1997-2001 Porsche Boxster 986 Service & Repair Manual

TechnicalManual -,Bc,'K..S:T£.,- Technical Information Contents: Group 0 Diagnosis Part 2 (as of Repair Group 69) WKD 483 521 TITEL.CHP

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. The integration of the technical information published in the "Boxster" Technical Manual with the descriptive matter on repairs provides the user with a complex reference work that combines into one book associated or cross-referenced material of relevance to workshops and originating from various information media. The "Boxster" Technical Manual consists of 15 folders, subdivided into the following Groups 0 Entire vehicle -General 0 Diagnosis, part 1 (up to Repair Group 45) *1 0 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 The two folders with Group Dare to be regarded as one folder; i.e. file the "Technical Information" notices only in front of the repair descriptions in the folder "GroupD -Diagnosis, part 1" (up to Repair Group 45). *2 The second folder "Group 0 -Diagnosis, part 2" (as of Repair Group 69) includes the further Repair Groups belonging to Group O. *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 "Group 1 -Engine, part 1" (up to Repair Group 13). *4 The second folder "Group 1 -Engine, part 2" (as of Repair Group 15) includes the further Repair Groups belonging to Group 1. VORW.CHP Foreword Printed in Germany -34, October 1999

Foreword Boxster *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 "Group9 -Circuit diagrams, part 1" (up to the '99 model). *6 The second folder "Group9 -Circuit diagrams, part 2" (as of the '00 model) includesthe further circuit diagrams belongingto Group 9. The "Boxster" Technical Manual has the same structure in each folder, with the following breakdown for all Groups: I Titte page, "Boxster" Technical Manual > Foreword Title page: "Technical Information" > Table of Contents,Technicalinformation > 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 TechnicalInformation is in the front part of each folder -numbered according to the Groups. The Table of Contentsassignedto each Group will be periodicallyupdated. Following the Technical Information, separated by a title page, the instructions on repairs -assigned according to the Groups or broken down into 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

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

Overview of repair groups Boxster Group 4: 4 40 42 44 45 46 47 48 Running gear Frontwhee! suspension, drive shafts Rearwheel suspension, drive shafts Wheels,tires, suspensionalignment Anti-LockBrake 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 Door front, central locking system Group 6: 6 60 61 63 64 66 68 69 Body equipment, exterior Sliding roof Convertible top, hardtop Bumpers Glazing, windcw 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 8 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: 9 97 Circuit diagrams Wiring (up to and includingthe '99 model) Group 9: 9 97 Circuit diagrams Wiring (from the '00 model) 8 Overview of repair groups Printed in Germany -34, October 1999 REPGRU.CHP

Boxster Table of Contents 0 Diagnosis, part 2 (as of Repair Group 69) 69 6901 6901 Airbag diagnosis System B 04. .. System B 05. .. 69 -D 1 69 -D 21 72 I I 7298 Seat memory diagnosis System SOl 72 -D 1 80 I 80 O[ Heating diagnosis System H01 .. 80-0 1 90 I 9001 Alarm system diagnosis SystemI16 90-01 90 9025 Instrument cluster diagnosis SystemKOX 90 -D 49 91 I I 91 Q1 PCM diagnosis System N 01 . 91 -0 91 : 9161 ParkAssistent diagnosis System POI 91 -0 39 94 94192 Headlight beam adjustment diagnosis SystemHBAOl 94 -D 1 96: I 96101 Alarm system diagnosis SystemI32 96 -0 1 .8 1 0 Diagnosis, part 2 (as of Repair Group 69) Printed in Germany -36, 1999 986TOC

Boxster Airbag diagnosis 6901 . 8 69 01 Diagnosis/troubleshooting, airbag Printed in Germanv -17. 1997 69 -D 1 986D691

Airbag diagnosis Boxster Contents overview Page General information 69-0 3 Menu (overviewof the possible menus) 69 -D 4 Component arrangement 69 -D 5 Function, individual components 69 -D 6 69 -D 7 System description Tools 69-0 8 Connector assignment, triggering unit 69 -D 9 Fault memory {overview of possible faults} 69. D 10 Fault overview 69 -0 11 Test points 69 -D 12 Events 69 -D 17 Lock 69 -0 18 Extract coding 69 -D 19 Modifycoding 69 -D 20 69 01 Diagnosis/troubleshooting, airbag Printed in Germany -17, 1997 69 -D 2 986D691

Airbag diagnosis Boxster General information The airbag system is constantlymonitored by a diagnosis unit in the triggering unit. Any fault is signalled by a warning light. The following components must be removed and replaced following an accident in which the airbag system was triggered: The warning light for the airbag system lights up in the event of a fault. Contact unit The airbag warning light lights for approx. 3 seconds after the ignition is switched on and goes out if no fault has been entered in the fault memory. Airbag unit, driver's side Airbag unit, passenger's side, if fitted and if triggered. If it lights up again,this indicates a fault in the system. The fault can be read out with the Porsche SystemTester 2. The triggering unit must be replaced after the airbag is triggered for the third time. Note A period of 10 seconds is required to enablethe triggering unit to identity all faults in the system. In order to guarantee that every possible fault source is checked during the vehicle test, the ignition must be switched on for at least 10 seconds. The fault memory must be cleared following a fault in the airbag system and after it has been remedied. The replacement of a component must be noted in the Guarantee and Maintenance booklet. To do this, attach the documentation number in a free panel intendedfor that purpose. The documentationnumber is attached to the replacementpart as a tear-off sticker. 69 01 Diagnosis/troubleshooting, airbag Printed in Germany -17, 1997 69 -D 3 986D691

Airbag diagnosis Boxster Menu Overview of the possible menus Faultmemory Events Lock Extract coding Modify coding Faultmemory: see Page 69 -D 10 Events: see Page 69 -D 17 Lock: see Page 69 -0 18 Extract coding: see Page 69 -D 19 Modifycoding: see Page 69 -D 20 Note Observe safety instructions (see Service No. 69) when working on the airbag system. 69 -D 4 69 01 Diagnosisjtlroubleshooting, airbag Printed in Germany -17,1997 986D691

1997-2001 Porsche Boxster 986 Service & Repair Manual

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