Porsche Boxster Service Manual: 1997-2001

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A B C D E F G H I J K L M N O P Q R S T U V W X Y Z

A

Abbreviations and acronyms
 97-5
ABS (antilock brakes)
 see Antilock brakes (ABS)
 see also Brakes
 see also Porsche Stability Management (PSM)
A/C
 blower 87-8
  resistor 87-9
 capacities 87-3
 compressor 87-9
 condenser 19-16, 87-6
 control panel 87-3
 evaporator 87-6
 expansion valve 87-6
 fault detection 87-4
 housing 87-2
 pressure switch 87-6
 receiver-drier 87-6
 refrigerant 87-3
 sensor default values 87-4
 troubleshooting 87-4
 vent flaps and motors 87-2, 87-6
 see also Heater
Accelerator linkage
 10-9, 10-13
Aerodynamic lift
 02-15
Air-conditioning
 see A/C
 see also Heater
Air filter
 replacing 03-28
Airbag system (SRS)
 02-18
 control module 69-3, 69-8
 crash sensor 69-8, 69-9
 deployment 69-2
 driver airbag 69-10
  contact spring 69-11
 inspecting 03-33
 passenger airbag 69-3, 69-13
 replacement recommendations 69-4
 seat occupancy sensor 69-3
 side impact (door) airbag 69-14
 smart 69-3
 warning light 69-2
Air flow flap
 87-2, 87-6
Air flow sensor
 24-12
Alarm
 96-7
 see also Anti-theft system
Alignment
 44-2
Alternator (generator)
 27-10
 charging system 27-10
 troubleshooting 27-2, 27-10
Amplifier
 91-5
Antenna
 91-3, 91-4
Anti-theft system
 components 96-4
 with alarm 96-6
 without alarm 96-5
Antifreeze (engine coolant)
 03-14, 19-1
Antilock brakes (ABS)
 ABS 5.3 45-3
 ABS/TC 5.3 45-4
 hydraulic unit / control module 45-8
 identification 45-2
 PSM 45-5
 see also Brakes
 see also Porsche Stability Management (PSM)
ATF (automatic transmission fluid)
 03-19, 37-4
Automatic transmission
 applications 02-13, 37-1
 control module pin assignments, 37-3
 electrical components 37-2
 fluid 03-19, 37-4
  cooler 19-2
 gear position switch 37-16
 gear ratios 37-2
 identification plate 37-1
 removing / installing 37-7
 shift knob 37-15
 shift cable 37-15
 torque converter 32-1
Axle joint
 03-32, 42-15

B

B-pillar trim
 70-6
Back-up light switch
 automatic transmission 37-16
 manual transmission 34-14
Battery
 charging 27-5
 disconnection notes 27-1
 maintenance 03-34
 removing / installing 27-4
 service 03-34
 testing 27-6
 troubleshooting 27-2
Bearing, wheel
 front 40-9
 rear 42-11
Belt, drive
 03-27, 13-3
Blade, wiper
 92-2
Blower
 see A/C
Board computer
 90-3, 90-4, 90-7, 91-7
Body
 02-15, 02-24, 02-25
 dimensions 02-16
Brake fluid
 03-14, 47-2
Brake light switch
 94-6
Brakes
 02-23
 bleeding 47-3
 booster 47-6
 caliper 47-6
 fluid 03-15, 47-2
 master cylinder 47-5
 pads 03-30, 46-2
 parking brake 03-38, 46-5
 rotor 03-30, 46-3
 troubleshooting 47-1
 see also Antilock brakes (ABS)
Bridge points (BS)
 EWD-6
Bulb applications
 exterior 94-4
 instrument 90-9
 interior 96-1
Bumper
 front 63-2
 rear 63-5

C

Caliper, brake
 47-6
Camber
 44-2
Camshaft sensor
 24-2, 28-3
Camshaft timing chain
 02-5, 02-28
Capacities, fluid
 A/C system 87-3
 automatic transmission 37-4
 coolant 19-1
 differential 03-19
 manual transmission 03-18
 oil 17-1
Carbon canister, activated
 24-5
Caster
 44-3
Catalytic converter
 02-11, 02-22, 26-3
 diagnostic monitor 24-23
Cautions
 00-2
CD changer
 91-3
Center brake light
 94-12
Center console
 70-5
Central locking
 96-8
Charging system
 27-10
Check Engine light
 02-10, 03-11, 24-3, 24-21
Climate control
 see A/C
 see also Heater
Clock
 90-6
Clutch
 bleeding 30-6
 checking 03-36
 fluid 03-15, 30-5
 hydraulics 30-5
 interlock switch 30-5
 mechanical 30-3
 replacing 30-2
 throw-out bearing 30-2, 30-4
 troubleshooting 30-2
Codes, fault
 24-22
Coil
 28-4
Coil spring
 see Front suspension
 see also Rear suspension, strut assembly
Communication
 components 91-1
Component locations
 97-4
Compressor
 87-9
Condenser
 19-16, 87-6
Constant velocity (CV) joint
 03-32, 42-15
Control arm
 40-3
Convertible top
 02-17, 02-24
 components 61-1
 emergency closing 61-4
 service 61-7
 service position 03-24
 troubleshooting 61-5
Coolant (antifreeze)
 03-14, 19-1
 hydrometer 19-2
Coolant pump
 19-7
Cooling system
 antifreeze 03-14, 19-1
 automatic transmission fluid cooler 19-2
 bleeding 19-5
 coolant pump 19-2, 19-7
 cooling fans 19-13
 draining and filling 19-5
 engine oil cooler 17-4
 flushing 19-4
 leak test 19-3
 radiator 19-15
 radiator air inlet duct 03-29
 reservoir 19-10
 thermostat 19-9
 troubleshooting 19-3
 see also Heater
 see also Maintenance
Crankshaft seals
 13-4
Crankshaft sensor
 24-2, 28-4
Crash sensor
 front 69-8
 side impact 69-9
Cruise control
 switch 48-3
CV joint
 03-32, 42-15
Cylinder head cover
 15-2

D

Dashboard
 70-1
Deck lid
 see Trunk lid
Diagnosis system
 03-11, 24-21
Diagnostic monitors
 24-23
Diagnostic trouble code (DTC)
 03-11, 24-26
 DME M 5.2.2 24-27
 DME M 7.2 24-34
 P-codes 24-27
Differential oil
 03-19
DME (digital motor electronics)
 02-22, 02-26, 02-29
 adaptation 24-6
 applications 02-8, 24-1
 camshaft sensor 24-2
 crankshaft sensor 24-2
 engine coolant temperature (ECT) sensor 24-8
 evaporative control system 02-19,
24-5, 24-24
 FIO (fuel injector / ignition coil / oxygen sensor heater) relay 24-7
 main relay 20-1, 24-8
 mass air flow sensor 24-12
 MIL 03-11, 24-21
 overview 02-9
 oxygen sensor 26-4
 secondary air injection 02-11, 24-4, 24-24
 system overview 02-8, 24-3
 see also Engine control module (ECM)
 see also Engine management
 see also Fuel injector
 see also Fuel pressure
 see also Fuel pump
 see also Ignition system
Dome light
 96-2
Door
 57-1
 check strap, lubricating 03-36
 lock 57-6
 panel 57-3
 window
  see Door window
Door glass
 see Door window
Door lock
 57-6
Door sill trim
 70-6
Door window
 adjusting 64-5
 controls 64-3
 drop-down feature 64-2
 glass 64-4
 motor 64-9
 regulator 64-10
 standardization 64-9
Drains
 50-4
Drive axle
 42-15
Drive belt
 03-27
Drive cycle
 24-25
DTC (diagnostic trouble code)
 see Diagnostic trouble code (DTC)

E

ECM
 see Engine control module (ECM)
ECT
 24-8
Electrical components
 97-4
Electric cooling fan
 19-13
Electrical switches
 see Switches
Electrical system
 abbreviations and acronyms EWD-5
 battery disconnection notes 27-1
 component location table 97-4
 component photos 97-14
 engine 27-1
 terminal designations EWD-4
 troubleshooting 97-38
 wire color codes EWD-2
Electrical wiring diagrams
 EWD-9
Electronic immobilizer
 96-7, 96-10, 96-10
Emblems
 66-7
Emergency brake
 see Parking brake
Emergency flasher
 94-6
Engine
 02-25
 applications 02-3
 components 02-3
 crankshaft seal
  pulley seal 13-4
  rear main seal 13-5
 displacement 02-21
 drive belt 03-27, 13-3
 engine coolant temperature (ECT) sensor 24-8
 grounds 97-30
 management
  see DME (digital motor electronics)
 mount 10-16
 oil 17-1
 oil cooler 17-4
 on-board diagnostics 24-21
 pulley system 13-1
 removing / installing 10-1
 speed sensor
  see Crankshaft sensor
 see also Cooling system
 see also DME (digital motor electronics)
 see also Engine control module (ECM)
 see also Exhaust system
 see also Ignition system
 see also Lubrication system
Engine compartment blower
 19-13
Engine compartment vent
 66-6
Engine control module (ECM)
 24-12
 pin assignments
  DME M 5.2.2 24-13
  DME ME 7.2 24-15
  DME ME 7.8 24-18
Engine coolant temperature (ECT) sensor
 24-8
Engine cooling fan
 19-13
Engine covers
 front cover 03-26
 top cover 03-26
Engine management
 see DME (digital motor electronics)
Evaporative control system
 24-5
 diagnostic monitor 24-24
Evaporator
 87-6
Exhaust manifold
 26-1
Exhaust system
 02-11, 02-22
 catalytic converter 02-11, 02-22, 26-1, 26-3, 26-4
 checking 03-33
 diagrams 26-7
 manifold 26-1, 26-7, 26-8
 oxygen sensor 26-4
Expansion valve
 87-6
Exterior lights
 see Lights

F

Fan
 A/C blower 87-8
 engine compartment blower 19-13
 engine cooling fans 19-13
Fault code
 03-11
 see also Diagnostic trouble code (DTC)
Fault memory
 03-11
Fender
 front 50-2
Filters
 air 03-31
 fuel 03-31
 oil 03-12
 ventilation microfilter 03-34
Firing order
 28-1
Fluids and lubricants
 03-11
 see also Capacities, fluid
Flywheel, dual-mass
 30-1
Foglight
 94-10
Front oil seal
 13-4
Front suspension
 02-27
 coil spring applications 40-6
 components 40-2
 control arm 40-3
 ride height 44-3
 strut assembly 40-5
 sway bar 40-4
 wheel bearing 40-9
Fuel filter
 03-31, 20-2
Fuel injection
 02-9
 see also DME (digital motor electronics)
 see also Fuel injector
Fuel injector
 02-10, 24-10
 relay 24-7
Fuel level sender
 20-1
 see also Fuel pump
Fuel pressure
 operating fuel pump for tests 20-3
 pressure test 20-4
 regulator
  1997- 2001 24-10
  2002 - 2004 20-2
 relieving pressure 20-3
 testing 20-3
 volume 20-4
 see also Fuel pump
Fuel pump
 1997 - 2001 20-1
 2002 - 2004 20-2
 fuse and relay 20-1
 removing / installing 20-7
 troubleshooting 20-3
Fuel system
 20-1
 diagnostic monitor 24-24
Fuel tank
 draining 20-5
 filler flap 50-2
Fuel trim
 see DME (digital motor electronics), adaptation
Fuses
 97-10, 97-20

G

Gearshift knob
 automatic transmission 37-15
 manual transmission 34-14
Generator
 see Alternator (generator)
Glove compartment
 02-31
Grounds
 97-12, 97-30

H

Hand brake
 see Parking brake
Handle, door
 57-6
Hard top
 02-17
Hazard warning switch
 94-6
Headlight
 02-18, 02-20
 adjusting 94-7
 assembly 94-8
 replacing bulb 94-9
Heater
 components 80-1
 core 80-3
 troubleshooting 80-2
 see also A/C
 see also Cooling system
Hood
 see Trunk lid
Horn
 90-10
 alarm horn 96-4

I

Ignition lock cylinder
 48-5
Ignition electrical switch
 48-5
Ignition system
 02-12
 camshaft sensor 24-2, 28-3
 checking for spark 28-3
 coil 28-4
  relay 24-7
 crankshaft sensor 24-2, 28-4
 disabling 28-2
 firing order 28-1
 knock sensor 24-2, 28-5
 spark plugs 03-30
Immobilizer, electronic
 96-7, 96-10, 96-12
Injector
 see Fuel injector
Instruments
 02-26
 bulbs 90-9
 repairs 90-8
 versions 90-2
Interior
 02-25
 differences between Boxster and Boxster S 02-24
Interior lights
 checking 03-38
 see also Lights
Intermittent wiper switch
 92-4

K

Key
 96-6
Keyless entry
 02-25, 96-6
Knock sensor
 24-2, 28-5

L

Level sender, fuel
 20-1
License plate light
 94-13
Lights
 bulb applications
  exterior 94-4
  instrument 90-9
  interior 96-1
 controls 94-5
 interior 96-1
 repairs
  front 94-7
  rear 94-12
Litronic
 02-20
 see also Headlight
Locks
 door 57-6
 central locking 96-8
 trunk lid release 55-6
Lubrication system
 17-2
 air-oil separator 17-3
 oil cooler 17-2, 17-4
 oil filter 17-2
 oil level sensor 17-3
 oil pumps 15-7, 17-2
Luggage compartment lid
 see Trunk lid

M

M option codes
 see Option codes
Maintenance
 airbags, inspecting 03-33
 alignment 03-40, 44-2
 antifreeze 03-14, 19-1
 automatic transmission fluid 03-19, 37-4
 battery 03-34
 body exterior 03-35
 brake fluid 03-14, 47-2
 brake pads / rotors 03-30, 46-2
 clutch, checking 03-36
 coolant hoses 03-29
 coolant level 03-14
 CV joint boot, inspecting 03-32
 differential oil 03-19
 door check straps, hinges, lubricating 03-36
 door locks, checking 03-36
 drive belt 03-27, 13-3
 exhaust system, checking 03-33
 exterior lights, checking 03-37
 filters
  air 03-31
  fuel 03-31
  oil 03-12
 fluids and lubricants 03-11
see also Capacities, fluid
 front lid safety hooks, checking 03-36
 headlights, adjusting 03-38
 interior lights, checking 03-38
 manual transmission fluid 03-16
 oil 03-11
 parking brake 03-38, 46-5
 power steering fluid 03-16
 radiator air inlet duct 03-29
 seat belts, checking 03-39
 spark plugs 03-30
 suspension and steering components, checking 03-33
 tables 03-7
 test drive 03-41
 tires 03-40
 trunk lid locks, checking 03-36
 ventilation microfilter 03-34
 wipers and washers 03-24
Malfunction indicator light (MIL)
 03-11, 24-3, 24-21
Manifold, exhaust
 26-1, 26-7, 26-8
Manual transmission
 applications 02-12 , 34-1
 code stamp 34-2
 fluid 03-17
 identification label 34-2
 pilot bearing 30-4
 removing / installing
  5-speed 34-2
  6-speed 34-8
 shift knob 34-14
Mass air flow (MAF) sensor
 24-12
Master cylinder
 brake 47-5
 clutch 30-7
MIL (malfunction indication light)
 03-11, 24-3, 24-21
Mirror, outside rear view
 02-25, 66-1
Misfire
 diagnostic monitor 24-23
Model year news
 02-19
M-option codes
 02-33, EWD-7
MOST-bus
 02-31, 91-2, 91-9
MRS (multiple restraint system)
 69-1
Muffler
 26-2

N

Navigation
 91-8
Neutral safety switch
 see Automatic transmission, gear position switch

O

OBD (on-board diagnostics)
 03-11, 24-12
Oil cooler
 17-4
Oil level
 checking 03-11
 sensor 17-3
Oil pumps
 15-7, 17-2
Oil service
 03-12
On-board computer
 90-3, 90-4, 90-7, 91-7
On-board diagnostics (OBD)
 03-11, 24-21
Option codes
 02-33, EWD-7
Outside door handle
 57-6
Outside mirror switch
 66-1
Oxygen sensor
 26-4
 diagnostic monitor 24-23
 heater relay 24-7
  LSF 02-29

P

P-codes
 24-27
Pads, brake
 03-30, 46-2
Parking assistant
 02-20, 91-2
Parking brake
 03-38, 46-5
Parts
 03-5
Passenger compartment monitor
 96-10
PCM
 91-1, 91-8
Pilot bearing
 30-4
Porsche Communications Management (PCM)
 02-20, 02-26, 02-32, 91-1, 91-8
Porsche Stability Management (PSM)
 02-25, 02-27, 45-5
 precharge pump 45-5, 45-6, 45-10
 rotational rate sensor 45-5, 45-7,
45-11
 steering angle sensor 45-5, 45-7
 see also Antilock brakes (ABS)
 see also Brakes
Power mirror
 66-1
Power steering
 see Steering
Power window
 see Door window
Precharge pump
 45-5, 45-6, 45-10
PSM
 see Porsche Stability Management (PSM)
Pulley system
 130-1

R

Radiator
 19-15
Radiator cooling fans
 19-13
Radio
 91-4
Rain sensor
 92-1
Raising car safely
 03-2
Readiness codes
 24-25
Rear main seal
 13-5
Rear spoiler
 66-4
Rear suspension
 components 42-2
 control arms 42-9
 reinforcement plate 02-14
 ride height 44-3
 strut assembly 42-3
 sway bar 42-8
 track arm 42-9
 trailing arm 42-10
 wheel bearing 42-11
Rear window
 02-29
Receiver-drier
 87-6
Recirculation switch
 87-1
Refrigerant
 87-3
Relays
 97-11, 97-29
Reversing light switch
 see Back-up light switch
Ride height
 44-3
Roll bar
 02-17
Rotational rate sensor
 45-5, 45-7, 45-11
Rotor, brake
 checking 03-30
 replacing 46-1

S

Safety
 03-2
Scan tool
 24-22
Seal, crankshaft
 13-4
Seat
 02-25, 72-1
Seat belt
 02-27, 69-1, 69-5
 checking 03-39
Seat occupancy sensor
 69-3
Secondary air injection
 02-11, 24-4
 diagnostic monitoring 24-24
Shift knob
 automatic transmission 37-15
 manual transmission 34-14
Side impact (door) airbag
 69-14
Side turn signal light
 94-11
Siren
 96-4
Slave cylinder
 30-7
Sound system
 02-20, 02-21, 02-26, 02-28, 02-32,
91-3
Spark plug
 03-30
 well 15-8
Speakers
 91-6
Special Edition
 02-32
Speed sensor, wheel
 45-7
Spoiler, rear
 02-30, 66-4
Spring, coil
 see Front suspension
 see also Rear suspension, strut assembly
SRS (supplemental restraint system)
 see Airbag system (SRS)
Stabilizer bar
 see Sway bar
Starter
 27-8
 interlock switch 27-8, 30-5
 removing / installing 27-9
 troubleshooting 27-2, 27-8
Steering
 column covers 48-4
 column stalk switch 48-3
 fluid 03-16, 48-9
 fluid lines 48-13
 ignition lock 48-5
 pump 48-10
 rack 48-7
 wheel 48-2
 tie rod 48-6
Steering angle sensor
 45-5, 45-7
Stop light switch
 see Brake light switch
Strut
 front 40-5
 rear 42-3
Suspension
 see Front suspension
 see also Rear suspension
Sway bar
 front 40-4
 rear 42-8
Switches
 A/C 87-1
 back-up light
  automatic transmission 37-16
  manual transmission 34-14
 brake light 94-6
 clutch interlock 30-5
 convertible top 61-3
 cruise control 48-3
 hazard warning 94-6
 high beam 48-3
 ignition
  cylinder 48-5
  electrical switch 48-5
 light 94-5
 outside mirror 66-1
 pedal cluster 30-5, 94-6
 steering column stalk 48-3
 turn signal 48-3
 window 64-3
 wiper / washer 48-3
 see also Back-up light switch

T

Taillights
 94-12
TC (traction control)
 see Antilock brakes
 see also Porsche Stability management (PSM)
Test drive
 03-41
Thermostat
 19-9
Throw-out bearing
 30-2, 30-4
Tie rod
 48-6
Tightening fasteners
 03-4
 torques 03-5
Tiptronic
 control module pin assignments 37-3
 see also Automatic transmission
Tires
 44-1
 service 03-40
Toe
 44-3
Tools
 03-6
Torque converter
 32-1
Traction control (TC)
 see Antilock brakes
 see also Porsche Stability Management (PSM)
Transmission
 02-12, 02-23, 02-27
 mount 10-17
 see also Automatic transmission
 see also Manual transmission
Trim, interior
 B-pillar trim 70-6
 Center console 70-5
 Dashboard 70-1
 Doors panel 57-3
 Door sill trim 70-6
 Steering column covers 48-4
Trunk lid
 emergency release 02-27, 02-31,
55-1
 front 55-3
  components 55-2
  safety hooks, checking 03-36
  struts 55-3
 rear 55-4
  components 55-4
  struts 55-5
 release (latch) 55-6
Turn signal switch
 48-3

V

Vacuum booster
 47-6
VarioCam
 02-6, 02-28, 15-3
Vehicle identification number (VIN)
 01-1, 03-6
Vent flaps and motors
 87-2, 87-6
Ventilation microfilter
 replacing 03-34
Voltage tests
 97-38

W

Warnings
 00-1
Washer
 92-9
 see also Wiper
Washing
 03-35
Water drains
 50-4
Water pump
 19-2, 19-7
Waxing
 03-35
Wheel, steering
 48-2
Wheel alignment
 44-2
 ride height 44-3
Wheel bearing
 front 40-9
 rear 42-10
Wheel housing liner, front
 50-1
Wheel speed sensor
 45-7
Wheels
 44-1
Window
 see Door window
Wiper
 92-2
 checking 03-24
 fluid 03-24
 switch
  see Steering, column stalk switch
 see also Washer
Wiring
 color codes EWD-2
 diagrams EWD-9
 sample EWD-3
Working under car safely
 03-3

X

X-connectors
 EWD-8