1998-2004 Porsche 986 Boxster OEM Service & Repair Manual

F=3c::J~~I:=J-I~ 0 Technical Manual -~~~ Technical Information Repair 8 Contents: Group 0 Diagnosis Part 1 (up to Repair Group 45) 8 WKD 483 521 TlTEL.CHP 8

Boxster Foreword 8 Foreword The workshop documentation for the Boxster model has the designation"Boxster" Technical Manual and contains Technical Information as well as instructions on Repairs. The integration of the technical informationpublishedin the "Boxster" TechnicalManual with the descriptive matter on repairs provides the user with a complex referencework that combines into one book associated or cross-referenced material of relevanceto workshops and originating from various information media. The "Boxster" TechnicalManual consists of 15 folders, subdividedinto the following Groups 0 Entire vehicle -General 0 Diagnosis, part 1 (up to Repair Group 45) *1 e o Diagnosis, part 2 (as of RepairGroup 69) *2 1 Engine, part 1 (up to RepairGroup 13) *3 1 Engine,part 2 (as of RepairGroup 15) *4 2 Fuel, exhaust,engine electronics 3 Transmission, manualtransmission 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 includingthe '99 model) *5 9 Circuit diagrams, part 2 (as of the '00 model) *6 I *1 The two folders with Group 0 are to be regarded as one folder; i.e. file the "TechnicalInformation" notices only in front of the repair descriptions in the folder "Group0 -Diagnosis, part 1" (up to Repair Group 45). 8 I *2 The second folder "Group0 -Diagnosis, part 2" (as of Repair Group 69) includesthe further Repair Groupsbelongingto Group O. I *3 The two folders with Group 1 are to be regarded as one folder; i.e. file the "Technical Information" notices only in front of the repair descriptions in the folder "Group1 -Engine, part 1" (up to Repair Group 13). I *4 The second folder "Group1 -Engine, part 2" (as of Repair Group 15) includesthe further Repair Groups belongingto Group 1. e Foreword Printed in Germany -34, October 1999 VORW.CHP ---

Foreword Boxster 8 I *5 The two folders with Group 9 are to be regarded as one folder; i.e. file the "Technical Information" notices only in front of the repair descriptions in the folder "Group 9 -Circuit diagrams, part 1" (up to the '99 model). I *6 The second folder "Group 9 -Circuit diagrams, part 2" (as of the '00 model) includes the further circuit diagrams belonging to Group 9. 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, Technical information e > Technical information -Title page: "Repair" > Repair Groups: overview > Table of Contents, repairs > General/technical data > Instructions on 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. Following the Technical Information, separated by a title page, the instructions on repairs -assigned according to the Groups or broken down into Repair Groups -are included in the folder. The instructions on repairs will be extended and updated by means of supplements. 8 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. e Foreword VORW.CHP Printed in Germany -34, October 1999 "~~

Boxster Overview of repair groups 8 Group 0: Entire vehicle -General 0 Maintenance 03 I Group 0: Diagnosis 0 Sales check 01 On-board diagnosis 03 DMEdiagnosis 24 Tiptronic diagnosis 37 ABS diagnosis 45 I Group 0: Diagnosis 0 Airbag diagnosis 69 Seat memory diagnosis 72 Heatingdiagnosis 80 Alarm system diagnosis 90 PCMdiagnosis 91 ParkAssistent diagnosis 91 8 HBA diagnosis 94 Group 1: Engine 1 Engine-Crankcase, suspension 10 Engine-Crankshaft, pistons 13 Group 1: Engine 1 Engine -Cylinder head,valve drive 15 Engine -Lubrication 17 Engine-Cooling 19 Group 2: Fuel, exhaust, engine electronics 2 Fuel supply, control 20 Exhaust system, turbocharging 21 Fuel system, electronic injection 24 Fuel system, K-Jetronic 25 Exhaust system 26 Starter, power supply, cruise control 27 Ignition system 28 8 Group 3: Transmission, manual transmission 3 Clutch,control 30 Manual transmission-Actuation, housing 34 Manual transmission-Gears, shafts, intogearsh. 35 Final drive, differential,differential lock 39 Group 3: Transmission, automatic transmission 3 Torque converter 32 Automatic transmission-Actuation, housing 37 Automatic transmission-Gears, control 38 Final drive, differential,differential lock 39 8 0 . f . vervlew 0 repair groups Printed in Germany -34, October 1999 REPGRU.CHP J

Overview of repair groups Boxster Group 4: 4 40 42 44 45 46 47 48 Running gear Frontwheel suspension, drive shafts Rear wheel suspension, drive shafts Wheels,tires, suspensionalignment Ant~Lock Brake System (ABS) Brakes-Brake mechanics Brakes -Hydraulics, regulator, booster Steering Group 5: 5 50 51 53 55 57 Body Body front Body center, roof,frame Body rear Lids, flaps Doorfront,central locking system Group 6: 6 60 61 63 64 66 68 69 Body equipment, exterior Sliding roof Convertible top, hardtop Bumpers Glazing, window control Exterior equipment Interior equipment Passenger protection Group 7: Body equipment, interior Linings, insulation Seat frames Seatupholsteries, covers 7 70 72 74 Group 8: 8 80 85 87 88 Air conditioning Heating Ventilation Air conditioning Auxiliary air conditioning system Group 9 9 90 91 92 94 96 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 9 97 Group 9: Circuit diagrams Wiring (up to and includingthe '99 model) 9 97 Group 9: Circuit diagrams Wiring (from the '00 model) Overview of repair groups Printed in Germany -34, October 1999 REPGRU.CHP

0 Diagnosis, part 1 (up to Repair Group 45) 0 0 0 General Installation location, diagnostic socket. Operating instructions, Porsche System Tester 2 ... 0-01 0-03 24 2401 DMEdiagnosis System M08 . 24-01 37 3701 Tiptronic diagnosis System G 40 ... 37-01 45 4502 Anti-lock brake system diagnosis System ABS5.3 and ABS/TC 5.3 45 -D 1 1 0 Diagnosis, part 1 (up to Repair Grolup 45) Printed in Germany -34, 1999 986TOC

Boxster Diagnostics 0 8 Installation location, diagnostic socket The diagnostic socket for the tester is located in- side the vehicle near to the driver (left-hand drive vehicles) or the passenger(right-hand drive vehicles)belowthe instrumentpanel. 8 -:: ' ,. .,,- '., : 12.96 8 8 Installation location, diagnostic socket 0 -D 1 Printed in Germany, 1996 986O_1 "'c

Boxster Diagnosis 0 8 Operating instructions, Porsche System Tester 2 8 ~C:J~5C=HE System Tester 2 F1 F2 F3 F4 F5 F6 F7 F8 . 8 8 Operating instructions, Porsche System Tester 2 0 -D 3 Printed In Germany -4, 1996 9860_D3 ,"

0 Diagnosis Boxster 8 General infom1ation Use The Porsche System Tester 2 is a modular, port- The following tasks can be performed: able diagnostic and measuringsystem. It can be used in any location to perform diagnostic -Reading out the control-module identification tests on electronic control modules. -Reading out the fault memory The Tester consists of a computer unit, a main memory, a hard disk, a VGA display panel,a -Erasing the fault memory nickel metal hydride battery and a measuring unit for measurement of current, voltage and re- -Testing the drive links sistance values. -Testing the input signals 8 The Porsche System Tester 2 can be operated with the built-inkeys or using a connectable -Reading out actual values country-specificPS/2 keyboard (option). I -Control module programming Data and measuredvalues can be printed out on one of the ten DIN A4 printers currently ap- -Current, voltage and resistance measure- proved by Porsche. ments The integrated LCD panel is used as the dis- play. A monitor can also be connected(VGA corr M If . ti ) a unctions nec on. The Porsche System Tester 2 is a high-quality If a printer or PS/2 keyboard is connected, the electronic device. In order to prevent damage corresponding device type must be set under to the unit due to improper use, please observe Configuration in the start-up screen. the operating instructions. The Tester thus can be used to check all sys- If the Tester no longer responds when any key 8 tems that possess a diagnostic interface confor- is pressed, it must be set to a defined state: ming with the ISOstandard. 1. Press the F1 and F8 keys in addition to the "ON/OFF" key. 2. Release the "ON/OFF" key, then the F1 and F8keys. 8 0 -D 4 Operating instructions, Porsche System Tester 2 9860_D3 Printed in Germany -4, 1996

Boxster Diagnosis 0 8 Perform this switch-off procedure only if the unit no longer responds when any key is pressed. This procedure can damagethe hard disk under certain circumstances if it is performed during normal operation. It may be necessary to repeat input of data created within this diagnostic appli- cation. Problems during operation are indicatedto the user via the informationline (info line). Example: "DiagnosisCard not inserted". 8 8 8 Operating instructions, Porsche System Tester 2 0 -D 5 Printed in Germany -3, 1996 9860_D3 -