Porshe Boxter 1999 User manual

TechnicalManual
-.8c:;~.s:;~-
Technicallnformation
Contents:
Group 2
Fuel,exhaust,engineelectronics
WKD483 521

Boxster Foreword
Foreword
Theworkshopdocumentationfor the Boxstermodelhasthe designation"Boxster" Technical Manual
and containsTechnical Information aswell as instructionson Repairs.
Theintegrationof the technicalinformationpublishedin the "Boxster"TechnicalManualwith the
descriptivematter on repairs providesthe userwith a complexreferencework thatcombinesinto 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
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 and includingthe '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 repair descriptionsin the folder "Group0 -Diagnosis, part 1"
(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
Repair Group 13).
*4 Thesecondfolder "Group1 -Engine,part2"(as of RepairGroup 15)includesthefurtherRepair
Groupsbelongingto Group1.
VORW.CHP
Foreword
Printed in Germany -34, October 1999

Foreword Boxster
*5 Thetwo folders with Group9 are to be regardedas one folder;i.e. file the "TechnicalInformation"
notices onlyin front of the repair descriptionsinthe folder "Group9 -Circuit diagrams,part 1" (up to
the '99 model).
*6 Thesecondfolder "Group9 -Circuit diagrams,part2"(as of the '00 model)includesthefurther
circuitdiagramsbelongingto Group9.
The"Boxster"TechnicalManualhasthe same structure in each folder,with the following breakdownfor
all Groups:
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 in the 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 brokendown into RepairGroups-are includedinthe folder.
Theinstructionsonrepairswillbeextendedandupdatedbymeansofsupplements.
Note
Sheetsthatalreadyexistinthe"Boxster"TechnicalManualandareupdatedor revisedandthereby
exchangedbya supplementaredesignated"Replacementsheet".Revisionsor technicalmodificationson
pagesofthesereplacementsheetsareidentifiedfortheuserwitha verticalbaratthemargin.
Foreword
Printed in Germany -34, October 1999
VORW.CHP

Boxster Overview of repair groups
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
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
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

Overview of repair groups Boxster
4
40
42
44
45
46
47
48
Group 4: Running gear
Frontwheel suspension,drive shafts
Rearwheel suspension,drive shafts
Wheels,tires, suspensionalignment
Ant~LockBrakeSystem(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
Group 7: Body equipment, interior
Linings,insulation
Seatframes
Seatupholsteries,covers
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

Boxster Contents
2Fuel,exhaust, engineelectronics
20
20
20
20
20
20
20- 1
20- 3
20- 5
20 -9
20-11
Fuel supply, control
Checking fuel pressure.Checking quantity delivered by fuel pump. ...
Removing and installing fuel pump.Calibrating fuel/evel sensor system.Removing and installing fuel return line.
24-
24-
24-
24-
24-
24-
24-
24-
24-
24-
24-
24-
24-
24-
24-
24-
24-
Fuel system, electronic injection
Disassembling and assembling fuel ring pipe.Disassembling and assembling intake distributor. ...
Diagram of hose connections.Disassembling and assembling air guide cowl.Programming DME control module.Removing and installing mass air flow sensor.Removing and installing DME control module.Removing and installing oxygen sensor.Removing and installing throttle body -Boxster S ...
Removing throttle body -Boxster SInstalling throttle body -Boxster SRemoving and installing injection valves -Boxster S ..
Removing injection valves -Boxster SInstalling injection valves -Boxster SRemoving and installing intake distributor -Boxster S .
Removing intake distributor -Boxster SInstalling intake distributor -Boxster S
26 !
26 01155 Exhaustsystem
Replacingexhaustsystem. ... 26 -1
27
27
27
27
27
27- '1
27- 3
27- 5
27- 7
Starter, power supply, cruise control
Removing and installing starter.Removing and installing three-phase generator. .
Removing and installing cruise control actuator. .
Removing and installing starter -Boxster S ...
1
2 Fuel, exhaust, engine electronics
Printed in Germany -32, 1999 986TOC
02
66
66
15
39
0101
1901
19
..1
.7.13
.1i5
.1,9
.23
25
2i7
311
3'3
39
47
49
55
611
6p
76
6019
2219
8419
6019

Contents Boxster
2706 Workinstructionsafterdisconnectingthebattery . ...27 -9
28
274419
28 7319
Ignition system
Removingandinstallingrotor for hallsender
Removingandinstallingpulsesender. .. ..28 -1
..28 -3
8
8
.2Fuel, exhaust, engine electronics
Printed in Germany -32, 1999
2986TOC

Boxster Fuel supply, actuation
20 02 01 Checking fuel pressure
Special tools
No.
A
B
Special tool
P378a
9559
Explanation
Designation
Pressuregauge
Connectionline
20 02 01 Checking fuel pressure
Printed in Germany, 1996 20 -1 986201

Fuel supply, actuation Boxster
Checking fuel pressure
Checking
1. Undocoveringcap on test connectionoffuel
collectionpipeandremove.
I~
~~
2. Connectpressuregauge(specialtool P 378a)
with connectingline(specialtool 9559) and
connectto test connection.
a~
-
"
~ J ~
\ .I
.~
i
~
=
---'"'-"
"i
\\\ V\j~,..
~.:;;f... .
~; 4. Nominal test values:
~~~
Stationary engine 3.8 ::!:0.2 bar
Engine idling 3.3 ::!:0.2 bar
"3'
~.l
-I
3.Actuatingfuelpump Thesealor sealingring in the brass closurecap
is not exchangeable.It mustthereforebe used
onlyonce.
with PorscheSystemTester2:
Thefuel pumpcanbe actuatedwiththe
PorscheSystemTester 2 or bybridgingthe
fuel-pumprelay. Tighteningtorque of newbrassclosurecap
2.5:t 0.5Nm(2.0:t 0.5ftlb.).
Viafuel-pumprelaywithoutTester:
Disconnectfuel-pumprelayfrom the central
electricalboardandbridge contacts30 and
87 (identifiedas 3 and5 onthe central electri-
cal board)witha fusedshop-madecable.The
fuel pump must nowoperateor deliverfuel.
20 -2 20 02 01 Checking fuel pressure
Printed in Germany. 1996
986201
r

Boxster Fuel supply, actuation
20 66 01 Checking quantity delivered by fuel pump
Precondition:
Fuelfilter andelectrical supplyin order,
~
1. Relievepressureinfueltankbyopeningtank
cap. //
/
//
/
//
//
/
2. ConnectPorscheSystemTester 2. //
/
//
3. Raisevehicle //
4. Removerear undersidepanel, -
5. Disconnectfuelreturnline.Collectresidual
fuel. 368 -96
6. Holdfuel linein a measuringcontainer.Actu-
atefuel pumpwiththe PorscheSystemTester
2 and allowfuelto flowfor 30 secondsinto a
measuringcontainer.
Quantity supplied must be at least
850 cm3/30 s, i.e. after 30 secondsat least
850 cm3offuel mustbe presentinthe
measuringcontainer.
367 -96
20 -3
20 66 01 Checking quantity delivered by fuel pump
Printed in Germany, 1996 986201

Boxster Fuel supply, actuation
820 66 19 Removing and installing fuel pump
2066 19 Removing and installing fuel pump
Printed in Germany. 1996 20-5
986201

Fuel supply, actuation Boxster
Removing and installing fuel pump
Removal
1. Undobatteryterminalsandbatteryholder. Lift
battery outby holdingstrap. /1/-.,
.Q /A
2. Undobatterysupportcover(fourhexagon
nuts,wrenchsize13). ~
~
3. Disengagefuellineanddisconnectelectrical
plugconnection.
446 -96
5. Extractresidualfuel.
Note
Observesafetyregulations.
=1 6. Liftfuel gaugeand disconnectelectricalplug
connectionandfuel pipes.
,
I-" t1
--
'- ::--u-
445 -96
4. UndounionnutwithVWspecialtool3217,
447 -96
7. Puton fuel-proofglove,holdthe fuel pump
fastenedto tank floor,turn it to left(approx.
15°, bayonetlock)andremovefuelpump.
20 66 19 Removing and installing fuel pump
Printed in Germany. 1996
20-6 986201

Fuel supply, actuation
Boxster
Installation
Positionfuel pump;the edge ofthe fuel-pump
housingfaces the fueltank sendingunitinstal-
lation-positionmarkings.
3. Insertfuel tank sendingunitandturn untilthe
markingonthe sendingunitmatchesthe mark-
ing onthe fueltank.
~
\=-
-
~v
rJ)
-
-
-'-'-
"
149-96 448 -96
2. Placefuel pumpin this positionontank floor
bayonetfixture andturn fuel pumpto the right
asfar as the stop. Thencheckproper seating
offuel pumpby pullingit up.
4.Tightenunionnutwithspecialtool3217.
Tighteningtorquewithnewunionnutandnew
sealingring:70 Nm(52ftlb.).
5. Attachfuel linesandelectricalplug connec-
tion.Thefuel linesmust audiblyengage.
Correct engagement must be checked
with a gentle pull.
Thecolour-codedplug (green)mustbefitted
to the connectionidentifiedwith "V".
8
8
20 -7
20 66 19 Removing and installing fuel pump
Printed in Germany, 1996 986201

Fuel supply, control
Boxster
20 15 01 Calibrating fuel level sensor system
&-Select menuitem Tankcalibration
Warning!
Danger of fire and injury! -Confirm calibration
> Observegeneral safety
regulationsonthe fuel system. Thefuel levelsensorsystem has nowbeen
calibrated.
> Wearprotectivegloves
Note
Thefuel levelsensorsystem neednotbe
calibratedif the battery wasdisconnectedor a
plugconnectionon the instrumentclusteror fuel
levelsensorwasremoved.Thevaluesremain
stored inthe instrumentcluster.
Note
Calibrationis necessaryafter replacementofthe
fuel tank,fuel levelsensoror instrumentcluster.
Removebattery anddetachbattery cover.
A rangeon remainingfuel of lessthan 15 km is
notdisplayedinthe instrumentcluster.
2. Removefuel level sensor;refer to ServoNo.
20 66 19 (Removingfuel pump).
3. Usinga fuelextractor, completelydrain
the fuel tankthroughthe fuel levelsensor
opening.Fuelextractor: Referto the
WorkshopEquipmentManual,Chapter3
"WorkshopEquipmenf'.
4. Reinstallthe fuel levelsensor and,with
"ignitionoff', fill the tankwith 12 litres of fuel,
5. Performtank calibrationwith the Porsche
SystemTester 2.
Selectvehicletype (911 Boxster)
-Select control modules
Selectinstrumentcluster
.20 -920 15 01 Calibrating fuel level sensor system
Printed in Germany -29, 1999 986209

Fuel supply, controlBoxster
20 39 19 Removingand installing fuel return line
&Warning:
Danger of fire and injury!
> Observegeneral safety
regulationsonthe fuel system.
> Wearprotective gloves,
Removal
1.Moveconvertibletopto serviceposition.
2. Detachnegativeterminalof battery
(aff 10 mm). 367_96
3. Placeprotectivecoveronground, 9. Lowervehicle.
4. Removeenginecompartmentliningandlid 10. Removeholderfor servo return line,
electricalplugconnectionandground
strap. (Hexagon-headbolt M6 x 12)
5. Removerear wall liningand rear wallcover
6. Raisevehicleandremoveengineunderside
guard.
7. Unclipfuel return linefrom the lineholder
on the body.
8. Detachthe fuel return line.
Pressunlockingbuttonsand simultaneously
pull off the line. Immediatelysealthe fuel
line supports with a suitableplug.
86_99
20 39 19 Removing and installing fuel return line
Printed in Germany -25, 1999 9862011
20 -11

Fuel supply, control Boxster
11. Undoreturn line(wrenchsize 17);
simultaneouslycounter(wrenchsize 19).
Removereturnline.
85_99
Installation
1. Fastenfuel return lineto pressure regulator,
simultaneouslycounter.
2. Fitholder.
3. Puton rear wall cover, rear wall lining,
enginecompartmentliningandengine
compartmentlid.
4. Liftthevehicle.
5. Positionfuel return linein a straightline.
Theplug (plug part) must audiblyengage
inthe plug~ncoupling.
Thenpull slightlyto ensurethatthe connection
is properlylocked. Clipfuel returnlineonto
the body.
6. Connectbattery,closeconvertibletop.
7. Start engineand carry out tightnesstest.
8. Fitengineundersideguard
9. Readout faultmemory. Enterradio code.
Removing and installing fuel return line
Printed in Germany -25. 1999
20 39 19
9862011
20 -12

Disassembling and assembling fuel ring pipe
rij-1
2
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~::!:1
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f-3
16
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8 ~
9 ~
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@-14
1-12
@-13
24 -2 24 30 37 Disassembling and assembling fuel ring pipe
986241 Printed in Germany. 1996
~
0

Boxster Fuel system -Electronic injection
Disassembling and assembling fuel ring pipe
Note:
No. Designation Qty. Removal Installation
Closurecap 1Note
Thesealor sealingring in
the closurecap is not ex-
changeable.It mustthere-
fore be used onlyonce.
Tighteningtorque:
2.5.:t0.5 Nm(2.:t0.5
ftlb.). Wrenchsize 13 mm.
2Valve 1
3Hexagon-headbolt M6x12 4
4Hexagon-headbolt 1
5Fasteningclampforthrottle
cable16x15
Clamp
1
61Ensurecorrect seating.
7Pressureregulator 1Pushor plugvacuumcorr
trol pipeintothe left-hand
intakedistributor rubber
sleeve(see assemblyirr
structions),
Replace
8a-ring20x2.5 1
9D-ring5x2.5 1Replace
10 FuelreturnlineM14xl.5 1Ensureit is counteredwith
a wrenchwhilebeing loos-
ened.
Tighteningtorque
25.:f:.5 Nm (18 .:f:.3.5
ftlb.)
Wrenchsize 17 mm.
Ensureit is countered
with a wrenchwhilebeing
tightened.
11 Clamp 6Ensurecorrectseating.
24 30 37 Disassembling and assembling fuel ring pipe
Printed in Germany, 1996 986241
24 -3

Fuel system -Electronic injection Boxster
Note:
No. Designation Qty. Removal Installation
12 Injectionvalve 6
13 O-ring 6Replace
14 a-ring 6Replace
15 Fuel ring pipe 1
16 FuelsupplylineM16xl.5 1Ensureit is counteredwith
a wrenchwhilebeing loos-
ened.
Tighteningtorque:
30 + 5 Nm (22 + 3.5
ftlb.J.
Wrenchsize 19 mm. En-
sure it is counteredwith
a wrenchwhilebeingtight-
ened!
24 -4 24 30 37 Disassembling and assembling fuel ring pipe
986241 Printed in Germany, 1996

Fuel system -Electronic injection
Boxster
Assembly instructions
Fitting vacuum control pipe on the intake
distributor
Mountthe vacuumcontrol pipe betweenfuel
pressureregulatorandintakedistributor atthe
left-handrubbersleeve.Routethe vacuumcon-
trol pipeso it is tension-free.
-I'
I~~1
"~I\
/1/
375-96
8
8
24 -5
24 30 37 Disassembling and assembling fuel ring pipe
Printed in Germany, 1996 986241