www.WorkshopManuals.co.uk
Technical Manual -~~.s:TLr
Technical Information
Contents: Group 1
Engine Part 1 (up to Repair Group 13)
WKD483 521 19
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www.WorkshopManuals.co.uk Boxster
Engine,part 1 (up to RepairGroup 13)
Supplement Overview
Supplement
Edition
Article number
Topic
05/1996
Basic edition
2
08/1996
Modifiedrepair group
WKD483521.02
9
03/1997
Generalsupplement
WKD483521.09
12
07/1997
Generalsupplement
WKD483521.12
15
08/1997
Generalsupplement
WKD483521.15
16
11/1997
Generalsupplement
WKD483521.16
18
01/1998
Generalsupplement
WKD483521.18
19
03/1998
Generalsupplement
WKD483521.19
20
03/1998
Generalsupplement
WKD483521.20
23
07/1998
25
02/1999
Generalsupplement
WKD483521.25
27
06/1999
Generalsupplement
WKD483521.27
30
07/1999
Generalsupplement
WKD483521.30
31
08/1999
Generalsupplement
WKD483521.31
32
09/1999
Generalsupplement
WKD483521.32
34
10/1999
Generalsupplement
WKD483521.34
35
12/1999
Generalsupplement
WKD483521.35
36
12/1999
Generalsupplement
WKD483521.36
42
11/2000
Generalsupplement
WKD483521.42
Supplement
WKD483521
I General supplement
Overview
Printed in Germany -42,
2000
Masterltl
Purchased from www.WorkshopManuals.co.uk
WKD483521.23
.
www.WorkshopManuals.co.uk Foreword
Boxster
Table of Contents
1
Foreword Foreword
Foreword
-1
page
Use
-2
page
.
t
Table of Contents Printed in Germany -42,
2000
mastereV_l
Purchased from www.WorkshopManuals.co.uk
1 1
www.WorkshopManuals.co.uk Foreword
Boxster
Foreword This manual contains Technicallnformation as well as instructions on repairs for Porsche vehicles. It is intendedfor the sole use of workshopsbelongingto PorscheAG. The descriptionsform the basis for professionaland correct maintenance and repair work. The content of the work procedures described is based on the level of training of a fitter who has completed vocationaltraining and has a sound knowledgeof the product. This level of knowledgeis necessaryin order to carry out the work described. Warning notes
The warning notes and safety instructionsare classified by the respective signalisingword (Danger,Warning,Caution)besidethe warningsymbol.
Warnsagainst death or very serious injury whichwill certainly occur if the instructions are not observed.
Warnsagainst death or very serious injury which may occur if the instructions are not observed.
Warns against minor injury or damage to property instructions
if the
are not observed.
To prevent injuryand restricted operating and traffic safety of the vehicle,or damage to the vehicle as the result of incorrect work, read these instructions carefullyand observethem withoutfail. It is not possiblefor PorscheAG to give a detailed evaluationof all danger situationsfor the personscarrying out the work. It is therefore imperativethat all persons carrying out repair and maintenance work on Porschevehicles use their specialistknowledgeto ensure that their own safety is not at risk and the procedure chosenwill not have anynegative effects on the vehicle -especially with regard to
safety. It is therefore expresslyspecified that all work involvedin the work proceduresdescribed shouldbe carried out onlyin accordancewith the valid guidelinesand regulationsof the local authorities responsible with respect to health and accidentpreventionand environmen-
Foreword
-1 page 1
Printed in Germany-42, 2000
vorwort
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www.WorkshopManuals.co.uk Foreword
tal protection, and in compliancewith the legal requirementsof individualcountries.
Notes Notes contain advisory informationrelated to the work procedure which makes the fitter's work easier. The following pictogram indi.
cates thisinformation:
rn Note! Containsadvisoryinformationwhich makes the work procedure eas-
Ier. Due to the continuous developmentand improvementof our vehicles, there may be discrepanciesbetweenthe actual technical status of the vehiclesand the work descriptions. Anyexisting deviationsare corrected by meansof supplements,and the scope of the descriptions is extendedwith supplements. PorscheAG retainsthe right to implementchangesat anytime and without prior notice.
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Boxster
www.WorkshopManuals.co.uk Boxster
Foreword
Use The wprkshop documentationfor the Boxster (986) model hasthe desig~ation -"Boxster (986)" Technical Manual- and containsTechnical Infor~ation as well as instructionson repairs. The integration of the technicalinformationpublishedin the "Boxster l TeChnical.Manual
{~86) vides
with the descriptive
he user with a complex
reference
matter on r~pair~ pro-
work that combines Into
one b ok associated or cross-referencedmaterial of relevanceto works ops and originatingfrom variousinformationmedia.
The"~oxster(986)"TechnicalManualconsistsof 15 folders,subdividedIntothe followingGroups .0
!
ntire vehicle -General
.0
iagnosis,1 Engine,part 1 (up to RepairGroup 45)
.0
iagnosis,1 Engine,part 2 (as of RepairGroup 69)
.1
ngine, part 1 (up to RepairGroup 13)
.1
ngine, part 2 (as of RepairGroup 15)
.2
uel, exhaust,engine electronics
.3
ransmission,manualtransmission
.3
ransmission,automatictransmission
.4
unninggear
.5
ody
.6
Body equipment,exterior
.7
Body equipment, interior
.8
/ 9 Air conditioning/ Electrics
.9
qircuit diagrams, part 1 (up to and including'99 model)
.9
qircuit diagrams, part 2 (as of and including'00 model)
The two folders with Group0 are to be regarded as one folder; i.e. file the "Technicallnformation"notices only in the folder "Group0 Diagnosis,part I" -up to Repair Group 45-. The s~condfolder Group 0 Engine,part 2 -as of Repair Group 69- inFludesthe further RepairGroupsbelongingto Group 1. The two folders with Group1 are to be regarded as one folder; i.e. file the "TechnicaiInformation"onlyin front of the repair descriptions in the folder Group 1 -Engine, part 1 -up to Repair Group 13-. The s~condfolder Group 1 Engine,part 2 -as of Repair Group 15- inFludesthe further RepairGroupsbelongingto Group 1.
Use Printed in Germany -42,
-2 page 1 2000
handhabung
Purchased from www.WorkshopManuals.co.uk
www.WorkshopManuals.co.uk Foreword The two folders with Group9 are to be regarded as one folder; i.e. file the "Technicallnformation"notices only in the folder Group9 Circuit diagrams, part 1 -up to '99 model-. The second folder Group 9 Circuit diagrams, part 2 -as of '00 model- includesthe further Repair Groupsbelongingto Group9. The "Boxster (986)"TechnicalManualhas the same structure in each folder I with the following breakdownfor all Groups:
Title page: "Boxster
(986)" 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 seen from the breakdown,the publishedTechnicallnformation is in the front part of each folder -numbered accordingto the Groups.The Table of Contentsassignedto each Groupwill be periodicallyupdated. Followingthe TechnicalInformation, separated by a title page,the instructionson ~epairs-assigned according to the Groupsor broken down into R~pairGroups-are included in the folders. The instructions on repairswill be extended and updated by means of supplements.
rn Note! Sheets that alreadyexist in the "Boxster(986)" TechnicalManual and are updatedor revisedand therebyexchangedby a supplement are designatedin the footer with the supplementnumbercorresponding to the current version: e.g. "Printed in Germany-2,2000"
[I) Note! Due to a systemmodificationin the TechnicalLiterature production, the fol/owingprocedureshave changedin model year 2000!
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Boxster
www.WorkshopManuals.co.uk Boxster
Foreword
1 -The previous record the supplement omitted.
sheet in the folder "'O-General" and
contents
A supplement
rately in each folder.
sheet -red sheet- have been
overview now aplpears sepaThe new supplement
sheet can be destroyed
contents
after the supplement
is filed in
the folder.
[IJ Note! The supplementoverviewsheet is replaced with the relevant supplementin the correspondingfolder and must no longer be maintainedby hand. 2 -The
page numbering
in the new and the replaced
ters are no longer continuous. given an additional
chap-
Each new chapter is now
chapter number followed
by the
page number e.g. -2 Page 11 ~ Rep. Gr. 0; General 3 -The old page numbering
still applies to E~xisting chap-
ters and those that are not replaced.
Use Printed in Germany -42,
-2 page 3 2000
handhabung
Purchased from www.WorkshopManuals.co.uk
www.WorkshopManuals.co.uk Overview of repair groups
Boxster
Group 0: Group 0:
Group 0:
Entire vehicle -General
0
Maintenance
03
Diagnosis
0
Sales check On-boarddiagnosis DMEdiagnosis Tiptronic diagnosis ABS diagnosis
01
Group 2:
Group 3:
Group 3:
69 72 80 90 91 91 94
1
Engine Engine-Crankcase, suspension Engine-Crankshaft, pistons
Group 1:
24 37 45
0
Diagnosis Airbag diagnosis Seat memory diagnosis Heatingdiagnosis Alarm system diagnosis PCMdiagnosis ParkAssistentdiagnosis HBAdiagnosis
Group 1:
03
10 13
1
Engine Engine-Cylinder head,valve drive Engine-Lubrication Engine-Cooling
15 17 19
Fuel, exhaust, engine electronics
2
Fuel supply,control Exhaustsystem, turbocharging Fuel system, electronic injection Fuelsystem, K-Jetronic Exhaustsystem Starter, power supply, cruise control Ignition system
20 21 24 25 26 27 28
Transmission,
3
manual transmission
30 34 35
Clutch, control Manual transmission -Actuation, housing Manual transmission -Gears, shafts, into gearsh, Final drive, differential, differential lock
39
Transmission, automatic transmission
3
Torque converter Automatic transmission-Actuation, housing Automatic transmission-Gears, control Final drive, differential,differential lock
32 37 38 39
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Overview of repair groups
Group 4:
4
Running gear
40 42 44 45 46 47 48
Front whee! suspension, drive shafts Rear wheel suspension, drive shafts Wheels, tires, suspension alignment Anti-Lock Brake System (ABS) Brakes -Brake mechanics Brakes -Hydraulics, regulator, booster Steering
Group 5:
5
Body
Bodyfront Bodycenter,roof,frame Bodyrear Lids,flaps Door front,centrallockingsystem
50 51 53 55 57
Group 6:
Body equipment, exterior Slidingroof Convertible top, hardtop Bumpers Glazing,windowcontrol Exteriorequipment Interiorequipment Passengerprotection
6
Group 7:
Body equipment, interior Linings,insulation Seatframes Seatupholsteries, covers
7
Group 8:
Air conditioning Heating Ventilation Air conditioning Auxiliaryair conditioningsystem
8 80 85 87 88
Group 9
Electrics
9
Group 9: Group 9:
60 61 63 64 66 68 69 70 72 74
Instruments,alarm system Radio,telephone,on-boardcomputer, navigation Windshieldwiper and washer system Lights, lamps, switches exterior Lights, lamps, switches interior, theft protection
90 91
Circuit diagrams
9
Wiring (up to and including the '99 model)
97
Circuit diagrams
9
92
94
96
97
Wiring (from the '00 model)
Overview of repair groups Purchased from www.WorkshopManuals.co.uk d in Germany
-34,
October
1999
www.WorkshopManuals.co.uk Boxster
Engine, part 1 (up to Repair Group 13)
Table of Contents
1
Engine, part 1 (up to Repair Group 13)
1
Engine
1 1
Tightening Teoonical Differences
data torques between engine for Boxster M96/20 engine
2.5 M96/20 I,
2.71
(2.5 and
I), Boxster M96/21
S
(3.2 (3.2
I)I), engines M96/22
(2.7
I)
1-01 1-05 1-1 page
10
Engine -Crankcase,
100121
Installing Removing Disassembling
Adjusting Adjusting Tighteningtorques Special Removing Special Installing
engine,tools. tools notes engine, engine... tool
engine
and
M96/20
M96/20 assembling
1
suspension .,..",.,
(2.5
(2.51)
I)
engine crankcase positive ,.".,.".".,.".",.".",.",.""" with with
manual
manual
crankcase
halves,
transmission transmission
engineventilation.
M96/20,
M96/21,
1001 23
100137 105037
10-1
page
1
10-1
page
1
10-1
page
3
10-1
page
5
10-5
page
1
10-5
page
1
10-5
page
3
10-5
page
5
10-5
page
5
10-5
page 21
10-9 10-21
10 1037 M96/22 Removing Installing Removing
Assembling Tighteningtorques Adjusting Adjusting Mounting Special Tighteningtorques Removing Special Special Installing
engine, tools... tools.. notes engine, engine,engine tool instructions tool engine
the
M96/20 crankcase M96/21 M96/20
(2.5
(2.5 (3.21)
halves
I)
I)
with
with and
TiptronicM96/22 Tiptronic
transmission (2.7 transmission
I)
with
manual
transmission
,
,
100121
100123
100121 Installing
1001
Adjusting Special Removing
engine, tools.
tool
engine
M96/21
(3.2
I)
and
M96/22
(2.7
I)
with
manual
transmission
231
Specialtools.
Purchased from www.WorkshopManuals.co.uk Table of Contents
10-25
page
1
10-25
page
3
10-25
page
4
10-25
page
8
10-33
page
1
10-33
page
1
10-33
page
3
10-33
page
4
10-50
page
1
10-50
page
1
10-50
page
3
10-50
page
4
10-50
page
5
10-50
page 22
10-57
page
1
10-57
page
1
10-57
page
3
10-57
page
4
10-73
page
1
10-73
page
1
www.WorkshopManuals.co.uk Boxster
Engine, part 1 (up to Repair Group 13)
Adjustingtool Tighteningtorques Special notes Installing engine
,
103037
Disassembling
13
Engine -Crankshaft,
137819 137720 138219 137319 137337 134937 134819 131019 137419 135919 131019 131019
Removing Removing Disassembling
and and and
and assembling
installing installing installing and
assembling
engine
carrier
10-73
page
3
10-73
page
5
10-73
page
5
10-73
page 20
10-87
page
1
pistons tensioning pistons drive deflection belttensioner crankshaft
belt
bearing beltfor -Boxster
rollers roller sealing engine tensioner
housing
for
for S
type ring ring
drive drive
(engine M96/22 with
belt...
belt
crankshaft.
installed) installed)
(2.7
I)
13-1 13-4a 13-4c
13-4e 13-40
13-5 13-19 13-23 13-41 13-47
13-49 13-77
Purchased from www.WorkshopManuals.co.uk Table of Contents
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Engine
Tighteningtorques for engine M96/20 (2.51), M96/21 (3.21), M96/22 (2.7 I)
Screws,bearing housing Initialtightening: Finaltightening:
20 (15) 1 x 900
Connecting-rodscrews with connecting-roddesignation...7R Initialtightening: Finaltightening:
M9 x 1.25
Connecting-rodscrewswith connecting-roddesignation...7R Initialtightening: Finaltightening:
M9x 1.25
Oil guide to bearing housing Screws,crankcase halves
20 (15) 1 x 900
20 (15) 1 x 1100 M6 (micro-encapsulated)
10
M6
10 (7.5)
Additionalbolts
M9 x 150
22 (16)
Crankcase/bearinghousing
M9 x 94
22 (16)
Oil suction pipe to crankcase
M6
10 (7.5)(7.5)
Air/oil separator to crankcase
M6
10
Oil pan to crankcase
M6
10 (7.5)
M18 x 1.5
50 (37)
S80 x 3
25:f:1 (19:t1)
MI0
45 (33)
Oil drain plug to oil pan Oil filter to crankcase Coolantguide housingto crankcase Intermediate-shaftflange
M6 (micro-encapsulated)
10 (7.5)
Lock nut on intermediate-shaftflange
M8xI
13 (9.5)
Screwplug for piston pin assemblybore of cylinder bank 4 -6
M27x 2
80 (59)
M6
10(7.5)
Bolt for slide rail Belt pulleyto crankshaft Initialtightening: Finaltightening:
M16 x 15 50 (37) 1 x 900
Thrustplate to double-massflywheel
M8
Drive plate to crankshaft(Tiptronic) Initialtightening: Finaltightening:
MID x 1 x 25 (12.9)
23 (17) 25 (18) 1 x 900
Coolantpump to crankcase
M6
10(7.5)
Chaintensioner to crankcase
M27 x 2
80 (59)
MID
60(44)
Belttensioner roller to lever for tensioningelement Belt deflection roller 1 to crankcase
MID x 145 (B.B.)
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46 (34)
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Engine
Location
Thread
Tightening torque Nm (ftlb.)
Belt deflection roller 2 to bracket for hydraulic
23 (17)
pump
Belt pulleyto generator Belt pulleyto hydraulicpump Cylinderhead to crankcase 1 st step Completelyundone 2nd step 3rd step 4th step
M16 x 1.5
65:1:5(48:1:3.5)
M8 x 12
23 (17)
MI0 x 230 30 (22) 600 torque angle 600 torque angle again
Flat-basetappet housingto cylinder head
M6
10 (7.5)
Camshaftbearing saddlesto cylinder head
M6
10(7.5)
Cylinder-headcover to cylinder head
M6
13(9.5)
M14 x 1.25
30+3 (22+2) first fitting 25+5 (18+3.5) re-fitting
M6 x 15 (10.9)
14(10)
M27x2
80 (59)
Spark plugs Camshaftdrive wheel and drive plate to camshaft Chaintensioner to cylinder head
10 (7.5)
M6 (micro-encapsulated)
Intake pipe to cylinder head Plug, oil-pressureduct to cylinder head Oil extraction pump to cylinder head Oil-levelsender to crankcase Oxygensensor to catalytic converter Knock sensor
10(7.5)
MID xl M6
10 (7.5)
M14 x 1.25
max. 20 (15)
M18
55:t5 (41:t3.5)
M8
20:t2 (15:tl.5)
10(7.5)
M6(micro-encapsulated)
Hall-effectsensor
M6
10(7.5)
NTC coolanttemperature sensor
M14x 1.5
25:t5 (18:t3.5)
Oil pressure switch
M14x 1.5
2O::t5 (15:t3.5)
Starter
MID
45 (33)
Generator
MID
45 (33)
Ignition coil to cylinder head
M6
10(7.5)
Power steering pump to bracket
M8
23 (17)
Pressurepipe of hydraulicpump
M16
24 (18)
Oil supply tank to hydraulicpump
M8
23 (17)
M22x 1.5
32 (24)
M6
10 (7.5)
Speed sender
Checkvalve for auxiliaryair injection Coolantpump to crankcase
Purchased from www.WorkshopManuals.co.uk Tightening torques for engine M96j20 (2.5 I), M96j21 (3.2 I), M96j22...
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1
Engine
Technical data
Engine
14O_98
Engine type:
M 96/20
Number of cylinders
6
Bore
mm
85.5
Stroke
mm
72
Displacement
cm3
2480
11.0: 1
Compression ratio
Max. engine power as per 80/1269/EWG as per SAEJ 1349 at engine speed
kW HP rpm
150 201 6000
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Max. torque as per 80/1269/EWG at engine speed
Nm (ftlb.
245 (181)
rpm
4500
Max. litre output as per 80/1269/EWG
kW/I,HP/I
60.48/82.26
Idle speed -manual transmission Tiptronic sel. lever in P or N Tiptronic sel. lever in drive position and A/C on Rpm limitation at
rpm rpm rpm rpm rpm
790 750 790 800 6700
Engine weight Manualtransmission Tiptronic transmission
kg kg
182.2 172.7
Boxster
Valvecontrol
DOHCwith camshaft adjustment(VarioCam)
Valve arrangementper cylinder
2 inlet,2 outlet,suspendedparallelV-arrangement
Valve clearance
Hydraulicvalve clearance compensation
Valve timing with 1 mm valve travel
Inlet opens 150 after TOC Inlet closes 460 after BOC Outlet opens 380 before BOC Outletcloses 70 before TOC
Engine cooling Type
Liquid cooling,two electric fans
Engine lubrication
Integrated dry sump
Oil cooling
Via oil-water heat exchanger
Oil pressure at 5000 rpm Oil temperature 90 °c
bar
approx.5
Oil consumption
1/1000 km
up to 1.5
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Engine
Fuel system
DME 5.22 with sequentialfuel injection
Fueldelivery
1 electr. fuel pump
System pressure without vacuum
3.6
bar
FuelRON/MON
4.0
at least 98/88
Fuel consumption as per 93/116/EG
VIDD km VIDD km VIDD km
City
Highway Overall Target CO2value
g/km
Emission control
Manualtransmission
Tiptronic
14.3 7.1
15.8 8.1 10.9
9.7 239
263
Oxygensensing and three-waycatalytic converter (metallic substrate)
Electrical system Nominal voltage
V
Alternator output
W/A Ah/A Ah/A
Battery, manual transmission Battery I Tiptronic
12 1680/120 60/280 70/320
Ignition
DME 5.22, with static high-voltagedistribution and cylinder-selectiveknock regulation
Ignition sequence
1-6-
2-4-3-5
Spark plugs
Bosch Beru Electrode gap
FR 7 LDC 4 14 FR 7 LDU
mm
0.8 + 0.1
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1
Engine
Differences between Boxster 2.5 I, 2.7 and Boxster S (3.2 I) engines
Foreword
The following chapter describes the main engine differences which apply to the Boxster.
Technical data
Engine
Boxster 2.5
Boxster 2.7
Boxster S (3.2 I)
Enginetype
M 96/20
M96/22
M 96/21
Numberof cylinders
6
6
6
Unit
Component
Bore
mm
85.5
85.5
93
Stroke
mm
72
78
78
Cubic capacity
cm3
2480
2687
3179
11.0:1
11.0:1
11.0:1
Compression ratio
Engineperformance
KW
150
162
185
at engine speed
rpm
6000
6400
6250
Torque
Nm {ftlb,
245 (181)
260 (192)
305 (226)
at engine speed
rpm
4500
4750
4500
Max. engine speed
rpm
6700
7200
7200
ME 5.2
ME 7.2
ME 7.2
E-gas
E-gas
Engine control
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1
Engine
Tightening torques for engine M96/20
Crankshaft, bearing housing, crankcase Location
Thread
Screws, bearing housing Initial torque: Finaltorque:
M9 x 127
Connecting-rod screws
M9 x 1.25
Tightening torque Nm Iftlb.1
20 (15) 1 x 900
Initial torque:
20 (15)
Final torque:
1 x 900
Oil guide on bearing housing
M6(micro-encaps.: 10 (7.5)
Screws for joining crankcase halves
M6
13 (10)
crankcase/bearing housing
M9 x 150 M9 x 94
22 (16) 22 (16)
Oil suction pipe to crankcase
M6
10 (7.5)
Air/oil separator to crankcase
M6
10 (7.5)
Oil pan to crankcase
M6
10 (7.5)
to oil pan
M18 x 1.5
50 (37)
Oil filter to crankcase
S80x3
25 :t 1 (18 :t 1)
Coolantguide housingto crankcase
MID
45 (33)
Intermediate-shaft flangeto crankcase
M6(micro-encaps.: 10
Additionalbolts,
Oil drain plug
Lock nut on intermediate-shaft flange
M8 xl
13 (10)
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(7.5)
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Engine
Location
Thread
Tightening torque Nm lftlb.1
Screw plug for piston pin mounting bore of cylinder bank 4 -6
M27x 2
80 (59)
Bolt for slide rail
M6
10
Pulley to
crankshaft
M16 x 15
Initial torque: Finaltorque:
50 (37) 1 x 900
Double-massflywheel to
crankshaft
MI0 x 1 x 50 (12.9)
Initial torque: Finaltorque:
25 (18) 1 x 900
Thrust plate to double-massflywheel
M8
23 (17)
Drive plate on crankshaft MID x 1 x 25 (12.9)
(Tiptronic) Initialtorque: Finaltorque:
25 (18) 1 x 900
Water pump to
crankcase
M6
10 (7.5)
Chaintensioner to crankcase
M27x 2
80 (59)
Belt tensioner roller on lever for tensioning element
MIa
60 (44)
Belt deflection roller 1 on crankcase
MID x 145 (8.8)
46 (34)
Belt deflection roller 2 on bracket for hydraulic pump
M8 x 55
23 (17)
Belt pulley on generator
M16 x 1.5
65 ::!: 5 (48 ::!: 3.5)
Belt pulley on hydraulic pump
M8 x 12
23 (17)
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Engine
Cylinder head
Cylinder head to crankcase Initial tightening tightening
MIO x 230
or
to flatten
1 st step
30 (22)
2nd step
Cylinderhead screws completelyundone
Final tightening
1 st step 2nd step 3rd step
20 (15) 60 0 turn 60 0 turn
Flat-basetappet housing on cylinder head
M6
10 (7.5)
Camshaftbearing saddles on cylinder head
M6
10 (7.5)
Cylinder-headcover on cylinder head
M6
13 (10.0)
Sparkplugs
M14 x 1.25
30 (22) + 3 (2.0) first fitting 25 (19) + 5 (3.5) re-fitting
Camshaftdrive pinion and drive plate on camshaft
M6 x 15 (10.9)
14 (10.5)
Chaintensioner on cylinder head
M27x 2
80 (59)
Intake pipe on cylinder head
M6 (micr~ncaps.)
10 (7.5)
Plug, oil-pressure duct on cylinder head
MID x 1
10 (7.5)
Oil return pump on cylinder head
M6
10 (7.5)
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Engine
Sensors, sending units, switches and ancillaries
Oil~evelsender on crankcase
M14 x 1.25
max. 20 (15)
Oxygensensor on catalytic converter
MI8
55 ::!: 5 (41 ::!: 3.5)
Knocksensor
M8
20:!: 2 (15:!: 1.5)
Hallsender
M6 (micro-encaps.) 10:t 0.5 (7.5:t 0.5
Speed sender
M6
10 :t 0.5 (7.5 :t 0.5)
coolant temperature
M14 x 1.5
25 :t 5 (19 :t 3.5)
Oil-pressureswitch
M14x 1.5
20:t 5 (19:t 3.5)
Starter
MID
45 (33)
Generator
MID
45 (33)
head cover
M6
10 (7.5)
Power steering pump (hydraulic pump) in bracket
M8
23 (17)
M16
24 (18)
steering pump
M8
23 (17)
Check valve for auxiliaryair pump
M22 x 1.5
32 (24)
M6
10 (7.5)
NTC
Ignitioncoil on cylinder
Pressurepipe on power steering pump Oil reservoir on power
Coolant pump
on crankcase
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Engine-Crankcase,suspension
Removing engine, M96/20 (2.5 I) with manual transmission
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Special tools
Purchased from www.WorkshopManuals.co.uk
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www.WorkshopManuals.co.uk Boxster
Engine-Crankcase, suspension
c
Retainerplate
9592
In conjunctionwith workshopjack
Adapter
9163/2
Or use adapter of transmission holding plate, special tool 9163 for the 928 model
Support plate
9592/2
Containedin scope of delivery of
9592/1 D
Supportfor manualtransmission
Containedin scope of delivery of
9592/1 E
Pressurepiece
Containedin scope of delivery of
9592/1 F
Screw M8 x 25
Containedin scope of delivery of
9592/1
Purchased from www.WorkshopManuals.co.uk 1001 21 Removing engine, M96/20 (2.5 I) with manual transmission
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Engine-Crankcase, suspension
Referto WorkshopEquipmentManual, Chapter 2.4, No.: 72
Spring-band clamp pliers
8
Testing tool for plug-in couplings
9623
Usedto check whetherthe plug-incouplings are seated properly. Suitable for pressure and return lines(nominal diameter 6 and nominaldiameter 10)
Adjusting tool
[I) Note! If the special tool 9592 is being used for the first time, (four)additional threaded holes must be applied.
1. Laythe supportplate9592/1 on the rear of the retainerplate ... 9592 andfastenwithfour hexagon-head boltsM8x 25.
Q
v Q
Q Q Q Q
2. Countersink the retainer plate at the designated bores
~
-arrows- with a 9 mm drill bit. The support plate serves as the
Q
drilling template.
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Q
Q
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Engine-Crankcase, suspension 3. Drill through the countersunkbores on the retainer plate with a ... drill bit sized 6.8 mm and then cut an M8 thread.
/;j../
~
...
4. Fastenthe special tool adapter 9163/2 with a hexagon-head bolt M8 x 25 (bolt quality 10.9) and hexagon-headbolts M8 x 16 (bolt quality 10.9) at the designatedposition"Boxster".The adapter and the support plate are fastened on the retainer plate with the M8 x 25 hexagon-headbolts. The M8 x 16 hexagon head bolts connect the adapter with the support plate.
5. Fastenthe supportfor the manualtransmission with1 M8x 25 ... bolt. 6. Fitcompleteretainerplateon the workshopjack.
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21
Removing engine, M96j20
(2.5 I) 1Nith manual transmission
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Engine-Crankcase,suspension
Drawing shows complete
engine retainer
plate fitted on the
...
workshop jack. l~
~
Removing engine
The engineis removed downwardscomplete with the manualtransmission. 1. Positionthe vehicle at the specified points on a lifting platform. 2. Openboth the luggage compartmentlids. 3. Cover the vehicle. Coverthe vehiclewith protective covers in such a way that the body can not be damaged. 4. Move convertibletop or convertible-topcompartmentlid to service position. Openthe convertibletop until the convertibletop compartmentlid is half open. 5. Detachingcloth covering. Disengagethe rear strip on the left and right sides of the cloth covering in downwarddirection. 6. Detachtension cables. Pressthe ball socket of the tension cable out of the ball head of the adjustingpiece on the left and
right. 7. Move convertibletop to serviceposition. To do so, press the tension bow of the convertibletop towards the main bow, until it reaches its lockingpoint. 8. Movethe convertible-topcompartmentlid to service position and secure. Disengagethe convertible-topcompartmentlinks at the extremebottom. To do so, disengagethe clips at the left and right and pull the links off the bolt.
...
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Engine -Crankcase, suspension
9. Press the converible-topcompartmentlinks forwards until the ... two bores coincide and a 5 mm mandrelcan be pushed throughthem. 10. Removeleft-handseat. For better accessibility,removethe left-handseat of the car. Unscrewthe four internal-serration screws, disconnectall the electrical plug connectionsand removethe seat.
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11. Openthe rear wall cover. To do so, removethe oddmentstray'" behindthe seats and removethe rear walllining. Thenundothe 6 fastening screws and the 2 fasteningnuts. (See-arrows-).
&
Caution!
Danger of short circuit! First remove the ground terminal. Cover the terminals.
Never connect (short circuit) the terminals. 12. Disconnect battery.Beforedisconnecting, find outthe relevant theftcodes(e.g.radio)if necessary.Atthebattery,disconnect the groundterminalandremovethe groundcable =>Rep.Gr. 2706. 13. Removethe rearspoiler=>Rep.Gr.66 5819; Removing and ... installingrearspoiler.
f
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21 Removing engine, M96j20
(2.5 I) with manual transmission
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Engine -Crankcase, suspension
14. Rempverear bumper. Whiledoing so, pay attentionto the con- ~ nectipnfor the numberplate lighting =} 63; Rep.Gr. 63 58 19; Removingand installingrear bumper.
15. Removeleft and right wheel housingtrims.
...
16. Rem0vethe rear part of the underbodycover.
... 5 ..I
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~ .m,
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Engine-Crankcase, suspension
17. Liftthe vehicle.Beforelifting,checkthatall fasteningpointsof ~ the diagonalbracesare easilyaccessible.Payparticularattention to thethreadedpart-C-.
\A
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c B
18. Undothe fastening screw -C- and the collar nuts -0- and remove the diagonal braces -8- together with the holder -E-.
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19. Removestabilizer.
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c
y, 20. To do so, unscrewthe two fastening screws at each of the two bearing surfaces on the left and right.
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B
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Engine-Crankcase, suspension
21. Unscrewthe stabilizeronthe left andright of the links.
...
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22. Detachrear crossmember(aluminium V-member) on the body.... /"
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trif'f(I~
/'\23. Undothe cable. Undothe enginecable on the rear-axlesupport. The cable must be counteredwith a suitablewrench and must not be twisted. 24. Undo halfshafts.To do so, undothe fastening screws of the halfshaftson the transmission. Fit protection on to the half-
shafts.
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-
!~ ~ ~
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Engine -Crankcase, suspension
25. Unclipand detach the oxygen sensor plug connectionfrom the ... holders of the rear-axlesupport. On an OBDII vehicle, additionally disconnectthe oxygen sensor plug connectionin the rear wing area. Pressthe heat shield aside and disconnectthe
plugs. 26. Removerear mufflers. To do so, secure the rear mufflers with a transmissionjack. Then undo the flange connectionbetween the catalytic converters and the exhaustmanifold. Undothe three hexagon-headbolts on the exhaustbracket.
.When
\
lowering,do not damage the oxygen sensors, cables and
plugs. .Attach
protective sleeves around the oxygensensor plugs.
View of the support
27. Removethe front lining in the rear luggagecompartment. Lever off plastic clips using a commerciallyavailableremoval tool (refer to Technical EquipmentManual,Chapter 2.4, No.
/II
0 "I
"-~I
21).
r-
28. Removethe rear-axlesupport. Unscrewthe four fastening screws and remove the rear-axlesupport to one side.
C-'
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(I
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Engine-Crankcase, suspension
29. Draincoolant.To do so, removethe screwplugof the coolant... circuiton the coolantguidehousing.Collectcoolantin a clean container.
30.
coolant Disconnect on
ings.
Collect
the coolant engine hoses. and
emerging
pull Open them the
coolant
off. supplyThenandclose return all lines open- for
in a clean
container.
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:.1/
/-:"
Open spring band clamp "\
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Engine-Crankcase, suspension
...
Pull off the hose
f'-..
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A Caution! Danger of fire! .Collect
emerging fuel.
.Avoid 31.
ignition sources and naked flames.
Detach the
the
fuel
vehicle
apart.
floor
Collect
immediately.
return by
line. pressing
emerging Then
Disconnect
open
gently
fuel. the
Close holder
the on the off the on the
fuel
return
button open body
line
and ends and
under
pull of the
line
remove
the
line. 32.
on Disconnect the left
two To ing
vehicle the steering undersidelines. (six Remove plastic.nuts). the
hydraulic do
so,
Pentosin
lines undo
the
must
of the
power
threaded
part
steering and
small Disconnect undersea
on the disconnect.
vehicle Any
the ling
floor. emerg-
be collected.
1::::::::Jm
33. Disengagethe retainingclips for the power-assistedsteering lines and the brake vacuumhose and removethe lines.
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(2.5 I) 1Nith manual transmission
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Engine-Crankcase, suspension
34. Unscrewthe heat shield on the transmission.To do so, unscrewthe two fastening nuts and removethe plate.
...
35. Disengageshift cables on the transmission. Disengagethe cables with the commerciallyavailabletool (see Workshop EquipmentManual,Chapter 2.4, No.: 21).
...
36. Detachthe shift cables. Unclipthe shift cables on the transmission mount. Thenpull the shift cables upwardsout of the engine compartmentand set them aside.
.When
the slave cylinder is removed, do not actuate the
clutch again.
37. Uncoupleclutch slave cylinder. To do so, unscrewthe fastening screwand removethe clutch slavecylinder. Tie the cylinder with a wire. 38. Disengagethe accelerator cable. Removethe cover on the deflector box and disengagethe accelerator cable.
...
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Engine-Crankcase, suspension Disengage the accelerator
cable
39. Disconnectthe electric plug on the hot film mass air flow sen- .. sor. Then disconnectthe connectinghose betweenthe hot film mass air flow sensor and the throttle body. To do so, disconnect the hose clamp on the hot film mass air flow sensor.
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40. Pressthe spring band clamp on the oil filler hose apart and push it aside. Pull off the oil filler hose; heat, if necessary.
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21
Removing engine, M96/20
(2.5 I) with manual transmission
1\\
www.WorkshopManuals.co.uk 41. Disconnectthe fuel supplyhose. Makesure withoutfail to coun-.. ter with a suitablewrenchwhen doing this. Collectemerging residualfuel. Then disconnectthe groundcable. 42. Disconnectvacuumline for the brake booster. To do so, remove the grey snap ring. Thenpush the inner sleeve -1againstthe outer sleeve -2- and pull off both sleevestogether in the direction of the arrow.
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,
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"" Snap ring
...
Inner and outer sleeve
~
43. DisconnectB+ separator box. To do so, undo the hexagonnut in the separator box. Removethe cable and lay to one side.
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Engine-Crankcase, suspension
44.
Remove so, suck
lock Close
the fluid supply out as tank much of as the possible. power
on the the
bottom opening
of the in the
expansion servo
pump
steering Then
tank with
and
open system. the
remove
a clean
bayonet To do
the
tank.
plug.
rn Note! .In
vehicles with air conditioning,the points 45 to 48 must also be carried out.
.Never evacuateand open the air-conditioningcircuit unlessthis is absolutelynecessary.
45. Removedrive belt. Markthe runningdirection of the drive belt ... with a coloured pen. Slacken belt by turning the tensioning pulley (wrenchsize 24 mm) clockwise,hold still and simultaneouslytake the belt off the drive pulleys.
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46. Undothe rear fastening screw of the air-conditioningcompres- ~ sor from above. The screw is positionedbetweenthe intake manifolds of the fifth and sixth cylinders.
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Engine-Crankcase, suspension
47. Loosenair-conditioningcompressor. To do so, undo the two front fastening screws-(arrows)-. Disconnectthe electrical
...
plug.
~
[IJ Note! The air-conditioningcompressor can be removedfrom the vehicle more easilyif the enginehas alreadybeen lowered. 48. Set the air-conditioningcompressor with the hosesconnected to one side or lift it out of the engine compartmentand set it on a suitable base. 49.
Remove out the
gage
rear the
fastening rear luggageclips compartment and remove
the lining.lining To from do so,thelever lug-
compartment.
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50. Disconnectthe plug connections(X3/1, X3/2 and X59) of the ... enginewiring harness. To do so, raise the lock at the side and
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pull the plug out. /,
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I
~
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Engine -Crankcase, suspension
...
51. Lock the ground point of the engine control module,
0
0
0
~
52. Unplug the engine control module. Open the topmost plug by
...
actuating the side button and pull out. Remove the other plugs from the top down. To do so, press the locking button in and push the locking bar upwards.
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53.
Uncover sleeve
guide the
on thethe engine luggage
the engine
wiring is
wiringcompartment harness.
harness to
be
lowered
towards
Toreardo
the
engine
wall so,
press inwards
the and rubber
compartment,
if
later.
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21 Removing engine, M96/20
(2.5 I) with manual transmission
~
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Engine-Crankcase, suspension
54. Disconnectthe plug connection at the guide tube of the oil dip- ... stick. To do so, press the two tabs together and unclip the tube.
rn Note!
~
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-
It is recommendedto position the complete retainer plate using a transmissionjack first. Onlythen should the workshopcar jack be placed underneath.
55. Placepre-assembled engineretainerplatewithtransmission supporton the crankcaseor transmission. View of the engine retainer plate
~
~
Plate positioned
and secured
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www.WorkshopManuals.co.uk ...
Car jack placed underneath
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-
---1-1
V & Caution! Risk of damage!
When undoing the multi-tooth nut, the mount is destroyed! 56. .Remove the transmission support with the hydraulic mounts. Undo the two fastening nuts on the left and right.
57. tening Undothe nuts. front enginecarrier. To do so, unscrewthe four fas58. Lower the engine-transmissionunitcarefully. Ensurethat there is sufficientclearancefor the components.The enginewiring harness must be guided during the lowering procedure.
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Boxster
Engine-Crankcase, suspension
(D ~~~
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}\
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Pay attention
Engine-Crankcase, suspension to the VarioCam
cable
... ,...,
~r
~ ~~ & Warning! Risk of damage! Onlyplace the vehicle on its wheelsor push it after the rearaxle support, the sheetmetal brace and both the diagonal braces have been installed.
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I \ """-1 (
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100119
Removing and installing engine
Special tools
No.
Designation
Special tool
Explanation
A
Supportingbridge
lQ-222A
For engine suspension
8
Supports
2 ea.
c
Retainerplate
9591/1 9592
0
Adapter
In conjunction with Steinbockcar jack Adapterfor transmissionmounting plate;use specialtool 9163, type
928
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www.WorkshopManuals.co.uk Engine, crankcase,
Boxster
suspension
Removing and i~stalling engine The engine and transmission transmission Removal
are removed downwards.
Before engine is removed,
the
must be detached.
b. Disconnect plugconnections.
I
1. Removecovers.Disconnect batteryandcover terminalor battery. Note Before disc j nnecting battery I move convertible top and eng ne-compartment cover to service po-
sition. 2. Putbody-protection coverson. 3. Raisecar! at specifiedjacking points 4. Undo en~inewiring harnessin rear luggage compartnjlent: 460 -96
a. Press out expandingrivets of lining with lever c. Pull out control unit plug.
d. Pushrubberbootthroughto enginecompartment.
(,
459 -96
405 -96
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Engine, crankcase, suspension
5. Removecomplete exhaustsystem. The following operations must be carried out first:
a. Removespoiler.
404-96
d. At rear axle, remove transverse member panel, left transverse member, right transverse member and stabilizer. 462-96
e. Disconnect oxygensensorplugconnection. f. Separateflangebetweenexhaustmanifoldand catalyticconverter.
b. Removerear panel.
g. Place transmissionjack under silencer. h. Undo hexagon-headbolts (3 ea.) at holder.
0 Ii
II
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463 -96
c. Rel!noveright and left wheel housing liners,
,//1
464 -96
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i
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Engine, crankcase, suspension
Lower exhaustsystem with transmissionjack. 6. Removetransmission. Removingand installingmanualtransmission: See Group 34, Page 34 -3. Removin~and installingTiptronic transIT..ssion. See Group 37, Page 37 -AI.
C.Undodrainplugon waterguidehousing.
~
7. Removeunderside panels,
III
8. Drain coolant:
a. Removecapfrom coolantexpansion tank.
/
b. Disconnectventline. 471 -96
:/
d. Clamp shut coolant hoses with hose clamps and drain coolant.
r~ 467-96
472 -96
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Engine-Crankcase,suspension
Installing engine, M96/20 (2.5 I) with manual transmission
Special tools
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10-5 page1
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