porsche 986 boxster
REPAIR MANUAL
PORSCHE 986 BOXSTER REPAIR MANUAL - English Workshop Manual, Wiring Diagram and Owners Manual to vehicles Porsche 986 Boxster (1996-2004). INDEX: INTRODUCTION (22 pages) ENTIRE VEHICLE - GENERAL (113 pages) General -Engine -Transmission -Running Gear -Body -Electrics -Technical Data -Plug-in couplings for pipelines (new system) -Lifting the vehicle -Power supply - general (work instructions after disconnecting the battery) -Technical data Boxster (2.7 I) -Technical data Boxster S (3.2 l) Sales Check -Removing transport arrangement -Convertible top: Checking operation coding alarm system for Great Britain and Belgium Maintenance -Maintenance schedule -Maintenance DIAGNOSIS, PART 1 (UP TO REPAIR GROUP 45) (161 pages) General -Installation location, diagnostic socket -Operating instructions, Porsche System Tester 2 DME diagnosis -System M 08 Tiptronic diagnosis -System G 40 Anti-lock brake system diagnosis -System ABS 5.3 and ABS/TC 5.3 DIAGNOSIS, PART 2 (AS OF REPAIR GROUP 69) (388 pages) Airbag Diagnosis -System B 04 -System B 05 Seat memory diagnosis -System S 01 Heating diagnosis -System H 01 Alarm system diagnosis -System I 16 Instrument cluster diagnosis -System K 0X PCM diagnosis -System N 01 ParkAssistent diagnosis -System P 01 Headlight beam adjustment diagnosis -System HBA 01 Alarm system diagnosis -System I 32 ENGINE, PART 1 (UP TO REPAIR GROUP 13) (285 pages) Engine -Technical data engine M96/20 -Differences between Boxster 2.5l, 27l and Boxster S (3.3l) engines -Tightening torques for engines M96/20 (2.5l), M96/21 (3.2l), M96/22 (2.7l) Engine - Crankcase, suspension -Removing engine, M96/20 (2.5l) with manual transmission -Special tools -Adjusting tool -Removing engine -Installing engine, M96/20 (2.5l) with manual transmission -Special tools -Adjusting tool -Special notes -Installing engine -Tightening torques -Disassembling and assembling engine -Disassembling and assembling positive crankcase ventilation -Disassembling and assembling crankcase halves, engine M96/20, M96/21, M96/22 -Mounting instructions -Assembling the crankcase halves -Tightening torques -Removing engine, M96/20 (2.5l) with Tiptronic transmission -Special tools -Adjusting tool -Removing engine -Installing engine, M96/20 (2.5l) with Tiptronic transmission -Special tools -Adjusting tool -Special notes -Installing engine -Tightening torques -Removing engine, M96/21 (3.2l) and m96/22 (2.7l) with manual transmission -Special tools -Adjusting tool -Removing engine -Installing engine, M96/21 (3.2l) and M96/22 (2.7l) with manual transmission -Special tools -Adjusting tool -Special notes -Installing engine -Tightening torques -Disassembling and assembling engine carrier Engine - Crankshaft, pistons -Removing and installing drive belt -Removing and installing deflection rollers for drive belt -Removing and installing tensioning roller for drive belt -Removing and installing belt tensioner -Disassembling and assembling belt tensioner -Disassembling and assembling bearing housing with crankshaft -Removing and installing crankshaft -Removing and installing pistons -Removing and installing crankshaft sealing ring (engine installed) -Removing and installing crankshaft sealing ring (engine installed) -Removing and installing pistons - Boxster S -Removing and installing pistons for engine type M96/22 (2.7l) ENGINE, PART 2 (AS OF REPAIR GROUP 15) (150 pages) Engine - Cylinder head, valve drive -Disassembling and assembling cylinder head -Removing and installing valve springs -Removing and installing valve stem seal -Removing and installing camshafts -Removing and installing valve tappets (engine removed) -Completing camshafts -Sealing cover for camshaft housing (cylinder head cover) -Checking guide for valve tappets -Removing and installing oil protection tube (engine installed) -Removing and installing valve tappet (engine installed) -Removing and installing closure cap for camshaft bore -Removing and installing sealing ring for intermediate shaft -Removing and installing solenoid hydraulic valve -Reworking cylinder head -Camshafts assignment Engine Lubrication -Removing and installing air/oil separator -Removing and installing oil pan (engine installed) -Removing and installing oil pump with coolant guide housing -Removing and installing oil extraction pumps -Removing and installing oil extraction pump (engine installed) -Removing and installing oil-water heat exchanger - Engine installed -Checking oil pressure Engine Cooling -Removing and installing cooling pump -Removing and installing coolant regulator -Removing and installing coolant temperature sensor -Draining and topping up with coolant -Checking cooling system for leaks FUEL, EXHAUST, ENGINE ELECTRONICS (96 pages) Fuel supply, control -Checking fuel pressure -Checking quantity delivered by fuel pump -Removing and installing fuel pump -Calibrating fuel level sensor system -Removing and installing fuel return line Fuel system, electronic injection -Disassembling and assembling fuel ring pipe -Disassembling and assembling intake distributor -Diagram of hose connections -Disassembling and assembling air guide cowl -Programming DME control module -Removing and installing mass air flow sensor -Removing and installing DME control module -Removing and installing oxygen sensor -Removing and installing throttle body - Boxster S -Removing throttle body - Boxster S -Installing throttle body - Boxster S -Removing and installing injection valve - Boxster S -Removing injection valves - Boxster S -Installing injection valves - Boxster S -Removing and installing intake distributor - Boxster S -Removing intake distributor - Boxster S -Installing intake distributor - Boxster S Exhaust system -Replacing exhaust system Starter, power supply, cruise control -Removing and installing starter -Removing and installing three-phase generator -Removing and installing cruise control actuator -Removing and installing starter - Boxster S -Work instructions after disconnecting the battery Ignition system -Removing and installing rotor for hall sendor -Removing and installing pulse sender TRANSMISSION, MANUAL TRANSMISSION (136 pages) Power transmission -Technical data (transmission G 86) Clutch, control -Disassembling and assembling clutch -Bleeding the clutch system -Removing and installing clutch pedal -Clutch boost spring: allocation and grease specification Manual transmission - Actuation, housing -Changing and checking transmission oil (transmission G 86) -Removing and installing the shift console -Removing and installing shift and selector cables -Adjusting intermediate lever (transmission connection) -Removing and installing transmission G 86 -Disassembling and assembling transmission G 86 -Disassembling and assembling transmission case cover (transmission G 86) -Disassembling and assembling transmission case (transmission G 86) Manual transmission - Gears, shafts, int. gearsh. -Disassembling and assembling the input shaft (transmission G 86) -Adjusting the input shaft (transmission G 86) -Disassembling and assembling output shaft (transmission G 86) Final drive - Differential, differential lock -Removing and installing differential (transmission G 86) -Disassembling and assembling the differential (transmission G 86) -Adjusting the drive set (transmission G 86) TRANSMISSION, AUTOMATIC TRANSMISSION (87 pages) Transmission -Technical data Automatic clutch - Torque converter -Removing and installing torque converter -Removing and installing sealing ring for torque converter Automatic transmission - Auction, ass. Housing -Removing and installing selector lever cable -Adjusting selector lever cable -Removing and installing selector knob -Removing and installing selector support -Removing and installing shiftlock solenoid -Removing and installing deflection lever -Removing and installing tiptronic transmission -Checking and topping up ATF fluid -Changing ATF fluid -Removing inner oil tube -Removing and installing multi-function switch -Removing and installing gasket for spur gear cover -Removing and installing sealing ring for selector shaft Automatic transmission - Gears, control -Removing and installing hydraulic control unit -Removing and installing sensor for transmission input speed -Removing and installing transmission speed sensor -Removing and installing wiring harness -Removing and installing ATF cooler Final drive - Differential, differential lock -Changing and checking transmission oil in final drive -Disassembling and assembling final drive -Removing and installing differential -Removing and installing sealing ring for short flanged shaft -Removing and installing long flanged shaft -Removing and installing sealing ring for long flanged shaft -Removing and installing double sealing ring for final drive/transm. housing RUNNING GEAR (206 pages) Running gear -Removing transport arrangement -Overview of Boxster running gear -General information - Boxster S -Notes on repair instructions - Boxster S Front wheel suspension, drive shafts -Tightening torques for front axle -Removing and installing rear spring strut -Disassembling and assembling front spring strut -Installing caster eccentric -Removing and installing front wheel bearing -Removing and installing front axle strut (control arm) Rear wheel suspension, drive shafts -Tightening torques for rear axle -Removing and installing rear spring strut -Disassembling and assembling rear spring strut -Removing and installing diagonal brace -Removing and installing cable -Removing and installing rear wheel bearing -Removing and installing rear tie rod (toe control arm) -Removing and installing drive shaft -Removing and installing rear axle strut (control arm) -Removing and installing rear stabilizer -Removing and installing rear-axle cross member -Removing and installing sheetmetal brace Wheels, tires, suspension alignment -Wheels and tyres (tyre pressure / mounting wheel on vehicle) -Adjustment values for suspension alignment -Alignment cards for Boxster/Boxster S -Complete suspension alignment -General tyre mounting instructions -Checking rims -Tyre mounting with conventional mounting machines -Identifying size of 18-inch Turbo wheels (Technologie wheels) -Tyre mounting for critical wheels/tyre pairs Anti-Lock Brake System (ABS) -Important information on ABS 5.3 and ABS/TC 5.3 -ABS 5.3 system description -ABS/TC 5.3 system description -Component arrangement (ABS and ABS/TC) -Function of individual components -ABS test with Porsche System Tester 2 -Removing and installing front speed sensor -Removing and installing rear speed sensor -Removing and installing hydraulic unit Brakes - Brake mechanics -Tightening torques for brake mechanics -Technical data (brake disc wear limit) -Technical data - Boxster S (brake disc wear limit) -measuring brake pad thickness -Removing and installing front disc brake pads -Removing and installing rear disc brake pads -Removing and installing front disc brake pads - Boxster S -Removing and installing rear disc brake pads - Boxster S -Adjusting brake push rod (adjusting stop light switch) -Adjusting parking brake shoes -Removing and installing front brake disc -Removing and installing rear brake disc -Removing and installing parking brake shoes -Measuring lateral runout of front brake discs -Measuring rear brake disc lateral runout -Removing and installing brake pedal Brakes - Hydraulics, regulator, booster -Tightening torques for brake hydraulics -Bleeding brakes -Changing brake fluid -Removing and installing brake master cylinder -Removing and installing brake booster Steering -Tightening torques for steering -Test and assembly work on power steering -Removing and installing steering wheel (airbag) -Replacing steering system after accident damage -Removing and installing steering gear -Plug couplings for steering hydraulics -Plug-in couplings for pipelines -Removing and installing ignition switch -Removing and installing lock barrel -Removing and installing hydraulic pump -Replacing steering lock BODY (237 pages) Body -Safety instructions for body repair -Safety instructions for disassembling components -Safety instructions for air conditioning -Safety instructions for fuel tank -Safety instructions for paintwork, glass, upholstery, linings -Safety instructions for airbag system -Safety instructions for door -Safety instructions for sliding roof -Safety instructions for rear spoiler -Safety instructions for rear window -Safety instructions for windscreen -Safety instructions for heat shields -Safety instructions for cabriolet convertible top -Safety instructions for roll-over protection system -Safety instructions for plug location plan (body) -Safety instructions for water drains (body) -Safety instructions for welding -Safety instructions for Teromix-6700 two-component adhesive -Safety instructions for hydraulic system -Safety instructions for hardtop -Safety instructions for belt strap holder -General information and quality notes -Electronic control modules -Protection against overvoltage -Replacing control modules -Tools and metalworking tools for body repairs -Repair check dimensions -Body parts of high-strength steel -Diagram of safety passenger compartment -Water drainage plan -Plug location plan -Body gap dimensions -Diagram - key to symbols for welding work -Seam seals -Accessories -Front lid -Doors -Rear lid -Work sequence for accident repair Body front -Removing and installing wheel housing liner -Removing and installing the wing -Replacing closing panel -Cutting out closing panel and front floor panel -Preparing closing panel and front floor panel for installation and fitting -Welding in closing panel and front floor panel -Tools and materials -Replacing wheel housings and side members (sectional repair) -Cutting out wheel housings and side member -Preparing wheel housings and side members for installation and fitting -Welding in wheel housing and side members -Replacing wheel housings -Removing wheel housing, lower shell and outer side member from the body -Preparing wheel housing, lower shell and outer side member for installation and fitting -Welding wheel housing, lower shell and outer side members into the body -Tools and materials -Cleaning front water drains -Replacing front wall -Cutting out front wall -Preparing front wall for installation and fitting -Welding in front wall -Tools and materials Body centre, roof, frame -Removing and installing underbody cover -Replacing outer lower side member -Separating outer lower side member -Preparation for installation of lower side member and fitting -Welding lower side member -Tools and materials -Replacing seat cross member -Cutting out seat cross member -Preparation of seat cross member for installation and fitting -Welding in seat cross member -Tools and materials Body rear -Removing and installing wheel housing liner -Replacing side section -Cleaning rear water drains -Replacing end cross member -Separating end cross member -Preparing the rear end cross member for installation and inserting -Inserting end cross member -Replacing rear trunk floor panel -Separating rear trunk panel -Preparing the rear trunk floor panel for installation and inserting -Inserting rear trunk floor panel -Replacing rear cover panel -Separating rear cover panel -Preparing the rear cover panel for installation and inserting -Inserting the rear cover panel -Tools and materials -Replacing rear wheel housing -Cutting through rear wheel housing -Preparing the rear wheel housing for installation and fitting -Welding in rear wheel housing -Tools and materials Lids, flaps -Disassembling and assembling front lid -Disassembling and assembling rear lid -Replacing the model logo -Disassembling and assembling release for lid -Disassembling and assembling release for rear lid -Removing and installing lid hinge -Removing and installing lower part of lid lock at rear -Disassembling and assembling release for front lid- from model year 2001 -Disassembling release for front lid -Assembling release for front lid -Disassembling and assembling release for rear lid - from model year 2001 -Disassembling release for rear lid -Assembling release for rear lid -Removing and installing lower part of front lid lock - from model year 2001 -Removing and installing bowden cable for lock actuation Door front, central locking system -Removing and installing door -Disassembling and assembling door -Disassembling door -Assembling door -Adjustment instructions for assembly of the door -Diagram: sheetmetal for assembly of the door -Basic setting of door lock -Basic setting of the door lock before installation -Standardising the system -Standardising the power windows -Blockage detection function -Precondition for operation of the power windows -Fitting the door window in the clamping jaws -Adjusting the door window angle in the vehicle's longitudinal direction -Adjusting the door window height -Adjustment procedure: -Checking the adjustment: -Adjustment of the door window pressing force on the door seal at the top and sides -Adjustment procedure: -Checking the adjustment: -Adjusting the lower stop of the power window unit -Disassembling and assembling door handle -Setting the door BODY EQUIPMENT, EXTERIOR (275 pages) Body equipment -Colour range for 1997 models -Colour range for 1998 models -Colour range for 1999 models -Colour range for 2000 models -Processing of Porsche 2-component window bonding agents -Overview of tools and materials -Mixing procedure -Colour range for 20001 models -Exterior paintwork solid -Exterior paintwork metallic / pearl -Special paintwork metallic / pearl Convertible top, hardtop -Removing and installing convertible top -Diagram of convertible top -Overview of convertible-top components up to model year 1999 -Overview of microswitch test plan up to model year 1999 -Overview of convertible-top components up to model year 2000 -Removing convertible top -Installing convertible top -Replacing convertible-top covering -Removal overview of the convertible-top covering components, part 1 -Removal overview of the convertible-top covering components, part 2 -Removal convertible-top covering -Installation overview of the convertible-top covering components, part 1 -Installation overview of the convertible-top covering components, part 2 -Installing the convertible-top covering -Replacing convertible-top frame -Overview of replacing convertible-top fram, part 1 -Overview of replacing convertible-top fram, part 2 -Overview of replacing convertible-top fram, part 3 -Overview of replacing convertible-top fram, part 4 -Replacing convertible-top frame -Conversion measure on the tension bow for the tension strap in vehicles produced before 12.04.2000 -Conversion measure on the tension bow for the roof liner in vehicles produced before 12.04.2000 -Removing and installing hardtop -Disassembling and assembling hardtop -Removal instructions for hardtop assembly fixture -Adjusting convertible top gear -Troubleshooting in convertible top operation -Removing and installing hardtop fastening -Adjusting the hardtop -Removing and installing roof liner -Removal overview of roof liner -Removing roof liner -Installation overview of roof liner -Installing roof liner -Replacing the tension cable -Removing the tension cable -Installing the tension cable -Care and cleaning of the convertible top -Cleaning the convertible top -Care of convertible top -Care of convertible-top seals Bumpers -Removing and installing front spoiler -Removing front spoiler -Installing front spoiler -Removing and installing rear spoiler -Disassembling and assembling front spoiler -Disassembling front spoiler -Assembling front spoiler -Disassembling and assembling front spoiler - Boxster S -Disassembling front spoiler -Assembling front spoiler -Removing and installing bumper and accessories Glazing, window control -Removing and installing the windscreen -Removing the windscreen -Fitting the windscreen -Overview of tools and materials -Removing and installing rear window (hardtop) -Removing and installing power window motor -Checking function of heating for rear window Exterior equipment -Disassembling and assembling the rear-view mirror -Removing and installing rear spoiler -Removing and installing the engine compartment vent -Checking function of heating for mirror glass Interior equipment -Removing and installing the interior rear-view mirror -Bonding the interior rear-view mirror -Removing and installing centre console (front section) -Removing and installing centre console -Disassembling and assembling centre console -Disassembling and assembling cover for the oddments tray -Removing and installing inner sill (passenger's side) -Removing inner sill -Installing inner sill -Removing and installing inner sill (driver's side) -Disassembling release for front lid -Assembling release for front lid Passenger protection -Safety regulations for airbag vehicles -Disposal of airbag units -Removing and installing the driver's airbag unit -Removing and installing the contact unit -Removing and installing the triggering unit for the airbag -Removing and installing the passenger's airbag unit -Removing and installing the side airbag unit -Removing and installing roll-over bar BODY EQUIPMENT, INTERIOR (80 pages) Linings, insulation -Disassembling and assembling the dashboard -Disassembling the dashboard -Removing the regulator for wiping interval -Removing the cigarette lighter -Assembling the dashboard -Installing the regulator for wiping interval -Installing the cigarette lighter -Removing and installing the dashboard -Removing and installing cowl panel cover -Disassembling and assembling door trim panel Seat frames -Removing and installing front seat -Disassembling and assembling the seat frame -Disassembling and assembling backrest frame Seat upholsteries, cover -Removing and installing covering from front seat -Removing and installing covering from front backrest AIR CONDITIONING (146 pages) Air conditioning -Technical data for the air conditioning system Heating -Removing and installing heat exchanger Ventilation -Removing and installing mechanical heating / fresh air control -Removing and installing heating / fresh air unit -Installing and adjusting bowden cables of the heating/fresh-air control -Removing and installing heater/fresh-air blower motor -Removing and installing drive motor for frsh-air/recirculation valve -Removing and installing bulb for rotary blower switch Air conditioning -Safety regulations when handling refrigerant R 134a -Assembly work on air the conditioning system -Nominal values for pressures and temperatures -Removing and installing pressure switch for the air-conditioning system -Removing and installing fluid tank -Removing and installing the compressor -Removing and installing the expansion valve -Installing and removing the heating/air-conditioning unit -Removing and installing the condensor -Removing and installing the magnetic coupling -Removing and installing drive motors of the heater/air-conditioning unit -Removing and installing drive motor for fresh-air/recirculation valve -Removing and installing outside temperature sensor -Removing and installing inside temperature sensor -Removing and installing footwell blower outlet sensor -Removing and installing blower driver -Removing and installing fan for condenser -Removing and installing ballast resistor for fan motor -Installing and removing the heating/air-conditioning unit ELECTRICS (146 pages) General -Work instructions after disconnecting the battery Instruments, alarm system -Removing and installing instrument cluster -Disassembling and assembling instrument cluster -Removing and installing horn -Setting ahead the total mileage counter in the instrument cluster Radio, telephone, on-board computer, navigation -Setting hands-free microphone to telephone type -Removing and installing sensor for ParkAssistent -Removing and installing display and operator control unit (PCM) -Removing and installing navigation unit -Removing and installing GPS antenna -Retrofitting mobile communication systems -Adjusting (calibrating) PCM navigation unit Windshield wiper and washer system -Removing and installing wiper link -Removing and installing wiper blades -Removing and installing wiper motor -Non-adjustable spray nozzles -Removing and installing tank for windscreen washer system -Removing and installing pump for windscreen washer system -Removing and installing pump for headlight washing system -Removing and installing fluid level indicator -Removing and installing spray nozzle for headlight washing system Lights, lamps, switches exterior -Removing and installing headlights -Headlights - basic adjustment in body -Removing and installing main light switch -Removing and installing hazard warning light switch -Masking film for left/right-hand traffic -Bulb overview and installation instructions -Removing and installing halogen bulb -Removing and installing bulb for parking light -Removing and installing bulb for fog light -Removing and installing bulb for direction indicator light -Removing and installing bulb for side direction indicator light -Removing and installing bulb for tail light -Removing and installing for number plate light -Removing and installing bulb for raised brake light -Removing and installing gas discharge lamp (Litronic headlights) -Removing and installing control module for gas discharge lamp -Removing and installing ignition unit for gas discharge lamp -Removing and installing servo motor for automatic headlight beam adjustment -Left / right traffic conversion for Litronic headlights -Troubleshooting on Litronic headlight (dipped beam) -Removing and installing angle sensor for automatic headlight beam adjustment -Removing and installing angle sensor for automatic headlight beam adjustment -Removing and installing control module for automatic headlight beam adjustment Lights, lamps, switches interior, theft protection -Removing and installing signal converter/immobiliser -Removing and installing passenger compartment monitoring sensor -Additional alarm system M 534 -Radio remote control in hand-held transmitter does not function -Vehicles with alarm system without radio remote control -Bulb overview and installation instructions -Removing and installing bulb for door warning light -Removing and installing bulb for luggage compartment light -Removing and installing bulb for interior light -Removing and installing bulb for instrument cluster -Teaching hand-held transmitter -Reading out and transferring remote control -Disassembling and assembling hand-held transmitter CIRCUIT DIAGRAMS (225 pages) Wiring -Removing and installing current distributor -Removing and installing fusible element in the current distributor -Allocation of free fuse connection points -Measurement of closed-circuit current -Repair of main wiring harness -Repair of rear wiring harness -Wiring diagram for '97 model Boxster -Wiring diagram for '98 model Boxster -Wiring diagram for '99 model Boxster CIRCUIT DIAGRAMS (213 pages) Wiring -Wiring diagram for '00 model Boxster (986) -Wiring plan for '01 model Boxster (986) 986 OWNER'S MANUAL (255 pages) -Table of Contents -Controls, Instruments -Shifting Gear -Mobile Roofs -Maintenance, Car Care -Practical Tips, Emergency Service -Vehicle Identification, Technical Data -Index
Porsche 986 Boxster (1996-2004) - Workshop Manual - Wiring Diagrams - Owners Manual
inicio - index
coche - car
moto
4x4
quad - buggy
cami n - truck
e-mail