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Technical Manual -~~.s:TLr
Technical Information
Contents: Group 1
Engine Part 1 (up to Repair Group 13)
WKD483 521 19
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www.WorkshopManuals.co.uk Boxster
Engine,part 1 (up to RepairGroup 13)
Supplement Overview
Supplement
Edition
Article number
Topic
05/1996
Basic edition
2
08/1996
Modifiedrepair group
WKD483521.02
9
03/1997
Generalsupplement
WKD483521.09
12
07/1997
Generalsupplement
WKD483521.12
15
08/1997
Generalsupplement
WKD483521.15
16
11/1997
Generalsupplement
WKD483521.16
18
01/1998
Generalsupplement
WKD483521.18
19
03/1998
Generalsupplement
WKD483521.19
20
03/1998
Generalsupplement
WKD483521.20
23
07/1998
25
02/1999
Generalsupplement
WKD483521.25
27
06/1999
Generalsupplement
WKD483521.27
30
07/1999
Generalsupplement
WKD483521.30
31
08/1999
Generalsupplement
WKD483521.31
32
09/1999
Generalsupplement
WKD483521.32
34
10/1999
Generalsupplement
WKD483521.34
35
12/1999
Generalsupplement
WKD483521.35
36
12/1999
Generalsupplement
WKD483521.36
42
11/2000
Generalsupplement
WKD483521.42
Supplement
WKD483521
I General supplement
Overview
Printed in Germany -42,
2000
Masterltl
Purchased from www.WorkshopManuals.co.uk
WKD483521.23
.
www.WorkshopManuals.co.uk Foreword
Boxster
Table of Contents
1
Foreword Foreword
Foreword
-1
page
Use
-2
page
.
t
Table of Contents Printed in Germany -42,
2000
mastereV_l
Purchased from www.WorkshopManuals.co.uk
1 1
www.WorkshopManuals.co.uk Foreword
Boxster
Foreword This manual contains Technicallnformation as well as instructions on repairs for Porsche vehicles. It is intendedfor the sole use of workshopsbelongingto PorscheAG. The descriptionsform the basis for professionaland correct maintenance and repair work. The content of the work procedures described is based on the level of training of a fitter who has completed vocationaltraining and has a sound knowledgeof the product. This level of knowledgeis necessaryin order to carry out the work described. Warning notes
The warning notes and safety instructionsare classified by the respective signalisingword (Danger,Warning,Caution)besidethe warningsymbol.
Warnsagainst death or very serious injury whichwill certainly occur if the instructions are not observed.
Warnsagainst death or very serious injury which may occur if the instructions are not observed.
Warns against minor injury or damage to property instructions
if the
are not observed.
To prevent injuryand restricted operating and traffic safety of the vehicle,or damage to the vehicle as the result of incorrect work, read these instructions carefullyand observethem withoutfail. It is not possiblefor PorscheAG to give a detailed evaluationof all danger situationsfor the personscarrying out the work. It is therefore imperativethat all persons carrying out repair and maintenance work on Porschevehicles use their specialistknowledgeto ensure that their own safety is not at risk and the procedure chosenwill not have anynegative effects on the vehicle -especially with regard to
safety. It is therefore expresslyspecified that all work involvedin the work proceduresdescribed shouldbe carried out onlyin accordancewith the valid guidelinesand regulationsof the local authorities responsible with respect to health and accidentpreventionand environmen-
Foreword
-1 page 1
Printed in Germany-42, 2000
vorwort
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www.WorkshopManuals.co.uk Foreword
tal protection, and in compliancewith the legal requirementsof individualcountries.
Notes Notes contain advisory informationrelated to the work procedure which makes the fitter's work easier. The following pictogram indi.
cates thisinformation:
rn Note! Containsadvisoryinformationwhich makes the work procedure eas-
Ier. Due to the continuous developmentand improvementof our vehicles, there may be discrepanciesbetweenthe actual technical status of the vehiclesand the work descriptions. Anyexisting deviationsare corrected by meansof supplements,and the scope of the descriptions is extendedwith supplements. PorscheAG retainsthe right to implementchangesat anytime and without prior notice.
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Boxster
www.WorkshopManuals.co.uk Boxster
Foreword
Use The wprkshop documentationfor the Boxster (986) model hasthe desig~ation -"Boxster (986)" Technical Manual- and containsTechnical Infor~ation as well as instructionson repairs. The integration of the technicalinformationpublishedin the "Boxster l TeChnical.Manual
{~86) vides
with the descriptive
he user with a complex
reference
matter on r~pair~ pro-
work that combines Into
one b ok associated or cross-referencedmaterial of relevanceto works ops and originatingfrom variousinformationmedia.
The"~oxster(986)"TechnicalManualconsistsof 15 folders,subdividedIntothe followingGroups .0
!
ntire vehicle -General
.0
iagnosis,1 Engine,part 1 (up to RepairGroup 45)
.0
iagnosis,1 Engine,part 2 (as of RepairGroup 69)
.1
ngine, part 1 (up to RepairGroup 13)
.1
ngine, part 2 (as of RepairGroup 15)
.2
uel, exhaust,engine electronics
.3
ransmission,manualtransmission
.3
ransmission,automatictransmission
.4
unninggear
.5
ody
.6
Body equipment,exterior
.7
Body equipment, interior
.8
/ 9 Air conditioning/ Electrics
.9
qircuit diagrams, part 1 (up to and including'99 model)
.9
qircuit diagrams, part 2 (as of and including'00 model)
The two folders with Group0 are to be regarded as one folder; i.e. file the "Technicallnformation"notices only in the folder "Group0 Diagnosis,part I" -up to Repair Group 45-. The s~condfolder Group 0 Engine,part 2 -as of Repair Group 69- inFludesthe further RepairGroupsbelongingto Group 1. The two folders with Group1 are to be regarded as one folder; i.e. file the "TechnicaiInformation"onlyin front of the repair descriptions in the folder Group 1 -Engine, part 1 -up to Repair Group 13-. The s~condfolder Group 1 Engine,part 2 -as of Repair Group 15- inFludesthe further RepairGroupsbelongingto Group 1.
Use Printed in Germany -42,
-2 page 1 2000
handhabung
Purchased from www.WorkshopManuals.co.uk
www.WorkshopManuals.co.uk Foreword The two folders with Group9 are to be regarded as one folder; i.e. file the "Technicallnformation"notices only in the folder Group9 Circuit diagrams, part 1 -up to '99 model-. The second folder Group 9 Circuit diagrams, part 2 -as of '00 model- includesthe further Repair Groupsbelongingto Group9. The "Boxster (986)"TechnicalManualhas the same structure in each folder I with the following breakdownfor all Groups:
Title page: "Boxster
(986)" Technical
Manual
> Foreword Title page: "Technical information' > Table of contents,Technicalinformation> Technicalinformation Title page: "Repair"
> RepairGroups: overview>Table of contents, repairs> General/ technical data> Instructionson repairs As can be seen from the breakdown,the publishedTechnicallnformation is in the front part of each folder -numbered accordingto the Groups.The Table of Contentsassignedto each Groupwill be periodicallyupdated. Followingthe TechnicalInformation, separated by a title page,the instructionson ~epairs-assigned according to the Groupsor broken down into R~pairGroups-are included in the folders. The instructions on repairswill be extended and updated by means of supplements.
rn Note! Sheets that alreadyexist in the "Boxster(986)" TechnicalManual and are updatedor revisedand therebyexchangedby a supplement are designatedin the footer with the supplementnumbercorresponding to the current version: e.g. "Printed in Germany-2,2000"
[I) Note! Due to a systemmodificationin the TechnicalLiterature production, the fol/owingprocedureshave changedin model year 2000!
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Boxster
www.WorkshopManuals.co.uk Boxster
Foreword
1 -The previous record the supplement omitted.
sheet in the folder "'O-General" and
contents
A supplement
rately in each folder.
sheet -red sheet- have been
overview now aplpears sepaThe new supplement
sheet can be destroyed
contents
after the supplement
is filed in
the folder.
[IJ Note! The supplementoverviewsheet is replaced with the relevant supplementin the correspondingfolder and must no longer be maintainedby hand. 2 -The
page numbering
in the new and the replaced
ters are no longer continuous. given an additional
chap-
Each new chapter is now
chapter number followed
by the
page number e.g. -2 Page 11 ~ Rep. Gr. 0; General 3 -The old page numbering
still applies to E~xisting chap-
ters and those that are not replaced.
Use Printed in Germany -42,
-2 page 3 2000
handhabung
Purchased from www.WorkshopManuals.co.uk
www.WorkshopManuals.co.uk Overview of repair groups
Boxster
Group 0: Group 0:
Group 0:
Entire vehicle -General
0
Maintenance
03
Diagnosis
0
Sales check On-boarddiagnosis DMEdiagnosis Tiptronic diagnosis ABS diagnosis
01
Group 2:
Group 3:
Group 3:
69 72 80 90 91 91 94
1
Engine Engine-Crankcase, suspension Engine-Crankshaft, pistons
Group 1:
24 37 45
0
Diagnosis Airbag diagnosis Seat memory diagnosis Heatingdiagnosis Alarm system diagnosis PCMdiagnosis ParkAssistentdiagnosis HBAdiagnosis
Group 1:
03
10 13
1
Engine Engine-Cylinder head,valve drive Engine-Lubrication Engine-Cooling
15 17 19
Fuel, exhaust, engine electronics
2
Fuel supply,control Exhaustsystem, turbocharging Fuel system, electronic injection Fuelsystem, K-Jetronic Exhaustsystem Starter, power supply, cruise control Ignition system
20 21 24 25 26 27 28
Transmission,
3
manual transmission
30 34 35
Clutch, control Manual transmission -Actuation, housing Manual transmission -Gears, shafts, into gearsh, Final drive, differential, differential lock
39
Transmission, automatic transmission
3
Torque converter Automatic transmission-Actuation, housing Automatic transmission-Gears, control Final drive, differential,differential lock
32 37 38 39
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Overview of repair groups
Group 4:
4
Running gear
40 42 44 45 46 47 48
Front whee! suspension, drive shafts Rear wheel suspension, drive shafts Wheels, tires, suspension alignment Anti-Lock Brake System (ABS) Brakes -Brake mechanics Brakes -Hydraulics, regulator, booster Steering
Group 5:
5
Body
Bodyfront Bodycenter,roof,frame Bodyrear Lids,flaps Door front,centrallockingsystem
50 51 53 55 57
Group 6:
Body equipment, exterior Slidingroof Convertible top, hardtop Bumpers Glazing,windowcontrol Exteriorequipment Interiorequipment Passengerprotection
6
Group 7:
Body equipment, interior Linings,insulation Seatframes Seatupholsteries, covers
7
Group 8:
Air conditioning Heating Ventilation Air conditioning Auxiliaryair conditioningsystem
8 80 85 87 88
Group 9
Electrics
9
Group 9: Group 9:
60 61 63 64 66 68 69 70 72 74
Instruments,alarm system Radio,telephone,on-boardcomputer, navigation Windshieldwiper and washer system Lights, lamps, switches exterior Lights, lamps, switches interior, theft protection
90 91
Circuit diagrams
9
Wiring (up to and including the '99 model)
97
Circuit diagrams
9
92
94
96
97
Wiring (from the '00 model)
Overview of repair groups Purchased from www.WorkshopManuals.co.uk d in Germany
-34,
October
1999
www.WorkshopManuals.co.uk Boxster
Engine, part 1 (up to Repair Group 13)
Table of Contents
1
Engine, part 1 (up to Repair Group 13)
1
Engine
1 1
Tightening Teoonical Differences
data torques between engine for Boxster M96/20 engine
2.5 M96/20 I,
2.71
(2.5 and
I), Boxster M96/21
S
(3.2 (3.2
I)I), engines M96/22
(2.7
I)
1-01 1-05 1-1 page
10
Engine -Crankcase,
100121
Installing Removing Disassembling
Adjusting Adjusting Tighteningtorques Special Removing Special Installing
engine,tools. tools notes engine, engine... tool
engine
and
M96/20
M96/20 assembling
1
suspension .,..",.,
(2.5
(2.51)
I)
engine crankcase positive ,.".,.".".,.".",.".",.",.""" with with
manual
manual
crankcase
halves,
transmission transmission
engineventilation.
M96/20,
M96/21,
1001 23
100137 105037
10-1
page
1
10-1
page
1
10-1
page
3
10-1
page
5
10-5
page
1
10-5
page
1
10-5
page
3
10-5
page
5
10-5
page
5
10-5
page 21
10-9 10-21
10 1037 M96/22 Removing Installing Removing
Assembling Tighteningtorques Adjusting Adjusting Mounting Special Tighteningtorques Removing Special Special Installing
engine, tools... tools.. notes engine, engine,engine tool instructions tool engine
the
M96/20 crankcase M96/21 M96/20
(2.5
(2.5 (3.21)
halves
I)
I)
with
with and
TiptronicM96/22 Tiptronic
transmission (2.7 transmission
I)
with
manual
transmission
,
,
100121
100123
100121 Installing
1001
Adjusting Special Removing
engine, tools.
tool
engine
M96/21
(3.2
I)
and
M96/22
(2.7
I)
with
manual
transmission
231
Specialtools.
Purchased from www.WorkshopManuals.co.uk Table of Contents
10-25
page
1
10-25
page
3
10-25
page
4
10-25
page
8
10-33
page
1
10-33
page
1
10-33
page
3
10-33
page
4
10-50
page
1
10-50
page
1
10-50
page
3
10-50
page
4
10-50
page
5
10-50
page 22
10-57
page
1
10-57
page
1
10-57
page
3
10-57
page
4
10-73
page
1
10-73
page
1
www.WorkshopManuals.co.uk Boxster
Engine, part 1 (up to Repair Group 13)
Adjustingtool Tighteningtorques Special notes Installing engine
,
103037
Disassembling
13
Engine -Crankshaft,
137819 137720 138219 137319 137337 134937 134819 131019 137419 135919 131019 131019
Removing Removing Disassembling
and and and
and assembling
installing installing installing and
assembling
engine
carrier
10-73
page
3
10-73
page
5
10-73
page
5
10-73
page 20
10-87
page
1
pistons tensioning pistons drive deflection belttensioner crankshaft
belt
bearing beltfor -Boxster
rollers roller sealing engine tensioner
housing
for
for S
type ring ring
drive drive
(engine M96/22 with
belt...
belt
crankshaft.
installed) installed)
(2.7
I)
13-1 13-4a 13-4c
13-4e 13-40
13-5 13-19 13-23 13-41 13-47
13-49 13-77
Purchased from www.WorkshopManuals.co.uk Table of Contents
(7.5)
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Engine
Tighteningtorques for engine M96/20 (2.51), M96/21 (3.21), M96/22 (2.7 I)
Screws,bearing housing Initialtightening: Finaltightening:
20 (15) 1 x 900
Connecting-rodscrews with connecting-roddesignation...7R Initialtightening: Finaltightening:
M9 x 1.25
Connecting-rodscrewswith connecting-roddesignation...7R Initialtightening: Finaltightening:
M9x 1.25
Oil guide to bearing housing Screws,crankcase halves
20 (15) 1 x 900
20 (15) 1 x 1100 M6 (micro-encapsulated)
10
M6
10 (7.5)
Additionalbolts
M9 x 150
22 (16)
Crankcase/bearinghousing
M9 x 94
22 (16)
Oil suction pipe to crankcase
M6
10 (7.5)(7.5)
Air/oil separator to crankcase
M6
10
Oil pan to crankcase
M6
10 (7.5)
M18 x 1.5
50 (37)
S80 x 3
25:f:1 (19:t1)
MI0
45 (33)
Oil drain plug to oil pan Oil filter to crankcase Coolantguide housingto crankcase Intermediate-shaftflange
M6 (micro-encapsulated)
10 (7.5)
Lock nut on intermediate-shaftflange
M8xI
13 (9.5)
Screwplug for piston pin assemblybore of cylinder bank 4 -6
M27x 2
80 (59)
M6
10(7.5)
Bolt for slide rail Belt pulleyto crankshaft Initialtightening: Finaltightening:
M16 x 15 50 (37) 1 x 900
Thrustplate to double-massflywheel
M8
Drive plate to crankshaft(Tiptronic) Initialtightening: Finaltightening:
MID x 1 x 25 (12.9)
23 (17) 25 (18) 1 x 900
Coolantpump to crankcase
M6
10(7.5)
Chaintensioner to crankcase
M27 x 2
80 (59)
MID
60(44)
Belttensioner roller to lever for tensioningelement Belt deflection roller 1 to crankcase
MID x 145 (B.B.)
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Engine
Location
Thread
Tightening torque Nm (ftlb.)
Belt deflection roller 2 to bracket for hydraulic
23 (17)
pump
Belt pulleyto generator Belt pulleyto hydraulicpump Cylinderhead to crankcase 1 st step Completelyundone 2nd step 3rd step 4th step
M16 x 1.5
65:1:5(48:1:3.5)
M8 x 12
23 (17)
MI0 x 230 30 (22) 600 torque angle 600 torque angle again
Flat-basetappet housingto cylinder head
M6
10 (7.5)
Camshaftbearing saddlesto cylinder head
M6
10(7.5)
Cylinder-headcover to cylinder head
M6
13(9.5)
M14 x 1.25
30+3 (22+2) first fitting 25+5 (18+3.5) re-fitting
M6 x 15 (10.9)
14(10)
M27x2
80 (59)
Spark plugs Camshaftdrive wheel and drive plate to camshaft Chaintensioner to cylinder head
10 (7.5)
M6 (micro-encapsulated)
Intake pipe to cylinder head Plug, oil-pressureduct to cylinder head Oil extraction pump to cylinder head Oil-levelsender to crankcase Oxygensensor to catalytic converter Knock sensor
10(7.5)
MID xl M6
10 (7.5)
M14 x 1.25
max. 20 (15)
M18
55:t5 (41:t3.5)
M8
20:t2 (15:tl.5)
10(7.5)
M6(micro-encapsulated)
Hall-effectsensor
M6
10(7.5)
NTC coolanttemperature sensor
M14x 1.5
25:t5 (18:t3.5)
Oil pressure switch
M14x 1.5
2O::t5 (15:t3.5)
Starter
MID
45 (33)
Generator
MID
45 (33)
Ignition coil to cylinder head
M6
10(7.5)
Power steering pump to bracket
M8
23 (17)
Pressurepipe of hydraulicpump
M16
24 (18)
Oil supply tank to hydraulicpump
M8
23 (17)
M22x 1.5
32 (24)
M6
10 (7.5)
Speed sender
Checkvalve for auxiliaryair injection Coolantpump to crankcase
Purchased from www.WorkshopManuals.co.uk Tightening torques for engine M96j20 (2.5 I), M96j21 (3.2 I), M96j22...
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1
Engine
Technical data
Engine
14O_98
Engine type:
M 96/20
Number of cylinders
6
Bore
mm
85.5
Stroke
mm
72
Displacement
cm3
2480
11.0: 1
Compression ratio
Max. engine power as per 80/1269/EWG as per SAEJ 1349 at engine speed
kW HP rpm
150 201 6000
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Max. torque as per 80/1269/EWG at engine speed
Nm (ftlb.
245 (181)
rpm
4500
Max. litre output as per 80/1269/EWG
kW/I,HP/I
60.48/82.26
Idle speed -manual transmission Tiptronic sel. lever in P or N Tiptronic sel. lever in drive position and A/C on Rpm limitation at
rpm rpm rpm rpm rpm
790 750 790 800 6700
Engine weight Manualtransmission Tiptronic transmission
kg kg
182.2 172.7
Boxster
Valvecontrol
DOHCwith camshaft adjustment(VarioCam)
Valve arrangementper cylinder
2 inlet,2 outlet,suspendedparallelV-arrangement
Valve clearance
Hydraulicvalve clearance compensation
Valve timing with 1 mm valve travel
Inlet opens 150 after TOC Inlet closes 460 after BOC Outlet opens 380 before BOC Outletcloses 70 before TOC
Engine cooling Type
Liquid cooling,two electric fans
Engine lubrication
Integrated dry sump
Oil cooling
Via oil-water heat exchanger
Oil pressure at 5000 rpm Oil temperature 90 °c
bar
approx.5
Oil consumption
1/1000 km
up to 1.5
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