Porsche BOXTER - User manual

TechnicalManual
-.8e;~~
TechnicalInformation
Contents:
Group9
Electrics
WKD483 521
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Boxster Foreword
Foreword
TheworkshopdocumentationfortheBoxstermodelhasthedesignation"Boxster" TechnicalManual
andcontainsTechnicalInformationaswellasinstructionsonRepairs.
The integrationof the technicalinformationpublishedin the "Boxster"TechnicalManualwith the
descriptivematter on repairsprovidesthe userwith a complexreferencework that combinesinto one
book associatedor cross-referencedmaterialof relevanceto workshopsandoriginatingfrom various
informationmedia.
The"Boxster"TechnicalManualconsistsof 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 (upto RepairGroup 13) *3
1 Engine,part 2 (asof 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 andincludingthe '99 model)*5
9 Circuitdiagrams,part 2 (asof 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 repairdescriptionsin the folder "Group0 -Diagnosis, part I"
(up to Repair Group 45).
*2 Thesecond folder "Group0 -Diagnosis, part 2"(as of Repair Group 69) includesthe further
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 1" (up to
RepairGroup13).
*4 Thesecondfolder "Group1 -Engine,part2"(as of RepairGroup 15)includesthefurtherRepair
Groupsbelongingto Group1.
VORW.CHP
Foreword
Printed in Germany -34, October 1999
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Foreword Boxster
.!i Thetwo folders with Group9 are to be regardedas one folder;i.e. file the "TechnicalInformation"
notices onlyin front of the repair descriptionsin the folder "Group9 -Circuit diagrams,part 1" (up to
the '99 model).
*Ei Thesecond folder "Group9 -Circuit diagrams,part 2" (as of the '00 model) includesthe further
circuitdiagramsbelongingto 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 the Groups.TheTable of Contentsassignedto eachGroupwill be
periodicallyupdated.
Followingthe TechnicalInformation,separatedbya title page,the instructionson repairs-assigned
accordingto the Groupsor brokendowninto RepairGroups-are includedinthe 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 groupsBoxster
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: 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, valve drive
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,powersupply,cruisecontrol
Ignitionsystem 3
30
34
35
39
Group 3: 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
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Overview of repair groups Boxster
4
40
42
44
45
46
47
48
Group 4: Running gear
Frontwhee!suspension,drive shafts
Rearwheel suspension,drive shafts
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
Door front,centrallocking system
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
Air conditioning
Auxiliaryair conditioningsystem
9
90
91
92
94
96
Group 9 Electrics
Instruments,alarmsystem
Radio,telephone,on-boardcomputer,navigation
Windshieldwiper andwashersystem
Lights,lamps,switchesexterior
Lights,lamps,switches interior,theft protection
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 Table of Contents
8Air conditioning
8
8
Air conditioning
Technical data for the air conditioning system 8 -1
80
8023 19 Heating
Removingandinstallingheatexchanger 80
85
85
85
85
85
85
85
85- 1
85- 3
85- 7
85-11
85-13
85-15
Ventilation
Removing and installing mechanical heating / fresh air control. ..
Removing and installing heating / fresh air unit.Installing and adjusting bowden cables of the heating/fresh-air control
Removing and installing heater/fresh-air blower motor.Removing and installing drive motor for fresh-air/recirculation valve.
Removing and installing bulb for rotary blower switch.
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87
87.
87.
87.
87
87.
87.
87.
87.
87.
87.
87.
87.
87-
87-
87.
87.
87.
87.
87.
Air conditioning
Safety regulations when handling refrigerant R 134aAssembly work on air the conditioning system.Nominal values for pressures and temperatures.Removing and installing pressure switch for the air-conditioning system.
Removing and installing fluid tank.Removing and installing the compressor.Removing and installing the expansion valve.Installing and removing the heating /air-conditioning unit.Removing and installing the condenser.Removing and installing the magnetic coupling.Removing and installing drive motors of the heater/air-conditioning unit.
Removing and installing drive motor for fresh-air/recirculation valve. ..
Removing ~nd installing outside temperature sensor.Removing and installing interior temperature sensor.Removing and installing footwell blower outlet sensor.Removing and installing blower driver.Removing and installing fan for condenser.Removing and installing ballast resistor for fan motor.Installing and removing the heatingjair-conditioning unit.
1
8 Air conditioning
Printed in Germany -12, 1997 986TOC
10
15
11
30
78
10
19
19
06
19
19
19
03
0317
8319
5519
3419
7019
0119
5019
2719
2019
2019
5919
8219
5819
7819
5319
6919
0219
-1
-2
-13-15
.17
.19
.23
-25.29
-31.33
-35
37
.39
.41
.43
.45
-47
-49
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Air conditioning
Boxster
8Technical data for the air-conditioning system
Compressor type 7 S8 16
Refrigerantquantity 850 g refrigerant R 134a
195 :f: 15 cm3NO8
Refrigerant oil in the compressor
Tightening torque in Nm (ftlb.]
Hexagon-head bolts on Thread
M6 9 (6.5)
Expansionvalve
6 (4.5)
M5
M8 23 (17)
Compressor
M8 23 (17)
Refrigerantline
M 10 26...36(19...27)
Oilfiller screw
M6 6 (4.5)
Fluidtank
M8 14(10.5)
Flangeconnectionsof
refrigerantlines
Note
Wheninstallingthe refrigerantlines,the screwconnectionsandthe a-rings mustbewettedwith
refrigerantoil.
The refrigerant oil must be disposed of as special-category waste.
8 -1
8 Technical data for the air-conditioning system
Printed in Germany -12, 1997 9868_1
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Boxster Heating
80 23 19 Removing and installing heat exchanger
Removal
1. Removecoversfrom heatingandair-condition-
ing system,batteryandfluid reservoir. Discon-
nectbattery andcoverterminalor battery.
6. Releaseheatexchangerandpullit upandout.
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2. Removethe entirewiper linkwith wiper motor
(seeRepairGroup92). '""-'
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3. Loosenrightdomestrutandbracketatthe
cowlframeandremove. ~~---='
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~288 -96
'/ ""
\Installation
1.Sealcoverovertheheatexchangerairtight
withbutyladhesive.
\. 2. Replacecoverifdamaged.
I~
287 -96
4. Clampshutbothheaterhosesinfrontofthe
heatexchangerusinga commerciallyavailable
hoseclamp.Loosenheaterhosesattheheat
exchangerandpulloff.
3. The heatexchangeris connectedto the en-
ginecooling system,and coolantflows
throughit whenthe engineis running. After re-
movingor installingthe heatexchangerI vent
the coolingsystem(seeRepairGroup19).
5. Carefullyremovecoverovertheheatex-
changer.
80 -1
80 23 19Removing and installing heat exchanger
Printed in Germany. 1996 986801
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Boxster Ventilation
85 10 19 Removing and installing mechanical heating and fresh-air control
Removal
1. Carefullyunclipbafflefromtheheatingand
fresh-aircontrol.
Installation
1. Clipin Bowdencablesandroute carefully(do
not bend),
2. Unscrewfasteningscrews (4 ea.)andpullcorr
trol moduleout ofthe dashboard. 2. Engageelectricalplugconnections:do not
jam cables.
3. Pulloffelectricalplugconnection.UnclipBow-
dencablesandpulloutupwardsor detach
cables.LabelBowdencablesbeforeremoval.
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289 -96
85 10 19 Removing and installing mechanical heating and fresh-air control
Printed in Germany, 1996 986851
85 -1
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Ventilation
Boxster
85 15 19 Removing and installing heating and fresh-air control
Removal
1.Removecoversoverheatingandfresh-aircon-
trol, batteryandfluidreservoir.Disconnectbat-
teryandremove.
4. Looseninstrumentpanelanduncliprightside
upwards.Disconnectelectricalplug connec-
tions.
2. Removesteeringwheelandloosensteering-
columnpanel.Complywithsafetyregulations
whenhandlingairbagunits(seeRepairGroup
169).
3. Loosencentral screw (clamp)atthe steering-
columnswitchfrom belowandpullforward a
little. Removetop coverand disconnectelectri-
cal plugconnections.Removesteering-column
switch.
108- 96
5. Removesteering-columncover(4screws).
107-96
109 -96
85 -3
85 15 19 Removing and installing heating and fresh-air control
Printed in Germany, 1996 986853
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Ventilation Boxster
6. Removeradioandheatingandfresh-aircon-
trol. Unclipswitchtrimontheleftandright.
Disconnectelectricalplugconnection.Loosen
centreoffixingframeandremove.
11. Loosendashboardonthe bottom, centre,
leftandright. Carefullyremovedashboard
andpull off speakercable.
111 -96
369-96 12. Loosencentretunnelsupportatthe top of
supportingframe andloosenbottom tunnel
holder.
7. Removeleftsidenozzleanddisconnectelec-
tricalplugconnection.Unclipcoverofsun
sensoranddefrosterpanelandremove.
8. Loosenpassengercompartmentmonitorand
disconnectelectricalplugconnection. --
A1co""'""'-"-"' c
"'""
9. Removebottom rightair guide.Removepas-
sengerairbagunit.
Complywith safetyregulationswhenhandling
airbagunits(seeRepairGroup69).
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10. Removefront cover of centre console.
Loosenfuse carrier andloosendiagnosis
plug inthe leftfootwell.
112 -96
85 15 19 Removing and installing heating and fresh-air control
986853 Printed in Germany, 1996
85 -4
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Boxster Ventilation
13. Removeleft air guide. Justloosendefroster
duct. Loosencentre air distributorhousing
andremove.
18. Loosenholderof heatingandfresh-aircon-
trol on the upper right of the passengerside.
14. Disconnectelectricalplugconnectionfrom
heatingandfresh-aircontrol.
15. Loosenbattery positiveconnectionatthe cur-
rentdistributorand currentdistributor at the
firewallcover. ~
--
---
:~"'~;~;;;/
~
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~
/
114- 96
19.Carefullylowerheatingandfresh-aircontrol
intothefootwellandremove.Donotdamage
electricalplugconnectionsor cable.
/\"f;'
/C/
113-96 Installation
1. Ensurecorrect seatingof air-distributor
housingandair guides.Engageelectricalplug
connectionsandroute electricalcables care-
fully(do notjam).
16. Clampshutboth heater hosesin front of the
heatexchangerwith a commerciallyavailable
hoseclamp.Loosenheatinghosesatthe
heatexchangerandplugthe connections. 2. Complywithsafetyregulationswhenhandling
airbagunits(seeRepairGroup69).
7, Loosenheatingandfresh-aircontrol atthe
coverfirewall(3 nuts),
85 15 19 Removing and installing heating and fresh-air control
Printed in Germany, 1996 986853
85 -5
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Ventilation Boxster
3. Adjuststeering-columnswitch:
Measurewith a depthgaugebetweenend of
steeringshaftandsteering-columnswitch
cover plate(seefigure).
Adjustment dimension 55 :t 0.5 mm
115 -96
4. Replacegasketbetweencurrentdistributor
andfirewall if necessary.Afterthe currentdis-
tributor is mountedonthe firewall(tightening
torque 15 Nm(11 ftlb.))the batterycableis
tightenedwith a new hexagonnutM8.
Tighteningtorque 15 Nm(11 ftlb.).
5. The heatexchangeris connectedto the en-
ginecooling system,and coolantflows
throughit whenthe engineis running. After re-
movingor installingthe heatingandfresh-air
control,ventthe coolingsystem(seeRepair
Group19).
85 15 19 Removing and installing heating and fresh-air control
986853 Printed in Germany, 1996
85-6
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Boxster Ventilation
85 11 06 Installing and adjusting bowden cables of the heating/fresh-air control
Note
Installthe heating/fresh-aircontrolwithinstalled
bowdencables. The sleevesofthe bowden
cablesare adjustedatthe fasteningpointson
the heating/fresh-airunit.
Adjusting temperature valve
1. Turntemperaturecontrolto left-handstop
(cold).Temperaturevalve closed;no passage
to the heatexchanger.
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~
AB
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00
534 -96
536 -96
A-Bowden cable,temperaturevalve
B -Bowden cable,footwelVdefrostvalve
C-Bowden cable,centralvalve
2. Engagebowdencableintheadjustinglever.
85 -7
85 11 06 Installing and adjusting bowden cables of the heating/fresh-air control
Printed in Germany -5, 1996 986857
,"-~
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Ventilation Boxster
3. Pushadjustinglever of the temperaturevalve
upto its stop andusethe retainingclip to
fastenthe sleeveofthe bowdencableonthe
fasteningpoint.
2. Engagebowdencableintheadjustinglever.
3. Pushadjustinglever of the footwelljdefrost
valveupto its stop andusethe retainingclip
to fastenthe sleeveof the bowdencableto
the fasteningpoint.
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537 -96
538 -96
Adjusting footwelljdefrost valve
1. Turnrotaryknobfor airdistributionto thesym-
bolforthefootwell.Defrosteroutletclosed;
nopassageto thewindscreen.
Adjustingcentral valve
1. Turnrotary knobfor air distributionto the sym-
bolfor the footwell.Air outletto the centre
andsideventsclosed(SeeFigure534/2 -96).
2. Engagebowdencableinthe adjustinglever.
53412 -96
85 11 06 Installing and adjusting bowden cables of the heating/fresh-air control
986857 Printed in Germany -5, 1996
85-8
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VentilationBoxster
3. Pushadjustingleverofthecentralvalveupto
itsstopanduseretainingcliptofastenthe
sleeveofthebowdencableto thefastening
point.
~
539 -96
Note
Performafunctiontestafterinstallingthebow-
dencables.Testlimitpositionoftherotary
knobsfor airdistributionandadjustingleversof
thevalves.
85 11 06 Installing and adjusting bowden cables of the heating/fresh-air control
Printed in Germany -5, 1996 986857
85 -9
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VentilationBoxster
85 30 19 Removingand installing heater/fresh-air blowermotor
Remove and install heater/fresh-air blower
motor with installed heating/fresh-air unit.
Removal
1. Removefootwellbulkheadand right air guide.
Pulloff electricalplugconnectiononthe
blowermotor andremovewire from the
holder.
Thefigureshowstheheating/fresh-airunitwhen
removed.
531 -96
Note
Whenthe housinglid is removed,the blower
motor is simultaneouslydetachedfrom its
guide.Holdthe blowermotor and carefully
removeit in downwarddirection.
""""
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cb
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530-96
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a
2. Pulloffelectricalplugconnectiononthebal-
lastresistorandundobothfasteningscrews
onthehousinglid.
Theballastresistorandhousinglidare
a spare part.
532-96
85 -11
85 30 19 Removing and installing heater/fresh-air blower motor
Printed in Germany -5, 1996 986857
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Ventilation Boxster
In!;tallation
1.Installblowermotorandfastenhousinglid,
2. Tightenfasteningscrewscarefully
(plastichousing).
3. Engageelectricalplugconnectionsandper-
formafunctiontest.
8~) -12 85 30 19 Removing and installing heater/fresh-air blower motor
986857 Printed in Germany -5, 1996
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Boxster Ventilation
85 78 19 Removing and installing drive motor for fresh-air/recirculation valve
I~emove and install drive motor on installed
heating/fresh-air unit Note
Ifthe rotary knobfor air distributionis setto De-
frost (windscreen)withthe recirculationbutton
switchedon,the recirculationbutton is automat-
icallyswitchedoff.
Removal
1.Presstherecirculationbuttonbeforeremoval
(fresh-airsupplyinterrupted),Thedrivemotor
oftheinstalledheating/fresh-airunitcanbe
removedinthisposition(recirculation). Installation
1.Theremovalorinstallationpositionofthe
drivemotorandfresh-air/recirculationvalve
cannotbechanged.
2. Removefootwellbulkheadandrightairguide.
Disconnectelectricalplugconnectionofthe
drivemotorandundofasteningscrew. 2.Tightenfasteningscrewcarefully
(plastichousing),
3. Engageelectricalplugconnectionandroute
wirecarefully.
~~~'-
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4. Performafunctiontestafterinstallation.
~
542 -96
3. Swiveldownthedrivemotorandremoveto
theside.
85 78 19 Removing and installing drive motor for fresh-air/recirculation valve
Printed in Germany -5. 1996 986857
85 -13
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Ventilation
Boxster
Removing and installing bulb for rotary blower switch
85 10 19
Installation
1. Insertbulbwithconnectinghose.Detachcon-
nectinghoseby twisting it offthe bulb.
Removal
1. Pulloffrotaryblowerswitch.
2. Pulloutbulb.Thebulbcanbepulledoutby
pushingaconnectinghoseofavacuumline
ontoit(seediagramofhoseconnections,Re-
pairGroup24).
2.Checkfunctionofthebulb.
535 -96
85 -15
85 10 19 Removing and installing bulb for rotary blower switch
Printed in Germany -5, 1996 986857
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Purchased from www.WorkshopManuals.co.uk