Porsche Boxster 1999 Manual de usuario

Technical Manual

-..8<:;~s:;~-

TechnicalInformation

Contents:

Group0

Entirevehicle-

General

WKD483 521

Foreword

Boxster

Foreword

The workshop documentation for the Boxster model has the designation "Boxster" Technical Manual

and contains Technical Information as well as instructions on Repairs.

Theintegrationof 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" Technical Manual consists of 15 folders, subdivided into the following Groups

a Entire vehicle -General

a Diagnosis, part 1 (up to Repair Group 45) *1

a Diagnosis, part 2 (as of Repair Group 69) *2

1 Engine, part 1 (up to Repair Group 13) *3

1 Engine, part 2 (as of Repair Group 15) *4

2 Fuel, exhaust, engine electronics

3 Transmission, manual transmission

3 Transmission, automatic transmission

4 Running gear

5 Body

6 Body equipment, exterior

7 Body equipment, interior

8 / 9 Air conditioning / Electrics

9 Circuit diagrams, part 1 (up to and including the '99 model) *5

9 Circuit diagrams, part 2 (as of the '00 model) *6

*1 Thetwo folders with Group0 areto 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 thefolder "Group1 -Engine, part I" (up to

RepairGroup 13).

*4 Thesecond folder "Group1 -Engine, part 2" (as of Repair Group 15) includesthe further Repair

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 repairdescriptionsinthe folder "Group9 -Circuit diagrams,part 1"(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" 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,Technicalinformation

> Technicalinformation

Title page: "Repair"

> RepairGroups:overview

> Table of Contents,repairs

> General/technical data

> Instructionson 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.

Followingthe TechnicalInformation,separatedbya title page,the instructionson repairs-assigned

accordingto the Groupsor brokendowninto RepairGroups-are includedin the folder.

The instructions on repairs will be extended and updated by means of supplements.

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.

Foreword

Printed in Germany -34, October 1999

VORW.CHP

Record sheet for supplements to

We ask that you file the supplement under the appropriate Repair Groups and enter them in the

table below to provide an overview.

Supplement No. Datefiled Signature

alreadyfiled

3II

4II

6II

7II

9II

10 II

11 II

12 "

13 I J

15 1/

16 II

RECORDSHEET .CHP

Record sheet for supplements to

We ask that you file the supplement under the appropriate Repair Groups and enter them

in the table below to provide an overview.

SupplementNo. Date filed Signature

EINTRAG2.CHP

Boxster Structure of Technical Manual -Repair

Boxster Technical Manual -Repair

General

The Technical Manual -Repair -describes all essential work operations requiring special instructions to

ensure that repairs are performed properly. It should be in the hands of the workshop foremen and the

workshop personnel, as careful compliance with the stated instructions is a precondition for maintaining

the traffic and operating safety of the vehicle. In addition, of course, the generally customary basic safety

rules for the repair of motor vehicles are unrestrictedly applicable.

Structure

Overview of Repair Groups

Contents

Technicaldata/ general

Descriptionof repairs

Breakdown of Repair Groups

Tools, special tools and materials required for repair

Exploded drawing and illustration of sequence

Legend for exploded drawing and description of sequence

Instructions for assembly and adjustment

The Technical Manual is regularly expanded by supplements, which must be incorporated immediately to

preserve the usefulness of the Manual. As verification of completeness, the record sheet should be com-

pleted.

Boxster Technical Manual -Repair

Printed in Germany, 1996 STRUCTURE.CHP

Structure of Technical Manual -Repair Boxster

Structure of exploded view

Al7 A

BccB17

E"gme-lubrica,;o" Boxst.. 80x"., Enome -Lubricat;on

Removing and installing oil pump with coolant guide housing Removingand installing oil pump with coolant guide housing

K Nota

J No Deolloa".. QIy. Removal 1.-

1 Cooiarnd,ain"ugMIO,l

2 s..ing ,ingA10, 135

3 H.xagDf'headbolt

M10, 100

4 HexagDf'headbo~

M10, 100

5 HexagDf'headbOt

M6,2Q

6 HexagDf'headbOt

M6,70

7 H.,ago"",ad bOt

M6,70

8 Gasket

"ght.,;ng ""QUe

IO+5,""17+35fUbl

Always repl~,

Tightenilg torqlE

45 Nm 133 ftibJ

Tlghteni1gtorQue

45 '"" 133ftibl

Tlghteni1gtorQue

10~17ftibJ

Always 'eplace; ;nsert m

fit any;1 coo... guide

housi1g has been OIl!

onto craMcsse

-'e"ace; insert or

fit oriy Wcoolant gu;de

housing hes been put

onto c,ankcase

9 Gasket

10 Qlp","p,"lj,coaa"'g,ida

""",ng

11 ~,

12 Ofing

13 ~'g.;1!1g.depin Alwaysreplace

Tighter;ngtor...

25Nm(18ftib)

F 17 20 19Removin. andmstal'n. oilpump w;thcoolantguidehousing

E'86m GPri"od...,m"Y"'6

17.6

J-

Imprint, supplementnumber,

year of printing

Title of explodedview

Itemnumberof explodedview,in

disassemblysequence

Specialinstructionsto befollowed

duringinstallationor removal

RepairGroup,numbers

RepairGroup,text

Vehicletype

Pagenumber

InternalPorschenumber

Work operation,consistingof

"After-sales service number"

and "Title"

Structure of exploded view

Printed in Germany, 1996

STRUCTURE.CHP

Boxster Structure of Technical Manual -Repair

Structure of sequence description

ABccB

57 Door front. _I kick'" system Bo'ste, Boxlt., Doorfront,0'_' --I syIIem

HRemoving and installing door HRemovingand installing door

1Remo,;ngdOG'

J K

No ed,," L'""'"c60"'

LooSe1fa'-l screws

Loosendoorbr~e

~screwfa_,. screwfrcxn-Ii,.,

~screw hexagoosockethe., bat screw00Ul,-

brM'

Loosen hexagona screw \\\U1draw plug camection -..

wards 100 cfi~t

Pun__rds out of the runges

3 ~scOlrleCtplugcomectioo

loosen latch striker

Install door

No Procedure Inslructions

H...- Hang-in docwti,.. from-.aoo tigtttenfastening

screw

2 AsseniJle-brake

Comect

4 Assemblelatchstriker

Screw -brake to body with hexaeon socket head bat

Comet! plug tomection, insert frcxn bel"" am set...

with liexagMhead bat,

Screw latch strik~ to the Bi]iw MjJst latch s1rik~ so

thatthe_tOltourtorre~s"""ther..side-

,.,.

575137Ro",,",nl0"'-"" doo.

"""."""'",...

57.2 57 -3

DFD

E""'1

G==

-H

Imprint, supplement number I

yearofprinting

Title of sequencedescription

Sequencenumberinorder of sequence

Procedureinthe sequence

Descriptionor explanationofthe

procedure

RepairGroup,numbers

RepairGroup,text

Vehicletype

Pagenumber

InternalPorschenumber

Workoperation,consistingof

"After-sales service number"

and"Title"

8Structure of sequence description

Printed in Germany, 1996 STRUCTURE.CHP

Overview of repair groupsBoxster

Group 0: Entire vehicle -General

Maintenance 0

Group 0: Diagnosis

Salescheck

On-boarddiagnosis

DMEdiagnosis

Tiptronicdiagnosis

ABSdiagnosis

Group 0: 0

Diagnosis

Airbag diagnosis

Seat memory diagnosis

Heating diagnosis

Alarm system diagnosis

PCM diagnosis

ParkAssistent diagnosis

HBAdiagnosis

Group 1: Engine

Engine-Crankcase, suspension

Engine-Crankshaft, pistons 1

Group 1: Engine

Engine-Cylinder head,valvedrive

Engine-Lubrication

Engine-Cooling

Group 2: Fuel, exhaust, engine electronics

Fuelsupply,control

Exhaustsystem,turbocharging

Fuelsystem,electronicinjection

Fuelsystem,K-Jetronic

Exhaustsystem

Starter,powersupply,cruisecontrol

Ignitionsystem

Group 3: Transmission, manual transmission

Clutch,control

Manualtransmission-Actuation, housing

Manualtransmission-Gears, shafts,intogearsh.

Finaldrive, differential,differentiallock

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

Group 4: 4

Running gear

Frontwheel suspension,drive shafts

Rearwheelsuspension,driveshafts

Wheels,tires, suspensionalignment

Ant~LockBrakeSystem(ABS)

Brakes-Brake mechanics

Brakes-Hydraulics, regulator,booster

Steering

Group 5: 5

Body

Bodyfront

Bodycenter, roof, frame

Bodyrear

Lids,flaps

Door front, central lockingsystem

Group 6: 6

Body equipment, exterior

Slidingroof

Convertibletop,hardtop

Bumpers

Glazing,windowcontrol

Exteriorequipment

Interiorequipment

Passengerprotection

Group 7: Body equipment, interior

Linings,insulation

Seatframes

Seatupholsteries,covers

Group 8: 8

Air conditioning

Heating

Ventilation

Air conditioning

Auxiliary air conditioning system

Group 9 9

Electrics

Instruments, alarm system

Radio, telephone, on-board computer, navigation

Windshield wiper and washer system

Lights, lamps, switches exterior

Lights, lamps, switches interior, theft protection

Group 9: Circuit diagrams

Wiring(upto andincludingthe '99 model)

Group 9: Circuit diagrams

Wiring(fromthe '00 model)

Overview of repair groups

Printed in Germany -34, October 1999

REPGRU.CHP

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