Porsche Boxster S User manual

TechnicalManual
-~~s::~
TechnicalInformation
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Boxster(986) Bodyequipment,exterior
Supplement Overview
Supple-
ment Edition Topic Article number
05/1996 Basicedition WKD483521
208/1996 Generalchanges WKD483521.02
711/1996 Generalchanges WKD483521.07
10 04/1997 Assemblyinstructionsfor hardtopassemblyfix-
ture WKD483521.10
12 07/1997
08/1997
08/1997
11/1997
01/1998
03/1998
07/1998
Generalremarksonthe airbag WKD483521.12
WKD483521.14
14 Generalchanges
FolderseparationGroups5 and6 WKD483521.15
15
16
18 WKD 483521.16
Generalsupplement
WKD483521.18
Generalremarksonthe airbag
WKD483521.20
20
23 Generalsupplement WKD483521.23Assemblyinstructionsfor hardtopassemblyfix-
ture WKD483521.25
25
26
29
Generalsupplement WKD483521.26
Generalsupplement WKD483521.29
02/1999
04/1999
07/1999
07/1999
08/1999
09/1999
Generalsupplement WKD483521.30
Changesinmodelyear2000
30
31 FolderseparationGroups6 and 7 WKD483521.31
Removingandinstallingconvertible-toproof
liner WKD483521.32
32
WKD483521.36
12/1999
36 Removingandinstallingthe sideairbagunit WKD483521.37
OS/2000
37 Generalsupplement WKD483521.38
07/2000 Generalsupplement
38
39
40
WKD483521.39
Changesinmodelyear2001
08/2000 WKD483521.40
Replacingfolder 6
09/2000
Supplement Overview
Printed in Germany -40, 2000 Master6
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Boxster (986) Foreword
Table of Contents
0Foreword
Foreword
ForewordUse . 1
1
-1 page
-2 page
Table of Contents
Printed in Germany -37,2000 masterY
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Boxster (~86) Foreword
Foreword
Thismanurl containsTechnicallnformationaswell asinstructions
on repairsfor Porschevehicles.Itis intendedfor the soleuse of
workshop belongingto PorscheAG.
ThedeSC
~Ptionsform the basisfor professionalandcorrect mainte-
nanceandrepairwork. Thecontentofthework procedures
describedis basedonthe leveloftrainingof afitter whohascom-
pletedvo ationaltrainingandhasa soundknowledgeofthe prod-
uct. Thislevelof knowledgeis necessaryin orderto carry outthe
work described.
Warning notes
Thewarningnotesand safetyinstructionsareclassifiedbythe
respectivesignalisingword (Danger,Warning,Caution)besidethe
warningsymbol.
To preventinjuryandrestrictedoperatingandtraffic safetyofthe
vehicle,or damageto the vehicleasthe resultof incorrectwork,
readtheseinstructionscarefullyandobservethem withoutfail.
Itis notpossiblefor PorscheAGto givea detailedevaluationof all
dangersituationsfor the personscarryingoutthework. Itis there-
fore imperativethatallpersonscarryingoutrepairandmaintenance
work onPorschevehiclesusetheir specialistknowledgeto ensure
thattheir ownsafetyis notatriskandtheprocedurechosenwill not
haveanynegativeeffects onthe vehicle-especiallywith regardto
safety.
Itis thereforeexpresslyspecified
proceduresdescribedshouldbec
the validguidelinesandregulation.
blewith respectto healthandacc
-1 page 1
Foreword
Printedin Germany-37, 2000 vorwort
Warns against death or very serious injury which will cer-
tainly occur if the instructions are not observed.
Warnsagainstdeathor veryseriousinjury whichmayoccur
if theinstructionsare notobserved.
Warns against minor injury or damage to property if the
instructions are not observed.
thatallworkinvolvedinthe workarried
outonlyinaccordancewith
s ofthe localauthoritiesresponsi-
identpreventionandenvironmen-
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Boxster (986)
Foreword
,~
talprotection, andincompliancewiththe legalrequirementsof
individualcountries.
Notes
Notescontainadvisoryinformationrelatedto thework procedure
whichmakesthe fitter's work easier.Thefollowingpictogramindi.
catesthis information:
[IJ Note!
Containsadvisoryinformationwhichmakestheworkprocedureeas-
ter.
Dueto the continuousdevelopmentand improvementofour vehi-
cles,there maybe discrepanciesbetweenthe actualtechnicalsta-
tus ofthe vehiclesandthework descriptions.Anyexisting
deviationsare corrected bymeansof supplements,andthe scope
ofthe descriptionsis extendedwith supplements.
PorscheAGretainsthe rightto implementchangesatanytime and
withoutpriornotice.
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Boxster(98G) Foreword
Use
Theworkshopdocumentationfor the Boxster(986) model hasthe
designation
-"Boxster (986)" Technical Manual- andcontainsTechnical
Informationaswell as instructionson repairs.
Theintegrationofthetechnicalinformationpublishedinthe"Boxster
(986)"TechnicalManualwiththe descriptivematteron repairspro-
videsthe userwith a complexreferencework that combinesinto
onebookassociatedor cross-referencedmaterialofrelevanceto
workshopsandoriginatingfrom variousinformationmedia.
The"Boxster(986)"TechnicalManualconsistsof 15 folders, subdi-
videdintothefollowingGroups
.0 Entirevehicle-General
.0 Diagnosis,1 Engine,part1 (upto RepairGroup45)
.0 Diagnosis,1 Engine,part2 (asof RepairGroup69)
.1 Engine,part1 (upto RepairGroup13)
.1 Engine,part 2 (asof RepairGroup15)
.2 Fuel,exhaust,engineelectronics
.3 Transmission,manualtransmission
.3 Transmission,automatictransmission
.4 Runninggear
.5 Body
.6 Bodyequipment,exterior
.7 Bodyequipment,interior
.8 / 9 Air conditioning/ Electrics
.9 Circuitdiagrams,part1 (upto andincluding'99 model)
.9 Circuitdiagrams,part 2 (asof andincluding'00 model)
Thetwo folderswith Group0 areto be regardedas one folder; i.e,
file the "Technicallnformation"noticesonlyinthe folder "Group0
Diagnosis,part I" -up to Repair Group 45-.
Thesecondfolder Group0 Engine,part 2 -as of Repair Group
69- includesthefurther RepairGroupsbelongingto Group1.
Thetwo folderswithGroup1 areto be regardedas one folder;i.e.
filethe liTechnicallnformation"onlyinfront oftherepairdescriptions
inthe folder Group1 -Engine, part1 -up to Repair Group 13-.
-2 page 1
Use
Printed in Germany -37 I 2000 handhabung
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Boxster(986)
Foreword
Thesecondfolder Group1 -Engine, part 2 -as of Repair Group
15- includesthe further RepairGroupsbelongingto Group1.
Thetwo folders withGroup9 areto be regardedas one folder;i.e.
file the "Technicallnformation"noticesonlyinthefolder Group9 Cir-
cuit diagrams,part1 -up to '99 model-,
Thesecondfolder Group9 Engine,part 2 -as of '00 model-
includesthefurther RepairGroupsbelongingto Group9.
The"Boxster(986)"TechnicalManualhasthe samestructurein
eachfolder,withthefollowingbreakdownfor allGroups:
Title page: "Boxster (986)" Technical Manual
> Foreword
Title page: "Technical information'
> Tableof contents,Technicalinformation>Technicalinformation
Title page: "Repair"
> RepairGroups:overview>Tableof contents,repairs> General/
technicaldata> Instructionsonrepairs
As canbe seenfrom the breakdown,the publishedTechnicallnfor-
mationis inthe front part ofeachfolder-numbered accordingto
the Groups.TheTableof Contentsassignedto eachGroupwill be
periodicallyupdated.
Followingthe TechnicalInformation,separatedbya title page,the
instructionson repairs-assigned accordingto theGroupsor bro-
kendownintoRepairGroups-are includedinthefolders.
Theinstructionson repairswillbeextendedandupdatedbymeans
ofsupplements.
rn Note!
Sheetsthat alreadyexistin the "Boxster(986)"TechnicalManual
andareupdatedor revisedandtherebyexchangedbyasupplement
are designatedin the footer withthe supplementnumbercorre-
spondingto thecurrentversion:e.g. "Printedin Germany-2,-
2000"
[IJ Note!
Dueto a systemmodificationintheTechnicalLiteratureproduction,
the followingprocedureshavechangedin modelyear2000!
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Boxster (986) Foreword
1 -The previous record sheet in the folder "O-Genera!" and
the supplement contents sheet -red sheet- have been
omitted. A supplement overview now appears sepa-
rately in each folder. The new supplement contents
sheet can be destroyed after the supplement is filed in
the folder.
rn Note!
Thesupplementoverviewsheetis replacedwiththerelevant
supplementinthecorrespondingfolderandmustnolongerbe
maintainedbyhand.
2 -The page numbering in the new and the replaced chap-
ters are no longer continuous. Each new chapter is now
given an additional chapter number followed by the
page number e.g.-2 Page 11 ~ Rep. Gr. 0; General
3 -The old page numbering still applies to existing chap-
ters and those that are not replaced.
-2 page 3
Use
Printedin Germany-37, 2000 handhabung
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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
Airbagdiagnosis
Seatmemorydiagnosis
Heatingdiagnosis
Alarmsystemdiagnosis
PCMdiagnosis
ParkAssistentdiagnosis
HBAdiagnosis
Group 1: 1
10
13
Engine
Engine-Crankcase, suspension
Engine-Crankshaft, pistons
Group 1: 1
15
17
19
Engine
Engine-Cylinder head,valvedrive
Engine-Lubrication
Engine-Cooling
Group 2: 2
20
21
24
25
26
27
28
Fuel, exhaust, engine electronics
Fuelsupply,control
Exhaustsystem,turbocharging
Fuelsystem,electronicinjection
Fuelsystem,K-Jetronic
Exhaustsystem
Starter,power supply,cruisecontrol
Ignitionsystem
Group 3: 3
30
34
35
39
Transmission, manual transmission
Clutch,control
Manualtransmission-Actuation, housing
Manualtransmission-Gears, shafts,intogearsh,
Finaldrive, differential,differentiallock
Group 3: 3
32
37
38
39
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
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Overview of repair groups Boxster
C;roup 4: 4
40
42
44
45
46
47
48
Running gear
Frontwheelsuspension,drive shafts
Rearwheel suspension,drive shafts
Wheels,tires, suspensionalignment
Anti-LockBrakeSystem(ABS)
Brakes-Brake mechanics
Brakes-Hydraulics, regulator,booster
Steering
(~roup 5: 5
50
51
53
55
57
Body
Bodyfront
Bodycenter,roof,frame
Bodyrear
Lids,flaps
Doorfront,centrallockingsystem
(iroup 6: 6
60
61
63
64
66
68
69
Body equipment, exterior
Slidingroof
Convertibletop, hardtop
Bumpers
Glazing,windowcontrol
Exteriorequipment
Interiorequipment
Passengerprotection
(~roup 7: Body equipment, interior
Linings,insulation
Seatframes
Seatupholsteries,covers
7
70
72
74
8
80
85
87
88
Ciroup 8: Air conditioning
Heating
Ventilation
Air conditioning
Auxiliaryair conditioningsystem
9
90
91
92
94
96
C;roup 9 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
C;roup9: Circuit diagrams
Wiring (up to and including the '99 model)
9
97
C;roup9: Circuit diagrams
Wiring(fromthe'00 model)
Overview of repair groups
Printed in Germany -34, October 1999
REPGRU.CHP
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Boxster(986) Bodyequipment,exterior
Table of Contents
6Body equipment, exterior
6
6
6
6
6
6
6-1
6-3
6-5
6-7
6-8
6-8
6-8
6-9
6-9
6-9
6-9
1
1
2
1
1
1
1
6
Body equipment
Colour range for 1997 modelsColour range for 1998 modelsColour range for 1999 modelsColour range for 2000 modelsProcessing of Porsche 2-component window bonding agents
Overview of tools and materialsMixing procedureColour range for 2001 modelsExterior paintwork solidExterior paintwork metallic/pearlSpecial paintwork metallic/pearl
61
610119
612855
61-1 page 1
61-1 page 2
61-1 page 4
61-1 page 5
61-1 page 7
61-1 page 9
61-1 page 13
61-11 page 1
61-11 page 3
61-11 page 5
61-11 page 6
61-11 page 11
61-11 page 13
61-11 page 14
61-27 page 1
61-27 page 2
61-27 page 4
61-27 page 6
61-27 page 8
61-27 page 9
613055
61-27 page 15
61-27 page 16
61-43
610219
Convertible top, hardtop
Removing and installing convertible topDiagram of convertible topOverview of convertible-top components up to model year 1999Overview of microswitch test plan up to model year 1999Overview of convertible-top components as of model year 2000Removing convertible topInstalling convertible topReplacing convertible-top covering """""""""""""""""."""""""
Removal overview of the convertible-top covering components, part 1Removal overview of the convertible-top covering components, part 2Removing convertible-top coveringInstallation overview of the convertible-top covering components, part 1Installation overview of the convertible-top covering components, part 2Installing the convertible-top coveringReplacing convertible-top frame """""""".""""""""""""""""",
Overview of replacing convertible-top frame, part 1Overview of replacing convertible-top frame, part 2Overview of replacing convertible-top frame, part 3Overview of replacing convertible-top frame, part 4 ,Replacing convertible-top frameConversion measure on the tension bow for the tension strap in vehicles
produced before 12.04.2000Conversion measure on the tension bow for the roof liner in vehicles produced
before 12.04.2000Removing and installing hardtop
Table of Contents
Printed in Germany -40, 2000 Master6
page
page
page
page
page
page
page
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Boxster (986)
Bodyequipment, exterior
610237
6102
617705
610115
610101
611719
610215
610919
61-49
61-69
61-81
61-85
61-89
61-95
61-101
61-107 page
61-107 page
61-107 page
61-107 page
61-107 page
61-108 page
61-108 page
61-108 page
61-109 page
61-109 page
61-109 page
61-109 page
1
2
3
6
7
1
1
2
1
1
2
3
614356
612830
Disassembling and assembling hardtop ,
Removal instructions for hardtop assembly fixture
Adjusting convertible top gear ,
Adjusting Cabriolet convertible top. ,
Troubleshooting in convertible top operation ,
Removing and installing hardtop fastening. ,
Adjusting the hardtop ,
Removing and installing roof liner. ,
Removal overview of roof liner ,
Removing roof linerInstallation overview of roof liner. ,
Installing roof linerRe'placingthetensioncableRemoving the tension cableInstalling the tension cableCare and cleaning of the convertible top.Cleaning the convertible topCare of convertible topCare of convertible-top seals
63
631519 63.1 page
63.1 page
63-1 page
63-7
63-15 page
63-15 page
63-15 page
63-16 page
63-16 page
63-16 page
63-17 page
1
2
4
635519
631537 1
2
4
1
2
4
1
631537
631019
Bumpers
Removing and installing front spoiler.Removing front spoilerInstalling front spoilerRemoving and installing rear spoilerDisassembling and assembling front spoiler.DisassemblingfrontspoilerAssembling front spoilerDisassembling and assembling front spoiler -Boxster S
DisassemblingfrontspoilerAssembling front spoilerRemoving and installing bumper and accessories.
64
641219 1
2
5
7
64-1 page
64-1 page
64-1 page
64-1 page
64-9
64-17
64-19
Glazing, window control
Removing and installing the windscreen..Removing the windscreen.FittingthewindscreenOverview of tools and materials..Removing and installing rear window (hardtop)
Removing and installing power window motor
Checking function of heating for rear window
648619
645419
648601
66
668937 66-1
Exterior equipment
Disassemblingandassemblingthe rearviewmirror
Table of Contents
Printedin Germany-40, 2000
II Master6
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Boxster(986) Body equipment, exterior
665819
665619
667801
66-5
66-11
66-15
Removing and installing rear spoiler.Removing and installing the engine compartment vent
Checking function of heating for mirror glass.
68
682719
682713
681719
681719
681737
68-1
68-5
68-9 page
68-13 page
68-14 page
68-14 page
68-15 page
68-15 page
68-15 page
68-16 page
68-16 page
68-16 page
1
4
1
2
4
680519
Interior equipment
Removing and installing the interior rearview mirror. ,
Bonding on the interior rearview mirror ,
Removing and installing centre console (front section) ,
Removing and installing centre console ,
Disassembling and assembling centre console ,
Disassembling and assembling cover for the oddments tray
Removing and installing inner sill (passenger's side) "'.""'.'
Removing inner sill ,
Installing inner sillRemoving and installing inner sill (driver's side)DisassemblingreleaseforfrontlidAssembling release for front lid
680519 2
4
69,
69
6959
695819
695419
695319
695919
696319
697219
69-1
69-3
69-9
69-11
69-13
69-15
69-17
69-51
Passenger protection
Safety regulations for airbag vehicles.Disposal of airbag units """"""""""""""""'"
Removing and installing the driver's airbag unitRemoving and installing the contact unit.Removing and installing the triggering unit for the airbag
Removing and installing the passenger's airbag unitRemoving and installing the side airbag unit..Removing and installing roll-over bar.
Table of Contents
Printed in Germany -40, 2000 Master6
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Body equipment, exterior
Boxster
Colour range for 1997 models
6
Exterior paintwork metallic / pearl:
Exterior paintwork solid:
Code
Designation Code Designation
92T
Snowwhite 3AT Arcticsilvermetallic
92U*
3AU. Arcticsilvermetallic
Snowwhite
3AW
747 Azuremetallic
Black
3AX*
Black 741* Azuremetallic
746
80K Blackpearl
Indianred
744*
84A* Blackpearl
Indianred
3AY
3AR Oceanbluemetallic
Turquoiseblue
3AZ.
3AS* Oceanbluemetallic
Turquoiseblue
Arenaredpearl 84R
12L
Pastelyellow
84S*
12M* Arenared pearl
Pastelyellow
25HDragonflyturquoisemetallic
Dragonflyturquoisemetallic 25K*
=Water-basedpaints
6.01
9866_O1
Color range
Printed in Germany, 1996
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Bodyequipment, exterior
Boxster
6Colour range for 1999 models
Exterior paintwork solid:
Designation Code
3AT
Glacierwhite
3AU*
Glacierwhite
Black 747
Black 741*
Guardsred 80K
Guardsred 84A*
12L
Pastelyellow
Pastelyellow 12M*
Speedyellow 12G
Speedyellow 12H*
Darkblue 374
Darkblue 3C7*
= Water-basedpaints
6 -05
Colour range
Printed in Germany -26, 1999 9866_O5
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t5 Body equipment, exterior Boxster
Exterior paintwork metallic / pearl:
Designation Designation Code
Code
Arcticsilvermetallic 92T Wimbledongreenmetallic 231
Arctic silvermetallic 92U. Wimbledongreenmetallic 286*
Pine-greenmetallic 22E
Zenithbluemetallic 3AW
Pine-greenmetallic 284*
Zenithbluemetallic 3AX*
Violetmetallic 39G
Blackpearl 746
Violetmetallic 3AE*
Blackpearl 744*
Cobaltbluemetallic 37U
Oceanbluemetallic 3AY
Cobaltbluemetallic 3GB.
Oceanbluemetallic 3AZ*
Polarsilvermetallic 92E
Arenared pearl 84R
Polarsilvermetallic 92M*
Arenared pearl 84S*
Slatemetallic 22D
Oceanjade metallic 25H
Slatemetallic 23F*
Oceanjade metallic 25K*
Midnight blue metallic 37W
Iris blue metallic 39N
Midnightbluemetallic 39CF*
39V.Iris bluemetallic
= Water-basedpaints
6 -06 Colour range
Printed in Germany -26, 1999
9866_O5
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6
Boxster Body equipment, exterior
6Colour range for 2000 models
Exterior paintwork solid: Exterior paintwork metallic / pearl:
Designation Code Designation Code
Biarritzwhite 9A3 Arctic silvermetallic 92T
Biarritzwhite 9A2* Arctic silvermetallic 92U*
Black 747 Zenithbluemetallic 3AW
Black 741* Zenithbluemetallic 3AX*
Guardsred 80K Blackmetallic 746
Guardsred 84A* Blackmetallic 744*
Speedyellow 12G Oceanbluemetallic 3AY
Speedyellow 12H* Oceanbluemetallic 3AZ*
Arenared metallic 84R
Arenaredmetallic 845*
Junglegreenmetallic 2A2
Junglegreenmetallic 2Al*
Vesuviometallic 40W
Vesuviometallic 40X*
Paladiometallic 554
Paladiometallic 555*
= Water-basedpaints
6 -07Colourrange
Printed in Germany -30, 1999 9866_O7
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6
Boxster(986) Body equipment
Overview of tools and materials
H12
~
H10
H8
~
.
r'(@),
--=:::::::"
.H5
H1 H2 H3 H4
Mixingrod 9528
-8- Bonding gun 9586
~ Rep.Gr.2.2;WorkshopEquipment
Manual
~ Rep.Gr.2.2;WorkshopEquipment
Manual
Containsset componentsHI-H12
-H- Adhesiveset000.043.204.34
6 Processing of Porsche 2-component window bonding agents
Printedin Germany-38, 2000 a6xxxxx5 6-8 page 1
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Boxster(986)
Body equipment
Mixiing procedure
6 Processing of Porsche 2-component window bonding agents
a6xxxxx5 Printed in Germany -38, 2000
6-8. page 2
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6
Boxster(986) Body equipment
rn Note!
Inadditionto this manual,observetherelevantjob descriptionsfor
insta:llingcarwindows(Group64)in the TechnicalManual!
No. Procedure Instructions
1Preparing cartridge component A -H4-
2Transferringcontentsof componentA
3Preparing cartridge component B -H5-
Transferringcontentsof componentB4
5Screwingmixingrod -A- intoplace
MixingcomponentAandcomponentB
Clampanadjustibleelectric powerdrill ina conventional
horizontalclamp. Pre-seta speed of 900 -1,200 rpm.
Piercethemembraneinthe nozzleconnectionof compo-
nentA(aluminiumcartridge)-H4- with a screwdriverand
extendtheopening.Removethe flangedcoverfrom the
end ofthe cartridge.
Screwthe shortfiller nozzle(blue)-H8- onto thenozzle
connectionof componentA.
Unscrewthe screwcap -HIO- on the emptymixingcar-
tridge -H6-, insertthe preparedcartridge (componentA)
-H4- into the bondinggun-B- and insertthefiller nozzle
-H8- asfar aspossibleintothe mixingcartridge -H6-.
PresscomponentAfullyintothe mixingcartridge.
Aftertransferringthe contents,pullthefiller nozzleofthe
cartridge (componentA)-H8- out ofthe mixingcartridge.
Cutoffthe pointofthe nozzleconnectionof componentB
(plasticcartridge)-H5- with a knife.
Screwthe injectionnozzle(yellow)-H9- onto the nozzle
connectionof componentB.
Insertthepreparedcartridge (componentB)-H5- into the
bondinggun-B- andinsertthe injectornozzle-H9- asfar
aspossibleintothe mixingcartridge-H6-. Presscompo-
nentBfullyintothe mixingcartridge.
After transferringthe contents,pullthe injectornozzleof
the cartridge (componentB)-H9- out ofthe mixingcar-
tridge.
Closethe mixingcartridge -H6- with a screwcap -HIO-
andscrewthemixingrod -A- byhandintothemixer ofthe
mixingcartridge.
Clampthe mixingrod inthe preparedpowerdrill. Switch
the powerdrillonandallowitto turn ata speedof900 -
1,200rpm. Duringoperation,movethe mixingcartridge
axiallyfrom oneendstopto the other 25 times -arrows-.
Note:performthe stroke movementsrapidly.Thecar-
tridge pistonis securedatthe rearandcan notfall out dur-
ingthe mixingprocedure.
6
6 Processing of Porsche 2-component window bonding agents
Printedin Germany-38. 2000 a6xxxxx5 6-8 page3
.Observe the safety instructions of the individual adhesive
set components.
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