20
RECORDSHEET .CHP

Record sheet for supplements to
We ask that you file the supplement under the appropriate Repair Groups and enter them
in the table below to provide an overview.
SupplementNo. Date filed Signature
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
EINTRAG2.CHP

Boxster Structure of Technical Manual -Repair
Boxster Technical Manual -Repair
General
The Technical Manual -Repair -describes all essential work operations requiring special instructions to
ensure that repairs are performed properly. It should be in the hands of the workshop foremen and the
workshop personnel, as careful compliance with the stated instructions is a precondition for maintaining
the traffic and operating safety of the vehicle. In addition, of course, the generally customary basic safety
rules for the repair of motor vehicles are unrestrictedly applicable.
Structure
Overview of Repair Groups
Contents
Technicaldata/ general
Descriptionof repairs
Breakdown of Repair Groups
Tools, special tools and materials required for repair
Exploded drawing and illustration of sequence
Legend for exploded drawing and description of sequence
Instructions for assembly and adjustment
The Technical Manual is regularly expanded by supplements, which must be incorporated immediately to
preserve the usefulness of the Manual. As verification of completeness, the record sheet should be com-
pleted.
Boxster Technical Manual -Repair
Printed in Germany, 1996 STRUCTURE.CHP

Structure of Technical Manual -Repair Boxster
Structure of exploded view
Al7 A
BccB17
E"gme-lubrica,;o" Boxst.. 80x"., Enome -Lubricat;on
HH
Removing and installing oil pump with coolant guide housing Removingand installing oil pump with coolant guide housing
K Nota
J No Deolloa".. QIy. Removal 1.-
1 Cooiarnd,ain"ugMIO,l
2 s..ing ,ingA10, 135
3 H.xagDf'headbolt
M10, 100
4 HexagDf'headbo~
M10, 100
5 HexagDf'headbOt
M6,2Q
6 HexagDf'headbOt
M6,70
7 H.,ago"",ad bOt
M6,70
8 Gasket
"ght.,;ng ""QUe
IO+5,""17+35fUbl
Always repl~,
Tightenilg torqlE
45 Nm 133 ftibJ
Tlghteni1gtorQue
45 '"" 133ftibl
Tlghteni1gtorQue
10~17ftibJ
1
8
Always 'eplace; ;nsert m
fit any;1 coo... guide
housi1g has been OIl!
onto craMcsse
-'e"ace; insert or
fit oriy Wcoolant gu;de
housing hes been put
onto c,ankcase
9 Gasket
10 Qlp","p,"lj,coaa"'g,ida
""",ng
11 ~,
12 Ofing
13 ~'g.;1!1g.depin Alwaysreplace
Tighter;ngtor...
25Nm(18ftib)
F 17 20 19Removin. andmstal'n. oilpump w;thcoolantguidehousing
E'86m GPri"od...,m"Y"'6
17.6
D
G
A
B
C
D
E
F
=
-
H
J-
Imprint, supplementnumber,
year of printing
Title of explodedview
Itemnumberof explodedview,in
disassemblysequence
Specialinstructionsto befollowed
duringinstallationor removal
RepairGroup,numbers
RepairGroup,text
Vehicletype
Pagenumber
InternalPorschenumber
Work operation,consistingof
"After-sales service number"
and "Title"
K=
Structure of exploded view
Printed in Germany, 1996
STRUCTURE.CHP

Boxster Structure of Technical Manual -Repair
Structure of sequence description
ABccB
57 Door front. _I kick'" system Bo'ste, Boxlt., Doorfront,0'_' --I syIIem
HRemoving and installing door HRemovingand installing door
J
1Remo,;ngdOG'
J K
No ed,," L'""'"c60"'
LooSe1fa'-l screws
Loosendoorbr~e
~screwfa_,. screwfrcxn-Ii,.,
~screw hexagoosockethe., bat screw00Ul,-
brM'
Loosen hexagona screw \\\U1draw plug camection -..
wards 100 cfi~t
Pun__rds out of the runges
3 ~scOlrleCtplugcomectioo
loosen latch striker
Install door
No Procedure Inslructions
H...- Hang-in docwti,.. from-.aoo tigtttenfastening
screw
2 AsseniJle-brake
Comect
4 Assemblelatchstriker
Screw -brake to body with hexaeon socket head bat
Comet! plug tomection, insert frcxn bel"" am set...
with liexagMhead bat,
Screw latch strik~ to the Bi]iw MjJst latch s1rik~ so
thatthe_tOltourtorre~s"""ther..side-
,.,.
575137Ro",,",nl0"'-"" doo.
"""."""'",...
G
57.2 57 -3
DFD
E""'1
A
B
C
D
E
F
G==
-H
J
K
L
Imprint, supplement number I
yearofprinting
Title of sequencedescription
Sequencenumberinorder of sequence
Procedureinthe sequence
Descriptionor explanationofthe
procedure
-
RepairGroup,numbers
RepairGroup,text
Vehicletype
Pagenumber
InternalPorschenumber
Workoperation,consistingof
"After-sales service number"
and"Title"
8Structure of sequence description
Printed in Germany, 1996 STRUCTURE.CHP

Overview of repair groupsBoxster
Group 0: Entire vehicle -General
Maintenance 0
03
Group 0: Diagnosis
Salescheck
On-boarddiagnosis
DMEdiagnosis
Tiptronicdiagnosis
ABSdiagnosis
0
01
03
24
37
45
Group 0: 0
69
72
80
90
91
91
94
Diagnosis
Airbag diagnosis
Seat memory diagnosis
Heating diagnosis
Alarm system diagnosis
PCM diagnosis
ParkAssistent diagnosis
HBAdiagnosis
1
10
13
Group 1: Engine
Engine-Crankcase, suspension
Engine-Crankshaft, pistons 1
15
17
19
Group 1: Engine
Engine-Cylinder head,valvedrive
Engine-Lubrication
Engine-Cooling
2
20
21
24
25
26
27
28
Group 2: Fuel, exhaust, engine electronics
Fuelsupply,control
Exhaustsystem,turbocharging
Fuelsystem,electronicinjection
Fuelsystem,K-Jetronic
Exhaustsystem
Starter,powersupply,cruisecontrol
Ignitionsystem
3
30
34
35
39
Group 3: Transmission, manual transmission
Clutch,control
Manualtransmission-Actuation, housing
Manualtransmission-Gears, shafts,intogearsh.
Finaldrive, differential,differentiallock
3
32
37
38
39
Group 3: Transmission, automatic transmission
Torqueconverter
Automatictransmission-Actuation, housing
Automatictransmission-Gears, control
Finaldrive,differential,differentiallock
Overview of repair groups
Printed in Germany -34, October 1999 REPGRU.CHP

Overview of repair groups Boxster
Group 4: 4
40
42
44
45
46
47
48
Running gear
Frontwheel suspension,drive shafts
Rearwheelsuspension,driveshafts
Wheels,tires, suspensionalignment
Ant~LockBrakeSystem(ABS)
Brakes-Brake mechanics
Brakes-Hydraulics, regulator,booster
Steering
Group 5: 5
50
51
53
55
57
Body
Bodyfront
Bodycenter, roof, frame
Bodyrear
Lids,flaps
Door front, central lockingsystem
Group 6: 6
60
61
63
64
66
68
69
Body equipment, exterior
Slidingroof
Convertibletop,hardtop
Bumpers
Glazing,windowcontrol
Exteriorequipment
Interiorequipment
Passengerprotection
Group 7: Body equipment, interior
Linings,insulation
Seatframes
Seatupholsteries,covers
7
70
72
74
Group 8: 8
80
85
87
88
Air conditioning
Heating
Ventilation
Air conditioning
Auxiliary air conditioning system
Group 9 9
90
91
92
94
96
Electrics
Instruments, alarm system
Radio, telephone, on-board computer, navigation
Windshield wiper and washer system
Lights, lamps, switches exterior
Lights, lamps, switches interior, theft protection
9
97
Group 9: Circuit diagrams
Wiring(upto andincludingthe '99 model)
9
97
Group 9: Circuit diagrams
Wiring(fromthe '00 model)
Overview of repair groups
Printed in Germany -34, October 1999
REPGRU.CHP

Boxster Table of Contents
0Entire vehicle -General
0
0 -1
0 -3
0 -5
0 -15
0 -25
0 -31
0 -41
0 -47
0 -49
General
Engine.Transmission.RunninggearBody.ElectricsTechnical data.Plug~n couplings for pipelines (new system) ..
Lifting the vehiclePower supply -general (work instructions after
disconnecting the battery)
Technical data Boxster (2.7 I)Technical data Boxster S (3.2 I) 0-53
a -65
01 01- 1
01 -3
01 -5
Sales check
Removing transport arrangement.Convertible top: Checking operation.Coding alarm system for Great Britain and Belgium
03 Maintenance
Maintenanceschedule
Maintenance. ..., 1
03- 1
032000
1
0 Entire vehicle -General
Printed in Germany -35, 1999 986TOC

Boxster Entire vehicle -General
0Power unit -general
6-cylinder aluminium opposed-cylinder engine, water-cooled
mm 85.5/ 72
cm3 2480
11.0 : 1
kW/HP 150 / 204
rpm 6000
Nm (ftlb.) 245 (181)
rpm 4500
Type
Bore / stroke
Displacement (actual)
Compression ratio
Max. engine power
at engine speed
Max. torque
at engine speed
Enginecontrol
Cylinderhead
Camshaftdrive
Type offuel
Bosch M5.2 with static high-voltage distribution, sequential
injection, cylinder-specific knock control, stereo oxygen-sensor control
and diagnostic system.
2 overhead camshafts with hydraulic valve clearance compensation
Porsche VarioCam
RON98 premium unleaded
0 -1
0 Power unit -general
Printed in Germany -8, 1996 986O_1

Entire vehicle -General Boxster
Engine-cooling diagram
1 -Opposed-cylinderengine,water-cooled
2 -Expansiontank
3 -Fan for engine-compartmentcooling
4 -Water circuit
0 Power unit -general
Printed in Germany -8, 1996
0-2 986O_1

Entire vehicle -General
Boxster
0Transmission -general
Manual transmission (G86)
8 -TransmissioncasecoverI-1st gear
2 -2nd gear 9 -Input shaft
3 -3rd gear 10 -Output shaft
11 -Ball bearing
4 -4th gear
5 -5th gear 12-Differential
6 -Reversegear 13 -Tapered roller bearing
7 -Transmission housing 14 -Tapered roller bearing
0-3
0 Transmission -general
Printed in Germany, 1996 986O_1

Entire vehicle -General Boxster
Tiptronic transmission (A86)
12
.f==~~~~~~::=:s=~=~~~'ii=
=;::::,
--r~ --
I
~~,
~-i -Sit
~
~
-==--
--llr
~I\
~---=-..F-"
~~tt~1 -
1"
.~
='~:
~
~
!i;;;;;:;-' .Q 9
"-+-
~
10 ,~::~~~~~~--==~~:7-IV
56 7 8
.~~f;;;~=:~iz:=72t!!~
3 4
283 .96
6 -ATF drainplug
7-Transmission inputspeedsensor
8 -ATF filler screw
9 -Gasket for ATFpan
10 -Gasket for spurgear
1 -Torque converter
2 -Sealing ring for torqueconverter
3 -ATF filter
4 -ATF pan
5 -Hydraulic control unit
0 Transmission -general
Printed in Germany, 1996
0-4 986O_1

Boxster Entire vehicle -General
.
0Running gear. general
Running gear. overview
Front axle / steering
McPherson wheel suspension with offset spring. Twin-tube gas pressure shock absorbers in standard or
sports model.
In order to obtain greater stiffness with reduced intrinsic weight as compared with steel, the following
components have been made from aluminium:
Control arms, diagonal brace, track rod, wheel carriers and cross members / side member.
Rack-and-pinionsteering gear (i = 16.9 : 1)with hydraulic assistance.
Steering wheel longitudinally adjustable (40 mm).
.0-5
0 Running gear -general
Printed in Germany, 1996 986O_1

Entire vehicle -General Boxster
Rear axle
McPherson wheel suspension with offset spring.
Twin-tube gas-filled shock absorbers in standard or sports model.
In order to obtain greater stiffness with reduced intrinsic weight as compared with steel, the following
components have been made from aluminium:
Control arms, diagonal brace, track rod, wheel carriers and side members.
"'"
'/
/"
~
~~ /'
(
\
/""
'-,
~ ,J-:;~ ./
/
~
;;:-::::: "'"
\
~'~"""""""~-':':'
~"
'oc-
383-96
.0 Running gear -general
Printed in Germany, 1996
0-6 986O_1

0
Entire vehicle -GeneralBoxster
Wheels and tyres
RearFront
Standard
Wheels:
Tyres: 6J X 16
205/55 R 16 7J X 16
225/50 R 16
Brakes
Hydraulicdual-circuitbrakesystemwith front-
axle/ rear-axlebrake-circuitdistribution.
Vacuumbrake booster, internallyventilated
brakediskswithfour-pistonfixed caliper at front
andrear axles.
On special request
Wheels: 7J X 17
Tyres: 205/50 R 17 8.5J X17 255/40 R 17 ABS 5.3 (3-channel system) standard.
ABS/TC 5.3 (4-channel system) on special re-
quest.
TC = Traction Control, consisting of ASR
(anti-slip control) and ABD (Automatic Brake Dif-
ferential).
Parkingbrake(handbrake):
Drumbrakeacting mechanicallyon both rear
wheels.
0-7
0 Running gear -general
Printed in Germany, 1996 986O_1

Boxster En'tire vehicle -General
Information on ABS5.3 and ABS/fC 5.3
General
ThePorscheBoxsteris equippedas standard
with ananti~ockbrakingsystem(ABS5.3).
"TractionControl(TCr is availableon special re-
quest onthe basis ofABS5.3. Traction Con-
trol (TC)is a combinationofanti-slipcontrol
(ASR)andAutomaticBrakeDifferential(ABD).
TC is a further system for increasing driv-
ing safety.
Differences between ABS 5.3 and ABS/TC
5.3
ABS 5.3 = 3-channel system
(diagram: see Page 0 -11).
ABS;rC 5.3 = 4-channelsystem
(diagram:see Pagea -13).
The essential distinguishing features between
ABS and ABS;rC are:
Compared with the ABS 5 (ABS 5 in the 993),
ABS 5.3 has been optimized with regard to in-
stalled volume and weight. Control unit (No.1),
hydraulic unit (No.7), pump-motor relay and
valve relay (No.2) of ABS 5.3 and ABS/TC 5.3
form a unit that is located next to the brake
master cylinder.
Number of brake lines at intermediate piece
(No. 8/ Figure 181 -96):
ABS 5.3 = 3 brake lines
ABS/TC 5.3 = 4 brake lines
TC off switch for switching driving stability
control on and off is not available on vehicles
with Solo ABS (ABS 5.3)
,
1
'"
,
"
/",
a~
(
2, 8,'"
TC (ASRjABDI warning light and
TC (ASRjABD) function light
(information light) in vehicles with ABSjTC.
These lights light up when the ignition is
switched on (lamp check).
These lights are not allocated in the instru-
ment cluster in vehicles with ABS 5.3 (Solo
ABS).
A figure showing the warning lights and func-
tion light is shown on Page a -14.
181 -96
Diagnosis and system tests on both systems
are carried out with the Porsche System Tes-
ter 2.
0 Running gear -general
Printed in Germany, 1996 0-9
986O_1

Entire vehicle -General Boxster
ABS 5.3 (3-channel system) system description
This function and the input signals are continu-
ously monitored. If a fault is detected, the con-
trol unit switches the ABS function off, switches
on the ABS warning light and stores the fault in
a non-volatile memory in the control unit.
ABS operation
The ABS control unit receives a signal from the
brake~ight switch and the AC voltage signals
from the four speed sensors. These signals are
converted into digital wheel-speed signals inde-
pendently of each other by two microproces-
sors. The wheel slip (approximately proportional
to the computed vehicle reference speed) is
formed from these wheel-speed signals.
In addition, whenever a journey is begun and a
speed of 6 km/h is exceeded, a test pro-
gramme is started. The solenoid valves and the
pump motor are electrically actuated and
checked. If a fault is detected, the control unit
switches the ABS function oft, the ABS warning
light is switched on and the fault is stored.
Ifvehicle deceleration and excess slip are de-
tected at a wheel, the pressure-holding phase is
initiated, i.e. the inlet valve for the relevant
wheel is closed to prevent a further increase in
pressure. If in spite of the pressure being held
constant the wheel tends to continue to lock up,
the pressure in the wheel cylinder is reduced.
For this purpose, the outlet valve is opened and
the brake fluid is pumped back to the brake mas-
ter cylinder via the return pump (pressure-reduc-
tion phase) until the wheel turns again. Then, de-
pending on the control cycle, further appropriate
cycles are initiated.
0 J;~unninggear -general
Printed in Germany, 1996
0 -10 986O_1