Porsche Boxster S User manual

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0
Technical Manual
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Technical Information
Repair
8
Contents:
Group 0
Diagnosis
Part 1 (up to Repair Group 45)
8
WKD483 521
TlTEL.CHP
8

Boxster Foreword
8
Foreword
Theworkshopdocumentationfor the Boxstermodelhasthe designation"Boxster" Technical Manual
andcontainsTechnical Information aswell as instructionson Repairs.
Theintegration ofthe technicalinformationpublishedin the "Boxster"TechnicalManualwith the
descriptivematter on repairs providesthe userwith a complexreferencework that combinesinto one
book associatedor cross-referencedmaterialof relevanceto workshopsandoriginatingfrom various
informationmedia.
The "Boxster"TechnicalManualconsists of 15 folders,subdividedintothe followingGroups
0 Entirevehicle-General
0 Diagnosis,part 1 (upto RepairGroup45) *1
eo Diagnosis,part 2 (asof RepairGroup69) *2
1 Engine,part 1 (upto RepairGroup 13) *3
1 Engine,part 2 (as of RepairGroup 15) *4
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 and includingthe '99 model)*5
9 Circuitdiagrams,part 2 (as of the '00 model)*6
I *1 Thetwo folders with Group0 are to 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).
8I *2 Thesecond folder "Group0 -Diagnosis, part 2" (as of Repair Group 69) includesthe further
RepairGroupsbelongingto GroupO.
I *3 Thetwo folderswith Group1 are to be regardedas one folder;i.e. file the "TechnicalInformation"
notices onlyin front of the repair descriptionsin the folder "Group1 -Engine, part 1" (up to
Repair Group 13).
I *4 Thesecond folder "Group1 -Engine, part 2" (as of Repair Group 15) includesthe further Repair
Groupsbelongingto Group1.
eForeword
PrintedinGermany-34, October1999 VORW.CHP
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Foreword Boxster
8
I *5 The two folders with Group 9 are to be regarded as one folder; i.e. file the "Technical Information"
notices only in front of the repair descriptions in the folder "Group 9 -Circuit diagrams, part 1" (up to
the '99 model).
I *6 The second folder "Group 9 -Circuit diagrams, part 2" (as of the '00 model) includes the further
circuit diagrams belonging to Group 9.
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, Technical information e> Technical information
-Title page: "Repair"
> Repair Groups: overview
> Table of Contents, repairs
> General/technical data
> Instructions on 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.
Following the Technical Information, separated by a title page, the instructions on repairs -assigned
according to the Groups or broken down into Repair Groups -are included in the folder.
The instructions on repairs will be extended and updated by means of supplements. 8
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.
e
Foreword
VORW.CHP Printed in Germany -34, October 1999
"~~

Boxster Overview of repair groups
8Group 0: Entire vehicle -General 0
Maintenance 03
I Group 0: Diagnosis 0
Salescheck 01
On-boarddiagnosis 03
DMEdiagnosis 24
Tiptronicdiagnosis 37
ABSdiagnosis 45
I Group 0: Diagnosis 0
Airbagdiagnosis 69
Seatmemorydiagnosis 72
Heatingdiagnosis 80
Alarmsystemdiagnosis 90
PCMdiagnosis 91
ParkAssistentdiagnosis 91
8 HBAdiagnosis 94
Group 1: Engine 1
Engine-Crankcase, suspension 10
Engine-Crankshaft, pistons 13
Group 1: Engine 1
Engine-Cylinder head,valvedrive 15
Engine-Lubrication 17
Engine-Cooling 19
Group 2: Fuel, exhaust, engine electronics 2
Fuelsupply,control 20
Exhaustsystem,turbocharging 21
Fuelsystem,electronicinjection 24
Fuelsystem,K-Jetronic 25
Exhaustsystem 26
Starter,power supply,cruisecontrol 27
Ignitionsystem 28
8Group 3: Transmission, manual transmission 3
Clutch,control 30
Manualtransmission-Actuation, housing 34
Manualtransmission-Gears, shafts,intogearsh. 35
Finaldrive, differential,differentiallock 39
Group 3: Transmission, automatic transmission 3
Torqueconverter 32
Automatictransmission-Actuation, housing 37
Automatictransmission-Gears, control 38
Finaldrive,differential,differentiallock 39
80.f.
vervlew 0 repair groups
Printed in Germany -34, October 1999 REPGRU.CHP
J

Overview of repair groups Boxster
Group 4: 4
40
42
44
45
46
47
48
Running gear
Frontwheel suspension,drive shafts
Rearwheel suspension,drive shafts
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
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
Group 9 9
90
91
92
94
96
Electrics
Instruments,alarmsystem
Radio,telephone,on-boardcomputer,navigation
Windshieldwiper andwashersystem
Lights,lamps,switchesexterior
Lights,lamps,switches interior,theft protection
9
97
Group9: 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

0Diagnosis, part 1 (upto RepairGroup45)
0
0
0
General
Installation location, diagnostic socket.Operating instructions, Porsche System Tester 2 ... 0-01
0-03
24
2401 DMEdiagnosis SystemM08 . 24-01
37
3701 Tiptronic diagnosis SystemG40 ... 37-01
45
4502 Anti-lockbrake systemdiagnosis SystemABS5.3andABS/TC5.3 45 -D 1
1
0 Diagnosis, part 1 (up to Repair Grolup 45)
Printed in Germany -34, 1999 986TOC

Boxster Diagnostics 0
8
Installation location, diagnostic socket
Thediagnosticsocketfor the tester is locatedin-
sidethe vehiclenearto the driver(left-hand
drive vehicles)or the passenger(right-handdrive
vehicles)belowthe instrumentpanel.
8
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12.96
8
8Installation location, diagnostic socket 0 -D 1
Printed in Germany, 1996 986O_1
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Boxster Diagnosis 0
8
Operatinginstructions, PorscheSystemTester2
8 ~C:J~5C=HE SystemTester2
F1 F2 F3 F4 F5 F6 F7 F8 .
8
8
Operating instructions, Porsche System Tester 2 0 -D 3
Printed In Germany -4, 1996 9860_D3
,"

0 Diagnosis Boxster
8
General infom1ation
Use
ThePorscheSystemTester 2 is a modular,port- Thefollowingtasks can be performed:
ablediagnosticandmeasuringsystem. Itcan
be usedin anylocationto perform diagnostic -Reading outthe control-moduleidentification
tests on electroniccontrol modules. -Reading out the faultmemory
TheTester consists of a computerunit, a main
memory, a hard disk,a VGAdisplaypanel,a -Erasing the faultmemory
nickelmetalhydridebattery anda measuring
unitfor measurementof current,voltageandre- -Testing the drive links
sistancevalues. -Testing the inputsignals 8ThePorscheSystemTester 2 can be operated
with the built-inkeysor usinga connectable -Reading out actualvalues
country-specificPS/2 keyboard(option). I-Control moduleprogramming
Dataandmeasuredvaluescan be printedout
on one of the ten DINA4 printers currentlyap- -Current, voltageandresistancemeasure-
provedbyPorsche. ments
TheintegratedLCDpanelis used asthe dis-
play. A monitorcanalso be connected(VGAcorr M If .
ti ) a unctions
necon. ThePorscheSystemTester 2 is a high-quality
Ifa printer or PS/2 keyboardis connected,the electronicdevice.Inorder to preventdamage
correspondingdevicetype mustbe set under to the unitdueto improper use,pleaseobserve
Configurationin the start-upscreen. the operatinginstructions.
TheTester thus canbe usedto check all sys- Ifthe Tester nolongerrespondswhenanykey 8
tems that possessa diagnosticinterfaceconfor- is pressed,it mustbe setto a definedstate:
mingwith the ISOstandard. 1. Pressthe F1and F8keysin additionto the
"ON/OFF"key.
2. Releasethe "ON/OFF"key,thenthe F1 and
F8keys.
8
0 -D 4 Operating instructions, Porsche System Tester 2
9860_D3 Printed in Germany -4, 1996

Boxster Diagnosis 0
8Performthis switch-offprocedureonlyifthe unit
no longerrespondswhenanykeyis pressed.
This procedurecan damagethe hard disk under
certaincircumstancesif it is performedduring
normaloperation.It maybe necessaryto repeat
input of data created withinthis diagnosticappli-
cation.
Problemsduringoperationare indicatedto the
uservia the informationline(infoline).Example:
"DiagnosisCard notinserted".
8
8
8Operating instructions, Porsche System Tester 2 0 -D 5
Printed in Germany -3, 1996 9860_D3
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0 Diagnosis Boxster
8
1
~O~E SyslemTesler2"" 8
F1 F2 F3 F4 F5 F6 F7 F8 .
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3 8
8
0 -D 6 Operating instructions, Porsche System Tester 2
9860_D3 Printed in Germany -3, 1996

Boxster Diagnosis 0
8
Design of the Tester
1 9.5" LCD panel, 2.3 Print key
monochrome To print out data, measured values, screen dis-
Resolution: 640 x 480 pixels (picture ele- play (hardcopy), working log and warranty log
ments) 2.4 This key is used to jump to the beginning
./" 2.5 Used in combination with key 2.4 or 2.6
. . to control the brightness
~ (J)
Shift 2.6 This key is used to jump to the end
E)--ft
~ --2.7 Used to move the cursor up
8 ..Ii U
Ct,i--2.8 Used to move the cursor to the left
/\
.2.9 Used to move the cursor to the right and
to select drive links, input signals and actual
<. m> values
..2.10 Used to move the cursor down
..J .v E -of 2.11 Enter key
2.12 Used to change the active screen part
"""- «- -»
"'" --2.13 Back key
~-
ESC-2.14 Continue key
8 2.15 Escape key
2 Keypad 3 Softkeys
2.1 Jump key Softkeys can be have different functions.
Used to change to the selection menu for con- The functions are displayed at the bottom
trol module-specific functions edge of the screen.
2.2 On/Off switch
8Operating instructions, Porsche System Tester 2 0 -D 7
Printed in Germany -3, 1996 9860_D3
"cc-

0 Diagnosis Boxster
8
Connections
2 4
~
A ~-I-~ ~ ~~ ~ ~~ to\\ I~ 80 ~ If?J~ ~ ~ ~ -,\ /~
1 3 5 6 7 8 9
1 -Ground connection Note
..Before current,voltageor resistancemeasure-
2 -Connections for voltageandresistancemeas- ments:Usethe ground
urements.
..lead to connectthe ground socket(1) to the ve- 83 -Connections for currentmeasurementswith hicleground pointprior
a clamp-onammeter.
to connectingthe diagnosislead.
4 -Two slots for PCMCIAcards. The upper slot
isfor the DiagnosisCard.
5 -Socket for mainspower supplyunit.
6 -Serial port for connectionof a mouse.
7 -Connection socketfor a PS/2 keyboard.
8 -Socket for VGAmonitor.
9 -Paralle! port for connectionof a printer or a
CD-ROMdrive. 8
0 -D 8 Operating instructions, Porsche System Tester 2
9860_D3 Printed in Germany -3, 1996

Boxster Diagnosis 0
8
Diagnosis Card Voltage supply
Three types of voltage supply are possible for
thePorscheSystemTester2:
-Internal rechargeable battery (operating time
approx. 20 min)
-Vehicle battery (supply via plugged-on diag-
nosis lead,.Diagnosis Card)
-Mains power supply.
Before putting the unit into operation, make
sure that the mains voltage and the voltage spe-
8cified on the mains power supply unit are the
612-96 same.
The Diagnosis Card is the interface between the
Porsche System Tester 2 and the vehicle. Adjusting illumination of LCD panel
The Diagnosis Card is responsible for the diag-
P k 2 5 d k 2 4. t t I d I ' It ress ey .an ey .
nosls repor s, con ro -mo ue programming vo - D.Ib. ht"" ISpay rig er
age and for voltage supply to the Porsche
System Tester 2 via the vehicle battery. Press key 2.5 and key 2.6
II..Displaydarker
The Diagnosis Card can be left in the Tester.
Working log
During diagnosis, e.g. when the fault memory is
8 being read out, a "save" symbol appears near
the softkeys. This item is saved in the working
log if the corresponding softkey is pressed.
The working log can be printed out with key 2.3.
It is thus possible to document all stored faults,
for example.
8Operating instructions, Porsche System Tester 2 0 -D 9
Printed in Germany -3, 1996 9860_D3
",-" ,

0 Diagnosis Boxster
8
Starting diagnosis
1. Connectthe PorscheSystemTester 2 to the The Off-delaytime can be changedin the Con-
diagnosticsocket(datalink connector)in the figurationmenu.The defaultOff-delaytime is 3
vehicle. minutes.
2. Switchon the PorscheSystemTester 2 (it will Automaticswitch-offis precededby a rhythmic
be readyfor operationin approx.60 seconds). beeping
3. Switchon the ignition. sound(10 seconds).The PorscheSystemTester
2will remain
4. Selectthe vehicletype andinitiatediagnosis
with key2.14. switchedon if the mainspower supplyis con-
ThePorscheSystemTester 2 startsto nectedor a keyis
searchfor control modulesandthen lists all a
control modulesit finds. Controlmodulesthat pressedwithinthis time. .,
are not installed(e.g. Tiptroniccontrol module
onvehicleswith manualtransmission)are dis-
playedin grey. Software update
Note Thesoftwarecan be updatedusingthe supplied
Ifno control modulesare detected,check CD-ROM
whetherthe ignitionis on or whetherterminal
15 is presenton the diagnosticsocket. drive. 1. ConnectCD-ROMdrivewith the Porsche
SystemTester 2.
Iffaults are stored in a control module,this is
identifiedwiththe # symbolas before. 2. ConnectPorscheSystemTester 2 andthe CO-
RaMdriveto the
mainspowersupplyunit.
Automatic switch-off
ThePorscheSystemTester 2 switchesitself off 3. LoadCD-ROMinthe driveandclosethe drive. 8
after an Off-delayif "
4. Switchonthe PorscheSystemTester 2.
-no voltage is suppliedvia the mainspower 5SItUSftw 'tII t' '" th C f"
I't'th h'Ibtt .e ec 0 are Insa a Ion In e onIgura-
suppy urn or via e ve ICe aery t"
Ionmenu.
or
-no data are beingtransferredvia an inter-
face (no key pressed,no communication
with control module).
8 rh
0 -D 10 Operating instructions, Porsche System Tester 2
9860_D3 Printed in Germany -3, 1996
e"""""~~," ."""'*"

Boxster DME diagnosis 24
824 01 Diagnosis/Troubleshooting DME
.Diagnosis/froubleshooting
8
DME
System M 08
8
8~ -
24 01 DiagnosisjTroubleshooting DME 24 -D 1
Printed in Germany -23, 1998 98624D1
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24 DMEdiagnosis Boxster
8
Contents overview
Page
General information on diagnosis 24 -D 3
General information on DME 24 -D 4
Menu (overview of possible menus) 24 -D 6
Component arrangement on the vehicle 24 -D 8
Assignment on relay carrier/relay support 24 -D 9 8
Component arrangement on the engine 24 -D 11
Function of components 24 -D 13
Tools 24 -D 22
DME connector assignment 24 -D 25
Fault overview 24 -D 27
Programming DME control module 24 -D 28a
Test points 24 -D 29 8
DME setpoints 24 -D 53
8
24 -D 2 24 01 DiagnosisjTroubleshooting DME
98624Dl Printed in Germany -23, 1998
"""'44"""""";""""':

Boxster DMEdiagnosis 24
8
General infom1ation
Diagnosis
Monitoringof signalsbytheDMEcontrolmodule
permitsthesystemto performreliableandexact
diagnosis.Furthermore,certainadditionalfunc-
tionssuchasthedrivelinkstestandinputsig-
nalstestcanbeactivatedandcheckedwiththe
PorscheSystemTester2.
Thefaultmemorycanbereadoutanderased
withthenewPorscheSystemTester2.Thedata
linkconnectorislocatedbelowthekneeguard
8 onthedriver'sside.
\
I
I i~fj~~
~~
625-96
8
82401 Diagnosis/TroubleshootingDME 24 -D 3
Printed in Germany -4, 1996 98624D1
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DME diagnosis Boxster
General
Afurther-developedMotronic(DME)systemwiththedesignationM5.2.2is installedto producetheinjec-
tionsignal,to calculatetheignitiontimingangle,to realiseadaptivecontrolsofvarioussystems,andto
performdiagnosticfunctions.
Essential characteristics of the DME
.Electronic map-basedignitionwith stationary
high-voltagedistribution .Engine compartmenttemperaturesensorto
controlthe enginecompartmentpurgefan
.Sequential injection .Radiator fan control bythe DMEcontrol mod-
ule
.Mixture controlledseparatelyfor each cyl-
inderbank .Starting relayactivationanddisabling
.Adaptive stereooxygensensorclosed~oop
control .Control oftheIVCcompressorrelay
Activationof the CheckEnginelightin the
eventof misfiresdamagingto the catalytic
converter
.Floating oxygensensors
Oxygensensorheatingcontrolledvia ground
side TorquereductionuponTractionControlde-
mandby meansof ignitiontiming retardation
andinjectionsuppression
.Hall-effect sensorinstalledon inletcamshaft
for cylinderbank1 -3 .Electronically controlledventilationof the car-
boncanister
Control ofVarioCamvalvesfor cylinderbanks
1 -3 and 4 -6 .Airbag controlmoduleswitches off fuel pump
inthe eventof an accident
.New hotfilm mass air flow sensor
.Intake air temperaturesensorinstalledin hot
film massair flowsensor .Programmed idle speedchangedin the case
ofTiptronicvehiclesandengagedtrans-
missionrange
Cylinder-chargingcontrolwith newtwo-wind-
ing lACY(positioner) Torquereductionduringshiftingoperationsof
theTiptronictransmission
.
.Adaptive throttle potentiometer
.Facility to injectdisturbancesfortestingthe
oxygensensorcontrolloop(e.g.for inspec-
tionandmaintenance)
Adaptiveknockregulation
.Oil temperaturemeasurement
.New temperaturesensorfor enginetempera-
ture measurementandanaloguedisplayin
the instrumentcluster
2401 DiagnosisjTroubleshooting DME
Printed in Germany -4, 1996
24 -D 4 98624Dl

Boxster DME diagnosis 24
8
Additionally for USAvehicles:
.Complete scope ofOBDIIfunctionswith acti-
vation of the CheckEnginelight
.Secondary air system
.Two additionaloxygensensorsbehindthe
catalyticconverters
.Additional Hall-effectsensorfor camshaftof
cylinderbank4 -6
8
8
8
2401 Diagnosis/Troubleshooting DME 24 -D 5
Printed in Germany -4, 1996 98624Dl
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