Scheme 107
| Engine Type | M 96/20 | |
|---|---|---|
| Number of cylinders | 6 | |
| Bore | Mm | 85.5 |
TECHNICAL DATA ENGINE M96/20 (2.5L)
| Engine Type | M 96/20 | |
|---|---|---|
| Stroke | Mm | 72 |
| Displacement | Cm [sup3 ] | 2480 |
| Compression ratio | 11.0 : 1 | |
| Max. engine power | ||
| As per 80/1269/EWG | KW | 150 |
| As per SAE J 1349 | HP | 201 |
| At engine speed | Rpm | 6000 |
| Max. torque | ||
| As per 80/1269/EWG | Nm (ft.lb) | 245 (181) |
| At engine speed | Rpm | 4500 |
| Max. liter output | ||
| As per 80/1269/EWG | KW/l, HP/l | 60.48/82.26 |
| Idle speed - manual transmission | Rpm | 790 |
| Tiptronic sel. lever in P or N | Rpm | 750 |
| Tiptronic sel. lever in drive position | Rpm | 790 |
| And A/C on | Rpm | 800 |
| Rpm limitation at | Rpm | 6700 |
| Engine weight | ||
| Manual transmission | Kg | 182.2 |
| Tiptronic transmission | Kg | 172.7 |
| Valve control | DOHC with camshaft adjustment (VarioCam) | |
| Valve arrangement per cylinder | 2 inlet, 2 outlet, suspended parallel V-arrangement | |
| Valve clearance | Hydraulic valve clearance compensation | |
| Valve timing with 1 mm valve travel | Inlet opens 15° after TDC | |
| Valve timing with 1 mm valve travel | Inlet closes 46° after BDC | |
| Valve timing with 1 mm valve travel | Outlet opens 38° before BDC | |
| Valve timing with 1 mm valve travel | Outlet closes 7° before TDC | |
TECHNICAL DATA ENGINE M96/20 (2.5L)
| Engine Cooling | |
|---|---|
| Type | Liquid cooling, two electric fans |
ENGINE COOLING M96/20 (2.5L)
| Engine Lubrication | Integrated dry sump | |
|---|---|---|
| Oil cooling | Via oil-water heat exchanger | |
| Oil pressure at 5000 rpm | ||
| Oil temperature 90°C | Bar | Approx. 5 |
| Oil consumption | I/1000 km | Up to 1.5 |
ENGINE LUBRICATION INTEGRATED DRY SUMP (2.5L)
| Fuel System | DME 5.22 with sequential fuel injection | |
|---|---|---|
| Fuel delivery | 1 electr. fuel pump | |
| System pressure without vacuum | Bar | 3.6... 4.0 |
| Fuel RON/MON | At least 98/88 |
ENGINE FUEL SYSTEM INJECTION (2.5L)
| Fuel Consumption as per 93/116/EG | |||
|---|---|---|---|
| Manual transmission | Tiptronic | ||
| City | I/100 km | 14.3 | 15.8 |
| Highway | I/100 km | 7.1 | 8.1 |
| Overall | I/100 km | 9.7 | 10.9 |
| Target CO2 value | G/km | 239 | 263 |
| Emission control | Oxygen sensing and three-way catalytic converter (metallic substrate) | ||
FUEL CONSUMPTION (2.5L)
| Electrical System | Specification | |
|---|---|---|
| Nominal voltage | V | 12 |
| Alternator output | W/A | 1680/120 |
| Battery, manual transmission | Ah/A | 60/280 |
| Battery, Tiptronic | Ah/A | 70/320 |
| Ignition | DME 5.22, with static high-voltage distribution and cylinder-selective knock regulation | |
| Ignition sequence | 1 - 6 - 2 - 4 - 3 - 5 | |
| Spark plugs | ||
| Bosch | FR 7 LDC 4 | |
| Beru | 14 FR 7 LDU | |
| Electrode gap | Mm | 0.8 + 0.1 |
ELECTRICAL SYSTEM ENGINE M96/20 (2.5L)
The following information describes the main engine differences which apply to the Boxster.
| Component | Unit | Boxster 2.5L | Boxster 2.7L | Boxster S (3.2L) |
|---|---|---|---|---|
| Engine type | M 96/20 | M96/22 | M 96/21 | |
| Number of cylinders | 6 | 6 | 6 | |
| Bore | Mm | 85.5 | 85.5 | 93 |
| Stroke | Mm | 72 | 78 | 78 |
| Cubic capacity | Cm 3 | 2480 | 2687 | 3179 |
| Compression ratio | 11.0:1 | 11.0:1 | 11.0:1 | |
| Engine performance | KW | 150 | 162 | 185 |
| At engine speed | Rpm | 6000 | 6400 | 6250 |
| Torque | Nm (ft.lb) | 245 (181) | 260 (192) | 305 (226) |
| At engine speed | Rpm | 4500 | 4750 | 4500 |
| Max. engine speed | Rpm | 6700 | 7200 | 7200 |
| Engine control | ME 5.2 | ME 7.2 | ME 7.2 | |
| E-gas | E-gas |
DIFFERENCES BETWEEN BOXSTER 2.5L, 2.7L AND BOXSTER S (3.2L) ENGINES
| Location | Thread | Tightening torque Nm (ft.lb) |
|---|---|---|
| Screws, bearing housing Initial tightening: Final tightening | M9x127 | 20 (15) 1 x 90° |
| Connecting-rod screws with connecting-rod designation...7R Initial tightening: Final tightening | M9 x 1.25 | 20 (15) 1 x 90° |
| Connecting-rod screws with connecting-rod designation...7R Initial tightening: Final tightening | M9 x 1.25 | 20 (15) 1 x 110° |
| Oil guide to bearing housing | M6 (micro-encapsulated) | 10 (7.5) |
| Screws, crankcase halves | M6 | 10 (7.5) |
| Additional bolts | M9 x 150 | 22 (16) |
| Crankcase/bearing housing | M9 x 94 | 22 (16) |
| Oil suction pipe to crankcase | M6 | 10 (7.5) |
| Air/oil separator to crankcase | M6 | 10 (7.5) |
| Oil pan to crankcase | M6 | 10 (7.5) |
| Oil drain plug to oil pan | M18 x 1.5 | 50 (37) |
| Oil filter to crankcase | S80 x 3 | 25+/-1 (19+/-1) |
| Coolant guide housing to crankcase | M10 | 45 (33) |
| Intermediate-shaft flange | M6 (micro-encapsulated) | 10 (7.5) |
| Lock nut on intermediate-shaft flange | M8 x 1 | 13 (9.5) |
| Screw plug for piston pin assembly bore of cylinder bank 4 - 6 | M27 x 2 | 80 (59) |
| Bolt for slide rail | M6 | 10 (7.5) |
| Belt pulley to crankshaft Initial tightening: Final tightening | M16 x 15 | 50 (37) 1 x 90° |
| Thrust plate to double-mass flywheel | M8 | 23 (17) |
| Drive plate to crankshaft (Tiptronic) Initial tightening: Final tightening | M10 x 1 x 25 (12.9) | 25 (18) 1 x 90° |
| Coolant pump to crankcase | M6 | 10 (7.5) |
| Chain tensioner to crankcase | M27 x 2 | 80 (59) |
| Belt tensioner roller to lever for tensioning element | M10 | 60 (44) |
| Belt deflection roller 1 to crankcase | M10 x 145 (8.8.) | 46 (34) |
| Belt deflection roller 2 to bracket for hydraulic pump | M8 x 55 | 23 (17) |
| Belt pulley to generator | M16 x 1.5 | 65+/-5 (48+/-3.5) |
| Belt pulley to hydraulic pump | M8 x 12 | 23 (17) |
| Cylinder head to crankcase 1st step Completely undone 2nd step 3rd step 4th step | M10 x 230 | 30 (22) 60° torque angle 60° torque angle again |
| Flat-base tappet housing to cylinder head | M6 | 10 (7.5) |
| Camshaft bearing saddles to cylinder head | M6 | 10 (7.5) |
| Cylinder-head cover to cylinder head | M6 | 13 (9.5) |
| Spark plugs | M14 x 1.25 | 30+3 (22+2) first fitting 25+5 (18+3.5) refitting |
| Camshaft drive wheel and drive plate to camshaft | M6 x 15 (10.9) | 14 (10) |
| Chain tensioner to cylinder head | M27 x 2 | 80 (59) |
| Intake pipe to cylinder head | M6 (micro-encapsulated) | 10 (7.5) |
| Plug, oil-pressure duct to cylinder head | M10 x 1 | 10 (7.5) |
| Oil extraction pump to cylinder head | M6 | 10 (7.5) |
| Oil-level sender to crankcase | M14 x 1.25 | Max. 20 (15) |
| Oxygen sensor to catalytic converter | M18 | 55+/-5 (41+/-3.5) |
| Knock sensor | M8 | 20+/-2 (15+/-1.5) |
| Hall-effect sensor | M6 (micro-encapsulated) | 10 (7.5) |
| Speed sender | M6 | 10 (7.5) |
| NTC coolant temperature sensor | M14 x 1.5 | 25+/-5 (18+/-3.5) |
| Oil pressure switch | M14 x 1.5 | 20+/-5 (15+/-3.5) |
| Starter | M10 | 45 (33) |
| Generator | M10 | 45 (33) |
| Ignition coil to cylinder head | M6 | 10 (7.5) |
| Power steering pump to bracket | M8 | 23 (17) |
| Pressure pipe of hydraulic pump | M16 | 24 (18) |
| Oil supply tank to hydraulic pump | M8 | 23 (17) |
| Check valve for auxiliary air injection | M22 x 1.5 | 32 (24) |
| Coolant pump to crankcase | M6 | 10 (7.5) |
TIGHTENING TORQUES FOR ENGINE M96/20 (2.5L), M96/21 (3.2L), M96/22 (2.7L)
| Designation | Unit | Boxster 2.7 | Boxster S 3.2 |
|---|---|---|---|
| Engine type | M 96/23 | M 96/24 | |
| No. of cylinders | 6 | 6 | |
| Valves/cylinders | 4 | 4 | |
| Effective displacement | Cm 3 | 2687 | 3179 |
| Bore/stroke | Mm/mm | 85.5/78 | 93/78 |
| Max. engine power (EU) | KW/HP | 168/228 | 191/260 |
| At engine speed | Rpm | 6300 | 6200 |
| Max. torque | Nm (ft.lb) | 260 (192) | 310 (229) |
| At engine speed | Rpm | 4700 | 4600 |
| Compression | 11 : 1 - 0.6 | 11 : 1 - 0.6 | |
| Max. liter output | KW/l (HP/l) | 62.52 (84.85) | 60.08 (81.79) |
| Idle speed (without air conditioning) | Rpm | 680 +/- 40 | 680 +/- 40 |
| Maximum engine speed - governor | Rpm | 7200 | 7200 |
| Engine weight, manual transmission as per DIN 70020 A | Kg | 193.9 | 195.9 |
| Engine weight, Tiptronic transmission as per DIN 70020 A | Kg | 186.7 | 187.6 |
ENGINE DATA FOR ENGINES M 96/23 AND M 96/24 - AS OF MY 2003
| Designation | Boxster 2.7 | Boxster S 3.2 |
|---|---|---|
| Type | 6-cylinder aluminum opposed-cylinder engine, water cooled | 6-cylinder aluminum opposed-cylinder engine, water cooled |
| Valve control | Via flat-base tappets | Via flat-base tappets |
| Camshaft adjustment | DOHC, Porsche VarioCam with axial camshaft adjuster | DOHC, Porsche VarioCam with axial camshaft adjuster |
| Valve arrangement | 2 inlet valves, 2 exhaust valves suspended in parallel V arrangement | 2 inlet valves, 2 exhaust valves suspended in parallel V arrangement |
| Diameter of inlet valve | 33.3 mm | 37.1 mm |
| Diameter of exhaust valve | 28.1 mm | 32.5 mm |
| Valve travel of inlet | 9.85 mm | 10.5 mm |
| Valve travel of outlet | 9.85 mm | 10 mm |
| Valve clearance | Hydraulic valve clearance compensation | Hydraulic valve clearance compensation |
| Timing: Inlet opens | 21° before TDC/19° after TDC | 26° before TDC/14° after TDC |
| Inlet closes | 9° before BDC/49° after BDC | 20° before BDC/60° after BDC |
| Outlet opens | 39° before TDC | 39° before TDC |
| Outlet closes | 8° before TDC | 6° before TDC |
ENGINE DESIGN FOR ENGINES M 96/23 AND M 96/24 - AS OF MY 2003
| Designation | Boxster 2.7 | Boxster S 3.2 |
|---|---|---|
| Cooling type/installation location | Liquid cooling - cross flow, radiator in front of vehicle | Liquid cooling - cross flow, radiator in front of vehicle |
| No. of radiators | 2 | 3 |
| Electric fan | 2, controlled in two stages | 2, controlled in two stages |
| Coolant filling capacity (Tiptronic) | Approx. 18 I (19 I) | Approx. 22 I (23 I) |
ENGINE COOLING DATA FOR ENGINES M 96/23 AND M 96/24 - AS OF MY 2003
| Designation | Boxster 2.7 | Boxster S 3.2 |
|---|---|---|
| Type | Integrated dry sump | Integrated dry sump |
| Oil cooling | Via oil-water heat exchanger | Via oil-water heat exchanger |
| Oil filter | On pressure side behind oil pump | On pressure side behind oil pump |
| Oil pressure at n = 5,000 rpm at 90° C | Approx. 5 bar | Approx. 5 bar |
| Oil pressure indicator | Oil pressure indicator light | Oil pressure indicator light |
| Oil consumption max I/1,000 km | 1.0 | 1.0 |
| Oil change quantity without filter | 8.0 L | 8.0 L |
| Oil change quantity with filter | 8.25 L | 8.25 L |
TECHNICAL DATA FOR ENGINES M 96/23 AND M 96/24 - AS OF MY 2003
| Location | Thread | Tightening torque Nm (ft.lb) |
|---|---|---|
| Bearing housing bolts: initial tightening + final tightening | M9 x 127 | 25 (19) + 90° torque angle |
| Con-rod bolts (replace): initial tightening + final tightening | M9 x 1.25 | 20 (15) + 110° torque angle |
| Oil guide pan-head screw on bearing housing | M6 x 16 (micro-encapsulated) | 10 (7.5) |
| Bolts for crankcase halves | M6 x 35 (10.9) (2 micro-encapsulated) | 13 (9.5) |
| Additional bolts for bearing housing 4 - 6 | M9 x 150 | 22 (16) |
| Additional bolts for bearing housing 1 - 3 | M9 x 94 | 22 (16) |
| Oil suction pipe on crankcase | M6 x 20 (micro-encapsulated) | 10 (7.5) |
| Air/oil separator to crankcase (swirl pots) | M6 x 20 | 10 (7.5) |
| Oil pan on crankcase | M6 x 20 | 10 (7.5) |
| Oil filter on crankcase | S80 x 3 | 25 (19)+/- 1 |
| Coolant guide housing on crankcase | M6 x 20 and M6 x 70 | 10 (7.5) |
| Intermediate-shaft flange | M6 x 20 (micro-encapsulated) | 10 (7.5) |
| Hexagon collar nut on intermediate-shaft flange | M8 x 1 | 12 (9) + 1 |
| Screw plug for piston pin assembly bore of cylinder bank 4 - 6 | M27 x 2 | 80 (59) |
| Bolt for slide rail | M6 | 10 (7.5) |
| Belt pulley on crankshaft: initial tightening + final tightening | M16 x 1.5 (a/f 24) | 50 (37) + 90° torque angle |
| Thrust plate on double-mass flywheel | Pan-head screw M8 x 16 | 23 (17) |
| Drive plate for converter on crankshaft (Tiptronic) old : initial tightening + final tightening | M10 x 1 x 25 (12.9) pan-head screw | 25 (19) + 90° torque angle |
| Drive plate for converter on crankshaft (Tiptronic) new : initial tightening + final tightening | M10 x 1 x 25 (12.9) pan-head screw | 25 (19) + 120° torque angle |
| Double-mass flywheel on crankshaft: initial tightening + final tightening | M10 x 1 x 50 (12.9) pan-head screw | 25 (19) + 120° torque angle |
| Coolant pump on crankcase | M6 x 25 and M6 x 30 | 10 (7.5) |
| Chain tensioner on crankcase | M27 x 2 | 80 (59) |
| Belt tensioner roller on lever for tensioning element | M10 | 60 (44) |
| Belt deflection roller 1 on crankcase | M10 x 145 (8.8.) | 46 (34) |
| Belt deflection roller 2 on bracket for hydraulic pump | M8 x 55 | 23 (17) |
| Belt pulley on hydraulic pump | M8 x 12 | 23 (17) |
| Cylinder head on crankcase, 1st step, then undo all screws | M10 x 230 Toro screw | 30 (22) |
| 2. step | 20 (15) | |
| 3. step | 70° torque angle | |
| 4. step | 70° torque angle | |
| Flat-base tappet housing on cylinder head | M6 x 35 pan-head screws | 10 (7.5) |
| Camshaft bearing saddles on cylinder head | M6 x 35 and M6 x 40 pan-head screws | 10 (7.5) |
| Cylinder-head cover on cylinder head | M6 x 30 (10.9) | 13 (9.5) |
| Camshaft drive wheel and drive plate on camshaft | M6 x 12 (10.9) | 14 (10.5) |
| Central screw, camshaft adjustment device (replace) | M12 | 50 (37) + 110° torque angle |
| Chain tensioner on cylinder head | M27 x 2 | 80 (59) |
| Intake distributor on intake pipe | M6 x 35 (micro-encapsulated) | 10 (7.5) |
| Intake pipe on cylinder head | M6 x 35 | 10 (7.5) |
| Exhaust manifold on cylinder head | M8 x 28 | 23 (17) |
| Rear muffler holder | M8 x 25 and M8 x 30 | 23 (17) |
| Screw plug, oil-pressure duct on cylinder head | M14 x 1.5 | 20 (15) |
| Oil extraction pump on cylinder head | M6 x 20 (micro-encapsulated) | 10 (7.5) |
| Oil-level sensor on crankcase | M14 x 1.25 | Max. 20 (15) |
| Knock sensor | M8 | 20 (15)+/- 2 |
| Hall-effect sensor | M6 (micro-encapsulated) | 10 (7.5) +/- 0,5 |
| Speed sender | M6 (micro-encapsulated) | 10 (7.5) +/- 0,5 |
| NTC coolant temperature sensor | M14 x 1.5 | 25 (19) +/- 5 |
| Oil pressure switch | M14 x 1.5 | 20 (15) +/- 5 |
| Oil pressure sensor | M14 x 1.5 | 30 (22) +/- 5 |
| Starter | M10 | 46 (34) |
| Generator | M10 | 6 (34) |
| Hexagon nut, B+ cable to generator | M8 | 15 (11) |
| New spark plug | M14 x 1.25 | 30 (22) |
| Used spark plug | M14 x 1.25 | 25 (19) |
| Ignition coil to cylinder head | M6 pan-head screw | 10 (7.5) |
| Cover with holder for hydraulic valves | M6 pan-head screw | 10 (7.5) |
| Power steering pump on bracket | M8 | 23 (17) |
| Check valve for auxiliary air injection | M22 x 1.5 | 32 (24) |
| Combination valve for secondary air | M6 | 10 (7.5) |
| Pressure pipe of hydraulic pump | M16 x 1.5 | 24 (18) |
TIGHTENING TORQUES FOR ENGINE M96/23 (2.7L), M96/24 (3.2L) - AS OF MY 2003
