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
7 Body equipment, interior
8 / 9 Air conditioning / Electrics
9 Circuit diagrams, part 1 (up to and including the '99 model) *5
9 Circuit diagrams, part 2 (as of the '00 model) *6
.1
The two folders with Group 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).
*2
The second folder "Group 0 -Diagnosis, part 2" (as of Repair Group 69) includes the further
Repair Groups belonging to Group O.
.3
The two folders with Group 1 are to be regarded as one folder; i.e. file the "Technical Information"
notices only in front of the repair descriptions in the folder "Group 1 -Engine, part 1" (up to
Repair Group 13).
*4
The second folder "Group 1 -Engine, part 2" (as of Repair Group 15) includes the further Repair
Groups belonging to Group 1.
Foreword
Printed in Germany -34, October 1999
VORW.CHP
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.
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.
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.
87.
87.
87.
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
1
Boxster
Air conditioning
8
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
M823 (17)
M8
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
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
\\\
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,.--
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6. Release heat exchanger and pull it up and out.
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~)
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--=
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288 -96
Installation
1. Seal cover over the heat exchanger airtight
with butyl adhesive.
I~
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
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.;
M
~=\ ~-
j~'
289 -96
~
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85 10 19 Removing and installing mechanical heating and fresh-air control
Printed in Germany, 1996 986851
85 -1
Boxster
Ventilation
85 15 19Removing 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
VentilationBoxster
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
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
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
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
c
A
...
/"
B
0
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h
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00
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
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.
\)
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IU-
y
://:
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/"
-/
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
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
VentilationBoxster
85 30 19Removing 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
""""
J'
cb
j
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.
~
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-
I~
a
{/
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;-
85 30 19 Removing and installing heater/fresh-air blower motor
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
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
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
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
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
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
I;
,
:
/
\.
A -High-pressure
B -Low-pressure
The charging valves are located in the area of
the front right spring strut.
1 -96
87-4
8.
~::.~:::::::::=::::=:::.;.,,-'
~~~
87 03 17 Assembly work on the air-conditioning system
986871 Printed in Germany -1996
Boxster
Removing refrigerant by suction and
cleaning
Air conditioning
A
A
B
A
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
(:Ieaning the refrigerant
BJJ'(-..
.:::::~~~~~=~
A
A
A
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
Boxster
Draining off old refrigerant oil
Air conditioning
B
A
~
-
~
m
HFA 134a
~.
A
A 8*3
"1} """'f
*2
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
E'vacuating
Air conditioning
B
Boxster
B
A -closeB -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
Topping up with new refrigerant oil
A
A
A -close
1 -ON/OFF
87 03 17 Assembly work on the air-conditioning system
Printed in Germany -1996 986871
B -open
87 -9
Filling via the high-pressure side
Air conditioning
Boxster
AI'
A
.-.
-
HFA 134a
A
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
m
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