2000 porsche boxster 986 service repair manual

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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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

~

~

.,

=-~

\)

Special tools

Purchased from www.WorkshopManuals.co.uk

A\

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

www.WorkshopManuals.co.uk Boxster

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.

/-

~~~

Q

Q

g

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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.

.\

\

\ \.

(l>/

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

(J

c B

18. Undothe fastening screw -C- and the collar nuts -0- and remove the diagonal braces -8- together with the holder -E-.

\A

~I

~i (J

19. Removestabilizer.

\~ \

~

c

y, 20. To do so, unscrewthe two fastening screws at each of the two bearing surfaces on the left and right.

1/

d

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B

~

J/J ~

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Engine-Crankcase, suspension

21. Unscrewthe stabilizeronthe left andright of the links.

...

/ ~

;:.~::;:::;;;':'1 /

~

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-'

\..0--

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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.

:~ /

J\ .:.;1

:.1/

/-:"

Open spring band clamp "\

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\

\"

",

Purchased from www.WorkshopManuals.co.uk

'" '"

--

www.WorkshopManuals.co.uk Boxster

Engine-Crankcase, suspension

...

Pull off the hose

f'-..

""

~/ .~I

/ \Jlf

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.

...

t-d /'

-/)

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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.

I

/ ('

'"

":::,

~ ~ ,J

40. Pressthe spring band clamp on the oil filler hose apart and push it aside. Pull off the oil filler hose; heat, if necessary.

--~

-t

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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.

() -~I

,

~

"" 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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~"---'

-~: 1

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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.

~I -;--;-

:" "

50. Disconnectthe plug connections(X3/1, X3/2 and X59) of the ... enginewiring harness. To do so, raise the lock at the side and

/oN

\~\

pull the plug out. /,

~I

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I

~

www.WorkshopManuals.co.uk Boxster

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.

1

g

10\\

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!

~

-'\

-

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

Purchased from www.WorkshopManuals.co.uk 1001 21 Removing engine, M96/20 (2.5 I) with manual transmission

www.WorkshopManuals.co.uk ...

Car jack placed underneath

\\

-

---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.

~~ ~

Boxster

Engine-Crankcase, suspension

(D ~~~

Purchased from www.WorkshopManuals.co.uk 10 01 21 Removing engine, M96/20 (2.5 I) with manual transmission

}\

www.WorkshopManuals.co.uk Boxster

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.

Purchased from www.WorkshopManuals.co.uk

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

Purchased from www.WorkshopManuals.co.uk 10-1

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

~\\' //

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

Purchased from www.WorkshopManuals.co.uk

10-5 page1

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