Porsche 986 Boxster 1996 to 2004 - Service Repair Manual - Wiring Diagram - Owners

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PORSCHE 986 BOXSTER - SERVICE MANUAL / REPAIR MANUAL

- English Service Manual, Wiring Diagram and Owners Manual to vehicles Porsche 986 Boxster 1996 to 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

AND MORE....