2002 porsche boxster 986 service repair manual

TechnicalManual
-~~.s:TLr
TechnicalInformation
Contents:
Group 1
Engine
Part 1 (up to Repair Group 13)
WKD483 521 19
www.WorkshopManuals.co.uk
Purchased from www.WorkshopManuals.co.uk

Overview of repair groups
Boxster
0
03
Group 0: Entire vehicle -General
Maintenance
0
01
03
24
37
45
Group 0: Diagnosis
Salescheck
On-boarddiagnosis
DMEdiagnosis
Tiptronic diagnosis
ABSdiagnosis
0
69
72
80
90
91
91
94
Group 0: Diagnosis
Airbag diagnosis
Seatmemorydiagnosis
Heatingdiagnosis
Alarm system diagnosis
PCMdiagnosis
ParkAssistent
diagnosis
HBAdiagnosis
1
10
13
Group 1: Engine
Engine-Crankcase, suspension
Engine-Crankshaft, pistons
1
15
17
19
Group 1: Engine
Engine-Cylinder head,valve drive
Engine-Lubrication
Engine-Cooling
2
20
21
24
25
26
27
28
Group 2: Fuel, exhaust, engine electronics
Fuelsupply,control
Exhaustsystem, turbocharging
Fuelsystem,electronic injection
Fuelsystem, K-Jetronic
Exhaustsystem
Starter, powersupply, cruise control
Ignitionsystem
3
30
34
35
39
Group 3: Transmission, manual transmission
Clutch, control
Manual transmission -Actuation, housing
Manual transmission -Gears, shafts, into gearsh,
Final drive, differential, differential lock
3
32
37
38
39
Group 3: Transmission, automatic transmission
Torqueconverter
Automatictransmission-Actuation, housing
Automatictransmission-Gears, control
Finaldrive, differential,differentiallock

Boxster
4
40
42
44
45
46
47
48
Group 4: Running gear
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
5
50
51
53
55
57
Group 5: Body
Bodyfront
Bodycenter,roof,frame
Bodyrear
Lids,flaps
Doorfront,centrallockingsystem
6
60
61
63
64
66
68
69
Group 6: Body equipment, exterior
Slidingroof
Convertible
top, hardtop
Bumpers
Glazing,
window
control
Exteriorequipment
Interiorequipment
Passenger
protection
7
70
72
74
Group 7: Body equipment, interior
Linings,
insulation
Seatframes
Seatupholsteries,
covers
8
80
85
87
88
Group 8: Air conditioning
Heating
Ventilation
Air conditioning
Auxiliary
air conditioning
system
9
90
91
92
94
96
Group 9 Electrics
Instruments,alarm system
Radio,telephone,on-boardcomputer, navigation
Windshield
wiper and washersystem
Lights, lamps,switchesexterior
Lights, lamps,switches interior, theft protection
9
97
Group9: Circuit diagrams
Wiring (up to and including the '99 model)
9
97
Group9: Circuit diagrams
Wiring (from the '00 model)
d in Germany -34, October 1999

Engine, part 1 (up to Repair Group 13)
Boxster
Table of Contents
1 Engine, part 1 (up to Repair Group 13)
1
1
1
Engine
Teoonical data engine M96/20
Differences between Boxster 2.5 I, 2.71 and Boxster S (3.2 I) engines
Tightening torques for engine M96/20 (2.5 I), M96/21 (3.2 I), M96/22 (2.7 I)
1
1-01
1-05
1-1 page
10
100121 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
1001 23
100137
105037
10 1037
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
100121
100123
100121
Engine -Crankcase, suspension
Removing engine, M96/20 (2.51) with manual transmission
Special tools
Adjusting tool
Removing engine .,..",., ,.".,.".".,.".",.".",.",."""
Installing engine, M96/20 (2.5 I) with manual transmission
Special tools.
Adjusting tool
Special notes
Installing engine...
Tighteningtorques
Disassembling and assembling engine
Disassembling and assembling positive crankcase ventilation.
Disassembling and assembling crankcase halves, engine M96/20, M96/21,
M96/22 Mounting instructions ,
Assembling the crankcase halves
Tighteningtorques
Removing engine, M96/20 (2.5 I) with Tiptronic transmission
Special tools..
Adjusting tool ,
Removing engine
Installing engine, M96/20 (2.5 I) with Tiptronic transmission
Special tools...
Adjusting tool
Special notes
Installing engine
Tighteningtorques
Removing engine, M96/21 (3.21) and M96/22 (2.7 I) with manual transmission
Special tools.
Adjusting tool
Removing engine
Installing engine, M96/21 (3.2 I) and M96/22 (2.7 I) with manual transmission
Special
tools.
1001 231
Table of Contents

Engine, part 1 (up to Repair Group 13) Boxster
10-73 page 3
10-73 page 5
10-73 page 5
10-73 page 20
10-87 page 1
Adjustingtool
Special notes
Installing engine
Tighteningtorques ,
Disassembling and assembling engine carrier
103037
13
137819
137720
138219
137319
137337
134937
134819
131019
137419
135919
131019
131019
13-1
13-4a
13-4c
13-4e
13-40
13-5
13-19
13-23
13-41
13-47
13-49
13-77
Engine -Crankshaft, pistons
Removing and installing drive belt
Removing and installing deflection rollers for drive belt
Removing and installing tensioning roller for drive belt...
Removing and installing belttensioner
Disassembling and assembling belt tensioner
Disassembling and assembling bearing housing with crankshaft.
Removing and installing crankshaft
Removing and installing pistons
Removing and installing crankshaft sealing ring (engine installed)
Removing and installing crankshaft sealing ring (engine installed)
Removing and installing pistons -Boxster S
Removing and installing pistons for engine type M96/22 (2.7 I)
Table of Contents

Boxster Engine
Tighteningtorquesfor engineM96/20 (2.51), M96/21 (3.21), M96/22 (2.7
I)
20 (15)
1 x 900
M9x 1.25
20 (15)
1 x 900
M9x 1.25
20 (15)
1 x 1100
10
10
22
22
10
10
10
50
25:f:1
45
10
13
80
M6 (micro-encapsulated)
M6
M9 x 150
M9x 94
M6
M6
M6
M18 x 1.5
S80 x 3
MI0
M8xI
M27x 2
10(7.5)
M6
M16 x 15
50 (37)
1 x 900
23 (17)
M8
MIDx 1 x 25 (12.9)
25 (18)
1 x 900
10(7.5)
80 (59)
60(44)
M6
M27x 2
MID
46 (34)
Screws,bearinghousing
Initialtightening:
Finaltightening:
Connecting-rod
screwswith connecting-roddesig-
nation...7R
Initialtightening:
Finaltightening:
Connecting-rodscrewswith connecting-roddesig-
nation...7R
Initialtightening:
Finaltightening:
Oilguideto bearinghousing
Screws,crankcasehalves
Additionalbolts
Crankcase/bearinghousing
Oilsuctionpipeto crankcase
Air/oil separatorto crankcase
Oilpanto crankcase
Oildrainplugto oil pan
Oilfilter to crankcase
Coolantguidehousingto crankcase
Intermediate-shaft
flange
Lock nuton intermediate-shaft
flange
Screwplugfor piston pin assemblybore of cylin-
der bank 4 -6
Boltfor sliderail
Beltpulleyto crankshaft
Initialtightening:
Finaltightening:
Thrustplateto double-mass
flywheel
Driveplateto crankshaft(Tiptronic)
Initialtightening:
Finaltightening:
Coolantpumpto crankcase
Chaintensionerto crankcase
Belttensionerrollerto leverfor tensioningele-
ment
Beltdeflectionroller 1 to crankcase MID x 145 (B.B.)
(7.5)
(7.5)
(16)
(16)
(7.5)(7.5)
(7.5)
(37)
(19:t1)
(33)
(7.5)
(9.5)
(59)

Engine Boxster
Location Thread Tightening torque Nm (ftlb.)
23 (17)
M16 x 1.5
M8 x 12
MI0 x 230
65:1:5
(48:1:3.5)
23 (17)
30 (22)
600 torque angle
600 torque angle again
M6
M6
M6
M14x 1.25
Beltdeflectionroller 2 to bracketfor hydraulic
pump
Beltpulleyto generator
Beltpulleyto hydraulicpump
Cylinderheadto crankcase
1st step
Completelyundone
2nd step
3rd step
4th step
Flat-basetappethousingto cylinderhead
Camshaftbearingsaddlesto cylinderhead
Cylinder-head
coverto cylinderhead
Sparkplugs
M6x 15 (10.9)
M27x2
MID xl
M6
M14x 1.25
M18
M8
Camshaftdrivewheelanddrive plateto camshaft
Chaintensionerto cylinderhead
Intakepipeto cylinderhead
Plug, oil-pressureductto cylinderhead
Oilextractionpumpto cylinderhead
Oil-levelsenderto crankcase
Oxygensensorto catalyticconverter
Knocksensor
Hall-effectsensor
Speedsender
NTCcoolanttemperaturesensor
Oilpressureswitch
Starter
Generator
Ignitioncoil to cylinderhead
Powersteeringpumpto bracket
Pressurepipe of hydraulicpump
Oilsupplytankto hydraulicpump
Checkvalvefor auxiliaryair injection
Coolantpumpto crankcase
10(7.5)
10(7.5)
13(9.5)
30+3 (22+2) first fitting
25+5 (18+3.5) re-fitting
14(10)
80 (59)
10(7.5)
10(7.5)
10 (7.5)
max. 20 (15)
55:t5 (41:t3.5)
20:t2 (15:tl.5)
10(7.5)
10(7.5)
25:t5 (18:t3.5)
2O::t5(15:t3.5)
45 (33)
45 (33)
10(7.5)
23 (17)
24 (18)
23 (17)
32 (24)
10 (7.5)
M6(micro-encapsulated)
M6
M14x 1.5
M14x 1.5
MID
MID
M6
M8
M16
M8
M22x 1.5
M6
Tightening torques for engine M96j20 (2.5 I), M96j21 (3.2 I), M96j22...

Engine
Boxster
1 Technical data
Engine
14O_98
M 96/20
Engine type:
6
Number of cylinders
85.5
Bore mm
72
Stroke mm
cm3 2480
Displacement
11.0: 1
Compression ratio
Max.enginepower
as per 80/1269/EWG
as per SAEJ 1349
at enginespeed
kW
HP
rpm
150
201
6000

Engine Boxster
Max.torque
as per 80/1269/EWG
at enginespeed
Nm(ftlb.
rpm
245 (181)
4500
Max. litre output
as per 80/1269/EWG kW/I,
HP/I 60.48/82.26
790
750
790
800
6700
Idle speed-manual transmission rpm
Tiptronic sel. lever in P or N rpm
Tiptronicsel. lever in drive position rpm
andA/C on rpm
Rpmlimitation at rpm
Engineweight
Manualtransmission
Tiptronictransmission
kg
kg
182.2
172.7
Valvecontrol DOHCwith camshaftadjustment(VarioCam)
Valvearrangementper cylinder 2 inlet,2 outlet,suspended
parallelV-arrangement
Valveclearance Hydraulicvalveclearancecompensation
Valve timing with 1 mm valve travel Inletopens 150after TOC
Inletcloses 460after BOC
Outletopens380before BOC
Outletcloses 70before TOC
Engine cooling
Type Liquidcooling,two electric fans
Engine lubrication Integrated dry sump
Oil cooling Viaoil-waterheatexchanger
Oil pressure at 5000 rpm
Oiltemperature90 °c approx.5
bar
1/1000 km up to 1.5
Oil consumption

Engine
Boxster
Fuel system DME5.22 with sequentialfuel injection
Fueldelivery 1 electr. fuel pump
Systempressure withoutvacuum bar 3.6 4.0
FuelRON/MON at least 98/88
Fuel consumption
as per 93/116/EG
Manual
transmission Tiptronic
VIDDkm
VIDDkm
VIDDkm
g/km
14.3
7.1
9.7
239
15.8
8.1
10.9
263
City
Highway
Overall
Target CO2value
Emission control Oxygensensingand three-waycatalytic
converter(metallicsubstrate)
Electrical system
Nominal voltage
Alternator output
Battery, manual transmission
Battery I Tiptronic
V
W/A
Ah/A
Ah/A
12
1680/120
60/280
70/320
Ignition DME5.22, with static high-voltagedistribution
and cylinder-selective
knock regulation
Ignition sequence 1-6- 2-4-3-5
FR7 LDC4
14 FR7 LDU
0.8 + 0.1
Spark plugs
Bosch
Beru
Electrodegap mm

Boxster Engine
1 Differences betweenBoxster 2.5 I, 2.7 and Boxster S (3.2 I) engines
Foreword
The following chapter describes the main engine differences which apply to the Boxster.
Technical data
Engine
Component Unit Boxster2.5 Boxster2.7 Boxster S (3.2 I)
Enginetype M 96/20 M96/22 M 96/21
Numberofcylinders 6 6 6
85.5 85.5 93
Bore mm
Stroke 72 78 78
mm
cm3 2687 3179
2480
Cubic capacity
11.0:1 11.0:1 11.0:1
Compression ratio
KW 150 162 185
Engine
performance
6000 6400 6250
at enginespeed rpm
245 (181) 260 (192) 305 (226)
Torque Nm {ftlb,
4750 4500
at engine speed 4500
rpm
6700 7200 7200
Max.enginespeed rpm
ME 5.2 ME 7.2
E-gas
ME 7.2
E-gas
Engine control

Engine
Boxster
Tightening torques for engine M96/20
1
Crankshaft, bearing housing, crankcase
Location Thread Tightening torque
Nm Iftlb.1
Screws,bearinghousing
Initialtorque:
Finaltorque:
M9 x 127
20 (15)
1 x 900
Connecting-rod screws
Initial torque:
Final torque:
M9 x 1.25
20 (15)
1 x 900
Oilguide on
bearinghousing M6(micro-encaps.: 10 (7.5)
Screwsfor joining crankcase
halves 13 (10)
M6
M9 x 150
M9 x 94
22 (16)
22 (16)
Additionalbolts,
crankcase/bearinghousing
Oil suctionpipe to
crankcase M6 10 (7.5)
Air/oil separatorto
Oil panto
Oil drain plug
to oil pan 50 (37)
M18 x 1.5
S80x3 25 :t 1 (18:t 1)
Oilfilter to crankcase
Coolantguide housingto
crankcase 45 (33)
MID
Intermediate-shaft
flangeto
crankcase 10
(7.5)
M6(micro-encaps.:
13 (10)
M8xl
Lock nut on
intermediate-shaft flange

Thank you very much for
your reading. Please Click
Here. Then Get COMPLETE
MANUAL. NO WAITING
NOTE:
If there is no response to
click on the link above,
please download the PDF
document first and then
click on it.

Engine Boxster
Location Thread Tightening torque
Nm lftlb.1
Screwplug for piston pin mounting
bore of cylinderbank 4 -6 M27x 2 80 (59)
Boltfor slide rail M6 10
(7.5)
Pulley to
crankshaft M16 x 15
Initialtorque:
Finaltorque:
50 (37)
1 x 900
Double-mass
flywheelto
crankshaft MI0 x 1 x 50 (12.9)
Initialtorque:
Finaltorque:
25 (18)
1 x 900
Thrustplate to
double-mass
flywheel M8 23 (17)
Driveplate on crankshaft
(Tiptronic) MID x 1 x 25 (12.9)
Initialtorque:
Finaltorque:
25 (18)
1 x 900
Waterpumpto
Chaintensionerto
crankcase M27x 2 80 (59)
Belttensionerroller on lever
for tensioningelement 60 (44)
MIa
Beltdeflectionroller 1 on
crankcase MID x 145 (8.8) 46 (34)
Beltdeflectionroller 2 on
bracketfor hydraulicpump M8 x 55 23 (17)
M16 x 1.5 65 ::!:5 (48 ::!:3.5)
Belt pulley on generator
23 (17)
Belt pulley on hydraulic pump M8 x 12

Engine
Boxster
Cylinder head
Cylinderheadto crankcase
Initial tightening or
tightening to flatten
1st step
2nd step
MIO x 230
30 (22)
Cylinderhead screws completelyundone
Final tightening
1st step
2nd step
3rd step
20 (15)
60 0 turn
60 0 turn
Flat-basetappet housing
on cylinderhead M6 10 (7.5)
Camshaftbearingsaddles
on cylinder head M6 10 (7.5)
Cylinder-head
cover
on cylinderhead M6 13 (10.0)
Sparkplugs M14 x 1.25 30 (22) + 3 (2.0) first fitting
25 (19) + 5 (3.5) re-fitting
Camshaftdrive pinionand
drive plate on camshaft M6 x 15 (10.9) 14 (10.5)
Chaintensioner
on cylinderhead M27x 2 80 (59)
Intakepipe on cylinder head M6 (micr~ncaps.) 10 (7.5)
Plug,oil-pressureduct
on cylinderhead MIDx 1 10 (7.5)
Oil return pump
on cylinderhead M6 10(7.5)

Engine Boxster
Sensors,sending units, switches and ancillaries
Oil~evel
sender
on crankcase M14 x 1.25 max. 20 (15)
Oxygensensor on
catalytic converter MI8 55 ::!:5 (41 ::!:3.5)
Knocksensor M8 20:!: 2 (15:!: 1.5)
Hallsender M6 (micro-encaps.) 10:t 0.5(7.5:t 0.5
Speedsender M6 10:t 0.5 (7.5:t 0.5)
NTC
coolanttemperature M14 x 1.5 25 :t 5 (19:t 3.5)
Oil-pressureswitch M14x 1.5 20:t 5 (19:t 3.5)
Starter MID 45 (33)
Generator MID 45 (33)
Ignition
coiloncylinder
headcover M6 10 (7.5)
Powersteering pump
(hydraulicpump)in bracket M8 23 (17)
Pressurepipe on power
steeringpump M16 24 (18)
Oil reservoir on power
steeringpump M8 23 (17)
Checkvalvefor
auxiliaryair pump M22 x 1.5 32 (24)
Coolant pump
on crankcase M6 10 (7.5)

Boxster Engine-Crankcase,suspension
Removing engine, M96/20 (2.5 I) with manual transmission
~
~
.,
=-~
) A
Specialtools

2002 porsche boxster 986 service repair manual

Recommended

Recommended

More Related Content

What's hot

What's hot (18)

Similar to 2002 porsche boxster 986 service repair manual

Similar to 2002 porsche boxster 986 service repair manual (12)

More from fjjksekksemm

More from fjjksekksemm (20)

Recently uploaded

Recently uploaded (20)

2002 porsche boxster 986 service repair manual