Porsche Boxster S User manual

TechnicalManual
-.8e;~s:;TL.,,-
Technicallnformation
Contents:
Group 3
Transmission,manualtransmission
WKD483 521
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Boxster Foreword
Foreword
Theworkshopdocumentationfor the Boxstermodelhasthe designation"Boxster" Technical Manual
and containsTechnical Information as well as instructionson Repairs.
Theintegrationofthetechnicalinformationpublishedinthe"Boxster"TechnicalManualwiththe
descriptivematteronrepairsprovidestheuserwitha complexreferenceworkthatcombinesintoone
bookassociatedor cross-referencedmaterialofrelevanceto workshopsandoriginatingfromvarious
informationmedia.
The"Boxster"TechnicalManualconsists of 15 folders,subdividedinto the followingGroups
0 Entirevehicle-General
0 Diagnosis,part 1 (upto RepairGroup45) *1
0 Diagnosis,part 2 (asof RepairGroup69) *2
1 Engine,part 1 {up to 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,part 1 (upto and includingthe '99 model)*5
9 Circuitdiagrams,part 2 (as of the '00 model)*6
*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"
(upto RepairGroup45).
*2 Thesecondfolder "Group0 -Diagnosis,part2"(as of RepairGroup69) includesthefurther
RepairGroupsbelongingto GroupO.
*3 Thetwo folders with Group1 are to be regardedas one folder;i.e. file the "TechnicalInformation"
notices onlyin front of the repair descriptionsin the folder "Group1 -Engine, part I" (up to
RepairGroup13).
*4 Thesecondfolder "Group1 -Engine,part2"(as of RepairGroup 15)includesthefurtherRepair
Groupsbelongingto Group1.
Foreword
Printed in Germany -34, October 1999 VORW.CHP
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Foreword Boxster
*5 Thetwo folders with Group9 are to be regardedas one folder;i.e. file the 'TechnicalInformation"
notices onlyin front of the repairdescriptionsinthe folder "Group9 -Circuit diagrams,part I" (up to
the '99 model).
*6 Thesecond folder "Group9 -Circuit diagrams,part 2" (as of the '00 model) includesthe further
circuit diagramsbelongingto Group9.
The"Boxster"TechnicalManualhasthesamestructureineachfolder,withthefollowingbreakdownfor
allGroups:
Title page, "Boxster" Technical Manual
> Foreword
Title page: "Technical Information"
> Table of Contents,Technicalinformation
> Technicalinformation
Title page: "Repair"
> RepairGroups:overview
> Table of Contents,repairs
> General/technical data
> Instructionson repairs
As can be seenfrom the breakdown,the publishedTechnicalInformationis inthe front part of each
folder -numbered accordingto theGroups.TheTableof Contentsassignedto eachGroupwill be
periodicallyupdated.
Followingthe TechnicalInformation,separatedbya title page,the instructionson repairs-assigned
accordingto the Groupsor brokendowninto RepairGroups-are includedin the folder.
Theinstructionsonrepairswillbeextendedandupdatedbymeansofsupplements.
Note
Sheetsthat alreadyexist in the "Boxster"TechnicalManualandare updatedor revisedand thereby
exchangedbya supplementare designated"Replacementsheet".Revisionsor technicalmodificationson
pages of these replacementsheetsare identifiedfor the userwith a vertical bar at the margin.
Foreword
Printed in Germany -34, October 1999
VORW.CHP
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Overview of repair groups
Boxster
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: 0
69
72
80
90
91
91
94
Diagnosis
Airbagdiagnosis
Seatmemorydiagnosis
Heatingdiagnosis
Alarmsystemdiagnosis
PCMdiagnosis
ParkAssistentdiagnosis
HBAdiagnosis
1
10
13
Group 1: Engine
Engine-Crankcase, suspension
Engine-Crankshaft, pistons 1
15
17
19
Group 1: Engine
Engine-Cylinder head,valvedrive
Engine-Lubrication
Engine-Cooling
2
20
21
24
25
26
27
28
Group 2: Fuel, exhaust, engine electronics
Fuelsupply,control
Exhaustsystem,turbocharging
Fuelsystem,electronicinjection
Fuelsystem,K-Jetronic
Exhaustsystem
Starter,power supply,cruisecontrol
Ignitionsystem 3
30
34
35
39
Group 3: Transmission, manual transmission
Clutch, control
Manual transmission -Actuation, housing
Manual transmission -Gears, shafts, intogearsh
Final drive, differential, differential lock
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
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4
40
42
44
45
46
47
48
Group 4: Running gear
Front wheel suspension, drive shafts
Rear wheel suspension, drive shafts
Wheels, tires, suspension alignment
Anti-Lock Brake System (ABS)
Brakes -Brake mechanics
Brakes -Hydraulics, regulator, booster
Steering
5
50
51
53
55
57
Group 5: Body
Bodyfront
Bodycenter,roof,frame
Bodyrear
Lids,flaps
Doorfront,centrallockingsystem 6
60
61
63
64
66
68
69
Group 6: Body equipment, exterior
Slidingroof
Convertibletop, hardtop
Bumpers
Glazing,windowcontrol
Exteriorequipment
Interiorequipment
Passengerprotection 7
70
72
74
Body equipment, interior
Linings,insulation
Seatframes
Seatupholsteries,covers
Group 7:
8
80
85
87
88
Group 8: 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 9
97
Group 9: 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
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Boxster Contents
3Transmission, manual transmission
3
3
Power transmission
Technicaldata (transmissionG86) 31
30
30 50 37
3001 07
3005 19
30
30.
30-
30.
30-
Clutch, control
Disassembling and assembling clutch.Bleeding the clutch system.Removing and installing clutch pedal.Clutch boost spring: allocation and grease specification
834
34
34
34
34
34
34
34
34-
34-
34-
34-
34-
34-
34-19
34 -25
343737
Manual transmission -Actuation, housing
Changing and checking transmission oil (transmission G 86)Removing and installing the shift console.Removing and installing shift and selector cables.Adjusting intermediate lever (transmission connection)Removing and installing transmission G 86Disassembling and assembling transmission G 86Disassembling and assembling transmission case cover
(transmission G 86)Disassembling and assembling transmission case (transmission G 86)
35
35 40 37
35 40 15
35 59 37
35 -1
35 -9
35-11
Manual transmission -Gears, shafts, into gearsh.
Disassembling and assembling the input shaft (transmission G 86)
Adjusting the input shaft (transmission G 86)Disassembling and assembling output shaft (transmission G 86) .
39
39
39
39
39 -1
39 -5
39-11
Final drive -Differential, differential lock
Removing and installing differential (transmission G 86)Disassembling and assembling the differential (transmission G 86)
Adjusting the drive set (transmission G 86)
3 Transmission, manual transmission
Printed in Germany -24, 1998 1
986TOC
1
5
7
15
01
08
12
33
35
35
55
55
19
19
15
19
37
37
, 1
2a
2e
.2m
3
.11
0919
0937
0815
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3
Transmission
Boxster
3Technical data (transmission G86)
5-speed manual transmission G 86
-
~
1
'-Y
34350001
Type Code letter Installed in Model year
Equipment
G 86/00
G 86/00
G 86/01
CWA
OW
EFO
5-speed
5-speed
5-speed
97/98
99
00
Boxster
Boxster
Boxster
3 Technical data (transmission G 86)
Printed in Germany -30, 1999
3 -1
9863_1
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3Transmission Boxster
Technical data (transmission G86)
Identification of the transmission G 86
171~96
Identification and construction date of the
transmission:
.
07 6
Example: CWA 14
CWA
14
07
6
= Code letter
= Day
= Month (July)
= Year (1996) of manufacture
.3 Technical data (transmission G 86)
Printed in Germany -30, 1999
3-2 9863_1
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Boxster Transmission
Technical data (transmission G 86)
1st gear 8 -Transmissioncase cover
2 -2nd gear 9 -Input shaft
3 -3rd gear 10 -Output shaft
4 -4th gear 11 -Ball bearing
5 -5th gear 12 -Differential
6 -Reverse gear 13 -Tapered rollerbearing
7-Transmissionhousing 14 -Tapered roller bearing
3 Technical data (transmission G 86)
Printed in Germany, 1996 3-3
9863_1
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3
Transmission
Boxster
Technical data (transmission G 86/00/01J
Manual transmission
3-5
3 Technical data (transmission G 86)
Printed in Germany -30, 1999 9863_1
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Boxster Transmission
Technical data (transmission G86)
Tightening torques
Screwplug, oil drainage
andoil filling M24 25 (18)
Guidesleevefor release
bearingon transmissionhousing M8 35 (26)
Retainingplate,reversinglight
switchontransmissionhousing M8 25(18)
Plug,reversinglightswitch
on transmissionhousing M8 10(7)
Transmissioncasecoveron
transmissionhousing 25 (18)
M8
Switchinterlockon
transmissionhousing M8 25 (18)
Screwsfor relayshaft
ontransmissionhousing M22
M26 40 (29)
40 (29)
Torxscrewfor
reverseidlershaft M8 35 (26)
Coverfor interiorshiftrod
ontransmissionhousing 20 (15)M8
Interlock(5th andreversegears)
ontransmissionhousing M8 10(7)
Balljournalfor releaselever
ontransmissionhousing M8 25 (I8)
Coverfor finaldrive
ontransmissionhousing M8 25 (18)
Crownwheelon differential
housing MID 60 (45) + 450 rotary angle
3-7
3 Technical data (transmission G 86)
Printed in Germany. 1996 QRR~ 1
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Transmission Boxster
Bracketfor shiftcableson
transmissionhousing MID 45 (33)
Rockerholderon
transmissionhousing M8 23 (17)
Gearshiftleveron
interiorshiftrod M6 23 (17)
Transmission
onengine MI2 MID 85 (63) 45 (33)
Transmissionsupporton
transmissionhousing MID 65 (48)
Hydraulic mount on
support side part M8 25 (18)
Driveshafton
transmissionflange M8 39 (29)
Clutchslavecylinderon
transmission M8 23 (17)
3-8 3 Technical data (transmission G 86)
Printed in Germany, 1996
9863_1
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Clutch, control Boxster
Disassembling and assembling clutch
8
I
6
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r0
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,t1)0~ 0 ~~~;ii)
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0
11
3
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4I
5
30 -2 30 50 37 Disassembling and assembling clutch
986301 Printed in Germany, 1996
I
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Clutch, controlBoxster
Note:
No. Designation Qty. Removal Installation
1
Releaselever 1
2Releasebearing 1Do notwash out bear-
ings. Replacenoisybear-
ings. Do not grease slid-
ing surface of release
bearingor guidetube
3Retainerspring
64Cylinder-head
bolt
Note
The bolts always must be tightened and loosend in
several steps and crosswise in order to prevent
deformation of the thrust-plate housing
5Thrustplate
61
Driveplate
7 Pan-headscrew
MIO x I x 50 8
81
Centrewith mandrel,VW
specialtool 3176
Initialtorque 25 Nm
(18 ftlb.)
Finaltorque 900
Ensurethe centringpin is
seatedfirmly
9
Double-mass
flywheel
Needlebush
30 -3
30 50 37 Disassembling and assembling clutch
Printed in Germany, 1996 986301
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Boxster Clutch, corltrol
30 01 07 Bleeding the clutch system
Important notes Filling/bleeding
Theclutchhydraulicsmustalwaysbefilledor
bledusinga pressurefillingandbleedingdevice.
Furthermore,thebleedervalvemustbeopened
sufficientlyandthegaugepressuremustbeap-
prox.1.5bar.
1.Fillthefluidreservoirupto theupperedge
withnewbrakefluid.
Connect bleeding device to the fluid
reservoir.
Beforethe system is filled or bled,the clutch
pedal mustbe in the "pedal fully depressed"
position.
Note
U~ie only new DOT 4 brake fluid.
Important: Asthere is no system pressure,
servo kinematiceffectswill causethe clutch
pedalto moveforwardabruptly. Inorder to
avoiddamageI the pedal mustbe guided
manually.
Thisbrakefluidisavailableunderthefollowing
part number:
Containerquantity1 litre = 000.043.203.66
Containerquantity30 litres= 000.043.203.67
Bleedthe systemuntilno more bubblesappear
atthe bleedervalve(usea collectingbottlewith
transparenthose).
Ifthe systemwas open previously(e,g. for com-
ponentreplacement),the minimum filling or
bleeding time must be 30 seconds.
682 -96
2. Movepedalto thefullydepressedposition.
Whendoingso,guidethepedalbyhandso
thatitdoesnotmoveforwardabruptly.
3. Switchonthebleedingdevice.Bleedingpress-
ureapprox.1.5bar.
30 -530 01 07 Bleeding the clutch system
Printed in Germany -5, 1996 986305
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Clutch, control Boxster
5. Switchoffanddisconnectthebleedingdevice.
Correctthebrakefluidlevelifnecessary.
4. Thebleedervalveon the clutchslavecylinder
mustbe openeduntil clear,bubble-freebrake
fluidemerges.
Usea collectingbottlefor preciseexamination
ofthe emergingbrakefluidfor cleanlinessand
freedomfrom bubbles.
~~""
'-
>1Jr
~
~
189 -96
690/1 -96
Note
Ifthe systemwasopen previously(e.g.for com-
ponentreplacement),the minimumfillingor
bleedingtime mustbe 30 seconds.
30 -6 30 01 07 Bleeding the clutch system
Printed in Germany. 5, 1996
986305
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Boxster Clutch, actuation
30 05 19 Removing and installing the clutch pedal
Pedal-group versions (distinction)
1. Thepedalsof Boxstervehiclesas of
Mod.'98 (asof Mod. W)are identicalto
the 996 pedals,withthe exceptionof the
boostspringandboost-springbracket.
Important notes
Thedescription belowappliesto left-handdrive
vehicles.
Onright-handdrive vehicles,the clutch pedal
leveris located directly nextto the brake
pedal(separatedbythe steeringoutertube
inthe case of left-handdrivevehicles).
Assembly/disassemblyfor right-handdrive
vehiclesis similarto the procedurefor
left-handdrivevehicles.
2. TheBoxsterpedalsbefore Mod.'98
(beforeMod. W)differ from the pedals
as of Mod. '98 inthe followingrespects:
Bracketfor clutch boostspring cannotbe
unscrewed.Consequently,the boost-spring
bracketcannotandneednotbe adjusted.
Furthermore,thedistancebetweenthe bearing
pinsof the boostspring is 3 mm less.
Beforethe start of disassemblywork onthe
pedals,the clutch boostspring mustbe fixed
with a cotter pin (arrowatNo.5).
Important:securethe cotter pin (bendit over).
Pedalbearingaxlewith differentfastening
method >arrows< (clampingof the
steeringoutertube andfixing of the
pedal-bearingaxle)
No return spring on the brake pedal
465_98
32_1_98
BoxsterpedalsbeforeMod.'98
30 05 19 Removing and installing the clutch pedal
Printed in Germany -24, 1998 986307
30-7
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Removing and installing the clutch pedal
~---
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.5a :
5b / ~
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2
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465_98
A = Clutchpedalarea
B = Brakepedalarea
.Removing and installing the clutch pedal
Printed in Germany -24, 1998
30 05 19
986307
30 -8
':::-
6x "'..""'.
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Clutch, actuationBoxster
A = Clutch pedal area
No. Designation Qty. Removal Note:
Installation
1
Switch 1Releasebyturning90°,
andpull out of the
installationopening
Before installation,pull
operatingplungerout of
theswitchasfar asitwillgo
Replaceif necessary
2
3
4
5
1
1
1Replace
Retainingclip
Pin
Clamp
Boostspringwith bracket
(bracketcannotbe
removedbefore Mod.'98)
1Secureboostspringwith
cotter pin (arrowat No.5)
Insertthecotterpin(0'3 mm)
intothe assemblyboreand
bendoverends.
Thenundothethreefastening
nutsofthe bracket(arrows)
andremovethe boostspring
togetherwithbracketand
clutchpedallever(No.6)
5a Boostspring bearing 2
Installthe assembly
consistingof bracket,
boostspringandclutch
pedallever.
Observeproperallocation
whenreplacingthe boost
spring.**
Observeassemblyand
adjustmentspecification
for the bracket(assembly
instructionsunder
Installation,step 3)
Replaceif necessary.
Alwaysobservenotewith
regardto greasing**
Alwaysobservenotewith
regardto greasing**
5b Pin 1
6Clutchpedallever 1Removetogetherwithboost
springNo.5 andbracket
Bushings 2 Remainin the clutch pedal Check,replaceif
lever necessary.
Lubricate.Usegrease
specified*
Lubricatethe bushingsofthe clutchandbrakepedals(6Xand 14X)with"Optimol,OptitempLG 2"
grease,part No.: 000.043.203.37 (deliveryquantity:80 g tube).
6X
*Informationcan be foundin RepairGroup30 -Servo No. 30 Clutchboostspring:allocationand
grease specification.Inthe casewherelubricatingthe boostspring bearingsurfaces is not
permissible,the assemblyinstructionsunder Installation,steps2.1 and 2.2 can alsobe followed.
30 -9
3005 19 Removing and installing the clutch pedal
Printed in Germany -24, 1998 986307
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Clutch, actuation Boxster
Notes on removal and installation
Removal
4. Detachdiagnosticsocket.
&Warning
Danger of injury and damage
during disassembly and assem-
bly work!
Clutch boost spring can
disassemble automatically!
Beforethe start of disassembly
work inthe area of the clutch
pedallever(exception:clutch
pedal switch),the clutch boost
spring mustbe fixed witha
cotter pin (Fig.478_98).
1. Disconnectbatterygroundcable.
2. Removedriver'sseat(tofacilitatework).
5. Detachrelaycarrier, unclipandlowerintothe
footwell.
3. Removeair duct(A).
Theair duct is pluggedin,
86_98
6. Releaseclutchpedalswitch byturning it 900
andpull it out of the installationopening.
290_1_97
30 -10 30 05 19
986307 Removing and installing the clutch pedal
Printed in Germany. 24, 1998
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