Porsche Boxster S Manual de usuario

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

Group 0: 0

Diagnosis

Salescheck

On-boarddiagnosis

DMEdiagnosis

Tiptronicdiagnosis

ABSdiagnosis

Group 0: 0

Diagnosis

Airbagdiagnosis

Seatmemorydiagnosis

Heatingdiagnosis

Alarmsystemdiagnosis

PCMdiagnosis

ParkAssistentdiagnosis

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,power supply,cruisecontrol

Ignitionsystem 3

Group 3: Transmission, manual transmission

Clutch, control

Manual transmission -Actuation, housing

Manual transmission -Gears, shafts, intogearsh

Final drive, differential, differential lock

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

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

Group 5: Body

Bodyfront

Bodycenter,roof,frame

Bodyrear

Lids,flaps

Doorfront,centrallockingsystem 6

Group 6: Body equipment, exterior

Slidingroof

Convertibletop, hardtop

Bumpers

Glazing,windowcontrol

Exteriorequipment

Interiorequipment

Passengerprotection 7

Body equipment, interior

Linings,insulation

Seatframes

Seatupholsteries,covers

Group 7:

Group 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 9

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

www.WorkshopManuals.co.uk

Purchased from www.WorkshopManuals.co.uk

Boxster Contents

3Transmission, manual transmission

Power transmission

Technicaldata (transmissionG86) 31

30 50 37

3001 07

3005 19

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-

34-19

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 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 -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

.2m

.11

0919

0937

0815

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Transmission

Boxster

3Technical data (transmission G86)

5-speed manual transmission G 86

'-Y

34350001

Type Code letter Installed in Model year

Equipment

G 86/00

G 86/01

CWA

EFO

5-speed

97/98

Boxster

3 Technical data (transmission G 86)

Printed in Germany -30, 1999

3 -1

9863_1

www.WorkshopManuals.co.uk

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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

= Code letter

= Day

= Month (July)

= Year (1996) of manufacture

.3 Technical data (transmission G 86)

Printed in Germany -30, 1999

3-2 9863_1

www.WorkshopManuals.co.uk

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

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Purchased from www.WorkshopManuals.co.uk

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

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