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