Porsche Boxster 1999 User Manual

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Page 1

Technical Manual

-.8e;~~

Technical Information

Contents:

Group 9

Electrics

WKD 483 521

Page 2

Boxster

Foreword

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

The two folders with Group 0 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 0 -Diagnosis, part I"

(up to Repair Group 45).

The second folder "Group 0 -Diagnosis, part 2" (as of Repair Group 69) includes the further Repair Groups belonging to Group O.

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).

The second folder "Group 1 -Engine, part 2" (as of Repair Group 15) includes the further Repair Groups belonging to Group 1.

Foreword

Printed in Germany -34, October 1999

VORW.CHP

Page 3

Foreword

.!i

The two folders with Group 9 are to be regarded as one folder; i.e. file the "Technical Information"

Boxster

notices only in front of the repair descriptions in the folder "Group 9 -Circuit diagrams, part 1" (up to

the '99 model).

*Ei

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 > 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.

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.

VORW.CHP

Foreword

Printed in Germany -34, October 1999

Page 4

Overview of repair groupsBoxster

Group 0: Entire vehicle -General

Maintenance

Group 0:

Group 1:

Diagnosis Sales check

On-board diagnosis DME diagnosis

Tiptronic diagnosis ABS diagnosis

Diagnosis

Airbag diagnosis

Seat memory diagnosis

Heating diagnosis Alarm system diagnosis

PCM diagnosis

ParkAssistent diagnosis HBA diagnosis

Engine

Engine -Crankcase, suspension Engine -Crankshaft, pistons

Engine

Engine -Cylinder head, valve drive Engine -Lubrication

Engine -Cooling

03 0

24 37

45 0

72 80 90 91 91

Group 2:

Group 3:

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

Transmission, manual transmission

Clutch, control

Manual transmission -Actuation, housing

Manual transmission -Gears, shafts, into gearsh.

Final drive, differential, differential lock

Transmission, automatic transmission Torque converter

Automatic transmission -Actuation, housing Automatic transmission -Gears, control

Final drive, differential, differential lock

24 25

37 38 39

Overview of repair groups

Printed in Germany -34, October 1999

REPGRU.CHP

Page 5

Overview of repair groups

Boxster

Group 4:

Group 5:

Group 6:

Group 7:

Running gear

Front whee! 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

Body

Body front Body center, roof, frame Body rear

Lids, flaps

Door front, central locking system

Body equipment, exterior

Sliding roof Convertible top, hardtop

Bumpers

Glazing, window control Exterior equipment Interior equipment

Passenger protection

Body equipment, interior

Linings, insulation

Seat frames

Seat upholsteries, covers

40 42

45 46

47 48

50 51 53

55 57

6 60

61 63

64 66 68 69

72 74

Group 8:

Group 9

Group 9:

Air conditioning

Heating

Ventilation

Air conditioning

Auxiliary air conditioning system 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

Circuit diagrams

Wiring (up to and including the '99 model)

Circuit diagrams

Wiring (from the '00 model)

90 91

REPGRU.CHP

Overview of repair groups

Printed in Germany -34, October 1999

Page 6

Boxster

Table of Contents

8 8

8023 19

85 85

85 85 85

11 30

19 19 19

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 fresh-air/recirculation valve.

Removing and installing bulb for rotary blower switch.

Air conditioning

8 -1

85- 1 85- 3 85- 7

85-11

85-13 85-15

87 87 87 87 87 87 87 87 87 87 87 87 87 87 87 87

0317

8319 5519 3419 7019 0119 5019 2719 2019 2019 5919 8219 5819 7819

5319

6919 0219

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 condenser. 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 ~nd installing outside temperature sensor. Removing and installing interior 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 heatingjair-conditioning unit.

87.

87. 87

87.

87. 87-

87-

87.

-2

-13-15

.17 .19 .23

-25.29

-31.33

-35

37 .39 .41 .43

.45

-47

-49

8 Air conditioning

Printed in Germany -12, 1997

-1

986TOC

Page 7

Boxster

Air conditioning

Compressor type 7 S8 16

Refrigerant quantity

Refrigerant oil in the compressor

Hexagon-head bolts on

Expansion valve

Technical data for the air-conditioning system

Compressor

Refrigerant line

Oil filler screw

850 g refrigerant R 134a

195 :f: 15 cm3 NO 8

Thread

M6 M5 M8 23 (17)

M 10

Tightening torque in Nm (ftlb.]

9 (6.5) 6 (4.5)

23 (17)

26...36 (19...27)

Fluid tank Flange connections of

refrigerant lines

Note When installing the refrigerant lines, the screw connections and the a-rings must be wetted with

refrigerant oil.

The refrigerant oil must be disposed of as special-category waste.

M6 M8

6 (4.5)

14 (10.5)

8 Technical data for the air-conditioning system

Printed in Germany -12, 1997 9868_1

8 -1

Page 8

Boxster

Heating

80 23 19

Removal

1. Remove covers from heating and air-conditioning system, battery and fluid reservoir. Disconnect battery and cover terminal or battery.

2. Remove the entire wiper link with wiper motor (see Repair Group 92).

3. Loosen right dome strut and bracket at the cowl frame and remove.

\ " '" '"

Removing and installing heat exchanger

\\\

~,~

\ \ -

,.--

6. Release heat exchanger and pull it up and out.

~ ~---='

'""-'

,: "'"

)

::::::;;;;~!)

--=

a:\~

288 -96

Installation

1. Seal cover over the heat exchanger airtight with butyl adhesive.

4. Clamp shut both heater hoses in front of the heat exchanger using a commercially available hose clamp. Loosen heater hoses at the heat exchanger and pull off.

5. Carefully remove cover over the heat exchanger.

287 -96

2. Replace cover if damaged.

3. The heat exchanger is connected to the engine cooling system, and coolant flows through it when the engine is running. After removing or installing the heat exchanger I vent the cooling system (see Repair Group 19).

80 23 19Removing and installing heat exchanger

Printed in Germany. 1996 986801

80 -1

Page 9

Boxster

Ventilation

85 10 19

Removal

1. Carefully unclip baffle from the heating and fresh-air control.

2. Unscrew fastening screws (4 ea.) and pull corr trol module out of the dashboard.

3. Pull off electrical plug connection. Unclip Bowden cables and pull out upwards or detach cables. Label Bowden cables before removal.

Removing and installing mechanical heating and fresh-air control

.,..

Installation

1. Clip in Bowden cables and route carefully (do not bend),

2. Engage electrical plug connections: do not

jam cables.

..U.;

~=\ ~-

j~'

289 -96

I!!-

85 10 19 Removing and installing mechanical heating and fresh-air control

Printed in Germany, 1996 986851

85 -1

Page 10

Boxster

Ventilation

85 15 19 Removing and installing heating and fresh-air control

Removal

1. Remove covers over heating and fresh-air control, battery and fluid reservoir. Disconnect bat-

tery and remove.

2. Remove steering wheel and loosen steeringcolumn panel. Comply with safety regulations

when handling airbag units (see Repair Group

169).

3. Loosen central screw (clamp) at the steeringcolumn switch from below and pull forward a

little. Remove top cover and disconnect electri-

cal plug connections. Remove steering-column switch.

4. Loosen instrument panel and unclip right side upwards. Disconnect electrical plug connections.

108- 96

5. Remove steering-column cover (4 screws).

107-96

85 15 19 Removing and installing heating and fresh-air control

Printed in Germany, 1996 986853

109 -96

85 -3

Page 11

Ventilation Boxster

6. Remove radio and heating and fresh-air control. Unclip switch trim on the left and right.

Disconnect electrical plug connection. Loosen

centre of fixing frame and remove.

369-96

7. Remove left side nozzle and disconnect electrical plug connection. Unclip cover of sun

sensor and defroster panel and remove.

11. Loosen dashboard on the bottom, centre, left and right. Carefully remove dashboard

and pull off speaker cable.

111 -96

12. Loosen centre tunnel support at the top of

supporting frame and loosen bottom tunnel holder.

8. Loosen passenger compartment monitor and disconnect electrical plug connection.

9. Remove bottom right air guide. Remove pas-

senger airbag unit.

Comply with safety regulations when handling

airbag units (see Repair Group 69).

10. Remove front cover of centre console. Loosen fuse carrier and loosen diagnosis plug in the left footwell.

"'""

l \ \)

A1co""'""'-"-"' c

-..co

112 -96

85 -4

85 15 19 Removing and installing heating and fresh-air control

986853 Printed in Germany, 1996

Page 12

Boxster

Ventilation

13. Remove left air guide. Just loosen defroster duct. Loosen centre air distributor housing

and remove.

14. Disconnect electrical plug connection from

heating and fresh-air control.

15. Loosen battery positive connection at the current distributor and current distributor at the

firewall cover.

(

\"f;'

18. Loosen holder of heating and fresh-air control on the upper right of the passenger side.

---

:~"'~;~;;;/

114- 96

19. Carefully lower heating and fresh-air control into the footwell and remove. Do not damage electrical plug connections or cable.

/C/

113-96

16. Clamp shut both heater hoses in front of the heat exchanger with a commercially available

hose clamp. Loosen heating hoses at the

heat exchanger and plug the connections.

7, Loosen heating and fresh-air control at the

cover firewall (3 nuts),

Installation

1. Ensure correct seating of air-distributor housing and air guides. Engage electrical plug connections and route electrical cables carefully (do not jam).

2. Comply with safety regulations when handling

airbag units (see Repair Group 69).

85 15 19 Removing and installing heating and fresh-air control

Printed in Germany, 1996 986853

85 -5

Page 13

3. Adjust steering-column switch: Measure with a depth gauge between end of steering shaft and steering-column switch

cover plate (see figure).

Adjustment dimension 55 :t 0.5 mm

Ventilation

Boxster

4. Replace gasket between current distributor and firewall if necessary. After the current dis-

tributor is mounted on the firewall (tightening

torque 15 Nm (11 ftlb.)) the battery cable is tightened with a new hexagon nut M8.

Tightening torque 15 Nm (11 ftlb.).

5. The heat exchanger is connected to the engine cooling system, and coolant flows through it when the engine is running. After removing or installing the heating and fresh-air

control, vent the cooling system (see Repair

Group 19).

115 -96

85-6

85 15 19 Removing and installing heating and fresh-air control

986853 Printed in Germany, 1996

Page 14

Boxster

Ventilation

85 11 06

Note Install the heating/fresh-air control with installed

bowden cables. The sleeves of the bowden cables are adjusted at the fastening points on the heating/fresh-air unit.

Installing and adjusting bowden cables of the heating/fresh-air control

...

A -Bowden cable, temperature valve B -Bowden cable, footwelVdefrost valve C -Bowden cable, central valve

"';~

536 -96

Adjusting temperature valve

1. Turn temperature control to left-hand stop (cold). Temperature valve closed; no passage to the heat exchanger.

534 -96

2. Engage bowden cable in the adjusting lever.

,"-~

85 11 06 Installing and adjusting bowden cables of the heating/fresh-air control

Printed in Germany -5, 1996 986857

85 -7

Page 15

Ventilation

Boxster

3. Push adjusting lever of the temperature valve up to its stop and use the retaining clip to fasten the sleeve of the bowden cable on the

fastening point.

~(o))

IU-

://:

537 -96

2. Engage bowden cable in the adjusting lever.

3. Push adjusting lever of the footwelljdefrost valve up to its stop and use the retaining clip to fasten the sleeve of the bowden cable to the fastening point.

538 -96

Adjusting footwelljdefrost valve

1. Turn rotary knob for air distribution to the symbol for the footwell. Defroster outlet closed;

no passage to the windscreen.

53412 -96

Adjusting central valve

1. Turn rotary knob for air distribution to the symbol for the footwell. Air outlet to the centre and side vents closed (See Figure 534/2 -96).

2. Engage bowden cable in the adjusting lever.

85-8

85 11 06 Installing and adjusting bowden cables of the heating/fresh-air control

986857 Printed in Germany -5, 1996

Page 16

3. Push adjusting lever of the central valve up to its stop and use retaining clip to fasten the sleeve of the bowden cable to the fastening

point.

VentilationBoxster

539 -96

Note

Perform a function test after installing the bowden cables. Test limit position of the rotary knobs for air distribution and adjusting levers of

the valves.

85 11 06 Installing and adjusting bowden cables of the heating/fresh-air control

Printed in Germany -5, 1996 986857

85 -9

Page 17

VentilationBoxster

85 30 19 Removing and installing heater/fresh-air blower motor

Remove and install heater/fresh-air blower motor with installed heating/fresh-air unit.

Removal

1. Remove footwell bulkhead and right air guide. Pull off electrical plug connection on the blower motor and remove wire from the holder.

The figure shows the heating/fresh-air unit when removed.

Note

531 -96

""""

530-96

2. Pull off electrical plug connection on the bal-

last resistor and undo both fastening screws on the housing lid. The ballast resistor and housing lid are

a spare part.

When the housing lid is removed, the blower motor is simultaneously detached from its guide. Hold the blower motor and carefully remove it in downward direction.

,hr~

85 30 19 Removing and installing heater/fresh-air blower motor

Printed in Germany -5, 1996 986857

532-96

85 -11

Page 18

In!;tallation

1. Install blower motor and fasten housing lid,

2. Tighten fastening screws carefully (plastic housing).

3. Engage electrical plug connections and perform a function test.

Ventilation

Boxster

8~) -12

85 30 19 Removing and installing heater/fresh-air blower motor

986857 Printed in Germany -5, 1996

Page 19

Boxster

Ventilation

85 78 19 Removing and installing drive motor for fresh-air/recirculation valve

I~emove and install drive motor on installed heating/fresh-air unit

Removal

1. Press the recirculation button before removal (fresh-air supply interrupted), The drive motor

of the installed heating/fresh-air unit can be

removed in this position (recirculation).

2. Remove footwell bulkhead and right air guide. Disconnect electrical plug connection of the

drive motor and undo fastening screw.

/ '-

~~~'-

Note

If the rotary knob for air distribution is set to Defrost (windscreen) with the recirculation button

switched on, the recirculation button is automat-

ically switched off.

Installation

1. The removal or installation position of the drive motor and fresh-air/recirculation valve cannot be changed.

2. Tighten fastening screw carefully (plastic housing),

3. Engage electrical plug connection and route wire carefully.

4. Perform a function test after installation.

542 -96

3. Swivel down the drive motor and remove to the side.

85 78 19 Removing and installing drive motor for fresh-air/recirculation valve

Printed in Germany -5. 1996 986857

85 -13

Page 20

Boxster

Ventilation

85 10 19

Removal

Removing and installing bulb for rotary blower switch

1. Pull off rotary blower switch.

2. Pull out bulb. The bulb can be pulled out by pushing a connecting hose of a vacuum line

onto it (see diagram of hose connections, Re-

pair Group 24).

Installation

1. Insert bulb with connecting hose. Detach connecting hose by twisting it off the bulb.

2. Check function of the bulb.

535 -96

85 10 19 Removing and installing bulb for rotary blower switch

Printed in Germany -5, 1996 986857

85 -15

Page 21

Boxster

Air conditioning

8703

The refrigerant R 134a which is used is known

as a safety refrigerant. This means that this refrigerant is non-flammable, non-explosive, nontoxic, non-irritating, odorless and tasteless. Des-

pite this, you should still follow the points below.

1. Avoid all contact with liquid or gaseous refrigerants. Treat affected skin in the same way as in the case of freezing. Rinse immediately with cold water and then consult a physician. Wear

safety goggles to protect your eyes. If refrige-

rant still gets in your eyes, consult a physician immediately. Wear rubber gloves to protect your hands.

2. When carrying out repairs on the air-conditioning system, the system must be emptied by suction and the refrigerant must be purified. Chlorine-free refrigerants must also not be allowed to escape into the atmosphere and

must be disposed of correctly. Due to their chemical composition, different refrigerants must not be mixed with each other

(not even in small quantities),

Safety regulations when handling refrigerant R 134a

4. Refrigerant bottles must not be thrown and must not be subjected to direct sunlight or

other heat sources for an extended period when full. The maximum permissible temperature of a filled refrigerant bottle must not ex-

ceed 45 °C.

3. Never perform welding work on parts of the closed air-conditioning system or in its immediate vicinity. Whether or not the system is filled with refrigerant, the heating causes a very strong overpressure which can cause damage to the system or even lead to an explosion. R 134a is completely non-toxic at normal tem-

peratures, but it decomposes upon contact

with a flame or at high temperatures.

87 03 Safety regulations when handling refrigerant R 134a

Printed in Germany -1996 986871

87. 1

Page 22

Air conditioning

Boxster

87 03 17

Service unit SECU 134

Assembly work on the air-conditioning system

87-2

1797 -87

87 03 17 Assembly work on the air-conditioning system

986871 Printed in Germany -1996

Page 23

Boxster

Air conditioning

1 -Low-pressure pressure gauge

2 -High-pressure pressure gauge

3 -Torr meter

4 -Low-pressure shut-off valve (blue)

5 -High-pressure shut-off valve (red)

6 -Torr meter shut-off valve (black)

7 -Vacuum pump shut-off valve (yellow)

8 -Low-pressure flange

9 -High-pressure flange

10 -Refrigerant inlet shut-off valve

11 -Refrigerant outlet shut-off valve

23 -Filling cylinder with weight scale

24 -Filling cylinder shut-off valve

25 -Filling cylinder high-pressure gauge

26 -Refrigerant oil suction nozzle

27 -Refrigerant oil reservoir inspection glass

Note The manufacturer's operating and repair instruc.

tions must be observed when carrying out all work on the service unit.

12 -Refrigerant oil inlet shut-off valve

13 -Refrigerant oil vent valve

14 -Moisture indicator

15 -Oil tank vacuum flange

16 -Hourmeter

17 -Pilot light SUCTION END

18 -Pressure switch SUCTION/CLEANING

19 -Main switch ON/OFF

20 -Pressure switch HEATING

21 -Pilot light FAULT

22 -Pressure switch VACUUM PUMP

87 03 17 Assembly work on the air-conditioning system

Printed in Germany -1996 986871

87-3

Page 24

Air conditioning

Boxster

Assembly work involving the refrigerant system

During all work on the air-conditioning system

which necessitates opening the refrigerant sys-

tem, the system contents must first be dis-

posed of correctly. When doing so, follow the

safety regulations.

Dirt and moisture must be kept out of the air-conditioning system's pipe system. Thorough cleanliness must therefore be ensured during all work. System components must never be cleaned on the inside with hot steam. Use only nitrogen for

cleaning purposes.

When replacing a component, all openings must be closed off with suitable plugs.

General assembly sequence

1. Remove refrigerant by suction.

2. Remove faulty part.

3. Evacuate.

4. Check the system for leaks.

5. Rinse with refrigerant.

6. Empty the system by suction again.

7. Evacuate.

Fill.

Note

Pay attention to sealing rings when disconnect-

ing or connecting the hose connections.

A -High-pressure B -Low-pressure

The charging valves are located in the area of the front right spring strut.

1 -96

87-4

~::.~:::::::::=::::=:::.;.,,-'

~~~

87 03 17 Assembly work on the air-conditioning system

986871 Printed in Germany -1996

Page 25

Boxster

Removing refrigerant by suction and cleaning

Air conditioning

Note Close all valves before carrying out each work step.

A-close

Suction removal, start

1 -ON/OFF

2 -SUCTION/CLEANING

* Pressure too high/filling cylinder full.

Drain off refrigerant from the filling cylinder into a refrigerant bottle (approx. 50 %).

B -open

end

3 -SUCTIONjEND 4 -ON/OFF

87 03 17 Assembly work on the air-conditioning system

Printed in Germany -1996 986871

87-5

Page 26

(:Ieaning the refrigerant

BJJ'(-..

.:::::~~~~~=~

A-close

Cleaning, start

1 -ON/OFF 2 -SUCTION/CLEANING

* Pressure too high/filling cylinder full.

**One revolution OPEN. After approx. 15 minutes CLOSED.

87 -6

87 03 17 Assembly work on the air-conditioning system

986871 Printed in Germany -1996

B -open

end

3 -CLEANING/END

4 -ON/OFF

Page 27

Boxster

Draining off old refrigerant oil

Air conditioning

HFA 134a

A 8*3

"1} """'f

A -close

1 -ON/OFF

Instructions

* 1 open to *2 OFF, then *1 CLOSED and *3 OPEN.

87 03 17 Assembly work on the air-conditioning system

Printed in Germany -1996 986871

B -open

87-7

Page 28

E'vacuating

Air conditioning

Boxster

A -close B -open

1 -ON/OFF

2 -VACUUM PUMP

Evaluation time at least 15 minutes.

87 -8

87 03 17 Assembly work on the air-conditioning system

986871 Printed in Germany -1996

Page 29

Topping up with new refrigerant oil

A -close

1 -ON/OFF

87 03 17 Assembly work on the air-conditioning system

Printed in Germany -1996 986871

B -open

87 -9

Page 30

Filling via the high-pressure side

Air conditioning

Boxster

AI'

.-.

HFA 134a

A -close

1 -ON/OFF

2 -HEATING

* Pressure 8 ...10 bar.

* * If pressure is less than 8 bar.

After using the SECU, perform internal suction removal (see Page 87 -5);

first close the hand valves on both suction lines.

87 -10

87 03 17 Assembly work on the air-conditioning system

986871 Printed in Germany -1996

B -open

Page 31

Boxster Air conditioning

Refilling the air-conditioning system

Note

In the event of insufficient refrigeration performance, remove the refrigerant by suction, top up with the stipulated quantity and check the

system for leaks.

1. Remove the refrigerant by suction using the service unit.

2. Determine the refrigerant oil quantity after the refrigerant has been removed by suction.

3. Fill up with new refrigerant oil.

4. Evacuate.

5. Fill with the stipulated amount of refrigerant.

6. Check the system for leaks,

87 03 17 Assembly work on the air-conditioning system

Printed in Germany -16, 1997 986871

87 -11

Page 32

Distribution of the oil quantity in the refrigerant circuit

Total oil quantity

195:t 15 cm3

After suction removal from the system, the following quantities remain in the

condenser 2 x 20 cm3

evaporator

approx. 40 cm3

approx. 30 cm3

fluid tank with lines

compressor

approx. 30 cm3

approx. 50 cm3

circulating oil quantity in the refrigerant circuit

approx. 60 cm3

Note

In new vehicles, the amount of oil removed by suction is approx. 15 ...40 cm3.

Oil removed by suction must be returned to the

system.

Refrigerant oil removed from a previously run air-conditioning system may no longer be used

(special-category waste). After the refrigerant has been removed by suction and a component has been replaced,

the oil quantity must be determined and topped up by the quantity remaining in the removed

component.

87 -12

87 03 17 Assembly work on the air-conditioning system

986871 Printed in Gennany -16, 1997

Page 33

Nominal values for pressures and temperatures

Note

The temperature of the air from the "centre" dashboard vents must lie within the prescribed tolerance range within 5 minutes, depending on the ambient temperature (see diagram).

General test prerequisites

Close doors, windows and sliding roof Insert temperature probe into centre vent

Measure ambienttemprature

Open all dashboard vents Switch ignition on Press recirculating-air button Set temperature control to maximum cooling

Switch fresh-air blower to stage 4

Start engine

Operate air condition while idling

Set engine speed to 2000 rpm (start of time measurement)

If the prescribed nominal values are not reached, the cooling system must be checked for leaks and re-

paired.

"'ro

Centre vent temperature as a function of ambient temperature

Ambient temperature in °C

30 35 40

87 Nominal values for pressures and temperatures

Printed in Germany, 1996 9868713

87 -13

Page 34

Air conditioning

f\lominal values for pressures and temperatures

Boxster

L~ """""""

High pressure in cold circuit as a function of ambient temperature

1,8

1,7

Ambient temperature in °C

25 30

35 40

1,6

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1,5

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(II (II

1,4

(I)

1:1-

1,3

(:)

_.J

Low pressure in cold circuit as a function of ambient temperature

8:7 -14

15 20 25

Ambient temperature in DC

87 Nominal values for pressures and temperatures

9868713 Printed in Germany, 1996

35 40

~~::;;:~~..~

k~~::::::::~

[~::::::::::;;;;;;;~c:::::::~..

Page 35

Boxster Air conditioning

87 83 19

Removing and installing pressure switch for the air-conditioning system

Removal

1. Remove the cover above the heatingjair-conditioning system.

2. Remove refrigerant by suction using the service unit.

3. Pull off the cable plug on the pressure switch.

4. Undo and unscrew the pressure switch.

Installation

1. Replace the O-ring on the pressure switch and wet it with refrigerant oil.

Tightening torque: 3 Nm (2.2 ftlb)

2. Refrigerant oil removed from a previously run air-conditioning system may no longer be used

(special-category waste).

2-96

87 83 19 Removing and installing pressure switch for the air-conditioning system

Printed in Germany -1996 986871

87 -15

Page 36

Boxster

Air conditioning

87 55 19

Removing and installing the fluid tank

Removal

1. Remove the cover above the heating/air-conditioning system and fluid tank.

2. Remove refrigerant by suction using the service unit.

3. Undo the hose clamp on the fluid tank. Undo both hexagon-head bolts on the fluid tank and remove the fluid tank upwards. Immediately close lines with plugs so that they are air-tight.

Note The fluid tank must be replaced if the system

suffers from operational faults (e.g. accident

damage or air-conditioning system depress-

urized),

Refrigerant oil removed from a previously run airconditioning system may no longer be used (special-category waste).

Installation

1. Do not remove the plug until shortly before installation. Replace the a-ring on the branch piece and on the refrigerant line, and wet the

new O-rings with refrigerant oil.

2. Tighten both hexagon-head bolts on fluid tank

with 6 Nm (4.4 ftlb).

3. Determine the quantity of the refrigerant oil and fill up again with refrigerant oil (volume

removed by suction + 30 cm3).

3-96

87 55 19 Removing and installing the fluid tank

Printed in Germany -1996 986871

87 -17

Page 37

Boxster

Air conditioning

87 34 19

Removal

Removing and installing the compressor

1. Remove the cover above the heating/airconditioning system.

2. Remove refrigerant by suction using the service unit.

3. Remove the left seat. Disconnect the battery and cover the terminal or battery. Remove the lid for the engine compartment and rear wall flap behind the seats.

4. Relieve the drive belt on the tensioning pulley and remove the belt.

5. Detach the battery positive connector at the B+ connection on the engine. Undo the B+ connection (2 screws M6) on the engine and put it aside.

6. Remove the fluid of the power steering in

the supply tank until below the connection.

Remove the servo-tank (bayonet lock).

Observe the marking (arrow) during

installation. Seal off the connection

against dirt.

7. Undo the compressor fastening screw between the intake pipes, cylinders 4 and 5.

," "'" L

26-96

8. Undo the refrigerant lines at the compressor.

Immediately close the connections and lines

with plugs so that they are air-tight.

...:--/

87 34 19 Removing and installing the compressor

Printed in Germany -12, 1997 986871

25-96

«0

j (-

,,-?--=

..?.-=

? -",,:jJ

99-96

87 -19

Page 38

Air conditioning

Boxster

9. Undo the front compressor fastening screws (2 ea.) and disconnect the electrical plug

connection.

27-96

10. Carefully remove the compressor to the front.

Installation

Note

New compressors are under pressure and are filled with the required amount of oil for the refrigerant circuit. The remaining oil quantity in the in-

dividual components must therefore be taken into account.

1. First, open the cap on the high-pressure side and relieve the pressure from the compressor

(A).

2. Open the oil filler screw (8) on the compressor.

Ii"

III

3. Empty approx. 80 cm3 of refrigerant oil out of the compressor and into a measuring

glass. The remaining quantity of oil (approx.

120 cm3) remains in the compressor.

Note

Refrigerant oil from the compressor or refrigerant oil removed by suction from a previously run air-{;onditioning system may no longer be used (special-category waste),

4. Tightening torque for the compressor

fastening screws on the engine

(screws M8): 23 Nm (17 ftlb.)

5. Tightening torque for refrigerant line

(screws M8 x 32): 23 Nm (17 ftlb.) Use fastening screws from the new compressor. Replace O-rings and wet

with refrigerant oil.

6. Do not remove the plugs for the lines and compressor connection until shortly before installation.

7. Tightening torque for oil filler screw

(MID xI): 26...36 Nm (19...27 ftlb.:

Always replace the sealing ring.

fr:

78-96

~~~d

87 -20

87 34 19 Removing and installing the compressor

986871 Printed in Germany -12, 1997

Page 39

Boxster

Running-in regulations for new compressor

Note Fill the air-conditioning system (fluid) via the high-

pressure side from the refrigerant circuit with

the engine "OFF"

Air conditioning

If possible, all air outlet nozzles "OPEN",

circulating air "CLOSED"

2. Start the engine and allow idle speed to stabilize (approx. 5 seconds).

3. Set the fan to max. output.

4. Switch on the air-conditioning system (AC

switch) and allow it to run uninterrupted for at least 2 minutes at 1500 rpm.

5. After 2 minutes uninterrupted compressor operation time, the oil distribution in the airconditioning system is completed and the compressor can be run up to the max. engine

speed.

87 34 19 Removing and installing the compressor

Printed in Germany -1996 986871

87 -21

Page 40

Boxster

Air conditioning

8770 19

Removal

1. Remove the cover above the heatingjair-conditioning system.

2. Remove refrigerant by suction with the service unit.

3. Undo the air-conditioning lines at the expan-

sion valve. Close connections and lines immedi-

ately with plugs so that they are air-tight.

4. Undo the expansion valve and remove it. Im-

mediately close the lines to the evaporator

with plugs so that they are air-tight.

Removing and installing the expansion valve

3. Tightening torques:

Screw M5 Screw M6

6 Nm (4.5 ftlb)

9 Nm (6.5 ftlb)

/'-

81-96

Installation

1. Do not remove plugs until shortly before installation. Replace O-rings and wet the new rings with refrigerant oil.

2. Refrigerant oil removed by suction from a pre-

viously run air-conditioning sytem may no longer be used (special-category waste).

'=P_~l~1)

Page 41

87 01 19

Removal

Installing and removing the heating/air-conditioning unit

1. Remove the covers over the heating/air-conditioning system, battery and fluid tank. Discon-

nect and remove the battery.

2. Remove refrigerant by suction using the service unit.

3. Detach the air-conditioning lines at the expan-

sion valve. Close the connections and lines

with plugs immediately so that they are air-

tight.

4. Remove the steering wheel and loosen the steering column panel. Observe the safety regulations for handling airbag units (see Re-

pair Group 69).

5. Undo the central screw (clamp) on the steering column switch from below and pull it for-

wards slightly. Remove the cover at the top

and disconnect the electrical plug connec-

tions. Remove the steering column switch.

6. Detach the instrument panel and unclip the right side upwards. Disconnect the electrical

plug connections.

108 -96

7. Remove the steering column cover (4 screws).

107-96

87 01 19 Installing and removing the heating/air-conditioning unit

Printed in Germany, 1996 9868725

109 -96

87 -25

Page 42

Air conditioning

8. Remove the radio and heatingjair-conditioning controller. Unclip the switch panel on the left and on the right. Disconnect the electrical plug connections. Undo the retaining frame in the center and remove it.

Boxster

111 -96

14. Undo the center tunnel support on the support frame at the top and on the tunnel holder at the bottom.

110 -96

9. Remove the left side nozzle and disconnect the electrical plug connection. Unclip and remove the sun sensor cover and defrost

panel.

10. Undo the interior monitoring system and disconnect the electrical plug connection.

11. Remove the air guide at the bottom right.

Remove the passenger's airbag unit. Ob. serve the safety regulations for handling air. bag units (see Repair Group 69).

12. Remove the front cover of the center con-

sole. Undo the fuse holder and diagnosis plug in the left footwell.

13. Undo the control panel at the bottom, center, left and right. Carefully remove the con-

trol panel and detach the loudspeaker cable.

1--\0

II'

112 -96

15. Remove the left air guide. Only loosen the defrost channel. Undo and remove the center air distributor casing.

16. Disconnect the central plug connections

(2 ea.) from the heaterjair-conditioning unit.

87 -26

87 01 19 Installing and removing the heating/air-conditioning unit

9868725 Printed in Germany, 1996

Page 43

Boxster

17. Disconnect the battery positive terminal on the current distributor and the current distributor on the cover front wall.

~--_':_'-""'--::-";':;"'~\'

, (

Air conditioning

18. Disconnect both heating hoses upstream of the heat exchanger with the standard hose clamp. Disconnect the heating hoses on the

heat exchanger and plug the connections.

19. Undo the heater/air-conditioning unit on the lid firewall (3 nuts). Pull off the water drainage hose from the heater/air-conditioning

unit.

20. Undo the holder of the heater/air-conditioning unit from the passenger's side at the top

right.

":I;;

114-96

21. Carefully lower and remove the heater/airconditioning unit downwards into the footwell. Do not damage the electrical plug connections or cables.113-96

Installation

1. Ensure that the air distributor casing and air guides are correctly positioned. Engage the

electrical plug connections and carefully lay

the electrical cables (do not pinch).

2. Observe the safety regulations for handling airbag units

(see Repair Group 69).

87 01 19 Installing and removing the heating/air-conditioning unit

Printed in Germany, 1996 9868725

87 -27

Page 44

Air conditioning

Boxster

3. Set the steering column switch: Use a depth gauge to measure between the end of the steering axle and the metal cover

of the steering column switch (see figure).

Adjustment dimension 55 :t 0.5 mm

4. Replace the seal between the current distribu-

tor and firewall if necessary. After fitting the

current distributor on the firewall (tightening

torque 15 Nm), tighten the battery cable with

a new M8 hexagon nut. Tightening torque: 15 Nm (11 ftlb).

6. The heat exchanger is connected to the engine-cooling system, and coolant flows

through it when the engine is running. The cool-

ing system must be bled after removal or installation of the the heaterjair-conditioning unit

(see Repair Group 19).

55 t 0,5

115-~

5. Replace the a-rings for the refrigerant lines at the expansion valve and wet the new O-rings with refrigerant oil.

Note

If the heatingjair-conditioning unit is replaced, the refrigerant oil in the evaporator must be topped up. Determine the quantity of the refrige-

rant oil and top up again with refrigerant oil (vol-

ume removed by suction + 20 cm3).

Refrigerant oil removed by suction from a pre-

viously run air-conditioning system may no

longer be used (special-category waste).

87 -28

87 01 19 Installing and removing the heating/air-conditioning unit

9868725 Printed in Germany, 1996

Page 45

Boxster

Air conditioning

87 50 19

Removal

Removing and installing the condenser

1. Remove the cover above the heatingjair-conditioning system.

2. Remove the refrigerant by suction using the service unit.

3. Completely remove the front spoiler. Remove

the air guide to the condenser and pull off the

electrical plug connection on the temperature sensor.

4. Undo the refrigerant line on the condenser. Immediately close connections and lines with

plugs so that they are air-tight.

5. Undo the fastening screws (2 screws) from the condenser and pull the condenser to the side out of the holder.

Installation

1. Do not remove the plugs for the lines and condenser connection until shortly before installa-

tion.

2. Replace a-rings and wet the new a-rings with refrigerant oil.

3. Tightening torques:

Refrigerant lines M610 Nm (7.4 ftlb)

Condenser 4.0 :to.5 Nm

(3.0 :t 0.4) Nm

When loosening or tightening the M8 refrigerant lines on the condenser, always counter with a 21-mm open-ended wrench.

4. Determine the quantity of the refrigerant oil and top up again with refrigerant oil (volume removed by suction + 20 cm3).

146-96

Note

Refrigerant oil removed by suction from a previously run air-conditioning system may no longer be used (special-category waste),

87 50 19 Removing and installing the condenser

Printed in Germany, 1996 9868725

87 -29

Page 46

Boxster

Air conditioning

87 27 19

Removal

1. Use a standard strap wrench to securely hold the pressure plate, and undo the fastening

Removing and installing the magnetic coupling

screw.

~~~

209 -96 210 -96

Installation

1. Place the magnetic coil on the compressor housing. The locking pin must engage in the

locking hole.

~;;:;;;; ~~I

2. Screw a screw M8 into the thread of the pressure plate until the pressure plate can be removed manually. Remove the spacer

washers.

3. Use standard Seeger circlip ring pliers to remove the Seeger circlip ring. Manually remove the belt pulley.

4. Unscrew the cable of the magnetic coil from the compressor housing. Remove the Seeger circlip ring. Remove the magnetic coil from the compressor housing.

2. Install the Seeger circlip ring. The slanted surface (arrow) of the Seeger circlip ring faces upwards (to the fastening screw).

1930 -87

87 27 19 Removing and installing the magnetic coupling

Printed in Germany, 1996 9868725

87 -31

Page 47

Air conditioning

3. Tighten the pressure plate fastening screw. Tightening torque: 14 Nm (10 ftlb)

Check the air gap of the magnet coupling

1. Check the air gap between the pressure plate and belt pulley with a depth gauge.

Boxster

211 -96

2. Place a rule on the outer edge of the belt pulley. Use a depth gauge to measure up to the pressure plate. Apply battery voltage to the magnetic coupling and measure the distance (air gap) to the attracted pressure plate. Al-

ways measure at at least three points on the pressure plate in order to obtain a mean value. Distance: 0.5 mm :t 0.15 mm

3. If the air gap is not in the tolerance range, it

must be adjusted with the aid of the spacer

washers.

Page 48

Boxster

Air conditioning

87 20 19

Removing and installing drive motors of the heating/air-conditioning unit

Note Removal and installation of drive motor for tem-

perature valve, central valve and footwell/de-

frost valve. Removal or installation is performed

with the heating/air-conditioning unit installed.

Drive motor for temperature valve

~-./\

Removal

1. Remove footwell bulkhead and air guides. Unclip centre console cover at the front and remove the footwell vent (3 screws).

2. Press pivot pin on the adjusting lever together and disengage the deflection lever.

3. Unscrew drive motor of the heating/air-condi-

tioning unit and disconnect the electrical plug connection.

Drive motor for footwelljdefrost

Drive motor for central valve

549 -96

; I';;!~\':

552 -96

1. Unscrew drive motor with bracket from the heating/air-conditioning unit (2 screws).

2. Swivel drive motor to the side and disengage the deflection lever.

3. Disconnect electrical plug connection and detach bracket from the drive motor.550 -96

87 20 19 Removing and installing drive motors of the heating/air-conditioning unit

Printed in Germany -5, 1996 9868733

87 -33

Page 49

Installation

1. Ensure that the deflection levers are seated correctly.

2. Tighten fastening screws carefully (plastic housing).

3. Engage electrical plug connections and route wire carefully.

4. Perform function test after installation of the drive motors.

Air conditioning Boxster

87 -34 87 20 19

Removing and installing drive motors of the heating/air-conditioning unit

9868733 Printed in Germany -5, 1996

Page 50

Boxster Air conditioning

87 20 19 Removing and installing drive motor for fresh-air/recirculation valve

Removing and installing drive motor on the installed heating/air-conditioning unit

Removal

1. The recirculation button must be pressed before removal (fresh-air supply blocked). The drive motor can be removed from the installed

heatingjair-conditioning unit in this position (re-

circulation).

2. Remove footwell and right air guide. Disconnect electrical plug connection of the drive

motor and undo fastening screw.

3. Disengage pivot pin on the adjusting lever with

a screwdriver.

-=======~ \ \ \

A~o

_"\

Installation

1. The removal or installation position of the drive motor and fresh-air/recirculation valve

cannot be changed.

2. Ensure that the deflection lever of the outsideair valve is seated correctly.

3. Tighten fastening screw carefully (plastic housing).

4. Engage electrical plug connection and route

wire carefully.

5. Perform a function test after installation.

1--,

551/1 -96

4. Swivel down the drive motor and remove it to the side.

87 20 19 Removing and installing drive motor for fresh-air/recirculation valve

Printed in Germany -5, 1996 9868733

87 -35

Page 51

Boxster

Air conditioning

87 59 19 Removing and installing outside temperature sensor

Removing and installing outside temperature sensor on the installed heating/air-conditioning unit

Removal

1. Remove footwell bulkhead and right-hand air guide. Remove drive motor for fresh-air/recir-

culation valve.

2. Pull off electrical plug connection on the outside temperature sensor. Turn temperature sensor by 900 and pull it out.

,- -

1= 0-

I-

---

Installation

1. Place temperature sensor on the intake duct and turn by 900 (tighten),

2. Engage electrical plug connection and route

the wire carefully.

3. Install drive motor for fresh-air/recirculation valve and perform a function test.

607/1 -96

87 59 19 Removing and installing outside temperature sensor

Printed in Germany -5, 1996 9868737

87 -37

Page 52

Boxster

Air conditioning

87 82 19

Removal

1. Pull off cover for temperature sensor ..Undo three T orx screws of the right side vent and

carefully pull the side vent out of the dashboard. One Torx screw is located behind the cover.

Removing and installing interior temperature sensor

2. Press locking tabs together slightly and remove temperature sensor from the dashboard.

Installation

1. Engage electrical plug connection, ensuring that the temperature sensor is seated

properly in the dashboard.

2. The cover simultaneously serves as the intake grille for the fan and must not be closed off.

608 -96

3. Pull off electrical plug connection.

87 82 19 Removing and installing interior temperature sensor

Printed in Germany -5, 1996 9868737

87 -39

Page 53

Boxster

Air conditioning

87 58 19

Removing and installing footwell blower outlet sensor

Removal

1. Remove footwell bulkhead. Unclip centre console cover at the front and remove the foot-

well vent (3 screws).

2. Turn blower outlet sensor by 900 and pull it out.

Installation

1. Position temperature sensor on the heating/airconditioning unit housing and turn by 900

(tighten),

2. Engage the electrical plug connection and route the wire carefully.

609 -96

3. Pull electrical plug connection off blower outlet sensor.

87 58 19 Removing and installing footwell blower outlet sensor

Printed in Germany -5. 1996 9868737

87 -41

Page 54

Boxster

Air conditioning

87 78 19 Removing and installing blower driver

Removal

1. Remove footwell bulkhead and right ai( guide. Unscrew fastening screw and detach the

blower driver from the heatingjair-conditioning

unit housing from below.

~,IV>"~~-~ =

n~E;!:;::::1

610 -96

Installation

1. Engage the electrical plug connection and slide the blower driver into the upper bracket.

2. Tighten the fastening screw carefully (plastic housing). Install the air guide and footwell bulkhead.

3. Perform function test on heater/fresh-air blower motor.

2. Pull blower driver out of the upper bracket and remove in downward direction.

3. Pull off the electrical plug connection,

87 78 19 Removing and installing blower driver

Printed in Germany -5, 1996 9868737

87 -43

Page 55

Page 56

Air conditioning Boxster

Ilrlstallation

1.. After installation, check whether the fan can rotate freely.

2. Tighten front wheel to the specified torque

(130 Nm (96 ftlb.)}.

~~7 -46

87 53 19

9868737

Removing and installing fan for condenser

Printed in Germany -5, 1996

Page 57

Boxster

Air conditioning

87 69 19

Removing and installing ballast resistor for fan motor

Note

The ballast resistor is available as a spare part and can be replaced by crimping it onto the old wires.

1. Disconnect the battery and cover the terminal or battery.

6. Using a commercially available crimping tool, join the wires with crimp connectors.

7. After crimping, solder the crimp connectors.

Slide heat-shrink tubing over the crimp connec-

tors and then shrink the tubing with a hot-air gun.

2. Unclip ballast resistor from the holder from below. 8. Carefully route the wires and, if necessary, fix

in place with plastic tape.

645 -96

3. Cut off wires approx. 30 mm behind the old ballast resistor.

4. Slide heat-shrink tubing over the wires to the plug connection (2 x) and to the fan motor

(1 x).

5. Shorten wires of the new ballast resistor to approx. 30 mm and strip approx. 5 mm of insulation off all wire ends.

87 69 19 Removing and installing ballast resistor for fan motor

Printed in Germany -5, 1996 9868737

87 -47

Page 58

Boxster

Air conditioning

87 02 19

2. Unscrew fastening screws (2 ea.) and pull the heating/air conditioning control out of the

Installing and removing the heating/air conditioning control

dashboard.

437.97

Performing system test1. Unclip cover.

1. Connect and switch on the Porsche System Tester 2.

2. Select air conditioning and menu item "System test".

The following conditions must be

observed for the system test:

Vehicle speed < 10 km/h

Engine start detected and 10 seconds elapsed since engine start

Terminal 15 supply voltage OK

3. Disconnect the plug connections

Note Basic adaptation to the system must be

performed with a new heating/air conditioning

control. This is indicated by flashing of the

displays for approx. 5 to 10 seconds each time

the ignition is switched on.

Basic adaptation is performed during the system test.

5 Volt supply voltage OK

Engine temperature < 110°C

Outside temperature> 3 °C

The following tests are performed:

Display of all segments in the control module

The drive motors are traversed across the entire range once

The measured positioning travel is subjected to a plausibility test and stored as a fault if

necessary

87 02 19 Installing and removing the heating/air conditioning control

Printed in Germany -12, 1997 9868749

87 -49

Page 59

Two different voltage values are set on the fresh-air fan and tested

The A/C circuit is tested via the DME

All fault paths are tested, and any faults are stored

Basic adaptation has been completed after the system test. The display must no longer flash.

Air conditioning

Boxster

87 -50

87 02 19

Installing and removing the heating/air conditioning control

9868749 Printed in Germany -12, 1997

Page 60

Technical Manual

T echnicallnformation

Group 9

Electrics

-~~TL"".-

Page 61

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

The two folders with Group 0 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 0 -Diagnosis, part 1"

(up to Repair Group 45).

The second folder "Group 0 -Diagnosis, part 2" (as of Repair Group 69) includes the further Repair Groups belonging to Group O.

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).

The second folder "Group 1 -Engine, part 2" (as of Repair Group 15) includes the further Repair Groups belonging to Group 1.

Foreword

Printed in Germany -34, October 1999

VORW.CHP

Page 62

Foreword

*!j

The two folders with Group 9 are to be regarded as one folder; i.e. file the "Technical Information"

Boxster

notices only in front of the repair descriptions in the folder "Group 9 -Circuit diagrams, part 1" (up to

the '99 model).

.Ei

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 > 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.

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.

VORW.CHP

Foreword

Printed in Germany -34, October 1999

Page 63

Boxster

Overview of repair groups

Group 0: Entire vehicle -General

Maintenance

Group 0:

Group 1:

Diagnosis

Sales check On-board diagnosis DME diagnosis

Tiptronic diagnosis ABS diagnosis

Diagnosis

Airbag diagnosis

Seat memory diagnosis

Heating diagnosis

Alarm system diagnosis

PCM diagnosis

ParkAssistent diagnosis HBA diagnosis

Engine

Engine -Crankcase, suspension Engine -Crankshaft, pistons

Engine

Engine -Cylinder head, valve drive Engine -Lubrication

Engine -Cooling

0 03

01 03

24 37

72 80 90 91 91

17 19

Group 2:

Group 3:

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

Transmission, manual transmission

Clutch, control Manual transmission -Actuation, housing Manual transmission -Gears, shafts, into gearsh, Final drive, differential, differential lock

Transmission, automatic transmission

Torque converter

Automatic transmission -Actuation, housing Automatic transmission -Gears, control

Final drive, differential, differential lock

24 25

30 34

39 3

37 38 39

Overview of repair groups

Printed in Germany -34, October 1999

REPGRU.CHP

Page 64

Overview of repair groups

Boxster

(iroup 4:

(iroup 5:

(iroup 6: 6

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

Body

Body front Body center, roof, frame

Body rear

Lids, flaps

Door front, central locking system

Body equipment, exterior

Sliding roof Convertible top, hardtop

Bumpers

Glazing, window control Exterior equipment Interior equipment

Passenger protection

<:iroup 7: Body equipment, interior

Linings, insulation

Seat frames

Seat upholsteries, covers

45 46

55 57

60 61 63

<:iroup 8:

(iroup 9

(:roup 9:

<:iroup 9:

Air conditioning

Heating Ventilation Air conditioning

Auxiliary air conditioning system

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

Circuit diagrams

Wiring (up to and including the '99 model)

Circuit diagrams Wiring (from the 'DO model)

90 91

97 9

REPGRU.CHP

Overview of repair groups

Printed in Germany -34, October 1999

Page 65

Boxster

Contents

915715 917519 911019 911219 911319

911215

19 37 19 15

Electrics

General

Work instructions after disconnecting the battery. .

Instruments, alarm system

Removing and installing instrument cluster. Disassembling and assembling instrument cluster. Removingandinstallinghorn 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.

9- 1

90- 1 90- 3 90- 5 90- 7

91 91 91 91

91 91

92 19 19 92 27 19 921519

9266

92 60 19 92 56 19

92 78 19

92 67 19

92 72 19

941 941

94 a

944

941

942

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.

92 -1 92 -3 92 -5

92- 7

92 -9

92 -11

92-13 92-15

92-17

94- 1 94- 3 94- 7 94- 9 94-11 94-15

519505519719513

9 Electrics

Printed in Germany -32, 1999

986TOC

Page 66

Contents

Boxster

94 23 19 94 27 19 9467 19 94 56 19 94 53 19 94 33 19

9429 19

94 70 19 9423 19 94 57 19

94 58 19

9494 19

94 1505

94 1501

94 78 19

94 79 19

9498 19

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 taillight. Removing and installing bulb 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.

.94.94.94.94-

.94-

.94.94.94.94-

.94.

.94-

94-39 94-41 94-43

94-45

17 19

23 25

27 29

33 35

94-47

94 -49

Lights, lamps, switches interior, theft protection

Removing and installing signal converter/immobiliser 96 -1

Removing and installing passenger compartment monitoring sensor. ...96 -3

AdditionalalarmsystemM534 96.5 Radio remote control in hand-held transmitter does not function. 96 -7

Vehicles with alarm system without radio remote control. 96. 9

Bulb overview and installation instructions. 96 -11 Removing and installing bulb for door warning light. 96 -13 Removing and installing bulb for luggage compartment light. 96 -15 Removing and installing bulb for interior light. 96 -17 Removing and installing bulb for instrument cluster. 96 -19 Teaching hand-held transmitter. 96 -21 Reading out and transferring remote control. 96 -23

Disassembling and assembling hand-held transmitter. 96 -27

986TOC

9 Electrics

Printed in Germany -32, 1999

Page 67

Boxster

General

Work instructions after disconnecting the battery

Effect of disconnection or total discharge of the battery on electrical systems in the vehicle, subsequent

measures:

1. Never disconnect battery with engine running.

2. Never start engine without securely connected

battery.

3. Do not use a boost charger to start the

engine.

4. Whenever possible, use jump leads with overvoltage protection.

5. Always disconnect the battery terminals before carrying out welding work on the vehicle.

6. Wiring harness plugs of control modules or other electronic components must be connected or disconnected with the ignition off. Exception: vehicles with the additional

equipment M 536 (alarm siren with tilt

sensor).

Note concerning M 536:

Control module memories:

Values and faults stored in the control modules

can be deleted if the battery is disconnected or

completely discharged.

Remedy:

If possible, all fault memories should be checked and, if necessary, printed out before the battery is disconnected.

Supply voltage fault entry:

The entry "supply voltage" could be stored in various control modules if the battery has been

completely discharged.

Remedy:

Delete the "supply voltage" entry from the control modules in question.

Test drive after connecting the battery:

The fault memories of all vehicle control modules should be read out again after the test drive.

In order to avoid triggering the alarm siren (in-

stalled on right next to the battery) of vehicles with M 536, the battery must be disconnected with the ignition on (all loads must be switched

off beforehand),

9 Work instructions after disconnecting the battery

Printed in Germany -32, 1999 9869_1

9 -1

Page 68

General

Boxster

24 70 DME control module:

After disconnection of the power supply, the idle speed might change or fluctuate briefly until the idle speed positioner (M 5.2) or the throttle adjusting unit (ME 7.2) is readapted. The mixture adaptation is also lost.

Rlemedy:

After the battery is connected: With the DME ME 7.2, it is necessary to carry

out a learning and adaptation routine as des-

cribed below:

Switch the ignition on for 1 minute without starting the engine. Do not actuate accelerator pedal.

Switch off ignition for at least 10 seconds.

This completes the adaptation of the throttle adjusting unit.

With all DME systems, the engine must run for several minutes before the engine control module can relearn the idle speed and

mixture adaptation values.

3'7 30 Tiptronic:

The stored pressure adaptation valves are lost if the power supply to terminal 30 is interrupted. This can result in poor shifting quality and rough

shift operations during the adaptation phase.

Remedy:

Perform a test drive. During the test drive, drive

the vehicle with varying load conditions and at va-

rious speeds so that all shift functions (manual and automatic programs) are executed at least once. This readapts the shifting pressures of the system and thereby re-establishes smooth shift-

ing.

64 52 Power windows:

The limit positions of the power windows are de-

leted from the control module when the battery

is disconnected and connected.

Remedy:

Manually close each power window as far as it will go, then press the rocker switch for closing the window again. The limit position of the respective power window is now stored in the control module again.

90 25 Instrument cluster: The trip counter is set to 0 when the power

supply is disconnected.

90 30 Clock:

Depending on the software version, the clock is

set to 12:00 a.m. or 1:00 a.m. when the power

supply is disconnected.

Remedy: Enter the current time again.

9-2

Note:

On vehicles with PCM, 91 10 PCM position 3.

9 Work instructions after disconnecting the battery

9869_1 Printed in Germany -32, 1999

Page 69

Boxster

General

90 80 On-board computer: Disconnection of the vehicle battery deletes the

memories for average speed and average con-

sumption. As a result, the displayed range on remaining

fuel can be markedly different or even O. The outside temperature indicator loses its

memory effect. In other words, the indicated outside temperature can be too high due to the heat radiated when the vehicle is hot.

91 20 Radio:

The radio reverts to the Code function when the

battery is disconnected and is thus no longer ready for operation.

Remedy:

Input the radio code. If the code card is un-

available, the radio code can be read from the DME control module (under "Vehicle data"). The code is also available from the Porsche IPAS.

91 10 PCM:

5. If the telephone card was inserted and the telephone was ready for operation, the telephone is subsequently disabled.

Remedy:

1. Input the PCM code. If the code card is unavailable, the PCM code can also be read from

the DME control module (under "Vehicle data"), This code is also available from the Porsche

IPAS.

2. Switch on the PCM with a free panoramic view

for approx. 20 minutes (to load GPS almanac).

3. The date and time are also adopted once the

GPS almanac has been loaded (see step 2); it

may be necessary to change over to summer

time (daylight-saving time). This time is transferred to the instrument cluster. If the time is then manually changed by means of the instru-

ment cluster, this time is adopted by the PCM

and synchronised with GPS time.

4. The stored stations are displayed again when station buttons 1 to 6 are pressed.

The PCM reverts to the Code input function when the battery is disconnected and is thus no longer ready for operation.

2. When the power supply is disconnected, the built-in GPS receiver loses the so-called Ha/ma-

nac. containing the satellite orbital paths.

3. The date and time are deleted when the bat-

tery is disconnected.

4. Radio stations stored by the customer are no

longer displayed.

5. The telephone is enabled again when the telephone PIN code is entered with the SIM telephone card inserted.

9 Work instructions after disconnecting the battery

Printed in Germany -32, 1999 9869_1

9-3

Page 70

Boxster Instruments, alarm system

90 25 19 Removing and installing instrument cluster

Removal

1. Disconnect the battery and cover the terminal or battery.

2. Switch on the hazard warning light switch (button comes out). On the sides of the button, there are small openings that project beyond the dashboard insert. Insert two small screwdrivers into the openings and pull off the button (A) toward the front.

108-96

96-507

3. The hazard warning light switch (8) is held in the dashboard insert by two locking hooks. Press the right locking hook toward the

switch, grip the button holder with a pair of

pliers and pull out the switch toward the front.

4. Undo 5.0 x 30 Torx screw on the dashboard insert.

5. Pull off dummy plug on the left side and undo the 5.0 x 30 Torx screw. Unclip the

dashboard insert and disconnect the electrical plug connections.

Note

If the vehicle is equipped with a "handsfree telephone," disconnect the microphone plug connection instead of the dummy plug.

6. Detach the instrument cluster from the

dashboard insert and remove it.

Installation

1. Engage electrical plug connections and fasten the dashboard insert on the dashboard.

2. Install hazard warning light switch. Press

button (A) onto the hazard warning light switch until the button engages audibly.

3. Connect the battery and perform a function

test.

90 25 19 Removing and installing instrument clust:er

Printed in Germany -12, 1997 986901

90 -1

Page 71

Boxster Instruments, alarm system

90 25 37

Note

The instrument cluster can be disassembled

into three components.

A -Front frame B -Display unit C -Electronic unit

Disassembling and assembling instrument cluster

(

~i;-

$' 4

.,.

iJ '.~

Opening instrument cluster

1. Remove adjusting knob for clock and daily trip mileage display.

2. Remove sheetmetal braces from the fastening eyelets on the left and right.

3. Release the electronic unit on both sides with a screwdriver (do not tilt).

The instrument cluster must be laid on a soft, dust-free surface to open it. When the instrument cluster is open, no dial

or solder joints on the display unit and electronic unit should be damaged or

touched.

486_98

487_98

4. Unclip the electronic unit at the bottom centre. The released green guide tabs are held outwards with a screwdriver. The electronic unit is taken up off of the display

unit evenly on alternate sides.

5. Remove fastening clips (new version) on the

indicator light housing and carefully remove

the display unit from the front frame.

90 25 37 Disassembling and assembling instrument cluster

Printed in Germany -24, 1998 986903

90-3

Page 72

Instruments, alarm system Boxster

Assembling instrument cluster

1" Carefully assemble display unit and front

frame. Engage fastening clips (new version),

2" Before assembly, check that both green

guide tabs on the electronic unit are pushed outwards.

3" Assemble the electronic unit and display

unit carefully and evenly (do not tilt). Engage fastening clip underneath in the centre. Press the locking tab in the upper part

of the electronic unit together and into the front frame holder.

4" Press both green guide tabs inwards over

the contact plugs with a screwdriver (do not tilt).

5, Press the sheetmetal braces on the left

and right over the fastening eyelets.

6" Replace adjusting knob for clock and daily

trip mileage display.

90 -4

90 25 37

Disassembling and assembling instrument cluster

986903 Printed in Germany -24, 1998

Page 73

Boxster Instruments, alarm system

90 50 19 Removing and installing horn

Note

Both horns are fastened on a bracket on the

right front side between the body and condenser.

/1"",

..,.

A -Horn, high-pitch

B -Horn, Jow-pitch

Removal

1. The high-pitch horn can be removed from below through the sound outlet opening. Pull off electrical plug connection and observe in-

stallation position of the horn.

2. Unscrew the M 6 hexagon nut from the bracket and remove the high-pitch horn

through the sound outlet opening.

633/1 -96

634-96

Note The entire front end must be removed in order

to remove the low-pitch horn.

Installation

1. Observe installation position of the horns. The horn must not touch the body or a bracket.

2. A toothed washer must be fitted between the horn and bracket.

Tightening torque

of the M 6 hexagon nut = 10 Nm (7.5 ftlb.)

9050 19 Removing and installing horn

Printed in Germany -5, 1996

90-5

986901

Page 74

Boxster

Instruments, alarrn system

90 12 15 Setting ahead total mileage counter in instrument cluster

Note

The kilometre reading must be set ahead after

replacement of the instrument cluster.

1. Set ahead with the Porsche System Tester 2.

-Select vehicle type (Boxster)

-Select control modules

-Select instrument cluster

-Select total mileage

-Input Vehicle Identification Number

-Confirm with key F7

-Input kilometre reading

-Code with key F8

2. The total mileage is adopted in the new instrument cluster after coding.

90 12 15 Setting ahead total mileage counter in instrument cluster

Printed in Germany -9, 1997 986907

90 -7

Page 75

Boxster

Radio, telephone, on-board computer, navigation

915715

Note

Setting handsfree microphone to tl~e telephone type

There is an adjustment possibility on the handsfree microphone for adopting it to the telephone system installed in the vehicle. The following positions must be set for the Nokia 2110 or Motorola:

Position 1 -free Position 2 -Nokia 2110 Position 3 -Motorola

11-97

Setting

1. Carefully unclip handsfree microphone from the dashboard insert and pull out.

2. Use a small screwdriver to set the position of the installed telephone system (e.g. Nokia

2110 pos. 2). The setting as delivered in new

cars is position 3.

3. Carefully clip the handsfree microphone into the dashboard insert again.

91 57 15 Setting handsfree microphone to the telephone type

Printed In Germany -9, 1997 986911

91-1

Page 76

Boxster

Radio, telephone, on-board (:omputer, navigation

91 75 19

Note Four sensors for the ParkAssistent are installed

in the rear spoiler. The rear spoiler must be taken oft in order to remove a defective sensor. The sensors are arranged in the order: outer left, inner left, inner right and outer right.

Removing and installing sensor for ParkAssistent

The sensor with holder in the rear spoiler

consists of six parts.

1 -Rosette

2 -Washer

3 -Sensor housing

4 -Isolating ring 5 -Sensor 6 -Retaining spring

39.97

..:l~=:==i

91 75 19 Removing and installing sensor for ParkAssistent

Printed in Germany -12, 1997 986913

91-3

Page 77

Radio, telephone, on-board computer, navigation Boxster

N'ote

The washer (No.2, Figure 410 -97) and retaining spring (No.6) have been omitted from the inner left and inner right sensors. The holding spring (Figure 413 -97) with new support facing the rear spoiler is installed for these two parts.

413-97

911 -4

91 75 19

Removing and installing sensor for ParkAssistent

986913 Printed in Gennany -12, 1997

Page 78

Boxster

Radio, telephone, on-board computer, navigation

Removal

1. Take off rear spoiler. Pull off electrical plug connection. Press together retaining spring at top and pull off.

'~~-~-

2. Slightly bend apart the holding lugs on the

sensor housing and push out the sensor.

Installation

Note Always fit the isolating ring (Figure B) before

installing the sensor (Figure A). The smooth surface of the isolating ring faces the sensor.

I I

411-97

40-97

Fit isolating ring and push sensor into the

sensor housing.

412-97

3. The washer remains over the sensor housing on the rear spoiler. Remove isolating ring from

the sensor.

2. Slide retaining spring over the sensor housing and press on until it meets the stop.

3. Engage electrical plug connections and fit rear

spoiler.

Note The electrical plug connection in the sensor

must always point to the centre of the vehicle.

The plug connection with marking (white

adhesive tape) on the wiring harness is always connected to outer left sensor.

91 75 19 Removing and installing sensor for ParkAssistent

Printed in Germany -12, 1997 986913

91-5

Page 79

Radio, telephone, on-board computer, navigation

Boxster

P'arkAssistent wiring harness

"late

The wiring harness is marked at one outer end

of the plug connection. Observe the allocation of

the plug connections to the sensors.

The outer plug connection with marking (white

adhesive tape) on the wiring harness is always connected to outer left sensor.

ParkAssistent control module

Note

The control module is fastened next to the

alarm system/central locking system control module under the driver's seat. When removing, remove the seat and detach the retaining plate

(two M6 x 16 hexagon-head bolts),

429-97

) I;,~~'

430-97

!~1 -6

91 75 19

Removing and installing sensor for ParkAssistent

986913 Printed in Gennany -12, 1997

Page 80

Boxster

Radio, telephone, on-board computer, navigation

911019

Removing and installing display and operator control unit (PCM)

Removal Old version

1. Unclip switch covers from below and disconnect electrical plug connections,

New version

1. Unclip the switch covers from below and let them dangle from the electric leads.

2. Press together both spring clamps on the display and operator control unit

and carefully pull out.

[t)

OJ 0

731_97

2. Detach and remove the central vent (4 Torx screws 5.0 x 22) at the centre vent. Carefully

3. Disconnect electrical plug connections from the display and operator control unit.

pull out the display and operator control unit and disconnect the electrical plug connections.

Note

The mounting points on the display and operator control unit for fastening it in the retaining bracket were modified in the current model year. The retaining bracket was adapted accordingly. As the result

of the modification, the previously installed retaining bracket (end digits 00) must be exchanged for the new retaining bracket (01). The new retaining bracket is included with the new display and operator control unit.

733_97

91 10 19 Removing and installing display and operator control unit (PCM)

Printed in Germany -18, 1998 986917

91 -7

Page 81

Radio, telephone, on-board computer, navigation

Boxster

Irlstallation

1. Engage the electrical plug connections and carefully lay the electrical leads (do not pinch).

2. After installation of a new display and operator control unit, the system must be activated with the Porsche System

Tester 2.

Connect and switch on the Porsche System

Tester 2.

Switch on ignition.

Switch on "PCM" by pressing the volume control (display remains dark),

Establish communication with the Porsche System Tester 2 and select "PCM",

Select "Modify coding",

Device code input

The display and operator control unit is

protected against theft by a device code. Furthermore, a code also protects the navigation unit against unauthorised users

Both codes must be input when the system

is commissioned. Input the device code for the display and operator control unit first.

Only the navigation code has to be input

again if the navigation unit is exchanged.

Select "PCM active"

Confirm "PCM active" with the F8 key.

91 -8

911019

Removing and installing display and operator control unit (PCM)

986917 Printed in Germany -18, 1998

Page 82

Boxster

Radio, telephone, on-board computer, navigation

911219

Note Special tool V 160 must be used to remove

the navigation unit

Removal

Removing and installing the navigation unit

1. Unclip the cover from the navigation unit on the left and right.

2. Insert special tool V 160 into the recesses of the navigation unit and engage.

~, ::::::::: ~ 2{tj~~;~~~ ]-0

-'~ '"--' 0 OL

( (

00 /

Installation

1. Engage the electrical plug connections and carefully lay the electrical leads (do not pinch),

2. Clip in cover on the left and right and perform a function test.

Device code input

The navi~ation unit is protected against theft by a device code. Only the navigation code has to be input again if the navigation unit is exchanged.

[ ~~J-"C~l c::: .

'::::J D1

) --P:"

73~97

3. Carefully push out the navigation unit rearward and disconnect plug connections.

91 12 19 Removing and installing the navigation unit

Printed in Germany -18, 1998 986917

91 -9

Page 83

Boxster

Radio, telephone, on-board computer, navigation

91 13 19

Note

The GPS antenna is located under a cover

in the centre of the dashboard. A light-emitting diode for the alarm system and the sun sensor are accommodated in this housing. The GPS is fastened underneath with a magnet.

Removal

Removing and installing GPS antenna

1. Unclip cover from behind and take out.

2. Undo both Torx T20 fastening screws

with an angled screwdriver.

Caution: Fastening screws could fall out.

Installation

1. Engage electrical plug connection and route lead carefully.

2. Install housing with GPS antenna and clip in cover.

Note

The GPS antenna must not be covered

by metallic or moist objects.

3. Remove housing with GPS antenna, disconnect electrical plug connection

on the bottom, and remove GPS antenna (magnet).

\,"1

73o_97

91 13 19 Removing and installing GPS antenna

Printed in Germany -18, 1998 986917

91 -11

Page 84

Radio, telephone, on-board computer, navigationBoxster

In general, it is necessary to get approval

for the installation of mobile communication

systems (car telephone, mobile phone, two-way

radios, etc. ) in a vehicle that received its type

approval after 1st January, 1996.

Mobile two-way radios (telephones) that are retrofitted must have a type approval for this vehicle and be identified with an e.

In the Driver's Manual of its vehicles Porsche

has approved mobile telephones and two-way

radios with a maximum transmission power of 10 W. Observe the installation specifications and recommendations listed there.

Porsche permits the installation and operation of two-way radios over 10 W for the radio services listed below

under the following preconditions:

Retrofitting mobile communication systems

When mobile phones and two-way radios are correctly installed, they are not influenced by important vehicle systems such as ABS, airbag and motronic. The

requirement is, however, that the installation and wiring of these systems is not altered. A wiring arrangement parallel to these systems and their wiring harnesses (especially sensor wires) is not permitted.

The transmission powers in the given

frequency range may not exceed the respective Pmax values at the antenna base.

The installation must be carried out

correctly and a non-reflecting adapted

external antenna must be used.

Always observe the operating and installation

instructions of the manufacturer for mobile

phones, two-way radios and antenna.

91 Retrofitting mobile communication systems

Printed in Germany -24, 1998 9869113

91-13

Page 85

Radio, telephone, on-board computer, navigation

Boxster

Frequency

band

Shortwave

up to 54 MHz

4m band

2m band

7acm

23cm

C-net

D-net E-net

If a mobile phone or two-way radio is installed

which does not conform to Porsche installation

conditions, the general certification of the

vehicle can be rendered null and void (EU

EMV Vehicle regulation 95/54). In this case it is necessary to have EMV experts inspect

the Porsche in order to observe the

protective goals.

Pmax/Watt

Cabrio

10 (PEP)

10 (eft.) 10 (eft.) 10 (eft.) 10 (eft.)

10 (eft.) 10 (PEP) 10 (PEP)

PmaxIW

Coupe

hardtop 50 (PEP)

(eft.)

50 (eft.) 20 (eft.) 25 (eft.)

20 (PEP) 10 (PEP)

Permitted location of antenna

on vehicle outside

on vehicle outside on vehicle outside

on vehicle outside

The optimum range of the two-way radios

can only be reached with an external antenna. Excessive electro-magnetic fields can occur in

the vehicle from the operation of mobile phones

and two-way radios without an external antenna or with an external antenna that is incorrectly installed (or defective). In this case, malfunctions of the electronic vehicle systems and damage

to health cannot be entirely ruled out.

In general, a suitably chosen antenna location and a reduction of transmission power if necessary ensure adherence to the limit

values of the DIN VDE 0848 Part 2

(Protection of persons in a frequency range of 30 kHz to 300 Ghz).

91 -14

9869113

Retrofitting mobile communication systems

Printed in Germany -24, 1998

Page 86

Boxster

Radio, telephone, on-board computer, navigation

911215

General

The PCM navigation unit must be calibrated after

maintenance work or commissioning. Calibration

is the prerequisite for exact route guidance.

Adjusting (calibrating) PCM navigation unit

The following components of the PCM navigation

unit must be calibrated or initialised:

GPS receiver: After an interruption in the

power supply (terminal 30), the installed GPS receiver loses its so-called almanac. The almanac stores the satellite orbits and ensures fast location of the individual

satellites when the system is started.

Distance sensor: The distance sensor

transmits the distance travelled to the PCM

navigation unit. The distance signal changes

if the circumference of the tyre changes (e.g. tyre change). This modification must

be calibrated by the PCM navigation unit afterwards.

Note: The distance sensor must be calibrated after

commissioning of the PCM navigation unit or after changing a tyre. If a system that has

already been calibrated is disconnected from

the power supply (terminal 30), the calibration

of the distance sensor is retained.

Gyroscope: The gyroscope detects

changes in the direction of travel and

must be calibrated after commissioning,

The gyroscope shows temperature-dependency. This temperature-dependency is compensated

by the system if the "cold" (not calibrated) system is switched on and left to stand for

approx. one hour.

Note:

The gyroscope must be calibrated after

commissioning only. If a system that has already been calibrated is disconnected from the power

supply (terminal 30), the calibration of the

gyroscope is retained.

Procedure after commissioning: Please observe the sequence!

Switch on the PCM with a free panoramic view for approx. 20 minutes (to load GPS almanac).

Drive on a motorway if possible at a speed greater than 60 km/h for a distance of approx. 50 km. (calibration of the distance measurement)

Drive approx. 10 km in an urban area and take frequent turn-offs. Stop for approx. 10 seconds occasionally. (calibration of the gyroscope)

Switch on the PCM navigation unit for

approx. one hour with the vehicle horizontal.

(temperature compensation of the gyroscope)

91 12 15 Adjusting (calibrating) PCM navigation unit

Printed in Germany -25, 1999 9869115

91-15

Page 87

Radio, telephone, on-board computer, navigation Boxster

Calibration is necessary after the following maintenance work:

After changing a tyre

After the power supply has been interrupted

Procedure after changing a tyre

-Drive on a motorway if possible at a speed greater than 60 km/h for a distance

of approx. 50 km. (Calibration of the

distance measurement).

Procedure after the power supply has been in1terrupted:

-Switch on the PCM with a free panoramic

view for approx. 20 minutes (to load GPS

almanac).

9JL -16

911215

9869115

Adjusting (calibrating) PCM navigation unit

Printed in Germany -25, 1999

Page 88

Boxster

Windshield wiper and washer system

92 19 19

Removal

1. Remove the covers over the heating/air-conditioning system, battery and fluid tank. Discon-

nect the battery and cover the terminal or bat-

tery.

Removing and installing the wiper link

2. Undo the wiper arm on the left and right and remove the cowl panel over the wiper link.

3. Remove the left dome strut. Undo the wiper link on the body (3 screws M6) and discon-

nect the electrical plug connection on the

wiper motor.

Installation

1. Observe the installation sequence for the fastening screws 1...3.

3.,.[1

4-96

4. Carefully remove the wiper link with wiper motor to the front.

4-96

2. Tightening torques: ( xx ) = ftlb

Wiper arm nut

Hexagon-head bolts

3. Before installing the dome strut, the vehicle must be on its wheels.

M8M617 Nm (12.5)

10 Nm (7.4)

~~~

l.~

92 19 19 Removing and installing the wiper link

Printed in Germany, 1996 986921

92 -1

Page 89

Boxster Windshield wiper and 1Nasher system

9227 19

Note

The wiper blades for the driver's and

passenger's side are different. The wiper

blade on the driver's side is straight. On the

passenger's side it is curved (see illustration).

This arrangement applies to left-hand drive and

right-hand drive vehicles.

Removing and installing the wiper blades

The clip installation position must be observed

when installing the wiper blades for left-hand

drive and right-hand drive vehicles.

A B

"'- -"'"-~~~-{

143-96

A -Passenger's side

B -Driver's side

Note

The spoiler edge of the wiper blade on the

driver's side must face downwards.

142.96

A -Clip for left-hand drive vehicles

B -Clip for right-hand drive vehicles

92 27 19 Removing and installing the wiper blades

Printed in Germany -12, 1997 986921

92 -3

Page 90

Boxster

Windshield wiper and washer system

92 15 19 Removing and installing the wiper motor

Removal

1. Remove the covers above the battery and fluid tank. Disconnect the battery and cover the terminal or battery.

2. Undo the fastening nut of the link. When doing so, hold in position using an open-end spanner

(width across flats 21 mm). Remove the link.

3. Undo the fastening screws on the wiper motor (3 screws M6) and the lower fastening screw

on the body. Carefully raise the wiper link and remove the wiper motor downwards.

Installation

1. Wiper motor in parking position. Fit the link. The installation position is identified by a a marking (parking position) on the console.

6-~

2. Connect the battery

5. Disconnect the electrical plug connection on the wiper motor.

5-96

3. Switch on the wiper motor and check the wiper position.

Tightening torques:

8Nm

Fastening screw, motor Fastening nut, link Hexagon-head bolt

M6 M8

17 (12.

10 Nm

(7.4)

(6),5)Nm

92 15 19 Removing and installing the wiper motor

Printed in Germany, 1996 986921

92 -5

Page 91

Boxster

Windshield wiper and washer system

9266

Non-adjustable spray nozzles

Note

The new spray nozzles for the windscreen washer system are not adjustable.

Do not insert a pointed object (needle) into

the nozzle bore.

The new spray nozzles must not be installed together with old spray nozzles.

A -Old version (adjustable)

B -New version (not adjustable)

662_97

92 66 Non-adjustable spray nozzles

Printed in Germany -21, 1998 986927

92 -7

Page 92

Boxster

Windshield wiper and washer system

92 60 19

Removing and installing tank for windscreen washer system

Removal

7 I tank

1. Remove left front wheel and remove the wheel housing liner.

2. Extract water from the tank and release and pull out the filler neck.

3. Disconnect the hose for the headlight cleaner nozzle at the headlight holder.

4. Carefully pull off the hose for the windscreen washer system.

5. Undo fastening screws and swing the holder

inward.

Removal

3 I tank

1. The 3 I tank is not equipped with a headlight cleaning system.

2. The tank is fastened only by one M8 x 35 hexagon-head bolt (tightening torque 20 Nm

(15.0 ftlb.)).

009_99

6. Pull tank forward out of the holder and swivel it down at the rear.

7. Disconnect electrical plug connections of pumps and fluid level indicator and remove the tank in downward direction.

010_99

Installation

7 I tank or 3 I tank

1. First push 7 I tank under the wing at front, then engage electrical plug connection of the pumps.

2. Push tank rearward into the holder and engage the electrical plug connection for the fluid level indicator.

92 60 19 Removing and installing tank for windscreen washer system

Printed in Germany -29, 1999 986929

92 -9

Page 93

Windshield wiper and washer system Boxster

3. Swivel the holder back (7 I tank) and fasten the tank. Tightening torque of the

hexagon-head bolts: M6 x 20 10 Nm (7.5 ftlb.) M8 x 35 20 Nm (15 ftlb.)

4. Engage hose for the headlight cleaning

system and carefully push on the hose

for the windscreen washer system.

5. Engage filler neck and fill in water. Perform a function test.

6. Install wheel housing liner and mount the left front wheel (tightening torque 130 Nm

(96 ftlb.)}.

92 -10

92 60 19

Removing and installing tank for windscreen washer system

986929 Printed in Germany -29, 1999

Page 94

Boxster

Windshield wiper and washer system

92 56 19

Removal

Removing and installing pump for windscreen washer system

1. Remove tank for windscreen washer system (refer to Service No. 92 60 19).

2. Remove hose to the spray nozzles at the tank and turn the pump outlet to the rear.

3. Lift pump out of the rubber sleeve.

Installation

1. Check rubber sleeve for pump, replace if necessary.

2. Install pump and tank, fill in water and perform a function test.

4. Pull hose off the pump.

Note A stuck hose can be pulled off more easily if it

is heated with a hot-air gun.

012_99

92 56 19 Removing and installing pump for windscreen washer system

Printed in Germany -29, 1999 986929

92-11

Page 95

Boxster

Windshield wiper and washer system

92 78 19 Removing and installing pump for headlight washing system

Removal

1. Remove tank for windscreen washer system (refer to Service No. 92 60 19).

2. Remove hose to the spray nozzles at the tank and turn the pump outlet to the rear.

3. Remove spacer between the pumps and lift pump out of the rubber sleeve.

Installation

1. Check rubber sleeve for pump, replace if

necessary.

2. Install pump and tank, fill in water and perform a function test.

4. Pull hose off the pump.

Note

A stuck hose can be pulled off more easily if it is heated with a hot-air gun.

011_99

92 78 19 Removing and installing pump for headlight washing system

Printed in Germany -29, 1999 986929

92 -13

Page 96

Boxster Windshield wiper and washer system

92 67 19 Removing and installing fluid level indicator

Removal

1. Remove tank for windscreen washer system (refer to Service No. 92 60 19).

2. Pull sensor for fluid level indicator out of the tank to the side.

'-",-

Installation

1. Check rubber sleeve for sensor I replace if

necessary.

2. Install sensor and tank, fill in water and perform a function test.

016_99

92 67 19 Removing and installing fluid level indicator

Printed in Germany -29, 1999 986929

92 -15

Page 97

Boxster Windshield wiper and washer system

92 72 19 Removing and installing spray nozzle for headlight washing system

Removal

1. Remove main headlights (refer to Servo No. 94 15 19).

2. Remove spray nozzle for headlight cleaning system on the left side.

3. Undo M6 hexagon nut from the spray nozzle holder.

4. Separate plug-in coupling and take out the spray nozzle.

/ \-.., ,

'-'!...

...

6. Remove spray nozzle for headlight cleaning system on the right side.

7. Undo M6 hexagon nut from the spray nozzle holder and lift the spray nozzle out.

-\\

..,..,.

8. Loosen hose clamp and pull hose off the spray nozzle.

\\~

207_99

206_99

Installation

5. Loosen hose clamp and pull hose off the spray nozzle.

Note A stuck hose can be pulled off more easily if it

is heated with a hot-air gun.

92 72 19 Removing and installing spray nozzle for headlight washing system

Printed in Germany -29, 1999 986929

1. Push hose as far as it will go onto the new spray nozzle and fasten the hose clamp.

2. Reinstall new spray nozzle with holder in the

same position. Tightening torque of the M6 hexagon nut 5 Nm (3.5 ftlb.)

92 -17

Page 98

Windshield wiper and washer system

3. Push plug-in coupling to lock with an audible click, then check the locking with a slight pull.

4. Install main head headlight and check position of the spray nozzle in the cover trim. Remove

the main head again and centre the spray

nozzle if necessary.

5. Install main headlight, check it and perform a function test.

Boxster

92 -18

92 72 19

Removing and installing spray nozzle for headlight washing system

986929 Printed in Germany -29, 1999

Page 99

Boxster

Lights, lamps, switches exterior

94 15 19

A -open B -close

Removing and installing headlights

11/1 -96

1. The tool kit contains a wrench for opening and closing the headlights.

2. When installing, press headlights firmly into the wing.

3. Insert plugs after installation,

Note

Headlights must not be covered with a front apron or foil when switched on.

986941

94 15 19 Removing and installing headlights

Printed in Germany -5, 1996

94 -1

Page 100

Boxster

Lights, lamps, switches exterior

94 15 05

Headlights: basic adjustment in the body

Note

The headlights have been fitted into the body at the factory.

Adjustments should be made only in the event of

an accident repair or replacement of headlights

Adjustment instructions

Items Band C

The headlamp housing should lie approximately

2 mm below the body edge.

Note

The fastening nuts of the adjusting components are fitted at the factory as shown in Figure 293 -96.

353 -96

Item A

The transition from the headlight housing to the

body is in the same plane (level).

293 -96

94 15 05 Headlights: basic adjustment in the body

Printed in Germany, 1996 986941

94 -3

Porsche Boxster 1999 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual