Repair manual
Wiring diagrams
Porsche Boxster 987 Repair Manual
Step-by-step repair and maintenance instructions for the Porsche Boxster 987 (2004–2006): removal, installation, adjustment, diagnostics and parameter checks with illustrations.
79sections
1693articles
ENManual language
- General safety regulations for refrigerants
- Emptying the refrigerant circuit
- Working on the refrigerant circuit
- Painting work on vehicles with air-conditioning
- Notes on general repairs
- Safety regulations for extraction and filling systems
- Technical data for air-conditioning system
- Instructions for repairing air-conditioning systems and storing spare parts
- Tools
- Preliminary work for removing and installing air-conditioning system regulator
- Removing air-conditioning system regulator
- Subsequent work for the air-conditioning system regulator
- Coding the air-conditioning control
- Warning notes for handling refrigerant
- Servicing equipment
- Installing sun sensor
- Preliminary work - servo motor for temperature mixing valve
- Removing servo motor for temperature mixing flap
- Subsequent work - servo motor for temperature mixing valve
- Preliminary work - servo motor for central distributor flap
- Removing servo motor for central distributor flap
- Subsequent work - servo motor for central distributor flap
- Preliminary work for footwell/defrost servo motor
- Removing footwell/defrost servo motor
- Subsequent work for footwell/defrost servo motor
- Preliminary work for magnetic clutch
- Removing the magnetic coupling
- Installing the magnetic coupling
- Subsequent work for magnetic clutch
- Check air gap of magnetic clutch
- Preliminary work for compressor
- Removing compressor
- Installing compressor
- Subsequent work for compressor
- Correct the refrigerant oil level in the "new" air-conditioning compressor
- Preliminary work for air-conditioning compressor
- General warning notes for air-conditioning compressor
- Tool for air-conditioning system
- Removing the air-conditioning compressor
- Subsequent work on compressor
- Preliminary work for line condenser-condenser
- Removing the condenser-condenser line
- Installing the condenser-condenser line
- Subsequent work for line condenser-condenser
- Preliminary work for compressor/condenser line
- Removing compressor/condenser line
- Installing compressor/condenser line
- Subsequent work for compressor/condenser line
- Preliminary work on compressor-condenser line
- Removing compressor-condenser line
- Installing compressor-condenser line
- Subsequent work on compressor-condenser line
- Laying compressor/condenser line
- Preliminary work for compressor/evaporator line
- Removing compressor/evaporator line
- Installing compressor/evaporator line
- Subsequent work for compressor/evaporator line
- Laying compressor/evaporator line
- Preliminary work for condenser
- Removing the condenser
- Rework on condenser
- Preliminary work for dryer
- General safety regulations for work on the air-conditioning systems.
- Tools for air-conditioning compressor
- Subsequent work for the dryer
- Removing temperature sensor
- Installing temperature sensor
- Preliminary work for outside temperature sensor
- Removing outside temperature sensor
- Installing outside temperature sensor
- Subsequent work for outside temperature sensor
- Preliminary work for expansion valve
- Removing expansion valve
- Installing expansion valve
- Rework on expansion valve
- Preliminary work for blower regulator
- Removing blower regulator
- Installing blower regulator
- Subsequent work for blower regulator
- Preliminary work for pressure switch
- Removing pressure switch
- Installing pressure switch
- Subsequent work for pressure switch
- Tools
- Notes
- Preliminary work
- Checking and topping up the ATF
- Subsequent work
- Topping up ATF
- Removing selector knob
- Installing selector knob
- Removing selector frame
- Installing selector frame
- Reworking
- Detaching selector lever cable inside vehicle
- Securing selector lever cable inside vehicle
- Securing selector lever cable on automatic transmission
- Removing Tiptronic rocker switch
- Installing Tiptronic rocker switch
- General warning notes for control units
- Subsequent work for Tiptronic control unit
- Reading out from and writing in to the Tiptronic control unit (also referred to generally as control unit below)
- Coding Tiptronic control unit
- Preliminary work for Tiptronic control module (also referred to generally as control unit below)
- Removing Tiptronic control unit
- Installing Tiptronic control unit
- Subsequent work for Tiptronic control module (also referred to generally as control unit below)
- Removing multi-functional switch
- Removing sealing ring for selector shaft
- Installing sealing ring for selector shaft
- Technical data
- Transmission ratios
- Removing converter bolts
- Removing automatic transmission
- Installing automatic transmission
- Install converter screw connection
- Dismantling
- Removing the automatic transmission
- Refitting the automatic transmission
- Removing seal for spur-gear cover
- Installing seal for spur-gear cover
- Installing ATF pan
- Removing ATF pan
- Installing ATF filter
- Installing deflection lever
- Danger of injury when working on car windows
- Material damage when removing the glass from car windows
- Material damage when inserting the glass into car windows
- Safety instructions for airbag system
- Safety instructions for the heat shield
- Preliminary work
- Removing the front bumper
- Installing the front bumper
- Subsequent work
- Tools
- Undoing front spoiler underneath
- Undoing front spoiler at the sides
- Disconnecting electrical plug connection
- Removing hose for headlight cleaning system
- Undoing front apron at the top
- Securing front spoiler at the top
- Securing front spoiler at the sides
- Locking hose for headlight cleaning system
- Locking electric plug connection
- Securing front spoiler underneath
- Removing cover cap
- Removing side covering frame
- Pulling off joining latch
- Affixing joining latch
- Install support
- Installing side covering frame
- Installing cover cap
- Removing spoiler trim
- Installing spoiler trim
- Removing front retaining strip
- Installing front retaining strip
- Adjusting front retaining strip
- Removing front impact pipe
- Install front impact pipe
- Removing support with heat shield at the sides
- Removing rear bumper
- Checking anti-chafing film
- Installing rear bumper
- Installing support with heat shield at the sides
- Functional dimensions of the bumper
- General warning notes
- Removing rear spoiler
- Installing rear spoiler
- Removing rear apron
- Installing rear apron
- Removing support
- Removing cover plate
- Removing retaining frame
- Installing retaining frame
- Installing cover plate
- Installing support
- Removing the lower retaining strip
- Removing frame
- Installing covering frame
- Installing the lower retaining strip
- Removing rear retaining strip
- Installing the rear retaining strip
- Function dimensions for rear retaining strip
- Removing the rear retaining strip
- Removing rear bumper horn
- Installing the rear bumper horn
- Removing rear impact pipe
- Removing impact absorber
- Install rear impact pipe
- Installing impact absorber
- Tools
- Safety instructions for body repairs
- Materials and tools
- Preliminary work for body repairs
- Removing roof
- Safety instructions for flying sparks during grinding and welding work
- Safety instructions for sharp-edged body and unit parts
- Danger of injury when welding
- Installing roof
- Installing roof sound absorber
- Subsequent work for body repairs
- Removing roof reinforcement
- Installing roof reinforcement
- Tools and materials
- Removing rear cross member
- Removing windscreen frame
- Installing windscreen frame
- Removing outer B-pillar reinforcement
- Installing inner B-pillar reinforcement
- Installing lower B-pillar reinforcement
- Installing outer B-pillar reinforcement
- Removing outer lower side member
- Installing outer lower side member
- Removing lower side member reinforcement
- Installing lower side member reinforcement
- Removing hinge pillar reinforcement
- Installing hinge pillar reinforcement
- Preliminary work
- Removing deformation element
- Installing deformation element
- Subsequent work
- Installing repair threaded bushing for seat cross member
- Table classification for seat cross member repairs
- Installing repair threaded bushing
- Table classification for suspension subframe repairs
- Removing cover for front underbody
- Installing cover for front underbody
- Removing cover for side underbody
- Removing cover for center underbody
- Installing cover for center underbody
- Installing cover for side underbody
- Removing cover for rear underbody
- Removing support for underbody cover
- Installing support for underbody cover
- Installing underbody cover
- Tools
- 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 plate
- Cleaning the convertible top
- Care of convertible top
- Care of convertible-top seals
- Preliminary work
- Removing tension cable
- Subsequent work
- Adjusting convertible top gear
- Adjusting stop for convertible top compartment lid
- Adjusting the adjusting eccentric for locating peg
- Move convertible top to service position
- Ending convertible top service position
- Diagram of convertible top
- Removing cabriolet convertible top
- Removing convertible top frame
- Installing convertible top frame
- Installing cabriolet convertible top
- Tools and materials
- Adjusting the hardtop
- Removing hardtop
- Installing hardtop
- Removing front lock
- Loosening cloth and cord from convertible top support
- Fastening cloth and cord to convertible top support
- Removing centering journal (convertible top and hardtop)
- Removing convertible-top peg mount
- Installing centering journal (convertible top and hardtop)
- Installing convertible-top peg mount
- Removing water drip pan
- Installing water drip pan
- Removing hardtop fastenings
- Installing pivot-pin locks
- Installing hardtop fastenings
- Removing convertible top lock
- Installing convertible top lock
- Removing cover strip
- Installing cover strip
- Removing rear seal (tension bow)
- Installing rear seal (tension bow)
- Loosening convertible top mechanism
- Removing tension cable of convertible-top covering
- Fastening convertible top mechanism
- Removing seal for convertible-top tip
- Removing shaped sheetmetal part with convertible-top covering
- Loosening convertible-top covering at the roof frame
- Loosening fold placer and folding aid
- Disconnecting electric plug connection at rear window
- Loosening convertible-top covering at the tension bow
- Removing slide
- Preparing convertible-top frame and convertible-top covering
- Installing convertible-top covering
- Fastening the convertible-top covering at the sides of the roof frame
- Fastening convertible-top covering at front
- Installing seal for convertible-top tip
- Fastening the slide
- Fastening tension cable of the convertible-top covering
- Fastening convertible-top covering on the tension bow
- Fastening convertible-top covering on the inside
- Connecting electric plug connection at rear window
- Installing tensioning straps
- Removing switch for roof
- Removing microswitch for roof
- Removing motor for drive mechanism
- Removing hinge for top box cover
- Removing guide rail
- Removing control unit for convertible top
- Installing control unit for convertible top
- Engine M96/25, M96/26 and M97/21
- Engine design
- Engine control
- Tools
- Preliminary work
- Removing engine
- Installing engine
- Subsequent work for installing engine
- Preliminary work for removing crankcase vent line
- Installing crankcase vent line
- Subsequent work for installing crankcase vent line
- Preliminary work for removing oil separator
- Removing oil separator
- Installing oil separator
- Subsequent work for installing oil separator
- Tools
- Removing pistons, preliminary work
- Removing pistons
- Installing pistons
- Subsequent work for installing pistons
- Securing connecting rod bolts
- Preliminary work
- Removing crankshaft
- Subsequent work
- Preliminary work for crankshaft sealing ring on flywheel side
- Removing crankshaft sealing ring on flywheel side
- Subsequent work for crankshaft sealing ring on flywheel side
- Preliminary work for double-mass flywheel
- Installing double-mass flywheel
- Subsequent work for double-mass flywheel
- Preliminary work for removing drive plate for converter
- Removing drive plate for converter
- Installing drive plate for converter
- Subsequent work after installing drive plate for converter
- Preliminary work for crankshaft sealing ring - belt pulley side
- Installing crankshaft sealing ring - belt pulley side
- Removing crankshaft sealing ring - belt pulley side
- Subsequent work for crankshaft sealing ring - belt pulley side
- Preliminary work for removing pulley
- Removing belt pulley - engine installed
- Installing belt pulley - engine installed
- Subsequent work for installing belt pulley
- Preliminary work for removing drive belt
- Removing drive belt
- Installing drive belt
- Subsequent work for installing drive belt
- Tools
- Preliminary work for checking camshaft timing
- Checking camshaft timing
- Subsequent work for checking camshaft timing
- Preliminary work for removing camshafts
- Removing camshaft - engine removed
- Installing camshaft - engine removed
- Camshaft designation M96.25
- Camshaft designation M96.26
- Allocation of chain tensioners
- Subsequent work for installing camshafts
- Preliminary work for bearing cover for intermediate shaft
- Removing bearing cover for intermediate shaft
- Installing bearing cover for intermediate shaft
- Subsequent work for bearing cover for intermediate shaft
- Removing bearing cover for intermediate shaft - up to engine number 61.504715
- Removing bearing cover for intermediate shaft - from engine number 61.504716
- Installing bearing cover for intermediate shaft - up to engine number 61.504715
- Installing bearing cover for intermediate shaft - from engine number 61.504716
- Removing bearing cover for intermediate shaft - up to engine number 62.504094
- Removing bearing cover for intermediate shaft - from engine number 62.504095
- Installing bearing cover for intermediate shaft - up to engine number 62.504094
- Installing bearing cover for intermediate shaft - from engine number 62.504095
- Preliminary work for bearing cover sealing ring
- Replacing sealing ring for bearing cover for intermediate shaft
- Subsequent work for bearing cover sealing ring
- Removing hydraulic valve for camshaft timing
- Installing hydraulic valve for camshaft timing
- Preliminary work for removing cylinder head
- Removing cylinder head
- Installing cylinder head
- Preliminary work for machining cylinder head
- Machining the cylinder head
- Subsequent work for machining cylinder head
- Preliminary work
- Subsequent work
- Removing cylinder head cover M97/21
- Installing cylinder head cover M97/21
- Removing cylinder head cover M96/25 and M96/26
- Installing cylinder head cover M96/25 and M96/26
- Removing actuator - camshaft removed
- Installing actuator - camshaft removed
- Installing hand-held transmitter key
- Tools
- Preliminary work
- Unclipping electric wire for micro switches
- Disconnect connection piece
- Removing door handle and bottom part of door handle
- Locking lock actuation
- Fitting door handle and bottom part of door handle
- Fit connection piece
- Clipping in the electric wire for micro switches
- Subsequent work
- Installing door lock
- Unclipping and disengaging the bowden cable
- Fitting the bowden cable
- Removing striker pin
- Installing striker pin
- Covering door with adhesive tape
- Removing seal for mirror triangle
- Disconnecting electrical plug connection
- Releasing door unit carrier
- Disconnecting electrical plug connection on microswitch
- Disconnecting the door lock electrical plug connection
- Locking electrical plug connection for door lock
- Locking electrical plug connection for microswitch
- Fastening door unit carrier
- Locking electrical plug connection
- Fitting seal for mirror triangle
- Removing adhesive tape
- Removing door handle
- Installing door handle
- Removing crash support
- Installing crash support
- Adjusting the front doors
- Adjusting rear door
- General warning notes
- Tools and materials
- Releasing hinge joint
- Releasing door arrester on body side
- Removing door
- Installing door
- Fastening the hinge joint
- Fastening door arrester on body side
- Removing lid and rubber sleeves
- Removing retaining clips
- Removing rubber buffer
- Installing rubber buffer
- Installing retaining clips
- Fit lid and rubber sleeves
- Safety instructions for body repairs
- Preliminary work for body repairs
- Removing door hinge (on body side)
- Safety instructions for flying sparks during grinding and welding work
- Safety instructions for sharp-edged body and unit parts
- Danger of injury when welding
- Installing door hinge (on body side)
- Subsequent work for body repairs
- Removing door arrester
- Installing door arrester
- Installing rubber seal for door
- Removing rubber seal for door
- Preliminary work - switch for central locking
- Removing central locking switch
- Subsequent work - switch for central locking
- Reading from and writing to the rear convenience system control unit
- Coding the control unit for rear convenience systems
- 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
- Preliminary work
- Subsequent work
- Removing front center air grille
- Installing front center air grille
- Removing front logo
- Removing side-section trim
- Installing side-section trim
- Tools
- Removing roof joint cover strip
- Installing roof joint cover strip
- Replacing the model logo Boxster
- Replacing the model logo Boxster S
- Replacing the model logo Cayman S
- Removing switch for rear-view mirror
- Removing right air inlet grille
- Removing left air inlet grille
- Removing flow duct on the right
- Removing inner left air guide
- Installing inner left air guide
- Installing flow duct on the right
- Installing left air inlet grille
- Installing right air inlet grille
- Safety instructions for rear spoiler
- Removing top section of the rear spoiler
- Removing bottom section of the rear spoiler
- Installing bottom section of the rear spoiler
- Installing top section of the rear spoiler
- Removing upper part of the rear spoiler
- Removing lower part of the rear spoiler
- Installing lower part of the rear spoiler
- Installing upper part of the rear spoiler
- Removing engine for rear spoiler
- Removing motor for rear spoiler
- Installing motor for rear spoiler
- Removing spoiler drive
- Installing spoiler drive
- General affixing regulations for the stone guard film
- Removing mirror adjusting motor
- Removing trim panel for mirror triangle
- Removing seal for mirror triangle
- Disconnecting electrical plug connection
- Removing rear-view mirror
- Installing rear-view mirror
- Locking electrical plug connection
- Fitting seal for mirror triangle
- Installing trim panel for mirror triangle
- Warning notes
- Removing the Roof Transport System
- Removing base plate of Roof Transport System
- Installing base plate of Roof Transport System
- Installing the Roof Transport System
- Tools
- Preliminary work
- Sequence for re-adjusting the drive set
- Calculating the total disc thickness "Stot" (S3 + S4)
- Checking disc thickness S4
- Checking disc thickness S3
- Calculating total disc thickness Stot (S1 + S2)
- Checking disc thickness S1 and S2 via circumferential backlash
- Subsequent work
- Removing differential
- Installing differential
- Fitting differential
- Removing sealing ring for halfshaft flange
- Installing sealing ring for halfshaft flange
- Installing double sealing ring
- Installing sealing ring
- Installing halfshaft flange
- Removing halfshaft flange
- Notes
- Checking and topping up oil for final drive
- Dismantling
- Topping up oil for final drive
- Diagram of body bonding points and sealing elements
- Measures for maintaining long-term body protection
- Prerequisite for maintaining the long-life guarantee
- Electronic control modules
- Battery trickle charge
- Protection against overvoltage when performing welding work
- Replacing control modules
- High-strength steel plates
- Highest-strength steel plates
- Tailored blanks
- Baked hardening
- Aluminum parts
- High-strength stainless steel
- Straightening body parts
- Welding work
- Reshaping
- Separation points
- Notes
- Work sequence for determining scope of damage to vehicles involved in an accident
- Identifiable deformations on the body structure
- No identifiable deformations on the body structure
- Procedure for accident repairs.
- Repair
- Tools
- Straightening systems
- Electrical equipment
- Mechanical equipment
- Compressed-air equipment
- Welding equipment
- Resistance spot welding
- Inert-gas arc welding (MAG procedure)
- Prerequisite for ensuring validity of the long-life guarantee
- Bottom of lower side member and floor
- Top of lower side member and floor
- Wheel housing and rear side section
- Bottom of engine compartment bulkhead
- Side of rear end
- Materials
- Note on seam seals
- Gap dimensions, body center
- Gap dimensions, body rear
- Convertible-top gap dimensions
- Gap dimensions, hardtop
- General
- Processing adhesives
- 2-component SIP
- Processing nozzle
- Safety instructions for body repairs
- Tools and materials
- Preliminary work for body repairs
- Safety instructions for flying sparks during grinding and welding work
- Safety instructions for sharp-edged body and unit parts
- Danger of injury when welding
- Subsequent work for body repairs
- Preliminary work
- Removing fuel tank cap
- Releasing tank filler neck
- Releasing bottom of wing
- Releasing top of wing
- Removing retaining strip
- Removing protective film
- Releasing wing from A-pillar
- Removing masking panel
- Installing masking panel
- Fastening wing to A-pillar
- Fastening top of wing
- Fastening bottom of wing
- Sticking in the protective film
- Installing retaining strip
- Fastening tank filler neck
- Installing fuel tank cap
- Subsequent work
- Removing lateral cap
- Removing upper cowl panel cover
- Disconnecting plug connection of spray nozzle for windscreen washer system
- Disconnecting water line for windscreen washer system
- Disconnecting plug connection for GPS antenna
- Disconnecting plug connection for radio antenna
- Removing lower cowl panel cover
- Installing cowl panel cover
- Locking plug connection for radio antenna
- Locking plug connection for GPS antenna
- Locking water line for windscreen washer system
- Locking plug connection of spray nozzle for windscreen washer system
- Securing upper cowl panel cover
- Installing lateral cover cap
- Preliminary work for air cleaner element
- Removing air-cleaner element
- Installing air-cleaner element
- Rework on air cleaner element
- Preliminary work for removing fuel ring pipe
- Removing fuel ring pipe
- Subsequent work for installing fuel ring pipe
- Preliminary work for removing fuel injector
- Removing fuel injector
- Installing fuel injector
- Subsequent work for installing fuel injector
- Preliminary work for removing throttle body
- Removing throttle body
- Work subsequent to installing throttle body
- Preliminary work for removing air flow sensor
- Removing air flow sensor
- Work subsequent to installing air flow sensor
- Intake system
- Preliminary work for removing intake distributor
- Installing intake-air distributor
- Subsequent work for installing intake distributor
- Tools
- Preliminary work for removing oxygen sensor in front of catalytic converter
- Removing oxygen sensor in front of catalytic converter
- Subsequent work for installing oxygen sensor in front of catalytic converter
- Precautionary measures when handling oxygen sensors
- Preliminary work on DME control unit 987
- General warning notes for control units
- Removing DME control module
- Subsequent work on DME control unit
- Programming new DME control module
- Programming DME control module
- Exhaust-gas standard
- Installing DME control module
- Preliminary work for removing oxygen sensor behind the catalytic converter
- Removing oxygen sensor behind the catalytic converter
- Installing oxygen sensor behind the catalytic converter
- Subsequent work for installing oxygen sensor behind the catalytic converter
- Tools
- Danger of injury when working on car windows
- Material damage when removing the glass from car windows
- Removing glass with cutting device - wire separator
- Applying protective film to the dashboard
- Guiding cutting thread into the passenger compartment
- Guiding cutting thread into the gap in the glass
- Separating glass as far as P2
- Separating glass as far as P3
- Separating glass as far as P4
- Separating glass as far as P5
- Fitting windscreen seal
- Warning note on hydrophobic window
- Checking front door window
- Mixing the components
- Cleaning the surface
- Reworking (coating) front door window
- Pre-treating adhesive flanges on vehicle windows
- Pre-treating adhesive flanges on vehicle body
- Double cartridge press
- Preliminary work
- General warning notes
- Tools and materials
- Removing windscreen
- Removing adhesive from the body
- Cleaning and priming areas that are free of adhesive residue or have paint damage or where there is newly built-up paint in the window aperture of the body
- Removing windscreen seal
- Removing adhesive from the windscreen
- Marking the bonding area
- Activating the bonding section of the windscreen
- Priming the windscreen
- Fitting windscreen into the body
- Preparing 2-component adhesive for processing
- Applying adhesive to the windscreen
- Pulling off protective film
- Inserting windscreen into the body
- Cleaning fields of vision
- Subsequent work
- Unclipping electric line for micro switches
- Removing microswitch for window opening controls
- Installing microswitch for window opening controls
- Clipping in the electric line for micro switches
- Removing front door window
- Installing front door window
- Securing front door window
- Inserting door trim panel
- Standardizing the power windows
- Blockage detection function
- Adjusting the door window angle in the vehicle's longitudinal direction
- Adjusting the door window height
- Removing the front window bay seal
- Installing the front window shaft seal
- Removing front power windows
- Adjusting the lower stop of the power window unit
- Installing front power windows
- Preliminary work for power window motor
- Removing power window motor
- Installing power window motor
- Subsequent work for window power motor
- Reading from and writing to the power windows motor (door control unit)
- Coding the power windows motor (door control unit)
- Removing switch for power windows
- Removing side window
- Installing side window
- Removing rear window (hardtop)
- Installing rear window (hardtop)
- Removing inner door sill trim (driver's side)
- Removing inner door sill trim (passenger's side)
- Installing inner door sill trim (driver's side)
- Installing inner door sill trim (passenger's side)
- Preliminary work
- Removing cover strip
- Installing cover strip
- Subsequent work
- Removing and installing support for glove compartment lid
- Removing glove compartment lid lock
- Installing glove compartment lock
- Installing support for glove compartment lid
- Removing lid for glove compartment
- Installing lid for glove compartment
- Removing footwell outlet vent cover
- Removing center console cover
- Installing center console cover
- Installing footwell outlet vent cover
- Removing glove compartment
- Installing glove compartment
- Removing shelf
- Installing shelf
- Removing cover for parking-brake lever
- Removing center console
- Installing center console
- Installing cover for parking-brake lever
- Removing cover for support frame
- Removing frame
- Removing Tiptronic cover
- Installing Tiptronic cover
- Installing frame
- Installing cover for support frame
- Removing sun visor
- Installing sun visor
- Removing CD holder.
- Installing CD holder
- Removing windstop
- Fitting fastening parts
- Installing windstop
- Removing luggage net
- Removing luggage mesh
- Installing luggage mesh
- Installing luggage net
- Preliminary work
- Removing release for front lid
- Subsequent work
- Preliminary work for servo motor for hood release
- Removing the servo motor for front lid release
- Subsequent work for servo motor for hood release
- Removing bowden cable for emergency release
- Pressing out bowden cable for emergency release
- Disconnecting electrical plug connection
- Removing lower part of lid lock
- Removing lid-release cable
- Inserting lid-release cable
- Installing lower part of lid lock
- Locking electrical plug connection
- Installing bowden cable for emergency release
- Inserting bowden cable for emergency release
- Removing upper part of front lid lock
- Checking lid function
- Tools
- Adjusting lid in X and Y direction
- Adjusting lid in Z direction
- Adjusting front lid
- Removing front lid
- Installing front lid
- Removing rubber pad
- Removing self-adhesive label
- Installing rubber pad
- Installing self-adhesive label
- Removing front lid hinge
- Installing front lid hinge
- Removing front pneumatic spring at lid end
- Installing front pneumatic spring at body end
- Installing front pneumatic spring at lid end
- Removing front lid seal
- Removing the front lid seal
- Fitting front lid seal
- Installing front lid seal
- Removing filler flap
- Removing plastic hinge
- Installing plastic hinge
- Installing filler flap
- Removing switching element for filler flap
- Removing release for rear lid
- Installing release for rear lid
- Installing rear wall cover
- Preliminary work on servo motor for emergency release
- Removing servo motor for emergency release
- Subsequent work on servo motor for emergency release
- Removing front emergency release
- Installing front emergency release
- Installing support for release handle
- Checking inner release of luggage compartment (Trunk Entrapment)
- Detach bowden cable.
- Removing rear lid release motor
- Locking bowden cables
- Checking motor for rear lid release
- Detaching bowden cables
- Removing rear lock lower part
- Installing rear lock lower part
- Removing rear upper part of lid lock
- Installing rear lid lock upper part
- Checking lid functions
- Adjusting rear lid
- Functional dimensions of rear lid
- Adjusting rear lid in X and Y direction
- Removing rear lid
- Install rear lid
- Installing rear lid
- Stick in adhesive labels rear lid
- Installing adjusting element
- Move rear lid to service position.
- Removing rear lid hinge
- Installing rear lid hinge
- Removing rear pneumatic spring
- Removing rear pneumatic spring at lid end
- Removing rear pneumatic spring at the body
- Installing rear pneumatic spring on body side
- Installing rear pneumatic spring at lid end
- Removing rear lid seal
- Removing main light switch
- Preliminary work - headlight mounts
- Removing headlight mount
- Installing headlight mount
- Subsequent work - headlight mounts
- Removing main headlight
- Installing main headlight
- Converting halogen headlights for left/right-hand driving
- Converting Bi-Xenon headlights for left/right-hand driving
- Preliminary work
- Removing halogen bulb
- Removing high beam halogen bulb
- Installing halogen bulb
- Installing high beam halogen bulb
- Subsequent work
- Bulb table
- Preliminary work for parking light bulb
- Subsequent work for parking light bulb
- Installing parking light bulb
- Removing tail light
- Installing tail light
- Removing brake light switch
- Installing stop light switch
- Removing number plate light
- Installing bulb for number plate light
- Installing number plate light
- Preliminary work for hazard warning light switch
- Removing hazard warning light switch
- Subsequent work for hazard warning light switch
- Tools
- Preliminary work - front control unit
- Removing front control unit
- Installing front control unit
- Subsequent work - front control unit
- Reading out and printing out values
- Coding (programming) the control unit
- Preliminary work - steering column switch
- Technical values - steering column switch
- Removing steering column switch
- Installing steering-column switch
- Subsequent work - steering column switch
- Installing side direction indicator light
- Preliminary work - bulb for front direction indicator light
- Subsequent work - bulb for front direction indicator light
- Preliminary work on control unit for gas discharge
- Removing cap of main headlight
- Installing main headlight cap
- Subsequent work on control unit for gas discharge
- Installing gas discharge lamp
- Preliminary work for fog-light bulb
- Installing bulb for fog light
- Subsequent work for fog-light bulb
- Removing auxiliary brake light
- Preliminary work for auxiliary brake light
- Installing auxiliary brake light
- Subsequent work for auxiliary brake light
- Installing auxiliary headlamp
- Subsequent work for auxiliary headlight
- Removing auxiliary headlamp
- Removing switch for reversing light (6-speed transmission)
- Removing switch for reversing light (5-speed transmission)
- Installing switch for reversing light (6-speed transmission)
- Preliminary work - front angle sensor for headlight levelling system
- Installing front angle sensor for headlight levelling system
- Subsequent work - front angle sensor for headlight levelling system
- Installing rear angle sensor for headlight levelling system
- Subsequent work - rear angle sensor for headlight levelling system
- Preliminary work - servo motor for headlight levelling system
- Installing servo motor for headlight levelling system
- Subsequent work - servo motor for headlight levelling system
- Preliminary work
- Removing contact switch for glove compartment light
- Subsequent work
- Removing footwell light
- Installing footwell light
- Removing door warning light
- Installing bulb for door warning light
- Installing door warning light
- Removing bulb for interior light
- Removing bulb for rear interior light
- Removing interior light
- Preliminary work for switch console
- Removing switch console
- Installing switch console
- Subsequent work for switch console
- Removing luggage compartment light in rear lid
- Removing luggage compartment light
- Installing bulb for light
- Installing luggage compartment light
- Replacing bulb for luggage compartment light
- Removing glove compartment light
- Installing glove compartment light
- Replacing bulb for reading light
- Removing bulb for reading light
- Installing bulb for reading light
- Main switch for power supply
- Vehicle electrical system - switching off
- Installing hand-held transmitter key
- Teaching hand-held transmitter
- Removing tilt sensor control unit
- Removing alarm horn
- Tools
- Control unit information for KESSY/PAS
- Obtaining read-out and saving vehicle data from control unit
- Removing KESSY/PAS control unit
- Installing KESSY/PAS control unit
- Programming new KESSY/PAS control unit
- Removing control unit for garage door opener
- Preliminary work for control unit for garage door opener/HomeLink
- Removing control unit for garage door opener/HomeLink
- Installing control unit for garage door opener/HomeLink
- Subsequent work for control unit for garage door opener/HomeLink
- HomeLink
- Garage door opener/HomeLink with fixed code system
- Garage door opener/HomeLink with variable code system
- Re-programming an individual button
- Erasing programmed signals on the HomeLink
- Preliminary work for interior monitoring sensor
- Removing interior monitoring sensor
- Subsequent work for interior monitoring sensor
- 70 IN Notes for the care of soft-look paint surfaces - as of MY 2005 (All Models)
- Light soiling (e. g. dust)
- Information
- Removing cover for wing flange
- Installing cover for wing flange
- Preliminary work
- Removing rear luggage compartment side trim panel
- Installing rear luggage compartment side trim panel
- Subsequent work
- Removing front luggage compartment trim panel (luggage compartment pan)
- Removing front luggage compartment trim panel (bulkhead)
- Removing cover for rear lock lower part
- Removing trim panel of rear luggage compartment pan
- Removing trim panel of rear luggage-compartment (bulkhead)
- Removing support for rear luggage-compartment trim panel
- Removing trim panel for tail light
- Installing trim panel for tail light
- Installing support for rear luggage-compartment trim panel
- Installing trim panel of rear luggage-compartment (bulkhead)
- Installing trim panel of rear luggage compartment pan
- Installing cover for lock lower part
- Removing carpet lining for cross member rear wall
- Removing carpet lining for rear spoiler
- Removing carpet lining for rear luggage-compartment pan
- Installing carpet lining for rear luggage-compartment pan
- Installing carpet lining for rear spoiler
- Installing carpet lining for cross member rear wall
- Installing luggage-compartment carpet lining at the sides
- Removing trim panel under the dashboard on the driver's side
- Disconnecting the electrical plug connections
- Locking electrical plug connections
- Installing trim panel under dashboard on the driver's side
- Removing the trim panel under the dashboard on the passenger's side
- Installing the trim panel under the dashboard on the passenger's side
- Removing the device carrier
- Undoing intermediate piece for defroster cover
- Removing dashboard
- Checking dashboard clamps
- Installing dashboard
- Securing intermediate piece for defroster cover
- Installing the device carrier
- Removing cover for center dashboard (defroster trim)
- Removing cover for dashboard (defroster trim) on right and left
- Installing cover for dashboard (defroster trim) on right and left
- Installing center dashboard cover (defroster trim)
- Removing trim panel for spring strut mount
- Installing trim panel for spring strut mounts
- Removing luggage compartment cover
- Installing rear luggage compartment cover
- Removing rear wall trim panel
- Removing retaining strip for securing luggage
- Installing rear wall trim panel
- Installing retaining strip for securing luggage
- Removing footrest
- Installing footrest
- Removing cover for lock support
- Installing cover for lock support
- Removing cover for rear lock carrier
- Installing cover for rear lock carrier
- Removing trim for the rear.
- Installing cover for rear
- Removing service tray
- Removing A-pillar trim
- Installing A-pillar trim
- Removing trim panel for mirror triangle
- Removing lever for door opener
- Removing covers for door trim panel
- Releasing door trim panel
- Removing actuating cable for door lock
- Checking fastening clips
- Installing actuating cable for door lock
- Locking electrical plug connection
- Installing door trim panel
- Installing covers for door trim panel
- Installing lever for door opener
- Installing trim panel for mirror triangle
- Tools
- Removing cover for door trim panel
- Installing cover for door trim panel
- Removing inner door handle
- Installing inner door handle
- Removing lid for oddments compartment
- Installing lid for oddments compartment
- Removing oddments tray
- Installing oddments tray
- Removing C-pillar trim panel
- Removing trim for roll-over bar
- Installing trim for roll-over bar
- Removing front roof trim panel
- Installing front roof trim panel
- Removing headliner
- Installing headliner
- Removing luggage compartment light in rear lid
- Removing rear lid hinge trim
- Installing rear lid hinge trim
- Removing cover for center window frame
- Removing trim panel for side window frame
- Removing rear light cover
- Installing rear light cover
- Removing side trim panel
- Installing side trim panel
- Tools
- Notes
- Preliminary work
- Checking and topping up transmission oil
- Subsequent work
- Filling in transmission oil
- Detaching shift and selector cables inside vehicle
- Installing shift and selector cables
- Securing shift and selector cables inside vehicle
- Detaching shift and selector cables at transmission
- Removing shift and selector cables
- Securing shift and selector cables at transmission
- Technical data
- Transmission ratios
- Dismantling
- Removing transmission
- Installing transmission
- Removing accessories
- Refitting transmission
- Fitting accessories
- Fitting transmission cover
- Fitting transmission housing
- Tools
- Materials
- General warnings for handling airbag and belt tensioner units
- Dangers for persons and the environment
- Protective measures and rules of behavior
- Behavior in cases of malfunction or danger
- Component exchange after airbag/belt tensioner triggering
- Preliminary work for contact unit
- General warnings for contact unit
- Work in wake of airbag contact unit
- Preliminary work
- Removing roll-over bar
- Adjusting roll-over bar
- Warning note for seat belts
- Checking procedure for seat belt
- Checking belt strap
- Checking automatic belt device (locking effect)
- Checking sash guides
- Checking mounting elements and mounting points
- Disposal of airbag and belt tensioner units
- Safety procedures when igniting airbag units
- Driver's side
- Passenger's side
- Side airbag
- Head airbag
- Belt tensioner
- Triggering of airbag units
- Safety instructions for seat-belt tensioner unit
- Removing deflector
- Removing seat-belt tensioner
- Installing seat-belt tensioner
- Installing deflector
- Subsequent work
- Removing front belt lock
- Preliminary work for front airbag sensor
- Preliminary work for center airbag sensor
- Safety instructions for airbag sensor
- Removing sensor for front airbag
- Removing sensor for center airbag
- Installing sensor for center airbag
- Work in wake of front airbag sensor
- Work in wake of center airbag sensor
- Preliminary work for triggering unit
- General warning notes for airbag triggering unit
- Removing triggering unit for airbag
- Subsequent work for triggering unit
- Triggering unit - reading out and writing in data
- Coding triggering unit
- Preliminary work for driver's airbag unit
- General warnings for driver's airbag unit
- Removing driver's airbag unit
- Installing driver's airbag unit
- Work in wake of driver's airbag unit
- Preliminary work - airbag unit, passenger's side
- Safety instructions, passenger's airbag unit
- Installing passenger's airbag unit
- Reworking for passenger's airbag unit
- Preliminary work for side airbag
- General warnings for side airbag
- Work in wake of side airbag
- Safety instructions for head airbag unit
- Removing head airbag unit
- Installing head airbag unit
- Work in wake
- Preliminary work for AWS control unit
- Removing AWS control unit
- Subsequent work for AWS control unit
- Reading and writing values for AWS control unit
- Tools
- Safety instructions for body repairs
- Materials and tools
- Preliminary work for body repairs
- Removing side section reinforcement
- Safety instructions for flying sparks during grinding and welding work
- Safety instructions for sharp-edged body and unit parts
- Danger of injury when welding
- Installing side section reinforcement
- Subsequent work for body repairs
- Tools and materials
- Possible separation points
- Removing side member
- Removing closing cross member
- Install closing cross member
- Removing retaining bracket for support tube
- Removing center side member
- Installing reinforcement plate
- Installing center side member
- Installing retaining bracket for support tube
- Removing side section
- Installing side section
- Removing front inner side section
- Installing front inner side section
- Removing light frame (section)
- Installing light frame (section)
- Preliminary work
- Removing heat protection cover
- Installing heat protection cover
- Subsequent work
- Removing seat rail cover
- Undoing seat screws at front
- Undoing seat screws at rear
- Releasing electrical line
- Disconnecting central plug
- Disconnecting electrical plug connection (power seat)
- Fastening electric line
- Connecting electrical plug connection (power seat)
- Locking central plug
- Fit seat rail cover
- Disconnecting the electrical plug connection of the AWS control module
- Locking the electrical plug connection of the AWS control module
- Subsequent work
- Preliminary work
- Removing switch for air cushion
- Installing backrest frame
- Removing cover for AWS sensor on left and right
- Removing frame for seat surface
- Removing backrest frame
- Installing frame for seat surface
- Installing cover for AWS sensor on left and right
- Removing air cushion for seat
- Removing control part trim panel
- Tools
- Removing air cushion for backrest
- Installing frame for side airbag
- Removing cushion carrier for front backrest
- Installing cushion carrier for front backrest
- Removing bowden cable for backrest release
- Removing cover for outer backrest
- Taking off foam part
- Fitting foam part
- Reworking
- Removing lumbar support
- Removing support for left backrest side part
- Installing support for left backrest side part
- Removing air cushion control valve
- Removing air cushion motor
- Removing backrest side support
- Installing backrest side support
- Reading out and printing out values
- Programming control unit
- Tools
- Preliminary work
- Removing padding for seat
- Installing padding for seat
- Subsequent work
- Tools and materials
- Removing cover for front seat
- Installing cover for front seat
- Removing creases in the cover
- Removing padding for front backrest
- Installing padding for front backrest
- Removing padding for front middle backrest
- Removing cover for front backrest
- Installing cover for backrest
- Removing cover for front middle backrest
- Installing cover for front middle backrest
- Removing backrest pocket
- Replacing cover for backrest pocket
- Installing backrest pocket
- Spare parts information
- Preliminary work for heating/fresh air unit
- Removing heating/fresh air unit
- Installing heating/fresh air unit
- Subsequent work for heater/air-conditioning unit
- Installing cover
- Preliminary work for the particle filter
- Removing particle filter
- Work subsequent to installing particle filter
- Preliminary work for heating and fresh air blower motor
- Removing heater/fresh-air blower motor
- Subsequent work for heater blower motor
- Preliminary work for defrost air guide
- Preliminary work for left air guide
- Preliminary work for right air guide
- Subsequent work for defrost air guide
- Subsequent work for left air guide
- Subsequent work for right air guide
- Preliminary work for central air vent
- Removing middle air vent
- Installing middle air vent
- Subsequent work for central air vent
- Removing air vent at door
- Installing air vent at door
- Preliminary work for fresh/recirc. air servo motor
- Removing fresh/recirc. air servo motor
- Subsequent work for fresh/recirc. air servo motor
- Removing rain sensor
- Installing rain sensor
- Preliminary work on wiper motor
- Touching up wiper motor
- Preliminary work for wiper link
- Installing wiper link
- Reworking wiper link
- Tools
- Preliminary work for adjusting wiper arm attack angle
- Adjusting wiper arm attack angle
- Subsequent work for adjusting wiper arm attack angle
- Removing wiper arm
- Installing wiper arm
- Removing wiper blade
- Installing wiper blade
- Preliminary work for wiper motor for rear window wiper system
- Removing wiper motor for rear window washer
- Installing wiper motor for rear window washer
- Reworking for wiper motor for rear window wiper system
- Installing grommet for wiper drive mechanism
- Removing wiper arm for rear window washer
- Removing wiper blade for rear window washer system
- Installing wiper blade for rear window washer system
- Preliminary work
- Removing pump for windscreen washer system
- Subsequent work
- Preliminary work - tank for windscreen washer system
- Removing tank for windscreen washer system
- Subsequent work - tank for windscreen washer system
- Preliminary work for spray nozzle of headlight washer system
- Removing spray nozzle for headlight washer system
- Subsequent work for spray nozzle of headlight washer system
- Preliminary work for removing hose for headlight washer system (front apron)
- Preliminary work for removing hose for headlight washer system (at tank)
- Removing hose for headlight washer (front apron)
- Removing hose for headlight washer (at reservoir)
- Subsequent work for installing hose for headlight washer system (front apron)
- Subsequent work for installing hose for headlight washer system (at tank)
- Removing pump for headlight washer
- Tools
- Preliminary work on vehicle
- Preliminary work
- Subsequent work
- Completing the vehicle
- Preliminary work - vehicle electrical system control unit
- Removing vehicle electrical system control unit
- Subsequent work - vehicle electrical system control unit
- Reading out and printing out values
- Coding (programming) the control module
- Preliminary work for interior monitoring sensor
- Subsequent work for interior monitoring sensor
- Removing lateral footwell trim on driver's side
- Removing lateral footwell trim on passenger's side
- Installing lateral footwell trim on driver's side
- Installing lateral footwell trim on passenger's side
- Preliminary work for ground strap and B+ line of battery
- Preliminary work for B+ line from power distributor to engine connection point
- Preliminary work for B+ line from starter to engine connection point
- Preliminary work for engine ground strap
- Removing ground strap and B+ line of battery
- Removing B+ line from power distributor to engine connection point
- Removing B+ line from starter to engine connection point
- Removing engine ground strap
- Installing ground strap and B+ line of battery
- Installing B+ line from power distributor to engine connection point
- Installing B+ line from starter to engine connection point
- Fitting ground strap to engine
- Subsequent work for ground strap and B+ line of battery
- Subsequent work for B+ line from power distributor to engine connection point
- Subsequent work for B+ line from starter to engine connection point
- Subsequent work for engine ground strap
- Spare parts information
- Disconnecting electric plug connection at rear window
- Connecting electric plug connection at rear window
- Removing support for left backrest side part
- Removing backrest side support
- Taking off foam part
- Installing components for airbag from triggering unit to passenger's airbag unit or seat-belt tensioner
- Optical waveguide variants
- Disconnecting optical waveguide
- Installing optical contacts on connector side
- Installing optical contacts on socket side
- Installing optical waveguide
- Requirements when working with LWL
- Storage, Packing, Transport
- Installing the LWL in the vehicle
- Repair
- Push-on connector - dust boots
- Optical fiber (LWL) - module
- Removing and installing optical contacts on connector side
- Removing and installing optical contacts on socket side
- Preliminary work for relay carrier 1
- Removing relay carrier 1 from the retaining frame
- Subsequent work on relay carrier 1
- Preliminary work for fusebox
- Undoing fusebox
- Subsequent work on fusebox
- Preliminary work for power distributor
- Removing power distributor
- Subsequent work for power distributor
- Preliminary work for relay carrier
- Installing relay carrier
- Subsequent work for relay carrier
- Preliminary work for fuse element
- Replacing fuse element
- Subsequent work for fuse element
- Connector - General information
- Removing main wire harness
- Removing main wire harness in passenger compartment
- Installing main wire harness in passenger compartment
- Installing front main wire harness
- Exposing main wire harness in passenger compartment
- Removing wire harness for front-end
- Installing wire harness for front-end
- Removing rear wire harness
- Installing rear wire harness
- Disconnect wire harness for door (driver's side) at the A-pillar
- Disconnect wire harness for door (passenger's side) at the A-pillar
- Locking wire harness for door (driver's side) at the A-pillar
- Locking wire harness for door (passenger's side) at the A-pillar
- Preliminary work for wire harness for front PASM
- Preliminary work for wire harness for rear PASM
- Removing wire harness for front PASM
- Removing wire harness for rear PASM
- Installing wire harness for rear PASM
- Subsequent work for wire harness for front PASM
- Subsequent work for wire harness for rear PASM
- Installing wire harness for front PASM
- Removing wire harness for engine
- Installing wire harness for engine
- Removing wire harness for backrest (front seat)
- Installing wire harness for backrest (front seat)
- Removing wire harness for electrically adjustable seat
- Installing wire harness for electrically adjustable seat
- Preliminary work on front ABS wire harness
- Preliminary work on rear ABS wire harness
- Removing front ABS wire harness
- Removing rear ABS wire harness
- Subsequent work on front ABS wire harness
- Subsequent work on rear ABS wire harness
- Installing front ABS wire harness
- Installing rear ABS wire harness
- Preliminary work for wire harness for passenger's airbag unit
- Preliminary work for wire harness for left seat-belt tensioner
- Preliminary work for wire harness for left head airbag (triggering unit to A-pillar connection point)
- Preliminary work for wire harness for right head airbag (triggering unit to A-pillar connection point)
- Preliminary work for head airbag wire harness (head airbag to A-pillar connection point)
- Installing wire harness for airbag from the A-pillar connection point to the head airbag
- Subsequent work for wire harness for passenger's airbag unit
- Subsequent work for wire harness for left head airbag (triggering unit to A-pillar connection point)
- Subsequent work for wire harness for right head airbag (triggering unit to A-pillar connection point)
- Subsequent work for head airbag wire harness (head airbag to A-pillar connection point)
- Preliminary work for wire harness in rear lid
- Removing wire harness in rear lid
- Installing wire harness in rear lid
- Subsequent work for wire harness in rear lid