Wiring Porsche Boxster S 986 рестайлинг

Scheme 1

Scheme 2

CURRENT DISTRIBUTOR REMOVAL SEQUENCE

INSTALLING THE CURRENT DISTRIBUTOR

Note. The following spare parts must be replaced

Hexagon nut M 6, 7 ea.

Hexagon nut M 8, 2 ea.

Service label, red

Depending on condition, flange seal, current distributor/firewall

Tie-wraps

Scheme 3

CURRENT DISTRIBUTOR INSTALLATION SEQUENCE

Removing fusible element from the current distributor

Note. See REMOVING AND INSTALLING CURRENT DISTRIBUTOR .

Scheme 4

Scheme 5

Scheme 6

1. Remove cover for current distributor and remove the service label.
2. Carefully lever off the cover -A-, e.g. with a screwdriver -arrow-.. (Scheme 5) This will break the locking tabs and the cover can be removed.
3. Remove the broken locking tabs from the current distributor.
4. Unscrew the two hexagon nuts M 5 -3- from the blown fusible element -1- and remove with the washers -2-. (Scheme 6)

INSTALLING FUSIBLE ELEMENT IN THE CURRENT DISTRIBUTOR

Note. The following spare parts must be replaced.

Hexagon nut M 8, 1 piece

Repair kit - replacement fusible element

Scheme 7

Scheme 8

1. Insert new fusible element -1-, using new washers -2- and new hexagon nuts -3- M 5. Tightening torque: 4 Nm (3 ft.lb). (Scheme 7)
2. Position and engage the blue after-sales service cover -A-. (Scheme 7)
3. Close the current distributor cover until it engages -arrow-. (Scheme 8)
4. Affix the blue service label.
5. See «INSTALLING THE CURRENT DISTRIBUTOR»(/porsche/boxster-s/986-2002-2004/remont/body-electrical/#wiring__installing-the-current-distributor).

ALLOCATION OF FREE FUSE CONNECTION POINTS

The load on the fusible elements in the current distributor was carefully set during development. Connecting additional loads could lead to an overload in the current distributor or to disturbances in the vehicle electrical system.

If an external load should nevertheless be installed subsequently, this must be connected directly to B+ with corresponding fuse protection (line fuse). Cables can be routed into the passenger compartment through the service opening in the firewall (closed off by a rubber sleeve behind the battery) and the appropriate seal.

TOOLS

Closed-circuit current should be measured using an analog ammeter or a digital multimeter with a long integration time (to filter out voltage peaks).

Scheme 9

PREPARATIONS ON THE VEHICLE

Note. Before measuring the closed-circuit current, determine the vehicle equipment (M-number, I-number) and establish the expected closed-circuit current with the aid of the attached table. See MEASUREMENT .

1. Open the front luggage compartment.
2. Using a suitable tool - for example, upper part of lock with a suitable handle - close lower part of luggage compartent lock while keeping the luggage compartment lid open.
3. Remove the ignition key and lock vehicle (alarm unit is primed).

CONNECT MEASURING INSTRUMENT

1. Set the measuring instrument to the highest possible current-measuring range.
2. With two alligator clips, connect the measuring instrument to the battery ground and to the unoccupied second body ground which is always available for RHD or LHD.
3. Remove ground strap from the body and secure against contact with the body. The entire vehicle current now flows through the ammeter.

MEASUREMENT

1. Select a measuring range which ensures that the pointer of the instrument is in the upper third of the scale, as far as possible. Switch over measuring range without interruption. Read off the measuring values after the waiting period specified in the table.
2. Do not switch on any electrical loads (opening the central locking system) during measurement.

Note. If the value of the closed-circuit current is higher than the value determined in the table, the cause must be established systematically. The recommended troubleshooting procedure: With the measuring instrument connected, remove the fuse of terminal 30 and the relays one after the other. Observe the display values of the measuring instrument when removing in order to recognize a reduction in current. After troubleshooting, screw the ground strap back onto the body in the proper manner. The measured values could vary by approx. 20%. The values listed in the table depend on the condition of the battery, the room temperature, and the engine temperature.

READING OFF THE MEASURING RANGE UP TO MY '01

1. Read off the measuring range only when 31 minutes have passed since the vehicle was locked.

READING OFF THE MEASURING RANGE AS OF MY '02

1. Read off the measuring range only when 61 minutes have passed since the vehicle was locked.

MEASURING TIME RANGE

CONTROL MODULE CLOSED-CIRCUIT CURRENT MEASUREMENT

Note. The combination wires for ABS and BVA (brake-pad wear indicator) are integrated in the wiring harness. In the event of damage, the integrated wires can be disconnected and replaced by repair wires. The disconnection points are located at the front left and front right above the radiator tank. After repair, the following function tests must be performed: ABS: Test with the Porsche System Tester 2. BVA: The indicator light must go out with the engine running and the brake linings intact. Disconnection point, front left: Join wires between the -arrows- with crimp connectors. (Scheme 10) Disconnection point, front right: Join wires between the -arrows- with crimp connectors. (Scheme 11)

REMOVAL

1. Take off cover of battery and radiator tank.
2. Disconnect the battery and cover terminal or battery.
3. Remove front wheel housing liner. Undo cable ties in the area of the wheel housing, and remove combination wire.
4. Carefully remove insulating tape from the combination wire in the area of the disconnection point and cut the old combination wire before the exit to the wheel housing (do not damage any other wires).

1. Install repair wire in the wheel housing. Join wires as specified in the table using a crimp connector and crimping tool.
2. Color coding of left and right hand sides of wires: Wire 1 - br/gn Wire 2 - br/bk Wire 3 - br Wire 4 - br/bl Wire 5 - br/wt br - brown bk - black bl - blue wt - white gn - green
3. Cut wires to the correct length in the area of the disconnection point. WIRE LENGTH Combination wire Front-end wire Color Length [mm] Color Length [mm] br/bk 20 br/bk 100 br/gn 40 br/gn 80 br/wt 60 br/wt 60 br/bl 80 br/bl 40 br 100 br 20
4. Exercise caution when stripping insulation from wiring. Other wires must not be damaged.
5. Push on the supplied heat-shrinking tubes.
6. Push the large heat-shrinking tube over all wires.
7. Strip 10 mm of insulation off the wires.
8. Join wires using crimp connector.
9. Shrink shrink-fit hoses with a hot-air gun.
10. It is essential that all wires are watertight.
11. Wrap commercially available PVC tape all around the area of the connection points.

Note. The combination wires for ABS and BVA (brake-pad wear indicator) are integrated in the wiring harness. In the event of damage, the integrated wires can be removed and replaced by repair wires. The disconnection point is plug connector X 2/2 for the passenger compartment/rear end (yellow) or connector points in the rear luggage compartment. After repair, the following function tests must be performed: ABS: Test with the Porsche System Tester 2. BVA: The indicator light must go out with the engine running and the brake linings intact. Plug connection X 2/2, -(arrow)- passenger compartment/rear end: Install preassembled contacts or join wires at connection points. (Scheme 12)

1. Disconnect the battery and cover terminal or battery.
2. Undo combination wire in the area of the rear wheel housing. Remove lining for rear wall of the convertible top compartment
3. Disconnect the plug connections
4. Detach control unit and retaining bracket for the plug connections on the rear wall of the convertible top compartment and expose the combination wires.
5. Carefully remove insulating tape from the combination wire as far as plug connector X 2/2 (do not damage any other wire).

Scheme 10

Scheme 11

1. Install repair wire in the wheel housing and route it to plug connection X 2/2.
2. Join wires at the connection points using a crimp connector and crimping tool. Install preassembled contacts in plug connection X 2/2.
3. Color coding of left and right hand sides of wires: Wire 1 - br/gn Wire 2 - br/bk Wire 3 - br Wire 4 - br/bl Wire 5 - br/wt br - brown bk - black bl - blue wt - white gn - green
4. Unlocking tool- to unlock the old contacts in the plug connection.
5. Unlock the old contacts of the combination wire with the unlocking tool, and remove. Install new contacts of the repair wire in the same location.
6. Plug connection X 2/2- (yellow).
7. Combination wire, rear left: Combination wire ABS and BVA in plug connection x 2/2 (yellow) br/wt in pin 1 (ABS) br/bl in pin 2 (ABS) br/bk in pin 3 (BVA)
8. Combination wire, rear right: br/wt in pin 6 (ABS) br/bl in pin 5 (ABS) br/bk in pin 4 (BVA)
9. The ground leads of the combination wires (brown) are the same on both right and left. Connection point No. 44 as shown in circuit diagram. Strip 10 mm of insulation off the wires. Push on heat-shrinking tube. Using a crimp connector, join brown wire of combination wire to brown wire of rear-end wiring harness Shrink heat-shrinking tube with a hot-air gun so that wires are watertight.
10. Brake pad wear indicator wires of the combination wire (brown/green) are identical on the left and right sides. Connection point No. 43 as shown in circuit diagram. Strip 10 mm of wire. Push on heat-shrinking tube. Using a crimp connector, join brown/green wire of combination wire to brown/green wire of rear-end wiring harness. Shrink heat-shrinking tube with a hot-air gun so that wires are watertight.
11. Wind commercially available PVC tape around wires.

OPTICAL FIBER (LWL) - MOST BUS

Note. Optical fiber (LWL) will be used as of model year 2003.

REQUIREMENTS WHEN WORKING WITH LWL

1. The plug connections must not be plugged or separated with tools.
2. The LWL and the plug connections must not come into contact with fluids such as water, creeping compound, preservative, anti-freeze protection, cleaning agent. They will impair the MOST system functions or cause complete system failure. Even plug connectors with plugged-in protective caps must not come into contact with the fluids listed.
3. If the optical contacts, plug connections, or sockets are not plugged in, or if there are no protective caps installed on the plug, contact with dust and other solid materials (lubricants) must also be avoided.
4. The optical contacts, plug connectors, or sockets must not be cleaned.

STORAGE, PACKING, TRANSPORT

1. The LWL must not be stored outside.
2. The LWL must be protected from direct sunlight during storage.
3. The LWL must be protected from high humidity during storage. Recommended storage conditions: Temperature - between -20°C and +40°C, humidity - between 40% and 60%.
4. The LWL must be stored in a box made of cardboard, or in a plastic bag.
5. Force must not be applied to the stored LWL which could deform or damage it.
6. The LWL must be stored with the dust boot attached.
7. While storing, the bending radius must not be smaller than 30 mm.
8. LWL with damaged surfaces must be replaced.

INSTALLING THE LWL IN THE VEHICLE

The following limit values listed must not be exceeded when installing a LWL in the vehicle.

1. Maximum permissible tensile load: 60 N (45 ft.lb)
2. Minimum bending radius after and during installation in the vehicle: 25 mm
3. Maximum number of torsions: 10 torsions per m

The following points must be observed when fitting the LWL and fitting wiring harnesses containing LWL

1. Damaged LWL must not be installed.
2. Before installing the LWL or wiring harness with LWL in the vehicle, it must be checked if the dust boots have been attached properly. If this is not the case, the LWL set must not be installed.
3. After and during the installation of LWL in the vehicle, the bending radius must not be smaller than 25 mm.
4. While the LWL is being installed in the vehicle, the LWL must not be pulled on to set the length of the wiring harness (max. tensile load 60 N (45 ft.lb.)) nor may the LWL be twisted or wound up.
5. After installing the LWL in the vehicle, the twisted LWL must be straightened out.
6. External forces on the LWL are to be avoided when installing the LWL in the vehicle.

REPAIR

The defective LWL must be replaced. The LWL will not be repaired.

When exchanging the LWL, the optical contacts from the plug connection must be removed.

DUST BOOT FOR OPTICAL CONTACTS

1. If a LWL is stored, transporated, or installed in a vehicle, then the dust boot must only be removed right before the LWL is used in the connector.
2. When testing the LWL, the dust boot must be put back on. The dust boots can be removed without the use of a locking mechanism.
3. Do not touch the exposed contact surfaces while or after removing the dust boot, as otherwise the optical contact could become damaged or dirty.

If a preassembled wiring harness is installed, there is a dust boot on the connector for the LWL.

The dust boots can be removed by activating the locking mechanism -arrow-. (Scheme 15)

Scheme 12

1. When testing the LWL, the dust boot must be put back on.
2. Do not touch the exposed contact surfaces while or after removing the dust boot, as otherwise the optical contact could become damaged or dirty.

The LWL is delivered with affixed plastic contacts. These contacts are latched in the connector housing in the case of repairs. Grey and black contacts with identical mechanical dimensions are used.

Grey contacts are used in the junction wiring harness >> control unit (optical input).

Black contacts are used in the junction control unit >> wiring harness.

Scheme 13

1. 1- Optical contact, black
2. 2- Optical contact, grey
3. 3- Joint connector side
4. 4- Joint socket side
5. 5- Socket side LWL module
6. 6- Optical contact, grey
7. 7- Optical contact, black
8. 8- Springs
9. 9- Spring cap

Scheme 14

Scheme 15

1. Remove PCM. Refer to «REMOVING AND INSTALLING DISPLAY AND OPERATOR»(/porsche/boxster-s/986-2002-2004/remont/entertainment-systems/#radio__removing-and-installing-display-and-operator) . Remove and install the operator control unit (PCM2). Disconnecting the plug connection on the amplifier
2. Remove cover for the brake booster.

Disconnecting the joint in the front luggage compartment

Scheme 16

Disconnecting the plug connection on the CD changer

Scheme 17

1. Remove the CD changer.

Unplugging the control unit plug connection for the telephone

Scheme 18

1. Remove passenger's seat. Refer to «REMOVING AND INSTALLING FRONT SEAT, - AS OF MY 1996»(/porsche/boxster-s/986-2002-2004/remont/seats/#seats) .
2. Removing control unit holder for telephone. Refer to «REMOVING AND INSTALLING CONTROL UNIT FOR THE TELEPHONE»(/porsche/boxster-s/986-2002-2004/remont/entertainment-systems/#radio__removing-and-installing-control-unit-for) .

Scheme 19

1. Open the secondary locking with the press-out tool. Insert the tool in the opening provided and lift the locking. The locking engages in the upper position. See «TOOLS»(/porsche/boxster-s/986-2002-2004/remont/body-electrical/#wiring).
2. Place the tool on the primary locking and lift the locking. -A- Optical contact, grey (Scheme 23) -B- Optical contact, black (Scheme 23)
3. Pull LWL, for example, -B- carefully in the -direction of the arrow-. (Scheme 23) If it is not possible to pull out the LWL, check again if the secondary locking is completely released and if the primary locking is raised sufficiently. Visual inspection of lockings, connector housing, and contacts for possible damage and if necessary, exchange the damaged parts.

INSTALLING OPTICAL CONTACTS ON CONNECTOR SIDE

1. Remove the dust boot right before plugging.
2. Check the proper condition of the contact.

Scheme 20

Scheme 21

1. Insert the optical contact -B- in the connector until it engages audibly. (Scheme 24) -A- Optical contact, grey (Scheme 24) -B- Optical contact, black (Scheme 24)
2. Lock the secondary locking -arrow- and check the optical contacts for tightness. (Scheme 25)

Scheme 22

Scheme 23

1. Release the spring cap on both sides and remove using the press-out tool. See «TOOLS»(/porsche/boxster-s/986-2002-2004/remont/body-electrical/#wiring).
2. Remove LWL module from the connector.
3. Place the tool for releasing the contact locking of the LWL module and lift the locking. -A- Optical contact, grey (Scheme 27) -B- Optical contact, black (Scheme 27)
4. Pull LWL, e.g., -B- carefully in the -direction of the arrow-. (Scheme 27) If it is not possible to pull out the LWL, check again if the locking is completely released. Visual inspection of lockings, connector housing, and contacts for possible damage and if necessary, exchange the damaged parts.

INSTALLING OPTICAL CONTACTS ON SOCKET SIDE

1. Remove the dust boot right before plugging.
2. Check the proper condition of the contact.
3. At a force of 10 N (7.5 ft.lb) the springs installed in the joint will be pressed together. This leads to an increase in attenuation, which could lead to system impairment and system failure. Therefore, a maximum of 10 N (7.5 ft.lb) can be used to pull the LWL from the joint.

Scheme 24

Scheme 25

1. Insert the optical contacts -B- and -A- in the module until it engages audibly. see scheme 28 Check the optical contacts for tightness.
2. Insert the module in the joint on the socket side. see scheme 29
3. Slide the spring cap on the joint until it can be felt to engage -arrow-. see scheme 29.

OPTICAL FIBER (LWL) - MODULE

In all MOST control units, at least one sending diode and one receiver diode are installed. The sending diode of a MOST device is connected to a receiver diode of a 2nd MOST device. This results in a ring where the light signal is reinforced in each control unit (in each control unit, the light signal is transformed into an electrical signal).

The graphic clarifies the cabling of the individual MOST control units which vary according to their equipment.

Scheme 26

1. MOST control units: -A- Radio/PCM, line -1- connected with an amplifier or CD - changer without a telephone. see scheme 30 -A- Radio/PCM, line -2- connected with a telephone, without amplifier or CD - changer. see scheme 30 -A- Radio/PCM, line -3- connected with a telephone and amplifier or CD - changer. see scheme 30 -B- amplifier, line -4- without CD - changer. see scheme 30 -B- amplifier, line -5- with CD - changer. see scheme 30 -C- CD - changer, without amplifier line -6-. see scheme 30 -D- telephone, line -2- and connected with an amplifier, CD - changer line -3-. see scheme 30 -E- LWL joint, this is located above the brake booster. see scheme 30

Scheme 27

Poses Online

See also:
• REMOVING AND INSTALLING COWL PANEL COVER
• WORK INSTRUCTIONS AFTER DISCONNECTING THE BATTERY
• REMOVING AND INSTALLING DISPLAY AND OPERATOR
• REMOVING AND INSTALLING FRONT SEAT, - AS OF MY 1996
• REMOVING AND INSTALLING CONTROL UNIT FOR THE TELEPHONE
• REMOVING AND INSTALLING CURRENT DISTRIBUTOR
• INSTALLING THE CURRENT DISTRIBUTOR
• MEASUREMENT