English Workshop Manual, Wiring Schematics and User Manual to vehicles Porsche 986 Boxster (1996-2004).
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PORSCHE 986 BOXSTER - SERVICE MANUAL / REPAIR MANUAL
- English Workshop Manual, Wiring Schematics and User Manual to vehicles Porsche 986 Boxster (1996-2004).
INDEX:
INTRODUCTION (22 pages)
ENTIRE VEHICLE - GENERAL (113 pages)
General
-Engine
-Transmission
-Running Gear
-Body
-Electrics
-Technical Data
-Plug-in couplings for pipelines (new system)
-Lifting the vehicle
-Power supply - general (work instructions after disconnecting the battery)
-Technical data Boxster (2.7 I)
-Technical data Boxster S (3.2 l)
Sales Check
-Removing transport arrangement
-Convertible top: Checking operation coding alarm system for Great Britain and Belgium
Maintenance
-Maintenance schedule
-Maintenance
DIAGNOSIS, PART 1 (UP TO REPAIR GROUP 45) (161 pages)
General
-Installation location, diagnostic socket
-Operating instructions, Porsche System Tester 2
DME diagnosis
-System M 08
Tiptronic diagnosis
-System G 40
Anti-lock brake system diagnosis
-System ABS 5.3 and ABS/TC 5.3
DIAGNOSIS, PART 2 (AS OF REPAIR GROUP 69) (388 pages)
Airbag Diagnosis
-System B 04
-System B 05
Seat memory diagnosis
-System S 01
Heating diagnosis
-System H 01
Alarm system diagnosis
-System I 16
Instrument cluster diagnosis
-System K 0X
PCM diagnosis
-System N 01
ParkAssistent diagnosis
-System P 01
Headlight beam adjustment diagnosis
-System HBA 01
Alarm system diagnosis
-System I 32
ENGINE, PART 1 (UP TO REPAIR GROUP 13) (285 pages)
Engine
-Technical data engine M96/20
-Differences between Boxster 2.5l, 27l and Boxster S (3.3l) engines
-Tightening torques for engines M96/20 (2.5l), M96/21 (3.2l), M96/22 (2.7l)
Engine - Crankcase, suspension
-Removing engine, M96/20 (2.5l) with manual transmission
-Special tools
-Adjusting tool
-Removing engine
-Installing engine, M96/20 (2.5l) with manual transmission
-Special tools
-Adjusting tool
-Special notes
-Installing engine
-Tightening torques
-Disassembling and assembling engine
-Disassembling and assembling positive crankcase ventilation
-Disassembling and assembling crankcase halves, engine M96/20, M96/21, M96/22
-Mounting instructions
-Assembling the crankcase halves
-Tightening torques
-Removing engine, M96/20 (2.5l) with Tiptronic transmission
-Special tools
-Adjusting tool
-Removing engine
-Installing engine, M96/20 (2.5l) with Tiptronic transmission
-Special tools
-Adjusting tool
-Special notes
-Installing engine
-Tightening torques
-Removing engine, M96/21 (3.2l) and m96/22 (2.7l) with manual transmission
-Special tools
-Adjusting tool
-Removing engine
-Installing engine, M96/21 (3.2l) and M96/22 (2.7l) with manual transmission
-Special tools
-Adjusting tool
-Special notes
-Installing engine
-Tightening torques
-Disassembling and assembling engine carrier
Engine - Crankshaft, pistons
-Removing and installing drive belt
-Removing and installing deflection rollers for drive belt
-Removing and installing tensioning roller for drive belt
-Removing and installing belt tensioner
-Disassembling and assembling belt tensioner
-Disassembling and assembling bearing housing with crankshaft
-Removing and installing crankshaft
-Removing and installing pistons
-Removing and installing crankshaft sealing ring (engine installed)
-Removing and installing crankshaft sealing ring (engine installed)
-Removing and installing pistons - Boxster S
-Removing and installing pistons for engine type M96/22 (2.7l)
ENGINE, PART 2 (AS OF REPAIR GROUP 15) (150 pages)
Engine - Cylinder head, valve drive
-Disassembling and assembling cylinder head
-Removing and installing valve springs
-Removing and installing valve stem seal
-Removing and installing camshafts
-Removing and installing valve tappets (engine removed)
-Completing camshafts
-Sealing cover for camshaft housing (cylinder head cover)
-Checking guide for valve tappets -Removing and installing oil protection tube (engine installed)
-Removing and installing valve tappet (engine installed)
-Removing and installing closure cap for camshaft bore
-Removing and installing sealing ring for intermediate shaft
-Removing and installing solenoid hydraulic valve
-Reworking cylinder head
-Camshafts – assignment
Engine – Lubrication
-Removing and installing air/oil separator
-Removing and installing oil pan (engine installed)
-Removing and installing oil pump with coolant guide housing
-Removing and installing oil extraction pumps
-Removing and installing oil extraction pump (engine installed)
-Removing and installing oil-water heat exchanger - Engine installed
-Checking oil pressure
Engine – Cooling
-Removing and installing cooling pump
-Removing and installing coolant regulator
-Removing and installing coolant temperature sensor
-Draining and topping up with coolant
-Checking cooling system for leaks
FUEL, EXHAUST, ENGINE ELECTRONICS (96 pages)
Fuel supply, control
-Checking fuel pressure
-Checking quantity delivered by fuel pump
-Removing and installing fuel pump
-Calibrating fuel level sensor system
-Removing and installing fuel return line
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 S
-Installing throttle body - Boxster S
-Removing and installing injection valve - Boxster S
-Removing injection valves - Boxster S
-Installing injection valves - Boxster S
-Removing and installing intake distributor - Boxster S
-Removing intake distributor - Boxster S
-Installing intake distributor - Boxster S
Exhaust system
-Replacing exhaust system
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
-Work instructions after disconnecting the battery
Ignition system
-Removing and installing rotor for hall sendor
-Removing and installing pulse sender
TRANSMISSION, MANUAL TRANSMISSION (136 pages)
Power transmission
-Technical data (transmission G 86)
Clutch, control
-Disassembling and assembling clutch
-Bleeding the clutch system
-Removing and installing clutch pedal
-Clutch boost spring: allocation and grease specification
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 86
-Disassembling and assembling transmission G 86
-Disassembling and assembling transmission case cover (transmission G 86)
-Disassembling and assembling transmission case (transmission G 86)
Manual transmission - Gears, shafts, int. 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)
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)
TRANSMISSION, AUTOMATIC TRANSMISSION (87 pages)
Transmission
-Technical data
Automatic clutch - Torque converter
-Removing and installing torque converter
-Removing and installing sealing ring for torque converter
Automatic transmission - Auction, ass. Housing
-Removing and installing selector lever cable
-Adjusting selector lever cable
-Removing and installing selector knob
-Removing and installing selector support
-Removing and installing shiftlock solenoid
-Removing and installing deflection lever
-Removing and installing tiptronic transmission
-Checking and topping up ATF fluid
-Changing ATF fluid
-Removing inner oil tube
-Removing and installing multi-function switch
-Removing and installing gasket for spur gear cover
-Removing and installing sealing ring for selector shaft
Automatic transmission - Gears, control
-Removing and installing hydraulic control unit
-Removing and installing sensor for transmission input speed
-Removing and installing transmission speed sensor
-Removing and installing wiring harness
-Removing and installing ATF cooler
Final drive - Differential, differential lock
-Changing and checking transmission oil in final drive
-Disassembling and assembling final drive
-Removing and installing differential
-Removing and installing sealing ring for short flanged shaft
-Removing and installing long flanged shaft
-Removing and installing sealing ring for long flanged shaft
-Removing and installing double sealing ring for final drive/transm. housing
RUNNING GEAR (206 pages)
Running gear
-Removing transport arrangement
-Overview of Boxster running gear
-General information - Boxster S
-Notes on repair instructions - Boxster S
Front wheel suspension, drive shafts
-Tightening torques for front axle
-Removing and installing rear spring strut
-Disassembling and assembling front spring strut
-Installing caster eccentric
-Removing and installing front wheel bearing
-Removing and installing front axle strut (control arm)
Rear wheel suspension, drive shafts
-Tightening torques for rear axle
-Removing and installing rear spring strut
-Disassembling and assembling rear spring strut
-Removing and installing diagonal brace
-Removing and installing cable
-Removing and installing rear wheel bearing
-Removing and installing rear tie rod (toe control arm)
-Removing and installing drive shaft
-Removing and installing rear axle strut (control arm)
-Removing and installing rear stabilizer
-Removing and installing rear-axle cross member
-Removing and installing sheetmetal brace
Wheels, tires, suspension alignment
-Wheels and tyres (tyre pressure / mounting wheel on vehicle)
-Adjustment values for suspension alignment
-Alignment cards for Boxster/Boxster S
-Complete suspension alignment
-General tyre mounting instructions
-Checking rims
-Tyre mounting with conventional mounting machines
-Identifying size of 18-inch Turbo wheels (Technologie wheels)
-Tyre mounting for critical wheels/tyre pairs
Anti-Lock Brake System (ABS)
-Important information on ABS 5.3 and ABS/TC 5.3
-ABS 5.3 system description
-ABS/TC 5.3 system description
-Component arrangement (ABS and ABS/TC)
-Function of individual components
-ABS test with Porsche System Tester 2
-Removing and installing front speed sensor
-Removing and installing rear speed sensor
-Removing and installing hydraulic unit
Brakes - Brake mechanics
-Tightening torques for brake mechanics
-Technical data (brake disc wear limit)
-Technical data - Boxster S (brake disc wear limit)
-measuring brake pad thickness
-Removing and installing front disc brake pads
-Removing and installing rear disc brake pads
-Removing and installing front disc brake pads - Boxster S
-Removing and installing rear disc brake pads - Boxster S
-Adjusting brake push rod (adjusting stop light switch)
-Adjusting parking brake shoes
-Removing and installing front brake disc
-Removing and installing rear brake disc
-Removing and installing parking brake shoes
-Measuring lateral runout of front brake discs
-Measuring rear brake disc lateral runout
-Removing and installing brake pedal
Brakes - Hydraulics, regulator, booster
-Tightening torques for brake hydraulics
-Bleeding brakes
-Changing brake fluid
-Removing and installing brake master cylinder
-Removing and installing brake booster
Steering
-Tightening torques for steering
-Test and assembly work on power steering
-Removing and installing steering wheel (airbag)
-Replacing steering system after accident damage
-Removing and installing steering gear
-Plug couplings for steering hydraulics
-Plug-in couplings for pipelines
-Removing and installing ignition switch
-Removing and installing lock barrel
-Removing and installing hydraulic pump
-Replacing steering lock
BODY (237 pages)
Body
-Safety instructions for body repair
-Safety instructions for disassembling components
-Safety instructions for air conditioning
-Safety instructions for fuel tank
-Safety instructions for paintwork, glass, upholstery, linings
-Safety instructions for airbag system
-Safety instructions for door
-Safety instructions for sliding roof
-Safety instructions for rear spoiler
-Safety instructions for rear window
-Safety instructions for windscreen
-Safety instructions for heat shields
-Safety instructions for cabriolet convertible top
-Safety instructions for roll-over protection system
-Safety instructions for plug location plan (body)
-Safety instructions for water drains (body)
-Safety instructions for welding
-Safety instructions for Teromix-6700 two-component adhesive
-Safety instructions for hydraulic system
-Safety instructions for hardtop
-Safety instructions for belt strap holder
-General information and quality notes
-Electronic control modules
-Protection against overvoltage
-Replacing control modules
-Tools and metalworking tools for body repairs
-Repair check dimensions
-Body parts of high-strength steel
-Diagram of safety passenger compartment
-Water drainage plan
-Plug location plan
-Body gap dimensions
-Diagram - key to symbols for welding work
-Seam seals -Accessories
-Front lid
-Doors
-Rear lid
-Work sequence for accident repair
Body front
-Removing and installing wheel housing liner
-Removing and installing the wing
-Replacing closing panel
-Cutting out closing panel and front floor panel
-Preparing closing panel and front floor panel for installation and fitting
-Welding in closing panel and front floor panel
-Tools and materials
-Replacing wheel housings and side members (sectional repair)
-Cutting out wheel housings and side member
-Preparing wheel housings and side members for installation and fitting
-Welding in wheel housing and side members
-Replacing wheel housings
-Removing wheel housing, lower shell and outer side member from the body
-Preparing wheel housing, lower shell and outer side member for installation and fitting
-Welding wheel housing, lower shell and outer side members into the body
-Tools and materials
-Cleaning front water drains
-Replacing front wall
-Cutting out front wall
-Preparing front wall for installation and fitting
-Welding in front wall
-Tools and materials
Body centre, roof, frame
-Removing and installing underbody cover
-Replacing outer lower side member
-Separating outer lower side member
-Preparation for installation of lower side member and fitting
-Welding lower side member
-Tools and materials
-Replacing seat cross member
-Cutting out seat cross member
-Preparation of seat cross member for installation and fitting
-Welding in seat cross member
-Tools and materials
Body rear
-Removing and installing wheel housing liner
-Replacing side section
-Cleaning rear water drains
-Replacing end cross member
-Separating end cross member
-Preparing the rear end cross member for installation and inserting
-Inserting end cross member
-Replacing rear trunk floor panel
-Separating rear trunk panel
-Preparing the rear trunk floor panel for installation and inserting
-Inserting rear trunk floor panel
-Replacing rear cover panel
-Separating rear cover panel
-Preparing the rear cover panel for installation and inserting
-Inserting the rear cover panel
-Tools and materials
-Replacing rear wheel housing
-Cutting through rear wheel housing
-Preparing the rear wheel housing for installation and fitting
-Welding in rear wheel housing
-Tools and materials
Lids, flaps
-Disassembling and assembling front lid
-Disassembling and assembling rear lid
-Replacing the model logo
-Disassembling and assembling release for lid
-Disassembling and assembling release for rear lid
-Removing and installing lid hinge
-Removing and installing lower part of lid lock at rear
-Disassembling and assembling release for front lid- from model year 2001
-Disassembling release for front lid
-Assembling release for front lid
-Disassembling and assembling release for rear lid - from model year 2001
-Disassembling release for rear lid
-Assembling release for rear lid
-Removing and installing lower part of front lid lock - from model year 2001
-Removing and installing bowden cable for lock actuation
Door front, central locking system
-Removing and installing door
-Disassembling and assembling door
-Disassembling door
-Assembling door
-Adjustment instructions for assembly of the door
-Diagram: sheetmetal for assembly of the door
-Basic setting of door lock
-Basic setting of the door lock before installation
-Standardising the system
-Standardising the power windows
-Blockage detection function
-Precondition for operation of the power windows
-Fitting the door window in the clamping jaws
-Adjusting the door window angle in the vehicle's longitudinal direction
-Adjusting the door window height
-Adjustment procedure:
-Checking the adjustment:
-Adjustment of the door window pressing force on the door seal at the top and sides
-Adjustment procedure:
-Checking the adjustment:
-Adjusting the lower stop of the power window unit
-Disassembling and assembling door handle
-Setting the door
BODY EQUIPMENT, EXTERIOR (275 pages)
Body equipment
-Colour range for 1997 models
-Colour range for 1998 models
-Colour range for 1999 models
-Colour range for 2000 models
-Processing of Porsche 2-component window bonding agents
-Overview of tools and materials
-Mixing procedure
-Colour range for 20001 models
-Exterior paintwork solid
-Exterior paintwork metallic / pearl
-Special paintwork metallic / pearl
Convertible top, hardtop
-Removing and installing convertible top
-Diagram of convertible top
-Overview of convertible-top components up to model year 1999
-Overview of microswitch test plan up to model year 1999
-Overview of convertible-top components up to model year 2000
-Removing convertible top
-Installing convertible top
-Replacing convertible-top covering
-Removal overview of the convertible-top covering components, part 1
-Removal overview of the convertible-top covering components, part 2
-Removal convertible-top covering
-Installation overview of the convertible-top covering components, part 1
-Installation overview of the convertible-top covering components, part 2
-Installing the convertible-top covering
-Replacing convertible-top frame
-Overview of replacing convertible-top fram, part 1
-Overview of replacing convertible-top fram, part 2
-Overview of replacing convertible-top fram, part 3
-Overview of replacing convertible-top fram, part 4
-Replacing convertible-top frame
-Conversion measure on the tension bow for the tension strap in vehicles produced before 12.04.2000
-Conversion measure on the tension bow for the roof liner in vehicles produced before 12.04.2000
-Removing and installing hardtop
-Disassembling and assembling hardtop
-Removal instructions for hardtop assembly fixture
-Adjusting convertible top gear
-Troubleshooting in convertible top operation
-Removing and installing hardtop fastening
-Adjusting the hardtop
-Removing and installing roof liner
-Removal overview of roof liner
-Removing roof liner
-Installation overview of roof liner
-Installing roof liner
-Replacing the tension cable
-Removing the tension cable
-Installing the tension cable
-Care and cleaning of the convertible top
-Cleaning the convertible top
-Care of convertible top
-Care of convertible-top seals
Bumpers
-Removing and installing front spoiler
-Removing front spoiler
-Installing front spoiler
-Removing and installing rear spoiler
-Disassembling and assembling front spoiler
-Disassembling front spoiler
-Assembling front spoiler
-Disassembling and assembling front spoiler - Boxster S
-Disassembling front spoiler
-Assembling front spoiler
-Removing and installing bumper and accessories
Glazing, window control
-Removing and installing the windscreen
-Removing the windscreen
-Fitting the windscreen
-Overview of tools and materials
-Removing and installing rear window (hardtop)
-Removing and installing power window motor
-Checking function of heating for rear window
Exterior equipment
-Disassembling and assembling the rear-view mirror
-Removing and installing rear spoiler
-Removing and installing the engine compartment vent
-Checking function of heating for mirror glass
Interior equipment
-Removing and installing the interior rear-view mirror
-Bonding the interior rear-view mirror
-Removing and installing centre console (front section)
-Removing and installing centre console
-Disassembling and assembling centre console
-Disassembling and assembling cover for the oddments tray
-Removing and installing inner sill (passenger's side)
-Removing inner sill
-Installing inner sill
-Removing and installing inner sill (driver's side)
-Disassembling release for front lid
-Assembling release for front lid
Passenger protection
-Safety regulations for airbag vehicles
-Disposal of airbag units
-Removing and installing the driver's airbag unit
-Removing and installing the contact unit
-Removing and installing the triggering unit for the airbag
-Removing and installing the passenger's airbag unit
-Removing and installing the side airbag unit
-Removing and installing roll-over bar
BODY EQUIPMENT, INTERIOR (80 pages)
Linings, insulation
-Disassembling and assembling the dashboard
-Disassembling the dashboard
-Removing the regulator for wiping interval
-Removing the cigarette lighter
-Assembling the dashboard
-Installing the regulator for wiping interval
-Installing the cigarette lighter
-Removing and installing the dashboard
-Removing and installing cowl panel cover
-Disassembling and assembling door trim panel
Seat frames
-Removing and installing front seat
-Disassembling and assembling the seat frame
-Disassembling and assembling backrest frame
Seat upholsteries, cover
-Removing and installing covering from front seat
-Removing and installing covering from front backrest
AIR CONDITIONING (146 pages)
Air conditioning
-Technical data for the air conditioning system
Heating
-Removing and installing heat exchanger
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 frsh-air/recirculation valve
-Removing and installing bulb for rotary blower switch
Air conditioning
-Safety regulations when handling refrigerant R 134a
-Assembly 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 condensor
-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 and installing outside temperature sensor
-Removing and installing inside 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 heating/air-conditioning unit
ELECTRICS (146 pages)
General
-Work instructions after disconnecting the battery
Instruments, alarm system
-Removing and installing instrument cluster
-Disassembling and assembling instrument cluster
-Removing and installing horn
-Setting ahead the total mileage counter in the instrument cluster
Radio, telephone, on-board computer, navigation
-Setting hands-free microphone to telephone type
-Removing and installing sensor for ParkAssistent
-Removing and installing display and operator control unit (PCM)
-Removing and installing navigation unit
-Removing and installing GPS antenna
-Retrofitting mobile communication systems
-Adjusting (calibrating) PCM navigation unit
Windshield wiper and washer system
-Removing and installing wiper link
-Removing and installing wiper blades
-Removing and installing wiper motor
-Non-adjustable spray nozzles
-Removing and installing tank for windscreen washer system
-Removing and installing pump for windscreen washer system
-Removing and installing pump for headlight washing system
-Removing and installing fluid level indicator
-Removing and installing spray nozzle for headlight washing system
Lights, lamps, switches exterior
-Removing and installing headlights
-Headlights - basic adjustment in body
-Removing and installing main light switch
-Removing and installing hazard warning light switch
-Masking film for left/right-hand traffic
-Bulb overview and installation instructions
-Removing and installing halogen bulb
-Removing and installing bulb for parking light
-Removing and installing bulb for fog light
-Removing and installing bulb for direction indicator light
-Removing and installing bulb for side direction indicator light
-Removing and installing bulb for tail light
-Removing and installing for number plate light
-Removing and installing bulb for raised brake light
-Removing and installing gas discharge lamp (Litronic headlights)
-Removing and installing control module for gas discharge lamp
-Removing and installing ignition unit for gas discharge lamp
-Removing and installing servo motor for automatic headlight beam adjustment
-Left / right traffic conversion for Litronic headlights
-Troubleshooting on Litronic headlight (dipped beam)
-Removing and installing angle sensor for automatic headlight beam adjustment
-Removing and installing angle sensor for automatic headlight beam adjustment
-Removing and installing control module for automatic headlight beam adjustment
Lights, lamps, switches interior, theft protection
-Removing and installing signal converter/immobiliser
-Removing and installing passenger compartment monitoring sensor
-Additional alarm system M 534
-Radio remote control in hand-held transmitter does not function
-Vehicles with alarm system without radio remote control
-Bulb overview and installation instructions
-Removing and installing bulb for door warning light
-Removing and installing bulb for luggage compartment light
-Removing and installing bulb for interior light
-Removing and installing bulb for instrument cluster
-Teaching hand-held transmitter
-Reading out and transferring remote control
-Disassembling and assembling hand-held transmitter
CIRCUIT DIAGRAMS (225 pages)
Wiring
-Removing and installing current distributor
-Removing and installing fusible element in the current distributor
-Allocation of free fuse connection points
-Measurement of closed-circuit current
-Repair of main wiring harness
-Repair of rear wiring harness
-Wiring diagram for '97 model Boxster
-Wiring diagram for '98 model Boxster
-Wiring diagram for '99 model Boxster
CIRCUIT DIAGRAMS (213 pages)
Wiring
-Wiring diagram for '00 model Boxster (986)
-Wiring plan for '01 model Boxster (986)
986 OWNER'S MANUAL (255 pages)
-Table of Contents
-Controls, Instruments
-Shifting Gear
-Mobile Roofs
-Maintenance, Car Care
-Practical Tips, Emergency Service
-Vehicle Identification, Technical Data
-Index