Maintenance: Other Porsche Boxster 986 рестайлинг

READ OUT FAULT MEMORY

The method of reading out the fault memory is described in the operating instructions for the Porsche System Tester 2. The operating instructions are supplied with each Tester. The Porsche System Tester 2 is connected to the vehicle via a 16-pin diagnosis socket. The diagnosis socket is located inside the vehicle below the instrument panel near to the driver (left-hand drive vehicles) or the passenger (right-hand drive vehicles) -arrow-.. (Scheme 10)

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ENGINE MAINTENANCE SPECIAL TOOLS DESCRIPTION

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1. Position the vehicle at the specified points using a lifting platform.
2. Open the rear luggage compartment lids.
3. Cover the vehicle with a protective cover in such a way that the body can not be damaged.
4. Move convertible top or convertible-top compartment lid to service position. To do this, open the convertible top until the convertible top compartment lid is half open.
5. Detach cloth covering. Disengage the rear strip on the left and right sides of the cloth covering in downward direction.
6. Detach tension cables. Press the ball socket of the tension cable out of the ball head on the adjusting piece on the left and right.
7. To do so, press the tension bow of the convertible top towards the main bow, until it reaches its locking point. NOTE: The retaining clips for the convertible top compartment lid linkage must be removed using special tool no. 131.
8. Unclip the convertible top compartment lid linkage. To do so, pull off the retaining clips on the left and right and pull the links off the bolt.
9. Push the convertible-top compartment lid forwards until the two bores in the convertible top compartment links line up. Subsequently insert a mandrel into the bores (diameter 5 mm).
10. Remove trims. NOTE: If the vehicle has a loudspeaker in the upper oddments tray, the power connections on the right vehicle side must be disconnected before removing. Turn the two fastening screws of the upper oddments tray by approx. 90° to the left and remove the oddments tray. Turn the two rear fastening screws of the upper cover by approx. 90° to the right and remove the cover. NOTE: The carpeted rear wall and the rear maintenance cover must be removed if work has to be carried out on the secondary units or on the belt drive.
11. Unscrew the four plastic nuts of the carpeted rear wall and pull the rear wall upwards out of the vehicle.
12. Open engine compartment closure cap. To do so, turn the 5 fastening screws by approx. 90° to the left and remove the cap from the vehicle.
13. Open the maintenance cover behind the seats. To do so, unscrew the 7 fastening screws and the 2 fastening nuts and remove the maintenance cover.

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1. Reinstall the maintenance cover behind the seats. Tighten the seven fastening screws and the two fastening nuts (next to the cable bushing) with 10 Nm (7.5 ft.lb).
2. Fit the trims. Refit the carpeted rear wall. To do so, place the carpeted rear wall above the 4 tucker bolts and press into the seams of the connecting trims. Press on the 4 plastic fastening nuts. Fit the engine compartment closure cap. Place the cap onto the opening in the engine room and turn the 5 bayonet screws by approx. 90° to the right. Fit the top carpet trim and turn the two rear bayonet screws by approx. 90° to the right. NOTE: If the vehicle has an additional loudspeaker in the rear compartment, the electrical connections for it must be joined together before assembly. Fit rear compartment and turn the 2 bayonet screws to the right by approx. 90°.
3. Hold the convertible-top compartment lid with one hand and pull the retaining mandrel from the convertible-top compartment links. NOTE: The retaining clips for the convertible-top compartment links must be renewed.
4. Push the convertible-top compartment links onto the bolt again on the left and right and secure using a new retaining clip.
5. Push the tension bow downwards again and push the ball head of the tension cables onto the left and right of the convertible top.
6. Attach the cloth covering in the two plastic clips on the rear wall of the convertible-top compartment.
7. Completely close the convertible top

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1. Protect the luggage compartment floor against soiling with a suitable cover. NOTE: The engine cooling system is factory-filled with a coolant which does not need to be changed. The coolant should not be mixed with other coolants Only Original Porsche anti-freeze should be used when changing or topping up the coolant. A conclusion about the anti-freeze content can not be made on the intensity of the coolant color in the expansion tank. CAUTION: Danger of scalding Coolants can be extremely hot and pressurized. Wear suitable protective equipment. Carefully open the lid on the expansion tank.
2. Carefully undo the lid on the coolant expansion tank.
3. Check the anti-freeze content with a frost protection testing device. If it is lower than - 35°C, it should be corrected accordingly.
4. Check the engine coolant level. This should not lie below the minimum marking when cold.
5. Check the cooling system for leaks. To do this, apply a test pressure of approx. 1 bar using the cooling system test device and check the hose connections for leakage or tighten the screw hose clamps. Subsequently remove the cooling system test device.
6. Check cooling device for external dirt. The cooling device should not contain too much dirt. If necessary, it can be cleaned with a vacuum cleaner.
7. Replace the cover on the coolant expansion tank and tighten.

Note. The oil filter only has to be replaced after every second oil change.

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1. Jack up the vehicle at the points provided. WARNING: Danger of scalding from draining oil! Wear protective equipment specified.
2. Undo oil drain plug and collect the engine oil in a disposal container. Dispose of the waste oil in accordance with legal requirements.
3. Clean oil drain plug and screw in with new aluminum sealing ring. Tightening torque 50 Nm (37 ft.lb).
4. Affix the luggage compartment protective cover.
5. Fill in engine oil. The oil change quantity is approx. 8.5 liters after a dripping time of approx. 20 minutes.

Note. For Porsche engine oil recommendations, refer to OVERVIEW OF APPROVED ENGINE OILS .

Note. The oil filter only has to be replaced after every second oil change.

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1. Jack up the vehicle at the points provided. WARNING: Danger of scalding from draining oil! Wear protective equipment specified.
2. Undo oil drain plug and collect the engine oil in a disposal container. Dispose of the waste oil in accordance with legal requirements.
3. Clean oil drain plug and screw in with new aluminum sealing ring. Tightening torque 50 Nm (37 ft.lb).
4. Undo oil filter with the special tool (release key) 9204 and unscrew.
5. Remove oil filter housing vertically downward. Drain remaining oil into a disposal container.
6. Remove filter element. Remove the filter downwards and dispose of in accordance with legal mage requirements. NOTE: Do no remove O-ring with a sharp object
7. Clean oil filter housing -1- and replace O-ring seal. Clean the oil filter housing thoroughly inside and outside and replace the O-ring -3-. The O-ring should not be levered off or cut with a sharp object (for example, screwdriver). (Scheme 39)
8. Install filter element.
9. Install oil filter housing and tighten to 25 Nm (18.5 ft.lb). Tightening torque 25 Nm (18.5 ft.lb).
10. Fill in engine oil. The oil change quantity is approx. 8.75 liters after a dripping time of approx. 20 minutes.

Note. For Porsche engine oil recommendations, refer to OVERVIEW OF APPROVED ENGINE OILS .

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1. Jack up the vehicle at the take-up points provided.
2. Disconnect connection cable of the ignition coils.
3. Undo the two fastening screws (M6 x 25) of the plug coils and remove the 6 plug coils.
4. Unscrew the spark plugs using the spark-plug wrench.
5. Replace spark plugs. Tighten new spark plugs to 30 Nm (22 ft.lb), tighten remounted spark plugs to 25 Nm (18.5 ft.lb).
6. Push on plug coils and tighten the fastening screws (M6 x 25) to 10 Nm (7.5 ft.lb). Subsequently push on the connecting cable of the plug coils.
7. Lower vehicle.

Note. The rear wall cover and the maintenance cover must be removed for maintenance operations on the belt drive.

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1. Remove maintenance cover. To do so, undo the 7 fastening screws and the 2 fastening nuts.
2. Mark belt travel direction with a colored pen. WARNING: Risk of damage! Never remove Polyrib belt when warm. The belt would deform and could be damaged.
3. Turn the tensioning roller -7- on the socket wrench (wrench size 27 mm) clockwise and simultaneously remove the belt from the drive pulleys. (Scheme 45)
4. Visually inspect the condition of the belt and replace it if necessary. Check belt pulley for damage.
5. Install Polyrib (Serpentine) belt in the order shown.
6. Twist the tensioning roller -7- clockwise and simultaneously place the belt on the idler pulley -8-.. (Scheme 46)Subsequently relieve the tensioning roller slowly.
7. Visually check whether the belt is correctly positioned on all wheels.

Scheme 48

1. Refit maintenance cover and rear wall trim. The 7 fastening screws and the 2 fastening nuts are tightened to 10 Nm (7.5 ft.lb). (Scheme 46)

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1. Open engine compartment. To do so, remove the top cover below the convertible top.
2. Press both spring clips on the air cleaner housing outwards (in the engine compartment on the left vehicle side) and raise the air cleaner housing slightly.
3. Pull out air cleaner element. To do so, first pull out the air cleaner drawer and then pull out the filter element after it.
4. Remove drawer with the filter element from the air cleaner housing and remove the air cleaner element.

INSTALLING AIR CLEANER ELEMENT

Note. The air cleaner housing should not be cleaned with compressed air. The hot film mass airflow meter can fire damaged if compressed air is used for cleaning.

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1. Check air cleaner housing for soiling and if necessary wipe out the air cleaner housing with a lint-free cloth.
2. Insert the new filter element into the air cleaner drawer.
3. Position pushing unit with filter insert onto the air cleaner housing. Carefully insert the filter element first with both hands and then the push the drawer in after it.
4. Push the drawer firmly against the air cleaner housing. Both spring clips must lock with an audible click.

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1. Remove underside panel. NOTE: Collect the emerging fuel in a suitable container and dispose of according to country-specific conditions.
2. Pull filter ground plug connector off the filter. (Scheme 55) Subsequently release and remove the fuel hose connection by pressing lightly on the grey surfaces. Open the plug connection
3. Undo the screw hose clamp and remove and replace the filter element.
4. Reinstall the filter element and tighten the screw hose clamp.
5. Joint the connections of the fuel lines in a straight line. The plug connections must audibly engage. Subsequently push the ground cable onto the filter element.

CHANGING THE ENGINE OIL AND OIL FILTER - AS OF MY 2003

CHANGING THE ENGINE OIL, WITHOUT OIL FILTER

Note. The oil filter only has to be replaced after every second oil change interval.

Note. To be able to fill the correct quantity of oil after draining the old oil, a dripping time of 20 minutes should be allowed.

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1. Unscrew closure cap on the oil filler neck.
2. Undo and unscrew the oil drain plug (hexagon socket a/f 8). Drain engine oil into an oil collection container. Dispose of the waste oil in accordance with legal requirements.
3. Clean oil drain plug and screw in with new aluminum sealing ring. Tightening torque of the oil drain plug M18 x 1.5 50 Nm (37 ft.lb)
4. Position the luggage compartment protective cover on the service tray.
5. Fill the engine oil slowly using a suitable filler container in order to avoid the oil overflowing on the filler tube. Don't forget to screw the cap on again tightly.

Note. For Porsche engine oil recommendations, refer to OVERVIEW OF APPROVED ENGINE OILS .

Filling capacity (after a dripping time of 20 minutes): 8.0 liters

CHANGING THE ENGINE OIL, WITH OIL FILTER

Note. The oil filter only has to be replaced after every second oil change interval.

Note. To be able to fill the correct quantity of oil after draining the old oil, a dripping time of 20 minutes should be allowed.

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1. Unscrew closure cap on the oil filler neck.
2. Unscrew the oil drain plug (a/f 4 hexagon socket) and collect the engine oil in a disposal container. Dispose of the waste oil in accordance with legal requirements.
3. Clean oil drain plug and screw in with new aluminum sealing ring. Tightening torque of the oil drain plug M18 x 1.5 50 Nm (37 ft.lb)
4. Undo oil filter with the special tool (release key) 9204 and unscrew.
5. Remove oil filter housing vertically downwards. Drain remaining oil into an oil collection container. Dispose of the waste oil in accordance with legal requirements.
6. Remove filter element. Remove the paper filter downwards and dispose of in accordance with legal requirements. NOTE: Never remove and install O-ring with a sharp object! Do not scratch the sealing surface of the oil filter housing.
7. Lever off the old O-ring on the housing groove with a screwdriver.
8. Clean oil filter housing -1- on the inside and outside. (Scheme 65) Replace O-ring.
9. Insert a new filter element.
10. Screw in the oil filter housing with the special tool (release key) 9204 and tighten it to the specified torque. Tightening torque for oil filter housing: 25 Nm (19 ft.lb)
11. Position the luggage compartment protective cover on the service tray.
12. Fill the engine oil slowly using a suitable filler container in order to avoid the oil overflowing on the filler tube. Don't forget to screw the cap on again tightly. Filling capacity with filter (after a dripping time of 20 minutes): 8.25 liters

Note. For Porsche engine oil recommendations, refer to OVERVIEW OF APPROVED ENGINE OILS .

FILL IN TRANSMISSION OIL

Note. Top up only with transmission oil approved by Porsche.

Filling capacity: 2.25 liters

Scheme 68

1. Clean oil drainage and oil filler screw.
2. Screw in oil drain plug. Tightening torque: 25 Nm (19 ft.lb)
3. Fill in oil. At a filler quantity of 2.25 liters, the oil level lies 11 mm below the oil filler opening. Check using an angled wire hook.
4. Screw in oil filler screw. Tightening torque: 25 Nm (19 ft.lb)
5. Install sheetmetal brace. Refer to «REMOVING AND INSTALLING SHEETMETAL BRACE»(ref-199511-S09119309322005101900000) .

Note. Top up only with transmission oil approved by Porsche.

Filling capacity: 2.8 liters

1. Clean oil drainage and oil filler screw.
2. Screw in oil drain plug. Tightening torque: 30 Nm (22 ft.lb)
3. Fill with oil up to the bottom edge of the oil filler opening.
4. Screw in oil filler screw. Tightening torque: 30 Nm (22 ft.lb)
5. Install sheetmetal brace. Refer to «REMOVING AND INSTALLING SHEETMETAL BRACE»(ref-199511-S09119309322005101900000) .

REPLACING ATF

Note. Fill only with ATF approved by Porsche.

Filling capacity: approx. 9.0 liters

Change quantity: approx. 3.5 liters

Scheme 69

1. Remove sheetmetal brace. Refer to «REMOVING AND INSTALLING SHEETMETAL BRACE»(ref-199511-S09119309322005101900000).
2. Place oil collection pan under the transmission.
3. Unscrew drainage screw -1- and drain ATF. (Scheme 69) NOTE: Without ATF, the engine must not be started and the vehicle must not be towed.
4. Replacing sealing ring for drainage screw and screw in screw -1-. (Scheme 69) Tightening torque: 40 Nm (30 ft.lb)
5. Unscrew the filler screw -2- and fill up ATF with special tool filling system V.A.G 1924 until ATF escapes from the hole of the filler screw. (Scheme 69)
6. Move selector lever to position "P" and allow engine to idle.
7. With engine running, top up ATF again until excess ATF emerges from the bore of the filler screw.
8. With the brake pedal pressed, change through all selector lever positions, remaining in each position for approx. 10 s.
9. Check the ATF level again and top up if necessary. NOTE: All instructions and test conditions for "Checking and topping up ATF fluid" must be observed. See «TRANSMISSION MAINTENANCE: CHECKING AND TOPPING UP THE ATF»(ref-199492-S34625294892005101900000).
10. Install sheetmetal brace. Refer to «REMOVING AND INSTALLING SHEETMETAL BRACE»(ref-199511-S09119309322005101900000).

CHECKING ATF

Note. Top up only ATF approved by Porsche. The stipulated fluid level -3- is extremely important for perfect functioning of the automatic transmission, it is correct if there is a slight amount of ATF escaping at the filler screw bore -2- at temperatures between 30°C and 40°C. (Scheme 70)

Scheme 70

REMOVING ATF FILTER

1. Drain ATF. See «TRANSMISSION MAINTENANCE: REPLACING ATF»(ref-199492-S22514437432005101900000) .
2. Remove ATF pan. To do so, unscrew the screws crosswise and remove ATF pan.
3. Remove ATF filter. To do so, unscrew the screws and pull out filter downwards.

Scheme 71

1. Insert ATF filter and fasten with screws -arrow-. (Scheme 71) Tightening torque: 6 Nm (4.5 ft.lb) NOTE: Thinly coat gasket at suction collar with Vaseline.
2. Clean magnets - in overview 8 - and lay them in the seams of the ATF pan. Ensure contact overfull area.
3. Fit ATF pan with new seal. Tighten screws - in overview 5 - in diagonally opposite sequence in several stages. Tightening torque: 10 Nm (7.5 ft.lb)
4. Fill in ATF. See «TRANSMISSION MAINTENANCE: REPLACING ATF»(ref-199492-S22514437432005101900000).

CHANGING TRANSMISSION OIL IN FINAL DRIVE

Note. Use only oils approved by Porsche.

Filling capacity: 0.8 liters

Note. There is no oil drainage screw on the final drive.

Scheme 72

1. Unscrew the oil filler screw and remove oil by suction using a suitable hand pump while the transmission is warm from operation.
2. Fill with transmission oil using filling system V.A.G 1924. NOTE: Filling must be carried out very slowly because there is a baffle plate in the cover of the final drive.
3. Screw in oil filler screw with new sealing ring.

Tightening torque: 30 Nm (22 ft.lb)

CHECKING CLUTCH FREE PLAY

The clutch master cylinder has an inner stop. The push rod and the clutch pedal are always pressed against this stop by the boost spring. Due to the automatic hydraulic adjustment of the clutch, it is not possible to determine the clutch play by checking at the clutch pedal.

CHECKING THE PEDAL END POSITION (PEDAL RETURN/RETURN FORCE)

1. Check that the pedal is in end position by pulling at the pedal (without the use of force) towards the driver's seat.

Note. The pedal must not give way during the process! If it gives way, the fault is in Vie boost spring or in the pedals!

The clutch push rod and the boost spring are not adjustable. The boost spring has 2 functions, namely to provide pedal force assistance and to return the pedal. The following are some of the points which are requirements for perfect clutch operation

1. Correct bleeding of the clutch hydraulics
2. No leaks in the hydraulic system
3. Pedal return to the starting position
4. Installation position of the pedals in accordance with the series condition

TRACK ROD JOINTS: CHECK THE PLAY AND DUST BELLOWS

Note. The rubber dust bellows and bellows on the steering gear and on the tie rods can be damaged by external influences, e.g. stone impact, or during assembly work! If a rubber dust bellows leaks, the joint or the tie rod must be replaced, because dirt or moisture entering will destroy the joint!

1. Check the play and dust bellows.
2. Check the function of the dust bellows, bellows and joints and ensure that they are free of leaks.

AXLE JOINTS: CHECK THE PLAY AND DUST BELLOWS

1. Check play.
2. Visually inspect the dust bellows for damage. NOTE: When doing so, the rubber dust bellows should be pressed down with the fingers in order to reveal hidden cracks! If a rubber dust bellow leaks, the corresponding joint or control arm must be replaced, because dirt or moisture entering will destroy the joint! CAUTION: Danger of material damage if the vehicle is raised incorrectly or if the vehicle is driven incorrectly onto the lifting platform! Lift the vehicle only at the take-up points provided! Make sure the screw connections for the diagonal braces are accessible! When driving onto a platform lift, make sure that there is sufficient distance between the platform lift and the vehicle! In order to avoid damage to the side members and side member panels, the mounting plates of the platform lift must be raised!
3. Inspect the dust bellows of the axle joints (ball joints) on the suspension (front and rear) as follows: Put the vehicle onto a lifting platform with the steering lock disengaged. Perform a visual inspection after cleaning. NOTE: In the vicinity of the brake cover panels, no visual inspection is possible in a small area! Check this area by touch! NOTE: The procedure for the front axle is as follows: Turn the front wheels as far as they will go Perform a visual inspection of the visible surfaces on the left and on the right After turning the front wheels to the other steering stop, check the other half of each rubber dust bellows

CHECKING CONDITION

tires are a safety element which fulfil the demands placed on them only if they have the correct air pressure and a sufficient tread depth.

1. The air pressure must never be lower than the values specified (these are minimum pressures)!
2. A visual inspection of the tires must be carried out!

1. Check the condition and the tire pressure. Valve caps protect the valve from dust and dirt and therefore from damage.
2. Always screw on the caps tightly and replace missing valve caps.

TIRE PRESSURES

tire pressure of cold tires (approx. 20° C)

COLD TIRES PRESSURE SPECIFICATIONS

PARKING BRAKE: CHECKING THE FREE PLAY OF THE PARKING BRAKE LEVER

1. Checking the free play of the handbrake lever. The parking brake has asbestos-free brake linings.

Note. The handbrake with asbestos-free brake linings must never be adjusted in such a way that the lining must grind down during operation! The handbrake must be adjusted if the handbrake lever can be pulled up by more than 4 teeth with medium force application (without a braking effect)!

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1. Remove the rear wheels.
2. Undo the parking brake lever and push back the disc brake pads of the rear axle until the brake disc can rotate freely. NOTE: To make the turnbuckle accessible, open the cover of the tray behind the parking brake lever and remove the rubber inlay and also the insert.
3. Undo the adjustment nuts -arrow- on the turnbuckle until the cables are without pretension. (Scheme 75)
4. With a screwdriver, turn the adjustment device through a wheel bolt threaded hole so that the brake disc can no longer be moved. NOTE: The parking brake shoe adjustment device of the Boxster has a finer toothing than the Boxster S! The parking brake shoes and the return springs are also different! Only for Boxster: Next, turn back the adjustment fixture through 9 notches again (release approx. 5 notches until the brake disc can be turned freely, then release another 4 notches). Only for Boxster S: Subsequently turn back the adjustment fixture through 5 notches again (release approx. 3 notches until the brake disc can be moved freely, then release another 2 notches).
5. Repeat the procedure on the other wheel.
6. Pull up the parking brake lever by 2 teeth and adjust the adjustment nut of the turnbuckle until both wheels can be turned manually with difficulty.
7. Release the parking brake lever and check whether both wheels can be turned freely.

BRAKE HOSES AND LINES

1. Carry out visual inspection for leaks, damage, routing and corrosion.

CHECKING LID LOCK, FRONT AND REAR

1. Check that the lid locks engage by insertion of the lock upper parts when the lids (front and rear) are closed and that they disengage again when the lid releases are pulled.

CHECKING SAFETY HOOK, FRONT LID

1. Check that the front lid is held down by the lower part of the lock of the safety hook after the lid lock is opened.
2. Check whether the return spring on the lower part of the lock pulls back the safety hook as far as the stop.

CHECKING INNER RELEASE OF LUGGAGE COMPARTMENT (TRUNK ENTRAPMENT)

1. Check whether the upper part of the lock automatically disengages from the lower part of the lock.

Scheme 75

1. Engage the upper part of the lock 996 551 051 02 = tool (Porsche spare part) in the lower part of the lock -direction of arrow-. (Scheme 77)
2. Unlock unlocking lever in the luggage compartment. Check whether the upper part of the lid lock disengages automatically.

INSTALLING PARTICLE FILTER

1. Insert a new particle filter into the housing guide.
2. Check that the filter is correctly fitted and in the correct installation position.
3. Insert antenna part at the top, screw in both top and bottom fastening screws. Tightening torque 6 Nm (4.5 ft.lb).

Scheme 76

1. Open the luggage compartment lid.
2. Remove the luggage compartment mat on the wheel housing wall.
3. Open the cover for the headlight adjustment screws.
4. Clean the cover lens and switch on the dipped beam headlights. NOTE: The vehicle must be on a horizontal surface! Make the adjustment with the regulator switch set to 0 (headlight beam adjustment)! Use a standard 5 mm ball-head screwdriver to make the headlight adjustment (free blade length 150 mm)! Only the lower screw may be turned for height adjustment; for lateral adjustment the upper and lower screws must be turned in the same direction and for the same number of rotations!
5. Make the adjustment with the vehicle ready for driving (fuel tank full, driver's seat occupied by a person or 75 kg, the tire pressure must correspond to the stipulated values) using a headlight adjustment unit. Lateral adjustment Height and lateral adjustment Fog light adjustment

SETTING

Note. Set the headlight adjustment unit to 10 cm/10 m (1%)! With this alignment, preference must be given to the central zone around the salient point of the light/dark limit!

First, make the vertical adjustment of the dipped beam headlights.

Scheme 77

1. To do this, line up the light/dark borderline running upwards at an angle on the right-hand side with the dotted 15° line of the adjustment unit. Next, perform the horizontal adjustment of the dipped beam headlights.
2. To do this, line up the left, horizontal part of the light/dark limit (in the case of driving on the right) with the dotted horizontal line of the adjustment unit. NOTE: The distance between the headlights and the adjustment unit should be as small as possible! It should not exceed 30 cm, because if the distance is greater, it is no longer possible to define the formation of the tight/dark limit in the adjustment unit clearly!
3. Secure the plugs after making the adjustment.
4. For Xenon headlights the ignition must be switched off and on after adjustment with the lights switched on.
5. After this, the adjustment must be checked again. Adjusting the main headlights, USA version

ADJUSTING THE MAIN HEADLIGHTS, USA VERSION

Note. A new adjustment may only be made in the case of accident repairs or replacement of the main headlights!

1. Vertical and horizontal adjustment must be carried out with a headlight adjustment unit.

REMOVING MAIN HEADLIGHT

Note. Risk of damage to headlights due to chafing and excessive temperatures. Headlights must not be covered when they are switched on, e.g. wing protection or film.

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Scheme 80

1. Release the side carpet by unscrewing plastic nut -A- -arrow-. (Scheme 82)
2. Pull rubber stopper -B- off the release opening. (Scheme 83)
3. Place the socket wrench from the tool kit on the release axle.
4. The toggle of the socket wrench should point horizontally to the rear.
5. Turn the socket wrench through approx. 180° -arrow A- and leave it in position. see scheme 84
6. The headlight is now unlocked and can be pulled forwards out of the wing.
7. Turn the socket wrench back until it points vertically -arrow B- downwards. see scheme 84

INSTALLING MAIN HEADLIGHT

Note. Do not attach any covers (for example, stone shields or films) in the area of the headlights.

Scheme 81

Scheme 82

Scheme 83

1. Insert the headlight into the guide rails and push it fully into the wing -arrow-. see scheme 85
2. Press the headlight to the rear, turning the socket wrench at the same time until the wrench points horizontally to the rear -arrow C-. In the process, the headlight lock must engage with an audible and perceptible click. see scheme 85
3. Check the correct seating of the headlight, for example, by pulling gently in the area of the fog light.
4. Insert rubber stopper in the release opening.
5. Screw the side carpet tight with the plastic screw -A-. see scheme 87

WARTUNG ELEKTRIK: WINDSCREEN WIPER/WASHER SYSTEM, HEADLIGHT WASHER

1. Use only soapy water to clean the exterior lights and the plastic headlight lenses!
2. Never use chemical cleaning agents!
3. To avoid scratches, do not rub with dry or only damp cloths, paper towels or insect-removal sponges!

Note. The headlight washer nozzles are preset! It is not necessary to adjust them!

1. Check the function, fluid levels and nozzle settings.

1. Turn ignition key and check function of warning and indicator lights (visual inspection).
2. Actuate power windows and check operation.
3. Check function of rear window heater.
4. Adjust heater blower and fans to high and low and check the air vents for air throughput.
5. Check operation of front seats. Check operation of radio.
6. Check operation of door mirror adjustment possibilities.
7. Check operation of orientation lights.
8. Actuate central locking and check operation.
9. Operate cigarette lighter and check functioning.

Note. The following test items are included in the test drive.

1. Actuating the remote control of the central locking and checking operation.
2. Front seats: Checking adjustment possibilities for operation.
3. Checking footbrake operation and actuation travel. Starting engine, checking operation.
4. Actuating clutch, checking operation. Actuating steering, checking operation.
5. Shifting gear, checking operation.
6. Parking assistant: Selecting reverse gear and checking operation.
7. Activating the automatic cruise control during the test drive and checking operation.
8. Actuating TC/ PSM switch during the test drive and checking operation.
9. Checking operation of heating adjustment when engine is warm.
10. Checking operation of air-conditioning system when the engine is running.
11. Checking operation of the instruments.

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