Fuel System, Electronic Injection: Specifications Porsche Boxster 986 рестайлинг

Tightening torques

TIGHTENING TORQUES - CATALYTIC CONVERTER IN FRONT OF CATALYTIC CONVERTER

TIGHTENING TORQUES - OXYGEN SENSOR BEHIND CATALYTIC CONVERTER

Scheme 25

Includes

24 42 21 Removing throttle body - Boxster S

24 42 23 Installing throttle body - Boxster S

Scheme 26

Removal overview

Scheme 27

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

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Scheme 33

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 34

Installation overview

Scheme 35

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

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Scheme 41

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 42

Includes

24 40 22 Removing injection valves - Boxster S

24 40 24 Installing injection valves - Boxster S

Scheme 43

Removal overview

Scheme 44

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

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Scheme 50

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 51

Installation overview

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Scheme 58

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 59

Includes

24 46 21 Removing intake distributor - Boxster S

24 46 23 Installing intake distributor - Boxster S

Scheme 60

INTAKE DISTRIBUTOR REMOVING & INSTALLING PROCEDURE (BOXSTER S)

Removal overview

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Scheme 70

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»(ref-199494-S14131964892005101900000) ) 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 71) 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 71

INTAKE DISTRIBUTOR REMOVAL & INSTALLATION PROCEDURE (BOXSTER S)

Installation overview

Scheme 72

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 73

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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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