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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Purchased from www.WorkshopManuals.co.uk