Porsche BOXTER - User manual

TechnicalManual

-.8e;~~

TechnicalInformation

Contents:

Group9

Electrics

WKD483 521

www.WorkshopManuals.co.uk

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Boxster Foreword

Foreword

TheworkshopdocumentationfortheBoxstermodelhasthedesignation"Boxster" TechnicalManual

andcontainsTechnicalInformationaswellasinstructionsonRepairs.

The integrationof the technicalinformationpublishedin the "Boxster"TechnicalManualwith the

descriptivematter on repairsprovidesthe userwith a complexreferencework that combinesinto one

book associatedor cross-referencedmaterialof relevanceto workshopsandoriginatingfrom various

informationmedia.

The"Boxster"TechnicalManualconsistsof 15 folders,subdividedinto the followingGroups

0 Entirevehicle-General

0 Diagnosis,part 1 (upto RepairGroup45) *1

0 Diagnosis,part 2 (asof RepairGroup69) *2

1 Engine,part 1 (upto RepairGroup 13) *3

1 Engine,part 2 (asof RepairGroup 15) *4

2 Fuel,exhaust,engineelectronics

3 Transmission,manualtransmission

3 Transmission,automatictransmission

4 Runninggear

5 Body

6 Bodyequipment,exterior

7 Bodyequipment,interior

8 / 9 Air conditioning/ Electrics

9 Circuitdiagrams,part1 (upto andincludingthe '99 model)*5

9 Circuitdiagrams,part 2 (asof the '00 model)*6

.1 Thetwo folders with Group0 are to be regardedas one folder;i.e. file the "TechnicalInformation"

notices onlyin front of the repairdescriptionsin the folder "Group0 -Diagnosis, part I"

(up to Repair Group 45).

*2 Thesecond folder "Group0 -Diagnosis, part 2"(as of Repair Group 69) includesthe further

RepairGroupsbelongingto GroupO.

.3 Thetwo folders with Group1 are to be regardedas one folder;i.e. file the "TechnicalInformation"

notices onlyin front of the repair descriptionsin the folder "Group1 -Engine, part 1" (up to

RepairGroup13).

*4 Thesecondfolder "Group1 -Engine,part2"(as of RepairGroup 15)includesthefurtherRepair

Groupsbelongingto Group1.

VORW.CHP

Foreword

Printed in Germany -34, October 1999

www.WorkshopManuals.co.uk

Purchased from www.WorkshopManuals.co.uk

Foreword Boxster

.!i Thetwo folders with Group9 are to be regardedas one folder;i.e. file the "TechnicalInformation"

notices onlyin front of the repair descriptionsin the folder "Group9 -Circuit diagrams,part 1" (up to

the '99 model).

*Ei Thesecond folder "Group9 -Circuit diagrams,part 2" (as of the '00 model) includesthe further

circuitdiagramsbelongingto Group9.

The"Boxster"TechnicalManualhasthesamestructureineachfolder,withthefollowingbreakdownfor

allGroups:

Title page, "Boxster" Technical Manual

> Foreword

Title page:"Technical Information"

> Table of Contents,Technicalinformation

> Technicalinformation

Title page: "Repair"

> RepairGroups:overview

> Table of Contents,repairs

> General/technical data

> Instructionson repairs

As can be seenfrom the breakdown,the publishedTechnicalInformationis inthe front part of each

folder -numbered accordingto the Groups.TheTable of Contentsassignedto eachGroupwill be

periodicallyupdated.

Followingthe TechnicalInformation,separatedbya title page,the instructionson repairs-assigned

accordingto the Groupsor brokendowninto RepairGroups-are includedinthe folder.

Theinstructionsonrepairswillbeextendedandupdatedbymeansofsupplements.

Note

Sheetsthat alreadyexist in the "Boxster"TechnicalManualandare updatedor revisedand thereby

exchangedbya supplementare designated"Replacementsheet".Revisionsor technicalmodificationson

pages of these replacementsheetsare identifiedfor the userwith a vertical bar at the margin.

Foreword

Printed in Germany -34, October 1999

VORW.CHP

www.WorkshopManuals.co.uk

Purchased from www.WorkshopManuals.co.uk

Overview of repair groupsBoxster

Group 0: Entire vehicle -General

Maintenance 0

Group 0: Diagnosis

Salescheck

On-boarddiagnosis

DMEdiagnosis

Tiptronicdiagnosis

ABSdiagnosis

Group 0: 0

Diagnosis

Airbagdiagnosis

Seatmemorydiagnosis

Heatingdiagnosis

Alarmsystemdiagnosis

PCMdiagnosis

ParkAssistentdiagnosis

HBAdiagnosis

Group 1: Engine

Engine-Crankcase, suspension

Engine-Crankshaft, pistons 1

Group 1: Engine

Engine -Cylinder head, valve drive

Engine -Lubrication

Engine -Cooling

Group 2: Fuel, exhaust, engine electronics

Fuelsupply,control

Exhaustsystem,turbocharging

Fuelsystem,electronicinjection

Fuelsystem,K-Jetronic

Exhaustsystem

Starter,powersupply,cruisecontrol

Ignitionsystem 3

Group 3: Transmission, manual transmission

Clutch,control

Manualtransmission-Actuation, housing

Manualtransmission-Gears, shafts,intogearsh.

Finaldrive,differential,differentiallock

Group 3: Transmission, automatic transmission

Torqueconverter

Automatictransmission-Actuation, housing

Automatictransmission-Gears, control

Finaldrive, differential,differentiallock

Overview of repair groups

Printed in Germany -34, October 1999 REPGRU.CHP

www.WorkshopManuals.co.uk

Purchased from www.WorkshopManuals.co.uk

Overview of repair groups Boxster

Group 4: Running gear

Frontwhee!suspension,drive shafts

Rearwheel suspension,drive shafts

Wheels,tires, suspensionalignment

Anti-LockBrakeSystem(ABS)

Brakes-Brake mechanics

Brakes-Hydraulics, regulator,booster

Steering

Group 5: 5

Body

Bodyfront

Bodycenter, roof, frame

Bodyrear

Lids,flaps

Door front,centrallocking system

Group 6: Body equipment, exterior

Slidingroof

Convertibletop, hardtop

Bumpers

Glazing,windowcontrol

Exteriorequipment

Interiorequipment

Passengerprotection 7

Body equipment, interior

Linings,insulation

Seatframes

Seatupholsteries,covers

Group 7:

Group 8: Air conditioning

Heating

Ventilation

Air conditioning

Auxiliaryair conditioningsystem

Group 9 Electrics

Instruments,alarmsystem

Radio,telephone,on-boardcomputer,navigation

Windshieldwiper andwashersystem

Lights,lamps,switchesexterior

Lights,lamps,switches interior,theft protection

Group 9: Circuit diagrams

Wiring(upto andincludingthe '99 model)

Group 9: Circuit diagrams

Wiring(fromthe '00 model)

Overview of repair groups

Printed in Germany -34, October 1999

REPGRU.CHP

www.WorkshopManuals.co.uk

Purchased from www.WorkshopManuals.co.uk

Boxster Table of Contents

8Air conditioning

Air conditioning

Technical data for the air conditioning system 8 -1

8023 19 Heating

Removingandinstallingheatexchanger 80

85- 1

85- 3

85- 7

85-11

85-13

85-15

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.

87.

87-

87.

Air conditioning

Safety regulations when handling refrigerant R 134aAssembly 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.

8 Air conditioning

Printed in Germany -12, 1997 986TOC

0317

8319

5519

3419

7019

0119

5019

2719

2019

5919

8219

5819

7819

5319

6919

0219

-1

-2

-13-15

.17

.19

.23

-25.29

-31.33

-35

.39

.41

.43

.45

-47

-49

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Air conditioning

Boxster

8Technical data for the air-conditioning system

Compressor type 7 S8 16

Refrigerantquantity 850 g refrigerant R 134a

195 :f: 15 cm3NO8

Refrigerant oil in the compressor

Tightening torque in Nm (ftlb.]

Hexagon-head bolts on Thread

M6 9 (6.5)

Expansionvalve

6 (4.5)

M8 23 (17)

Compressor

M8 23 (17)

Refrigerantline

M 10 26...36(19...27)

Oilfiller screw

M6 6 (4.5)

Fluidtank

M8 14(10.5)

Flangeconnectionsof

refrigerantlines

Note

Wheninstallingthe refrigerantlines,the screwconnectionsandthe a-rings mustbewettedwith

refrigerantoil.

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

8 -1

8 Technical data for the air-conditioning system

Printed in Germany -12, 1997 9868_1

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Boxster Heating

80 23 19 Removing and installing heat exchanger

Removal

1. Removecoversfrom heatingandair-condition-

ing system,batteryandfluid reservoir. Discon-

nectbattery andcoverterminalor battery.

6. Releaseheatexchangerandpullit upandout.

~) )

2. Removethe entirewiper linkwith wiper motor

(seeRepairGroup92). '""-'

,: "'"

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

3. Loosenrightdomestrutandbracketatthe

cowlframeandremove. ~~---='

u--=

\"'"'" \\\ a:\~

~,~ .~ \\ -

,.--

~288 -96

'/ ""

\Installation

1.Sealcoverovertheheatexchangerairtight

withbutyladhesive.

\. 2. Replacecoverifdamaged.

287 -96

4. Clampshutbothheaterhosesinfrontofthe

heatexchangerusinga commerciallyavailable

hoseclamp.Loosenheaterhosesattheheat

exchangerandpulloff.

3. The heatexchangeris connectedto the en-

ginecooling system,and coolantflows

throughit whenthe engineis running. After re-

movingor installingthe heatexchangerI vent

the coolingsystem(seeRepairGroup19).

5. Carefullyremovecoverovertheheatex-

changer.

80 -1

80 23 19Removing and installing heat exchanger

Printed in Germany. 1996 986801

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Boxster Ventilation

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

Removal

1. Carefullyunclipbafflefromtheheatingand

fresh-aircontrol.

Installation

1. Clipin Bowdencablesandroute carefully(do

not bend),

2. Unscrewfasteningscrews (4 ea.)andpullcorr

trol moduleout ofthe dashboard. 2. Engageelectricalplugconnections:do not

jam cables.

3. Pulloffelectricalplugconnection.UnclipBow-

dencablesandpulloutupwardsor detach

cables.LabelBowdencablesbeforeremoval.

.,..

..U.;

I!!-

~=\~-

j~'

289 -96

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

Printed in Germany, 1996 986851

85 -1

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Ventilation

Boxster

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

Removal

1.Removecoversoverheatingandfresh-aircon-

trol, batteryandfluidreservoir.Disconnectbat-

teryandremove.

4. Looseninstrumentpanelanduncliprightside

upwards.Disconnectelectricalplug connec-

tions.

2. Removesteeringwheelandloosensteering-

columnpanel.Complywithsafetyregulations

whenhandlingairbagunits(seeRepairGroup

169).

3. Loosencentral screw (clamp)atthe steering-

columnswitchfrom belowandpullforward a

little. Removetop coverand disconnectelectri-

cal plugconnections.Removesteering-column

switch.

108- 96

5. Removesteering-columncover(4screws).

107-96

109 -96

85 -3

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

Printed in Germany, 1996 986853

www.WorkshopManuals.co.uk

Purchased from www.WorkshopManuals.co.uk

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