986 Group 2 Fuel-Exhaust PDF

TechnicalManual
-.8c:;~.s:;~-
Technicallnformation
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Contents:
Group 2
Fuel, exhaust, engine electronics
WKD 483 521

Boxster Foreword
Foreword
The workshop documentationfor the Boxster model has the designation "Boxster" Technical Manual
and contains Technical Information as well as instructions on Repairs.
The integration of the technical informationpublishedin the "Boxster"TechnicalManualwith the

descriptive matter on repairs provides the user with a complex reference work that combines into one
book associated or cross-referencedmaterial of relevanceto workshops and originating from various
information media.
The "Boxster"TechnicalManualconsists of 15 folders, subdividedinto the following Groups

0 Entire vehicle -General
0 Diagnosis,part 1 (up to Repair Group 45) *1
0 Diagnosis,part 2 (as of RepairGroup 69) *2
1 Engine,part 1 (up to Repair Group 13) *3
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1 Engine,part 2 (as of Repair Group 15) *4
2 Fuel, exhaust,engine electronics
3 Transmission,manualtransmission
3 Transmission,automatic transmission
4 Runninggear
5 Body
6 Body equipment,exterior
7 Body equipment,interior
8/ 9 Air conditioning/ Electrics
9 Circuit diagrams, part 1 (up to and includingthe '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 "TechnicalInformation"
notices only in front of the repair descriptions in the folder "Group0 -Diagnosis, part 1"
(up to Repair Group 45).
*2 The second folder "Group0 -Diagnosis, part 2" (as of Repair Group 69) includes the further
Repair Groups belongingto Group O.
*3 The two folders with Group 1 are to be regarded as one folder; i.e. file the "TechnicalInformation"
notices only in front of the repair descriptions in the folder "Group1 -Engine, part 1" (up to
Repair Group 13).
*4 Thesecond folder "Group1 -Engine, part 2" (as of Repair Group 15) includesthe furtherRepair
Groupsbelongingto Group1.
Foreword
Printed in Germany -34, October 1999 VORW.CHP
Foreword Boxster
*5
The two folders with Group 9 are to be regarded as one folder; i.e. file the "TechnicalInformation"
notices only in front of the repair descriptions in the folder "Group9 -Circuit diagrams, part 1" (up to
the '99 model).
*6
Thesecond folder "Group9 -Circuit diagrams,part 2" (as of the '00 model) includesthe further
circuitdiagramsbelongingto Group9.
The "Boxster" TechnicalManualhas the same structure in each folder, with the following breakdownfor
all Groups:
Title page, "Boxster" Technical Manual

> Foreword
Title page: "Technical Information"

> Table of Contents,Technicalinformation
> Technical information
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Title page: "Repair"
> Repair Groups: overview
> Table of Contents, repairs
> General/technical data
> Instructions on repairs
As can be seen from the breakdown,the publishedTechnical Informationis in the front part of each
folder -numbered according to the Groups. The Table of Contentsassignedto each Group will be
periodicallyupdated.
Followingthe 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.
Theinstructionson repairswill be extendedand updatedby meansof supplements.
Note
Sheetsthat alreadyexistin the "Boxster"TechnicalManualandare updatedor revisedand thereby

exchangedby a supplement are designated"Replacement sheet".Revisions or technicalmodificationson
pagesof these replacement sheetsare identifiedfor the userwith a verticalbar at the margin.
Foreword
VORW.CHP Printed in Germany -34, October 1999
Boxster Overview of repair groups
Group 0: Entire vehicle -General 0

Maintenance 03
Group 0: Diagnosis 0
Salescheck 01
On-boarddiagnosis 03
DMEdiagnosis 24
Tiptronicdiagnosis 37
ABSdiagnosis 45
Group 0: Diagnosis 0
Airbag diagnosis 69
Seat memorydiagnosis 72
Heatingdiagnosis 80
Alarm system diagnosis 90
PCMdiagnosis 91
ParkAssistentdiagnosis 91
HBAdiagnosis 94
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Group 1: Engine 1
Engine-Crankcase, suspension 10
Engine -Crankshaft, pistons 13
Group 1: Engine 1
Engine-Cylinder head,valve drive 15
Engine-Lubrication 17
Engine-Cooling 19
Group 2: Fuel, exhaust, engine electronics 2
Fuelsupply,control 20
Exhaustsystem,turbocharging 21
Fuelsystem,electronicinjection 24
Fuelsystem,K-Jetronic 25
Exhaustsystem 26
Starter,powersupply,cruisecontrol 27
Ignitionsystem 28
Group 3: Transmission, manual transmission 3

Clutch, control 30
Manualtransmission-Actuation, housing 34
Manualtransmission-Gears, shafts, into gearsh, 35
Final drive, differential,differential lock 39
Group 3: Transmission, automatic transmission 3

Torqueconverter 32
Automatic transmission-Actuation, housing 37
Automatic transmission-Gears, control 38
Final drive, differential,differential lock 39
Overview of repair groups

Printed in Germany -34, October 1999 REPGRU.CHP
Overview of repair groups Boxster
Group 4: Running gear 4

Frontwheel suspension,drive shafts 40
Rear wheel suspension,drive shafts 42
Wheels,tires, suspensionalignment 44
Ant~LockBrake System (ABS) 45
Brakes -Brake mechanics 46
Brakes -Hydraulics, regulator, booster 47
Steering 48
Group 5: Body 5
Bodyfront 50
Bodycenter,roof,frame 51
Bodyrear 53
Lids,flaps 55
Door front,centrallockingsystem 57
Group 6: Body equipment, exterior 6

Slidingroof 60
Convertible
top, hardtop 61
63
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Bumpers
Glazing,windowcontrol 64
Exteriorequipment 66
Interiorequipment 68
Passengerprotection :69
Group 7: Body equipment, interior 7

Linings,insulation 70
Seatframes 72
Seatupholsteries,covers 74
Group 8: Air conditioning 8

Heating 80
Ventilation 85
Air conditioning 87
Auxiliaryair conditioningsystem 88
Group 9 Electrics 9
Instruments,
alarmsystem 90
Radio,telephone,on-boardcomputer,navigation 91
Windshieldwiperandwashersystem 92
Lights,lamps,switchesexterior 94
Lights,lamps,switchesinterior,theftprotection 96
Group 9: Circuit diagrams 9

Wiring (up to and includingthe '99 model) 97
Group 9: Circuit diagrams 9

Wiring(fromthe '00 model) 97
Overview of repair groups

REPGRU.CHP Printed in Germany -34, October 1999
Boxster Contents
2 Fuel, exhaust, engine electronics
20 Fuel supply, control
20 02 Checking fuel
quantity pressure. delivered by fuel pump. ... 20- 1
2066 20- 3
20 66 1901 Calibrating
Removing and
fuel/evel installing sensor fuel system.
pump.
return line. 20- 5
20 15 20 -9
20 39 19 20-11
Fuel system, electronic injection
Disassembling and assembling fuel

intake ring distributor.pipe. ... 24- ..1
24- .7.13
24-
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Removing
Removing
Disassembling
Programming
Diagram of and
and hose DME
installing
and connections.
assembling
control throttle
oxygen
DME
mass module. control
air air sensor.
body flow guide module.
-Boxster
sensor. cowl. S ...
24- .1i5
24- .1,9
24- .23
24- 25
24- 2i7
24- 311
Removing
Installing throttle
throttle
and installing body body -Boxster
-Boxster
injection valves
S S -Boxster S .. 24- 3'3
24- 39
24- 47
Installing
Removing injection
and
injection installing valvesvalves intake
-Boxster
-Boxster distributor S S -Boxster S . 24- 49
24- 55
24- 611
Removing
Installing intakeintake distributor
distributor -Boxster
-Boxster S S 24- 6p
24- 76
26 ! Exhaust system
26 01155 Replacingexhaustsystem. ... 26 -1
27 Starter, power supply, cruise control
27 6019 Removing and installing three-phase

starter. generator. . 27- '1
27 2219 27- 3
27 8419 Removing and installing cruise control actuator. . 27- 5
27 6019 Removing and installing starter -Boxster S ... 27- 7
2 Fuel, exhaust, engine electronics 1

Printed in Germany -32, 1999 986TOC
0101
Contents Boxster
2706 Workinstructionsafter disconnecting

the battery . ...27 -9
28 Ignition system
274419 Removingand installingrotor for hall sender ..28 -1
28 73 19 Removingand installingpulse sender. .. ..28 -3
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8
.
2 2 Fuel, exhaust, engine electronics
986TOC Printed in Germany -32, 1999
Boxster Fuel supply, actuation
20 02 01 Checking fuel pressure
Special tools
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No. Designation Special tool Explanation
A Pressuregauge P 378a
B Connection
line 9559
20 02 01 Checking fuel pressure 20 -1

Printed in Germany, 1996 986201
Fuel supply, actuation Boxster
Checking fuel pressure
Checking
1. Undo covering cap on test connection of fuel

collection pipe and remove.
2. Connectpressure gauge (specialtool P 378a)

~~
a~
with connecting line (special tool 9559) and
connectto test connection.
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.I
"
.~
=---'"'-"
~
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4. Nominal test values:
~;
Stationary engine 3.8 ::!:0.2 bar
-I ~.l Engine idling 3.3 ::!:0.2 bar
3. Actuatingfuel pump The seal or sealing ring in the brass closure cap
is not exchangeable.It must therefore be used
with Porsche System Tester 2: onlyonce.
The fuel pump can be actuated with the
Porsche System Tester 2 or by bridging the Tighteningtorque of new brass closure cap
fuel-pumprelay. 2.5 :t 0.5 Nm (2.0:t 0.5 ftlb.).
Via fuel-pumprelay without Tester:

Disconnectfuel-pumprelay from the central
electrical board and bridge contacts 30 and
87 (identifiedas 3 and 5 on the central electri-
cal board) with a fused shop-madecable. The
fuel pump must now operate or deliver fuel.
20 -2 20 02 01 Checking fuel pressure

986201 Printed in Germany. 1996
r"3'~-I~~~
20 66 01 Checking quantity delivered by fuel pump
Precondition:
Fuelfilter and electrical supplyin order,
1. Relievepressurein fueltank by openingtank /

/
/ /
cap. / /
/ /
/
2. ConnectPorsche SystemTester 2. / /
/
/ /
/ /
3. Raisevehicle /
4. Removerear underside panel, - /

5. Disconnect
fuel returnline. Collectresidual
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fuel. 368 -96
6. Hold fuel line in a measuringcontainer. Actu-

ate fuel pump with the Porsche System Tester
2 and allowfuel to flow for 30 seconds into a
measuringcontainer.
Quantity supplied must be at least
850 cm3/30 s, i.e. after 30 seconds at least
850 cm3 of fuel must be present in the
measuringcontainer.
367 -96
~
20 66 01 Checking quantity delivered by fuel pump 20 -3
8
20 66 19 Removing and installing fuel pump
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2066 19 Removing and installing fuel pump 20-5

Printed in Germany. 1996
986201
Fuel supply, actuation Boxster
Removing and installing fuel pump
Removal
1. Undo battery terminals and battery holder. Lift

battery out by holding strap. /1/-.,
.Q /A
2. Undobatterysupportcover(fourhexagon ~
nuts,wrenchsize 13). ~
3. Disengage
fuel lineand disconnectelectrical
plugconnection.
446 -96
5. Extractresidualfuel.
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Note
Observesafetyregulations.
=1 6. Lift fuel gauge and disconnectelectrical plug
,
I-" connectionand fuel pipes.
t1
'-
::--u-
445 -96
4. Undounionnutwith VWspecialtool 3217,
447 -96
7. Put on fuel-proofglove, hold the fuel pump

fastenedto tank floor, turn it to left (approx.
15°, bayonet lock) and remove fuel pump.
20-6 20 66 19 Removing and installing fuel pump

--
Installation
Positionfuel pump; the edge of the fuel-pump 3. Insertfuel tank sending unit and turn until the
housingfaces the fuel tank sending unit instal- marking on the sending unit matches the mark-
lation-positionmarkings. ing on the fuel tank.
\
~ -
=-
--- v
rJ)
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'-'-
149-96 448 -96
2. Place fuel pump in this position on tank floor 4. Tightenunionnutwith specialtool 3217.
bayonetfixture and turn fuel pump to the right Tighteningtorquewith newunionnutand new
as far as the stop. Then check proper seating sealingring: 70 Nm (52 ftlb.).
of fuel pump by pulling it up.
5. Attach fuel lines and electrical plug connec-
tion. The fuel lines must audiblyengage.
Correct engagement must be checked
with a gentle pull.
The colour-codedplug (green) must be fitted
to the connectionidentifiedwith "V".
8
20 66 19 Removing and installing fuel pump 20 -7
"~
8
Boxster Fuel supply, control
20 15 01 Calibrating fuel level sensor system
Warning! -Select menu item Tank calibration
& Danger of fire and injury!
> Observegeneral safety

-Confirm calibration
regulations on the fuel system. The fuel level sensor system has now been
calibrated.
> Wear protective gloves
Note
Note The fuel level sensor system need not be

calibrated if the battery was disconnectedor a
Calibration is necessaryafter replacementof the
plug connectionon the instrumentcluster or fuel
fuel tank, fuel level sensor or instrumentcluster.
level sensor was removed. The valuesremain
stored in the instrumentcluster.
Removebattery and detach battery cover.
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A range on remainingfuel of less than 15 km is
2. Removefuel level sensor; refer to ServoNo.
not displayed in the instrumentcluster.
20 66 19 (Removingfuel pump).
3. Using a fuel extractor, completelydrain

the fuel tank through the fuel level sensor
opening. Fuel extractor: Refer to the
Workshop EquipmentManual,Chapter 3
"WorkshopEquipmenf'.
4. Reinstallthe fuel level sensor and, with

"ignitionoff', fill the tank with 12 litres of fuel,
5. Perform tank calibration with the Porsche

System Tester 2.
Select vehicle type (911 Boxster)
-Select control modules
Select instrumentcluster
. 20 15 01
Printed
Calibrating fuel level sensor system
in Germany -29, 1999 986209
20 -9
Boxster Fuel supply, control
20 39 19 Removingand installing fuel return line
Warning:
& Danger of fire and injury!
> Observegeneral safety

regulations on the fuel system.
> Wear protective gloves,
Removal
1. Moveconvertibletop to serviceposition.
2. Detachnegativeterminalof battery
(aff 10 mm).
367_96
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3. Placeprotectivecoveron ground,
9. Lower vehicle.
4. Removeenginecompartment
liningandlid
10. Removeholder for servo return line,
5. Removerear wall lining and rear wall cover electrical plug connectionand ground
strap. (Hexagon-headbolt M6 x 12)
6. Raisevehicleand removeengineunderside
guard.
7. Unclip fuel return line from the line holder

on the body.
8. Detach the fuel return line.

Press unlocking buttons and simultaneously
pull off the line. Immediatelyseal the fuel
line supports with a suitable plug.
86_99
20 39 19 Removing and installing fuel return line 20 -11

Printed in Germany -25, 1999 9862011
Fuel supply, control Boxster
11. Undo return line (wrench size 17);

simultaneouslycounter (wrench size 19).
Removereturn line.
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85_99
Installation
1. Fastenfuel return line to pressure regulator,
simultaneouslycounter.
2. Fit holder.
3. Put on rear wall cover, rear wall lining,

engine compartment lining and engine
compartmentlid.
4. Lift the vehicle.
5. Positionfuel return line in a straight line.

The plug (plug part) must audiblyengage
in the plug~ncoupling.
Then pull slightly to ensure that the connection
is properlylocked. Clip fuel return line onto
the body.
6. Connectbattery,closeconvertibletop.
7. Start engine and carry out tightnesstest.
8. Fit engine underside guard
9. Read out fault memory. Enter radio code.
20 -12 20 39 19 Removing and installing fuel return line

9862011 Printed in Germany -25. 1999
Disassembling and assembling fuel ring pipe
rij-1
J_o:oo 2
~::!:1
\
\0 16
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\~\
,..::.:::,
~...1~1
5-~ I
8 ~
9 ~
/::J
15
~ ~"""""""""""~~~
~
~
0 @-14
1-12
@-13
24 -2 24 30 37 Disassembling and assembling fuel ring pipe

6-~7.
f-3
4-'1
~
Boxster Fuel system -Electronic injection
Disassembling and assembling fuel ring pipe
Note:
No. Designation Qty. Removal Installation
Closurecap 1 Note
The seal or sealing ring in
the closure cap is not ex-
changeable. It must there-
fore be used only once.
Tighteningtorque:
2.5 .:t 0.5 Nm (2 .:t 0.5
ftlb.). Wrench size 13 mm.
2 Valve 1
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3 Hexagon-headbolt M6x12 4
4 Hexagon-headbolt 1
5 Fasteningclampfor throttle 1
cable16x15
6 Clamp 1 Ensure correct seating.
7 Pressureregulator 1 Pushor plug vacuum corr

trol pipe into the left-hand
intake distributor rubber
sleeve(see assemblyirr
structions),
8 a-ring 20x2.5 1 Replace
9 D-ring5x2.5 1 Replace
10 FuelreturnlineM14xl.5 1 Ensure it is counteredwith Tighteningtorque
a wrench while being loos- 25 .:f:.5 Nm (18 .:f:.3.5
ened. ftlb.)
Wrench size 17 mm.
Ensure it is countered
with a wrench while being
tightened.
11 Clamp 6 Ensurecorrectseating.
24 30 37 Disassembling and assembling fuel ring pipe 24 -3

Fuel system -Electronic injection Boxster
Note:
12 Injectionvalve 6
13 O-ring 6 Replace
14 a-ring 6 Replace
15 Fuel ring pipe 1
16 Fuel supply line M16xl.5 1 Ensure it is counteredwith Tighteningtorque:

a wrench while being loos- 30 + 5 Nm (22 + 3.5
ened. ftlb.J.
Wrenchsize 19 mm. En-
sure it is countered with
a wrench while being tight-
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ened!
24 -4 24 30 37 Disassembling and assembling fuel ring pipe

986241 Printed in Germany, 1996
Assembly instructions
Fitting vacuum control pipe on the intake

distributor
Mountthe vacuum control pipe betweenfuel

pressure regulator and intake distributor at the
left-handrubber sleeve. Routethe vacuum con-
trol pipe so it is tension-free.
-
I'
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"~I\
/1/
375-96
8
24 30 37 Disassembling and assembling fuel ring pipe 24 -5
~1
I~
8
Disassembling and assembling intake distributor
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24 -8 24 46 37 Disassembling and assembling intake distributor

Disassembling and assembling intake distributor

Note:
1 Hexagon-head
bolt 6x35 12 Tightening torque: 10 Nm
(7 ftlb.)
2 Hose clamp 90-110/9 2
3 Intakedistributor 2
3a O-ring 48x3 6
4 Rubber sleeve 2 Connectingbores for va-
cuum control pipes face
the front (in direction of
travel),
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5 Hoseclamp90-110/9 2
6 Intermediatepiece 1
7 1
Sealingring Replace
8 Checkvalve 1 Ensure correct installation
position. Assemblewith
black side facing rubber
sleeve (see assembly ir}.
structionsJ.
9 Temperaturesensor for in- 1
take air
10 Grommet 1
6.0x18
12 Closure cap 1
13 a-ringllx2.5 1 Replace
14 Hexagorrhead
bolt 2
6.0x18
15 Adapter 1
16 O~ringllx2.5 1 Replace
17 Hexagon-head
bolt 1
24 46 37 Disassembling and assembling intake distributor 24 -9

Note:
18 Fasteningclampfor vent 1
line
19 Ventline 1
20 Tankventingvalve 1
21 Hoseclamp8-16/9 1
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Assembly instructions
Assembling intake distributor
Tightenthe micro-encapsulatedhexagorrhead
bolts M6x 16 in the prescribedsequence.
Tightening torque 9.7 Nm (7 ftlb.).
171-97
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Fitting vacuum control pipe on the intake
distributor
Mountthe vacuumcontrolpipebetweenthe fuel

pressureregulatorandthe intakedistributorat
182 -97
the left-handrubbersleeve.Routethe vacuum
controlpipeso that it is tension-free.
Aligning rubber sleeves between distributor
pipe and intake distributors.
Line up the rubber sleeveswith the markings

(arrows)and tighten the inner hose clamps.
Pushthe distributor pipe betweenthe intake ""<

distributors and align so that the dimension"X" "
is the same on both right and left. Tightenthe
outer hose clamps. 1/ '\ .\
Secure the support betweenthe throttle body

andcrankcase.
375-96
24 46 37 Disassembling and assembling intake distributor 24 -11

"~
IIII
Fitting check valve on intake distributor.
Theblackside of checkvalvemustface rubber

sleeve.Layvacuumhosetension-free.
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377-96

9862411 Printed in Germany. 10, 1997
24 Diagram of hose connections: air injection
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24 Diagram of hose connections: air injection

Item Designation
= Secondaryair pump
2 = Pneumaticanti-run-onvalve
3 = Electronicswitch-over
valve
for secondaryair
4 = Checkvalve
5 = Vacuumreservoir
6 = Checkvalve
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A Intake air from engine compartment
B -> to camshafthousings/
cylinderheads
c -> to intake distributor
D -> to vacuum reservoir
381-96
24 -13
9862413
~~W$~))
1
.6
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Disassembling and assembling air guide cowl
Note:
1 Hoseclamp 1
86 x 12
2 Hoseclamp 1
86 x 12
3 Intake cowl 1
4 Hose clamp 1 Tighten only after intake
cowl has been fastened
5 Resonance
tube 1
(only on vehicleswith
Tiptronic)
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6 Hose clamp 1
53 x 12
7 Silencerwith 1
plastic damping film
8 Holder 1
9 M6 hexagonnut 1
10 Combinationscrew 1
M6 x 15 (micro-encaps.)
11 Holder for resonancetube 1
12 Rubbersleeve
24 35 37 Disassembling and assembling air guide cowl 24 -17

Boxster Fuel system, Electronic injection
2470 Programming DME control module
General
Whena DME control module is replaced, the

new DMEcontrol module must be programmed. With the information about the VehicleIdent.
This sets the new DME control module to the Number and catalytic converter item number,
catalytic converter version installed,among the associated programme can be selected
other things. from the allocationtable.
Four catalytic converter versions are available Figure 308_98 showswhere the catalytic
in the Porsche System Tester 2: converter item number can be found on
the vehicle.
1. OBD II control module (W-range)
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2. RoW control module (bi-metal catalytic
converter)
3. OBD II control module (V-range)
4. OBD II control module (tri-metal catalytic

converter, X-range) 7
/
Note:
The OBD II control modules (V, W or X-range)

are installed in USA vehicles.
\
Catalyticconverter item number 308_98
Work preparation
The following vehicle data must be provided

Programming
before programming of the new DMEcontrol mo-
1. Connectand switch on the Porsche System
dule can begin:
Tester 2 and switch on the ignition.
VehicleIdent.No.
2. SelectBoxster in the Vehicletypemenu.
CatalyticconverterItemNo. corresponding
3. Select DME in the Control unit menu and
to the catalyticconverterversionused
press the double arrow key [»].
DME and immobilizer programming codes
4. Select Program control unit in the
(from the Porsche IPAS system)
DMEfunction selection menu and press
the double arrow key [»].
2470 Programming DME control modul,e 24 -19

I~
Fuel system, Electronic injection Boxster
5. Select "Readcontrol units"and press the 15. The followingmessageappearson the screen:
double arrow key [»]. Input new immobilizercode"
Inputimmobilizercode and press the double
6. InstallnewDMEcontrolmodule. arrow key [»].
7. Select Program control unit in the Control 16. The followingmessageappearson the screen:
unit programming menu and press the double "Pleaseconfirm input"
arrow key [»]. Confirm input with the [F7]key.
8. Ensure that all requirementsrequested on the 17. The followingmessageappearson the screen:
screen are fulfilled and then press the double "Selectdata record"
arrow key [»]. Select data record according to the allocati-
on table and press the double arrow key
9. The following message appears on the screen: [»].
"InputVehicleIdent. Number".
Use the double arrow key [»] to accept the The control module will now be programmed.
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number displayed on the screen. Programmingwill take approx. 5 minutes.
10. The followingmessageappearson the screen: & , > Never interrupt the programming
Warning:
"Pleaseconfirm input"
Confirm input with the [F7] key. process
18. The following messagewill appear after the

11. The followingmessageappearson the screen:
programmingtime has elapsed:
"Input old DMEprogramming code"
"Programmingwas completed successfully"
Input DMEprogramming code and press the
Press the double arrow key [»], switch the
double arrow key [»].
ignition off and then on again.

This completes programming of the DMEcontrol
"Pleaseconfirminput" module.
Confirm input with the [F7] key.
Warning:
"Inputnew programming code"
Input new DME programming code and press
& Risk of damage if allocation is
incorrect!
the double arrow key [»]. > Ensure correct allocation of the
data record in the control module
14. The followingmessage appearson the screen: to the installed catalytic converter
.P/ease confirm input" (refer to the allocation table),
Confirm input with the [F7] key.
24 -20 2470 Programming DME control module

9862419 Printed in Germany -21, 1998
Boxster Fuel system, Electronic injection
Catalytic converter version Vehicle Ident. Number Catalytic converter item number
II control module (V-range) WPOxx2xxxVxxxxxxx 996.113.031.06
996.113.032.06
RoWcontrol module (bi-metal WPOZZZxxxVxxxxxxx 996.113.021.06

catalytic converter) 996.113.022.06
996.113.921.01
996.113.922.01
RoWcontrol module (bi-metal WPOZZZxxxWxxxxxxx 996.113.021.08

catalytic converter) 996.113.022.08
996.113.021.09
996.113.022.09
996.113.921.01
996.113.922.01
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OBDII controlmodule(W-range) VVPOxx2xxxVVxxxxxxx 996.113.021.05
996.113.022.05
996.113.021.06
996.113.022.06
996.113.021.08
996.113.022.08
996.113.021.09
i996.113.022.09
RoWcontrolmodule(tri-metal WPOZZZxxxXxxxxxxx 996.113.021.10
catalyticconverter.X-range) 996.113.022.10
OBDII control module (tri-metal WPOxx2xxxXxxxxxxx 996.113.021.10
catalytic converter, X-range) 996.113.022.10
996.113.931.00
996.113.932.00
Allocation table
2470 Programming DME control module 24 -21

IOBD
1
11
Information:
The DME control module can also be

reprogrammed using the Porsche System
Tester2.
In this case, the old data record will be
overwritten by a new record.
Program map/data must be selected in

Step 7 if reprogramming is necessary.
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24 -22 2470 Programming DME control module

Boxster Fuel system, electronic injection
24 45 19 Removing and installing mass air flow sensor
Removal
1. Move convertible top or convertibletop

compartment lid to service position.
2. Remove linings for convertible top rest

and engine compartment lid.
3. Pull off electrical plug connectionon

the mass air flow sensor.
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406_98
Installation
.,.
1. Fit mass air flow sensor with seal and fasten
with 5.0 x 20 oval-headscrews.
Tighteningtorque 3 -4 Nm (2.0 -3.0 ftlb).
2. Check whether a seal is present and

the sensor is seated correctly. Fit plug.
412_98
3. Fit lining and engine compartment lid,

4. Undo oval-headscrews with a commercially
availableTorx T 20 tool (with a bore in
the drive tip).
8
24 45 19 Removing and installing mass air flow sensor 24 -23
~
8
~
24 70 19 Removing and installing DME control unit
Removal 4. Take off control module.

1. Put rear body-protectioncover on the vehicle. Open locking clip and pull the control
module connector off.
2. Press off expanding rivets of the luggage
Installation
compartment lining with a removal tool
(refer to Technical EquipmentManual, 1. Engagecontrol module connector in
Chapter 2.4, No. 21). the control module guide and press and
lock the plug onto the terminal strip.
2. Fastenthe control module.

Tighteningtorque 10 Nm (7.5 ftlb.).
3. Fit luggage compartmentlining.
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459_96
3. Undo four hexagon nuts (wrenchsize 10 mm).
33o_98
24 70 19 Removing and installing DME control unit 24 -25

24 69 19 Removing and installing oxygen sensor
Tools
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41O_98
Item Designation Special tool Explanation

Open-endring Commercially Refer to Workshop Equipment
wrench (angled) available Manual,Chapter2.4, No. 98
24 69 19 Removing and installing oxygen sensor 24 -27

Fuel system, electronic injection Boxster
8
Warning
& Oxygen sensor can be damaged if handled improperly.
> Do not remove the plastic cap on the thread until just prior to fitting the oxygen sensor.
The thread grease must under no circumstancescome into contact with the plug.
> Protect sensors -before and after fitting -against mechanicalshocks.
> Sensors that were dropped on the floor must not be used owing to the risk of a broken
ceramic insulator.
> The cables must not be twisted or kinked when the sensorsare screwed in.
Avoid pulling on the cable and plug.
> Cleanlinessin the housing of the plug connectionis of utmost importancefor the function
of the oxygen sensor.
Particles of dirt can impair the function of the oxygen sensor. Therefore,the plug must be
cardiagn.com
protected against any and all types of soiling.
> Sensorswith soiled or damaged plug must no longer be used.
> Protect the cables and plugs when transporting the exhaustsystem with the sensors
alreadyfitted.
> High-pressurecleaning equipmentmust not be used in the area of the sensors and plug
connections.
8
24 -28 24 69 19 Removing and installing oxygen sensor
Removal
1. Disconnect
the electricalplugconnection 2. Undo oxygen sensor using the specified ring
of the oxygen sensors. wrench (wrenchsize 22 mm).
~
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cardiagn.com
The figure shows how to disconnect 328_98 The figure shows oxygen sensor 347_98
the plug connection to the oxygen behind the catalytic converter,
sensor behind the catalytic converter, cylinder bank 1 -3.
cylinder bank 4 -6
Installation
1. Screw in the oxygen sensor whilst
~ \ simultaneouslyturning the cable with it.
Tighteningtorque: 50 -60 Nm (37 -44 ftlb.)
/11 1
~ Note
Different tightening torque if the specified

t:7 special tool is used.
Tightening torque: 38 -46 Nm (28 -34 ftlb.)
/~
The figure shows how to disconnect 411_98
the plug connection at the rear-axle
support for the oxygen sensor ahead
of the catalytic converter, cylinder
bank 4 -6.
24 69 19 Removing and installing oxygen sensor 24 -29
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2442 19 Removing and installing throttle body -Boxster 5
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24400011
Includes:
24 42 21 Removing throttle body -Boxster S
24 42 23 Installing throttle body -Boxster S
2442 19 Removing and installing throttle body -Boxster S 24 -31

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24 42 21 Removing throttle body -Boxster 5
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2442 21 Removing throttle body -Boxster 5 24 -33

Printed in Germany -3D, 1999 9862433
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!4400011
Removing throttle body -Boxster 5
Removal overview:
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. 24 -34 24 42 21 Removing throttle body -Boxster S

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Removing throttle body -Boxster 5
1 Undoingintakemanifold
2 Removingcrankcase venting
3 Removingrubber sleeve
4 Disconnectingelectric plug
5 Undoing throttle body holder
6 Removing throttle body from flange
cardiagn.com
. 2442
Printed
21 Removing throttle
in Germany -30, 1999
body -Boxster S
9862433
24 -35
Removing throttle body -Boxster S
No. Procedure Instructions
1 Undoingintakemanifold
Openthe hose clamp on the throttle body. Pull off the

connectionhose betweenthe air cleaner housing and the
throttle body and put it aside.
cardiagn.com
2 Removingcrankcaseventing
Removethe crankcaseventing on the throttle body. To do

this, push the connecting plug on the grooved surfaces
together and pull off simultaneously.
3 Removing
rubbersleeve
Undothe two rubber sleeveson the centre part of the

intake distributor and push outwards.
24 -36 24 42 21 Removing throttle body -Boxster 5

8
4 Disconnectingelectric plug
Disconnectthe electric plug on the throttle body. To do

this, gently push plug on the left and right and remove.
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5
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Undoing throttle body holder
Unscrewthe fastening nuts on the throttle body holder and

~ . take the throttle body and the centre part of the intake
t' distributor out of the enginecompartment.
"
24400008
6 Removing
throttle bodyfrom flange
Unscrewthe four fastening screws on the throttle body

and remove the throttle body. Do not use the moulded
rubber seal again.
2442 21 Removing throttle body -Boxster S 24 -37

'"
24 42 23 Installing throttle body -Boxster S
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24 42 23 Installing throttle body -Boxster 5 24 -39

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Installing throttle body -Boxster S
Installation overview:
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/
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24400012
24 -40 24 42 23 Installing throttle body -Boxster 5

1 Replacingseal
2 Fitting throttle body
3 Tighteningthrottle body holder
4 Securingrubbersleeve
5 Connectingelectric plug
6 Putting on crankcase venting
Fasteningintake hose
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24 42 23 Installing throttle body -Boxster S 24 -41

8
Replacingseal
Replacethe moulded rubber seal betweenthe centre part

of the intake distributor and the throttle body. When
inserting the seal, make sure that the lug on the seal
is located in the groove provided.
\
\
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/
24400010
cardiagn.com
2 Fitting throttle body
Lay the throttle body holder on the right hand side of the
throttle body. Screw in the four fastening screws and
tighten to 9.7 Nm (7.0 ftlb.).
24400009
3 Tightening
throttle bodyholder
Place the throttle body with the centre part of the intake
distributor into the enginecompartment. Push on the
rubber sleevesand tighten the fastening nuts on the
throttle body holder to 9.7 Nm (7 ftlb.).
24 -42 24 42 23 Installing throttle body -Boxster S

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4 Securingrubbersleeves
Align the rubber sleeveson the intake distributor and

tighten the four hose clamps.
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5 Connectingelectric plug
Connectthe electric plug on the throttle body again.

The plug must audiblyengage.
6 Puttingon crankcaseventing
Put the crankcaseventing back onto the centre part of the

intake distributor. The plug must audiblyengage.
24 42 23 Installing throttle body -Boxster S 24 -43


7 Fasteningintakehose
Put on the connecting hose betweenthe air cleaner and

the throttle body. Align the two markings as shown in the
diagram and tighten the hose clamp.
cardiagn.com
24 -44 24 42 23 Installing throttle body -Boxster S

24 40 20 Removing and installing injection valves -Boxster S
ffJ
cardiagn.com
2440001:
Includes:
24 40 22 Removing injection valves -Boxster S
24 40 24 Installing injection valves -Boxster 5
24 40 20 Removing and installing injection valves -Boxster S 24 -47

t
24 40 22 Removing injection valves -Boxster 5
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24400013
24 40 22 Removing injection valves -Boxster S 24 -49

Removing injection valves -Boxster S
Removal overview:
cardiagn.com
24400019
8
24 -50 24 40 22 Removing injection valves -Boxster S
9862449 Printed in Germany-3D, 1999
Removal overview:
1 Removingpassenger's seat
2 Openingmaintenancecover
3 Removing
fuel lineon pressureregulator
4 Undoingfuel returnline
5 Unscrewingfastening screws
6 Removinginjection valves
cardiagn.com

Removing
passenger'sseat
/ ~~""
Removethe passenger'sseat for better accessibility.
Unscrewthe four fastening screws for this purpose.
Disconnectthe electrical connectionsunder the seat and
take the seat out of the vehicle.
cardiagn.com
24400002
2 : ", Openingmaintenancecover
Removerear wall lining. Then remove the maintenance

cover. Unscrewthe seven hexagon-headbolts and the two
fastening nuts for this purpose. Take the maintenance
cover out of the vehicle.
24400003
3 Removingfuel line on pressure regulator
Make sure to place a cloth beneaththe screwed

connectionsince fuel emerges when opening. Undothe
fuel line from the vehicle interior (through the maintenance
cover). Counterwith a second open-endedwrench when
doing this in order to preventdamage to the pressure
regulator.
24 -52 24 40 22 Removing injection valves -Boxster 5

,/
4 Undoingfuel return line
Place a cloth beneaththe screwed connection of the fuel

return line. Undo the screwed connection of the fuel return
line at the back end of the right ring pipe. Counterwith an
open-endedwrench to avoid damage.
cardiagn.com
Unscrewthe two fastening screws of the fuel ring pipe on

the left and right of the intake system (diagram shows only
one side of the ring pipe). Disconnectthe electrical
connections of the injection valves. To do this, press the
metal spring on the plug and pull off the plug at the same
time. Carefullylift the fuel ring pipe upwards out of the
enginecompartment. Undothe fastening screws on the
intake distributor for this purpose.
6 Removinginjectionvalves
/
/ Pushthe fastening clips of the injection valve to do this.
/ \
Then pull the injectionvalve concerned out of the fuel ring
pipe. Do not use the old sealing rings again.
\
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24 40 24 Installing injection valves -Boxster S
cardiagn.com
24400013
24 40 24 Installing injection valves -Boxster S 24 -55

,
Installing injection valves -Boxster S
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24400020
24 -56 24 40 24 Installing injection valves -Boxster 5

,-.t,i
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1 Installing injection valves
2 Fasteningfuel ring pipe
3 Tighteningfuel line on pressure regulator
4 Tighteningfuel returnline
5 Closing maintenancecover
6 Installing passenger's seat
cardiagn.com
.
1 Installinginjection valves
Fit new sealing rings on the respective injectionvalve. Align

the injection valve so that the lug on the valve and the lug
on the fuel ring pipe lie directly above one another. Push
on the fastening clip again.
cardiagn.com
24400015
2 Fasteningfuel ring pipe
Lift the fuel ring pipe back into the engine compartment.
Carefullyinsert the injection valvesinto the opening in the
intake distributor. Tighten the two fastening screws on the
left and right of the fuel ring pipe to 9.7 Nm (7 ftlb.).
Connectelectrical connectionsagain. Then tighten the
fastening screws on the intake distributor to 9.7 Nm
(7 ftlb.).
3 Tighteningfuel line on pressure regulator
Positionthe union nut on the fuel line and tighten. Make

sure to counter with a wrench when doing this. The
screwed connection must be checked for leaks.
24 -58 24 40 24 Installing injection valves -Boxster S

4 Tighteningfuel return line
Tighten the screwed connection of the fuel return line at

the back end of the right ring pipe. Counterwith an
open-endedwrench to avoid damage. The screwed
connection must then be checked for leaks.
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Place the maintenancecover in the vehicle. Tightenthe

sevenfastening screws and the two fastening nuts. Fit
cover again.
6 Installingpassenger's seat
Lift the passenger's seat into the vehicleinterior. Connect

electrical connections.Tightenthe four fastening screwsto
65 Nm (48 ftlb.).

24 46 23 Removing and installing intake distributor -Boxster S
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.-(i .I,...
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24400022
Includes:
24 46 21 Removing intake distributor -Boxster S
2446 23 Installing intake distributor -Boxster 5
24 46 23 Removing and installing intake distributor -Boxster S 24 -61

24 46 21 Removing intake distributor -Boxster S
cardiagn.com
24400022
24 46 21 Removing intake distributor -Boxster S 24 -63

Removing intake distributor -Boxster S
5
~
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24400029
24 -64 24 46 21 Removing intake distributor -Boxster S


Note:
1 Hoseclamp 8
2 Rubber sleeve 2
3 Rubber sleeve with vacuum 2
connection
4 Vacuumconnectionfor 1 ReplaceO-ring
brake booster
5 Closure cap 1 ReplaceO-ring
6 Temperature sensor 1
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7 Bleeder valve for carbon 1
canister
8 Left intakedistributor 1
9 Right intake distributor 1
10 Tuning pipe 1
11 Centre part of intake 1
distributor

Removaloverview:
cardiagn.com
24460005

Removaloverview:
1 Removingpassenger's seat
2 Opening maintenance cover
3 Removing
throttle body
4 Removingtuning pipe
5 Removingsecondaryair pump
6 Undoingfuel return line
cardiagn.com
7 Undoingfuel line
8 Undoing vacuum line

Removingpassenger's seat
Removethe passenger'sseat for better accessibility.

Unscrewthe four fastening screws for this purpose.
Disconnectthe electrical connectionsunder the seat
and take the seat out of the vehicle.
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2 Openingmaintenancecover
Removerear wall lining. Then remove the maintenance

cover. Unscrewthe seven hexagon-headbolts and the two
fastening nuts for this purpose. Take the maintenance
cover out of the vehicle.
3 Removing
throttle body(Serv.No.: 24 42 21)
Undo the four hose clamps on the throttle body. Push

the two rubber sleevesoutwards as far as they will go.
Unscrewthe fastening nuts. Removecrankcase vent.
Removecentre part of intake distributor with throttle body,
24400004
24 -68 24 46 21 Removing intake distributor -Boxster 5

9862463 Printed in Germany -3D, 1999
4 / ~ Removingtuning pipe
Undothe four hose clamps. Pull off the vacuum hose on

the left rubber sleeve. Pushthe two rubber sleeves
outwards as far as they will go. Take out the tuning pipe
and pull the vacuum hose off the control box.
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5 Removingsecondaryair pump (USAvehicles only)
Undothe starter ground cable on the body. Openthe

spring band clamp using commerciallyavailable
spring-bandclamp pliers No. 72 or No. 73 and push to the
rear. Undothe three fastening screws on the secondaryair
pump. Disconnectelectrical connectionand remove pump
from vehicle.
6 Undoingfuel returnline
Place a clean cloth under the screwed connectionand

collect emerging fuel. Undothe screwed connectionon the
pressure regulator. An open-endedwrench must be used
to counter it in order to avoid damage.

Printed in Germany -3D, 1999 9862463
..,.,..
7 Undoingfuel line
Place a clean cloth under the screwed connection. Undo

the screwed connection of the fuel line. Counterwith an
open-endedwrench to avoid damage. Pull out the
temperature switch for the engine compartmentblower
and set aside.
'/
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24400017
8 Undoingvacuum lines
Disconnectthe vacuum lines to the brake booster. To

do this, unscrewthe two screws on the intake manifold.
Unscrewthe fastening screw of the bleeder valve for the
carbon canister on the left intake manifold. Disconnect
electric plug. Removethe crankcase vent on cylinder
bank 1 -3. Unclipthe switch-overvalve for the tuning
pipe and set aside.
Openthe omega clips on the fuel ring pipe and disengage

the wiring harnesses.Unscrewthe two fastening screws
on the fuel ring pipe respectively. Unscrewthe six
fastening screws on the intake system on all sides. Raise
the intake distributor pipes gently and immediatelyseal the
intake channelsin the cylinder head with a clean, lint-free
cloth so that no dirt can enter. Lift the intake distributor
upwards out of the enginecompartment.

"""'
24 46 23 Installing intake distributor -Boxster S
cardiagn.com
24400022
24 46 23 Installing intake distributor -Boxster S 24 -73

Installing intake distributor -Boxster 5
5
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11
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24400029
8
24 -74 24 46 23 Installing intake distributor -Boxster S
~
8
Installing intake distributor -Boxster S
Note:
1 Hoseclamp 8
2 Rubber sleeve 2
3 Rubber sleeve with vacuum 2
connection
4 Vacuumconnection for 1 ReplaceO-ring

brake booster
5 Closure cap 1 ReplaceO-ring
6 Temperature sensor 1
8
cardiagn.com
7 Bleeder valve for carbon 1
canister
8 Left intake distributor 1
9 Rightintakedistributor 1
10 Tuning pipe 1
Centre part of intake 1

distributor

'"
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/
:--
cardiagn.com
'--1JJ
24460006

Installationoverview:
Tighteningfastening screws
2 Fitting vacuum lines
3 Tighteningfuel line
4 Tighteningfuel returnline
5 Installing secondaryair pump (USAvehicles only)
6 Installingtuning pipe
cardiagn.com
7 InstallingthrottJebody
9 Installing passenger's seat

Tighteningfastening screws
Replacethe seals on the intake distributor. Payattention

to the position of the lugs when doing this. Fit the intake
manifoldswith the fuel ring pipe and take the cloths out
of the intake channels.Replacethe micro-encapsulated
screws on the intake system and tighten to 9.7 Nm
(7 ftlb.).
cardiagn.com
2 Fittingvacuumlines
Put on the vacuum line to the brake booster with a new

a-ring. Tightenthe two fastening screws. Tighten the
fastening screw of the bleeder valve for the carbon
canister on the left intake manifold. Put on the crankcase
vent on cylinder bank 1 -3. Clip in the switch-overvalve for
the tuning flap.
3 Tightening
fuel line
Tighten the screwed connection of the fuel line. Make sure

to counter with an open-endedwrench when doing this.
Check screwed connectionfor leaks.
./
/
24400017
24 -78 24 46 23 Installing intake distributor -Boxster 5

'"
'
4 Tighteningfuel return line
Tightenthe screwed connection of the fuel return line

Then check the screwed connectionfor leaks.
cardiagn.com
5 Installing secondaryair pump (USAvehicles only)
Tighten the starter ground cable on the body. Openthe

spring band clamp using commerciallyavailable
spring-bandclamp pliers No. 72 or No. 73 and push it on.
Tightenthe three fastening screws on the secondaryair
pump to 9.7 Nm (7 ftlb.). Connectelectrical connection.
6 Installingtuning pipe
Move tuning pipe into installationposition. Pushthe two

rubber sleevesover the pipe and align. Align the tuning
pipe so that the two arrows are lined up. Then tighten the
four fastening screws and connectthe vacuum lines to the
vacuum modulator and the rubber sleeves.
24 46 23 Installing intake distributor -Boxster 5 24 -79

7 Installingthrottlebody
Move throttle body into installationposition. Pushthe two

rubber sleevesover it and tighten the four hose clamps.
Push on the connector tube betweenthe air cleaner and
the throttle, and tighten the hose clamp. Tighten the
fastening nuts to 9.7 Nm (7 ftlb.).
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Tighten the seven hexagon-headbolts and the two

fastening nuts. Affix rear wall lining.
9 Installingpassenger'sseat
/
Lift the passenger's seat into the vehicle. Connect
electrical connections.Tightenthe four fastening screws
to 65 Nm (48 ftlb.J.
24400002

Boxster Exhaust system
26 01 55 Replacing exhaust system
cardiagn.com
386 .96
26 01 55 Replacing exhaust system 26 -1

Printed in Germany. 1996 986261
Exhaustsystem Boxster
Replacing exhaust system
cardiagn.com
26 -2 26 01 55 Replacing exhaust system

Replacing exhaust system
Location Thread Tightening torque
1 Hexagonnut 5
M8 x 35
3 Clamp 1 Replace, bolt points
upwards
4 Connectingsleeve 1 Push in the direction of Replace, bolt points
catalytic converter upwards
5 Connectortube 1 Pay attention to markings
(rings and arrows).
See Assemblyinstructions
cardiagn.com
6 Catalytic converter 1
Cylinder bank 1 -3
7 Gasket 1 Replace
8 Closingbolt 1 Wrench size 8 mm
9 Washer7.4 1
10 Shield 1
Holder 1
12 Oxygen sensor 1 Tighteningtorque
(only08011vehicles) 55 -60 Nm (41 -44 ftlb.).
13 Holder for oxygen 1

sensors -joint
13a Expandingrivet
14 Plug 1 Tighteningtorque
(vehicles without 08011) 30 Nm (22 ftlb.)
15 Sealingring 1 Replace
(exhaust-gassample point) 10 Nm (7.5 ftlb.)

Exhaust system Boxster
18 Clamp 1 Replace
19 Connectingsleeve 1 Replace
20 Connectortube 1 Payattentionto markings
(ringsand arrows).
21 Catalyticconverter 1
Cylinder bank 4 -6
22 Gasket 1 Replace
23 Shield
24 Oxygensensor 1 Tighteningtorque
55 -60 Nm (41 -44 ftlb).
cardiagn.com
30 Nm (22 ftlb.)
27 Plug
(exhaust-gassample point)
28 Sealing ring 1 Replace
29 Hexagon nut M8 2
30 Reinforcing
plate 2 Payattention to the
installationposition.
See Assembly instructions
31 Hexagon nut M8 2
32 Washer 2
M8 x 20 (Tiptronic)
M8 x 60 (manualtransmissi-
on)
34 Adapter
35 Holder
36 Hexagon nut M8 1
37 Retainerplate
38 Muffler
26-4 26 01 55 Replacing exhaust system

986261 Printed in Gennany -35, 1999
Boxster Exhaust system
Installation notes exhaust system -general
The 900 bend in the connector tube betweenthe The position of the sleeves is located in the
end muffler and the catalytic converter must be middle betweenthe arrowheadson the con-
mounted facing the catalytic converter. It is nector tube and the two circumferentialgrooves
designated by embossed arrowheads.The on the socket piece of the catalytic converter.
arrows are visible from above and below. Whenmounted correctly, only one groove
In order to separate the connector tube and the should be visible.
catalytic converter, the connecting sleeve must
always be pushed in the direction of the cataly-
tic converter.
-f"
cardiagn.com
456_96
455_96
Note:
The connecting sleeves must alwaysbe re-

placed. Whenusing used connecting sleeves,
there is a danger that the exhaustsystem will
leak.

,
I,j?'
Exhaust system Boxster
Assembly instructions on the exhaust system components
Installation position of the sleeves After assemblywork on the exhaustsystem, the

Theopeningsof the sleevesor the fastening ventilationopenings should be checked for distor-
screwsmustpointupwards. tion; if necessary,the panel should be aligned.
cardiagn.com
466_96
457_96
Installation of end muffler

The flow edge of the reinforcing plates for the
muffler holder must point forwards in the directi-
on of travel and towards the centre of the engi-
ne.
26010011
Check heat shield panel
. 26 -6 26 01 55 Replacing exhaust system

Boxster Starter, power supply, cruise control
27 60 19 Removingand installing starter
Removal 5. Loosencable at teminal 30 (M8) and terminal

1. Disconnect
batteryandcoverterminalor bat- 50 (M6) at solenoidswitch. Undo both hexa-
tery. Openenginecompartmentlid. gon-headbolts MIO on the starter and
remove ground cable. Withdrawstarter up-
2. Removeair guidefrom betweenthrottlebody wards from its bracket.
andair filter. Takeout ventlinefrom between
intakedistributorandoil separator.
3. Loosen both hose clamps at intake distributor. t=-

Unscrewfastening screws (M6)for fuel pipe at
intake distributor.
.--,~
:::~:~~
~~
~:::-- ~
cardiagn.com
/I
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~L 3+96
Installation
\.
Tightening torques:
Terminal30 NutM8 15 Nm (11 ftlb.)

33-96 Terminal50 NutM6 6.5 Nm (5 ftlb.)
Hexagorrheadbolt MID 45 Nm (33 ftlb.)
4. Loosenbracketfor throttlebodyon the crank-
case.Swingintakedistributorandthrottle
bodyupwardsby approximately 450 and
removebracketon the throttlebody.
27 60 19 Removing and installing starter 27-1

rd
./11
Boxster Starter, power supply I' cruise control
27 22 19 Removing and installing generator
Removal 6. lift generator up and out of the slotted gener-

1. Disconnect the batteryandcoverterminal ator bracket. Unscrewfastening screw and re-
or battery.Removerightseat.Openrearwall move with deflection roller.
coverbehindthe seats.
7. Thegeneratormustbe turnedclockwiseso
2. Openenginecompartmentlid and disconnect thatthe swivelarm is nearthe crankcaseand
the cablelug of the B+ linesto the generator the holdingarm projectsbeyondthe fastening
andto the starter at the B+ connectionpoint. eye.
3. Relievethe drive belt at the tensioningpulley 8. Carefullypull the generator forward a little and
andremovethe belt. undo the electrical connections,or press the
plug connectionto the generator housing, re-
4. Undoright-hand fasteningscrews(in direction lease (arrow A) and pull off. Pull out generator
to the front.
cardiagn.com
of travel)and unscrew.
5. Undoleft-handfasteningscrew(withdeflection
roller)by threeturns.A gentletap on the fa- ~
~
steningscrewloosensthe threadedbushingin
/""~
the generatorarm (usealuminiummandrel).
:~~:;:::::??
'-/
\\
640_96
35_96
27 22 19 Removing and installing generator 27 -3

-,
27 Starter, power supply, cruise control Boxster
Installation Tool for holding the free-wheel pulley

Tightening torques:
For 2.7 I Boxster and 3.2 I Boxster 5
(manual transmission only)
Hexagon nut a/f 24 M16xl.5 65:t5 Nm 2.7 I as from Engine No. 65 Y 02460
(48:t3.5 ftlb.) 3.2 I as from Engine No. 67 Y 00936
Hexagon-head
bolts MIa 45 Nm Usean aff 17 multiple-tooth
adapterto holdthe
(33 ftlb.) free-wheel pulley.
Hexagonnutaff 13 M8 15 Nm Nf 17 multiple-toothadapter:seeWorkshop
(11.0ftlb.) EquipmentManual,chapteron commercially
availabletools,No. 32-1.
The line to the generator must be on top when
the cable lug of the B+ lines to the generator
and to the starter is reconnectedto the B+ con-
nector. Engage plug connection and route wire
carefully.
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Undoing and tightening the belt pulley
Note
The belt pulleycan be undoneandtightened
usinga standardcommercially availabletool.
Tools:doubleoffsetringwrenchaff 24, screw-
driverinsertfor internalserrationscrewaff 10,
cross handleandtorquewrench.
27220001
The hexagon nut a/f 24 must be countered with

the ring wrench during tightening. The shaft is Note
tightened to the prescribed tightening torque of Counterwith a double ring wrench when tighten-
65 :t 5 Nm (48 :t 3.5 ftlb.) using the screw- ing with the a/f 17 multiple-toothadapter. The
driver insert and the torque wrench. shaft is tightened to the prescribed tightening
torque of 80 :t. 5 Nm (59 :t. 5 ftlb.) using the
screwdriver insert (a/f 10 internal serration
screw) and torque wrench.
.
27 -4 27 22 19 Removing and installing generator
Boxster Starter r power supply r cruise control
27 84 19 Removing and installing cruise-control actuator
Note 5. Loosen adjustingpiece at cruise-controlactua-

The cruise-controlactuator is fastened with tor (bayonetlock) and disengagecruise-con-
three screws to the pedal bearing block above trol cable.
the accelerator.
0
y
.;"'/
'-.~
~
~/
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~ ~~
~
n 213 -96
212 -96
A -Snap ring
1. Removeair guide and footwell air vent of the
heating and air conditioningsystem. Remove B -Adjusting piece
brake~ightswitch from pedal bearing block.
C -Threaded part
2. Only loosenfasteningscrewson the cruise-
D -Cruise-control actuator
controlactuator.
3. Drawcruise-controlactuator to the rear and

extract to the side. Disconnectelectrical plug
connection.
4. Loosen snap ring at adjusting piece (displace

it) and push threaded part through along with
cruise-controlcable.
27 84 19 Removing and installing cruise-control actuator 27 -5

Printed in Germany -1996 986271
~./
~
Starter, power supply, cruise control Boxster
Adjusting cruise-control cable
291 -96 292 -96
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Sequence1...4 Sequence
5...7
1. Loosen snap ring 1 at adjustingpiece 2 (dis-

place it) and push threaded part 3 through
along with cruise-controlcable.
2. Engagecruise-controlcableon cruise-<;ontrol
actuatorandclip on adjustingpiece4 (bay-
onetlock).
3. Unscrewthreadedpart 5 untilthe accelerator

plateis noticeablypulled.
4. Drawacceleratorplatefirmlybackagainstits
idle stop.
5. Pushsnapring 6 back(fixingit).
6. Makefine adjustmentby turningthe

threadedpart 7.
Permissible
play:a + 1 mm.
27 -6 27 84 19 Removing and installing cruise-control actuator

986271 Printed in Germany -1996
27 60 19 Removing and installing starter -Boxster S
Removal
1. Moveconvertibletop to serviceposition. 5. Detachthe cableof terminal30 (M8)and ter-

Disconnectthe batteryandcoverterminalor minal50 (M6)on the solenoidswitch.Undo
battery.Openthe engine-i:ompartment lid. bothhexagon-head bolts MID on the starter
andremovethe groundlead. Lift starter out of
2. Undohoseclampbetweenthrottle bodyand the holder.
air cleaner.Disconnect ventlinebetweenin-
take distributorandoil separator.
3. Loosenbothinnerhoseclampsat the intake

\' '"/
distributor.
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~ ,
":"...
)\ -:
1/
~
1_/1
27600002
6
~ Installation
/
~ ?
Tightening torques:
\\ Terminal30 NutM8 15 Nm (11.0 ftlb.)
Terminal50 NutM6 6.5 Nm (5.0 ftlb.)
27600001
Hexagon-head bolt M10 45 Nm (33 ftlb.)
4. Undoholderfor the throttle bodyon the crank-

case.Swivelthe intakedistributorwith throttle
bodyupwardby approx.450 anddetachthe
oil filler hose.
27 60 19 Removing and installing starter -Boxster S 27 -7
~
Boxster Starter I power supply, cruise control
2706 Work instructions after disconnecting the battery
Effect of disconnection or total dischar- Control module memories:

ge of the battery on electrical systems
in the vehicle, subsequent measures: Valuesandfaultsstoredin the controlmodules
can be deletedif the batteryis disconnected
or
1. Neverdisconnectbatterywith enginerunning. completelydischarged.
2. Neverstart enginewithoutsecurelyconnected Remedy:

battery. If possible,all faultmemoriesshouldbe
checkedand,if necessary,printedout before
3. Do not usea boostchargerto start the en-
the batteryis disconnected.
gine.
4. Wheneverpossible,usejumpleadswith over- Supply voltage fault entry:

voltageprotection.
cardiagn.com
The entry "supplyvoltage"could be stored in
5. Alwaysdisconnectthe batteryterminalsbe- various control modules if the battery has been
fore carryingoutweldingwork on the vehicle. completelydischarged.
6. Wiring harness plugs of control modulesor Remedy:

other electronic components must be con- Delete the "supply voltage" entry from the con-
nected or disconnectedwith the ignition off. trol modules in question.
Exception:vehicles with the additional
equipmentM 536 (alarm siren with tilt sen- Test drive after connecting the battery:
sor).
The fault memories of all vehicle control mod-
Note concerning M 536: ules should be read out again after the test
In order to avoid triggering the alarm siren (in- drive.
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),
27 06 Work instructions after disconnecting the battery 27 -9

24 70 DME control module: Remedy:
Perform a test drive. During the test drive, drive
After disconnection of the powersupply,the idle the vehicle with varying load conditions and at
speedmightchangeor fluctuatebrieflyuntilthe various speeds so that all shift functions (manual
idle speed positioner (M 5.2) or the throttle and automatic programs)are executed at least
adjustingunit(ME7.2) is readapted.Themixture once. This readapts the shifting pressures of the
adaptationis also lost. system and thereby re-establishessmooth shif-
ting.
Remedy:
After the batteryis connected: 64 52 Power windows:
With the DME ME 7.2, it is necessaryto carry The limit positions of the power windows are de-
out a learning and adaptation routine as des- leted from the control module when the battery
cribed below: is disconnectedand connected.
Switchthe ignitionon for 1 minutewithout Remedy:
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startingthe engine.Do notoperateaccelera-
Manually closeeachpowerwindowas far as it
tor pedal.
will go, thenpressthe rockerswitchfor closing
the windowagain.The limitpositionof the re-
Switchoff ignitionfor at least 10 seconds.
spectivepowerwindowis nowstoredin the
Thiscompletesthe adaptationof the throttle controlmoduleagain.
adjustingunit.
90 25 Instrument cluster:
With all DME systems,the engine must run
for several minutes before the engine con- Thetrip counteris set to 0 whenthe power
trol modulecan relearn the idle speed and supplyis disconnected.
mixtureadaptationvalues.
90 30 Clock:
37 30 Tiptronic:
Depending on the softwareversion,the clock is
Thestoredpressureadaptationvalvesare lost if set to 12:00 a.m. or 1:00 a.m.whenthe power
the powersupplyto terminal30 is interrupted. supplyis disconnected.
Thiscan resultin poor shiftingqualityandrough
shiftoperationsduringthe adaptationphase. Remedy:
Enterthe currenttime again.
Note:
Onvehicleswith PCM,91 10 PCMposition3.
27 -10 27 06 Work instructions after disconnecting the battery

986279 Printed in Gemlany -32, 1999
90 80 On-board computer: 5. If thetelephone
cardwasinsertedandthetele-
phonewas readyfor operation,the telephone
Disconnection of the vehiclebatterydeletesthe is subsequentlydisabled.
memoriesfor averagespeedandaveragecon-
sumption. Remedy:
As a result,the displayedrangeon remaining 1. Inputthe PCMcode. If the code card is un-
fuel can be markedlydifferentor evenO. available,the PCMcode can also be read from
Theoutsidetemperatureindicatorlosesits the DMEcontrol module(under "Vehicledata").
memoryeffect.In other words,the indicated This code is also availablefrom the Porsche
outsidetemperaturecan be too highdueto the IPAS.
heatradiated whenthevehicleis hot.
2. Switchon the PCMwith a free panoramicview
91 20 Radio: for approx.20 minutes(to loadGPSalmanac).
Theradiorevertsto the Codefunctionwhenthe 3. The date and time are also adopted once the
batteryis disconnected
and is thusno longer GPSalmanac has been loaded (see step 2); it
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readyfor operation. may be necessaryto change over to summer
time (daylight-savingtime). This time is trans-
Remedy: ferred to the instrumentcluster. If the time is
Inputthe radio code. If the code card is una- then manuallychanged by means of the instru-
vailable,the radio code can be read from the DME ment cluster, this time is adopted by the PCM
control module(under'Vehicledata"),The code is and synchronisedwith GPStime.
also availablefrom the Porsche IPAS.
4. Thestoredstationsare displayedagainwhen
stationbuttons1 to 6 are pressed.
91 10 PCM:
5. Thetelephoneis enabledagainwhenthe tele-
1. ThePCMrevertsto the Codeinputfunction
phonePINcodeis enteredwith the SIMtele-
whenthe batteryis disconnected
andis thus
phonecard inserted.
no longerreadyfor operation.
2. Whenthe power supply is disconnected,the

built~nGPSreceiver loses the so-called"alma-
nac" containingthe satellite orbital paths.
3. Thedateandtime are deletedwhenthe

batteryis disconnected.
4. Radiostationsstored by the customerare no

longerdisplayed.
27 06 Work instructions after disconnecting the battery 27 -11

28 44 19 Removing and installing rotor for hall sensor
Tools
("\
..40
0
VW 402
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Designation Special tool Explanation
Extractor Commerciallyavailable
B Spacer VW545/2
C Pressure plate VW402
D Pressurepiece 9628
28 44 19 Removing and installing rotor for hall sensor 28 -1

Ignition system Boxster
Removal 3. Use the pressure piece (special tool 9628)

1. Heat rotor area with a hot-airgun. to press the rotor onto its seat. Use pressure
Pull off rotor with a commercially plate VW402 as the camshaft support
availableextractor. surface on the workshop press.
Place a spacer, e.g. VW545/2,
betweenthe spindle and camshaft.
,}L,
cardiagn.com
~
"-="'
/
I
/
,,-
-'"/1 ~ 365_98
366_98
Installation
1. Thoroughlyclean the rotor mounting surface.
Coat the seat area with Loctite 270.
2. Fit new rotor in the correct position by hand.
.~
~
407_98
28 -2 28 44 19 Removing and installing rotor for hall sensor

986281 Printed in (~ermany -23, 1998
Q
Boxster Ignition system
28 73 19 Removingand installing pulse sender
Removal
1. Removerightrear wheel.
2. Disconnectplug connection;to do this, press

the clip and simultaneouslypull off the plug.
Pull the lower plug half out of the holder
to the right.
~l
P Engineremoved for the sake of clarity 403_98
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Installation
1. Install pulse sender.
t\ Tighteningtorque of the pan-headscrew
~~~~
\~ -'1.//
(M6x16): 10:t0.5 Nm (7.5:f:O.5ftlb.).
Engineremoved for the sake of clarity 316_98 2. Push in lower plug half on the holder.
3. Unclip cable (arrow 1). 3. Push plug on until it audiblyengages.

Undo M6 x 16 pan-headscrew (arrow 2)
(wrench size 4 mm) and remove
the pulse sender.
28 73 19 Removing and installing pulse sender 28 -3


986 Group 2 Fuel-Exhaust PDF

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TechnicalManual

WKD 483 521

The integration of the technical informationpublishedin the "Boxster"TechnicalManualwith the

The "Boxster"TechnicalManualconsists of 15 folders, subdividedinto the following Groups

Title page, "Boxster" Technical Manual

Title page: "Technical Information"

Followingthe Technical Information,separated by a title page, the instructions on repairs -assigned

Theinstructionson repairswill be extendedand updatedby meansof supplements.

Sheetsthat alreadyexistin the "Boxster"TechnicalManualandare updatedor revisedand thereby

Group 0: Entire vehicle -General 0

Group 3: Transmission, manual transmission 3

Group 3: Transmission, automatic transmission 3

Overview of repair groups

Group 4: Running gear 4

Group 6: Body equipment, exterior 6

Group 7: Body equipment, interior 7

Group 8: Air conditioning 8

Group 9: Circuit diagrams 9

Group 9: Circuit diagrams 9

Overview of repair groups

2 Fuel, exhaust, engine electronics

20 Fuel supply, control

Fuel system, electronic injection

Disassembling and assembling fuel

27 Starter, power supply, cruise control

27 6019 Removing and installing three-phase

2 Fuel, exhaust, engine electronics 1

2706 Workinstructionsafter disconnecting

20 02 01 Checking fuel pressure

20 02 01 Checking fuel pressure 20 -1

Checking fuel pressure

1. Undo covering cap on test connection of fuel

2. Connectpressure gauge (specialtool P 378a)

-I ~.l Engine idling 3.3 ::!:0.2 bar

Via fuel-pumprelay without Tester:

20 -2 20 02 01 Checking fuel pressure

20 66 01 Checking quantity delivered by fuel pump

Fuelfilter and electrical supplyin order,

1. Relievepressurein fueltank by openingtank /

4. Removerear underside panel, - /

6. Hold fuel line in a measuringcontainer. Actu-

2066 19 Removing and installing fuel pump 20-5

Removing and installing fuel pump

1. Undo battery terminals and battery holder. Lift

4. Undounionnutwith VWspecialtool 3217,

7. Put on fuel-proofglove, hold the fuel pump

20-6 20 66 19 Removing and installing fuel pump

149-96 448 -96

20 15 01 Calibrating fuel level sensor system

Warning! -Select menu item Tank calibration

& Danger of fire and injury!

> Observegeneral safety

Note The fuel level sensor system need not be

3. Using a fuel extractor, completelydrain

4. Reinstallthe fuel level sensor and, with

5. Perform tank calibration with the Porsche

Select vehicle type (911 Boxster)

-Select control modules

20 39 19 Removingand installing fuel return line

& Danger of fire and injury!

> Observegeneral safety

> Wear protective gloves,