Repair manual
Wiring diagrams
Porsche Boxster 986 Repair Manual
Step-by-step repair and maintenance instructions for the Porsche Boxster 986 (1996–2002): removal, installation, adjustment, diagnostics and parameter checks with illustrations.
65sections
675articles
ENManual language
- Changes to convertible-top frame as of model year 2003
- Replacing convertible-top covering
- Installing the convertible-top covering
- Removing convertible-top covering
- Replacing 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
- 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
- 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
- Structure
- General
- Operating conditions "Freeze frame"
- ECM signal output
- Warm up cycle
- Driving cycle
- Trip
- Readiness code
- Freeze Frame
- Fault shedding
- Fault healing
- Fault erasing counter
- Use
- Malfunctions
- Voltage supply
- Adjusting illumination of LCD panel
- Working log
- Automatic switch-off
- Software update
- Main menu
- Fault memory
- Erase fault memory
- Actual values
- Drive links
- Input signals
- Drive link active
- Vehicle data
- Control module programming
- Mode 1
- Mode 2
- Mode 4
- Mode 5
- $00 Supported PID's
- Data A
- Data B
- Data C
- Data D
- $OF Intake air temperature
- Mode 3
- Tools
- Fault types
- MIL (Check Engine Malfunction Indicator Light)
- Mass Air Flow Sensor Signal implausible
- Mass Air Flow Sensor, below lower limit
- Function
- Intake Air Temperature Circuit - Low Input
- Intake Air Temperature Sensor, below lower limit
- Check Intake Air Temperature Sensor in mass air flow sensor
- ECT Sensor signal implausible
- ECT Engine Coolant Temperature - Malfunction
- Resistance values
- Check Intake Air Temperature Sensor
- Check Output Voltage of ECM
- 117 Throttle Position Sensor - Below Limit
- Check voltage supply to TP sensor
- Check TP sensor
- Check oxygen sensor
- Check ECM final stage
- Aging of Oxygen Sensor Ahead of Three Way Catalytic Converter (TWC) (cylinders 1 - 3)
- Aging of Oxygen Sensor Ahead of Three Way Catalytic Converter (cylinders 1 - 3) - Below Lower Limit
- Aging of Oxygen Sensor Ahead of Three Way Catalytic Converter (TWC) (cylinders 4 - 6)
- Manual transmission
- Tiptronic
- Check function of oxygen sensor
- Check oxygen sensor heating
- Aging of Oxygen Sensor After Three Way Catalytic Converter (TWC) (cylinders 1 - 3)
- Camshaft Position (CMP) Sensor 1 Signal Implausible, Short Circuit to Ground, Short Circuit to Plus
- Check power supply to CMP Sensor
- Check CMP Sensor signal
- Check signal wire from ECM to CMP Sensors
- Check signal wire from ECM to CMP Sensors for short circuit to ground
- Check signal wire from ECM to CMP Sensors for short circuit to B+
- Oil Temperature Sensor - Short Circuit to Ground
- Check temperature sensor
- Check wire from ECM to temperature sensor for short to ground
- Check wire from ECM to temperature sensor for short to B+
- Misfire Damaging to Catalytic Converter
- Misfire, Cylinder 1, Damaging to Catalytic Converter
- Misfire, Cylinder 2, Damaging to Catalytic Converter
- Misfire, Cylinder 3, Damaging to Catalytic Converter
- Misfire, Cylinder 4, Damaging to Catalytic Converter
- Misfire, Cylinder 5, Damaging to Catalytic Converter
- Misfire, Cylinder 6, Damaging to Catalytic Converter
- Misfire, Cylinder 1, Emission Related
- Misfire, Cylinder 2, Emission Related
- Misfire, Cylinder 3, Emission Related
- Misfire, Cylinder 4, Emission Related
- Misfire, Cylinder 5, Emission Related
- Misfire, Cylinder 6, Emission Related
- Misfire, Emission Related
- Checking quantity delivered by fuel pump
- Check triggering of fuel injectors
- Check signal with engine tester
- Secondary Air Injection System - Signal Implausible (Cylinders 1 - 3)
- In menu "Drive links", trigger secondary air injection (AIR) pump
- Check triggering of AIR pump
- Check electric change-over valve
- Check air change-over valve and air supply lines
- TWC Conversion Too Low (cylinders 1 - 3)
- Check triggering of the EVAP canister purge valve
- Check voltage supply and leads
- Check EVAP canister purge valve
- Check hose between EVAP canister purge valve and intake system
- Check EVAP canister purge valve for leaks
- Check ventilation lines for leaks
- EVAP Canister Purge Valve - Open Circuit
- Check voltage supply for EVAP canister purge valve
- Check control line for EVAP canister purge valve
- Check control line for EVAP canister purge valve for short circuit to B+
- Check control line for EVAP canister purge valve for short circuit to ground
- Check purge air line for blockage
- 96 EVAP Canister Shutoff Valve (Output Stage) - Open Circuit
- Check voltage supply for shutoff valve
- Check shutoff valve
- Check triggering wire for shutoff valve for continuity
- Check triggering wire for shutoff valve for short circuit to B+
- Check triggering wire for shutoff valve for short circuit to ground
- 99 Tank Pressure Sensor - Signal Implausible
- 99 Tank Pressure Sensor - Below Limit
- Check tank cap
- Check ventilation lines at EVAP canister
- Check ventilation lines at operating purge valve
- Check ventilation line at tank
- Check ventilation line at EVAP canister purge valve
- Check ventilation lines
- Read ABS control module fault memory
- Check speed sensor with ohmmeter
- Check speed signal with engine tester
- Idle Air Control - Engine speed too low
- Check IAC Valve
- Check CAN bus from ECM to Tiptronic control module for continuity
- Check CAN bus from ECM to Tiptronic control module for short to ground
- Check CAN bus from ECM to Tiptronic control module for short to B+
- Check CAN bus from ECM to Tiptronic control module for short circuit
- ECM faulty
- Oxygen sensor heating 1 ahead of catalytic converter - above upper limit
- Check resistance of oxygen sensor heating
- Oxygen sensor heating 1 behind catalytic converter - above upper limit
- Oxygen sensor heating 1 ahead of catalytic converter - below lower threshold
- Oxygen sensor heating 1 behind catalytic converter - below lower threshold
- Check resistance of H02S heating
- Check ECM final stage to B+
- Oxygen Sensing Adaptation Range 1 (Cylinders 1 - 3) Enrichment Limit
- Checking fuel pressure
- Checking volume supply of fuel pump
- Fuel injectors contaminated (carbonized)
- Oxygen Sensing Adaptation Range 1 (Cylinders 1 - 3) Lean Limit
- Check fuel pressure regulator, vacuum connection and fuel return line
- Oxygen Sensing Adaptation Range 2 (Cylinders 1 - 3) Lean Limit
- Oxygen Sensing Adaptation Range 2 (cylinder 1 - 3) - Enrichment limit
- Fuel injectors contaminated, carbonized
- Read specified values for Throttle Position Sensor
- Engine Compartment Temperature Sensor - Short Circuit to Ground
- Resistance value
- Check wire from ECM to temperature sensor for short circuit to ground
- Check wire from ECM to temperature sensor for short circuit to B+
- Injector Circuit Cylinder 1 - Short to B+
- Fuel injector, cylinder 1 - Short to Ground
- Check fuel injector
- Injector Circuit, Cylinder 2 - Short to B+
- Fuel Injector, cylinder 2 - Short to Ground
- Fuel Injector, cylinder 3 - Short to B+
- Fuel Injector, cylinder 3 - Short to Ground
- Injector Circuit, Cylinder 4 - Short to B+
- Fuel Injector, cylinder 4 - Short to Ground
- Fuel Injector, cylinder 5 - Short to B+
- Fuel Injector, cylinder 5 - Short to Ground
- Fuel Injector, cylinder 6 - Short to B+
- Fuel Injector, cylinder 6 - Short to Ground
- Timing Chain out of Position, Bank 2 - Below Lower Limit
- Timing Chain out of Position, Bank 2 - Above Upper Limit
- Timing Chain out of Position, Bank 1 - Below Lower Limit
- Knock Sensor 1 - Signal Implausible
- Knock Sensor 2 - Signal Implausible
- A/C compressor control - Interruption
- A/C compressor control - upper limit exceeded
- Check control wire for A/C relay, pin 2 for interruptions
- Check control wire for A/C relay, pin 2 for short circuit to B+
- Check control wire for A/C relay, pin 2 (terminal 85) for short circuit to ground
- End Stage Fuel Pump Relay - Short Circuit to Ground
- End Stage Fuel Pump Relay - Short Circuit to Plus
- P 1502
- Check fuel pump relay
- Idle Control Valve Opening Coil - Open
- Check coil resistance of IAC Valve
- Check triggering wire for short to ground
- Check B+ supply of actuator
- Check triggering wire for continuity
- Idle Air Control (IAC) Valve - Interruption
- Idle Air Control (IAC) Valve Closing Coil - Below Lower Limit
- Check signal wire for continuity
- Check signal wire for short circuit to ground
- Check signal wire for short circuit to B+
- Power Supply - Signal Implausible
- Power Supply - Below Lower Limit
- Check wire, terminal 30, for contact resistances
- Engine Compartment Purge Fan End-Stage - Open Circuit
- Engine Compartment Purge Fan End-Stage - Short Circuit to Ground
- Check relay
- Check wire from ECM to relay for continuity
- Check wire from ECM to relay for short circuit to ground
- Check wire from ECM to relay for short circuit to B+
- Fan End-Stage - Open Circuit
- Fan End-Stage - Short Circuit to Ground
- Check both relays
- Check wire from ECM to relays for continuity
- Check wire from ECM to relays for short circuit to ground
- Check wire from ECM to relays for short circuit to B+
- Malfunction Indication Light (MIL), Check engine - Interruption
- MIL Check engine - Short Circuit to Ground
- Standardized trouble codes SAE J 2012 (Diagnostic Trouble Codes)
- Monitoring the Fuel Tank Ventilation System (USA Vehicles with Tank Pressure Diagnosis as of Model '98)
- Function of Tank Ventilation Diagnosis
- Diagnosis Card
- Starting diagnosis
- Short test
- Data output with a scan tool
- $01 Diagnosis system status
- $02 Trouble code
- Diagnostic conditions
- Diagnosis conditions
- Road test car or perform short test
- Road test vehicle or perform short test
- Diagnosis Procedure
- Diagnostic procedure
- Diagnostic condition
- ADJUSTING TOOL — Part 1
- ADJUSTING TOOL — Part 2
- MOUNTING INSTRUCTIONS — Part 1
- MOUNTING INSTRUCTIONS — Part 2
- MOUNTING INSTRUCTIONS — Part 3
- REMOVING DRIVE BELT
- INSTALLING DRIVE BELT
- FITTING PISTONS AND CONNECTING RODS
- FITTING PISTONS ON CYLINDER BANK 4 - 6
- REMOVING AND INSTALLING CRANKSHAFT SEALING RING - FLYWHEEL SIDE
- REMOVING CRANKSHAFT SEALING RING
- INSTALLING THE CRANKSHAFT SEALING RING
- CHECKING PISTON WEAR
- 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
- 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
- PRESUMABLE CAMSHAFTS
- SEALING COVER FOR CAMSHAFT HOUSING (CYLINDER HEAD COVER)
- CHECKING GUIDE FOR VALVE TAPPETS
- 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
- INSTALLING COOLANT PUMP
- CLEANING THE COOLING SYSTEM
- Engine Performance Diagnostic Routine Outline - General Information
- Engine Performance Safety Precautions
- Parasitic Load Explanation & Test Procedures - General Information 2
- Waveforms - Injector Pattern Tutorial - General Information 2
- Electrostatic Discharge Warning - General Information
- State Emission Standards - Diesel
- 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
- FILL IN TRANSMISSION OIL
- REPLACING ATF
- CHECKING ATF
- REMOVING ATF FILTER
- CHANGING TRANSMISSION OIL IN FINAL DRIVE
- CHECKING CLUTCH FREE PLAY
- CHECKING THE PEDAL END POSITION (PEDAL RETURN/RETURN FORCE)
- TRACK ROD JOINTS: CHECK THE PLAY AND DUST BELLOWS
- AXLE JOINTS: CHECK THE PLAY AND DUST BELLOWS
- CHECKING CONDITION
- TIRE PRESSURES
- PARKING BRAKE: CHECKING THE FREE PLAY OF THE PARKING BRAKE LEVER
- BRAKE HOSES AND LINES
- CHECKING LID LOCK, FRONT AND REAR
- CHECKING SAFETY HOOK, FRONT LID
- CHECKING INNER RELEASE OF LUGGAGE COMPARTMENT (TRUNK ENTRAPMENT)
- INSTALLING PARTICLE FILTER
- SETTING
- ADJUSTING THE MAIN HEADLIGHTS, USA VERSION
- 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
- 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 NOISES DUE TO POWER SUPPLY
- INTERFERENCE NOISES DUE TO ALL LOUDSPEAKERS
- REMOVING LOUDSPEAKER AMPLIFIER
- REMOVING AND INSTALLING CONTROL UNIT FOR THE TELEPHONE
- REMOVING SUBWOOFER
- INSTALLING SUBWOOFER
- REMOVING THE ANTENNA AMPLIFIER