Safety instructions when working on fuel system
| WARNING | Lethal danger of explosion and fire from escaping fuel and vapors. |
> Ensure adequate ventilation and extract all fuel vapors.
> Do not work on fuel system when engine is hot.
> No welding or grinding work when the fuel system is open.
> Smoking prohibited and no naked lights.
> Secure vehicle clearly, e. g with warning signs.
> Wear fuel-resistant protective gloves and goggles.
> Wear a breathing mask with active charcoal filter; do not breathe in any fuel vapors.
> Pay attention to cleanliness when working on the fuel system.
> Before opening fuel lines or fuel hoses, relieve the fuel pressure.
> Collect escaping fuel, absorb it if necessary with a suitable binding material and dispose of properly.
| WARNING | Skin and eye damage from toxic and caustic effects of fuel. |
> In case of contact with skin or eyes wash immediately with plenty of warm water and acid-free soap.
> Consult a doctor as soon as possible.
Fuel supply
| Designation | 987 | 987 S | Cayman S |
|---|---|---|---|
| Injection | Digitale Motor-Elektronik ME 7.8-40 (DME engine control module, ECM); injection valves controlled sequentially | ||
| Fuel delivery | One two-stage flow pump | ||
| Fuel system | Returnless fuel | ||
| Fuel quality/type | ROZ 98, unleaded | ||
| Tank contents | 64 / 65 liters | ||
| Reserve tank capacity | 10 liters | ||
Tools
Designation Type Number Explanation pressure gauge special tool P 378a Connecting cable special tool P 9559 PIWIS Tester special tool P 9718
Scheme 54
Scheme 55
Preliminary work
1. Install protective supports.
Scheme 56
2. Move convertible top to service position. Refer to 61 01 IN Diagram of convertible top - as of MY 2005 (Boxster, Boxster RHD, Boxster S, Boxster S RHD) .
Scheme 57
3. Remove engine compartment cover. Refer to 55 78 19 Removing and installing engine compartment lid - as of MY 2005 (Boxster, Boxster RHD, Boxster S, Boxster S RHD) .
4. Relieve fuel pressure in fuel system > 206601 Checking the fuel pump delivery rate .
Checking fuel pressure
Note. The battery voltage must not fall below 12 volts during the fuel pressure check.
1. Check the battery charge state using a voltmeter or the Porsche PIWIS Tester. The battery voltage must not fall below 12 volts during the check.
Scheme 58
| WARNING | Risk of fire from escaping fuel. Danger of fatal injury and damage to property. |
> Observe basic safety instructions when working on the fuel system, > 2001AW Basic safety instructions when working on the fuel system .
> Secure working area.
2. Attach or mount a warning sign in a clearly visible position on the vehicle.
Scheme 59
Note. Use the brass cap on the test connection of the fuel supply line only once as the sealing ring cannot be replaced. To avoid possible leaks, the cap must be replaced after removal.
3. Release metal cap on test connection at fuel collection pipe -Arrow- and screw it off by hand (a/f 13 mm). (Scheme 57)
Scheme 60
4. Connecting cable P 9559 must be connected using the pressure gauge P 378a (union nut a/f 17).
- A - Connection line (9559)
- B - Pressure gauge (378a)
Scheme 61
| WARNING | Risk of fire from escaping fuel. Danger of fatal injury and damage to property. |
> Observe basic safety instructions when working on the fuel system, > 2001AW Basic safety instructions when working on the fuel system .
> Secure working area.
5. Tighten the knurled union nuts of the connecting cable by hand on the test connection of the fuel collection pipe -Arrow-. Collect emerging fuel with a cloth. (Scheme 59)
Procedure when the engine is standing still
6. Connect the Porsche PIWIS Tester PIWIS Tester P 9718 to the input socket in the vehicle using the adapter lead and switch on the ignition. Switch on the Tester and select the vehicle (option: Diagnostics).
Scheme 62
7. Run the individual control unit search for DME using the Porsche PIWIS Tester. To do this, select DME with the tracer pen and press F12 >>.
Scheme 63
8. Once the individual control unit search for DME is complete, select the Drive links item, then select the fuel pump relay and activate it by pressing F8 - Start.
9. Read value on pressure gauge. --> Fuel pressure - engine not running: 3.8 bar +/-0.2 bar
Scheme 64
10. Deactivate the fuel pump relay on the PIWIS Tester by pressing F8 - Stop. Then, press F11 << to return to the start screen and switch off the Tester.
11. Switch off the ignition and remove PIWIS Tester adapter lead in the vehicle.
12. Checking the engine at idle speed: connect the pressure gauge P 378a as described above and start the engine. Switch off the engine after reading the fuel pressure. --> Fuel pressure - idle speed: 3.8 bar +/-0.2 bar
| WARNING | Risk of fire from escaping fuel. Danger of fatal injury and damage to property. |
> Observe basic safety instructions when working on the fuel system, > 2001AW Basic safety instructions when working on the fuel system .
> Secure working area.
13. Loosen the union nut on the connecting cable P 9559 for the pressure gauge P 378a on the test connection and remove special tool. Collect escaping fuel with a cloth.
Note. Use the brass cap on the test connection of the fuel supply line only once as the sealing ring cannot be replaced. To avoid possible leaks, the cap must be replaced after removal.
14. Position new closure cap on test connection and tighten (a/f 13 mm). --> Tightening torque: 2.5 (2 ftlb.) Nm +/-0.5 (0.5 ftlb.) Nm
Subsequent work
1. Mount engine compartment cover. Refer to 55 78 19 Removing and installing engine compartment lid - as of MY 2005 (Boxster, Boxster RHD, Boxster S, Boxster S RHD) .
2. Close convertible top.
3. Remove protective covers.
Designation Type Number Explanation pressure gauge special tool P 378a Connecting cable special tool P 9559 PIWIS Tester special tool P 9718
1. Fit protective covers to vehicle and in luggage compartment.
Scheme 65
2. Remove engine cover. Refer to 55 78 19 Removing and installing engine compartment lid - as of MY 2005 (Cayman S, Cayman S RHD) .
Note. The battery voltage must not fall below 12 volts during the fuel pressure check.
1. Check the battery charge state using a voltmeter or the Porsche PIWIS Tester. The battery voltage must not fall below 12 volts during the check.
| WARNING | Risk of fire from escaping fuel. Danger of fatal injury and damage to property. |
> Observe basic safety instructions when working on the fuel system, > 2001AW Basic safety instructions when working on the fuel system .
> Secure working area.
2. Attach or mount a warning sign in a clearly visible position on the vehicle.
Note. Use the brass cap on the test connection of the fuel supply line only once as the sealing ring cannot be replaced. To avoid possible leaks, the cap must be replaced after removal.
3. Release metal cap on test connection at fuel collection pipe -Arrow- and screw it off by hand (a/f 13 mm). see scheme 12
4. Connecting cable P 9559 must be connected using the pressure gauge P 378a (union nut a/f 17).
- A - Connection line (9559)
- B - Pressure gauge (378a)
| WARNING | Risk of fire from escaping fuel. Danger of fatal injury and damage to property. |
> Observe basic safety instructions when working on the fuel system, > 2001AW Basic safety instructions when working on the fuel system .
> Secure working area.
5. Tighten the knurled union nuts of the connecting cable by hand on the test connection of the fuel collection pipe -Arrow-. Collect emerging fuel with a cloth. (Scheme 65)
Procedure when the engine is standing still
6. Connect the Porsche PIWIS Tester PIWIS Tester P 9718 to the input socket in the vehicle using the adapter lead and switch on the ignition. Switch on the Tester and select the vehicle (option: Diagnostics).
7. Run the individual control unit search for DME using the Porsche PIWIS Tester. To do this, select DME with the tracer pen and press F12 >>.
8. Once the individual control unit search for DME is complete, select the Drive links item, then select the fuel pump relay and activate it by pressing F8 - Start.
9. Read value on pressure gauge. --> Fuel pressure - engine not running: 3.8 bar +/-0.2 bar
10. Deactivate the fuel pump relay on the PIWIS Tester by pressing F8 - Stop. Then, press F11 << to return to the start screen and switch off the Tester.
11. Switch off the ignition and remove PIWIS Tester adapter lead in the vehicle.
12. Checking the engine at idle speed: connect the pressure gauge P 378a as described above and start the engine. Switch off the engine after reading the fuel pressure. --> Fuel pressure - idle speed: 3.8 bar +/-0.2 bar
| WARNING | Risk of fire from escaping fuel. Danger of fatal injury and damage to property. |
> Observe basic safety instructions when working on the fuel system, > 2001AW Basic safety instructions when working on the fuel system .
> Secure working area.
13. Loosen the union nut on the connecting cable P 9559 for the pressure gauge P 378a on the test connection and remove special tool. Collect escaping fuel with a cloth.
Note. Use the brass cap on the test connection of the fuel supply line only once as the sealing ring cannot be replaced. To avoid possible leaks, the cap must be replaced after removal.
14. Position new closure cap on test connection and tighten (a/f 13 mm). --> Tightening torque: 2.5 (2 ftlb.) Nm +/-0.5 (0.5 ftlb.) Nm
1. Mount engine compartment cover. Refer to 55 78 19 Removing and installing engine compartment lid - as of MY 2005 (Cayman S, Cayman S RHD) .
2. Close convertible top.
3. Remove protective covers.
Scheme 66
1. Install engine cover. Refer to 55 78 19 Removing and installing engine compartment lid - as of MY 2005 (Cayman S, Cayman S RHD) .
2. Remove protective covers.
Calibrating fuel-level sensor system
| WARNING | Danger of fire and injury! Danger of fire and injury! |
> Observe general safety regulations on the fuel system!
> Wear protective gloves!
| WARNING | Lethal danger of explosion and fire from escaping fuel and vapors. |
> Ensure adequate ventilation and extract all fuel vapors.
> Do not work on fuel system when engine is hot.
> No welding or grinding work when the fuel system is open.
> Smoking prohibited and no naked lights.
> Secure vehicle clearly, e. g with warning signs.
> Wear fuel-resistant protective gloves and goggles.
> Wear a breathing mask with active charcoal filter; do not breathe in any fuel vapors.
> Pay attention to cleanliness when working on the fuel system.
> Before opening fuel lines or fuel hoses, relieve the fuel pressure.
> Collect escaping fuel, absorb it if necessary with a suitable binding material and dispose of properly.
| WARNING | Skin and eye damage from toxic and caustic effects of fuel. |
> In case of contact with skin or eyes wash immediately with plenty of warm water and acid-free soap.
> Consult a doctor as soon as possible.
Note. Tank calibration is necessary after replacement of the fuel tank, fuel-level sensor or instrument cluster. Calibrate the fuel-level sensor system - after replacing the instrument cluster - only if the function The fuel-level sensor system need not be calibrated if the battery was disconnected or a plug connection on the instrument cluster or fuel-level sensor was removed. The values remain stored in the instrument cluster. A range on remaining fuel of less than 15 km is not displayed in the instrument cluster. Read out values cannot be performed!
Empty the fuel tank, e. g. see Checking quantity delivered by fuel system. > 206601 Checking fuel delivery rate
1. Fill the fuel tank with 13 liters of fuel, metered by volume.
2. Wait for a short time to allow the tank sensor to settle down to the level.
3. Connect the Porsche System Tester to the vehicle and start the System Tester. Switch on the ignition. >> Continue.
4. Select vehicle type, then go to the list of control units.
5. Select Instrument cluster control unit, then press >>.
6. Select the Special functions menu, then press >>.
7. Select the Tank check menu, then press >>.
8. Carry out the tank calibration; the tester gives a reading in liters, which is then synchronized to 13 liters .
9. Check position of tank needle in instrument cluster. Tank needle in lower third.
10. Fill vehicle with fuel and check position of tank needle in instrument cluster. Wait for a few minutes. Tank needle shows full.
| Designation | Type | Number | Explanation | |
|---|---|---|---|---|
| Socket-wrench insert | Special tool | P 300 |
Preliminary work for carbon canister
1. Disconnect ground connection from battery. Refer to 27 06 IN External power connection, jump lead starting - as of MY 2005 (All Models) .
Scheme 67
2. USA version: Remove luggage-compartment lining -2- by unscrewing the eight sheetmetal screws -1- (Refer to 70 30 19 Removing and installing front luggage compartment cover - as of MY 2005 (All Models) ). see scheme 19
Scheme 68
3. Unscrew fastening screws for CD changer support -1-. The support is also fixed on the body side by two retaining clips -Arrows-. see scheme 20
Scheme 69
4. Lift up support together with CD changer and disengage retaining clips at the plenum panel -Arrows-. see scheme 21
5. Disconnect cable plug to CD changer.
6. RoW Version: Remove right front wheel using socket-wrench insert P 300 . Refer to 44 05 19 Removing and installing wheel - as of MY 2005 (All Models) .
7. Remove rear part of right front wheel housing liner. Refer to 50 56 19 Removing and installing front wheel housing liner - as of MY 2005 (All Models) .
Scheme 70
1. Unscrew collar nut M6 -1-. Carefully pull carbon canister out of body mounting points in direction of travel. (Scheme 66)
2. Release and remove plug-in couplings on the underside of the canister -2-. Unclip lines from the mountings on the canister -3-. (Scheme 66)
Scheme 71
1. Unclip cable plug from canister -1- and then disconnect. (Scheme 67)
2. Unscrew two Torx screws M6 -2- from plastic holder for the carbon canister and press holder -3- from guide in direction of travel. (Scheme 67)
Scheme 72
3. Lift carbon canister, release the small plug-in coupling -2- and pull it down and off. (Scheme 68)
Scheme 73
4. Lift carbon canister, release the large plug-in coupling -1- and pull it down and off. (Scheme 69)
Scheme 74
1. Wet rubber sleeves with water. Press canister into the body bores -1-. (Scheme 70)
2. Connect plug-in couplings to the underside of the canister and clip in the lines. Screw in collar nut M6 on the holder and tighten. --> Tightening torque: 7.5 ftlb.
Scheme 75
Plug-in couplings in the vehicle
1. Insert canister and connect the plug-in couplings which must engage audibly.
2. Slide plastic holder for the canister -3- into the guide and fix to the plenum panel. Screw in two Torx screws M6 -2- and tighten. --> Tightening torque: 7.5 ftlb. (Scheme 73)
3. Connect cable plug and clip into the cable guide on the canister -1-. (Scheme 73)
Subsequent work for carbon canister
1. USA version: Disconnect cable plug from CD changer.
2. Engage support together with CD changer on the plenum panel by means of the retaining clips -Arrows-. (Scheme 74)
3. Screw in and tighten fastening screws M6 -1- for CD changer support. --> Tightening torque: 10 (7.5 ftlb.) Nm see scheme 31
4. Install luggage-compartment lining -2- by screwing in the eight sheetmetal screws -1- (Refer to 70 30 19 Removing and installing front luggage compartment cover - as of MY 2005 (All Models) ). (Scheme 75)
5. RoW Version: Remove rear part of right front wheel housing liner. Refer to 50 56 19 Removing and installing front wheel housing liner - as of MY 2005 (All Models) .
6. Fit right front wheel using socket-wrench insert P 300 . Refer to 44 05 19 Removing and installing wheel - as of MY 2005 (All Models) .
7. Connect ground connection to battery. Refer to 27 06 IN External power connection, jump lead starting - as of MY 2005 (All Models) .
Designation Type Number Explanation measurement adapter special tool P 9705 PIWIS Tester special tool P 9718
Preliminary work for quantity delivered by fuel pump
Note. The battery voltage must not fall below 12 volts during the fuel delivery rate check.
1. Check the battery charge state using a voltmeter or the Porsche PIWIS Tester. The battery voltage must not fall below 12 volts during the check.
2. Remove rear cover for underbody. Refer to 51 94 19 Removing and installing cover for rear underbody - as of MY 2005 (All Models) .
Checking quantity delivered by fuel pump
Note. The battery voltage must not fall below 12 volts during the fuel delivery rate check.
| WARNING | Risk of fire from escaping fuel. Danger of fatal injury and damage to property. |
> Observe basic safety instructions when working on the fuel system, > 2001AW Basic safety instructions when working on the fuel system .
> Secure working area.
1. Attach or mount a warning sign in a clearly visible position on the vehicle.
2. Reduce fuel pump supply pressure. To do this, remove the cover of the fuse carrier in the left footwell and take out the fuse for the fuel pump - level D, fuse F1 (No. 1 from left) . Then start the engine for several seconds. This procedure does not cause an entry to be made in the fault memory. Insert the fuse again and replace the cover.
3. Connect the Porsche PIWIS Tester PIWIS Tester P 9718 to the input socket in the vehicle using the adapter lead, switch on the ignition and switch off all loads, such as the radio and air conditioning. Switch on the Tester and select the vehicle (option: Diagnostics).
4. Run the individual control unit search for DME using the Porsche PIWIS Tester. To do this, select DME with the tracer pen and press F12 >>.
5. Select the Drive links item and then select the fuel pump relay.
Scheme 76
6. Have a measurement adapter P 9705 , a fuel-resistant container, a measuring cup and a stopwatch to hand for measuring.
Scheme 77
| WARNING | Risk of fire from escaping fuel. Danger of fatal injury and damage to property. |
> Observe basic safety instructions when working on the fuel system, > 2001AW Basic safety instructions when working on the fuel system .
> Secure working area.
7. Disconnect rapid-action coupling on the fuel supply line -1- by pressing in the locking lug and pulling off the coupling. Clean up emerging residual fuel with a cloth, for example. see scheme 36
Scheme 78
8. Connect the measuring adapter P 9705 special tool to the rapid-action coupling on the fuel line. Make sure that the plug-in coupling is fitted correctly (must engage audibly) by pulling the line apart.
Scheme 79
9. Place the drainage hose after the pressure regulator into a petrol-resistant container. Make sure that the container does not tip over.
10. Activate the fuel pump relay on the Porsche PIWIS Tester. Press F8 - Start until fuel emerges at the drainage hose. Deactivate the fuel pump relay by pressing F8 - Stop and pour any leaked fuel from the container into a petrol-resistant container or into the fuel tank. Keep a stopwatch to hand for the following measurement.
11. Then, activate the fuel pump relay again by pressing F8 - Start and keep it going for 60 seconds. Start the stopwatch at the same time. Collect emerging fuel in an available container. Deactivate the fuel pump relay after 60 seconds by pressing F8 - Stop.
12. Pour the collected fuel into the measuring cup and compare the quantity with the vehicle-specific nominal values listed below. --> Volume: 2.0 l/min ; --> Volume: 2.3 l/min
13. Remove measurement adapter P 9705 and attach rapid-action coupling to fuel supply line. Collect escaping fuel. Make sure that the plug-in coupling is fitted correctly (must engage audibly) by pulling the line apart.
14. Switch off ignition, switch off the Porsche PIWIS Tester and disconnect adapter lead to the vehicle.
Subsequent work for quantity delivered by fuel pump
1. Install rear cover for underbody. Refer to 51 94 19 Removing and installing cover for rear underbody - as of MY 2005 (All Models) .
Poses Online
See also:
• 61 01 IN Diagram of convertible top - as of MY 2005 (Boxster, Boxster RHD, Boxster S, Boxster S RHD)
• 55 78 19 Removing and installing engine compartment lid - as of MY 2005 (Boxster, Boxster RHD, Boxster S, Boxster S RHD)
• 27 06 IN External power connection, jump lead starting - as of MY 2005 (All Models)
• 70 30 19 Removing and installing front luggage compartment cover - as of MY 2005 (All Models)
• 44 05 19 Removing and installing wheel - as of MY 2005 (All Models)
• 50 56 19 Removing and installing front wheel housing liner - as of MY 2005 (All Models)
• 51 94 19 Removing and installing cover for rear underbody - as of MY 2005 (All Models)
• > 206601 Checking the fuel pump delivery rate