Fuel System, Electronic Injection Porsche Boxster S 986 рестайлинг

Scheme 25

FUEL RING PIPE REMOVAL & INSTALLATION PROCEDURE

Fitting vacuum control pipe on the intake distributor

Mount the vacuum control pipe between fuel pressure regulator and intake distributor at the left-hand rubber sleeve. Route the vacuum control pipe so it is tension-free.

Scheme 26

Scheme 27

INTAKE DISTRIBUTOR REMOVAL & INSTALLATION PROCEDURE

Assembling intake distributor

Tighten the micro-encapsulated hexagon-head bolts M6 x 16 in the prescribed sequence.

Tightening torque 9.7 Nm (7 ftlb.).

Scheme 28

Aligning rubber sleeves between distributor pipe and intake distributors.

Line up the rubber sleeves with the markings (arrows) and tighten the inner hose clamps.

Push the distributor pipe between the intake distributors and align so that the dimension "X" is the same on both right and left. Tighten the outer hose clamps.

Secure the support between the throttle body and crankcase.

Scheme 29

Mount the vacuum control pipe between the fuel pressure regulator and the intake distributor at the left-hand rubber sleeve. Route the vacuum control pipe so that it is tension-free.

Scheme 30

Fitting check valve on intake distributor

The black side of check valve must face rubber sleeve. Lay vacuum hose tension-free.

Scheme 31

Scheme 32

Scheme 33

AIR GUIDE COWL REMOVING & INSTALLING PROCEDURE

Scheme 34

1. Move convertible top or convertible top compartment lid to service position.
2. Remove linings for convertible top rest and engine compartment lid.
3. Pull off electrical plug connection on the mass air flow sensor.
4. Undo oval-head screws with a commercially available Torx T 20 tool (with a bore in the drive tip).

Scheme 35

Installation

1. Fit mass air flow sensor with seal and fasten with 5.0 x 20 oval-head screws. Tightening torque 3 - 4 Nm (2.0 - 3.0 ftlb).
2. Check whether a seal is present and the sensor is seated correctly. Fit plug.
3. Fit lining and engine compartment lid.

Scheme 36

Scheme 37

1. Put rear body-protection cover on the vehicle.
2. Press off expanding rivets of the luggage compartment lining with a removal tool .
3. Undo four hexagon nuts (wrench size 10 mm).
4. Take off control module. Open locking clip and pull the control module connector off.

1. Engage control module connector in the control module guide and press and lock the plug onto the terminal strip.
2. Fasten the control module. Tightening torque 10 Nm (7.5 ftlb.).
3. Fit luggage compartment lining.

Scheme 38

Note. if the DME control module is replaced, it must be programmed using the Porsche System Tester. Thus, the DME control module can be adapted to the vehicle, the national variant and the equipment. The DME control module is located behind the right rear seat. If possible, before the DME control module is removed and replaced, a read-out of the vehicle data should be obtained from the Porsche System Tester. Symbol for the TAB key = ->| Follow the instructions for the Porsche System Tester.

Obtaining read-out and saving vehicle data from DME control module

1. Connect the Porsche System Tester to the vehicle and start the System Tester. Switch ignition on. >> to continue.
2. Select vehicle type using the cursor keys.
3. Using the ->| key, move from the vehicle type to the list of control units.
4. Select DME with the cursor keys and press the >> key.
5. Select "Control unit programming" with the cursor keys and press the >> key.
6. Select "Read-out control unit (vehicle data)" with the cursor keys and press the >> key.
7. The note "Vehicle data read-out complete" will appear on the screen of the Porsche System Tester.
8. After replacement of the DME control module, the vehicle data is installed in the menu "Program control unit".

Removing DME control module

Note. Switch ignition off and remove ignition key.

Scheme 39

Scheme 40

Scheme 41

1. Open rear luggage compartment lid and lever out the clips for the carpet lining using the removal tool. See «TOOLS»(/porsche/boxster-s/986-2002-2004/remont/fuel-system/#fuel-system-electronic-injection).
2. Fold over the carpet lining and unscrew the 3 fastening nuts.
3. Lift out the control module and push in plugs -A- -arrow- and remove. (Scheme 41)
4. Press in locking element -arrow- of plugs -B- and actuate latching lever -C-. (Scheme 41)
5. Remove the control module.

Scheme 42

Scheme 43

1. Push in plugs -B- on the DME control module and close the latching lever -C- until the lever engages. (Scheme 42)
2. Press in plugs -A- on the control module, until they engage. (Scheme 42)
3. Position control module and secure with the fastening nuts. Tightening torque: 10 Nm (7.5 ftlb.).
4. Fold back the carpet lining into position and fasten with the clips.
5. Program the DME control module with the Porsche System Tester. See «PROGRAMMING NEW DME CONTROL MODULE»(/porsche/boxster-s/986-2002-2004/remont/fuel-system/#fuel-system-electronic-injection__programming-new-dme-control-module) and «PROGRAMMING DME CONTROL MODULE»(/porsche/boxster-s/986-2002-2004/remont/fuel-system/#fuel-system-electronic-injection__programming-dme-control-module).

Programming new DME control module

1. If a new DME control module is to be installed in a vehicle, the DME code specified in IPAS and the immobilizer code must be entered in the DME control module.
2. You can get the codes from IPAS or from your importer by specifying the vehicle identification number.
3. During DME programming, it is essential to guarantee the power supply for the Porsche System Tester. In case of doubt, connect a charging unit to the vehicle battery.
4. Symbol for the TAB key = ->
5. The instructions of the Porsche System Tester have highest priority.
6. The procedure listed has been structured generally, changes or additions can be made.

1. Connect the Porsche System Tester to the vehicle and start the System Tester. Switch ignition on.
2. Select vehicle type using the cursor keys. Version 1: Using the ->| key, move from the vehicle type to the list of control units. Version 2: Using the >> key, move from the vehicle type to the list of control units. The Vehicle Ident. No. under item 6 only has to be confirmed and not entered.
3. Select DME with the cursor keys and press the >> key.
4. Select "Control unit programming" with the cursor keys and press the >> key.
5. Select "Control unit programming" with the cursor keys and press the >> key. Follow the displayed programming instructions from the Porsche System Tester.
6. Enter the Veh. Ident. No. with the cursor keys, continue with >> and confirm with F7.
7. Enter the new DME (IPAS) programming code and confirm with the >> key.
8. Check the DME programming code again; if the code is correct, confirm with the F7 key.
9. Enter the new immobilizer code (IPAS), confirm with the >> key, check the code again and confirm with the F7 key.
10. Select transmission type (manual transmission, Tiptronic), continue with >>.
11. Check the transmission type and code with F8.
12. Select the required program map and confirm with the >> key. See «VERSION (DATA RECORDS)»(/porsche/boxster-s/986-2002-2004/remont/fuel-system/#fuel-system-electronic-injection__version-data-records) .
13. The data and programming status is then loaded on to the DME control module. Do not interrupt the programming sequence.
14. When the programming period has expired, follow the instructions from the Porsche System Tester -CAN TIME OUT-.
15. Press the >> key. For the learning and adaptation routine of the throttle (E-gas), switch the ignition on for 1 minute without starting the engine and without actuating the accelerator pedal. Then switch the ignition off for at least 10 seconds. This completes the adaptation of the throttle adjusting unit and the programming sequence is complete.
16. Read out the fault memory and delete the fault -CAN TIME OUT - on every control unit that is connected to the CAN.

Programming DME control module

1. If the DME control module from a different Boxster vehicle with ME 7.2 is being used, proceed as follows. As a check, the DME code and the immobilizer code of the vehicle in which the control module is being installed (NEW) and of the vehicle from which the control module has been removed (OLD) are required.
2. You can get the necessary codes from IPAS or from your importer by specifying the vehicle identification number.
3. During DME programming, it is essential to guarantee the power supply for the Porsche System Tester, in case of doubt, connect a charging unit to the vehicle battery.
4. Symbol for the TAB key = ->
5. When programming maps, update the data records. Procedure is similar to - Control unit programming -. Follow the instructions for the Porsche System Tester. See «VERSION (DATA RECORDS)»(/porsche/boxster-s/986-2002-2004/remont/fuel-system/#fuel-system-electronic-injection__version-data-records) .

1. Connect the Porsche System Tester to the vehicle and start the System Tester. Switch ignition on.
2. Select vehicle type using the cursor keys. In the 911 Carrera- 911 (996). Version 1: Using the ->| key, move from the vehicle type to the list of control units. Version 2: Using the >> key, move from the vehicle type to the list of control units. The Vehicle Ident. No. under item 6 only has to be confirmed and not entered.
3. Select DME with the cursor keys and press the >> key.
4. Select "Control unit programming" with the cursor keys and press the >> key.
5. Select "Control unit programming" with the cursor keys and press the >> key. Follow the displayed programming instructions from the Porsche System Tester.
6. Enter the Veh. Ident. No. with the cursor keys, continue with >> and confirm with F7.
7. Enter the old DME (IPAS, vehicle - OLD) programming code with the cursor keys, continue with the >> key and, after checking the code, confirm with F7.
8. Enter the new DME (IPAS, vehicle - NEW) programming code with the cursor keys, continue with the >> key and, after checking, confirm with F7.
9. Enter the old immobilizer code (IPAS, vehicle -OLD), continue with the >> key, check the code again and confirm with F7.
10. Enter the new immobilizer code (IPAS, vehicle -NEW), continue with the >> key, check the code again and confirm with F7.
11. Select transmission type (manual transmission, Tiptronic), continue with >>.
12. Check the transmission type and code with F8.
13. Select the required program map and confirm with the >> key. See «VERSION (DATA RECORDS)»(/porsche/boxster-s/986-2002-2004/remont/fuel-system/#fuel-system-electronic-injection__version-data-records) .
14. The data status is loaded on to the DME control module. Do not interrupt the programming sequence.
15. When the programming period has expired, follow the instructions from the Porsche System Tester -CAN TIME OUT-.
16. Press the >> key. For the learning and adaptation routine of the throttle (E-gas), switch the ignition on for 1 minute without starting the engine and without actuating the accelerator pedal. Then switch the ignition off for at least 10 seconds. This completes the adaptation of the throttle adjusting unit and the programming sequence is complete.
17. Read out the fault memory and delete the fault -CAN TIME OUT - on every control unit that is connected to the CAN.

Programming map as of 7.2

1. Select "Control unit programming" with the cursor keys in the DME control module and press the >> key.
2. Select "Program map" >> and observe the programming instructions.
3. Enter old DME programming code, >>, confirm with F7 key.
4. Specify transmission type, >>, code with F8 key.
5. Select the required program map and confirm with the >> key. See «VERSION (DATA RECORDS)»(/porsche/boxster-s/986-2002-2004/remont/fuel-system/#fuel-system-electronic-injection__version-data-records) .
6. The tester shows whether the data status is current or not current.
7. Proceed further according to the tester instructions.

Programming map as of 7.8 min

Under the heading - DME, Control unit programming, Control unit type - it is possible to check whether the data record for this vehicle is up-to-date or not.

In the case of - Not up-to-date - the data record can be updated with - Program map -. The prerequisite is that a customer complaint has been submitted or that Porsche AG has arranged for this to be done in the context of a campaign.

In the case of - Up-to-date - the data record and the version are displayed.

Version (data records)

1. Please note that not all variants are separately listed in this chapter. This document should provide the contents of the data records.
2. Extended contents can be listed in the following tables.
3. The listed tables are included in the software status 13.0, Porsche System Tester. Therefore, higher software versions may feature extended or deviating contents.
4. The diagnosis software no. (see table) is not needed as of PST2 software 12.1.

In model year 2000 a new air flow sensor (HFM) was introduced. The introduction date was the 31st January 2000, as of the vehicle identification numbers

VEHICLE IDENTIFICATION NUMBERS

DIAGNOSIS SOFTWARE VERSION (ME 7.2, BOXSTER 2.7L)

DIAGNOSIS SOFTWARE VERSION (ME 7.2 BOXSTER S)

Control unit type as of model year 2003

Note. As of model year 2003, DME 7.8 min, the installed data status can be read out under the heading Control unit programming, Control unit type.

DIAGNOSIS SOFTWARE VERSION (ME 7.8 MIN, BOXSTER 2.7L)

DIAGNOSIS SOFTWARE VERSION (ME 7.8 MIN, BOXSTER S)

Scheme 44

SPECIAL TOOL DESIGNATION CHART

Scheme 45

SPECIAL TOOL DESIGNATION CHART - OXYGEN SENSOR

Removing oxygen sensor

1. Do not remove the plastic cap on the thread until just prior to fitting the oxygen sensor. The thread grease must under no circumstances come into contact with the plug.
2. Protect sensors - before and after fitting -against mechanical shocks.
3. Sensors that were dropped on the floor must not be used owing to the risk of a broken ceramic insulator.
4. The cables must not be twisted or kinked when the sensors are screwed in. Avoid puffing on the cable and plug.
5. Cleanliness in the housing of the plug connections is of utmost importance for the function of the oxygen sensor. Particles of dirt can impair the function of the oxygen sensor. Therefore, the plug must be protected against any and all types of soiling.
6. Sensors with soiled or damaged plug must no longer be used.
7. Protect the cables and plugs when transporting the exhaust system with the sensors already fitted.
8. High-pressure cleaning equipment must not be used in the area of the sensors and plug connections.
9. Contact and corrosion agents, e.g. Stabilant, must not be applied on the plug contacts of the oxygen sensors.

Scheme 46

Scheme 47

1. Disconnect plug connection behind the catalytic converter, cylinder bank 4-6.
2. Disconnect the plug connection in front of catalytic converter on rear-axle support, cylinder bank 4-6
3. Undo oxygen sensor using the specified ring wrench (wrench size 22 mm).

Scheme 48

Installing oxygen sensor

1. Screw in the oxygen sensor whilst simultaneously turning the cable with it.

Note. Different tightening torque if the specified tool is used.

TIGHTENING TORQUES - OXYGEN SENSOR

Precautionary measures when handling oxygen sensors

1. Do not remove the plastic cap on the thread until just prior to fitting the oxygen sensor. The thread grease must under no circumstances come into contact with the connector.
2. Protect sensors - before and after fitting -against mechanical shocks.
3. Sensors that were dropped on the floor must not be used owing to the risk of a broken ceramic insulator.
4. The cables must not be twisted or kinked when the sensors are screwed in. Avoid pulling on the cable and connector.
5. Cleanliness in the housing of the plug connections is of utmost importance for the function of the oxygen sensor. Particles of dirt can impair the function of the oxygen sensor. Therefore, the connector must be protected against any and all types of soiling.
6. Sensors with soiled or damaged connector must no longer be used.
7. Protect the cables and plugs when transporting the exhaust system with the sensors already fitted.
8. High-pressure cleaning equipment must not be used in the area of the sensors and plug connections.
9. Contact and corrosion agents, for example, Stabilant, must not be applied on the plug contacts of the oxygen sensors.

Removing and installing oxygen sensors in front of catalytic converter - as of MY 2003

Note. Observe precautionary measures when using oxygen sensors. See PRECAUTIONARY MEASURES WHEN HANDLING OXYGEN SENSORS !

Scheme 49

Scheme 50

Scheme 51

1. Remove respective rear wheel. To do this, use the socket wrench insert P 300 to avoid damaging the wheel.
2. Remove oxygen sensor cable and oxygen sensor plug from the holder on the axle support -arrow-. (Scheme 50)
3. Unlock and disconnect oxygen sensor plug by pulling the plug lock out sideways. Use a small screwdriver to open the plug lock at the side. (Scheme 51)
4. Undo oxygen sensor using an open-ended wrench (wrench size 22) and screw it out by hand.

Removing oxygen sensors in front of catalytic converter - USA

Oxygen sensor cylinder bank 1 - 3

1. 1- Sensor behind catalytic converter: black cable conduit
2. 2- Sensor in front of catalytic converter: blue cable conduit

Scheme 52

Scheme 53

1. Pull off oxygen sensor cable plug in front of catalytic converter (blue cable conduit) and expose oxygen sensor cable -1- .
2. Undo oxygen sensor -1- with an open-ended wrench or open ring wrench (wrench size 22) and screw it out by hand. Oxygen sensor cylinder bank 4 - 6: -1- Sensor behind catalytic converter: black cable conduit -2- Sensor in front of catalytic converter: blue cable conduit
3. Pull off oxygen sensor cable plug in front of catalytic converter (blue cable conduit) and expose oxygen sensor cable 1.
4. Undo oxygen sensor using an open-ended wrench (wrench size 22) and screw it out by hand.

Scheme 54

1. Position the oxygen sensor by hand and screw in as far as possible.
2. Tighten oxygen sensor with conventional open ring wrench Hazet 4681-3 and torque wrench. Tightening torque 55 (41) +/- 5 (3.5) Nm (ftlb.)
3. Connect the oxygen sensor connecting plugs and secure by inserting the plug lock.
4. Fit oxygen sensor cable and oxygen sensor plug on the holder on the axle support.
5. Mount respective rear wheel. To do this, use the socket wrench insert P 300 to avoid damaging the wheel.

Tightening torque 130 Nm (96 ftlb.)

Installing oxygen sensors in front of catalytic converter - USA

1. Position the oxygen sensor by hand and screw in as far as possible.
2. Tighten oxygen sensor with conventional open ring wrench Hazet 4681-3 and torque wrench. Tightening torque 55 (41) +/- 5 (3.5) Nm (ftlb.)
3. Route the blue oxygen sensor cable and secure it in the sheet metal brackets, wire retainers, or the cable guide.
4. Connect plug connection and insert in the holder.

Tightening torques

TIGHTENING TORQUES - CATALYTIC CONVERTER IN FRONT OF CATALYTIC CONVERTER

Removing and installing oxygen sensors behind catalytic converter - as of MY 2003

Note. Observe precautionary measures when using oxygen sensors. See PRECAUTIONARY MEASURES WHEN HANDLING OXYGEN SENSORS !

Scheme 55

Scheme 56

Scheme 57

1. Remove rear wheel housing liner on the corresponding side.
2. Remove rubber sleeve between oxygen sensor cable and heat insulation plate and expose oxygen sensor cable plug.
3. Unlock and disconnect oxygen sensor plug by pulling the plug lock out sideways. Use a small screwdriver to open the plug lock at the side.
4. Undo oxygen sensor using an open-ended wrench (a/f 22) and screw it out by hand.

Removing oxygen sensors behind catalytic converter - USA

Oxygen sensor cylinder bank 1-3

Scheme 58

1. Remove right rear wheel. To do this, use the socket wrench insert P 300 to avoid damaging the wheel. -1- Sensor behind catalytic converter: black cable conduit -2- Sensor in front of catalytic converter: blue cable conduit
2. Pull off oxygen sensor cable plug behind catalytic converter (black cable conduit) and expose oxygen sensor cable.
3. Undo oxygen sensor -2-with an open-ended wrench or open ring wrench (a/f 22) and screw it out by hand. Oxygen sensor cylinder bank 4 - 6: -1- Sensor behind catalytic converter: black cable conduit -2- Sensor in front of catalytic converter: blue cable conduit
4. Pull off oxygen sensor cable plug behind catalytic converter (black cable conduit) and expose oxygen sensor cable.
5. Undo oxygen sensor using an open-ended wrench (a/f 22) and screw it out by hand.

Installing oxygen sensors behind catalytic converter - RoW

1. Position the oxygen sensor by hand and screw in as far as possible.
2. Tighten oxygen sensor with conventional open ring wrench Hazet 4681-3 and torque wrench. Tightening torque 55 (41) +/- 5 (3.5) Nm (ftlb.)
3. Connect the oxygen sensor connecting plugs and secure by inserting the plug lock.
4. Fit rubber sleeve between oxygen sensor cable and heat insulation plate.
5. Install rear wheel housing liner on the corresponding side.

Installing oxygen sensors behind catalytic converter - USA

1. Position the oxygen sensor by hand and screw in as far as possible.
2. Tighten oxygen sensor with conventional open ring wrench Hazet 4681-3 and torque wrench. Tightening torque 55 (41) +/- 5 (3.5) Nm (ftlb.)
3. Route the black oxygen sensor cable and secure it in the sheet metal brackets, wire retainers, or the cable guide.
4. Connect plug connection and insert in the holder.
5. Fit right rear wheel. To do this, use the socket wrench insert P 300 to avoid damaging the wheel.

Tightening torque 130 Nm (96 ftlb.)

TIGHTENING TORQUES - OXYGEN SENSOR BEHIND CATALYTIC CONVERTER

Scheme 59

Includes

24 42 21 Removing throttle body - Boxster S

24 42 23 Installing throttle body - Boxster S

Scheme 60

Removal overview

Scheme 61

1. Undoing intake manifold
2. Removing crankcase venting
3. Removing rubber sleeve
4. Disconnecting electric plug
5. Undoing throttle body holder
6. Removing throttle body from flange

Scheme 62

Scheme 63

Scheme 64

Scheme 65

Scheme 66

Scheme 67

1. Undoing intake manifold Open the hose clamp on the throttle body. Pull off the connection hose between the air cleaner housing and the throttle body and put it aside.
2. Removing crankcase venting Remove the crankcase venting on the throttle body. To do this, push the connecting plug on the grooved surfaces together and pull off simultaneously.
3. Removing rubber sleeve Undo the two rubber sleeves on the centre part of the intake distributor and push outwards.
4. Disconnecting electric plug Disconnect the electric plug on the throttle body. To do this, gently push plug on the left and right and remove.
5. Undoing throttle body holder Unscrew the fastening nuts on the throttle body holder and take the throttle body and the centre part of the intake distributor out of the engine compartment.
6. Removing throttle body from flange Unscrew the four fastening screws on the throttle body and remove the throttle body. Do not use the moulded rubber seal again.

Scheme 68

Installation overview

Scheme 69

1. Replacing seat
2. Fitting throttle body
3. Tightening throttle body holder
4. Securing rubber sleeve
5. Connecting electric plug
6. Putting on crankcase venting
7. Fastening intake hose

Scheme 70

Scheme 71

Scheme 72

Scheme 73

Scheme 74

Scheme 75

1. Replacing seal Replace the moulded rubber seal between the centre part of the intake distributor and the throttle body. When inserting the seal, make sure that the lug on the seal is located in the groove provided.
2. Fitting throttle body Lay the throttle body holder on the right hand side of the throttle body. Screw in the four fastening screws and tighten to 9.7 Nm (7.0 ftlb.).
3. Tightening throttle body holder Place the throttle body with the centre part of the intake distributor into the engine compartment. Push on the rubber sleeves and tighten the fastening nuts on the throttle body holder to 9.7 Nm (7 ftlb.).
4. Securing rubber sleeves Align the rubber sleeves on the intake distributor and tighten the four hose clamps.
5. Connecting electric plug Connect the electric plug on the throttle body again. The plug must audibly engage.
6. Putting on crankcase venting Put the crankcase venting back onto the centre part of the intake distributor. The plug must audibly engage.
7. Fastening intake hose Put on the connecting hose between the air cleaner and the throttle body. Align the two markings as shown in the diagram and tighten the hose clamp.

Scheme 76

Includes

24 40 22 Removing injection valves - Boxster S

24 40 24 Installing injection valves - Boxster S

Scheme 77

Removal overview

Scheme 78

1. Removing passenger's seat
2. Opening maintenance cover
3. Removing fuel line on pressure regulator
4. Undoing fuel return line
5. Unscrewing fastening screws
6. Removing injection valves

Scheme 79

Scheme 80

Scheme 81

Scheme 82

Scheme 83

Scheme 84

1. Removing passenger's seat Remove the passenger's seat for better accessibility. Unscrew the four fastening screws for this purpose. Disconnect the electrical connections under the seat and take the seat out of the vehicle.
2. Opening maintenance cover Remove rear wall lining. Then remove the maintenance cover. Unscrew the seven hexagon-head bolts and the two fastening nuts for this purpose. Take the maintenance cover out of the vehicle.
3. Removing fuel line on pressure regulator Make sure to place a cloth beneath the screwed connection since fuel emerges when opening. Undo the fuel line from the vehicle interior (through the maintenance cover). Counter with a second open-ended wrench when doing this in order to prevent damage to the pressure regulator.
4. Undoing fuel return line Place a cloth beneath the screwed connection of the fuel return line. Undo the screwed connection of the fuel return line at the back end of the right ring pipe. Counter with an open-ended wrench to avoid damage.
5. Unscrewing fastening screws Unscrew the two fastening screws of the fuel ring pipe on the left and right of the intake system (diagram shows only one side of the ring pipe). Disconnect the electrical connections of the injection valves. To do this, press the metal spring on the plug and pull off the plug at the same time. Carefully lift the fuel ring pipe upwards out of the engine compartment. Undo the fastening screws on the intake distributor for this purpose.
6. Removing injection valves Push the fastening clips of the injection valve to do this. Then pull the injection valve concerned out of the fuel ring pipe. Do not use the old sealing rings again.

Scheme 85

Installation overview

Scheme 86

Scheme 87

Scheme 88

Scheme 89

Scheme 90

Scheme 91

Scheme 92

1. Installing injection valves Fit new sealing rings on the respective injection valve. Align the injection valve so that the lug on the valve and the lug on the fuel ring pipe lie directly above one another. Push on the fastening clip again.
2. Fastening fuel ring pipe Lift the fuel ring pipe back into the engine compartment. Carefully insert the injection valves into the opening in the intake distributor. Tighten the two fastening screws on the left and right of the fuel ring pipe to 9.7 Nm (7 ftlb.). Connect electrical connections again. Then tighten the fastening screws on the intake distributor to 9.7 Nm (7 ftlb.).
3. Tightening fuel line on pressure regulator Position the union nut on the fuel line and tighten. Make sure to counter with a wrench when doing this. The screwed connection must be checked for leaks.
4. Tightening fuel return line Tighten the screwed connection of the fuel return line at the back end of the right ring pipe. Counter with an open-ended wrench to avoid damage. The screwed connection must then be checked for leaks.
5. Closing maintenance cover Place the maintenance cover in the vehicle. Tighten the seven fastening screws and the two fastening nuts. Fit cover again.
6. Installing passenger's seat Lift the passenger's seat into the vehicle interior. Connect electrical connections. Tighten the four fastening screws to 65 Nm (48 ftlb.).

Scheme 93

Includes

24 46 21 Removing intake distributor - Boxster S

24 46 23 Installing intake distributor - Boxster S

Scheme 94

INTAKE DISTRIBUTOR REMOVING & INSTALLING PROCEDURE (BOXSTER S)

Removal overview

Scheme 95

Scheme 96

Scheme 97

Scheme 98

Scheme 99

Scheme 100

Scheme 101

Scheme 102

Scheme 103

Scheme 104

1. Removing passenger's seat Remove the passenger's seat for better accessibility. Unscrew the four fastening screws for this purpose. Disconnect the electrical connections under the seat and take the seat out of the vehicle.
2. Opening maintenance cover Remove rear wall lining. Then remove the maintenance cover. Unscrew the seven hexagon-head bolts and the two fastening nuts for this purpose. Take the maintenance cover out of the vehicle.
3. Removing throttle body (See «Removing throttle body - Boxster S»(/porsche/boxster-s/986-2002-2004/remont/fuel-system/#fuel-system-electronic-injection) ) Undo the four hose clamps on the throttle body. Push the two rubber sleeves outwards as far as they will go. Unscrew the fastening nuts. Remove crankcase vent. Remove centre part of intake distributor with throttle body.
4. Removing tuning pipe Undo the four hose clamps. Pull off the vacuum hose on the left rubber sleeve. Push the two rubber sleeves outwards as far as they will go. Take out the tuning pipe and pull the vacuum hose off the control box.
5. Removing secondary air pump (USA vehicles only) Undo the starter ground cable on the body. Open the spring band clamp using commercially available spring-band clamp pliers No. 72 or No. 73 and push to the rear. Undo the three fastening screws on the secondary air pump. Disconnect electrical connection and remove pump from vehicle.
6. Undoing fuel return line Place a clean cloth under the screwed connection and collect emerging fuel. Undo the screwed connection on the pressure regulator. An open-ended wrench must be used to counter it in order to avoid damage.
7. Undoing fuel line Place a clean cloth under the screwed connection. Undo the screwed connection of the fuel line. Counter with an open-ended wrench to avoid damage. Pull out the temperature switch for the engine compartment blower and set aside.
8. Undoing vacuum lines Disconnect the vacuum lines to the brake booster. To do this, unscrew the two screws on the intake manifold. Unscrew the fastening screw of the bleeder valve for the carbon canister on the left intake manifold. (Scheme 105) Disconnect electric plug. Remove the crankcase vent on cylinder bank 1-3. Unclip the switch-over valve for the tuning pipe and set aside.
9. Unscrewing fastening screws Open the omega clips on the fuel ring pipe and disengage the wiring harnesses. Unscrew the two fastening screws on the fuel ring pipe respectively. Unscrew the six fastening screws on the intake system on all sides. Raise the intake distributor pipes gently and immediately seal the intake channels in the cylinder head with a clean, lint-free cloth so that no dirt can enter. Lift the intake distributor upwards out of the engine compartment.

Scheme 105

INTAKE DISTRIBUTOR REMOVAL & INSTALLATION PROCEDURE (BOXSTER S)

Installation overview

Scheme 106

1. Tightening fastening screws
2. Fitting vacuum lines
3. Tightening fuel line
4. Tightening fuel return line
5. Installing secondary air pump (USA vehicles only)
6. Installing tuning pipe
7. Installing throttle body
8. Closing maintenance cover
9. Installing passenger's seat

Scheme 107

Scheme 108

Scheme 109

Scheme 110

Scheme 111

Scheme 112

Scheme 113

Scheme 114

Scheme 115

1. Tightening fastening screws Replace the seals on the intake distributor. Pay attention to the position of the lugs when doing this. Fit the intake manifolds with the fuel ring pipe and take the cloths out of the intake channels. Replace the micro-encapsulated screws on the intake system and tighten to 9.7 Nm (7 ftlb.).
2. Fitting vacuum lines Put on the vacuum line to the brake booster with a new O-ring. Tighten the two fastening screws. Tighten the fastening screw of the bleeder valve for the carbon canister on the left intake manifold. Put on the crankcase vent on cylinder bank 1-3. Clip in the switch-over valve for the tuning flap.
3. Tightening fuel line Tighten the screwed connection of the fuel line. Make sure to counter with an open-ended wrench when doing this. Check screwed connection for leaks.
4. Tightening fuel return line Tighten the screwed connection of the fuel return line. Then check the screwed connection for leaks.
5. Installing secondary air pump (USA vehicles only) Tighten the starter ground cable on the body. Open the spring band clamp using commercially available spring-band clamp pliers No. 72 or No. 73 and push it on. Tighten the three fastening screws on the secondary air pump to 9.7 Nm (7 ftlb.). Connect electrical connection.
6. Installing tuning pipe Move tuning pipe into installation position. Push the two rubber sleeves over the pipe and align. Align the tuning pipe so that the two arrows are lined up. Then tighten the four fastening screws and connect the vacuum lines to the vacuum modulator and the rubber sleeves.
7. Installing throttle body Move throttle body into installation position. Push the two rubber sleeves over it and tighten the four hose clamps. Push on the connector tube between the air cleaner and the throttle, and tighten the hose clamp. Tighten the fastening nuts to 9.7 Nm (7 ftlb.).
8. Closing maintenance cover Tighten the seven hexagon-head bolts and the two fastening nuts. Affix rear wall lining.
9. Installing passenger's seat Lift the passenger's seat into the vehicle. Connect electrical connections. Tighten the four fastening screws to 65 Nm (48 ftlb.).

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See also:
• ASSEMBLY INSTRUCTIONS
• PROGRAMMING NEW DME CONTROL MODULE
• PROGRAMMING DME CONTROL MODULE
• VERSION (DATA RECORDS)
• PRECAUTIONARY MEASURES WHEN HANDLING OXYGEN SENSORS