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
www.WorkshopManuals.co.uk
Purchased from www.WorkshopManuals.co.uk

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
www.WorkshopManuals.co.uk
Purchased from www.WorkshopManuals.co.uk

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
www.WorkshopManuals.co.uk
Purchased from www.WorkshopManuals.co.uk

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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Purchased from www.WorkshopManuals.co.uk

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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Purchased from www.WorkshopManuals.co.uk

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
www.WorkshopManuals.co.uk
Purchased from www.WorkshopManuals.co.uk

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
www.WorkshopManuals.co.uk
Purchased from www.WorkshopManuals.co.uk