1.2 Remove the 6 mounting screws (J-20 Torx) for the side storage bins.
Note:
These will be used later to mount the speakers.
1.3 Using the rotary tool with the cutoff bit, cut the epoxy holding the front of the storage bin to the storage compartment. A safety knife can be
used to cut any remaining glue away.
Caution!
The front of the storage compartment is made of very thin plastic. It is very easy to break it while removing the storage bin if all the glue is not
cut away
1.4 While depressing the side tabs, carefully move the storage bin to the rear and lift out of the storage compartment. (Figure 2)
1.5 Remove all remaining glue from the storage compartment using the rotary tool with the drum sander attachment. Install the speaker grilles
making sure that they are snapped in on both side tabs.
1.6 Glue the bottom edge of the speaker grille using the hot glue gun. Apply the glue also behind the side mounting tabs. This will keep the tabs
from spreading preventing the grille popping out.
1.7 Plug the speakers into the speaker harness. The speaker harness exits on the right side of the storage compartment. Install the speakers in the
storage compartment using 8 Torx screws (6 saved plus 2 supplied with the kit). Secure the harness with the cable clips. (Figure 3)
1.8 The storage compartment is now complete. Install it in the vehicle.
Note: If you are updating to the later style storage compartment, the old style compartment or hold down must be removed first. Install the
mounting hardware and rose in the new storage compartment before installing in the vehicle.
2. Installing the wiring harness from the radio to the speakers.
2.1 Remove the r/s rear panel, which covers the seatbelt retractor and roll bar mounting.
2.2 Remove the r/s rocker panel storage compartment and the plastic carpet support that's under it.
Showing posts with label (986). Show all posts
Showing posts with label (986). Show all posts
Wednesday, 26 August 2020
2000 Porsche Boxster (986) F6-2.7L Page 98
Filing:
Remove bulletin Group 9, # 0001, dated 9-29-00 from the Boxster Technical Manual and file this bulletin. Affix supersession decal across page
323 of Technical Bulletin Book Q.
Information:
On vehicles without rear speakers, a retrofit kit is now available to install them. They are installed in the hard plastic storage compartment behind
the seats. The addition of rear speakers will enhance stereo imaging and add the fader function to the radio. The kit can be installed in Boxsters with
either the base radio system M 441 (dashboard speakers) or optional M490 system (Harman Amplifier). The hard plastic storage compartment must
be ordered if the vehicle is not equipped with one.
On Model Years 1997-2002 the speakers are connected directly to the radio outputs regardless of options M441 or M490
On Model Years 2003 and up the speakers are connected to the radio outputs (M441) without external amplifier, or connected to the amplifier
outputs if M490 is present.
Note:
This kit will work with the Becker 210, 220, CDR 23 series radio or PCM 1 or 2.
Parts Information:
Tools:
Torx screwdriver # 20
Flat tip and Phillips screwdrivers
Diagonal cutters
Hot glue gun
Rotary tool with cut-off and drum sander attachments
Safety knife
Work Procedure:
Installation of the rear speakers and wiring harness.
1. Installing the speakers in the rear storage compartment.
1.1 Disconnect the battery. Remove the rear storage compartment and place it upside down on a work bench
Remove bulletin Group 9, # 0001, dated 9-29-00 from the Boxster Technical Manual and file this bulletin. Affix supersession decal across page
323 of Technical Bulletin Book Q.
Information:
On vehicles without rear speakers, a retrofit kit is now available to install them. They are installed in the hard plastic storage compartment behind
the seats. The addition of rear speakers will enhance stereo imaging and add the fader function to the radio. The kit can be installed in Boxsters with
either the base radio system M 441 (dashboard speakers) or optional M490 system (Harman Amplifier). The hard plastic storage compartment must
be ordered if the vehicle is not equipped with one.
On Model Years 1997-2002 the speakers are connected directly to the radio outputs regardless of options M441 or M490
On Model Years 2003 and up the speakers are connected to the radio outputs (M441) without external amplifier, or connected to the amplifier
outputs if M490 is present.
Note:
This kit will work with the Becker 210, 220, CDR 23 series radio or PCM 1 or 2.
Parts Information:
Tools:
Torx screwdriver # 20
Flat tip and Phillips screwdrivers
Diagonal cutters
Hot glue gun
Rotary tool with cut-off and drum sander attachments
Safety knife
Work Procedure:
Installation of the rear speakers and wiring harness.
1. Installing the speakers in the rear storage compartment.
1.1 Disconnect the battery. Remove the rear storage compartment and place it upside down on a work bench
2000 Porsche Boxster (986) F6-2.7L Page 97
Boxster
5/00 5517
Binder - 5, Body
2-10-00
New Microswitch For Front Lid Lock
Vehicle Type:
Boxster
Model Year:
As of 1997 (V)
Concern:
The microswitch located on the front trunk latch sticks intermittently.
Information:
In certain climatic conditions (cold or wet), the microswitch located on the bottom part of the front lid latch may stick. This could cause the
following conditions:
^ The light will not illuminate when the trunk is opened.
^ The light will not go out when the trunk is closed. This could lead to dead batteries.
^ The alarm horn will sound when locking the vehicle.
The microswitch has been installed in vehicles produced from the middle of February 2000, and can be identified by a yellow or blue paint dot on
the microswitch.
In case of complaints, the new version microswitch can be installed on earlier vehicles.
Parts Information:
Working Time:
Literature:
Boxster Technical Manual, Group 5:
Repair, 55 22 87 - Disassembling and assembling front lid
Technical Service Bulletin # 90301 Date: 030822
Audio System - Rear Speaker Retrofitting
Boxster
0301 9142
Binder - 8/9, A/C & Electrics
This bulletin replaces bulletin Group 9, # 0001, dated 9-29-00.
Date: 8-22-03
Vehicle Type:
Boxster/Boxster S
Model Year:
As of 1997 (V)
Concern:
Installation of the rear speaker kit.
5/00 5517
Binder - 5, Body
2-10-00
New Microswitch For Front Lid Lock
Vehicle Type:
Boxster
Model Year:
As of 1997 (V)
Concern:
The microswitch located on the front trunk latch sticks intermittently.
Information:
In certain climatic conditions (cold or wet), the microswitch located on the bottom part of the front lid latch may stick. This could cause the
following conditions:
^ The light will not illuminate when the trunk is opened.
^ The light will not go out when the trunk is closed. This could lead to dead batteries.
^ The alarm horn will sound when locking the vehicle.
The microswitch has been installed in vehicles produced from the middle of February 2000, and can be identified by a yellow or blue paint dot on
the microswitch.
In case of complaints, the new version microswitch can be installed on earlier vehicles.
Parts Information:
Working Time:
Literature:
Boxster Technical Manual, Group 5:
Repair, 55 22 87 - Disassembling and assembling front lid
Technical Service Bulletin # 90301 Date: 030822
Audio System - Rear Speaker Retrofitting
Boxster
0301 9142
Binder - 8/9, A/C & Electrics
This bulletin replaces bulletin Group 9, # 0001, dated 9-29-00.
Date: 8-22-03
Vehicle Type:
Boxster/Boxster S
Model Year:
As of 1997 (V)
Concern:
Installation of the rear speaker kit.
2000 Porsche Boxster (986) F6-2.7L Page 96
press the (F12) key. An OBDII preview is now displayed.
2.18 Press F5 to print.
Working Time:
Labor Operation Time Units Description
OBDII 099 30TU Complete OBDII printout with cover sheet as shown.
Submit to PC NA.
DISCLAIMERTechnical Service Bulletin # 5/00 Date: 000210
Trunk Microswitch - Sticks Intermittently
2.18 Press F5 to print.
Working Time:
Labor Operation Time Units Description
OBDII 099 30TU Complete OBDII printout with cover sheet as shown.
Submit to PC NA.
DISCLAIMERTechnical Service Bulletin # 5/00 Date: 000210
Trunk Microswitch - Sticks Intermittently
Tuesday, 25 August 2020
2000 Porsche Boxster (986) F6-2.7L Page 95
Range 1 Cylinder 1-3 (TRA)
Range 1 Cylinder 4-6 (TRA 2)
Range 2 Cylinder 1-3 (FRA)
Range 2 Cylinder 4-6 (FRA 2)
Oxygen sensing (FR)
Oxygen sensing (FR2)
Hot film MAF
Ambient pressure
When all eight of the above actual values have been selected, continue with (F12). Press F4 to "Save". Press the "Back" key (F11) twice to
return to the DME Function selection menu.
1.7 Select "Fault memory", and continue with (F12). Press F4 to save a summary of all recorded faults. Next, verify that the first recorded fault is
highlighted and then press F8. Now press F4 to "Save" the detail of the first recorded fault. Go "Back" with the (F11) key. Continue in the
same manner until all fault details have been saved.
1.8 After all faults have been saved, connect the PST2 to a compatible printer. Print the "Working log" as follows: Press the "ALT" key. From
the "Printout" menu, select "Working log". When "Working log" is highlighted, press the (F12) key. The printout will immediately follow.
1.9 Verify that the VIN printed on the printout is identical to that of the vehicle. Correct if necessary. Write the RO number and vehicle mileage
in the upper right hand corner of the first page of the printout. This will assist with vehicle information if the cover sheet is lost.
2.0 Generating an OBDII log (printout) for Boxster, 996 and 996 Turbo (ME 5.2.2, ME7.2, and ME 7.8)
2.1 Connect the keyboard and printer to the PST2.
2.2 Connect the PST2 to the vehicle. Start engine. Switch on the PST2.
2.3 Extremely Important!! Any previously stored information in the OBDII log must be deleted or it will be included with the current report.
You will be prompted to delete the OBDII log after it is selected (Step 2.7). Deleting the Working Log (F6) will not delete the OBDII log.
2.4 Note: The engine must be idling without any consumers on, and at operating temperature.
2.5 Press F5 (log button) and select OBDII log. Confirm with the (F12) button to start.
2.6 Read message and continue with (F12).
2.7 Press F8 to start the function.
2.8 You are now asked wether you want to delete the OBDII log. Select Yes (F7) then confirm with (F12).
2.9 You are now at the Warranty claim # screen. It is not necessary to input the number. Press the (F12) button to continue.
2.10 Enter the repair order number. Press the (F12) button to continue.
2.11 A control unit search will now be performed.
2.12 Enter the customer complaint, Press the (F12) button to continue.
2.13 Enter findings and fault cause (if they are known at this time). Press the (F12) button to continue.
2.14 Enter the affected / related components. Press the (F12) button to continue.
2.15 Enter fault recurrence (If the fault has come back). Press the (F12) button to continue.
2.16 The data is now determined. Press (F12) to continue.
Note:
The data is automatically saved. Do not press the save button. Doing so will save a duplicate copy in the print menu causing the report to be
printed out twice.
2.17 Print the OBDII log as follows: Press the (Print Screen) key. From the printout menu, select OBDII log. When OBDII log is highlighted,
Range 1 Cylinder 4-6 (TRA 2)
Range 2 Cylinder 1-3 (FRA)
Range 2 Cylinder 4-6 (FRA 2)
Oxygen sensing (FR)
Oxygen sensing (FR2)
Hot film MAF
Ambient pressure
When all eight of the above actual values have been selected, continue with (F12). Press F4 to "Save". Press the "Back" key (F11) twice to
return to the DME Function selection menu.
1.7 Select "Fault memory", and continue with (F12). Press F4 to save a summary of all recorded faults. Next, verify that the first recorded fault is
highlighted and then press F8. Now press F4 to "Save" the detail of the first recorded fault. Go "Back" with the (F11) key. Continue in the
same manner until all fault details have been saved.
1.8 After all faults have been saved, connect the PST2 to a compatible printer. Print the "Working log" as follows: Press the "ALT" key. From
the "Printout" menu, select "Working log". When "Working log" is highlighted, press the (F12) key. The printout will immediately follow.
1.9 Verify that the VIN printed on the printout is identical to that of the vehicle. Correct if necessary. Write the RO number and vehicle mileage
in the upper right hand corner of the first page of the printout. This will assist with vehicle information if the cover sheet is lost.
2.0 Generating an OBDII log (printout) for Boxster, 996 and 996 Turbo (ME 5.2.2, ME7.2, and ME 7.8)
2.1 Connect the keyboard and printer to the PST2.
2.2 Connect the PST2 to the vehicle. Start engine. Switch on the PST2.
2.3 Extremely Important!! Any previously stored information in the OBDII log must be deleted or it will be included with the current report.
You will be prompted to delete the OBDII log after it is selected (Step 2.7). Deleting the Working Log (F6) will not delete the OBDII log.
2.4 Note: The engine must be idling without any consumers on, and at operating temperature.
2.5 Press F5 (log button) and select OBDII log. Confirm with the (F12) button to start.
2.6 Read message and continue with (F12).
2.7 Press F8 to start the function.
2.8 You are now asked wether you want to delete the OBDII log. Select Yes (F7) then confirm with (F12).
2.9 You are now at the Warranty claim # screen. It is not necessary to input the number. Press the (F12) button to continue.
2.10 Enter the repair order number. Press the (F12) button to continue.
2.11 A control unit search will now be performed.
2.12 Enter the customer complaint, Press the (F12) button to continue.
2.13 Enter findings and fault cause (if they are known at this time). Press the (F12) button to continue.
2.14 Enter the affected / related components. Press the (F12) button to continue.
2.15 Enter fault recurrence (If the fault has come back). Press the (F12) button to continue.
2.16 The data is now determined. Press (F12) to continue.
Note:
The data is automatically saved. Do not press the save button. Doing so will save a duplicate copy in the print menu causing the report to be
printed out twice.
2.17 Print the OBDII log as follows: Press the (Print Screen) key. From the printout menu, select OBDII log. When OBDII log is highlighted,
2000 Porsche Boxster (986) F6-2.7L Page 94
Concern:
New procedure for submission of OBD II reports
Information:
Whenever an OBD II equipped vehicle (model year 1996 and later) enters the workshop with the check engine light illuminated, an OBD II report
must be generated before any work commences. Reports are required if the check engine light is illuminated, drive train replacements (engine and
transmission), and driveability problems that do not illuminate the check engine light.
There are two report formats that will be accepted:
1. 993, 993 Turbo (ME 5.2 systems) - Manual selection of fault codes and actual values (as required previously). This printout starts with 1.0 in
the work procedure.
2. Boxster, 996 and 996 Turbo (ME 5.2.2, ME7.2, and ME 7.8 systems) - The PST2 has the capability of creating an OBD II log (printout),
which contains all the vehicle information, fault codes, and actual values. This report starts with step 2.0 in the work procedure.
It is essential that copies of the OBD II report be filed respectively.
^ One copy of the OBD II printout along with a completed cover sheet should be faxed or mailed to:
Porsche Cars North America, Inc.
980 Hammond Drive
Atlanta, Ga. 30328
Fax Number: (770) 290-3711
ATTN: Technical Services
^ A second copy should be kept in the vehicle service file.
^ If an emission part was replaced is and requested for testing by PCNA, attach a third copy to it.
Note:
When compiling an OBDII report for Boxster, 996, and 996 Turbo, it is not necessary to duplicate the customer complaint and corrective action
taken on the cover sheet. This is already included in the PST2 report.
Failure to submit a properly printed OBD II report will result in denial of the warranty claim, and the parts being returned.
All OBD II faults and associated information must be retrieved and printed using the Porsche System Tester 2. Use the following procedure to
retrieve and print OBD II data. Do Not erase fault memory until a valid printout has been made!
Work Procedure:
The following PST2 keys are represented on the new keyboard as follows:
>>is now F12 (Continue)
>>is now F11 (Back)
Alt is now Print Screen (Print Menu)
Arrow up and down, left and right remains the same (Scroll / highlight to select)
1.0 Generating a Printout for 993, 993 Turbo (ME 5.2 systems).
1.1 Connect the keyboard and printer to the PSJ2 before turning it on. The new keyboard functions are indicated in parenthesis.
1.2 Connect the PST2 to the vehicle. Start engine. Switch on the PST2.
1.3 Select the appropriate vehicle. Press continue (F12) again to scan all control modules.
1.4 Extremely Important!! Any previously stored information in the work log must be deleted or it will be included with the current report.
Press F6 ("Erase work log") key, and confirming with F7 ("Yes") and then (F12).
1.5 Select the "DME" control module and continue (F12) to the DME Function selection menu. Select "Vehicle data" and continue (F12). Press
F4 to "Save". Go back (F11) to the DME Function selection menu.
1.6 Note: The engine must be idling without any consumers on, and at operating temperature. Select "Actual values", and continue with (F12).
Using the cursor keys (arrows), select and highlight the following Actual values:
New procedure for submission of OBD II reports
Information:
Whenever an OBD II equipped vehicle (model year 1996 and later) enters the workshop with the check engine light illuminated, an OBD II report
must be generated before any work commences. Reports are required if the check engine light is illuminated, drive train replacements (engine and
transmission), and driveability problems that do not illuminate the check engine light.
There are two report formats that will be accepted:
1. 993, 993 Turbo (ME 5.2 systems) - Manual selection of fault codes and actual values (as required previously). This printout starts with 1.0 in
the work procedure.
2. Boxster, 996 and 996 Turbo (ME 5.2.2, ME7.2, and ME 7.8 systems) - The PST2 has the capability of creating an OBD II log (printout),
which contains all the vehicle information, fault codes, and actual values. This report starts with step 2.0 in the work procedure.
It is essential that copies of the OBD II report be filed respectively.
^ One copy of the OBD II printout along with a completed cover sheet should be faxed or mailed to:
Porsche Cars North America, Inc.
980 Hammond Drive
Atlanta, Ga. 30328
Fax Number: (770) 290-3711
ATTN: Technical Services
^ A second copy should be kept in the vehicle service file.
^ If an emission part was replaced is and requested for testing by PCNA, attach a third copy to it.
Note:
When compiling an OBDII report for Boxster, 996, and 996 Turbo, it is not necessary to duplicate the customer complaint and corrective action
taken on the cover sheet. This is already included in the PST2 report.
Failure to submit a properly printed OBD II report will result in denial of the warranty claim, and the parts being returned.
All OBD II faults and associated information must be retrieved and printed using the Porsche System Tester 2. Use the following procedure to
retrieve and print OBD II data. Do Not erase fault memory until a valid printout has been made!
Work Procedure:
The following PST2 keys are represented on the new keyboard as follows:
>>is now F12 (Continue)
>>is now F11 (Back)
Alt is now Print Screen (Print Menu)
Arrow up and down, left and right remains the same (Scroll / highlight to select)
1.0 Generating a Printout for 993, 993 Turbo (ME 5.2 systems).
1.1 Connect the keyboard and printer to the PSJ2 before turning it on. The new keyboard functions are indicated in parenthesis.
1.2 Connect the PST2 to the vehicle. Start engine. Switch on the PST2.
1.3 Select the appropriate vehicle. Press continue (F12) again to scan all control modules.
1.4 Extremely Important!! Any previously stored information in the work log must be deleted or it will be included with the current report.
Press F6 ("Erase work log") key, and confirming with F7 ("Yes") and then (F12).
1.5 Select the "DME" control module and continue (F12) to the DME Function selection menu. Select "Vehicle data" and continue (F12). Press
F4 to "Save". Go back (F11) to the DME Function selection menu.
1.6 Note: The engine must be idling without any consumers on, and at operating temperature. Select "Actual values", and continue with (F12).
Using the cursor keys (arrows), select and highlight the following Actual values:
2000 Porsche Boxster (986) F6-2.7L Page 93
A. Mark the position of the locking tab (Figure 2, arrow A) on the oil filler hose. This is because the locking tab can not be seen during
installation (the locking tab points downward). Using a ballpoint pen, place a mark opposite the locking tab at the connection seam of
the oil filler hose (Figure 2, arrow B). During installation, this line marking must coincide with the connection seam of the oil filler
neck.
B. Heat the new oil filler hose in the area of the connection to the oil filler neck.
!CAUTION
The oil filler hose may be damaged/deformed by excessive heating with a hot-air gun.
> Heat the oil filler hose in the connection area to approximately 104 degrees F (lukewarm) with the hot-air gun.
1.10 Thread the spring-band clamp on to the oil filler neck and hold the clamp open.
1.11 Install the heated oil filler hose. A second person is required for this operation.
1.12 Secure the oil filler hose on the service unit with the spring-band clamp.
!CAUTION
Incorrect installation of the oil filler hose will increase the assembly time/costs. If the oil filler hose is incorrectly installed, the locking tab on
the crankcase side will not coincide with the flange.
> The locking tab attached to the oil filler hose must point vertically downwards on the oil filler neck side.
> Make sure the second person knows how to position the oil filler hose, so that the installation position is achieved correctly.
> During installation, make sure that the line marking on the oil filler hose coincides with the connection seam on the oil filler neck. Push the
hose into place as far as the stop markings on the oil filler neck.
1.13 Install the oil filler hose on the crankcase side and secure with the spring-band clamp.
1.14 Move the service unit back into position. Fasten it with the nuts/bolts. Engage the dipstick guide tube and insert the dipstick.
1.15 Reinstall the remaining parts.
Working Time:Technical Service Bulletin # 0101 Date: 011005
OBD II - New Report Submission Procedure
All
0101 0335
Binder - Group 0
This bulletin supersedes bulletin 9801, dated 12-3-98.
10/05/01
New Format of OBD II Reports
installation (the locking tab points downward). Using a ballpoint pen, place a mark opposite the locking tab at the connection seam of
the oil filler hose (Figure 2, arrow B). During installation, this line marking must coincide with the connection seam of the oil filler
neck.
B. Heat the new oil filler hose in the area of the connection to the oil filler neck.
!CAUTION
The oil filler hose may be damaged/deformed by excessive heating with a hot-air gun.
> Heat the oil filler hose in the connection area to approximately 104 degrees F (lukewarm) with the hot-air gun.
1.10 Thread the spring-band clamp on to the oil filler neck and hold the clamp open.
1.11 Install the heated oil filler hose. A second person is required for this operation.
1.12 Secure the oil filler hose on the service unit with the spring-band clamp.
!CAUTION
Incorrect installation of the oil filler hose will increase the assembly time/costs. If the oil filler hose is incorrectly installed, the locking tab on
the crankcase side will not coincide with the flange.
> The locking tab attached to the oil filler hose must point vertically downwards on the oil filler neck side.
> Make sure the second person knows how to position the oil filler hose, so that the installation position is achieved correctly.
> During installation, make sure that the line marking on the oil filler hose coincides with the connection seam on the oil filler neck. Push the
hose into place as far as the stop markings on the oil filler neck.
1.13 Install the oil filler hose on the crankcase side and secure with the spring-band clamp.
1.14 Move the service unit back into position. Fasten it with the nuts/bolts. Engage the dipstick guide tube and insert the dipstick.
1.15 Reinstall the remaining parts.
Working Time:Technical Service Bulletin # 0101 Date: 011005
OBD II - New Report Submission Procedure
All
0101 0335
Binder - Group 0
This bulletin supersedes bulletin 9801, dated 12-3-98.
10/05/01
New Format of OBD II Reports
2000 Porsche Boxster (986) F6-2.7L Page 92
^ DME 5.2, P1123 to P1130
^ DME 7.2, P1126, P1128, P1130, P1133
The new style hose was installed in production as of August 18, 2000 from the following VINs:
98 31S 62 0152 - Boxster
98 61S 66 0156 - Boxster S
98 81U 62 0474 - Boxster
98 91U 66 0382 - Boxster S
In case of complaints, the new style hose should be installed.
Parts Information:
Tools:
Changeover ratchet with extension
Socket wrench a/f 10
Small / large slotted screwdriver
Pointed-nose pliers
Hot-air gun
Spring-band clamp pliers
Work Procedure:
Installation of a new oil filler hose. To make replacement of the hose easier, the service unit (coolant expansion tank, dipstick, and oil filler neck)
should be unbolted from its mounting points and moved back. Enlist the help of a second person to help with the following procedure.
1.0 Place the body covers on the rear side sections and the rear bumper.
1.1 Move convertible top to service position. Disengage the convertible-top compartment lid and set it in a vertical position. Remove the upper
engine compartment lid panel and the upper engine compartment lid.
1.2 Remove the rear wall lining and the underside panel in the rear luggage compartment.
1.3 Remove the dipstick. Unclip the dipstick guide tube from the service unit.
1.4 Open the spring-band clamp at the connection point between the oil filler hose and the crankcase flange and push the clamp up on the oil
filler hose. Pull the oil filler hose off the crankcase.
1.5 Disconnect the electrical plug connection for the coolant-level indicator on the service unit. Unscrew the 4 fastening screws/nuts of the
service unit and pull it out approx. 1-1/2 inches into the luggage compartment. The spring-band clamp on the oil filler hose is now accessible.
1.6 A second person is required for the following operation: Open the spring-band clamp at the connection point between the oil filler hose and
the service unit (oil filler neck) and hold the clamp open. Have the 2nd person remove the oil filler hose from the oil filler neck.
1.7 Clean the flanges on the crankcase and the oil filler neck with a clean cloth.
1.8 Push a spring-band clamp on to the new oil filler hose on the crankcase side.
1.9 To make the assembly of the new oil filler hose on the oil filler neck easier, observe the following procedure:
^ DME 7.2, P1126, P1128, P1130, P1133
The new style hose was installed in production as of August 18, 2000 from the following VINs:
98 31S 62 0152 - Boxster
98 61S 66 0156 - Boxster S
98 81U 62 0474 - Boxster
98 91U 66 0382 - Boxster S
In case of complaints, the new style hose should be installed.
Parts Information:
Tools:
Changeover ratchet with extension
Socket wrench a/f 10
Small / large slotted screwdriver
Pointed-nose pliers
Hot-air gun
Spring-band clamp pliers
Work Procedure:
Installation of a new oil filler hose. To make replacement of the hose easier, the service unit (coolant expansion tank, dipstick, and oil filler neck)
should be unbolted from its mounting points and moved back. Enlist the help of a second person to help with the following procedure.
1.0 Place the body covers on the rear side sections and the rear bumper.
1.1 Move convertible top to service position. Disengage the convertible-top compartment lid and set it in a vertical position. Remove the upper
engine compartment lid panel and the upper engine compartment lid.
1.2 Remove the rear wall lining and the underside panel in the rear luggage compartment.
1.3 Remove the dipstick. Unclip the dipstick guide tube from the service unit.
1.4 Open the spring-band clamp at the connection point between the oil filler hose and the crankcase flange and push the clamp up on the oil
filler hose. Pull the oil filler hose off the crankcase.
1.5 Disconnect the electrical plug connection for the coolant-level indicator on the service unit. Unscrew the 4 fastening screws/nuts of the
service unit and pull it out approx. 1-1/2 inches into the luggage compartment. The spring-band clamp on the oil filler hose is now accessible.
1.6 A second person is required for the following operation: Open the spring-band clamp at the connection point between the oil filler hose and
the service unit (oil filler neck) and hold the clamp open. Have the 2nd person remove the oil filler hose from the oil filler neck.
1.7 Clean the flanges on the crankcase and the oil filler neck with a clean cloth.
1.8 Push a spring-band clamp on to the new oil filler hose on the crankcase side.
1.9 To make the assembly of the new oil filler hose on the oil filler neck easier, observe the following procedure:
2000 Porsche Boxster (986) F6-2.7L Page 91
Literature:
Disclaimer
Technical Service Bulletin # 9/00 Date: 001221
Engine - MIL ON/Oil Leaks/Rough Idle
Boxster
9/00 1715
Binder - 1, Engine, Part 2
12-22-00
New Design Oil Filler Hose
Vehicle Type:
Boxster, Boxster S
Model Year:
As of 1997 (V) / 2000 (Y)
Concern:
Oil filler hose between the crankcase and the service unit.
Information:
The oil filler hose (arrow, figure 1) can crack causing the following conditions:
^ Check Engine warning light lights up.
^ Engine oil leak on the crankcase in the area of the oil filler hose.
^ Rough running (rough idling, increased idle speed).
As a result of the incoming secondary air, the following fault code~ may be stored in the DME fault memory:
Disclaimer
Technical Service Bulletin # 9/00 Date: 001221
Engine - MIL ON/Oil Leaks/Rough Idle
Boxster
9/00 1715
Binder - 1, Engine, Part 2
12-22-00
New Design Oil Filler Hose
Vehicle Type:
Boxster, Boxster S
Model Year:
As of 1997 (V) / 2000 (Y)
Concern:
Oil filler hose between the crankcase and the service unit.
Information:
The oil filler hose (arrow, figure 1) can crack causing the following conditions:
^ Check Engine warning light lights up.
^ Engine oil leak on the crankcase in the area of the oil filler hose.
^ Rough running (rough idling, increased idle speed).
As a result of the incoming secondary air, the following fault code~ may be stored in the DME fault memory:
2000 Porsche Boxster (986) F6-2.7L Page 90
4.12 Route hose (Tekalan) between the heat shield and body panel toward the two vacuum modulators on the muffler. In the area of the two
vacuum modulators, guide the vacuum lines past the neat shield and vertically up to the connections.
4.13 Trim the hose (Tekalan) and connect to the vacuum modulator with one bent protective sheath each.
Reassembling the vehicle.
5.0 Fit the fuse board and relay carrier 1. Insert the relay into the relay socket of the electrical wiring harness.
5.1 Install the remaining interior parts including the seat.
5.2 Uncover and connect the batter!.
5.3 Hook up the PST2.
Perform a function test of the system.
6.0 form a control unit search.
6.1 Select menu item "instrument cluster" and then page down and select "Speedometer A signal".
6.2 Have a second person visually check the operation of the exhaust flaps. Using the F5 button, increase the speedometer A-signal. The
movement of the linkage from the vacuum modulator to the exhaust flap indicates the flap function. If the flap function is correct, vacuum
will be present at the vacuum modulators at a speed of approx. 27 to approx. 42 mph. The exhaust flaps are closed in this case (closing
process: linkage moves up).
Note:
The flaps are normally open, and are closed by the actuators.
6.3 Use the F6 button to reset the signal back to zero.
Completing the reassembly.
7.0 Fit the engine compartment cover, carpet, and storage compartment.
7.1 Install the top tension cables and close top. Calibrate if necessary.
7.2 Install the rear spoiler, bumper bar, and bumper cover.
7.3 Input the radio code and set the time in the instrument cluster.
7.4 Road test the vehicle and then read out the fault memory of the control units. If necessary, repair faults then clear fault memory.
Troubleshooting:
Fault symptoms and remedies.
8.0 Exhaust flaps perform only one control process:
- Connection reversed on switchover valve (Figure 5, Item C).
- Connect vacuum hoses as shown in the diagram in Figure 5.
8.1 Check engine light on:
- Read out fault memory of the DME control unit. Most likely the fault set will be due to an intake leak. Leak test the intake system with
the special pressure tester tool (# 9264/6).
- Check the insertion depth of vacuum hoses.
8.2 Exhaust flaps do not react completely or do not react at high acceleration.
- This results from the response characteristics of the exhaust flaps.
vacuum modulators, guide the vacuum lines past the neat shield and vertically up to the connections.
4.13 Trim the hose (Tekalan) and connect to the vacuum modulator with one bent protective sheath each.
Reassembling the vehicle.
5.0 Fit the fuse board and relay carrier 1. Insert the relay into the relay socket of the electrical wiring harness.
5.1 Install the remaining interior parts including the seat.
5.2 Uncover and connect the batter!.
5.3 Hook up the PST2.
Perform a function test of the system.
6.0 form a control unit search.
6.1 Select menu item "instrument cluster" and then page down and select "Speedometer A signal".
6.2 Have a second person visually check the operation of the exhaust flaps. Using the F5 button, increase the speedometer A-signal. The
movement of the linkage from the vacuum modulator to the exhaust flap indicates the flap function. If the flap function is correct, vacuum
will be present at the vacuum modulators at a speed of approx. 27 to approx. 42 mph. The exhaust flaps are closed in this case (closing
process: linkage moves up).
Note:
The flaps are normally open, and are closed by the actuators.
6.3 Use the F6 button to reset the signal back to zero.
Completing the reassembly.
7.0 Fit the engine compartment cover, carpet, and storage compartment.
7.1 Install the top tension cables and close top. Calibrate if necessary.
7.2 Install the rear spoiler, bumper bar, and bumper cover.
7.3 Input the radio code and set the time in the instrument cluster.
7.4 Road test the vehicle and then read out the fault memory of the control units. If necessary, repair faults then clear fault memory.
Troubleshooting:
Fault symptoms and remedies.
8.0 Exhaust flaps perform only one control process:
- Connection reversed on switchover valve (Figure 5, Item C).
- Connect vacuum hoses as shown in the diagram in Figure 5.
8.1 Check engine light on:
- Read out fault memory of the DME control unit. Most likely the fault set will be due to an intake leak. Leak test the intake system with
the special pressure tester tool (# 9264/6).
- Check the insertion depth of vacuum hoses.
8.2 Exhaust flaps do not react completely or do not react at high acceleration.
- This results from the response characteristics of the exhaust flaps.
2000 Porsche Boxster (986) F6-2.7L Page 9
Boxster S - 3.2 Liter
Technical Service Bulletin # 2/01 Date: 011222
A/C Control Assembly - Malfunctions/Faulty
Boxster
2/01 8702
Binder - Group 8/9 - Air Conditioning, Electrics
Electrical Plug on Heating / Air-conditioning Control
Date: 12-21-01
Vehicle Type:
Boxster / Boxster S
Model Year:
As of 1997 (V)
Concern:
Electrical plug connection on the heating / air-conditioning control.
Information:
Certain conditions, such as high humidity, can cause condensation to form on the central vent. The condensation then drips onto the electrical plug
connection of the heating / air-conditioning control causing corrosion to form on the electrical connector.
Technical Service Bulletin # 2/01 Date: 011222
A/C Control Assembly - Malfunctions/Faulty
Boxster
2/01 8702
Binder - Group 8/9 - Air Conditioning, Electrics
Electrical Plug on Heating / Air-conditioning Control
Date: 12-21-01
Vehicle Type:
Boxster / Boxster S
Model Year:
As of 1997 (V)
Concern:
Electrical plug connection on the heating / air-conditioning control.
Information:
Certain conditions, such as high humidity, can cause condensation to form on the central vent. The condensation then drips onto the electrical plug
connection of the heating / air-conditioning control causing corrosion to form on the electrical connector.
2000 Porsche Boxster (986) F6-2.7L Page 89
Note:
Make sure the rubber sleeves are completely on the tuning and distribution pipe before tightening the hose clamps.
4.4 Using the supplied bracket, attach the vacuum tank to it and install the assembly on the engine removal hook. The hook is located where the
transmission bolts onto the engine. The correct installed position of the vacuum tank is between the clutch Dell housing and the vehicle body.
4.5 Route the vacuum hose under the intake manifold from the rubber sleeve up to the vacuum an Cut the vacuum hose at the vacuum tank. See
figure 5 for vacuum system lay out.
4.6 Push the Y-piece (Figure 6, Item B) as far as it will go onto the connection nipple of the vacuum tank (Figure 6, Item C). Insert white side of
the check valve (Figure 6, Item D) as far as it will go into an output of the Y-piece (Figure 6, Item B).
4.7 Trim the hose (Tekalan) from the intake distributor to the check valve (Item D) and insert it 10 mm deep into the bent protective sheath (Item
E). Push Y-piece (Figure 7, Item A) as far as it will go onto the switchover valve (Item B).
Note:
Figure 6 is shown for vehicles with out secondary air.
4.8 Clip the switchover valve into the fitted long retaining bracket for the vacuum tank.
4.9 Route the hose (Tekalan) from the free connection of the Y-piece (Figure 6, Item B) to the switchover valve (Figure 7, Item B) and connect it
with the bent protective sheath.
4.10 Push 2-pin plug connection on the switchover valve and fix the electrical wiring harness to existing components (e.g. vacuum line).
4.11 Cut hose (Tekalan) in the middle and insert at least 10 mm deep into both free connections of the Y-piece on the switchover valve (Figure 7,
Make sure the rubber sleeves are completely on the tuning and distribution pipe before tightening the hose clamps.
4.4 Using the supplied bracket, attach the vacuum tank to it and install the assembly on the engine removal hook. The hook is located where the
transmission bolts onto the engine. The correct installed position of the vacuum tank is between the clutch Dell housing and the vehicle body.
4.5 Route the vacuum hose under the intake manifold from the rubber sleeve up to the vacuum an Cut the vacuum hose at the vacuum tank. See
figure 5 for vacuum system lay out.
4.6 Push the Y-piece (Figure 6, Item B) as far as it will go onto the connection nipple of the vacuum tank (Figure 6, Item C). Insert white side of
the check valve (Figure 6, Item D) as far as it will go into an output of the Y-piece (Figure 6, Item B).
4.7 Trim the hose (Tekalan) from the intake distributor to the check valve (Item D) and insert it 10 mm deep into the bent protective sheath (Item
E). Push Y-piece (Figure 7, Item A) as far as it will go onto the switchover valve (Item B).
Note:
Figure 6 is shown for vehicles with out secondary air.
4.8 Clip the switchover valve into the fitted long retaining bracket for the vacuum tank.
4.9 Route the hose (Tekalan) from the free connection of the Y-piece (Figure 6, Item B) to the switchover valve (Figure 7, Item B) and connect it
with the bent protective sheath.
4.10 Push 2-pin plug connection on the switchover valve and fix the electrical wiring harness to existing components (e.g. vacuum line).
4.11 Cut hose (Tekalan) in the middle and insert at least 10 mm deep into both free connections of the Y-piece on the switchover valve (Figure 7,
2000 Porsche Boxster (986) F6-2.7L Page 88
2.3 Using a 4.5 mm drill bit, drill a hole through the grommet (Figure 3, item A) in the rear luggage compartment. The hold is drilled in the 12
o-clock position.
2.4 From the engine compartment side, guide the plug pins of the second short wiring harness threw the drilled hole into the rear luggage
compartment.
2.5 Crimp the terminals, which were taped to that harness to the wire ends then insert the terminals into the connector housing.
2.6 Loop the extra wire and tie it to the main harness.
Installing the exhaust system.
3.0 On vehicles with 2.5 I engines, remove the old bracket (support) of the main muffler from the transmission.
3.1 Attach the blade (figure 4 item B) with the provided bolts to support A.
3.2 Install support A to the transmission.
Note:
If fitting brackets to a Tiptronic transmission, use the M8 X 35 bolts inserting them in the right mounting holes. If fitting bracket to a
manual transmission, use the M8 X 75 bolts, inserting them in the left holes.
3.3 Open the lateral clamps and install the cylindrical mounts on the top of the muffler.
3.4 Install the new main muffler on the mounts.
3.5 On vehicles with 2.7 or 3.2 engines, transfer over the cylindrical mounts before mounting the muffler.
Installing the components for pneumatic actuation of the exhaust flaps.
4.0 Position the rubber sleeve (described in step 1.11) with the connection nipple on the bottom, pointing to the passenger compartment. Fasten it
with its hose clamps.
4.1 If drilling a hole was necessary, install the sleeve with the hole pointing towards the passenger compartment. When the sleeve 5 reinstalled,
the nipple will be facing downward in the opposite direction.
4.2 Insert the hose (Tekalan) at least 25 mm deep into the connection nipple or the additional hole.
Installing the components for pneumatic actuation1 of the exhaust flaps.
4.3 Install the tuning pipe (2.7I and 3.2I engines) and the throttle body with the distribution piece on the intake manifold.
o-clock position.
2.4 From the engine compartment side, guide the plug pins of the second short wiring harness threw the drilled hole into the rear luggage
compartment.
2.5 Crimp the terminals, which were taped to that harness to the wire ends then insert the terminals into the connector housing.
2.6 Loop the extra wire and tie it to the main harness.
Installing the exhaust system.
3.0 On vehicles with 2.5 I engines, remove the old bracket (support) of the main muffler from the transmission.
3.1 Attach the blade (figure 4 item B) with the provided bolts to support A.
3.2 Install support A to the transmission.
Note:
If fitting brackets to a Tiptronic transmission, use the M8 X 35 bolts inserting them in the right mounting holes. If fitting bracket to a
manual transmission, use the M8 X 75 bolts, inserting them in the left holes.
3.3 Open the lateral clamps and install the cylindrical mounts on the top of the muffler.
3.4 Install the new main muffler on the mounts.
3.5 On vehicles with 2.7 or 3.2 engines, transfer over the cylindrical mounts before mounting the muffler.
Installing the components for pneumatic actuation of the exhaust flaps.
4.0 Position the rubber sleeve (described in step 1.11) with the connection nipple on the bottom, pointing to the passenger compartment. Fasten it
with its hose clamps.
4.1 If drilling a hole was necessary, install the sleeve with the hole pointing towards the passenger compartment. When the sleeve 5 reinstalled,
the nipple will be facing downward in the opposite direction.
4.2 Insert the hose (Tekalan) at least 25 mm deep into the connection nipple or the additional hole.
Installing the components for pneumatic actuation1 of the exhaust flaps.
4.3 Install the tuning pipe (2.7I and 3.2I engines) and the throttle body with the distribution piece on the intake manifold.
2000 Porsche Boxster (986) F6-2.7L Page 87
A. On Engine types M96/22 and /21 only (Egas)7 Loosen the throttle body/distribution pipe with both rubber sleeves and remove (See
figure 2). Remove right-hand rubber sleeve (Item A) from the tuning pipe.
B. For engine type M96/20 (non E-gas), remove the right-hand sleeve from the throttle body distribution pipe.
Note:
Non-E-gas engines do not a have tuning pipe.
C. Close all openings on the intake system with cloths.
D. Check whether there is a connection nipple on the removed right-hand rubber sleeve. If it doesn't have one, replace that rubber sleeve
with the rubber sleeve with connection nipple included with the parts.
E. If there is already a connection nipple with a vacuum line attached to that sleeve, you must drill a 3.5 mm hole to provide a vacuum
source for the actuating solenoids.
Note:
The position of the hole is facing the passenger compartment. Mark the hole to be drilled with a tire crayon before removing the sleeve.
Installing the wiring harness.
2.0 Plug the relay socket into any free slot in the relay carrier 1. Insert the branches of the electrical wiring harness into the associated jumper
plug of the relay carrier according to the table 1. Make sure the connector is inserted in the bridge connector that has a jumper connection.
2.1 Run the new wiring harness along with the vehicle wiring harness via the sill, up the left side into the rear luggage compartment. Attach it to
the vehicle harness with cable ties.
Note:
Make sure you leave enough wire up by the fuse board so you can reinstall it.
2.2 Crimp the terminals which were taped to that harness on the wire ends and insert them into the corresponding housing. See table 2.
Installing the wiring harness.
WARNING
Risk of damage to components in the luggage compartment or engine compartment during drilling due to drill chuck or drill.
> Remove existing components in the drilling area (luggage compartment or engine compartment).
> Mask drilling area and use a power drill with a bit stop.
figure 2). Remove right-hand rubber sleeve (Item A) from the tuning pipe.
B. For engine type M96/20 (non E-gas), remove the right-hand sleeve from the throttle body distribution pipe.
Note:
Non-E-gas engines do not a have tuning pipe.
C. Close all openings on the intake system with cloths.
D. Check whether there is a connection nipple on the removed right-hand rubber sleeve. If it doesn't have one, replace that rubber sleeve
with the rubber sleeve with connection nipple included with the parts.
E. If there is already a connection nipple with a vacuum line attached to that sleeve, you must drill a 3.5 mm hole to provide a vacuum
source for the actuating solenoids.
Note:
The position of the hole is facing the passenger compartment. Mark the hole to be drilled with a tire crayon before removing the sleeve.
Installing the wiring harness.
2.0 Plug the relay socket into any free slot in the relay carrier 1. Insert the branches of the electrical wiring harness into the associated jumper
plug of the relay carrier according to the table 1. Make sure the connector is inserted in the bridge connector that has a jumper connection.
2.1 Run the new wiring harness along with the vehicle wiring harness via the sill, up the left side into the rear luggage compartment. Attach it to
the vehicle harness with cable ties.
Note:
Make sure you leave enough wire up by the fuse board so you can reinstall it.
2.2 Crimp the terminals which were taped to that harness on the wire ends and insert them into the corresponding housing. See table 2.
Installing the wiring harness.
WARNING
Risk of damage to components in the luggage compartment or engine compartment during drilling due to drill chuck or drill.
> Remove existing components in the drilling area (luggage compartment or engine compartment).
> Mask drilling area and use a power drill with a bit stop.
2000 Porsche Boxster (986) F6-2.7L Page 86
Parts Information
Tools:
Work Procedure:
Prepping the vehicle.
1.0. Remove the driver side seat.
1.1 Move the convertible top to the service position and disengage both tension cables.
1.2 Remove the storage compartment, carpet., and engine compartment cover.
1.3 Disconnect and cover the negative battery terminal.
1.4 Remove the fuse board 1 and relay carrier.
1.5 Remove the driver-side doorsill by detaching the sill cover and disengaging the carpet.
1.6 Remove the left rear side panel lining.
1.7 Partially detach the water collection tray below the convertible top compartment lid on the driver's side.
1.8 Remove the rear spoiler.
1.9 Remove the rear bumper cover and bumper bar.
1.10 Remove the exhaust muffler.
1.11 Remove the throttle body distribution pipe and tuning pipe. Follow procedure below.
Tools:
Work Procedure:
Prepping the vehicle.
1.0. Remove the driver side seat.
1.1 Move the convertible top to the service position and disengage both tension cables.
1.2 Remove the storage compartment, carpet., and engine compartment cover.
1.3 Disconnect and cover the negative battery terminal.
1.4 Remove the fuse board 1 and relay carrier.
1.5 Remove the driver-side doorsill by detaching the sill cover and disengaging the carpet.
1.6 Remove the left rear side panel lining.
1.7 Partially detach the water collection tray below the convertible top compartment lid on the driver's side.
1.8 Remove the rear spoiler.
1.9 Remove the rear bumper cover and bumper bar.
1.10 Remove the exhaust muffler.
1.11 Remove the throttle body distribution pipe and tuning pipe. Follow procedure below.
2000 Porsche Boxster (986) F6-2.7L Page 85
DisclaimerTechnical Service Bulletin # 2/00 Date: 000626
Sport Exhaust System - Installation Procedures
Boxster
2/00
2601
Binder - 2, Fuel, Exhaust & Eng. EI.
Sport Exhaust System
Vehicle Type:
Boxster / Boxster S
Model Year:
As of 1997 (V)
Concern:
Service installation of the Sport Exhaust System
Information:
The Sports Exhaust System is available for 2.5 I M96/20, 2.7I M96/22, and 3.2I M96/21 engines. The sound behavior of the system is controlled as
a function of the vehicle speed. The sports exhaust system has two extra exhaust passage ways which are opened and closed by control flaps. The
flaps are activated by means of a control unit, which receives a speed signal from the speedometer. This exhaust system produces a sporty, powerful
sound when both flaps are open. Visible differences between the sports exhaust system and the standard exhaust system are:
^ Visible merging of the exhaust pipes below the rear bumper cover.
^ Eccentric double tailpipe with extra ports (Figure 1).
The exhaust pipe is made from polished, stainless steel. The engine power and exhaust behavior of the vehicle is not affected. The Porsche logo is
(T) visible from below when the system is installed.
Sport Exhaust System - Installation Procedures
Boxster
2/00
2601
Binder - 2, Fuel, Exhaust & Eng. EI.
Sport Exhaust System
Vehicle Type:
Boxster / Boxster S
Model Year:
As of 1997 (V)
Concern:
Service installation of the Sport Exhaust System
Information:
The Sports Exhaust System is available for 2.5 I M96/20, 2.7I M96/22, and 3.2I M96/21 engines. The sound behavior of the system is controlled as
a function of the vehicle speed. The sports exhaust system has two extra exhaust passage ways which are opened and closed by control flaps. The
flaps are activated by means of a control unit, which receives a speed signal from the speedometer. This exhaust system produces a sporty, powerful
sound when both flaps are open. Visible differences between the sports exhaust system and the standard exhaust system are:
^ Visible merging of the exhaust pipes below the rear bumper cover.
^ Eccentric double tailpipe with extra ports (Figure 1).
The exhaust pipe is made from polished, stainless steel. The engine power and exhaust behavior of the vehicle is not affected. The Porsche logo is
(T) visible from below when the system is installed.
Monday, 24 August 2020
2000 Porsche Boxster (986) F6-2.7L Page 84
Literature
Technical Service Bulletin # 99/04 Date: 040922
Antitheft - Aftermarket System Installation Warning
Boxster
9/04 9668
9/21/04
Binder - 9, Electrical
Installation of After Market Theft Prevention Systems
Vehicle Type:
Boxster/Boxster S
Model Year:
As of '97 (V)
Concerns:
Installing additional anti-theft protection (anti-car jacking systems) can cause malfunctions in the vehicle electrical/electronic system.
Information:
After market anti-car jacking systems are electrical/electronic equipment in the vehicle which expand the existing theft protection of the vehicle and
also support and facilitate the location of a stolen vehicle. Typically, the stolen vehicle is located via GPS/GSM or radar.
Malfunctions:
Investigations based on complaints have shown that after installing such a system, the following malfunctions can occur in the vehicle
electrical/electronic system:
- remote control does not function,
- interference in or poor radio reception,
- increased current draw,
- incorrect triggering of the theft warning system (vehicles with I No. 534 or 535).
In some countries, additional anti-theft protection (anti-car jacking systems) must be installed for insurance/technical reasons. These systems are
not approved by Porsche.
Measures:
Installing additional anti-theft protection (anti-car jacking system).
If the customer would like to have such a system installed, the customer should be informed about the possible, above-mentioned known-to-date
malfunctions. Due to the increased current draw, it is recommended that the customer use the Porsche battery maintainer.
Repairs on vehicles with additional anti-theft protection (anti-car jacking system).
If there are customer complaints regarding the above-mentioned malfunctions, the customer should be asked if such a system is installed in the
vehicle. Repair work relating to such systems cannot be claimed under warranty.
Please inform your sales and parts department personnel accordingly.
Technical Service Bulletin # 99/04 Date: 040922
Antitheft - Aftermarket System Installation Warning
Boxster
9/04 9668
9/21/04
Binder - 9, Electrical
Installation of After Market Theft Prevention Systems
Vehicle Type:
Boxster/Boxster S
Model Year:
As of '97 (V)
Concerns:
Installing additional anti-theft protection (anti-car jacking systems) can cause malfunctions in the vehicle electrical/electronic system.
Information:
After market anti-car jacking systems are electrical/electronic equipment in the vehicle which expand the existing theft protection of the vehicle and
also support and facilitate the location of a stolen vehicle. Typically, the stolen vehicle is located via GPS/GSM or radar.
Malfunctions:
Investigations based on complaints have shown that after installing such a system, the following malfunctions can occur in the vehicle
electrical/electronic system:
- remote control does not function,
- interference in or poor radio reception,
- increased current draw,
- incorrect triggering of the theft warning system (vehicles with I No. 534 or 535).
In some countries, additional anti-theft protection (anti-car jacking systems) must be installed for insurance/technical reasons. These systems are
not approved by Porsche.
Measures:
Installing additional anti-theft protection (anti-car jacking system).
If the customer would like to have such a system installed, the customer should be informed about the possible, above-mentioned known-to-date
malfunctions. Due to the increased current draw, it is recommended that the customer use the Porsche battery maintainer.
Repairs on vehicles with additional anti-theft protection (anti-car jacking system).
If there are customer complaints regarding the above-mentioned malfunctions, the customer should be asked if such a system is installed in the
vehicle. Repair work relating to such systems cannot be claimed under warranty.
Please inform your sales and parts department personnel accordingly.
2000 Porsche Boxster (986) F6-2.7L Page 83
> The tie-wraps for the strain-relief element of the belt buckle wiring harness for the seat-side plug must be installed according to the
following Steps 13.3 or 13.4 respectively.
13.3 Strain relief element for basic passenger's seat with option I No. 370 (elc. height adjustment):
Fasten the belt buckle wiring harness to the cushion carrier with a tie-wrap (Fig. 15).
13.4 Strain relief element for all other drivers and passenger's seats:
Bundle the leads in the plug housing with a tie-wrap (Figures 16 and 17).
14. Reinstall seat.
15. Connect the battery. Enter radio code, if necessary.
Working Time Measure 8
following Steps 13.3 or 13.4 respectively.
13.3 Strain relief element for basic passenger's seat with option I No. 370 (elc. height adjustment):
Fasten the belt buckle wiring harness to the cushion carrier with a tie-wrap (Fig. 15).
13.4 Strain relief element for all other drivers and passenger's seats:
Bundle the leads in the plug housing with a tie-wrap (Figures 16 and 17).
14. Reinstall seat.
15. Connect the battery. Enter radio code, if necessary.
Working Time Measure 8
2000 Porsche Boxster (986) F6-2.7L Page 82
12.4.4Join the leads in the wire-end ferrule using a pair of crimping pliers (Fig. 13, Item A).
12.4.5Solder the tips of the projecting ends of the leads (Item B).
12.4.6Insulate the soldered joint with 4 x 35 shrink tubing.
Caution!
Damage to the interior and the leads from the heating effect of the heat gun!
> Observe the blower outlet direction of the heat gun during the shrinking procedure.
> Close the open end of the shrink tubing using a pair of flat-nosed pliers (Item C).
12.4.7Snap the contact spring into the housing socket again.
12.4.8Use electrical tape to secure the lead to the wiring harness in the area of the shrink tubing.
12.5 Follow the same procedure for work on the other leads/contact springs. Trim the wires in such a way that the connection points are
offset with respect to each other.
12.6 Reassemble the plug in reverse order. When doing so, replace the previous plug cap (See Figure 10, Item A) with the plug cap
contained in the service set.
Caution!
Airbag warning light lights up if tie-wrap is insufficiently fastened.
> Bundle all leads on the vehicle-side plug on the plug cap using a tie-wrap (Figure 14).
12.7 Bundle the seat ground lead again. Add more banding if necessary.
13. Replace belt buckle.
A new belt buckle with gold-plated contact pins must be installed. A strain relief element for the belt buckle wiring harness is intended on the
seat-side plug.
13.1 Remove the previous belt buckle; see Boxster Technical Manual, Group 6, Repairs, 69 24 19 - Removing and installing the front belt
buckle.
13.2 Install the new belt buckle.
Distinguishing the belt buckles:
The belt buckles can be recognized by way of thee stamped number and by the plug color.
Driver's seat - 996.803.183.09, blue plug
Passenger's seat - 996.803.183.10, green plug.
Caution!
Airbag warning light lights up if tie-wrap is insufficiently fastened.
12.4.5Solder the tips of the projecting ends of the leads (Item B).
12.4.6Insulate the soldered joint with 4 x 35 shrink tubing.
Caution!
Damage to the interior and the leads from the heating effect of the heat gun!
> Observe the blower outlet direction of the heat gun during the shrinking procedure.
> Close the open end of the shrink tubing using a pair of flat-nosed pliers (Item C).
12.4.7Snap the contact spring into the housing socket again.
12.4.8Use electrical tape to secure the lead to the wiring harness in the area of the shrink tubing.
12.5 Follow the same procedure for work on the other leads/contact springs. Trim the wires in such a way that the connection points are
offset with respect to each other.
12.6 Reassemble the plug in reverse order. When doing so, replace the previous plug cap (See Figure 10, Item A) with the plug cap
contained in the service set.
Caution!
Airbag warning light lights up if tie-wrap is insufficiently fastened.
> Bundle all leads on the vehicle-side plug on the plug cap using a tie-wrap (Figure 14).
12.7 Bundle the seat ground lead again. Add more banding if necessary.
13. Replace belt buckle.
A new belt buckle with gold-plated contact pins must be installed. A strain relief element for the belt buckle wiring harness is intended on the
seat-side plug.
13.1 Remove the previous belt buckle; see Boxster Technical Manual, Group 6, Repairs, 69 24 19 - Removing and installing the front belt
buckle.
13.2 Install the new belt buckle.
Distinguishing the belt buckles:
The belt buckles can be recognized by way of thee stamped number and by the plug color.
Driver's seat - 996.803.183.09, blue plug
Passenger's seat - 996.803.183.10, green plug.
Caution!
Airbag warning light lights up if tie-wrap is insufficiently fastened.
2000 Porsche Boxster (986) F6-2.7L Page 81
12. Work on the "seat" plug connection (disconnection points X16 and X17 on the circuit diagram). The existing contact springs must be
replaced by gold-plated and greased springs on the vehicle-side plug of the "seat" plug connection.
Connector X16 = driver's side,
Connector X17 = passenger's side.
12.1 Unwrap the banding of the driver7s side wiring harness according to the new leads which are to be installed.
12.2 Open the vehicle-side plug. To do this, lever out the plug cap (Fig. 10, arrow A) at the pivot point using a small flat screwdriver. Then
lift the blue bar (arrow B) with the screwdriver and pull it out of the plug.
12.3 Carefully remove the movable side of the plug (arrow C), and pull the plug housing out (arrow D).
12.4 Work on the leads/contact springs in the plug (arrow 0).
Caution!
Possibility of mixing up the leads!
> Complete only one lead at a time.
> Work on the leads/contact springs in sockets B57, B67, B7 and B8 on the driver's side. On the passenger's side, work on only those
leads/contact springs that are in sockets B7 and B8.
> Trim the wires in such a way that the connection points are offset with respect to each other.
12.4.1Unlock and push out a contact spring using pressout tool 89058 (Fig. 11).
12.4.2Trim the lead in accordance with the new lead.
Note:
The new lead should be approx. 50 mm longer (allowance for wire-end ferrule and shrink tubing).
12.4.3Strip approx. 10 mm of insulation from the ends of both leads, twist the ends together and insert them in a 2.5 x 7 wire-end ferrule
replaced by gold-plated and greased springs on the vehicle-side plug of the "seat" plug connection.
Connector X16 = driver's side,
Connector X17 = passenger's side.
12.1 Unwrap the banding of the driver7s side wiring harness according to the new leads which are to be installed.
12.2 Open the vehicle-side plug. To do this, lever out the plug cap (Fig. 10, arrow A) at the pivot point using a small flat screwdriver. Then
lift the blue bar (arrow B) with the screwdriver and pull it out of the plug.
12.3 Carefully remove the movable side of the plug (arrow C), and pull the plug housing out (arrow D).
12.4 Work on the leads/contact springs in the plug (arrow 0).
Caution!
Possibility of mixing up the leads!
> Complete only one lead at a time.
> Work on the leads/contact springs in sockets B57, B67, B7 and B8 on the driver's side. On the passenger's side, work on only those
leads/contact springs that are in sockets B7 and B8.
> Trim the wires in such a way that the connection points are offset with respect to each other.
12.4.1Unlock and push out a contact spring using pressout tool 89058 (Fig. 11).
12.4.2Trim the lead in accordance with the new lead.
Note:
The new lead should be approx. 50 mm longer (allowance for wire-end ferrule and shrink tubing).
12.4.3Strip approx. 10 mm of insulation from the ends of both leads, twist the ends together and insert them in a 2.5 x 7 wire-end ferrule
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