Porsche Boxster S Manual de usuario

TechnicalManual

_.8G~.s;Zi!/-

TechnicalInformation

Repair

Contents:

Group 5

Body

WKD483 521 15

Boxster(986) Body

Supplement Overview

Supple-

ment Edition Topic Article number

05/1996 Basicedition WKD4835~1

208/1996 Generalchanges WKD 48352 ~.02

10 11/1996 Generalchanges WKD48352t.O7

04/1997 Assemblyinstructionsfor hardtopassemblyfix-

ture WKD48352t.l0

12 Generalremarksonthe airbag WKD48352t.12

14 Generalchanges WKD483521.14

FolderseparationGroups5 and6 WKD48352t.15

07/1997

08/1997

11/1997

01/1998

03/1998

07/1998

Generalsupplement WKD48352t.16

Generalremarksontheairbag WKD483521.18

Generalsupplement WKD48352t.20

Assembly instructions for hardtop assembly fix-I

ture WKD48352t.23

02/1999 Generalsupplement WKD48352t.25

04/1999 Generalsupplement WKD483521.26

07/1999 Generalsupplement WKD48352t.29

07/1999 Changesin modelyear 2000 WKD48352t.30

08/1999 FolderseparationGroups6 and 7 WKD48352t.31

09/1999 Removingandinstallingconvertible-toproof

liner WKD483521.32

Removingandinstallingthe sideairbagunit WKD48352~.36

12/1999

05/00

07/2000

08/2000

12/2000

Generalsupplement WKD483521.37

Generalsupplement WKD 483521.38

Changesinmodelyear2001 WKD483521.39

Bodyrepairs WKD483521.43

Boxster (~86) Foreword

Table of Contents

0Foreword

Foreword

Use 1

-1 pa~e

-2 pa~e

Table of Contents

Printed in Germany -37 I 2000 masterY

Boxster(~86) Foreword

Foreword

Thisman~alcontainsTechnicallnformationaswellas instructions

onrepair for Porschevehicles.Itis intendedfor the soleuseof

workshop belongingto PorscheAG.

Thedesc iptionsform thebasisfor professionalandcorrect mainte-

nancean repairwork. The contentofthe work procedures

describedis basedonthe leveloftrainingof afitter whohascom-

pletedvo ationaltrainingandhasa soundknowledgeofthe prod-

uct. ThisI vel of knowledgeis necessaryin orderto carry outthe

workdes ribed.

Warning notes

Thewarm

~g notesand safetyinstructionsareclassifiedbythe

respectiv signalisingword (Danger,Warning,Caution)besidethe

warnings mbol.

To preventinjuryandrestricted operatingandtraffic safetyofthe

vehicle,or damageto the vehicleasthe resultof incorrectwork,

readtheseinstructionscarefullyandobservethem withoutfail.

Itis notpossiblefor PorscheAGto givea detailedevaluationofall

dangersituationsfor the personscarryingoutthework. Itis there-

fore imperativethatallpersonscarryingoutrepairandmaintenance

work on Porschevehiclesusetheir specialistknowledgeto ensure

thattheirownsafetyis not atrisk andthe procedurechosenwill not

haveanynegativeeffects onthe vehicle-especiallywith regardto

safety.

Itis therefore expresslyspecifiedthatallwork involvedinthe work

proceduresdescribedshouldbecarriedoutonlyinaccordancewith

the validguidelinesandregulationsofthe localauthoritiesresponsi-

blewith respectto healthandaccidentpreventionandenvironmen-

-1 Rage 1

Foreword

Printedin Germany-37, 2000 vorwort

Warns against death or very serious injury which will cer-

tainly occur if the instructions are not observed.

Warns against death or very serious injury which may occur

if the instructions are not observed.

Warns against minor injury or damage to property if the

instructions are not observed.

Boxster(986)

Foreword

talprotection, andin compliancewiththe legalrequirementsof

individualcountries.

Notes

Notescontainadvisoryinformationrelatedto thework procedure

whichmakesthe fitter's work easier.Thefollowingpictogram indi-

catesthis information:

[IJ Note!

Containsadvisoryinformationwhichmakestheworkprocedureeas-

ier.

Dueto the continuousdevelopmentandimprovementofour vehi-

cles,theremaybe discrepanciesbetweenthe actualtechnicalsta-

tus ofthe vehiclesandthework descriptions.Anyexisting

deviationsarecorrected by meansof supplements,andthe scope

ofthe descriptionsis extendedwithsupplements.

PorscheAGretainsthe rightto implementchangesat anytime and

withoutpriornotice.

Boxster (986) Foreword

Use

Theworkshopdocumentationfor the Boxster(986)modelhasthe

designation

-"Boxster (986)" Technical Manual- andcontainsTechnical

Informationaswell asinstructionsonrepairs.

Theintegrationofthetechnicalinformationpublishedinthe"Boxster

(986)"TechnicalManualwiththe descriptivematter onrepairspro-

videsthe userwitha complexreferencework thatcombinesinto

onebookassociatedor cross-referencedmaterialofrelevanceto

workshopsandoriginatingfrom variousinformationmedia.

The"Boxster(986)"TechnicalManualconsistsof 15 folders, subdi-

videdintothefollowingGroups

.a Entirevehicle-General

.a Diagnosis,1 Engine,part1(upto RepairGroup45)

.a Diagnosis,1 Engine,part2 (asofRepairGroup69)

.1 Engine,part1 (upto RepairGroup13)

.1 Engine,part2 (asofRepairGroup15)

.2 Fuel,exhaust,engineelectronics

.3 Transmission,manualtransmission

.3 Transmission,automatictransmission

.4 Runninggear

.5 Body .

.6 Bodyequipment,exterior

.7 Bodyequipment,interior

.8/9 Airconditioning/ Electrics

.9 Circuitdiagrams,part1(uptoandincluding'99 model)

.9 Circuitdiagrams,part2 (asofandincluding'00 model)

Thetwo folders with Group0 areto be regardedas onefolder;i.e.

file the "Technicallnformation"noticesonlyinthe folder "Group0

Diagnosis,part 1" -up to Repair Group 45-.

Thesecondfolder Group0 Engine,part2 -as of Repair Group

69- includesthe furtherRepairGroupsbelongingto Group1.

Thetwo folderswith Group1 areto beregardedas one folder;i.e.

filethe "Technicallnformation"onlyinfrontoftherepairdescriptions

inthe folder Group1 -Engine, part1 -up to Repair Group 13-.

-2 page 1

Use

Printed in Germany -37, 2000 handhabung

Boxster(986)

Foreword

Thesecondfolder Group1 -Engine, part 2 -as of Repair Group

15- includesthe further RepairGroupsbelongingto Group1.

Thetwo folderswithGroup9 areto be regardedasonefolder;i.e.

filethe"TechnicalInformation"noticesonlyinthefolderGroup9 Cir-

cuit diagrams,part 1 -up to '99 model-.

Thesecondfolder Group9 Engine,part2 -as of '00 model-

includesthe further RepairGroupsbelongingto Group9.

The"Boxster(986)"TechnicalManualhasthe samestructurein

eachfolder,withthe followingbreakdownfor all Groups:

Title page: "Boxster (986)" Technical Manual

> Foreword

Title page: "Technical information"

> Tableofcontents, Technicalinformation>Technicalinformation

Title page: "Repair"

> RepairGroups:overview>Tableofcontents,repairs> General/

technicaldata> Instructionsonrepairs

Ascanbeseenfrom the breakdown,the publishedTechnicallnfor-

mationis inthe frontpart ofeachfolder-numbered accordingto

the Groups.TheTableofContentsassignedto eachGroupwillbe

periodicallyupdated.

Followingthe TechnicalInformation,separatedbyatitle page,the

instructionsonrepairs-assigned accordingto the Groupsor bro-

kendowninto RepairGroups-are includedinthefolders.

The instructionson repairswill beextendedandupdatedbymeans

of supplements.

rn Note!

Sheetsthat alreadyexistinthe "Boxster(986)"TechnicalManual

andareupdatedor revisedandtherebyexchangedbyasupplement

aredesignatedin the footer withthesupplementnumbercorre-

spondingto the currentversion:e.g. "Printedin Germany-2,-

2000"

rn Note!

Dueto asystemmodificationintheTechnicalLiteratureproduction,

thefollowingprocedureshavechangedinmodelyear2000!

Boxster (986) Foreword

1 -The previous record sheet in the folder "O-Genera!" and

the supplement contents sheet -red sheet- have been

omitted. A supplement overview now appears sepa-

rately in each folder. The new supplement contents

sheet can be destroyed after the supplement is filed in

the folder.

rn Note!

Thesupplementoverviewsheetis replacedwiththerelevant

supplementinthecorrespondingfolderandmustnolongerbe

maintainedbyhand.

2 -The page numbering in the new and the replaced chap-

ters are no longer continuous. Each new chapter is now

given an additional chapter number followed by the

page number e.g.-2 Page 11 =>Rep. Gr. 0; General

3 -The old page numbering still applies to existing chap-

ters and those that are not replaced.

-2 page 3

Use

Printedin Germany-37. 2000 handhabung

Boxster Overview of repair groups

Group 0: Entire vehicle -General

Maintenance 0

Group 0: 0

Diagnosis

Salescheck

On-boarddiagnosis

DMEdiagnosis

Tiptronicdiagnosis

ABSdiagnosis

Group 0: Diagnosis

Airbagdiagnosis

Seatmemorydiagnosis

Heatingdiagnosis

Alarmsystemdiagnosis

PCMdiagnosis

ParkAssistentdiagnosis

HBAdiagnosis

Group 1: 1

Engine

Engine-Crankcase, suspension

Engine-Crankshaft, pistons

Group 1: 1

Engine

Engine-Cylinder head,valvedrive

Engine-Lubrication

Engine-Cooling

Group 2: 2

Fuel, exhaust, engine electronics

Fuelsupply,control

Exhaustsystem,turbocharging

Fuelsystem,electronicinjection

Fuelsystem,K-Jetronic

Exhaustsystem

Starter,powersupply,cruisecontrol

Ignitionsystem

Group 3: 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

Frontwheelsuspension,driveshafts

Rearwheel suspension,driveshafts

Wheels,tires, suspensionalignment

Anti-LockBrakeSystem(ABS)

Brakes-Brake mechanics

Brakes-Hydraulics, regulator,booster

Steering

Group 5: 5

Body

Bodyfront

Bodycenter,roof,frame

Bodyrear

Lids,flaps

Doorfront,centrallockingsystem

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

Airconditioning

Auxiliaryairconditioningsystem

Group 9 Electrics

Instruments,alarmsystem

Radio,telephone,on-boardcomputer,navigation

Windshieldwiperandwashersystem

Lights,lamps,switchesexterior

Lights,lamps,switchesinterior,theftprotection

Group 9: 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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