Repair manual
Porsche Boxster S 986 facelift Repair Manual
Step-by-step repair and maintenance instructions for the Porsche Boxster S 986 facelift (2002–2004): removal, installation, adjustment, diagnostics and parameter checks with illustrations.
- General information
- REMOVAL
- REMOVING AND INSTALLING SELECTOR KNOB
- INSTALLATION
- REMOVING AND INSTALLING TIPTRONIC TRANSMISSION
- INSTALLING TIPTRONIC TRANSMISSION
- TIGHTENING TORQUES
- CHANGING ATF FLUID
- RECOMMENDED ATF FLUID
- REMOVING ATF FILTER
- REMOVE THE TIPTRONIC CONTROL UNIT
- CODING THE TIPTRONIC CONTROL UNIT
- TIGHTENING TORQUES FOR BRAKE HYDRAULICS
- BLEEDING BRAKES - VEHICLES WITH ABS AND ABS/TC
- PROCEDURE FOR BLEEDING
- STEP 1 : BLEED BRAKES AS USUAL
- STEP 2: BLEEDING THE ABD CIRCUIT (SECONDARY CIRCUIT) ON VEHICLES WITH TRACTION CONTROL (TC)
- BLEEDING BRAKES - VEHICLE WITH PSM
- STEP 2 : BLEEDING AT FRONT ON RIGHT WITH RUNNING BOOSTER PUMP
- CHANGING BRAKE FLUID - ALL TYPES
- INSTALLATION
- REMOVAL
- REPLACING BRAKE BOOSTER
- BELLOWS VERSIONS
- IN THE CASE OF REPLACEMENT
- CONVERTING BRAKE BOOSTER (BELLOWS)
- OVERVIEW OF BELLOWS CONVERSION
- ADDITIONAL ASSEMBLY - BOXSTER MODEL '97
- FITTING
- INSTRUCTIONS AND FUNCTION DESCRIPTION
- PRELIMINARY WORK
- REMOVING SUCKING JET PUMP
- TIGHTENING TORQUE FOR MECHANICAL BRAKE
- TECHNICAL DATA - BOXSTER
- TECHNICAL DATA WEAR LIMIT - BOXSTER
- TECHNICAL DATA - BOXSTER S
- TECHNICAL DATA WEAR LIMIT - BOXSTER S
- BRAKE DISCS - MEASUREMENT SHEET
- REMARKS ON MEASUREMENT SHEET
- MEASURING PREREQUISITES/MEASURING POINTS
- TEST 1 (BRAKE DISC THICKNESS)
- TEST 3 (BRAKE DISC THICKNESS TOLERANCE)
- CHECKING THE THICKNESS OF THE DISC BRAKE PADS
- REMOVING AND INSTALLING THE FRONT DISC BRAKE PADS
- INSTALLATION
- BEDDING IN THE BRAKE PADS
- REMOVING AND INSTALLING THE REAR DISC BRAKE PADS
- REMOVING AND INSTALLING THE FRONT DISC BRAKE PADS - BOXSTER S
- REMOVING AND INSTALLING THE REAR DISC BRAKE PADS - BOXSTER S
- ADJUSTING BRAKE PUSH ROD (ADJUSTING STOP LIGHT SWITCH)
- BRAKE LIGHT SWITCH SETTING
- CHECKING STOP LIGHT SWITCH ADJUSTMENT (NO. 1)
- ADJUSTING SWITCH IN THE EVENT OF INSUFFICIENT PEDAL TRAVEL
- 1 ST POSSIBILITY
- 2 ND POSSIBILITY
- ADJUSTING THE SWITCH IF THE PEDAL TRAVEL IS TOO LARGE
- CHECKING THE FREE PLAY OF THE PARKING BRAKE LEVER
- MEASURING THE FRONT BRAKE DISC LATERAL RUNOUT
- MEASURING THE BRAKE DISC THICKNESS TOLERANCE
- MEASURING THE REAR BRAKE DISC LATERAL RUNOUT
- CHECKING PERFORATED FRONT BRAKE DISCS (WEAR ASSESSMENT)
- VISUAL INSPECTION FOR CRACKS AND EVALUATING CRACKS
- EVALUATING CRACKS ON GREY CAST IRON BRAKE DISCS
- CHECKING BRAKE DISCS FOR MINIMUM THICKNESS
- Example of wear
- NOTES ON BEDDING IN NEW BRAKE PADS
- CHECKING PERFORATED REAR BRAKE DISCS (WEAR ASSESSMENT)
- EVALUATING THE CRACKS ON THE GREY CAST IRON BRAKE DISCS
- IMPORTANT NOTES
- PEDAL-GROUP VERSIONS (DISTINCTION)
- A - CLUTCH PEDAL AREA
- B - BRAKE PEDAL AREA
- REMOVAL
- General information
- Changes to convertible-top frame as of model year 2003
- Overview of microswitch test plan up to model year 1999
- Replacing convertible-top covering
- Installing the convertible-top covering
- Removing convertible-top covering
- Test and adjusting values
- Replacing convertible top frame
- Assembling convertible-top frame
- Conversion measure on the tension bow for the tension strap in vehicles produced before 12.04.2000
- Conversion measure on the tension bow for the roof liner in vehicles produced before 12.04.2000
- Materials and tools
- Tightening torques
- Preparation
- Removing rear window
- Turning hardtop
- Positioning the hardtop
- Making support cheeks
- Making swivel arm
- Fitting swivel and support cheeks on the basic plate
- Fitting mounting points for the hardtop locking lever on the ground plate
- Adjusting lid for convertible top compartment
- Test and adjustment values
- Troubleshooting in convertible top operation
- Troubleshooting on the relay carrier
- Replacing the tension cable
- Removing the tension cable
- Care and cleaning of the convertible top
- Cleaning the convertible top
- Care of convertible top
- Care of convertible-top seals
- CHANGING AND CHECKING TRANSMISSION OIL IN FINAL DRIVE
- INSTALLATION
- TIGHTENING TORQUES
- GENERAL
- DRIVE SET IN THE SERIES
- ADJUSTMENT OVERVIEW (TRANSMISSION G 86)
- Determining the installation position of the output shaft (actual measurement)
- Adjusting the output shaft (transmission G 86)
- DETERMINING "S4" AGAIN (TRANSMISSION G 86)
- ADJUSTING THE CROWN WHEEL (TRANSMISSION G 86)
- Adjusting the circumferential backlash (transmission G 86)
- TOOLS
- REMOVAL
- General information
- SPECIAL TOOLS
- ADJUSTING TOOL — Part 1
- ADJUSTING TOOL — Part 2
- TIGHTENING TORQUES
- MOUNTING INSTRUCTIONS — Part 1
- MOUNTING INSTRUCTIONS — Part 2
- MOUNTING INSTRUCTIONS — Part 3
- REMOVING DRIVE BELT
- INSTALLING DRIVE BELT
- ASSEMBLY INSTRUCTIONS
- FITTING PISTONS AND CONNECTING RODS
- FITTING PISTONS ON CYLINDER BANK 4 - 6
- TIGHTENING SEQUENCE
- REMOVING AND INSTALLING CRANKSHAFT SEALING RING - FLYWHEEL SIDE
- REMOVING CRANKSHAFT SEALING RING
- INSTALLING THE CRANKSHAFT SEALING RING
- CHECKING PISTON WEAR
- REMOVAL
- ASSEMBLY
- REMOVING CYLINDER HEAD COVER - CYLINDER BANKS 1 - 3 AND 4 - 6
- CYLINDER BANK 4- 6
- INSTALLING CYLINDER HEAD COVER - CYLINDER BANKS 1-3 AND 4-6
- REMOVING AND INSTALLING VALVE STEM SEAL
- DISASSEMBLING AND ASSEMBLING INLET CAMSHAFT - AS OF MY 2003
- DISASSEMBLING INLET CAMSHAFT
- ASSEMBLING INLET CAMSHAFT
- REMOVING AND INSTALLING CAMSHAFTS - UP TO MODEL YEAR 2002
- CAMSHAFTS OF CYLINDER BANK 1 - 3
- CAMSHAFTS OF CYLINDER BANK 4-6
- REMOVING AND INSTALLING CAMSHAFTS - AS OF MY 2003
- PRELIMINARY WORK
- ALLOCATION OF CAMSHAFT ADJUSTMENT DEVICE ON INLET CAMSHAFTS — Part 1
- ALLOCATION OF CAMSHAFT ADJUSTMENT DEVICE ON INLET CAMSHAFTS — Part 2
- PRESUMABLE CAMSHAFTS
- SEALING COVER FOR CAMSHAFT HOUSING (CYLINDER HEAD COVER)
- CHECKING GUIDE FOR VALVE TAPPETS
- INSTALLATION
- INSTALLING CLOSURE CAPS AT PULLEY SIDE OF CYLINDER HEAD 4 - 6
- INSTALLING CLOSURE CAPS AT FLYWHEEL SIDE OF CYLINDER HEAD 1 - 3
- REMOVING SEALING RING FOR INTERMEDIATE SHAFT
- REWORKING CYLINDER HEAD
- CAMSHAFT ASSIGNMENT
- REMOVING THE HYDRAULIC VALVE
- INSTALLING THE HYDRAULIC VALVE
- INSTALLING CYLINDER HEAD COVER - CYLINDER BANKS 1 - 3 AND 4 - 6 - USA vehicles
- REMOVING BEARING COVER
- INSTALLING BEARING COVER
- WEAR OF TIMING CHAINS, SPROCKETS, TENSIONING AND SLIDE RAILS
- REMOVING AND INSTALLING AIR/OIL SEPARATOR
- SEALING THE OIL PAN
- INSTALLING OIL PUMP
- INSTALLING OIL PUMP COVER
- ASSEMBLY WORK FROM BELOW
- ASSEMBLY WORK FROM ABOVE
- INSTALLING COOLANT PUMP
- DRAINING COOLANT
- TEST, SINGLE-STEP CAP
- TEST, TWO-STEP CAP
- CLEANING THE COOLING SYSTEM
- General information
- Fitting vacuum control pipe on the intake distributor
- Assembling intake distributor
- Aligning rubber sleeves between distributor pipe and intake distributors.
- Fitting check valve on intake distributor
- Installation
- Obtaining read-out and saving vehicle data from DME control module
- Removing DME control module
- Programming new DME control module
- Programming DME control module
- Programming map as of 7.2
- Programming map as of 7.8 min
- Version (data records)
- Control unit type as of model year 2003
- Removing oxygen sensor
- Installing oxygen sensor
- Precautionary measures when handling oxygen sensors
- Removing and installing oxygen sensors in front of catalytic converter - as of MY 2003
- Removing oxygen sensors in front of catalytic converter - USA
- Installing oxygen sensors in front of catalytic converter - USA
- Tightening torques
- Removing and installing oxygen sensors behind catalytic converter - as of MY 2003
- Removing oxygen sensors behind catalytic converter - USA
- Installing oxygen sensors behind catalytic converter - RoW
- Installing oxygen sensors behind catalytic converter - USA
- Danger of injury when raising vehicles
- Damage when raising vehicles
- Dangers of injury when welding
- Safety instructions for flying sparks during grinding and welding work
- Safety instructions for fuel tank
- Safety instructions for air conditioning
- Safety instructions for Teromix-6700 two-component adhesive
- Safety instructions for sharp-edged body and unit parts
- Safety instructions for airbag system
- Safety instructions for door
- Safety instructions for plug location plan (body)
- Safety instructions for water drains (body)
- Electronic control modules
- Protection against over voltage
- Replacing control modules
- Straightening systems
- Floorpan check dimensions
- Body parts of high-strength steel
- High-strength steel plates
- Tailored blanks
- Baked hardening
- Stranghtening body parts
- Welding work
- Reshaping
- Separation points
- Diagram - Body, model year 2002
- Plug location plan
- Gap dimensions, body
- Materials and tools
- Undersealing
- Tools and materials
- Accessories
- Top of front of vehicle, (radiator tank)
- Top of inside front of vehicle and floor
- Work sequence for accident repair
- Work sequence for determining scope of damaged vehicles involved in an accident
- Vehicle identification number
- Change identification data plate
- DISASSEMBLING AND ASSEMBLING THE INSTRUMENT PANEL
- DISASSEMBLING THE INSTRUMENT PANEL
- INSTALLING COVER AND CENTER NOZZLE FOR THE INSTRUMENT PANEL
- TIGHTENING TORQUES
- TIGHTENING TORQUE
- ADDITIONAL ASSEMBLY NOTES ON BOWDEN CABLE VARIANT A AND INNER DOOR HANDLE
- REMOVAL AND INSTALLATION OF BOWDEN CABLE VARIANT A
- INSTALLATION NOTE ON DOOR SEALING FILM FOR VEHICLES WITHOUT SIDE AIRBAG
- NOTES ON THE INSTALLATION OF PARTLY DETACHED DOOR SEALING FILMS
- FITTING SLIDING STRIP ON THE INNER DOOR PANEL
- MATERIALS AND TOOLS
- READ OUT FAULT MEMORY
- INSTALLING AIR CLEANER ELEMENT
- CHANGING THE ENGINE OIL AND OIL FILTER - AS OF MY 2003
- CHANGING THE ENGINE OIL, WITHOUT OIL FILTER
- CHANGING THE ENGINE OIL, WITH OIL FILTER
- DRAINING TRANSMISSION OIL
- FILL IN TRANSMISSION OIL
- TIGHTENING TORQUES
- REPLACING ATF
- CHECKING ATF
- TESTING CONDITIONS
- REMOVING ATF FILTER
- CHANGING TRANSMISSION OIL IN FINAL DRIVE
- CHECKING CLUTCH FREE PLAY
- CHECKING THE PEDAL END POSITION (PEDAL RETURN/RETURN FORCE)
- POWER STEERING: CHECK THE FLUID LEVEL
- STEERING GEAR: VISUAL INSPECTION OF THE BELLOWS
- TRACK ROD JOINTS: CHECK THE PLAY AND DUST BELLOWS
- AXLE JOINTS: CHECK THE PLAY AND DUST BELLOWS
- DRIVE SHAFTS: VISUAL INSPECTION OF THE BOOTS
- RUNNING GEAR ADJUSTMENT (WHEEL ALIGNMENT VALUES)
- MOUNTING OF ASSEMBLIES AND RUNNING GEAR
- CHECKING CONDITION
- TIRE PRESSURES
- CHECKING THE BRAKE FLUID LEVEL
- CHANGING BRAKE FLUID
- PARKING BRAKE: CHECKING THE FREE PLAY OF THE PARKING BRAKE LEVER
- BRAKE HOSES AND LINES
- BRAKE SYSTEM: VISUAL INSPECTION OF THE BRAKE PADS AND BRAKE DISCS FOR WEAR
- CHECKING LID LOCK, FRONT AND REAR
- CHECKING SAFETY HOOK, FRONT LID
- FUNCTION TEST, CHECKING DOOR LOCK
- TANK CAP LOCK FUNCTION TEST
- CHECKING DOOR AND LID TIGHTENING TORQUES
- CHECKING INNER RELEASE OF LUGGAGE COMPARTMENT (TRUNK ENTRAPMENT)
- FUNCTIONAL INSPECTION
- CONDITION INSPECTION
- INSTALLING PARTICLE FILTER
- SETTING
- ADJUSTING THE MAIN HEADLIGHTS, USA VERSION
- FOG LIGHT ADJUSTMENT
- REMOVING MAIN HEADLIGHT
- INSTALLING MAIN HEADLIGHT
- WARTUNG ELEKTRIK: WINDSCREEN WIPER/WASHER SYSTEM, HEADLIGHT WASHER
- SETTING HANDSFREE MICROPHONE TO THE TELEPHONE TYPE
- SETTING
- REMOVING AND INSTALLING SENSOR FOR PARK ASSISTANT
- INSTALLATION
- PARKASSISTENT, WIRING HARNESS
- PARKASSISTENT CONTROL MODULE
- REMOVING AND INSTALLING DISPLAY AND OPERATOR CONTROL UNIT (PCM)
- PROCEDURE FOR CHANGING THE "K-NUMBER" ON PCM CONTROL MODULE (AS OF PST2 SOFTWARE 13.0)
- INSTALLING DISPLAY AND OPERATOR CONTROL UNIT (PCM)
- CONNECTING AND SWITCHING ON THE PORSCHE SYSTEM TESTER 2
- DEVICE CODE INPUT
- REMOVING DISPLAY AND OPERATOR CONTROL UNIT (PCM 2)
- INSTALLING DISPLAY AND OPERATOR CONTROL UNIT (PCM 2)
- TEACHING DISPLAY AND OPERATOR CONTROL UNIT (PCM 2)
- REMOVING AND INSTALLING THE NAVIGATION UNIT
- REMOVING AND INSTALLING GPS ANTENNA
- RETROFITTING MOBILE COMMUNICATION SYSTEMS
- GENERAL
- PROCEDURE AFTER COMMISSIONING
- PROCEDURE AFTER CHANGING A TIRE
- PROCEDURE AFTER THE POWER SUPPLY HAS BEEN INTERRUPTED
- REMOVING AND INSTALLING CONTROL MODULE FOR PARKING ASSISTANT
- REDUCED SOUND QUALITY IN ONE OR MORE LOUDSPEAKERS
- REMEDYING PROBLEMS WITH THE AMPLIFIER
- INTERFERENCE NOISES
- INTERFERENCE NOISES, CHECKING CABLE CONNECTIONS
- INTERFERENCE NOISES DUE TO ALTERNATOR
- INTERFERENCE NOISES DUE TO ENGINE
- INTERFERENCE NOISE DUE TO ANTENNA
- INTERFERENCE NOISES DUE TO POWER SUPPLY
- INTERFERENCE NOISES DUE TO ALL LOUDSPEAKERS
- ELECTROMAGNETIC COMPATIBILITY (EMC) - TROUBLESHOOTING
- REMOVING LOUDSPEAKER AMPLIFIER
- REMOVING AND INSTALLING CONTROL UNIT FOR THE TELEPHONE
- REMOVING SUBWOOFER
- INSTALLING SUBWOOFER
- REMOVING THE ANTENNA AMPLIFIER
- Tightening torques for rear axle
- Carrier side section/cross member
- Axle strut
- Stabiliser
- Wheel carrier
- Spring strut
- Wheel fastening
- Drive shaft
- Engine mount
- Transmission mount
- Headlight beam adjustment
- Preliminary work and notes on assembly
- Distinguishing feature of coil springs and dampers
- Removal
- Installation
- Notes on removal and installation
- Tie rod replacement
- Removing and installing right drive shaft
- Removing and installing left drive shaft
- Fitting the drive shaft to the transmission: combinations permitted for the Boxster
- Removing and installing sheetmetal brace