Porsche Boxster S User manual

TechnicalManual
_.8G~.s;Zi!/-
TechnicalInformation
Repair
Contents:
Group 5
Body
WKD483 521 15

Boxster(986) Body
Supplement Overview
Supple-
ment Edition Topic Article number
05/1996 Basicedition WKD4835~1
208/1996 Generalchanges WKD 48352 ~.02
7
10 11/1996 Generalchanges WKD48352t.O7
04/1997 Assemblyinstructionsfor hardtopassemblyfix-
ture WKD48352t.l0
12 Generalremarksonthe airbag WKD48352t.12
14 Generalchanges WKD483521.14
15
16
18
20
23
FolderseparationGroups5 and6 WKD48352t.15
07/1997
08/1997
08/1997
11/1997
01/1998
03/1998
07/1998
Generalsupplement WKD48352t.16
Generalremarksontheairbag WKD483521.18
Generalsupplement WKD48352t.20
Assembly instructions for hardtop assembly fix-I
ture WKD48352t.23
25
26
29
30
31
32
02/1999 Generalsupplement WKD48352t.25
04/1999 Generalsupplement WKD483521.26
07/1999 Generalsupplement WKD48352t.29
07/1999 Changesin modelyear 2000 WKD48352t.30
08/1999 FolderseparationGroups6 and 7 WKD48352t.31
09/1999 Removingandinstallingconvertible-toproof
liner WKD483521.32
36
37
38
39
43
Removingandinstallingthe sideairbagunit WKD48352~.36
12/1999
05/00
07/2000
08/2000
12/2000
Generalsupplement WKD483521.37
Generalsupplement WKD 483521.38
Changesinmodelyear2001 WKD483521.39
Bodyrepairs WKD483521.43

Boxster (~86) Foreword
Table of Contents
0Foreword
Foreword
Foreword
Use 1
1
-1 pa~e
-2 pa~e
Table of Contents
Printed in Germany -37 I 2000 masterY

Boxster(~86) Foreword
Foreword
Thisman~alcontainsTechnicallnformationaswellas instructions
onrepair for Porschevehicles.Itis intendedfor the soleuseof
workshop belongingto PorscheAG.
Thedesc iptionsform thebasisfor professionalandcorrect mainte-
nancean repairwork. The contentofthe work procedures
describedis basedonthe leveloftrainingof afitter whohascom-
pletedvo ationaltrainingandhasa soundknowledgeofthe prod-
uct. ThisI vel of knowledgeis necessaryin orderto carry outthe
workdes ribed.
Warning notes
Thewarm
~g notesand safetyinstructionsareclassifiedbythe
respectiv signalisingword (Danger,Warning,Caution)besidethe
warnings mbol.
To preventinjuryandrestricted operatingandtraffic safetyofthe
vehicle,or damageto the vehicleasthe resultof incorrectwork,
readtheseinstructionscarefullyandobservethem withoutfail.
Itis notpossiblefor PorscheAGto givea detailedevaluationofall
dangersituationsfor the personscarryingoutthework. Itis there-
fore imperativethatallpersonscarryingoutrepairandmaintenance
work on Porschevehiclesusetheir specialistknowledgeto ensure
thattheirownsafetyis not atrisk andthe procedurechosenwill not
haveanynegativeeffects onthe vehicle-especiallywith regardto
safety.
Itis therefore expresslyspecifiedthatallwork involvedinthe work
proceduresdescribedshouldbecarriedoutonlyinaccordancewith
the validguidelinesandregulationsofthe localauthoritiesresponsi-
blewith respectto healthandaccidentpreventionandenvironmen-
-1 Rage 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.
Warns against death or very serious injury which may occur
if the instructions are not observed.
Warns against minor injury or damage to property if the
instructions are not observed.

Boxster(986)
Foreword
talprotection, andin compliancewiththe legalrequirementsof
individualcountries.
Notes
Notescontainadvisoryinformationrelatedto thework procedure
whichmakesthe fitter's work easier.Thefollowingpictogram indi-
catesthis information:
[IJ Note!
Containsadvisoryinformationwhichmakestheworkprocedureeas-
ier.
Dueto the continuousdevelopmentandimprovementofour vehi-
cles,theremaybe discrepanciesbetweenthe actualtechnicalsta-
tus ofthe vehiclesandthework descriptions.Anyexisting
deviationsarecorrected by meansof supplements,andthe scope
ofthe descriptionsis extendedwithsupplements.
PorscheAGretainsthe rightto implementchangesat anytime and
withoutpriornotice.

Boxster (986) Foreword
Use
Theworkshopdocumentationfor the Boxster(986)modelhasthe
designation
-"Boxster (986)" Technical Manual- andcontainsTechnical
Informationaswell asinstructionsonrepairs.
Theintegrationofthetechnicalinformationpublishedinthe"Boxster
(986)"TechnicalManualwiththe descriptivematter onrepairspro-
videsthe userwitha complexreferencework thatcombinesinto
onebookassociatedor cross-referencedmaterialofrelevanceto
workshopsandoriginatingfrom variousinformationmedia.
The"Boxster(986)"TechnicalManualconsistsof 15 folders, subdi-
videdintothefollowingGroups
.a Entirevehicle-General
.a Diagnosis,1 Engine,part1(upto RepairGroup45)
.a Diagnosis,1 Engine,part2 (asofRepairGroup69)
.1 Engine,part1 (upto RepairGroup13)
.1 Engine,part2 (asofRepairGroup15)
.2 Fuel,exhaust,engineelectronics
.3 Transmission,manualtransmission
.3 Transmission,automatictransmission
.4 Runninggear
.5 Body .
.6 Bodyequipment,exterior
.7 Bodyequipment,interior
.8/9 Airconditioning/ Electrics
.9 Circuitdiagrams,part1(uptoandincluding'99 model)
.9 Circuitdiagrams,part2 (asofandincluding'00 model)
Thetwo folders with Group0 areto be regardedas onefolder;i.e.
file the "Technicallnformation"noticesonlyinthe folder "Group0
Diagnosis,part 1" -up to Repair Group 45-.
Thesecondfolder Group0 Engine,part2 -as of Repair Group
69- includesthe furtherRepairGroupsbelongingto Group1.
Thetwo folderswith Group1 areto beregardedas one folder;i.e.
filethe "Technicallnformation"onlyinfrontoftherepairdescriptions
inthe folder Group1 -Engine, part1 -up to Repair Group 13-.
-2 page 1
Use
Printed in Germany -37, 2000 handhabung

Boxster(986)
Foreword
Thesecondfolder Group1 -Engine, part 2 -as of Repair Group
15- includesthe further RepairGroupsbelongingto Group1.
Thetwo folderswithGroup9 areto be regardedasonefolder;i.e.
filethe"TechnicalInformation"noticesonlyinthefolderGroup9 Cir-
cuit diagrams,part 1 -up to '99 model-.
Thesecondfolder Group9 Engine,part2 -as of '00 model-
includesthe further RepairGroupsbelongingto Group9.
The"Boxster(986)"TechnicalManualhasthe samestructurein
eachfolder,withthe followingbreakdownfor all Groups:
Title page: "Boxster (986)" Technical Manual
> Foreword
Title page: "Technical information"
> Tableofcontents, Technicalinformation>Technicalinformation
Title page: "Repair"
> RepairGroups:overview>Tableofcontents,repairs> General/
technicaldata> Instructionsonrepairs
Ascanbeseenfrom the breakdown,the publishedTechnicallnfor-
mationis inthe frontpart ofeachfolder-numbered accordingto
the Groups.TheTableofContentsassignedto eachGroupwillbe
periodicallyupdated.
Followingthe TechnicalInformation,separatedbyatitle page,the
instructionsonrepairs-assigned accordingto the Groupsor bro-
kendowninto RepairGroups-are includedinthefolders.
The instructionson repairswill beextendedandupdatedbymeans
of supplements.
rn Note!
Sheetsthat alreadyexistinthe "Boxster(986)"TechnicalManual
andareupdatedor revisedandtherebyexchangedbyasupplement
aredesignatedin the footer withthesupplementnumbercorre-
spondingto the currentversion:e.g. "Printedin Germany-2,-
2000"
rn Note!
Dueto asystemmodificationintheTechnicalLiteratureproduction,
thefollowingprocedureshavechangedinmodelyear2000!

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

Boxster Overview of repair groups
Group 0: Entire vehicle -General
Maintenance 0
03
Group 0: 0
01
03
24
37
45
Diagnosis
Salescheck
On-boarddiagnosis
DMEdiagnosis
Tiptronicdiagnosis
ABSdiagnosis
Group 0: Diagnosis
Airbagdiagnosis
Seatmemorydiagnosis
Heatingdiagnosis
Alarmsystemdiagnosis
PCMdiagnosis
ParkAssistentdiagnosis
HBAdiagnosis
0
69
72
80
90
91
91
94
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,powersupply,cruisecontrol
Ignitionsystem
Group 3: 3
30
34
35
39
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
Frontwheelsuspension,driveshafts
Rearwheel suspension,driveshafts
Wheels,tires, suspensionalignment
Anti-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
Doorfront,centrallockingsystem
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
Airconditioning
Auxiliaryairconditioningsystem
9
90
91
92
94
96
Group 9 Electrics
Instruments,alarmsystem
Radio,telephone,on-boardcomputer,navigation
Windshieldwiperandwashersystem
Lights,lamps,switchesexterior
Lights,lamps,switchesinterior,theftprotection
Group 9: 9
97
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