Porsche Boxster S User manual

Technical Manual
-~~s:.re.,-
Technical Information
Contents:
Group 7
Body equipment, interior
WKD483 521 31

Boxster(986) Bodyequipment,interior
Supplement Overview
Supple-
ment Edition Topic Article number
05/1996 Basicedition WKD483521
2
10 08/1996 Disassemblingandassemblingthe dashboard WKD483521.02
04/1997 WKD483521,10
I
General supplement on the seat
14 08/1997 WKD483521.14
Removingandinstallingcoveringfor front back-
rest
16
26 16/1997
04/1999
WKD483521.16Removingandinstallingcowlpanelcover
Disassemblingandassemblingdoortrim panel
(newbowdencable) WKD483521.26
31
36 08/1999 FolderseparationGroups6 and 7 WKD483521.31
12/1999
I
General remarks on the dashboard WKD483521.36
WKD483521.37
37 OS/2000 Generalsupplement
Supplement Overview
Printedin Germany-37, 2000 Master7

Boxster (986) Foreword
Table of Contents
0 Foreword
Foreword
ForewordUse . 1
1
-1 page
-2 page
Table of Contents
Printed in Germany -37, 2000 masterY

Boxster (986) Foreword
Foreword
ThismanualcontainsTechnicallnformationaswell asinstructions
on repairsfor Porschevehicles.Itis intendedfor the soleuse of
workshopsbelongingto PorscheAG.
Thedescriptionsformthe basisfor professionalandcorrect mainte-
nanceandrepairwork. The contentofthe work procedures
describedis basedonthe leveloftrainingofafitter who hascom-
pletedvocationaltrainingand hasa soundknowledgeofthe prod-
uct. Thislevelof knowledgeis necessaryin orderto carry outthe
workdescribed.
Warning notes
Thewarningnotesand safetyinstructionsareclassifiedbythe
respectivesignalisingword (Danger,Warning,Caution)besidethe
warningsymbol.
To preventinjuryandrestricted operatingandtraffic safetyofthe
vehicle,or damageto thevehicleasthe resultof incorrectwork,
readthese instructionscarefullyandobservethem withoutfail.
Itis notpossiblefor PorscheAGto givea detailedevaluationof all
dangersituationsfor the personscarryingoutthework. Itis there-
fore imperativethatallpersonscarryingoutrepairandmaintenance
work on Porschevehiclesusetheir specialistknowledgeto ensure
thattheirownsafetyis not atrisk andthe procedurechosenwill not
haveanynegativeeffects onthe vehicle-especiallywith regardto
safety.
Itistherefore expresslyspecified
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.
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.
thatallworkinvolvedintheworkarried
outonlyinaccordancewiths
ofthe localauthoritiesresponsi-
identpreventionandenvironmen-

Boxster(986)
Foreword
tal protection,andin compliancewiththe legalrequirementsof
individualcountries.
Notes
Notescontainadvisoryinformationrelatedto the work procedure
whichmakesthe fitter's work easier.Thefollowingpictogram indi-
catesthis information:
[IJ Note!
Containsadvisoryinformationwhichmakestheworkprocedureeas-
ter.
Dueto the continuousdevelopmentand improvementof our vehi-
cles,there maybe discrepanciesbetweenthe actualtechnicalsta-
tus ofthe vehiclesandthe work 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 as instructionson repairs.
Theintegrationofthetechnicalinformationpublishedinthe "Boxster
(986)"TechnicalManualwiththe descriptivematteronrepairs pro-
videsthe userwith a complexreferencework that combinesinto
onebook associatedor cross-referencedmaterialof relevanceto
workshopsandoriginatingfrom variousinformationmedia.
The"Boxster(986)"TechnicalManualconsists of 15 folders, subdi-
videdintothefollowingGroups
.0 Entirevehicle-General
.0 Diagnosis,1 Engine,part1 (upto RepairGroup45)
.0 Diagnosis,1 Engine,part 2 (asof RepairGroup69)
.1 Engine,part 1 (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 Airconditioning/ Electrics
.9 Circuitdiagrams,part1 (upto andincluding'99 model)
.9 Circuitdiagrams,part 2 (asofandincluding'00 model)
Thetwo folders withGroup0 areto be regardedasone folder;i.e.
file the "Technicallnformation"noticesonlyinthefolder"Group0
Diagnosis,part I" -up to Repair Group 45-.
Thesecondfolder Group0 Engine,part 2 -as of Repair Group
69- includesthe furtherRepairGroupsbelongingto Group1.
Thetwo folders withGroup1 areto be regardedasone folder;i.e.
filethe liTechnicallnformation"onlyinfront ofthe repairdescriptions
inthe folder Group1 -Engine, part1 -up to Repair Group 13-.
-2 page 1
handhabung
Use
Printed in Germany -37, 2000

Boxster(986)
Foreword
Thesecondfolder Group1 -Engine, part2 -as of Repair Group
15- includesthe further RepairGroupsbelongingto Group1.
Thetwo folders withGroup9 areto be regardedas one folder;i.e.
filethe "TechnicalInformation"noticesonlyinthe folder Group9 Cir-
cuit diagrams,part 1 -up to '99 model-.
Thesecondfolder Group9 Engine,part2 -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>Telchnicalinformation
Title page: "Repair'
> RepairGroups:overview>Tableof contents,repairs>General/
technicaldata> Instructionsonrepairs
As canbe seenfrom the breakdown,the publishedTechnicallnfor-
mationis inthe front part of eachfolder-numbered accordingto
theGroups.TheTable ofContentsassignedto eachGroupwill be
periodicallyupdated.
Followingthe TechnicalInformation,separatedbyatitle page,the
instructionson repairs-assigned accordingto the Groupsor bro-
kendowninto RepairGroups-are includedinthe folders.
Theinstructionsonrepairswillbeextendedandupdatedbymeans
ofsupplements.
rn Note!
Sheetsthat alreadyexistinthe "Boxster(986)"TechnicalManual
andareupdatedor revisedandtherebyexchangedbyasupplement
are designatedin the footer withthesupplementnumbercorre-
spondingto the currentversion:e.g. "Printedin Germany-2,-
2000"
rn Note!
Dueto a systemmodificationinthe TechnicalLiteratureproduction,
thefollowingprocedureshavechangedin modelyear20001

Boxster(986) Foreword
1 -The previous record sheet in the folder "O-General" 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
maintainedby hand.
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: Diagnosis
Salescheck
On-boarddiagnosis
DMEdiagnosis
Tiptronicdiagnosis
ABSdiagnosis
0
01
03
24
37
45
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
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

Overview of repair groups Boxster
Group 4: 4
40
42
44
45
46
47
48
Running gear
Frontwhee!suspension,drive shafts
Rearwheelsuspension,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
Body equipment, interior
Linings,insulation
Seatframes
Seatupholsteries,covers
7
70
72
74
Group 7:
8
80
85
87
88
Group 8: Air conditioning
Heating
Ventilation
Airconditioning
Auxiliaryairconditioningsystem
Group 9 9
90
91
92
94
96
Electrics
Instruments,alarmsystem
Radio,telephone,on-boardcomputer,navigation
Windshieldwiperandwashersystem
Lights,lamps,switchesexterior
Lights,lamps,switchesinterior,theftprotection
9
97
Group 9: Circuit diagrams
Wiring(upto and includingthe '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 (986) Body equipment, interior
Table of Contents
7Body equipment, interior
70
701837 70-1 page 1
70-1 page 2
70-1 page 8
70-1 page 8
70-1 page 9
70-1 page 15
70-1 page 15
70-13 page 1
70-17
70-21
701819
702219
705937
Linings, insulation
Disassembling and assembling the dashboard.
Disassembling the dashboard-Removing the regulator for wiping interval
-Removing the cigarette lighterAssembling the dashboard.-Installing the regulator for wiping interval..
-Installing the cigarette lighter.Removing and installing the dashboard.Removing and installing cowl panel cover ,
Disassembling and assembling door trim panel
72
720119
720937
721937
72-1
72-7
72-13
Seat frames
Removing and installing front seat.Disassembling and assembling the seat frame. ...
Disassembling and assembling backrest frame. ..
74
741319
741919
Seat upholsteries, cover
Removing and installing covering for front seat.Removing and installing covering for front backrest. .. 74-1
74-11
Table of Contents
Printed in Germany -37,2000 Master7

Boxster (986) Linings,insulation
Disassembling and assembling the dashboard
701837 Disassembling and assembling the dashboard
Printedin Germany-37,2000 a701837x 70-1 page1

Boxster (986) Linings,insulation
rn Note!
.The followingcomponentsmustbe removedbeforedisassemblingthe dashboard.
.=> Rep.Gr. 705719; RemovingandinstallingA-pittartrim.
.=> Rep.Gr.695819; Removingandinstallingthedriver'sairbag
.=> Rep.Gr.695919; Removingandinstallingthepassenger'sairbag
Removingthe alarmreadinesscoverand Liftthe alarmreadinesscover-2- andunclip it upwards
the defrostercover outoftheclip-4-. Thelenscover-3- canbeunclippedfor
replacementpurposes.
Liftthedefroster coversleftand right-5, 6- with a plastic
spatulaandunclipout ofthe clips -4-.
Removingthe alarmreadinessunit Undothefasteningscrews-7-, liftthe alarmreadinessunit
-8- anddisconnecttheelectricalconnection.
Removingthe loudspeaker Undothefasteningscrews-9-, raisethe outsideofthe
loudspeaker-10- andguideit out. Atthe plugconnection
-11-, pressthe lockingtab -arrow- anddisconnect.
Removingthe instrumentmount Toremovethe hazardwarninglightswitch:switchonthe
switch-12- (buttoncomesout).Therearesmallopenings
onthe sideswhichnowprojectoverthe instrumentcowl.
Inserttwo narrowscrewdriversintothe openings-arrow
A- andpull offthe buttontowardsthefront. Thehazard
warninglightswitch-13- is heldinthe instrumentbridge
-16- bytwo lockinghooks-arrow B-. Pressthe right lock-
inghooktowardthe switch,grip the buttonholderwith a
pair of pliersandpull outthe switchtowardthefront. Pull
offthe cover-14- onthe leftsideandundothe fastening
screws-15-. Liftthe instrumentmount-16- onthe leftand
rightandunclipfrom the clips -4-.
Disconnectingthe electricalplug connection Disconnectthe electricalconnection-17- onthe rear side
ofthe instrumentmount.Todoso, pressthelockingtab of
the plugconnectionandunlockthe lockingleverinthe
-direction of the arrow-.
2
3
4
5

Boxster (986)
Linings,insulation
~~"'""",
~~~~.../

Boxster(986) Linings,insulation
Removingthe sideventsandthe tempera- Pulloff the coveringcaps-20, 20A-. Undothe fastening
ture sensor screws-21- atthe side,removethe sidevent-22-
towardsthe front.
Unclipthetemperaturesensor-24- out ofthe dashboard
towardsthe rear.
Disconnectthe electricalplugconnection-23-.
Removingleftsideventsandmainlight Pullforwardthe controlbutton-25- ofthe lightswitch-31-
switch asfar as itwill go -in the direction of the arrow-
towardsthefront. Pressinthe lockingdeviceatthe lower
sideusinga smallscrewdriverandremovethe control but-
ton towardsthe front.
Undothefasteningscrews-21- atthe side,removethe
sideventtowardsthe front. Disconnectthe plug connec-
tion-30- ofthe mainlightswitch-31-.
Inorderto disassemblethe side vent,the coveringcap
-28-, thefasteningnut-26- andtheinnerrace -27- ofthe
mainlightswitch-31- canberemoved.Removelight
switch-31- from the side ventbyturningit slightlyin
clockwisedirection.
Removingthe steeringcolumnswitchcover Undothefasteningscrews-32- onthe lowersteering col-
umnswitchcover -36- andremovebothsteeringcolumn
covers-33, 36 or 35-,
Removingthe steeringcolumnswitch Undothefasteningscrew-37- inthe cover-38- andthe
steeringcolumnswitch-42- andremove.Disconnectthe
electricalplugconnection.
Inorderto disassemblethe steeringcolumnswitch-42-,
the slipring -41- canbe disconnectedby undoingthe fas-
teningscrews-39, 40-.
See:~ Rep.Gr.695419; Removingandinstallingthe con-
tactunit.
Removingthe steeringcolumncover Undothefasteningscrew-43- inthe steeringcolumn
cover-44- andunclipthe coverupwards.
7
8
9
10

Boxster (986) Linings,insulation
No. Procedure Instructions
Removingthe switchcover
12 Removingthe mechanicalheatingandfresh
air regulatorvariant-47A, 478, 47C-,
the electricalair-conditioningandheating
regulatorvariant-47- andthe car radio
-48, 49-
13 Removingdisplayandoperatorcontrol unit
(PCM)
14 Removingthe PCMretainingbracket
15 Removingthe centralvent
Uncliptheswitchcoveronthe left and right-45, 46-
towardsthefront.
Disconnectthe electricalplugconnectionsof thetip
switches.
See:=>Rep.Gr.851019; Removingandinstalling
mechanicalheatingandfresh-aircontrol.
See:=>Rep.Gr.870219; ~emovingandinstallingthe
heating/air-conditioningcontrol.
See: =>Rep.Gr.912019; Removingandinstallingthe car
radio.
Pressinandholdbothspring clips -arrow A-. Pulloutthe
displayandoperatorcontrol unit-50-. Disconnectthe
electricalplugconnections-51- onthe rearsideofthe dis-
playandoperatorcontrolunit.
See:=>Rep.Gr.911019; Removingandinstallingdisplay
andoperatorcontrol unit(PCM).
Raisethe retainingclip -arrow B- ofthe retainingbracket
-52- andguide it out ofthe cut-outofthe centralvents
-55-.
Pulloffthe groundcable-53-.
Undothefasteningscrews-54- andguidethe centralvent
-55- outofthedashboard-1-.
Undothefasteningscrews-56- from the insideofthe
retainingbracket-57-.
701837 Disassembling and assembling the dashboard
Printedin Germany-37. 2000 a701837x 70-1 page7

Boxster (986)
Linings,insulation
Removingthe regulator for wiping interval ... ~
;;;;;;;;;;;;;;'I;f/
1 -Disconnect the electrical plug connection.
2 -Press the locking tabs of the regulator for the wiping
interval -arrows A- outwards and guide the regulator out
of the front cover towards the front.
-it
--
Removingthe cigarette lighter
~
1 -Disengage the cover -arrow A- upwards.
2 -Press the lights bracket -arrow B- out to the side with a
narrow screwdriver.
-
3 -Disengage the cigarette lighter in the direction of
-arrow C- out of the front cover. ~, ~[.,