Porsche Boxster-Cayman 987 FSM 2005-2008 PDF

Porsche Boxster 987
Year: 2005-2008
Automotive-Manual.net
2007 Porsche Boxster S
GENERAL INFORMATION Maintenance, Self Diagnostics
GENERAL INFORMATION
Maintenance, Self Diagnostics
03 TEST DRIVE - AS OF MY 2005 (ALL MODELS)

TEST DRIVE - MAINTENANCE
The following test items are included in the test drive.
- Actuate remote control of central locking and check operation.
- Seats: check operation of adjustments.
- Check footbrake operation and actuation travel.
- Start engine, check operation.
- Actuate clutch, check operation.
- Actuate steering, check operation.
- Shift transmission, check operation.
- ParkAssist: select reverse gear and check operation.
- Activate cruise control during the test drive and check operation.
- Actuate PSM switch during the test drive and check operation.
- Actuate PASM switch during the test drive and check operation.
- Actuate Sport switch during the test drive and check operation.
- Check operation of heating adjustment when engine is warm.
- Check operation of air-conditioning system when engine is running.
- Check operation of instruments.
03 IN RUNNING GEAR MAINTENANCE: VISUAL INSPECTION OF BRAKE

LINES/BRAKE PADS/BRAKE DISCS - AS OF MY 2005 (ALL MODELS)
INFORMATION
Brake hoses and lines

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Thursday, September 24, 2009 9:14:15
9:14:12 AM Page 1 © 2005 Mitchell Repair Information Company, LLC.
- Carry out visual inspection for leaks, damage, routing and corrosion.
Brake system: visual inspection of the brake pads and brake discs for wear
WARNING: Risk of accident if brake pads and/or brake discs are not replaced in time.
 Injury and material damage due to impaired braking effect.
--> The brake pads must be replaced when the brake pad warning indicator lights up, but no later than when
there is a residual pad thickness of 2 mm.
--> Brake discs must be replaced on reaching the wear limits.
NOTE:  If brake pad wear is indicated by the warning light, the warning contact
(sender including wire and plug connection) must also be replaced.
 Replacing the warning contact can be avoided by replacing the brake pads
no later than when the pad thickness is 2.5 mm.
 Warning contacts must be replaced if the core of the line is worn.
 However, if only the plastic part of the warning contact is worn, there is no
need to replace it.
1. To check the brake pads, remove the wheels. Refer to 44 05 19 Removing and installing wheel - as of MY
2005 (All Models) .
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Thursday, September 24, 2009 9:14:12 AM Page 2 © 2005 Mitchell Repair Information Company, LLC.
Fig. 1: Checking brake pads

Courtesy of PORSCHE OF NORTH AMERICA, INC.
2. Visually inspect the brake pads for wear -Arrows- (wear limit 2 mm). See Fig. 1.
3. Carry out a visual inspection of the brake discs for wear --> 0300IN Running gear maintenance: Visual
inspection of brake lines/brake pads/brake discs - section on "Technical values".
TECHNICAL VALUES
Technical values
Designation Type Note, dimensions Wear limit

Pad thickness, front
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Boxster/Boxster S approx. 12 mm approx. 2 mm

Pad thickness, rear
Boxster/Boxster S approx. 10.5 mm approx. 2 mm
Brake disc thickness, new front
Boxster 24 mm 22 mm
Boxster S 28 mm 26 mm
Brake disc thickness, new rear
Boxster 20 mm 18 mm
Boxster S 24 mm 22 mm
03 IN RUNNING GEAR MAINTENANCE: AXLE JOINTS/DRIVE SHAFTS - AS

OF MY 2005 (ALL MODELS)
INFORMATION
Axle joints: checking play and dust boots
1. Check play.
2. Visually inspect the dust boots for damage.
NOTE:  When doing so, the rubber dust boots should be pressed down with the
fingers to reveal hidden cracks.
 If a rubber dust boot leaks, the corresponding joint or control arm must be
replaced, because any dirt or moisture that seeps in will destroy the joint.
3. Inspect the dust boots of the axle joints (ball joints) on the wheel suspension (front and rear) as follows:
 Place the vehicle on a lifting platform with the steering lock disengaged.
 Perform a visual inspection after cleaning.
NOTE:  Over a small area in the vicinity of the brake cover panels, no visual
inspection is possible.
 Check this area by touch.
The procedure for the front axle is as follows:
 Turn the front wheels as far as they will go

 Perform a visual inspection of the visible surfaces on the left and right
 After turning the front wheels to the other steering stop, check the other half of each rubber dust boot.
Drive shafts: visual inspection of boots
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- Perform a visual inspection of the boots for leaks and damage.
03 IN RUNNING GEAR MAINTENANCE: STEERING GEAR - VISUAL

INSPECTION OF BELLOWS AND TIE ROD JOINTS: - AS OF MY 2005 (ALL
MODELS)
CHECKING
Checking bellows
NOTE:  The bellows on the steering gear can be damaged by outside influences,
for example by stone damage or during assembly work.
 The steering gear can become leaky if dirt or moisture enters a leaky
bellows.
- Visually inspect bellows for damage.
Tie rod ends: check play and dust bellows
1. Raise the vehicle. Refer to 40 Tightening torques for front axle - as of MY 2005 (All Models) .
NOTE:  The rubber dust bellows and tie rods can be damaged by external
influences, e. g. stone impact, or during assembly work.
 If a rubber dust bellow leaks, the joint or the tie rod must be replaced
because any dirt or moisture that seeps in will destroy the joint.
2. Check play and dust bellows.
3. Check dust bellows and joints are in working order and free of leaks.
03 IN ADDITIONAL MAINTENANCE - AS OF MY 2005 (ALL MODELS)

ADDITIONAL MAINTENANCE
Notes
NOTE:  The engine oil and oil filter must be changed every 10,000 km (6,000 mls)
in vehicles which are operated in countries where leaded fuel is used.
 Maintenance item > Check drive belt< must always be performed 60,000
km (40,000 mls) after replacement of the drive belt.
Maintenance every 2 years
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Maintenance every 2 years OK

Prepare Long-Life Guarantee Condition Report
Change brake fluid. Refer to 47 08 55 Replacing brake fluid - as of MY 2005 (All
Models) .
Maintenance every 4 years
Maintenance every 4 years OK

Replace Tire sealant
Maintenance after 4 then every 2 years
Maintenance after 4 then every 2 years OK

Check Tire pressure monitoring system battery
Maintenance after 4, 8, 10 then every 2 years
Maintenance after 4, 8, 10 then every 2 years OK

Check the airbag system. Refer to 69 01 Airbag diagnosis - as of MY 2005 (All Models) .
Ancillary unit mounts and running gear: visual inspection of all rubber mounts for damage
03 24 00 MINOR MAINTENANCE - AS OF MY 2005 (ALL MODELS)

MINOR MAINTENANCE
 If the mileage for scheduled maintenance is not reached, minor
maintenance must be carried out after 2, 6, 10...... years.
 The terms "inspect" and "check" include all necessary subsequent work
such as adjustment, readjustment, corrections and replenishment. They
do not include the repair, replacement or overhaul of components or
assemblies.
km (40,000 mls) after replacement of the drive belt. Observe the chapter on
additional maintenance for this purpose.
Minor maintenance at:

30,000, 90,000, 150,000, 210,000 km etc. OK
20,000, 60,000, 100,000, 140,000 mls etc.
Diagnosis system: read out fault memory --> 033500 On-board diagnosis.
Change engine oil and oil filter. Refer to 17 01 55 Engine oil and oil filter change - as of
MY 2005 (All Models) .
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Vehicle underside and engine compartment: Visual inspection for leaks (oils and fluids) and
abrasion (lines and hoses)
Underbody panel: visual inspection for completeness, installation and damage
Coolant hoses: check condition
Radiators and air inlets: visual inspection for external contamination and blockage
Coolant: check the level and antifreeze protection. Refer to 19 01 Checking cooling system
- as of MY 2005 (Boxster, Boxster RHD, Boxster S, Boxster S RHD) . Refer to 19 01
Checking cooling system - as of MY 2005 (Cayman S, Cayman S RHD) .
Particle filter: replace filter element. Refer to 85 18 19 Removing and installing particle
filter - as of MY 2005 (All Models) .
Brake system: visual inspection of the brake pads and brake discs for wear --> Running
gear maintenance: visual inspection of brake lines/brake pads/brake discs
Brake hoses and lines: visual inspection for leaks, damage, routing and corrosion -->
Running gear maintenance: visual inspection of brake lines/brake pads/brake discs
Drive shafts: visual inspection of the boots for leaks and damage --> Running gear
maintenance: axle joints/drive shafts
Tires: check condition and Tire pressure. Refer to 44 Wheels and Tires/Tire pressure - as
of MY 2005 (All Models) .
Check the door locks, lid locks and safety hooks of the front lid to ensure that they are
secure and function properly. Refer to 01 01 Checking lid and doors - as of MY 2005 (All
Models) .
Vehicle lighting: check operation
All headlights: check adjustment
Horn: check operation. Refer to 01 IN Checking the function of the vehicle's lights - as of
Windscreen wiper/washer system, headlight washer system: check fluids and nozzle
settings; pay attention to antifreeze protection in winter months; check wiper blades. Refer
to 01 IN Windscreen washer/headlight cleaning system: Check operation, nozzle
settings - as of MY 2005 (All Models) .
Electrical equipment, warning and indicator lights: check function. Refer to 01 IN
Checking electrical equipment such as control and warning lights for functionality. -
as of MY 2005 (All Models) .
Test drive: Remote control, front seats, foot and parking brakes (also actuation travel),
engine, clutch, steering, transmission, ParkAssist, cruise control, PSM switch, PASM
switch, heating, air-conditioning system and instruments: check operation --> Test drive
Oils, fluids: visual inspection for leaks
03 26 00 MAJOR MAINTENANCE - AS OF MY 2005 (ALL MODELS)

MAJOR MAINTENANCE
 If the mileage for scheduled maintenance is not reached, major
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maintenance must be carried out after 4, 8, 12...... years.

 The terms "inspect" and "check" include all necessary subsequent work
such as adjustments, readjustments, corrections and replenishment. They
do not include the repair, replacement or overhaul of components or
assemblies.
km (40,000 mls) after replacement of the drive belt. Observe the chapter on
additional maintenance for this purpose.
Major maintenance at
60,000, 120,000, 180,000, 240,000 km etc./ OK
40,000, 80,000, 120,000, 160,000 mls etc.
Diagnostic system: read out fault memory --> 033500 On-board diagnosis (OBD)
Change engine oil and oil filter. Refer to 17 01 55 Engine oil and oil filter change - as of
Vehicle underside and engine compartment: visual inspection for leaks (oils and fluids) and
abrasion (lines and hoses)Underbody panels: visual inspection for completeness,
installation and damage
Coolant hoses: check condition
Radiators and air inlets: visual inspection for external contamination and blockage
Coolant: check the level and antifreeze protection. Refer to 19 01 Checking cooling
system - as of MY 2005 (Boxster, Boxster RHD, Boxster S, Boxster S RHD) . Refer to
19 01 Checking cooling system - as of MY 2005 (Cayman S, Cayman S RHD) .
Air cleaner: replace air cleaner element. Refer to 24 24 19 Removing and installing air
cleaner element - as of MY 2005 (All Models) .
Particle filter: replace filter element. Refer to 85 18 19 Removing and installing particle
filter - as of MY 2005 (All Models) .
Fuel system: visual inspection for damage, routing and secure fit of line connections
Handbrake: check the free play of the parking-brake lever. Refer to 46 83 16 Adjusting the
parking-brake shoes - as of MY 2005 (All Models) .
Brake system: visual inspection of the brake pads and brake discs for wear --> Running
gear maintenance: visual inspection of brake lines/brake pads/brake discs
Brake hoses and lines: visual inspection for leaks, damage, routing and corrosion -->
Running gear maintenance: visual inspection of brake lines/brake pads/brake discs
Clutch: check pedal end position
Steering gear: visual inspection of bellows for damage Tie rod ends: check the play and
dust bellows --> Running gear maintenance: steering gear - visual inspection of bellows
and tie rod joints
Axle joints: check the play and visually inspect the dust bellows for damage --> Running
gear maintenance: axle joints/drive shafts
Check that the threaded connections of the running gear adjustment at the front and rear are
secure
Drive shafts: visual inspection of the boots for leaks and damage --> Running gear
maintenance: axle joints/drive shafts
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Exhaust system: visual inspection for leaks and damage, check mounts
Tires: check condition and Tire pressure. Refer to 44 Wheels and Tires/Tire pressure - as
Check the door locks, lid locks and safety hooks of the front lid to ensure that they are
secure and functioning properly. Refer to 01 01 Checking lid and doors - as of MY 2005
(All Models) .
Seat belts: check operation and condition. Refer to 69 13 01 Checking seat belts - as of
Vehicle lighting: check operation
All headlights: check adjustment
Horn: check operation. Refer to 01 IN Checking the function of the vehicle's lights - as
Windscreen wiper/washer system, headlight washer system: check operation, fluid level
and nozzle settings, pay attention to antifreeze protection in winter months; check wiper
blades. Refer to 01 IN Windscreen washer/headlight cleaning system: Check operation,
nozzle settings - as of MY 2005 (All Models) .
Electrical equipment, warning and indicator lights: check function. Refer to 01 IN
Checking electrical equipment such as control and warning lights for functionality. -
Test drive: Remote control, front seats, foot and parking brakes (also actuation travel),
engine, clutch, steering, transmission, ParkAssist, cruise control, PSM switch, PASM
switch, heating, air-conditioning system and instruments: check operation --> Test drive
Oils, fluids: visual inspection for leaks
03 35 00 ON-BOARD DIAGNOSIS (OBD) - AS OF MY 2005 (ALL MODELS)

TOOLS
Designation Type Number Explanation

PIWIS tester special tool P 9718
READING OUT AND ERASING FAULT MEMORY
Reading out and erasing fault memory
WARNING: Sudden voltage interruption of the power supply to the control unit.
 Damage to control units.
--> During on-board diagnosis, it is essential to guarantee the power supply for the Porsche System Tester. A
battery charger with a current rating of at least 40 A must be connected to the vehicle battery.
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Fig. 2: Diagnostic socket

The PIWIS tester P 9718 is connected to the vehicle via a diagnostic socket. The diagnostic socket is located
inside the vehicle in the vicinity of the driver's A-pillar below the instrument panel.
1. Start the PIWIS Tester P 9718 and follow the instructions on the Tester.
2. Select vehicle type, press >> and start the automatic control unit search.
3. If an asterisk appears in front of the relevant control unit, read out the fault memory and follow the
instructions on the Tester.
03 60 00 ADDITIONAL MAINTENANCE OF DRIVE BELT - AS OF MY 2005

(ALL MODELS)
ADDITIONAL MAINTENANCE OF DRIVE BELT
Additional maintenance - checking drive belt OK

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Check drive belt at 60,000 km/40,000 mls or every 4 years. Refer to 13 78 19 Removing
and installing drive belt - as of MY 2005 (All Models) .
Check drive belt at 150,000 km/100,000 mls or every 10 years. Refer to 13 78 19
Removing and installing drive belt - as of MY 2005 (All Models) .
Check drive belt at 240,000 km/160,000 mls or every 16 years. Refer to 13 78 19
Removing and installing drive belt - as of MY 2005 (All Models) .
03 81 00 ADDITIONAL MAINTENANCE OF SPARK PLUGS - AS OF MY 2005

(ALL MODELS)
ADDITIONAL MAINTENANCE OF SPARK PLUGS
Additional maintenance for spark plugs
Additional maintenance, replacing spark plugs OK

Replace spark plugs every 90,000 km/60,000 mls or every 4 years. Refer to 28 70 20
Removing and fitting spark plugs - as of MY 2005 (All Models) .
03 83 00 ADDITIONAL MAINTENANCE EVERY 90,000 KM/60.000 MLS OR

EVERY 6 YEARS - AS OF MY 2005 (ALL MODELS)
ADDITIONAL MAINTENANCE EVERY 90,000 KM/60.000 MLS OR EVERY 6 YEARS
Additional maintenance every 90,000 km/60,000 mls or every 6 years OK

Replace drive belt. Refer to 13 78 19 Removing and installing drive belt - as of MY 2005
(All Models) .
03 88 00 ADDITIONAL MAINTENANCE EVERY 180,000 KM/120.000 MLS OR

EVERY 12 YEARS - AS OF MY 2005 (ALL MODELS)
ADDITIONAL MAINTENANCE EVERY 180,000 KM/120.000 MLS OR EVERY 12 YEARS
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Notes
Additional maintenance every 180,000 km/120,000 mls or every 12 years

Manual transmission: change oil. Refer to 34 01 55 Changing transmission oil - as of MY
2005 (Boxster, Boxster RHD) . Refer to 34 01 55 Changing transmission oil - as of MY
2005 (Boxster S, Boxster S RHD, Cayman S, Cayman S RHD) .
Additional maintenance every 180,000 km/120,000 mls or every 12 years

Automatic transmission: change ATF and ATF filter. Refer to 37 02 55 Changing ATF -
as of MY 2005 (All Models) . Refer to 37 58 55 Replacing ATF filter - as of MY 2005
(All Models) .
Automatic transmission: change oil in final drive. Refer to 39 90 55 Changing oil for final
drive - as of MY 2005 (All Models) .
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GENERAL INFORMATION Service Reminder Indicators - Porsche
GENERAL INFORMATION
Service Reminder Indicators - Porsche
OXYGEN SENSOR WARNING LIGHT
NOTE: Most vehicles are equipped with a Malfunction Indicator Light (MIL) or check
engine light. If light comes on and remains on while driving, the vehicle requires
some type of repair. See appropriate service and repair information. After
repairing fault(s) and clearing fault code(s), the Malfunction Indicator Light (MIL)
or check engine light should go out. Some models may use a dual-function
indicator light, which is also used to indicate emission component service is
due. After performing required service, reset indicator light.
ALL MODELS WITH OXYGEN SENSOR LIGHT
Oxygen sensor (O2S) light will come on at 30,000 mile intervals as a reminder to replace sensor. After
replacing sensor, reset warning light as follows:
1. On 911 models, disconnect battery ground cable and remove speedometer. Counter will be visible
through speedometer mounting hole. Using a thick piece of wire or a thin rod, press White reset button all
the way in against stop. Ensure warning light is out.
2. On 924 models, after replacing oxygen sensor and with vehicle still raised, locate mileage counter on left
engine mount. Using a thick wire or thin metal rod, push in reset button all the way to stop. Ensure
warning light is out.
3. On 928 and 928S with CIS system, counter is located to right of passenger seat floor (near door sill).
Remove counter cover retaining screw and cover. Press reset button all the way in against stop. Ensure
warning light is out.
SERVICE REMINDER INDICATOR (SRI)

CAYENNE (3.2L V6)
After changing the oil, the oil change service interval must be reset in the instrument cluster using the PST2
(Porsche System Tester 2). The country version for which the new vehicle was produced is stored in the control
modules. The PST2 automatically detects this country version before resetting the maintenance calculator.
For more information, see CAYENNE (V6) - ENGINE OILS APPROVED BY PORSCHE technical service
bulletin.
TIMING BELT TENSION INDICATOR LAMP

1985-1994 928S, 928 S4, 928 GT
The engine is equipped with a timing belt tension switch. If the timing belt tension indicator lamp comes on, use
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Fig. 1 as a guide to diagnosis. Lamp will turn off automatically when the correct timing belt tension is restored
or electrical problem is corrected.
Fig. 1: Diagnosing Timing Belt (Camshaft Drive Belt) Tension Indicator Lamp
NOTE: This information comes from Porsche technical service bulletin No. 9010, Group
1. Publication date of April 12, 1990.
TIRE PRESSURE MONITOR SYSTEM

2005-06 CAYENNE
NOTE: If tires have been rotated, tire pressure changed, or a tire pressure sensor or
wheel has been replaced, the TPM system must be reset.
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1. Select menu "TYRE PRESSURE", "SETTINGS, then "TYRES". Set tire type and tire size (both items
must be set).
NOTE: The tire type and size must be selected even if the settings for the new set
of wheels are the same as for the old wheels.
2. The learning process is now started, and will be completed when vehicle is driven. The current tire
pressure will not be displayed until the learning phase is complete. See Fig. 2.
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Fig. 2: Identifying TPM System Learning Phase Screen

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2007-08 BOXSTER, CAYENNE, CAYMAN & 911
NOTE: For diagnostic information, refer to WHEELS, TIRES, ALIGNMENT .
The Tire Pressure Monitoring System (TPMS) begins to "learn" the wheels after a wheel change, wheel
transmitter replacement or update of tire settings. During this process, the TPMS recognizes the tires and their
locations. The on-board computer displays the message "TPC INACTIVE - SYSTEM LEARNING".
The TPMS requires a certain amount of time to learn the wheels. During this time, the current tire pressure are
not available on the on-board computer. The wheel learning process takes place exclusively when vehicle is
being driven.
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ACCESSORIES & EQUIPMENT Bumpers
ACCESSORIES & EQUIPMENT
Bumpers
63 IN SAFETY INSTRUCTIONS - AS OF MY 2005 (ALL MODELS)

SAFETY INSTRUCTIONS FOR WORK ON CAR WINDOWS
Danger of injury when working on car windows
WARNING: Danger of cut injuries when removing and installing car windows!
 Cutting out glued car windows may lead to cut injuries to the skin
and eyes due to flying glass splinters and may result in cut injuries
from the knife of the cutter.
--> Always wear protective gloves when working on car windows.
--> Wear protective goggles when cutting out car windows.
--> Only replace the cutting knife with the power supply disconnected so that the cutter is not switched on
accidentally.
Material damage when removing the glass from car windows
CAUTION: Danger of damage to the label with the vehicle identification number!
 Danger of paint damage and damage to the label with the vehicle
identification number if windscreen is removed incorrectly!
--> When cutting out the windscreen, ensure that the label with the vehicle identification number is not
damaged!
Material damage when inserting the glass into car windows
CAUTION: Danger of material damage if specified curing time of adhesive is not

observed!
 There will not be a proper adhesive bond if the prescribed curing

time of the adhesive is not observed!
--> The vehicle must not be used until the curing time has elapsed.
--> Curing time: 3 hours
--> Temperature: at least 10°C

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--> Fixing time: approx. 1 hour
SAFETY INSTRUCTIONS FOR INSTALLATION WORK
Safety instructions for airbag system
CAUTION: Danger of injury due to unintentional activation of airbag units!
 Serious injury due to unintentional activation of airbag units!
--> The ground strap of the battery must be disconnected during work on the airbag system and alignment bench
jobs when the body is being repaired!
--> After the battery is disconnected, assembly work or work on the vehicle with a hammer or similar tools must
not be started until after a waiting period of 1 minute!
Safety instructions for the heat shield
CAUTION: The installation of deformed heat shields will cause damage!
 The installation of deformed heat shields will cause damage due to

parts heating up!
--> Damaged or distorted heat shields must be straightened or replaced.
--> Check heat shields for deformation, fixing of the aluminum braided cord, tears and missing or damaged
fixing tabs.
--> After fitting the bumper, check heat shields and aluminum braided cord for leaks.
63 10 19 REMOVING AND INSTALLING FRONT BUMPER - AS OF MY 2005

(ALL MODELS)
PRELIMINARY WORK
Preliminary work
1. Remove front apron. --> 631519 Removing and installing front apron - chapter on "Removing"
NOTE: Only open for vehicles with garage door function.
2. Remove control unit for garage door opener. Refer to 96 79 19 Removing and installing garage door
opener control unit - as of MY 2005 (All Models) .
REMOVING FRONT BUMPER
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Removing the front bumper
Installation Location:
Fig. 1: Installation position of front bumper

Fig. 2: Removing the front bumper

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1. Unscrew fastening screws -1- and remove bumper -2- . See Fig. 2.
INSTALLING FRONT BUMPER
Installing the front bumper
Fig. 3: Installation position of front bumper

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Fig. 4: Installing the front bumper

1. Position bumper -2- . See Fig. 4.
2. Screw in fastening screws -1- and tighten to the specified tightening torque. Tightening torque --> Final
tightening: 63 ftlb. . See Fig. 4.
SUBSEQUENT WORK
Subsequent work
1. Install control unit for garage door opener. Refer to 96 79 19 Removing and installing garage door opener
control unit - as of MY 2005 (All Models) .
2. Install front apron. --> 631519 Removing and installing front apron - chapter on "Installing"
63 15 19 REMOVING AND INSTALLING FRONT SPOILER - AS OF MY 2005

(ALL MODELS)
TOOLS

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assembly tool VW-tool T10118
PRELIMINARY WORK
Preliminary work
Remove cover for lock mount. Refer to 70 39 19 Removing and installing cover for front lock mount - as of
MY 2005 (All Models) . Refer to 70 39 19 Removing and installing cover for rear lock carrier - as of MY
2006 (Cayman S, Cayman S RHD) .
Remove front section of front wheel housing liner on the left and right. Refer to 50 56 19 Removing and
installing front wheel housing liner - as of MY 2005 (All Models) .
REMOVING FRONT SPOILER
Undoing front spoiler underneath
Fig. 5: Main illustration - front apron

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Fig. 6: Undoing front spoiler underneath

1. Unscrew fastening screws -1- underneath the front spoiler -2- . See Fig. 6.
Undoing front spoiler at the sides
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Fig. 8: Undoing front spoiler at the sides

1. Unscrew fastening screws -1- at the sides of the front spoiler -2- . See Fig. 8.
Disconnecting electrical plug connection
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Fig. 9: Main illustration of front apron

Fig. 10: Disconnecting electrical plug connection

1. Disconnect wiring harness -1- Press lug -arrow A- and pull plug connection apart -arrow B- . See Fig. 10.
Removing hose for headlight cleaning system

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NOTE:  Only in vehicles with headlight cleaning system!
NOTE:  A tight hose can be pulled off more easily if it is heated with a hot-air gun!
 Collect windscreen washer system fluid with a suitable container.
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Fig. 12: Removing hose for headlight cleaning system

1. Press in lock -2- and pull water feed line for headlight cleaning system -2- apart -in direction of arrow- . See
Fig. 12.
Undoing front apron at the top
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Fig. 14: Undoing front spoiler at the top

1. Open front end fixing devices -1- using assembly tool T10118 at the guides -2- of the front spoiler in -
direction of arrow- . See Fig. 14.
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Fig. 15: Undoing front spoiler at the top

2. Unscrew fastening screws -1- at the top of the front spoiler -2- . See Fig. 15.
3. Remove front spoiler -2- by pulling it towards the front. See Fig. 15.
INSTALLING FRONT SPOILER
Securing front spoiler at the top
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NOTE:  Ensure water and electrical lines are laid properly.
1. Check retaining strip for front apron and replace if necessary. --> 631719 Removing and installing
retaining strip
2. Check sheetmetal nuts -3- , replace if necessary. See Fig. 17.
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Fig. 17: Securing front spoiler at the top

3. Position the front spoiler -2- on the body at the front. See Fig. 17.
4. Screw in fastening screws -1- at the top on the front apron -2- and tighten to the specified torque. --> Final
tightening: 2.1 ftlb. . See Fig. 17, Fig. 18.
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Fig. 18: Securing front spoiler at the top

5. Engage locks -1- at the guides -2- of the front spoiler and lock in -direction of arrow- using a plastic wedge.
See Fig. 18.
Securing front spoiler at the sides
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Fig. 20: Securing front spoiler at the sides

1. Screw in fastening screws -1- laterally on the front apron -2- and tighten to the specified torque. --> Final
tightening: 2.1 ftlb. . See Fig. 20.
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Locking hose for headlight cleaning system

NOTE:  Only in vehicles with headlight cleaning system!
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Fig. 22: Locking hose for headlight cleaning system

1. Connect water feed line for headlight cleaning -1- -arrows- . See Fig. 22.
Locking electric plug connection
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Fig. 24: Locking electric plug connection

1. Press in -1- electric plug connection -arrow A- until it engages audibly. See Fig. 24.
Securing front spoiler underneath
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Fig. 26: Securing front spoiler underneath

1. Screw in fastening screws -1- at the bottom on the front apron -2- and tighten to the specified torque. -->
Final tightening: 2.8 (2 ftlb.) Nm . See Fig. 26.
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2. Check gap dimensions on lid, wing and main headlight. If necessary, unscrew fastening screws and adjust the
gap dimensions by moving the front spoiler. Refer to 50 IN Processing structural body adhesive - as of MY
2005 (All Models) .
SUBSEQUENT WORK
Subsequent work
Install front section of front wheel housing liner on the left and right. Refer to 50 56 19 Removing and
Install cover for lock mount. Refer to 70 39 19 Removing and installing cover for front lock mount - as of
MY 2005 (All Models) . Refer to 70 39 19 Removing and installing cover for rear lock carrier - as of MY
63 15 37 DISASSEMBLING AND ASSEMBLING FRONT APRON - AS OF MY

2005 (BOXSTER, BOXSTER RHD, BOXSTER S, BOXSTER S RHD)
PRELIMINARY WORK
Preliminary work
2. Remove auxiliary headlight. Refer to 94 71 19 Removing and installing auxiliary headlight - as of MY

2005 (Boxster, Boxster RHD, Boxster S, Boxster S RHD) .
3. Remove right and left flasher repeater. Refer to 94 53 19 Removing and installing side direction indicator
light - as of MY 2005 (All Models) .
NOTE:  Only for vehicles with headlight cleaning system.
4. Remove spray nozzle for headlight washer system. Refer to 92 72 19 Removing and installing spray nozzle
for headlight washer system - as of MY 2005 (All Models) .
5. Remove front ventilation grille. Refer to 66 04 19 Removing and installing front air grille - as of MY 2005
(Boxster, Boxster RHD, Boxster S, Boxster S RHD) .
6. Remove front wiring harness. Refer to 97 15 19 Removing and installing front wiring harness - as of MY
2005 (All Models) .
7. Remove hose for headlight washer system. Refer to 92 77 19 Removing and installing hose for headlight
washer - as of MY 2005 (All Models) .
Microsoft
8. Remove number plate cover.
DISASSEMBLING FRONT APRON
Removing cover cap

Microsoft
Fig. 28: Removing cover cap

1. Carefully press out the cover cap -2- with a screwdriver. The securing cord -3- the cover cap -2- and the front
end -1- are joined as they pull out. See Fig. 28.
Removing side covering frame
Microsoft

Fig. 30: Removing side covering frame

1. Carefully press in the lugs of the covering frame at the side -2- with a screwdriver -arrow A- . First remove
the covering frame -2- downwards -direction of arrow B- . Afterwards pull rearward -direction of arrow C-
out of the front end Fig. 30 -1- . See Fig. 30.
Microsoft
Removing support for wire harness

Microsoft
Fig. 32: Removing support for wire harness

1. Insert a screw driver between front apron -1- and support -2, 3- and carefully take off. Check support -2, 3- ,
replace if necessary. See Fig. 32.
2. Take off and check fastening nut -4- , replace if necessary. See Fig. 32.
Pulling off joining latch
Microsoft

Fig. 34: Pulling off joining latch

1. Pull off joining latch -2- from the front apron -1- . See Fig. 34.
ASSEMBLING FRONT SPOILER

Microsoft
Affixing joining latch

Fig. 36: Affixing joining latch

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1. Position joining latch -2- on the front apron -1- and bond. See Fig. 36.
Install support

1. Press in fastening nuts -4- . See Fig. 38.
Microsoft
Fig. 38: Installing support for wire harness

2. Position support -2, 3- on the front apron -1- and press in. See Fig. 38.
Installing side covering frame
Microsoft

Fig. 40: Installing side covering frame

1. Insert frame laterally -2- upwards into -direction of arrow A- the front apron -1- and lock -direction of
arrow B- . See Fig. 40.
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Installing cover cap

Fig. 42: Installing cover cap

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1. Pull the securing cord -3- into the eyelet of the front apron. Clip cap -2- into the front apron -1- . See Fig. 42.
SUBSEQUENT WORK
Subsequent work
1. Install number plate cover.
2. Install front wiring harness. Refer to 97 15 19 Removing and installing front wiring harness - as of MY
2005 (All Models) .
3. Install front ventilation grille. Refer to 66 04 19 Removing and installing front air grille - as of MY 2005
4. Install hose for headlight washer system. Refer to 92 77 19 Removing and installing hose for headlight
5. Install spray nozzle for headlight washer system. Refer to 92 72 19 Removing and installing spray nozzle
6. Install right and left flasher repeater. Refer to 94 53 19 Removing and installing side direction indicator
7. Install auxiliary headlight. Refer to 94 71 19 Removing and installing auxiliary headlight - as of MY 2005
63 15 37 DISASSEMBLING AND ASSEMBLING FRONT SPOILER - AS OF

MY 2006 (CAYMAN S, CAYMAN S RHD)
PRELIMINARY WORK
Preliminary work
2. Remove auxiliary headlight. Refer to 94 71 19 Removing and installing auxiliary headlight - as of MY

3. Remove right and left flasher repeater. Refer to 94 53 19 Removing and installing side direction indicator
Microsoft
4. Remove spray nozzle for headlight washer system. Refer to 92 72 19 Removing and installing spray nozzle
5. Remove front ventilation grille. Refer to 66 04 19 Removing and installing front air grille - as of MY 2005
(Cayman S, Cayman S RHD) .
6. Remove front wiring harness. Refer to 97 15 19 Removing and installing front wiring harness - as of MY
2005 (All Models) .
7. Remove hose for headlight washer system. Refer to 92 77 19 Removing and installing hose for headlight
8. Remove number plate cover.
DISASSEMBLING FRONT SPOILER
Removing cover cap

Microsoft

1. Carefully press out the cover cap -2- with a screwdriver. The securing cord -3- the cover cap -2- and the front
Removing spoiler trim
Microsoft

Fig. 46: Removing spoiler trim

1. Press out retaining pins and remove expanding clip -1- . See Fig. 46.
2. Unclip spoiler trim -2- from front apron -3- . See Fig. 46.
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Removing support for wire harness

Microsoft
Fig. 48: Removing support

1. Insert a screw driver between front apron -1- and the support -2, 3- and carefully remove. Check support -2,
3- , and replace if necessary. See Fig. 48.
2. Remove fastening nut -4- , inspect and replace if necessary. See Fig. 48.
3. Turn fastening clip -5- through 90° and remove. See Fig. 48.
Pulling off joining latch
Microsoft

Fig. 50: Pulling off joining latch

1. Pull joining latch -2- from the front spoiler -1- . See Fig. 50.
Disassembling cover for auxiliary headlight

Microsoft

Fig. 52: Disassembling cover for auxiliary headlight

1. Separate cover upper part -1- from cover lower part -2- at the locking tabs. See Fig. 52.
Microsoft
ASSEMBLING FRONT SPOILER
Assembling cover for auxiliary headlight

Fig. 54: Assembling cover for auxiliary headlight

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1. Position cover upper part -1- on cover lower part -2- and press together until the locking tabs engage. See
Fig. 54.
Affixing joining latch

Microsoft
Fig. 56: Affixing joining latch

1. Position joining latch -2- on the front spoiler -1- and affix in place. See Fig. 56.
Installing support for wire harness
Microsoft

Fig. 58: Installing support

1. Position fastening clip -5- on the front spoiler -1- and turn through 90°. See Fig. 58.
2. Press in fastening nut -4- . See Fig. 58.
3. Position support -2, 3- on the front apron -1- and press in. See Fig. 58.
Installing spoiler trim
Microsoft

Fig. 60: Installing spoiler trim

1. Insert spoiler trim -2- into the front spoiler -3- and lock it in place. See Fig. 60.
2. Fasten spoiler trim -2- with the expanding clips -1- by pressing in the retaining pins. See Fig. 60.
Microsoft


Microsoft
1. Pull the securing cord -3- into the eyelet of the front apron. Insert cap -2- into the front apron -1- . See Fig.
62.
SUBSEQUENT WORK
Subsequent work
1. Install number plate cover.
2. Install front wiring harness. Refer to 97 15 19 Removing and installing front wiring harness - as of MY
2005 (All Models) .
3. Install front ventilation grille. Refer to 66 04 19 Removing and installing front air grille - as of MY 2005
4. Install hose for headlight washer system. Refer to 92 77 19 Removing and installing hose for headlight
5. Install spray nozzle for headlight washer system. Refer to 92 72 19 Removing and installing spray nozzle
6. Install right and left flasher repeater. Refer to 94 53 19 Removing and installing side direction indicator
7. Install auxiliary headlight. Refer to 94 71 19 Removing and installing auxiliary headlight - as of MY 2006
63 17 19 REMOVING AND INSTALLING RETAINING STRIP FOR FRONT

APRON - AS OF MY 2005 (ALL MODELS)
PRELIMINARY WORK
Preliminary work
2. Remove control unit for garage door opener. Refer to 96 79 19 Removing and installing garage door
Microsoft
opener control unit - as of MY 2005 (All Models) .
REMOVING FRONT RETAINING STRIP
Removing front retaining strip
Fig. 63: Overview, front retaining strip

Microsoft
Fig. 64: Removing front retaining strip

1. Unscrew fastening nuts -2- and remove front retaining strip -1- . See Fig. 64.
INSTALLING FRONT RETAINING STRIP
Installing front retaining strip
Microsoft
Fig. 65: Overview, front retaining strip

Fig. 66: Installing front retaining strip

1. Position front retaining strip -1- on the body and tighten down slightly with the fastening nuts -2- . See Fig.
66.
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Adjusting front retaining strip
NOTE:  In order to reduce adjustment work to a minimum when assembling the

front spoiler, the front retaining strip must be aligned with the lower edge
of the lid according to the dimensions shown.
 However, the precondition for precise positioning of the components is
that the front lid is optimally adjusted and correctly locked in the lock in
accordance with the joining plan, before the front retaining strip is
assembled.
NOTE: All measurements refer to the position -V- --> Adjustment dimension: 632 mm
See Fig. 67.
1. Adjust the front lid according to the joining plan. Refer to 50 IN Processing structural body adhesive - as
Fig. 67: Adjustment dimensions, front retaining strip

2. After fitting the front retaining strip, check the distance -X- --> Adjustment dimension: 26 mm +/-1 mm
between front lid and retaining strip -Y- --> Adjustment dimension: 91 mm +/-0.5 mm . See Fig. 67.
3. Check retaining strip on both sides to dimension -W- --> adjustment dimension: 130 mm +/-0.5 mm to
wing and adjust. The measurements can be changed by undoing or moving the front retaining strip -1- . See Fig.
67.
4. Tighten fastening nuts -2- Tightening torque --> Final tightening: 10 (7.5 ftlb.) Nm . See Fig. 66.
SUBSEQUENT WORK
Microsoft
Subsequent work
1. Install control unit for garage door opener. Refer to 96 79 19 Removing and installing garage door opener
63 33 19 REMOVING AND INSTALLING FRONT BRACKET (IMPACT PIPE) -

AS OF MY 2005 (ALL MODELS)
PRELIMINARY WORK
Preliminary work
Removing front apron. --> 631519 Removing and installing front apron - "Removing" chapter
Remove front bumper. --> 631019 Removing and installing front bumper - "Removing" section
REMOVING FRONT BRACKET (IMPACT PIPE)
Removing front impact pipe
Fig. 68: Installation position of front impact pipe

Microsoft
Fig. 69: Removing front impact pipe

1. Undo fastening screws -1- . See Fig. 69.
2. Remove the impact pipe -2- and seal -3- . See Fig. 69.
INSTALLING FRONT BRACKET (IMPACT PIPE)
Install front impact pipe
Microsoft
Fig. 70: Installation position of front impact pipe

Fig. 71: Install front impact pipe

1. Position the seal impact pipe -3- and impact pipe -2- . See Fig. 71.
2. Screw in fastening screws -1- and tighten to the required tightening torque. --> Final tightening: 17 ftlb. .
Microsoft
See Fig. 71.
SUBSEQUENT WORK
Subsequent work
Install front bumper. --> 631019 Removing and installing front bumper - "Installing" section
Installing front apron. --> 631519 Removing and installing front apron - "Installing" chapter
63 50 19 REMOVING AND INSTALLING REAR BUMPER - AS OF MY 2005

(BOXSTER, BOXSTER RHD, BOXSTER S, BOXSTER S RHD)
PRELIMINARY WORK
Preliminary work
Remove rear apron. --> 635519 Removing and installing rear apron - chapter on "Removing" [987320
987321] --> 635519 Removing and installing rear apron - chapter on "Removing" [987310 987311]
GENERAL WARNING NOTES

parts heating up!
fixing tabs.
REMOVING REAR BUMPER
Removing support with heat shield at the sides
Microsoft
Fig. 72: Installation position of support with heat shield at the sides
Fig. 73: Removing support with heat shield at the sides

1. Unscrew fastening nuts -1, 2- and remove support with heat shield at the sides -3- . See Fig. 73.
Removing rear bumper

Microsoft
Fig. 74: Installation position of rear bumper

Microsoft
Fig. 75: Removing rear bumper

1. Unscrew fastening screws -1- , remove rear bumper -2 - or (USA/Canada version) -2A- with mounted lower
center heat shield -3- . See Fig. 75.
2. Unscrew fastening screw -4- with washer -5- . See Fig. 75.
3. Unscrew fastening screws -7- , remove lower center heat shield -3- and rear supports -8- If necessary
disassemble rear supports by unscrewing the fastening screws -7- Remove connecting angle -9- and fastening
nuts Fig. 75 -10- . See Fig. 75.
Checking anti-chafing film
Microsoft
Fig. 76: Installation position of anti-chafing film

Microsoft
Fig. 77: Checking anti-chafing film

NOTE: Replacing anti-chafing film:
 The bonding surface must be free from dirt, oil, and water residues.
 Ensuring there are no bubbles, bond in the anti-chafing film to the
dimension X= 0 - 2 mm at the hole opening and side panel surface.
1. Check anti-chafing film -1- , and replace if necessary. See Fig. 77.
2. Check fastening nuts -2- and replace if necessary. See Fig. 77.
INSTALLING REAR BUMPER

Microsoft
Installing rear bumper

Microsoft
Fig. 79: Installing rear bumper

1. Position lower center heat shield -3- together with rear support -8- and screw in with fastening screws -6- .
See Fig. 79.
2. Screw in fastening screw -4- with washer -5- . See Fig. 79.
3. Position connecting angle -9- and screw in with fastening screws -7- to the fastening nuts -10- . See Fig. 79.
4. Position rear bumper -2- or (USA/Canada version) -2A- with mounted center heat shield at the bottom -3- .
See Fig. 79.
5. Tighten fastening screws -1- --> Tightening torque: 85 (63 ftlb.) Nm . See Fig. 79.
Microsoft
6. Check the functional dimensions of the rear bumper and the correct assembly of the heat shield and correct if
necessary. --> 635019 Removing and installing rear bumper - chapter on "Adjusting"
Installing support with heat shield at the sides
NOTE: Make sure that the plastic tabs are incontact with the side panel at the top.
Microsoft
Fig. 81: Installing support with heat shield at the sides

1. Install support with heat shield at the sides -3- . See Fig. 81.
2. Tighten fastening nuts -1- --> Tightening torque: 2 (1.5 ftlb.) Nm . See Fig. 81.
3. Tighten fastening nuts -2- --> Tightening torque: 9.7 (7.0 ftlb.) Nm . See Fig. 81.
4. Check correct fitting of heat shield, and correct if necessary. --> 635019 Removing and installing rear
bumper - chapter on "Adjusting"
ADDITIONAL ASSEMBLY INSTRUCTIONS FOR INSTALLATION OF THE BUMPER
Microsoft
Functional dimensions of the bumper

rear apron, the rear bumper or bracket (impact pipes, impact absorbers)
must be positioned with respect to the lower edge of the rear lid according
to the dimensions shown.
that the rear lid is optimally adjusted and correctly locked in the lock in
accordance with the functional dimensions, before the rear bumper or rear
retaining strip are assembled.
1. Check the functional dimensions for the rear retaining strip, and correct if necessary. --> 635719 Removing
and installing rear retaining strip - chapter on "Adjusting"
2. The adjustment dimensions at the measuring points -V = 345 mm- are to be adjusted. See Fig. 82.
3. Set adjustment dimension for the upper edge of retaining strip -2- to rear lid, -3- lower edge -X = 72.5 mm- .
See Fig. 82.
Fig. 82: Adjustment dimensions of the bumper

4. Set adjustment dimension for the upper edge of bumper -1- to retaining strip, -2- upper edge -Y = 165 mm- .
See Fig. 82.
5. Set adjustment dimension for the lower edge of rear lid -3- to bumper, -1- upper edge -Z = 234 mm- . See
Fig. 82.
6. The measurements can be changed by undoing and moving the brackets (impact pipes, impact absorbers) or
Microsoft
retaining strip.
Correct assembly of the heat shields
CAUTION: Damage will result if heat shields are fitted incorrectly!
 Observe the following points during assembly!
--> Make sure the heat shields overlap correctly (arrows).
--> There should not be any continuous gaps along the entire length of the heat shields.
--> A gap of up to 2 mm wide and 30 mm long is permissible locally.
--> At least more than 80 % of the total sealing area should be sealed off without gaps.
Fig. 83: Correct assembly of the heat shields

A - Heat protection shield for upper exhaust system
B - Heat protection shield for lateral exhaust system (left and right)
C - Heat shield for rear exhaust system
SUBSEQUENT WORK
Subsequent work
Microsoft
Install rear apron. --> 635519 Removing and installing rear apron - chapter on "Removing" [987320
63 50 19 REMOVING AND INSTALLING REAR BUMPER - AS OF MY 2005

(CAYMAN S, CAYMAN S RHD)
PRELIMINARY WORK
Preliminary work
Remove rear apron. --> 635519 Removing and installing rear apron - chapter on "Removing"

parts heating up!
fixing tabs.
REMOVING REAR BUMPER
Removing support with heat shield at the sides
Microsoft
Fig. 85: Removing support with heat shield at the sides

1. Unscrew fastening nuts -1, 2- and remove support with heat shield at the sides -3- . See Fig. 85.
Removing rear bumper

Microsoft

Microsoft
Fig. 87: Removing rear bumper

1. Unscrew fastening screws -1- , remove rear bumper -2- or (USA/Canada version) -2A- with mounted lower
center heat shield -3- . See Fig. 87.
2. Unscrew fastening screw -4- with washer -5- . See Fig. 87.
3. Unscrew fastening screws -6- , remove lower center heat shield -3- and rear support -7- . See Fig. 87.
Checking anti-chafing film
Microsoft
Fig. 88: Installation position of anti-chafing film

Microsoft
Fig. 89: Checking anti-chafing film

NOTE: Replacing anti-chafing film:
 The bonding surface must be free from dirt, oil, and water residues.
 Ensuring there are no bubbles, bond in the anti-chafing film to the
dimension X= 0 - 2 mm at the hole opening and side panel surface.
1. Check anti-chafing film -1- , and replace if necessary. See Fig. 89.
INSTALLING REAR BUMPER

Microsoft
Installing rear bumper

Microsoft
Fig. 91: Installing rear bumper

1. Position lower center heat shield -3- together with rear support -7- and tighten with fastening screws -6- . See
Fig. 91.
2. Screw in fastening screw -4 - with washer -5- . See Fig. 91.
3. Position rear bumper -2- or (USA/Canada version) -2A- with mounted lower center heat shield -3- . See Fig.
91.
4. Tighten fastening screws -1- --> Tightening torque: 85 (63 ftlb.) Nm . See Fig. 91.
5. Check the functional dimensions of the rear bumper and the correct assembly of the heat shield and correct if
Microsoft
necessary. --> 635019 Removing and installing rear bumper - chapter on "Adjusting"
Installing support with heat shield at the sides
NOTE: Make sure that the plastic tabs are incontact with the side panel at the top.
Microsoft
Fig. 93: Installing support with heat shield at the sides

1. Install support with heat shield at the sides -3- . See Fig. 93.
2. Tighten fastening nuts -1- --> Tightening torque: 2 (1.5 ftlb.) Nm . See Fig. 93.
3. Tighten fastening nuts -2- --> Tightening torque: 9.7 (7.0 ftlb.) Nm . See Fig. 93.
4. Check correct fitting of heat shield, and correct if necessary. --> 635019 Removing and installing rear
bumper - chapter on "Adjusting"
ADDITIONAL ASSEMBLY INSTRUCTIONS FOR INSTALLATION OF THE BUMPER
Microsoft
Functional dimensions of the bumper

rear apron, the rear bumper or bracket (impact pipes, impact absorbers)
must be positioned with respect to the lower edge of the rear lid according
to the dimensions shown.
accordance with the functional dimensions, before the rear bumper or rear
retaining strip are assembled.
1. Check the functional dimensions for the rear retaining strip, and correct if necessary. --> 635719 Removing
and installing rear retaining strip - chapter on "Adjusting"
2. The adjustment dimensions at the measuring points -V = 345 mm- are to be adjusted. See Fig. 94.
3. Set adjustment dimension for the upper edge of retaining strip -2- to rear lid, -3- lower edge -X = 72.5 mm- .
See Fig. 94.
Fig. 94: Adjustment dimensions of the bumper

4. Set adjustment dimension for the upper edge of bumper -1- to retaining strip, -2- upper edge -Y = 165 mm- .
See Fig. 94.
5. Set adjustment dimension for the lower edge of rear lid -3- to bumper, -1- upper edge -Z = 234 mm- . See
Fig. 94.
6. The measurements can be changed by undoing and moving the brackets (impact pipes, impact absorbers) or
Microsoft
retaining strip.
Correct assembly of the heat shields
CAUTION: Damage will result if heat shields are fitted incorrectly!
 Observe the following points during assembly!
--> Make sure the heat shields overlap correctly (arrows).
--> There should not be any continuous gaps along the entire length of the heat shields.
--> A gap of up to 2 mm wide and 30 mm long is permissible locally.
--> At least more than 80 % of the total sealing area should be sealed off without gaps.
Fig. 95: Correct assembly of the heat shields

A - Heat protection shield for upper exhaust system
B - Heat protection shield for lateral exhaust system (left and right)
C - Heat shield for rear exhaust system
SUBSEQUENT WORK
Subsequent work
Microsoft
Install rear apron. --> 635519 Removing and installing rear apron - chapter on "Removing"
63 55 19 REMOVING AND INSTALLING REAR SPOILER - AS OF MY 2005

(BOXSTER S, BOXSTER S RHD)
General warning notes
General warning notes for rear apron --> 63 IN Safety instructions - as of MY 2005 (All Models).
PRELIMINARY WORK
Preliminary work
1. Remove rear light on right and left. Refer to 94 31 19 Removing and installing tail light - as of MY 2005
(All Models) .
2. Remove the rear spoiler. Refer to 66 58 19 Removing and installing rear spoiler - as of MY 2005
3. Push rear spoiler in and down.
REMOVING REAR SPOILER
Removing rear spoiler
Fig. 96: Installation location of rear apron

Microsoft
Fig. 97: Undoing rear spoiler at the sides

1. Unscrew fastening screws -1- at the sides of the rear spoiler -2- . See Fig. 97.
2. Remove retainer plate -3- . See Fig. 97.
Microsoft
Fig. 98: Loosening the rear spoiler at top

3. Unscrew fastening screws -1- at the top of the rear spoiler -2- . See Fig. 98.
4. Carefully pull rear apron -2- to the rear until the plug connection is accessible. See Fig. 98.
Microsoft
Fig. 99: Disconnecting plug connection

5. Press lug -arrow- of the plug connection -4- and separate. See Fig. 99.
6. Remove rear spoiler.
INSTALLING REAR SPOILER

parts heating up!
fixing tabs.
Installing rear spoiler
Microsoft

1. Check the heat shields on the vehicle before fitting the rear spoiler and replace the heat protection shield if
necessary. Check that the heat shields are properly fitted and correct if necessary. --> 635019 Removing and
installing rear bumper - chapter on "Checking"
Microsoft
Fig. 101: Connecting the plug connection

2. Plug in electrical plug connection -4- . See Fig. 101.
Fig. 102: Fastening the rear spoiler at top

3. Position rear spoiler -2- on the vehicle. See Fig. 102.
4. Screw in fastening screws -1- above and below on the rear apron -2- and tighten to tightening torque -->
Tightening torque: 2 ftlb. . See Fig. 102.
Microsoft
Fig. 103: Fastening rear spoiler at the sides

5. Engage retainer plate -3- in square opening. See Fig. 103.
6. Screw in fastening screws -1- laterally on the rear apron -2- and tighten to the specified torque. -->
DIMENSIONS OF TAILPIPES
Gap dimension of tailpipe
Microsoft
Fig. 104: Gap dimension of tailpipe

1. Check gap dimensions of tailpipes -1- to rear apron -2- , if necessary, adjust tailpipes -1- . See Fig. 104.
Projection from rear spoiler: -Y = 26,2 ± 2 mm- . See Fig. 104.
Distance from rear spoiler: -Z = 25 mm- . See Fig. 104.
center distance at the sides evenly to the left and right.
SUBSEQUENT WORK
Subsequent work
1. After rear apron assembly, check heat protection shields for correct assembly, if necessary, correct. -->
635019 Removing and installing rear bumper - chapter on "Checking"
2. Check rear gap dimensions, adjust if necessary. Refer to 50 IN Processing structural body adhesive - as of
3. Install rear apron. Refer to 66 58 19 Removing and installing rear spoiler - as of MY 2005 (Boxster,
Boxster RHD, Boxster S, Boxster S RHD) .
4. Install rear light on right and left. Refer to 94 31 19 Removing and installing tail light - as of MY 2005 (All
Models) .
Microsoft

(BOXSTER, BOXSTER RHD)
PRELIMINARY WORK
Preliminary work
(All Models) .
Removing rear spoiler

Microsoft
Fig. 106: Undoing rear spoiler at the sides

1. Unscrew fastening screws -1- at the sides of the rear spoiler -2- . See Fig. 106.
Microsoft
Fig. 107: Loosening the rear spoiler at top

3. Unscrew fastening screws -1- at the top of the rear spoiler -2- . See Fig. 107.
4. Carefully pull rear apron -2- to the rear until the plug connection is accessible. See Fig. 107.
Microsoft

5. Press lug -arrow- of the plug connection -4- and separate. See Fig. 108.
6. Remove rear spoiler.

parts heating up!
fixing tabs.
Installing rear spoiler
Microsoft

1. Check the heat shields on the vehicle before fitting the rear spoiler and replace the heat protection shield if
necessary. Check that the heat shields are properly fitted and correct if necessary. --> 635019 Removing and
installing rear bumper - chapter on "Checking"
Microsoft

2. Plug in electrical plug connection -4- . See Fig. 110.
Fig. 111: Fastening the rear spoiler at top

3. Position rear spoiler -2- on the vehicle. See Fig. 111.
4. Screw in fastening screws -1- above and below on the rear apron -2- and tighten to tightening torque -->
Microsoft

6. Screw in fastening screws -1- laterally on the rear apron -2- and tighten to the specified torque. -->
DIMENSIONS OF TAILPIPES
Microsoft

1. Check gap dimensions of tailpipes -1- to rear apron -2- , if necessary, adjust tailpipes -1- . See Fig. 113.
Projection from rear spoiler: -Y = 26,2 ± 2 mm- . See Fig. 113.
Distance from rear spoiler: -Z = 27 mm- . See Fig. 113.
center distance at the sides evenly to the left and right.
SUBSEQUENT WORK
Subsequent work
3. Install rear apron. Refer to 66 58 19 Removing and installing rear spoiler - as of MY 2005 (Boxster,
Models) .
Microsoft
63 55 19 REMOVING AND INSTALLING REAR APRON - AS OF MY 2006

PRELIMINARY WORK
Preliminary work
(All Models) .
REMOVING REAR APRON
Removing rear apron
Fig. 114: Installation position of rear apron

Microsoft
Fig. 115: Undoing rear apron at the sides

1. Unscrew fastening screws -1- at the sides of the rear apron -2- . See Fig. 115.
Microsoft
Fig. 116: Loosening rear apron at bottom

3. Unscrew fastening screws -1- at bottom of the rear apron -2- . See Fig. 116.
NOTE: Two persons are needed to disengage and engage the rear apron!
4. Unclip rear apron at the sides and carefully pull to the rear until the plug connection -4- can be reached. See
Fig. 117.
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5. Press locking tab -arrow- of the plug connection -4- and disconnect it. See Fig. 117.
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Fig. 118: Removing rear apron

6. Remove rear apron -1- . See Fig. 118.
INSTALLING REAR APRON

parts heating up!
fixing tabs.
Installing rear apron
Fig. 119: Installation position of rear apron

1. Before installing the rear apron, the following points must be carried out:
Microsoft
1.1. Inspect heat shield on vehicle and replace if necessary. --> 635019 Removing and installing rear bumper
- chapter on "Checking"
1.2. Check adjustment of rear lid, and correct if necessary. Refer to 55 90 15 Adjusting rear lid - as of MY
1.3. Check adjustment of rear retaining strip, and correct if necessary. --> 635719 Removing and installing
rear retaining strip - chapter on "Adjusting"
1.4. Check mounting points (fastening nuts) of rear apron, and replace if necessary.

NOTE: Two persons are needed to disengage and engage the rear apron!
2. Position rear apron on vehicle until the electric plug connection -4- can be connected. See Fig. 120.
Microsoft
Fig. 121: Installing rear apron

NOTE: Insert rear apron right and left into rail.
3. Position rear apron -1- fully on the vehicle. See Fig. 121.
Microsoft

Microsoft
Fig. 123: Screwing down rear apron at bottom

5. Screw down fastening screws -1- at the top and bottom of the rear apron -2- --> Tightening torque: 2.8 (2.1
ftlb.) Nm +/-20 % . See Fig. 122.
GAP DIMENSION OF TAILPIPE
Microsoft

CAUTION: Heating of vehicle parts.
 Damage will result if tailpipe is fitted incorrectly!
--> The following gap dimensions must be observed.
--> After the test drive check the gap dimension again and readjust if necessary.
1. Check gap dimension of tailpipe -1- to rear apron -2- and adjust tailpipe if necessary. Refer to 26 34 19
Removing and installing tailpipe - as of MY 2005 (Cayman S, Cayman S RHD) . See Fig. 124.
Microsoft
--> Gap dimension: 10 mm +/-2 mm
--> Gap dimension: 22 mm +2 mm -1 mm
--> Gap dimension: 20 mm +2 mm
SUBSEQUENT WORK
Subsequent work
3. Install rear apron. Refer to 66 58 19 Removing and installing rear spoiler - as of MY 2006 (Cayman S,
Cayman S RHD) .
Models) .
63 55 19 DISASSEMBLING AND ASSEMBLING REAR APRON - AS OF MY

2006 (CAYMAN S, CAYMAN S RHD)
PRELIMINARY WORK
Preliminary work
1. Remove rear spoiler. --> 635519 Removing and installing rear spoiler - chapter on "removing"
NOTE:  Only for vehicles with ParkAssist.
2. Remove sensor for ParkAssist. Refer to 91 75 19 Removing and installing sensor for ParkAssist - as of
3. Remove number plate light --> 94 44 19 REMOVING AND INSTALLING BULB FOR NUMBER
PLATE LIGHT - AS OF MY 2005 (ALL MODELS) .
4. Remove wiring harness for number plate light. Refer to 97 70 19 Removing and installing wiring harness
for number plate light - as of MY 2005 (All Models) .
NOTE:  Only for USA/Canada version vehicles.
5. Remove rear bumper horn. --> 636519 Removing and installing rear bumper horn - chapter on
Microsoft
"removing"
DISASSEMBLING REAR APRON
Removing support
Fig. 125: Main illustration of rear apron

NOTE:  When removing the support, do not loosen the retaining clips by placing
the screwdriver between the retaining clips and the rear end ribs!
 Use new retaining clips for installation.
Microsoft

1. Move retaining clips -3- as far as possible to one side and open up with a screwdriver -4- -Arrow A- Remove
retaining clips -3- . See Fig. 126.
2. Disengage support -2- in -direction of Arrow B- from rear apron -1- . See Fig. 126.
Removing cover cap
Microsoft


1. Carefully press out the cover cap -2- with a screwdriver. The securing cord -3- the cover cap -2- and the rear
Microsoft
Removing cover plate

Fig. 130: Removing cover plate

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1. Unlock cover plate -1- by pressing the locking tabs -arrows- and remove from the rear apron -2- . See Fig.
130.
Removing retaining frame

Microsoft
Fig. 132: Removing retaining frame

1. Insert a plastic wedge -3- between retaining frame -2- and rear apron -1- , release locking tabs and remove
retaining frame -2- . See Fig. 132.
ASSEMBLING REAR APRON
Installing retaining frame
Microsoft

Fig. 134: Installing retaining frame

1. Position retaining frame -2- on the rear apron -1- and press in until the locking tabs engage. See Fig. 134.
Installing cover plate

Microsoft

Fig. 136: Installing cover plate

1. Position cover plate -1- on the rear apron -2- and press in until the locking tabs engage -arrows- . See Fig.
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136.

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1. Pull the securing cord -3- into the eyelet of the rear apron -1- Insert cap -2- into the rear apron -1- . See Fig.
138.
Installing support

Microsoft
Fig. 140: Installing support

1. Insert support -2- in -direction of Arrow A- , align and fasten by pressing on new retaining clips -3- in the
rear apron -1- -Arrow B- . See Fig. 140.
SUBSEQUENT WORK
Subsequent work
1. Install rear bumper horn. --> 636519 Removing and installing rear bumper horn - chapter on
"Installing"
2. Install wiring harness for number plate light. Refer to 97 70 19 Removing and installing wiring harness for
number plate light - as of MY 2005 (All Models) .
3. Install number plate lights. --> 94 44 19 REMOVING AND INSTALLING BULB FOR NUMBER
4. Install sensor for ParkAssist. Refer to 91 75 19 Removing and installing sensor for ParkAssist - as of MY
Microsoft
2005 (All Models) .
5. Install rear spoiler. --> 635519 Removing and installing rear spoiler - chapter on "installing"
63 55 37 DISASSEMBLING AND ASSEMBLING REAR SPOILER - AS OF MY

PRELIMINARY WORK
Preliminary work
1. Remove rear spoiler. --> 635519 Removing and installing rear spoiler - chapter on "removing" [987320
987321] --> 635519 Removing and installing rear spoiler - chapter on "removing" [987310 987311]
2. Remove sensor for ParkAssist. Refer to 91 75 19 Removing and installing sensor for ParkAssist - as of
3. Remove number plate light. --> 94 44 19 REMOVING AND INSTALLING BULB FOR NUMBER
4. Remove wiring harness for number plate light. Refer to 97 70 19 Removing and installing wiring harness
for number plate light - as of MY 2005 (All Models) .
5. Remove rear bumper horn. --> 636519 Removing and installing rear bumper horn - chapter on
"removing"
DISASSEMBLING REAR SPOILER
Removing the lower retaining strip
Microsoft

Fig. 142: Removing the lower retaining strip

1. Bore out rivets -2- and lower retaining strip -1- . See Fig. 142.
Removing cover cap

Microsoft


1. Carefully press out the cover cap -2- with a screwdriver. The securing cord -3- the cover cap -2- and the rear
Microsoft
Removing frame

Microsoft
Fig. 146: Removing frame

1. Unlock frame -1- by pressing the lugs -arrows- and remove from the rear apron -2- . See Fig. 146.
ASSEMBLING REAR SPOILER
Installing covering frame

Microsoft

1. Position the frame -1- on the rear apron -2- and press in until the locking tabs -arrows- lock into place. See
Fig. 148.
Microsoft


1. Pull the securing cord -3- into the eyelet of the rear apron -1- Insert cap -2- into the rear apron -1- . See Fig.
150.
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Installing the lower retaining strip

Fig. 152: Installing the lower retaining strip

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1. Push on lower retaining strip -1- and fasten with tubular rivets -2- . See Fig. 152.
SUBSEQUENT WORK
Subsequent work
1. Install rear bumper horn. --> 636519 Removing and installing rear bumper horn - chapter on
"Installing"
2. Install wiring harness for number plate light. Refer to 97 70 19 Removing and installing wiring harness for
number plate light - as of MY 2005 (All Models) .
3. Install number plate lights. --> 94 44 19 REMOVING AND INSTALLING BULB FOR NUMBER
4. Install sensor for ParkAssist. Refer to 91 75 19 Removing and installing sensor for ParkAssist - as of MY
2005 (All Models) .
5. Install rear spoiler. --> 635519 Removing and installing rear spoiler - chapter on "installing" [987320
987321] --> 635519 Removing and installing rear spoiler - chapter on "installing" [987310 987311]
63 57 19 REMOVING AND INSTALLING THE REAR RETAINING STRIP - AS

OF MY 2005 (CAYMAN S, CAYMAN S RHD)
TOOLS

Sabre saw commercially 00000
available tool
PRELIMINARY WORK
Preliminary work
Remove rear apron. --> 635519 Removing and installing rear apron - chapter on "Removing"
TOOLS AND MATERIALS
Producing assembly fixture
NOTE:
Microsoft
 The following assembly fixtures must be produced for assembly work on

the rear retaining strip.
1. The following tools and materials are required for producing the assembly fixtures:
1.1. Sabre saw 00000
1.2. Measuring tape 00000
1.3. Commercially available hardwood block 00000
Fig. 153: Dimensions for assembly fixture

2. Make hardwood block for assembly fixtures -1- with the corresponding stated dimensions. See Fig. 153.
A - 120 mm
B - 72.5 mm
C - 72.5 mm
REMOVING THE REAR RETAINING STRIP
Removing rear retaining strip

Microsoft
Fig. 154: Installation location of rear retaining strip

1. Unclipping wiring harness for rear apron.
Fig. 155: Removing the rear retaining strip

Microsoft
2. Unscrew fastening nuts -1- and remove rear retaining strip -2- . See Fig. 155.
INSTALLING THE REAR RETAINING STRIP
Installing the rear retaining strip

Microsoft

1. Position rear retaining strip -2- . See Fig. 157.
2. Do up fastening nuts -1- gently. See Fig. 157.
3. Adjust the rear retaining strip. --> 635719 Removing and installing rear retaining strip - chapter on
"Adjusting"
ADDITIONAL ASSEMBLY INSTRUCTIONS FOR INSTALLING REAR RETAINING STRIP
Function dimensions for rear retaining strip
Microsoft

NOTE:  However, the precondition for precise positioning of the retaining strip is
accordance with the joining plan and the functional dimensions, before the
rear retaining strip is assembled.
1. Check the function dimensions for the rear lid, and correct if necessary. Refer to 55 90 15 Adjusting rear lid
- as of MY 2006 (Cayman S, Cayman S RHD) .
2. Insert assembly fixtures -1- at the measuring point -A = 276 mm- between the rear retaining strip -2- and rear
lid -3- . See Fig. 159.
Microsoft
Fig. 159: Adjusting the retaining strip

NOTE:  Ensure that the distance from the retaining strip to the side panel is
uniform on the right and the left.
3. Push rear retaining strip -2- upwards and screw down with the two fastening nuts -4- --> Tightening torque:
9.7 (7.0 ftlb.) ftlb. . See Fig. 159.
4. Clip in wiring harness for rear apron.
5. Install rear spoiler. --> 635519 Removing and installing rear spoiler - section on "Installing"
6. Check control dimension -X= 8 mm- between lid lower edge -1- and rear apron -2- , and if necessary readjust
lid -1- and rear retaining strip -3- . See Fig. 160.
Microsoft
Fig. 160: Function dimensions for rear retaining strip

7. After correct adjustment of the rear retaining strip and rear apron, complete the vehicle. --> 635519
Removing and installing rear apron - chapter on "Subsequent work"
63 57 19 REMOVING AND INSTALLING THE REAR RETAINING STRIP - AS

OF MY 2005 (BOXSTER, BOXSTER RHD, BOXSTER S, BOXSTER S RHD)
TOOLS

Sabre saw commercially 00000
available tool
PRELIMINARY WORK
Preliminary work
TOOLS AND MATERIALS
Producing assembly fixture
NOTE:  The following assembly fixtures must be produced for assembly work on
the rear retaining strip.
Microsoft
1. The following tools and materials are required for producing the assembly fixtures:
1.1. Sabre saw 00000
1.2. Measuring tape 00000
1.3. Commercially available hardwood block 00000
Fig. 161: Dimensions for assembly fixture

2. Make hardwood block for assembly fixtures -1- with the corresponding stated dimensions. See Fig. 161.
A - 120 mm
B - 72.5 mm
C - 72.5 mm
REMOVING THE REAR RETAINING STRIP
Removing the rear retaining strip
Microsoft

1. Unclipping wiring harness for rear apron

2. Unscrew fastening nuts -1- and take off rear retaining strip -2- Check sheetmetal nuts -3- , replace if
Microsoft
necessary. See Fig. 163.
INSTALLING THE REAR RETAINING STRIP
Installing the rear retaining strip

Microsoft
Fig. 165: Installing the rear retaining strip

1. Position rear retaining strip -2- with fastening nut attached -3- . See Fig. 165.
2. Position fastening nuts -1- carefully. See Fig. 165.
3. Adjust the rear retaining strip. --> 635719 Removing and installing rear retaining strip - chapter on
"Adjusting"
4. Tighten fastening nuts -1- Tightening torque --> Tightening torque: 7 ftlb. . See Fig. 165.
5. Clip in wiring harness for rear apron.
ADDITIONAL ASSEMBLY INSTRUCTIONS FOR INSTALLING REAR RETAINING STRIP
Function dimensions for rear retaining strip
Microsoft

NOTE:  However, the precondition for precise positioning of the retaining strip is
accordance with the joining plan and the functional dimensions, before the
rear retaining strip is assembled.
1. Check the function dimensions for the rear lid, and correct if necessary. Refer to 55 90 15 Adjusting rear lid
- as of MY 2005 (Boxster, Boxster RHD, Boxster S, Boxster S RHD) .
2. Move in assembly fixtures -1- at the measuring point -A = 276 mm- between the retaining strip -2- and rear
lid -3- . See Fig. 167.
Microsoft
Fig. 167: Adjusting the retaining strip

NOTE:  Ensure that the distance from the retaining strip to the side panel is
uniform on the right and the left.
3. Push retaining strip -2- upwards and screw down the two fastening nuts -4- Tightening torque --> Tightening
torque: 7 ftlb. . See Fig. 167.
SUBSEQUENT WORK
Subsequent work
63 65 19 REMOVING AND INSTALLING REAR BUMPER OVERRIDER - AS

PRELIMINARY WORK
Preliminary work
987321] --> 635519 Removing and installing rear apron - chapter on "Removing" [987120 987121] -->
635519 Removing and installing rear apron - chapter on "Removing" [987310 987311]
REMOVING REAR BUMPER OVERRIDER
Microsoft
Removing rear bumper horn
Fig. 168: Installation location of rear bumper overrider

Microsoft
Fig. 169: Removing rear bumper overrider

1. Insert a screwdriver laterally into the inner retaining bracket -1- Press in the locking tab and take off the
bumper overrider -2- . See Fig. 169.
INSTALLING REAR BUMPER OVERRIDER
Installing the rear bumper horn
Microsoft
Fig. 170: Installation location of rear bumper overrider

Fig. 171: Installing rear bumper overrider

1. Position bumper overrider -2- on the rear apron and clip together with the inner retaining bracket -1- . See
Fig. 171.
Microsoft
SUBSEQUENT WORK
Subsequent work
987321] --> 635519 Removing and installing rear apron - chapter on "Removing" [987120 987121] -->
635519 Removing and installing rear apron - chapter on "Removing" [987310 987311]
63 73 19 REMOVING AND INSTALLING REAR BRACKET (IMPACT PIPE,

IMPACT ABSORBER) - AS OF MY 2005 (ALL MODELS)
PRELIMINARY WORK
Preliminary work
1. Remove rear spoiler. --> 635519 Removing and installing rear spoiler - chapter on "removing" [987320
987321] --> 635519 Removing and installing rear spoiler - chapter on "removing" [987120 987121] -->
635519 Removing and installing rear spoiler - chapter on "removing" [987310 987311]
2. Remove rear bumper. --> 635019 Removing and installing rear bumper - chapter on
"Removing" [987310 987311 987320 987321] --> 635019 Removing and installing rear bumper - chapter
on "Removing" [987120 987121]
REMOVING REAR BRACKET (IMPACT PIPE, IMPACT ABSORBER)
Removing rear impact pipe
Fig. 172: Installation location of rear carrier

Microsoft
Fig. 173: Removing impact pipe

2. Remove the impact pipe -2- with seal -3- . See Fig. 173.
Removing impact absorber
Microsoft

Fig. 175: Removing impact absorber

2. Remove the impact absorber (Canada version) -2- with seal -3- . See Fig. 175.
Microsoft
INSTALLING REAR BRACKET (IMPACT PIPE, IMPACT ABSORBER)
Install rear impact pipe

Microsoft
Fig. 177: Installing impact pipe

1. Position the impact pipe -2- with seal -3- . See Fig. 177.
2. Screw in fastening screws -1- and tighten to the required tightening torque --> Tightening torque: 17 ftlb. .
See Fig. 177.
Installing impact absorber

Microsoft
Fig. 179: Installing impact absorber

1. Position the impact absorber (Canada version) -2- with seal -3- . See Fig. 179.
2. Screw in fastening screws -1- and tighten to the required tightening torque --> Tightening torque: 17 ftlb. .
See Fig. 179.
SUBSEQUENT WORK
Subsequent work
1. Install rear bumper. --> 635019 Removing and installing rear bumper - chapter on "Installing" [987310
987311 987320 987321] --> 635019 Removing and installing rear bumper - chapter on
"Installing" [987120 987121]
2. Install rear spoiler. --> 635519 Removing and installing rear spoiler - chapter on "installing" [987320
987321] --> 635519 Removing and installing rear spoiler - chapter on "installing" [987120 987121] -->
635519 Removing and installing rear spoiler - chapter on "installing" [987310 987311]
Microsoft
ACCESSORIES & EQUIPMENT Convertible top, hardtop
Convertible top, hardtop
61 02 IN ASSEMBLY INSTRUCTIONS FOR HARDTOP ASSEMBLY FIXTURE -

AS OF MY 2005 (BOXSTER, BOXSTER RHD, BOXSTER S, BOXSTER S
RHD)
TOOLS

Mounting component special tool P 9620
TOOLS AND MATERIALS
Tools and materials
Fig. 1: Hardtop assembly fixture

The following tools and materials are required to construct the fixture for work in the inner area:
Item Designation Explanation

Drill
Drill bit 6 mm
Drill bit 3 mm
Sabre saw
Measuring tape
B Support cheek (2x) Multiplex plate 25 mm thick, 600 x 120 mm
C Swivel arm (1x) Multiplex plate 25 mm thick, 550 x 200 mm
Microsoft
D Base plate (1x) Wood-core plywood 19 mm thick, 1500 x 900 mm

All materials listed are commercially available.
Mounting component P 9620 --> "Special tool Gr. 2.2.2; Workshop Equipment
Manual "
Set of fittings includes:
A1 Retaining bracket (1x)
A2 Hinge (1x)
A3 Base (2x)
A4 Straight pin 6 M6 x 40 (6x)
A5 Countersunk screw 4.5 x 20 (8x)
A6 Countersunk screw 6 x 20 (2x)
A7 Countersunk screw 6 x 20 with disc
(4x)
ASSEMBLY INSTRUCTIONS FOR HARDTOP ASSEMBLY FIXTURE
Making support cheeks
Make support cheeks -B- with basic material Multiplex plate 600 x 120 mm, 25 mm thick. See Fig. 2.
Fig. 2: Making support cheeks

A4 = Straight pin 6 M6 x 40 / B = Support cheek
1. Work procedure:
1.1. Transfer 160 mm radius to the multiplex plates.

Microsoft
1.2. Saw multiplex plates along the traced radius. The foot of the sabre saw must be tilted by 15° for this
purpose.
1.3. Drill four 6 mm holes in the support radii of each support cheek to provide clearance for the Tucker studs
on the hardtop body. Obtain the dimensions from the hardtop body.
1.4. Drill three holes, 20 mm deep, 6 mm for each support cheek, to secure the support cheeks -B- to the base
plate -D- with the straight pins contained in the set of fittings -A4- 6 m6 x 40 - attach to the support cheeks -B- .
See Fig. 2.
Making swivel arm
Make swivel arm -C- with basic material Multiplex plate 550 x 200 mm, 25 mm thick. See Fig. 3.
Fig. 3: Making swivel arm

-A1- = Retaining bracket. See Fig. 3.
-A2- = Hinge. See Fig. 3.
-A5- = countersunk screw 4.5 x 20. See Fig. 3.
-A6- = countersunk screw 6 x 20. See Fig. 3.
-C- = Swivel arm. See Fig. 3.
1. Work procedure:
1.1. Fit retaining bracket -A1- with 2 countersunk screws -A6- following the dimensions specified on the swivel
Microsoft
arm -C- . See Fig. 3.
1.2. Fit hinge -A2- with 4 countersunk screws -A5- following the dimensions specified on the swivel arm -C- .
See Fig. 3.
Fitting swivel and support cheeks on the basic plate
Basic material: Wood-core plywood 1500 x 900 mm, 19 mm thick
Fig. 4: Fitting swivel and support cheeks on the basic plate

-A3- = Base See Fig. 4.
-B- = Support cheek See Fig. 4.
-C- = Swivel arm See Fig. 4.
-D- = Base plate See Fig. 4.
1. Work procedure:
1.1. During assembly, all parts are positioned from the center!
1.2. Measure and mark the plate -D- . See Fig. 4.
1.3. Fasten completed swivel arm -C- on the hinge -A2- with four 4.5 x 20 countersunk screws in accordance
with the dimensions specified on the plate -D- . See Fig. 4.
1.4. Transfer hole pattern of the support cheeks -B- onto the base plate -D- in accordance with the specified
Microsoft
dimensions, and drill holes using a 6-mm drill bit. See Fig. 4.
1.5. Fit support cheeks -B- over the prefitted straight pins -A4- onto the plate -D- . See Fig. 4.
Fitting mounting points for the hardtop locking lever on the plate
Fit. mounting -A3- for the hardtop locking lever on the plate -D- . See Fig. 5.
Fig. 5: Fitting mounting points for the hardtop locking lever on the plate
-A3- = Base See Fig. 5.
-A7- = Hexagon-head bolt 6 x 20 with disc See Fig. 5.
-B- = Support cheek See Fig. 5.
-D- = Base plate See Fig. 5.
1. Work procedure:
1.1. Fit mounting points -A3- both with hexagon-head bolts -A7- according to the dimensions specified on the
plate -D- . See Fig. 5.
61 28 IN CARE AND CLEANING OF THE CONVERTIBLE TOP - AS OF MY

TOOLS
Microsoft
Fig. 6: Tequipment care case, Cabriolet

For the care and cleaning of the convertible top, use the Tequipment care case.
CLEANING THE CONVERTIBLE TOP
CAUTION: Risk of damage when removing snow and ice!
 The convertible top covering can become damaged or discolored if

not handled properly.
--> Never remove snow and ice with sharp objects.
The service life and appearance of the convertible top are largely dependent on proper care and operation.
The vehicle should be parked in the shade whenever possible, as the fabric, rubber material and color can be
harmed by extended exposure to sunlight.
1. Do not wash the convertible top every time the car is washed. It is normally sufficient to wash or rinse the
convertible top with clear water. In the event of heavy soiling, moisten the convertible top with lukewarm water
and Porsche Wash-Shampoo & convertible-top cleaner and rub gently with a sponge or soft brush. Then rinse
off the convertible top with clear water until no traces of the Porsche Wash-Shampoo & convertible-top cleaner
remain.
2. Remove bird droppings immediately, because the acids they contain will cause the rubber material to swell
and will make the convertible top leak.
3. Only open the convertible top when it is completely dry, because otherwise damp stains and abrasions may
occur which cannot be removed afterwards.
4. In the case of light soiling and always before washing, brush the convertible top with a soft brush or with a
strip of convertible-top covering (cut out of an old convertible-top covering) in the direction of the fabric lines
of the convertible-top material.
5. To prevent scratches on the flexible rear window, first remove all soiling from the exterior with plenty of
water.
Microsoft
CARE OF CONVERTIBLE TOP
1. In the case of leaks in the convertible-top covering or seams or in the folded sections, use the Porsche
convertible-top care product.
2. Do not use the Porsche convertible-top care product on painted surfaces, glass or the flexible rear window; if
this is used, remove the product immediately.
3. Do not remove stains on the convertible top or flexible rear window with petrol (fuel), stain remover,
benzene, paint thinners or other solvents; they attack the rubber layer between the fabrics and diminish the
water-tightness and the service life of the convertible top.
4. Recommendation: treat the convertible top with the Porsche convertible-top care product twice a year or
before installing the hardtop (winter driving).
CARE OF CONVERTIBLE-TOP SEALS
NOTE:  The convertible-top seals have an anti-friction coating or are flocked and
do not require any special care.
 Never grease or lubricate or spray on seals that are flocked or have an
anti-friction coating.
1. Clean soiled seals with clear water.
2. It is only possible to rinse the convertible top or use an automatic car wash after the flocked seals have dried.
61 43 55 REPLACING THE TENSION CABLE - AS OF MY 2005 (BOXSTER,

BOXSTER RHD, BOXSTER S, BOXSTER S RHD)
PRELIMINARY WORK
Preliminary work
Remove convertible top covering. --> 612855 Replacing convertible top covering - section on "Removing"
REMOVING TENSION CABLE
Removing tension cable
The following spare parts and tools are required for repairing the tension cable:
Microsoft
Fig. 7: Tension cable

A Tension cable
B Eye
Microsoft
Fig. 8: Removing tension cable

1. Disengage tension cable at the shaped sheetmetal part.
1.1. Cut open plastic sleeve -1- with a pair of scissors. See Fig. 8.
1.2. Disengage tension cable -3- from tension spring at the shaped sheetmetal part. See Fig. 8.
1.3. Cut through the tension cable -2- with side cutters and pull it out of the convertible top covering -4- . See
Fig. 8.
INSTALLING TENSION CABLE
Microsoft
Installing tension cable
Fig. 9: Fitting tension cable

1. Place eye on the tension cable and measure the total length.
1.1. Push the eye fully onto the end of the tension cable.
1.2. Measure total length of tension cable from center of eye to center of eye with a tape measure -dimension
X= 682 mm- . See Fig. 9.
Microsoft
Fig. 10: Fitting tension cable

2. Fit tension cable to the shaped sheetmetal part.
2.1. Pull tension cable -2- into the convertible top covering -4- . See Fig. 10.
2.2. Push shrink-fit hose -1- over the tension cable -2- . See Fig. 10.
2.3. Engage tension cable -2- in tension spring -3- at the shaped sheetmetal part. See Fig. 10.
2.4. Pull shrink-fit hose -1- over the tension spring. Shrink the heat-shrinking tube to the diameter of the tension
spring by heating it with a hot-air gun. See Fig. 10.
Microsoft
Fig. 11: Pressing tension cable

3. Press tension cable and the eye together.
CAUTION: Damage to eye
 Compress the eye with the hydraulic stamp press so that the eye is
only pressed in 1/4 of the diameter.
 If pressed together too strongly, the eye will crack.
-->
3.1. Using a commercially available hydraulic stamp press, press the eye -1- together with the tension cable -2- .
See Fig. 11.
SUBSEQUENT WORK
Subsequent work
Install the convertible-top covering. --> 612855 Replacing convertible top covering - section on "Removing"
61 72 ADJUSTING CONVERTIBLE TOP MECHANISM - AS OF MY 2005

Microsoft
PRELIMINARY WORK
Fig. 12: Installation location of convertible top gear

1. Convertible top in service position
1.1. Convertible top in service position: Open convertible top approx. 40 cm away from the windshield frame.
Pull Velcro of the fixing strap off tension bow and secure on centering peg in front. --> 6101 IN-convertible
top in service position
Microsoft
Fig. 13: Pressing out the push rod

2. Pressing out the push rod
2.1. Press ball socket -6- of push rod from ball head of main folding top bow.
Microsoft
Fig. 14: Pressing out push rod springs

3. Press left and right push rod springs 8 out of the ball head of the lever.
ADJUSTING CONVERTIBLE TOP GEAR
Microsoft
Fig. 15: Removing lever

1. Unscrew the fastening screw 1 out of the lever 2 and remove the cover 3 and lever 2 from the convertible top
gear 4 .
Microsoft
Fig. 16: Disengaging pliable shaft

2. Unclip clip 6 from the pliable shaft 5 and disengage the shaft from the drive motor 7 .
Adjusting marking version
Microsoft
Fig. 17: Adjusting lever on marking

3. Insert the pliable shaft of the convertible top gear to be adjusted 4 into the drive motor and adjust the marking
notch on the shaft arrow so that it is parallel with the marking notch on the convertible top gear arrow using
the rocker switch in the vehicle. (Adjusting convertible top gear synchronously on left and right).
Measuring variant
Microsoft
Fig. 18: Pushing on lever

4. Push lever 2 onto convertible top gear 4 .
Microsoft
Fig. 19: Measuring lever

5. Insert pliable shaft of convertible top gear to be adjusted 4 into drive motor and use the rocker switch to
adjust the center of the lever ball head 2 with respect to the side section sealing channel arrow (upper edge) so
that --> Dimension X : 195 mm +/-05 mm . (Adjust convertible top gear synchronously on left and right.)
Microsoft
Fig. 20: Fitting lever and cover

6. Position cover 3 and lever 2 on convertible top gear 4 and tighten with fastening screw 1 (micro-self-
locking). After loosening fastening screw 1 it must be replaced or secured with Loctite 243 at medium strength.
--> M12: 80 (59 ftlb.) Nm
Microsoft
Fig. 21: Inserting pliable shaft

7. Insert the pliable shaft 5 in the drive motor 4 and secure with the clip 6 .
SUBSEQUENT WORK
Microsoft
Fig. 22: Pressing in push rod

1. Engage push rod.
1.1. Press ball socket -6- of push rod onto ball head of main folding top bow.
Microsoft
Fig. 23: Pressing in push rod springs

2. Press left and right push rod springs 8 into the ball head of the lever.
3. End service position.
4. Functional test: open and close convertible top with the rocker switch. When opening and closing the
convertible top, the gap dimension between the --> dimension: 5 mm must be observed. If necessary, correct
by screwing the ball socket 9 in or out.
61 90 15 ADJUSTING CONVERTIBLE-TOP COMPARTMENT LID - AS OF MY

ADJUSTING CONVERTIBLE-TOP COMPARTMENT LID
Adjusting stop for convertible top compartment lid
Microsoft
Fig. 24: Installation position of stop for convertible top compartment lid
Adjust stop 1 for the convertible top compartment lid to match the contour of the side panel. The stops 1 come
in variants +1 mm to +5 mm as spare parts.
Microsoft
Fig. 25: Installing stop for convertible top compartment lid

1. Fit stop 1 on the sheetmetal bracket 2 in the water channel of the side panel. Adjust in accordance with
joining plan. Refer to 50 IN Processing structural body adhesive - as of MY 2005 (All Models) .
Adjusting the adjusting eccentric for locating peg
Microsoft
Fig. 26: Installation position of adjusting eccentric

1. Position adjusting eccentric on the body and tighten with the fastening nut 1 . --> Tightening torque: 9.7
(7.0 ftlb.) Nm
Microsoft
Fig. 27: Adjusting the adjusting eccentric for locating peg

2. Adjust upper part of adjusting eccentric 2 to match contour of side panel by screwing lower part of adjusting
eccentric 3 in or out in direction of travel . Refer to 50 IN Processing structural body adhesive - as of MY
2005 (All Models) .
61 01 IN CONVERTIBLE-TOP SERVICE POSITION - AS OF MY 2005

MOVE CONVERTIBLE TOP TO SERVICE POSITION
Microsoft
Fig. 28: Convertible top in service position

CAUTION: Operation of the convertible top in the service position!
 Material damage to convertible top frame and rear window!
--> When in the service position, the convertible top must not be electrically actuated to the "Close" position.
1. Switch on ignition.
Microsoft

2. Unlock convertible top and raise convertible-top compartment lid to its top position.
3. Switch off ignition and remove ignition key.
Fig. 30: Loosening cloth covering

Microsoft
4. Disengage strip on cloth covering -1- in a downward direction out of the combination holder -2- at the left
and right. See Fig. 30.
Fig. 31: Releasing tension cables

5. Raise convertible top -1- slightly at the rear -Arrow A- . Press the ball socket of the left and right tension
cables -2- out of the ball head of the adjusting piece -3- ( -Arrow B- ). See Fig. 31.

Microsoft
6. Pull Velcro fastener of the retaining strap -1- off the tension bow and engage it on the centering journal -2- at
the front. See Fig. 32.
ENDING CONVERTIBLE TOP SERVICE POSITION

1. Disengage retaining strap -1- at the front at the centering journal -2- and fasten Velcro fastener of retaining
strap to the tension bow. See Fig. 33.
Microsoft
Fig. 34: Pressing in tension cables

2. Swivel convertible top -1- down slightly at the rear ( -Arrow A- ). Pull tension cables -2- at the left and right
through the cloth covering -4- ( -Arrow B- ) and press ball socket in at the adjusting piece Fig. 34 -3- ( Fig. 34 -
Arrow C- ). See Fig. 34.
Fig. 35: Securing cloth covering

3. Engage strip on cloth covering -1- upwards into the combination holder -2- at the left and right. See Fig. 35.
4. Switch on ignition and move convertible top electrically to its original position.
5. Switch off the ignition.
Microsoft
61 01 IN DIAGRAM OF CONVERTIBLE TOP - AS OF MY 2005 (BOXSTER,

DIAGRAM OF CONVERTIBLE TOP
Diagram of convertible top
Fig. 36: Diagram of convertible top

1 - Roll-over bar
2 - Convertible-top support
3 - B-pillar
4 - Roof frame
5 - Main bow
6 - Tension strap
7 - Corner bow
8 - Convertible-top covering
9 - Tension bow
Microsoft
10 - Cloth
11 - Tension cable
12 - Water drip pan
61 01 15 ADJUSTING CABRIOLET CONVERTIBLE TOP - AS OF MY 2005

ADJUSTING CABRIOLET CONVERTIBLE TOP
Preliminary work
NOTE:  On vehicles that have been used for a long time with open convertible top
or with hardtop, it may be the case that the engaging of the locking hook
must be aided by pulling the convertible top towards the windscreen with
one of the finger plates in the convertible top frame. The folded
convertible-top covering must first stretch again.
 The requirement for adjusting the Cabriolet convertible top is that the lid
for the convertible top compartment must be adjusted.
 The requirement for adjusting the Cabriolet convertible top is that the roll-
over bar must be calibrated.
 The requirement for adjusting the Cabriolet convertible top is that the
convertible top gears must be adjusted.
Adjustment facility on push rods of convertible top gear
Microsoft
Fig. 37: Installation position for push rod

1. Convertible top in service position --> 6101IN Convertible-top service position
Microsoft

2. Press left and right push rod springs -8- out of the lever.
NOTE:  Prior damage to ball socket
Always press ball socket out tightly on the ball head.
Always press ball head in centered on the ball socket.

Microsoft
Carefully press push rod -6- out of the convertible top support at the left and right with a screwdriver while
keeping it tight to the ball head -3- . Swivel convertible top forward until the centering journals fit into the
convertible-top mount. Lock convertible top. See Fig. 39.
Fig. 40: Adjusting push rods on the convertible top drives

3. Loosen fastening screw -2- . Screw ball socket -1- of push rod in carefully as far as it will go. Unscrew ball
socket -1- until it is flush with the ball head -3- .
NOTE:  Prior damage to ball socket
Always press ball socket out tightly on the ball head.
Always press ball head in centered on the ball socket.
Fig. 41: Pressing in push rods

4. Press ball socket of push rod -6- into the ball head -3- of the convertible top support. See Fig. 41.
5. Loosen the fastening screw -2- . See Fig. 42.
Push rod pressed in on convertible top support.
Microsoft
Fig. 42: Tightening fastening screw

To adjust the push rod -4- , the lever -5- fitted with the push rod element -4a- must be pulled as far as possible -
in the direction shown -Arrow- - in the slot into the elastomer buffer. Secure at this position. Tighten the
fastening screw -2- . --> Tightening torque: 23 (17 ftlb.) Nm See Fig. 41, Fig. 42.

6. Fit push rod springs 8 on the left and right.
Adjustment facility for the tension ropes on convertible top frame
Microsoft
Fig. 44: Installation position for tension rope

Fig. 45: Installing tension rope on the convertible top frame

1. Position tension rope -1- on roll-over bar -2- and insert retaining pin -3- in -direction of arrow A- . Swivel
clamp -4- in Fig. 45 -direction of arrow B- and press it in on the tension rope. See Fig. 45.
Microsoft
Fig. 46: Adjusting tension ropes on convertible top frame

2. Loosen hexagon nuts -1 and 2- and adjust the contact pressure between the tension bow seal and the
convertible-top compartment lid by screwing the adjustment hexagon -3- in and out. See Fig. 45, Fig. 46.
Counter the hexagon nut -1- for the adjusting hexagon -3- and counter the hexagon nut -2- for the mount -4- .
See Fig. 46.
Adjust the contact pressure in such a way that a 0.5-mm check card can be pulled between the tension bow seal
and the sealing strip on the convertible-top compartment lid on all sides.
61 01 19 REMOVING AND INSTALLING CONVERTIBLE TOP - AS OF MY

REMOVING CONVERTIBLE TOP
Removing cabriolet convertible top
CAUTION: Removal of cabriolet convertible top
 Material damage (paint damage) to roll-over bar!
--> The cabriolet convertible top can only be removed from the vehicle together with the roll-over bar.
--> A second person is required to remove the convertible top.
REMOVING CONVERTIBLE TOP FRAME
Removing convertible top frame
NOTE:  The convertible top frame can be removed from the roll-over bar complete
with all convertible top bows and with the two convertible top supports.
 To do this, the roll-over bar must be removed from the vehicle together
with the convertible top frame.
Microsoft
Fig. 47: Removing convertible top frame

1. Remove three fastening screws -1- from the convertible top support -2- . See Fig. 47.
2. Pull the convertible top support -2- out by approx. 10 mm on both sides of the vehicle -arrow A- . See Fig.
47.
CAUTION: Removal of convertible top frame
--> A second person is required to remove the complete convertible top frame.
3. Remove the complete convertible top frame -3- with the two convertible top supports -2- backwards -arrows
B- off the roll-over bar -4- . See Fig. 47.
INSTALLING CONVERTIBLE TOP FRAME
Installing convertible top frame
NOTE:  To position the convertible top frame with respect to the convertible top
supports, the two convertible top supports must be pulled out by approx.
10 mm at the bottom.
 This is the only way to install it on the roll-over bar.
Microsoft
1. Pull the convertible top support (left and right side) out by approx. 10 mm at the bottom .
Fig. 48: Installing convertible top frame

CAUTION: Installation of convertible top frame
--> A second person is required to install the complete convertible top frame.
2. Place the complete convertible top frame -1- with the two convertible top supports -2- from behind -arrows
A- on the roll-over bar -3- and position it correctly. See Fig. 48.
3. Position convertible top support -2- on the roll-over bar -arrow B- and screw down with the three fastening
screws -4- . Tightening torque --> Tightening torque: 23 (17 ftlb.) Nm See Fig. 48.
INSTALLING CONVERTIBLE TOP
Installing cabriolet convertible top
CAUTION: Installation of cabriolet convertible top
Microsoft
--> The cabriolet convertible top can only be installed in the vehicle together with the roll-over bar.
--> A second person is required to help with installation.
Refer to 69 72 Removing and installing roll-over bar - as of MY 2005 (Boxster, Boxster RHD, Boxster S,
Boxster S RHD) .
61 02 15 ADJUSTING THE HARDTOP - AS OF MY 2005 (BOXSTER,

TOOLS

Star gauges for body gap special tool NR.127-1
dimensions
PRELIMINARY WORK
Preliminary work
1. Install hardtop. --> 610219 Removing and installing hardtop - "Installing" section
TOOLS AND MATERIALS
Star gauges for body gap dimensions NR.127-1
ADJUSTING THE HARDTOP
Microsoft
Fig. 49: Installation Location

Fig. 50: Removing trim panel

1. Remove trim panels on the rear hardtop locks.
Microsoft
Fig. 51: Loosening fastening screws

2. Loosen rear hardtop locks.
2.1. Loosen fastening screws -1- and -2- on the mounting plate by one turn of the thread. Unlock locking
element (installation position). See Fig. 51.
3. Laterally align the hardtop.
3.1. Shift hardtop sideways along the rear locks until the gap -Dimension A- runs parallel to the windscreen
frame. --> Adjustment dimension: 5.5 mm +/-1.0 mm See Fig. 52.
Microsoft
Fig. 52: Installation positions

Fig. 53: Laterally aligning the hardtop

Microsoft
Fig. 54: Adjusting front lateral offset

4. Set the lateral offset of the hardtop at the front.
4.1. The offset between the hardtop and the cowl panel at the front -Dimension B- is set by the convertible top
pin housing and must not be changed. The convertible top pin housing is set with respect to the convertible top,
See --> 610115 Adjusting Cabriolet convertible top. --> Check dimension: 2 mm +/-1.0 mm See Fig. 52.
5. Connect mounting plate with the hardtop lock.
5.1. Connect mounting plate with the hardtop lock and the fastening screws -2- .
Microsoft
Fig. 55: Laterally aligning the hardtop

6. Set gap dimension between hardtop and convertible top compartment lid.
6.1. Adjust gap -Dimension D and C- by shifting the hardtop on both sides of the vehicle. --> Adjustment
dimension: 5.5 mm +/-3.5 mm --> Adjustment dimension: 5.5 mm +/-3.5 mm See Fig. 52.
6.2. Screw down mounting plate with the fastening screws -1- and tighten to the specified tightening torque. -->
Tightening torque: 10 (7.5 ftlb.) Nm
Microsoft
Fig. 56: Aligning the height of the hardtop

7. Check for smooth operation and freedom from leaks; adjust the channel strips on the hardtop for the side
window if necessary.
7.1. Close side windows and check position of the side windows in relation to the hardtop, See also: Refer to 64
40 19 Removing and installing front door window - as of MY 2005 (All Models) .
7.2. Adjust retaining strip from hardtop to side window, if necessary.
Adjusting the channel strips:
Loosen fastening screws -3- and move retaining strip -2- . See Fig. 57.
Microsoft
Fig. 57: Fitting seal at sides of roof frame

Tighten fastening screws -3- . Press upper seal -4- into the profile of the retaining strip -5- .
7.3. If the windows touch the hardtop at their end position, increase the gap at the hardtop (towards the max.
value). If the side windows leak, decrease the gap at the hardtop at the rear (towards the min. value).
Microsoft
Fig. 58: Installing trim panel

8. Install trim panels for the rear hardtop locks.
8.1. Clip in the trim panel.
61 02 19 REMOVING AND INSTALLING HARDTOP - AS OF MY 2005

REMOVING HARDTOP
Microsoft

Fig. 60: Pulling off cover for hardtop locking mechanism

1. Pulling off cover for locking lever
1.1. Pull cover -1- of the front locking lever down and off. See Fig. 60.
Microsoft
Fig. 61: Opening the locking lever

2. Open the locking lever.
2.1. Press red knob -A- on the front locking lever -2- and open the catch fully -3- . See Fig. 61.
Microsoft
Fig. 62: Opening locking lever at the rear

3. Open locking lever at the rear.
3.1. Swivel the locking lever -4- forward until the pivot locks lift. See Fig. 62.
Microsoft
Fig. 63: Disconnecting rear window heating connector

4. Disconnect the electrical plug connection of the rear window heater.
4.1. Disconnect the electric plug connection -5- of the rear window heater, push on the plastic cover of the rear
window heater plug connection. See Fig. 63.
Microsoft
Fig. 64: Removing the hardtop

5. Remove the hardtop.
5.1. Carefully lift the hardtop at the rear window and lift off to the rear.
Microsoft
Fig. 65: Press in plastic cover

6. Press in plastic cover.
6.1. Press plastic cover -6- into the pivot-pin locks. See Fig. 65.
INSTALLING HARDTOP
Microsoft

NOTE: Before installing the hardtop for the first time, check that the pivot-pin locks are
installed and install them if necessary. --> 611719 Removing and installing
hardtop mounts. Also check the gap dimensions and adjust the hardtop as
required. --> 610215 Adjusting hardtop - chapter on "Adjusting"
Microsoft
Fig. 67: Opening the locking lever

1. Open the locking lever.
1.1. The locking lever -2- must be opened fully. See Fig. 67.
Fig. 68: Removing plastic cover

2. Remove plastic cover.
2.1. Lift the plastic cover -6- in the pivot-pin locks out carefully (keep plastic cover). See Fig. 68.
Microsoft
Fig. 69: Fitting the hardtop

3. Fit the hardtop.
3.1. Carefully lift the hardtop over the vehicle from behind and insert it forward into the mounts -7- on the
windscreen frame. See Fig. 69.
Microsoft
Fig. 70: Closing locking levers at the rear

4. Close the locking levers at the rear.
4.1. Pivot locks must be recessed fully in the pivot-pin locks; swivel both locking levers -4- back until they can
be felt to engage. See Fig. 70.
Microsoft
Fig. 71: Closing locking lever at the front

5. Close the locking lever at the front.
5.1. Swivel the locking lever -2- for the front lock to the rear. When doing so, the locking hook -3- must engage
in the windscreen frame. The white marking line on the red locking button must become visible when the
hardtop is locked properly. See Fig. 71.
Microsoft
Fig. 72: Pushing on cover of front locking lever

6. Push on the cover of the locking lever.
6.1. Push on the cover -1- of the front locking lever. See Fig. 72.
Microsoft
Fig. 73: Inserting connector for rear window heater

7. Connect the electric plug connection for the rear window heater.
7.1. Remove the plastic cover from the plug connection and connect the electric plug connection -5- for the rear
window heater. See Fig. 73.
8. Testing the rear window heater.
8.1. Press symbol of the rocker switch. The indicator light lights up; pressing the indicator light again switches
off the rear window heater. The indicator light also comes on when the plug connection for the rear window
heater is not plugged in.
61 02 37 DISASSEMBLING AND ASSEMBLING HARDTOP - AS OF MY 2005

PRELIMINARY WORK
Preliminary work
1. Remove rear window. Refer to 64 86 19 Removing and installing rear window - as of MY 2005 (Boxster,
2. Remove centering peg. --> 611019 Removing and installing front convertible-top mount - chapter on
Microsoft
"Removing"
DISASSEMBLING HARDTOP
Disassembling hardtop
Fig. 74: Removing cover strips and roof strip clips

1. Remove cover strips and roof strip clips.
1.1. Lift up the cover strip on left and right -2- using a plastic spatula and pull it out of the hardtop body -1- .
The roof strip clips are destroyed when they are removed.
2. Place outer roof panel of hardtop on the assembly fixture.
Microsoft
Fig. 75: Unclipping linings

3. Unclipping lining
3.1. Unclip lining -3- at sides and front from hardtop body -1- .
4. Remove hardtop locking mechanism. --> 61 02 19 Removing and installing hardtop - as of MY 2005
Microsoft
Fig. 76: Detaching seal at sides of roof frame

5. Detach seal at sides of roof frame.
5.1. The seal at the sides of the roof frame -1- is in two parts. Pull the upper seal -2- out of the profile of the
retaining strip -3- . See Fig. 76.
5.2. Unscrew fastening screws -4- from the retaining strip -3- . See Fig. 76.
5.3. Remove the seal below together with the retaining strip -5- from the roof frame -1- . See Fig. 76.
Microsoft
Fig. 77: Detaching seal at sides of roof frame

6. Loosen and disengage retaining strip and roof frame seal.
6.1. Unscrew tapping screws -1- from retaining strip -2- . See Fig. 77.
6.2. Unscrew pan-head screw -3- from the roof frame seal, detach the seal at the corners and remove it. See Fig.
77.
Microsoft
Fig. 78: Pulling off sealing rubber

7. Pull off sealing rubber.
7.1. Pull off the surrounding sealing rubber -1- to the rear and pull it out at the ends from the roof frame seal -2-
. See Fig. 78.
Microsoft
Fig. 79: Removing roof liner at front

8. Remove roof liner at front.
8.1. Lift front retaining strip -1- of roof liner -2- with a plastic spatula and pull it off. See Fig. 79.
Microsoft
Fig. 80: Detaching roof liner at sides

9. Detach roof liner at sides.
9.1. Lift up the roof liner -1- on the left and right sides with a plastic spatula and disengage from the sheetmetal
clips -2- . See Fig. 80.
Microsoft
Fig. 81: Detaching roof liner at rear and transverse struts

10. Detach roof liner at rear and transverse struts.
10.1. Pull plastic rail -2- on roof liner -1- to the rear and disengage. See Fig. 81.
10.2. Pull out transverse struts -3- with plastic sleeves -4- and remove the roof liner -1- . See Fig. 81.
Microsoft
Fig. 82: Loosening sound absorber from the hardtop body

11. Loosen sound absorber from the hardtop body.
11.1. Loosen the sound absorber -2- of the hardtop body -1- using a spatula. See Fig. 82.
Microsoft
Fig. 83: Disconnecting wiring harness of the heated rear window

12. Disconnecting wiring harness of the heated rear window
12.1. Drill out the 3.2 mm -27- tubular rivet. Disconnect electric plug connection -28- , remove wiring harness
with hardtop locking mechanism from hardtop body.
Microsoft
Fig. 84: Removing locking lever

13. Remove locking lever.
13.1. Unscrew and remove fastening screws -1- from the locking lever -2- . See Fig. 84.
Microsoft
Fig. 85: Pressing expander nuts out of the hardtop body

14. Press expander nuts out of the hardtop body.
14.1. Press expander nuts -1- out of the hardtop body -2- at the sides and front. See Fig. 85.
ASSEMBLING HARDTOP
Assembling hardtop
1. Set the hardtop down on the assembly fixture on the outer roof panel.
Microsoft
Fig. 86: Pressing expander nuts into the hardtop body

NOTE:  Please observe the colored installation position of the expander nuts!
 1A = yellow
 1B = white
 1C = green
 2A = red
 2B = white
2. Press expander nuts into the hardtop body.
2.1. Beginning in the direction of travel going left
2.2. One red -2A- expander nut. See Fig. 86.
2.3. Three yellow -1A- expander nuts. See Fig. 86.
2.4. One green -1C- expander nut. See Fig. 86.
2.5. One white -1B- expander nut. See Fig. 86.
2.6. Press three green -1C- expander nuts into the hardtop body. See Fig. 86.
Microsoft
2.7. Beginning in the direction of travel going right
2.9. Three yellow -1A- expander nuts. See Fig. 86.
2.10. One green -1C- expander nut. See Fig. 86.
2.12. Press three green -1C- expander nuts into the hardtop body. See Fig. 86.
2.13. Press the expander nuts at the front -1B- into the hardtop body in the direction of travel. See Fig. 86.
Fig. 87: Fitting wiring harness for the rear window heating
3. Fit wiring harness for rear window heater.
3.1. Position wiring harness with the hardtop locking mechanism, rivet the flat connector -3- onto the hardtop
body -1- with a 3.2 mm tubular rivet and connect the plug connection -4- .
Microsoft
Fig. 88: Sticking sound absorber in the hardtop body

4. Stick sound absorber on the hardtop body.
4.1. Position the self-adhesive sound absorber -2- in the hardtop body -1- and press firmly into place. See Fig.
88.
Microsoft
Fig. 89: Fitting locking lever

5. Fit locking lever.
5.1. Position locking lever -2- on hardtop body -1- and secure with fastening screws -3- . Tightening torque -->
Tightening torque : 10 (7.5 ftlb.) Nm See Fig. 89.
Microsoft
Fig. 90: Engaging roof liner at rear and transverse struts

6. Engage roof liner at rear and transverse struts.
6.1. Insert transverse struts -2- with plastic sleeves -3- into the hardtop body -3- . See Fig. 90.
6.2. Pull back plastic strip -4- of roof liner -5- and engage in groove of hardtop body -1- . See Fig. 90.
Microsoft
Fig. 91: Engaging roof liner at sides

NOTE:  If the hardtop body is new, the sheetmetal clips on the left and right must
be bent over to the outside using a plastic hammer.
7. Engage roof liner at sides.
7.1. Engage roof liner -1- at the left and right sides in the sheetmetal clips -2- . See Fig. 91.
Microsoft
Fig. 92: Fitting roof liner at front

8. Fit roof liner at front.
8.1. Position front retaining strip -2- of roof liner -1- and clip it in. See Fig. 92.
Microsoft
Fig. 93: Fitting rubber seal

9. Fit sealing rubber.
9.1. Insert self-adhesive sealing rubber -2- at the ends of the roof frame seal -1- . See Fig. 93.
9.2. Remove protective film of the sealing rubber and press firmly into place at the rear on all sides.
Microsoft
Fig. 94: Affixing Nitto tape to the hardtop body

10. Affix Nitto tape to the hardtop body.
10.1. Stick a 2 cm wide strip of Nitto tape -2- on the hardtop body -1- at the front left and right. See Fig. 94.
Microsoft
Fig. 95: Fitting roof frame seal and retaining strip

11. Fit roof frame seal and retaining strip.
11.1. Engage roof frame seal in the hardtop body at the corners and fasten with the fastening screw -1- .
Tightening torque --> Tightening torque : 10 (7.5 ftlb.) Nm See Fig. 95.
11.2. Position retaining strip -2- and screw down using the fastening screws -3- . See Fig. 95.
Microsoft
Fig. 96: Fitting seal at sides of roof frame

12. Fit seal at sides of roof frame.
12.1. The seal at the sides of the roof frame -1- is in two parts. Position lower seal with retaining strip -2- on
roof frame -1- and fasten with fastening screws -3- . See Fig. 96.
12.2. Press upper seal -4- into the profile of the retaining strip -5- . See Fig. 96.
13. Install hardtop locking mechanism. --> 61 02 19 Removing and installing hardtop - as of MY 2005
Microsoft
Fig. 97: Fitting lining

NOTE:  Once a trim panel has been clipped in, the old plastic clips are no longer
usable and must always be replaced.
14. Fit interior lining.
14.1. Clip lining -28- at the sides, front and rear into the hardtop body -1- .
Microsoft
Fig. 98: Applying putty at roof ends

15. Apply putty at roof ends.
15.1. Apply putty at roof ends front and rear.
Microsoft
Fig. 99: Clipping in roof strip clips and cover strips

NOTE:  Once a trim panel has been clipped in, the old plastic clips are no longer
usable and must always be replaced.
16. Clip in roof strip clips and cover strips.
16.1. Fit roof strip clips -30- .
16.2. Fit cover strip seal on the cover strip -31- .
16.3. Position cover strip on hardtop body -1- and press into the roof strip clips.
SUBSEQUENT WORK
Subsequent work
1. Install centering pin. --> 611019 Removing and installing front convertible-top mount - chapter on
"Removing".
2. Install rear window. Refer to 64 86 19 Removing and installing rear window - as of MY 2005 (Boxster,
61 05 19 REMOVING AND INSTALLING LATCH AT FRONT - AS OF MY 2005

Microsoft

PRELIMINARY WORK
Preliminary work
1. Remove interior light. Refer to 96 22 19 Removing and installing bulb for interior light - as of MY 2005
2. Remove operator control unit for garage door opener. Refer to 96 78 19 Removing and installing control
unit for garage door opener - as of MY 2005 (Boxster, Boxster RHD, Boxster S, Boxster S RHD) .
REMOVING LATCH AT FRONT
Removing front lock
Fig. 100: Installation position of front lock

Microsoft
Fig. 101: Removing front lock

1. Release the two fastening screws -1- and pull the front lock -2- down and off -arrow- from the windscreen
frame. See Fig. 101.
2. Push up the electric connecting lines for the interior light and the control unit for garage door opener through
the assembly openings on the front lock.
Microsoft
Fig. 102: Pulling off connector on microswitch for roof.

3. Pull off connector -1- on microswitch for roof -2- -arrow- . See Fig. 102.
INSTALLING LATCH AT FRONT
Installing front lock
Microsoft
Fig. 103: Pushing on connector for roof microswitch.

1. Push on connector -1- for roof microswitch -2- -arrow- . See Fig. 103.
2. Push the electric connecting lines for the interior light and the garage door opener control unit from above
through the assembly openings on the front lock.
Microsoft
Fig. 104: Installing front lock

NOTE: When fitting the front lock make sure the electric connecting lines are laid so
that they are not trapped.
3. Mount front lock -1- from below -arrow- on windscreen frame. See Fig. 104.
4. Tighten front lock with the two fastening screws -2- . --> Tightening torque: 7.5 ftlb. See Fig. 104.
SUBSEQUENT WORK
Subsequent work
1. Install operator control unit for garage door opener. Refer to 96 78 19 Removing and installing control unit
for garage door opener - as of MY 2005 (Boxster, Boxster RHD, Boxster S, Boxster S RHD) .
2. Install interior light. Refer to 96 22 19 Removing and installing bulb for interior light - as of MY 2005
61 09 19 REMOVING AND INSTALLING ROOF LINER - AS OF MY 2005

PRELIMINARY WORK
Microsoft
Preliminary work
1. Remove right and left side trim panels. Refer to 70 75 19 Removing and installing side trim panel - as of
MY 2005 (Boxster, Boxster RHD, Boxster S, Boxster S RHD) .
2. Remove windstop. Refer to 68 47 19 Removing and installing windstop - as of MY 2005 (Boxster,

REMOVING ROOF LINER
Loosening roof liner connection to tension bow
Fig. 105: Removing roof liner

1. Press out plastic expansion rivets -1- at the roof liner connection -2- on the right and left of the tension bow -
3- . See Fig. 105.
Move convertible top to service position
Microsoft
Fig. 106: Convertible top service position

2. Open convertible top to dimension -X= 60 cm- from windscreen frame and switch off ignition. See Fig. 106.
Loosening cloth and cord from convertible top support
Microsoft
Fig. 107: Loosening cord

1. Unscrew fixing clip -1- , remove cord -2- and metal pad -3- and then pull cord upwards (right and left). See
Fig. 107.
Microsoft
Fig. 108: Disengaging retaining straps

2. Disengage retaining straps -1- at left and right on hook of roof liner -2- -Arrow A- . See Fig. 108.
3. Pull hook of roof liner -2- downwards and disengage from the pin for the convertible top support -3- on right
and left -Arrow B- . See Fig. 108.
Microsoft

NOTE: Two persons are needed to disengage and engage the convertible top
mechanism!
4. Press ball socket of push rod -6- off the ball head of the main folding top bow on the right and left. See Fig.
109.
5. Carefully tip convertible top forward by hand until the convertible top frame touches the windscreen frame.
Microsoft
Fig. 110: Pulling out tightening strip

6. Pull out tightening strip -1- from ball pin of main folding top bow -2- on right and left. See Fig. 110.
Microsoft

mechanism!
7. Move convertible top to its original position and press ball socket of push rod -6- onto ball head of main
folding top bow. See Fig. 111.
Loosening roof liner
Microsoft
Fig. 112: Detaching the roof liner

1. Unclip roof liner -1- downwards at front and in center from bar of roof frame -2- , starting from the outside.
See Fig. 112.
Microsoft
Fig. 113: Loosening Velcro fasteners

2. Open Velcro fasteners -1- on the push rod -2- right and left. See Fig. 113.
Microsoft
Fig. 114: Disengaging cord

3. Disengage cord -1- of roof liner at buffer -2- on right and left B-pillar. See Fig. 114.
Fig. 115: Loosening Velcro fastener

4. Open Velcro fastener -1- on tension strap -2- right and left. See Fig. 115.
Microsoft

5. Remove surrounding section -1- of roof liner -2- from corner bow -3- . See Fig. 116.
Microsoft

6. Pull out tightening strip -2- of roof liner -1- outwards from main folding top bow -3- . See Fig. 117.
INSTALLING ROOF LINER
Installing roof liner
Microsoft
Fig. 118: Installing roof liner

1. Pull tightening strip -2- of roof liner -1- into the main folding top bow -3- and position it centrally and at the
sides. See Fig. 118.
Microsoft
Fig. 119: Fastening roof liner

2. Position roof liner -2- centrally on corner bow -3- and press into surrounding section -1- . See Fig. 119.
Microsoft
Fig. 120: Securing Velcro fastener

3. Place Velcro fastener -1- around tension strap -2- and press together (right and left). See Fig. 120.
Microsoft
Fig. 121: Engaging cord

4. Engage cord -1- of roof liner at buffer -2- on right and left B-pillar. See Fig. 121.
Microsoft
Fig. 122: Securing Velcro fasteners

5. Secure Velcro fasteners -1- to the push rod -2- right and left. To do this, position the loop up to the seam of
the Velcro strip and press the Velcro firmly together. See Fig. 122, Fig. 121.
Fig. 123: Fastening roof liner

6. Clip roof liner -1- upwards in center and at front onto bar of roof frame -2- , starting from the inside. See Fig.
123.
Fastening cloth and cord to convertible top support
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mechanism!
1. Press ball socket of push rod -6- off the ball head of the main folding top bow on the right and left. See Fig.
124.
Microsoft
Fig. 125: Fastening tightening strip

3. Pull tightening strip -1- outwards and engage with the third full slit over the ball pin on the main folding top
bow -2- on right and left. See Fig. 125.
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mechanism!
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Fig. 127: Fastening retaining straps

5. Pull hook of roof liner -1- downwards -Arrow A- and engage in the pin for the convertible top support -2- on
right and left. See Fig. 127.
6. Engage retaining straps -3- left and right on hook of roof liner -1- -Arrow B- . See Fig. 127.
Microsoft
Fig. 128: Fasten cord

7. Thread cord on pin -5- at bottom -(inset)- , fit cord -2- in the fixing clip -1- and fasten metal pad -3- to
convertible top support with water drip pan Fig. 128 -4- (right and left). See Fig. 128.
Do this in the following sequence: Fixing clip -1- , cord -2- , metal pad -3- and water drip pan -4- . See Fig.
128.
9. Close convertible top and switch off ignition.
Fastening roof liner connection to tension bow
Microsoft
Fig. 129: Fastening roof liner connection

1. Press plastic expansion rivets -1- at the roof liner connection -2- through the fastening holes of the cloth into
the tension bow -3- on the left and right. See Fig. 129.
SUBSEQUENT WORK
Subsequent work
1. Install the windstop. Refer to 68 47 19 Removing and installing windstop - as of MY 2005 (Boxster,
2. Install right and left side trim panels. Refer to 70 75 19 Removing and installing side trim panel - as of MY
61 10 19 REMOVING AND INSTALLING FRONT CONVERTIBLE-TOP MOUNT

- AS OF MY 2005 (BOXSTER, BOXSTER RHD, BOXSTER S, BOXSTER S
RHD)
PRELIMINARY WORK
Preliminary work
1. Move convertible top to service position. --> 6101 IN - Convertible top service position
Microsoft
NOTE: Only for vehicles with hardtop.
2. Remove hardtop. --> 610219 Removing and installing hardtop - section on "Removing"
Preliminary work
NOTE: Only for removing/installing or replacing convertible-top peg mount.
Remove the sun visor. Refer to 68 23 19 Removing and installing sun visor - as of MY 2005 (Boxster,
REMOVING FRONT CONVERTIBLE-TOP MOUNT
Removing centering journal (convertible top and hardtop)
Fig. 130: Installation location of front mount

Microsoft
Fig. 131: Removing centering journal

1. Unscrew fastening screws -1- and remove centering journal -2- . See Fig. 131.
Removing convertible-top peg mount
Microsoft
Fig. 132: Installation position of convertible-top peg mount

Fig. 133: Removing convertible-top peg mount

1. Unscrew fastening screws -1- and remove convertible-top peg mount -2- downwards -arrow- . See Fig. 133.
Installing centering journal (convertible top and hardtop)
Microsoft
Fig. 134: Installation location of front mount

Fig. 135: Installing centering journal

1. Position centering journal -2- on convertible top or hardtop frame -3- and screw in the fastening screws -1- .
Tightening torque --> Tightening torque: 4.5 (3.3 ftlb.) Nm See Fig. 135.
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Installing convertible-top peg mount
Fig. 136: Installation position of convertible-top peg mount

Fig. 137: Installing convertible-top peg mount

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1. Place convertible-top peg mount -2- on windscreen frame from below -arrow- , position it correctly and
screw down hand-tight using the fastening screws -1- . See Fig. 137.
2. To prevent rattling noises, the two convertible-top peg mounts (left and right) must be facing outwards with
respect to the centering pins fitted on the convertible top or hardtop when tightening the screws. The convertible
top must be closed or the hardtop must be fitted in order to check the adjustment.
3. Tighten fastening screws -1- . Tightening torque --> Final tightening: 10 (7.5 ftlb.) Nm See Fig. 137.
SUBSEQUENT WORK
Subsequent work
1. End service position. --> 6101IN IN - Convertible top service position
2. Check gap dimensions for convertible top, adjust if necessary. Refer to 50 IN Processing structural body
adhesive - as of MY 2005 (All Models) .
3. Install hardtop. --> 610219 Removing and installing hardtop - section on "Installing"
4. Adjust hardtop. --> 610215 Adjusting hardtop
SUBSEQUENT WORK
Subsequent work
NOTE: Only for removing/installing or replacing convertible-top peg mount.
Install sun visor. Refer to 68 23 19 Removing and installing sun visor - as of MY 2005 (Boxster, Boxster
RHD, Boxster S, Boxster S RHD) .
61 14 19 REMOVING AND INSTALLING WATER DRIP PAN - AS OF MY 2005

PRELIMINARY WORK
Preliminary work
Remove cabriolet convertible top. --> 610119 Removing and installing cabriolet convertible top - section on
"Removing"
REMOVING WATER DRIP PAN

Microsoft
Removing water drip pan
Fig. 138: Installation position of water drip pan

Fig. 139: Removing belt reel

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1. Remove fastening screw -1- on belt reel -2- and remove belt reel from roll-over bar -arrow- . See Fig. 139.
Fig. 140: Releasing fastening for convertible top support

2. Remove three fastening screws -1- from the convertible top support -2- . See Fig. 140.
CAUTION: Removal of water drip pan
--> Avoid using sharp-edged tools when inserting the spacing block between the convertible top support and
roll-over bar and when loosening the water drip pan from the roll-over bar.
3. Pull convertible top support -2- out by approx. 10 mm -arrow A- and use a spacing block -3- to secure it
between the roll-over bar and the convertible top support -arrow B- . See Fig. 140.
Microsoft
Fig. 141: Removing water drip pan

4. Loosen the water drip pan -1- from the two strips of double-sided adhesive tape -2- close to the fastening for
the convertible top support. See Fig. 141.
5. Pull the water drip pan -1- down and out -arrows- behind the convertible top support -3- . See Fig. 141.
INSTALLING WATER DRIP PAN
Installing water drip pan
Microsoft
Fig. 142: Installation position of water drip pan

Fig. 143: Installing water drip pan

1. Insert the water drip pan -1- behind the convertible top support -2- from below -arrows- . See Fig. 143.
2. Position the water drip pan -1- on the roll-over bar and press onto the two strips of double-sided adhesive
Microsoft
tape -3- close to the fastening for the convertible top support. See Fig. 143.
Fig. 144: Securing convertible top support

CAUTION: Installation of water drip pan
--> Avoid using sharp-edged tools when removing the spacing block between the convertible top support and
roll-over bar.
3. Remove spacing block -1- between the roll-over bar and convertible-top support -2- ( -arrow A- ). See Fig.
144.
4. Position convertible top support -2- on the roll-over bar -arrow B- and screw down with the three fastening
screws -3- . Tightening torque --> Tightening torque: 23 (17 ftlb.) Nm See Fig. 144.
Microsoft
Fig. 145: Installing belt reel

5. Place the belt reel -1- on the roll-over bar -arrow- , position it correctly and secure with the fastening screw -
2- . Tightening torque --> Tightening torque: 50 (37 ftlb.) Nm See Fig. 145.
SUBSEQUENT WORK
Subsequent work
Install cabriolet convertible top. --> 610119 Removing and installing cabriolet convertible top - section on
"Installing"
61 17 19 REMOVING AND INSTALLING HARDTOP FASTENINGS - AS OF MY

REMOVING HARDTOP FASTENINGS
Microsoft
Fig. 146: Installation location hardtop fastenings

WARNING: Material damage to convertible top frame and rear glass window!
 The convertible top must not be moved forwards electrically when in

service position.
-->
1. Open convertible top completely.
2. Remove side trim panel.
3. Move convertible top to service position.
3.1. --> 6101IN IN - convertible top service position
Microsoft
Fig. 147: Detaching cloth

4. Detach cloth.
4.1. Disengage strip on left and right of cloth -4- in downward direction. See Fig. 147.
Microsoft
Fig. 148: Detaching tension cable

5. Detach tension rope.
5.1. Press ball socket -5- of tension rope from ball head of adjusting piece. See Fig. 148.
Microsoft
Fig. 149: Detaching push rod

6. Detach push rod.
6.1. Press ball socket -6- of push rod from ball head of main folding top bow. See Fig. 149.
7. Swivel convertible top to the front.
7.1. Swivel convertible top to the extent that the screws -7A - and -7B- of the bracket become accessible. See
Fig. 150.
Microsoft
Fig. 150: Unscrewing fastening screws

8. Unscrew the fastening screws.
8.1. Lift tension bow and unscrew fastening screw -7A - over the convertible top compartment; fastening screw
-7B- is accessible as normal. See Fig. 150.
9.1. When operating the convertible top, make sure that the unclipped push bar does not jam in the convertible
top mechanism.
10. Remove bracket
INSTALLING PIVOT-PIN LOCKS
1. Remove hardtop mounts. --> 611719 Removing and installing mounts for hardtop - chapter on
"Removing".
Microsoft
Fig. 151: Installing pivot-pin locks

2. Remove plastic cover -D- from the bracket -A- . See Fig. 151.
NOTE: The pivot-pin locks are marked for a defined side of the vehicle.
3. Insert pivot-pin lock -B- into the bracket -A- . When inserting the twist locks, ensure that the latching tab of
the bracket engages exactly in the cut-out of the pivot-pin lock. See Fig. 151.
4. Screw down fit bolt -C- , in order to tightly clamp the pivot-pin lock -B- in the bracket -A- . Tightening
torque --> Tightening torque: 17 ftlb. See Fig. 151.
5. Press plastic cover -D- into the pivot-pin lock. See Fig. 151.
6. Install hardtop fastenings. --> 611719 Removing and installing mounts for hardtop - chapter on
"Installing"
INSTALLING HARDTOP FASTENINGS
Microsoft
Fig. 152: Installation location hardtop fastenings

WARNING: Material damage to convertible top frame and rear glass window!
 The convertible top must not be moved forwards electrically when in

service position.
-->
1. Insert bracket.
2. Swivel convertible top to the front.
2.1. When operating the convertible top, make sure that the unclipped push bar does not jam in the convertible
top mechanism. Both screws of the bracket are accessible in this intermediate position.
Microsoft
Fig. 153: Fasten bracket.

3. Screw on bracket.
3.1. Replace self-locking screws, position bracket with clearance of -X- --> Installation dimension: 8 mm
from upper edge of door seal and screw down with the fastening screws -7A- and -7B- . --> Tightening torque:
17 ftlb. +/-1.5 ftlb. See Fig. 153.
4. Move convertible top to service position.
4.1. --> 6101IN IN - convertible top service position
Microsoft
Fig. 154: Engaging push rod

5. Engage push rod.
5.1. Press ball socket -6- of push rod onto ball head of main folding top bow. See Fig. 154.
Microsoft
Fig. 155: Engaging tension rope

6. Engage tension rope.
6.1. Press ball socket -5- of tension rope onto ball head of adjusting piece. See Fig. 155.
Microsoft
Fig. 156: Attaching cloth covering

7. Attach cloth covering
7.1. Engage strip -4- on left and right of cloth from below. See Fig. 156.
9. Install side trim panel.
10. Adjust hardtop gap dimensions. --> 610215 Adjusting hardtop
61 19 19 REMOVING AND INSTALLING CONVERTIBLE TOP LOCK - AS OF

MY 2005 (BOXSTER, BOXSTER RHD, BOXSTER S, BOXSTER S RHD)
PRELIMINARY WORK
Preliminary work
Move convertible top to service position. --> 6101IN IN - Convertible top service position
REMOVING CONVERTIBLE TOP LOCK
Removing convertible top lock
Microsoft
Fig. 157: Installation position of convertible top lock

Fig. 158: Removing convertible top lock

1. Unscrew the four fastening screws -1- . See Fig. 158.

Microsoft
2. Remove convertible top lock -2- from the roof frame -3- in a downward direction -arrow- . See Fig. 158.
INSTALLING CONVERTIBLE TOP LOCK
Installing convertible top lock
Fig. 159: Installation position of convertible top lock

Microsoft
Fig. 160: Installing convertible top lock

1. Position convertible top lock -1- from below -arrow- on the roof frame -2- . See Fig. 160.
2. Coat the four fastening screws -3- with screw-locking lacquer and tighten. --> Tightening torque: 4.5 (3.5
ftlb.) Nm See Fig. 160.
SUBSEQUENT WORK
Subsequent work
1. End service position. --> 6101IN IN - Convertible top service position
2. Check gap dimensions for convertible top, adjust if necessary. Refer to 50 IN Processing structural body
61 21 19 REMOVING AND INSTALLING COVER STRIP - AS OF MY 2005

PRELIMINARY WORK
Preliminary work
Move convertible top to service position. --> 6101IN IN - convertible top service position
Microsoft
REMOVING COVER STRIP
Removing cover strip
Fig. 161: Installation position for cover strip

Microsoft
Fig. 162: Removing cover strip

1. Unscrew fastening screws -1- and remove cover strip -2- from roof frame -3- . See Fig. 162.
INSTALLING COVER STRIP
Installing cover strip
Microsoft

NOTE: Seal for convertible-top tip must not be trapped. There must be no gap between
seal and covering, and the seal with the covering must run evenly. If necessary,
pull the seal up and out and tap it in again.
Microsoft

1. Position cover strip -2- on roof frame -3- and screw down with the fastening screws -1- . Tightening torque --
> Tightening torque : 3.5 (2.5 ftlb.) Nm See Fig. 164.
SUBSEQUENT WORK
Subsequent work
End service position. --> 6101IN IN - convertible top service position
61 23 19 REMOVING AND INSTALLING REAR SEAL (TENSION BOW) - AS

PRELIMINARY WORK
Preliminary work
Microsoft

2. Open convertible top to the dimension -X= 50 cm- . See Fig. 165.
REMOVING REAR SEAL (TENSION BOW)
Removing rear seal (tension bow)
Microsoft
Fig. 166: Installation position of rear seal (tension bow)

Microsoft
Fig. 167: Removing rear seal

1. Pull headliner -1- out of the groove of the tension bow -2- . See Fig. 167.
INSTALLING REAR SEAL (TENSION BOW)
Installing rear seal (tension bow)
Microsoft

Microsoft

1. Position rear seal (tension bow) -1- on one side of tension bow -2- and tap gently into place with a plastic
hammer. See Fig. 169.
SUBSEQUENT WORK
Subsequent work
2. Close convertible top and switch off ignition.
61 28 55 REPLACING CONVERTIBLE-TOP COVERING - AS OF MY 2005

TOOLS

Assembly tool with T25 special tool P 9744
insert
PRELIMINARY WORK
Microsoft
Preliminary work
NOTE:  Always replace the spare parts contained in the "convertible-top covering"
scope of parts!
 The convertible-top covering must be replaced at a room temperature of at
least 15 degrees Celsius (59 Fahrenheit)!
1. Remove right and left side trim panels. Refer to 70 75 19 Removing and installing side trim panel - as of
2. Remove seal for convertible-top compartment lid. --> 619319 Removing and installing seal for lid -
chapter on "Removing"
3. Remove roof liner. --> 610919 Removing and installing roof liner - chapter on "Removing"

4. Open convertible top to the dimension - X= 50 cm- . See Fig. 170.
TOOLS AND MATERIALS
Tools and materials
Microsoft
Fig. 171: 9744 assembly tool

Assembly tool with T25 insert P 9744
REMOVING CONVERTIBLE-TOP COVERING
Loosening convertible top mechanism
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Fig. 172: Installation position for convertible-top covering

Microsoft

mechanism!
Two persons are needed to disengage and engage the convertible top
mechanism!
1. Press ball socket of push rod -6- off the ball head of the main folding top bow. See Fig. 173.
2. Carefully remove convertible top by hand to the rear.
Removing tension cable of convertible-top covering
Microsoft

Microsoft
Fig. 175: Removing tension cable of convertible-top covering

1. Unscrew side fastening screws -1- using assembly tool with T25 insert P 9744 from the tension cable -2-
and clamping rail -3- . See Fig. 175.
2. Carefully move convertible top forward by hand until the convertible top frame touches the windscreen
frame.
Microsoft
Fig. 176: Loosening clamping rail

3. At the front of the B-pillar (main folding top bow), unscrew the fastening screw -1- and swing the clamping
rail -2- upwards. See Fig. 176.
Fastening convertible top mechanism
Microsoft

Microsoft

mechanism!
mechanism!
Microsoft

Microsoft

Removing seal for convertible-top tip
Microsoft
Fig. 181: Installation position of seal for convertible-top tip

The seal on the roof frame is in two parts.
Microsoft
Fig. 182: Pulling off seal

1. Pull off lower lateral seal -1- out of the profile of the retaining strip -2- . See Fig. 182.
2. Unscrew fastening screws -3- at front of roof frame. See Fig. 182.
Microsoft
Fig. 183: Removing seal

3. Unscrew fastening screws -1- from the retaining strip -2- . Pull off seal for convertible-top tip -3- . See Fig.
183.
4. Remove additional seal -4- . See Fig. 183.
Removing shaped sheetmetal part with convertible-top covering
Microsoft

Microsoft
Fig. 185: Loosening shaped sheetmetal part with convertible-top covering

1. Unscrew fastening screws -1- from roof frame, and gently lift shaped metal part together with convertible top
covering -2- . See Fig. 185.
Loosening convertible-top covering at the roof frame
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Microsoft
Fig. 187: Loosening convertible-top covering on inside

1. Loosen Velcro fastener on inside -1- of convertible top covering -2- . See Fig. 187.
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Fig. 188: Removing convertible-top covering at front on roof frame 1.

2. Loosen convertible-top covering at front on roof frame and lay it down to the rear.
Loosening fold placer and folding aid

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Fig. 190: Unscrewing fold placer

NOTE: Do not pull out the fold placer.
1. Unscrew fastening screws -1- of fold placer -2- at left and right. See Fig. 190.
Microsoft
Fig. 191: Loosening folding aid

2. Drill out rivet -1- and washer -3- on folding aid -2- at left and right sides. See Fig. 191.
Loosening tightening strip and inner inlet aid
Microsoft

Microsoft
Fig. 193: Loosening tightening strip and inner inlet aid

1. Unscrew fastening screws -1- with washer -2- . Pull out inlet aid -3A- and tightening strip -3B- . See Fig.
193.
Disconnecting electric plug connection at rear window
Microsoft

CAUTION: Material damage when disconnecting the electric plug connection at the
rear window.
 The electric plug connection at the rear window may break off or
become loosened
--> Disconnect the plug connection carefully.
Microsoft

1. Carefully disconnect plug connection -2- on left and right from the connector -1- at the rear window. See Fig.
195.
Removing rear seal (tension bow)
Microsoft

Microsoft

1. Pull headliner -1- out of the groove of the tension bow -2- . See Fig. 197.
Loosening convertible-top covering at the tension bow
Microsoft

Microsoft
Fig. 199: Loosening convertible-top covering at the tension bow

1. Unscrew convertible-top covering end piece -1- from rear of tension bow -2- . See Fig. 199.
Removing slide
Microsoft

Microsoft
Fig. 201: Loosening slide

1. Press expanding pin of expansion rivet -1- out of the main folding top bow -Arrow A- from the inside. See
Fig. 201.
2. Pull out slide -2- from main folding top bow -Arrow B- , disengage cord -3- -Arrow C- and remove by the
loop -Arrow D- . See Fig. 201.
INSTALLING CONVERTIBLE-TOP COVERING
Preparing convertible-top frame and convertible-top covering
Microsoft

NOTE:  Always replace the spare parts contained in the "convertible-top covering"
scope of parts.
1. All pins and screw joints must be checked for tightness before the convertible-top covering is installed. -->
613055 Replacing convertible-top frame
2. Measure the center between the restraining straps and mark it on the tension bow.
3. Replace the tension strap. --> 613055 Replacing convertible-top frame - chapter on "Replacing"
Microsoft
Fig. 203: Fitting clamping rail

4. Pull clamping rail -3- into the pull strip -1- of the convertible top covering -2- in direction of arrow. See Fig.
203.
5. Slide clamping rail -3- through to the inside. Position fastening screw -4- on convertible top covering -2- and
screw in by hand by approx. 4 turns. See Fig. 203.
Microsoft
Fig. 204: Fitting slide

6. Pull slide -1- into the pull strip -2- of the convertible top covering in direction of arrow. See Fig. 204.
Installing convertible-top covering
Microsoft

Microsoft
Fig. 206: Fastening fold placer

NOTE: Make sure that the side of the shaped sheetmetal part does not scratch the
styling edge.
1. Lay convertible top covering on the convertible top frame.
2. Lay fold placer -2- over the push rod -3- , position on convertible top frame and tighten with the fastening
screw -1- . Tightening torque --> Tightening torque: 1.8 (1.5 ftlb.) Nm See Fig. 206.
Fastening the convertible-top covering at the sides of the roof frame
Microsoft

Microsoft
Fig. 208: Fastening the convertible-top covering at the sides of the roof frame
1. Lay the convertible-top covering -2- to the front and guide the shaped sheetmetal part into the roof frame
from above. See Fig. 208.
2. Fasten the convertible-top covering -2- with the fastening screws -1- , starting from the front bottom side of
the roof frame. Tightening torque --> Tightening torque : 3.5 (2.5 ftlb.) Nm See Fig. 208.
Fastening convertible-top covering at front
Microsoft

A self-adhesive strip is affixed to the front of the convertible top covering.
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Fig. 210: Fastening convertible-top covering at front

NOTE: There must be no bubbles, especially in the area of the lap seam. If necessary,
re-tighten convertible top covering with pliers.
1. Pull the protective paper off the adhesive tape and fold the convertible-top covering around the roof frame
into the groove without wrinkles.
2. Fix convertible top covering at front with clamps.
Installing seal for convertible-top tip
Microsoft

The seal for the convertible-top tip on the roof frame is in two parts.
Microsoft
Fig. 212: Installing seal for convertible-top tip

1. Remove protective film and fit additional seal -4- flush with the roof frame. See Fig. 212.
Microsoft
Fig. 213: Fastening seal for convertible-top tip

NOTE: Make sure the additional seal is clamped under the retaining strip.
2. Insert seal for convertible top tip -3- into roof frame at front corners, position retaining strip -2- on the side of
the roof frame and tighten with the fastening screws -1- . Tightening torque --> Tightening torque: 2.8 (2.0
NOTE: Seal for convertible-top tip must not protrude downwards in the corner area.
Make sure it is positioned correctly.
3. Screw down seal for convertible-top tip at the front corners with fastening screws -3- . Tightening torque -->
Tightening torque: 3.5 (2.5 ftlb.) Nm See Fig. 213.
4. Press lower seal -1- into profile of retaining strip -2- . See Fig. 213.

Microsoft

Fastening the slide
Microsoft

Microsoft
Fig. 217: Fastening convertible-top covering at front

1. Pull cord -3- from below through the loop on the convertible top covering -Arrow B- . Engage cord with
knot on slide -2- -Arrow A- . See Fig. 217.
NOTE: Make sure that the cord is routed above the pin of the main folding top bow.
2. Position slide -2- over leaf spring -Arrow C- and clip onto the main folding top bow. Drive in expanding pin
of expansion rivet -1- -Arrow D- . See Fig. 217.
Loosening convertible top mechanism
Microsoft

Microsoft

mechanism!
mechanism!
1. Press ball socket of push rod -6- off the ball head of the main folding top bow. See Fig. 173.
2. Carefully remove convertible top by hand to the rear.
Fastening tension cable of the convertible-top covering
Microsoft
Fig. 220: Main illustration of convertible top covering

Microsoft
Fig. 221: Removing tension cable of convertible-top covering

NOTE: For reasons of space, the front fastening screws of the clamping rail have to be
carefully tightened with zero torque using assembly tool with T25 insert P 9744.
1. Place tension bow -2- level with the clamping rail guide -3- and tighten the center fastening screw -1- using
assembly tool with T25 insert P 9744 on the main folding top bow. Tightening torque --> Tightening torque:
5 (3.5 ftlb.) Nm See Fig. 221.
NOTE: For reasons of space, the front fastening screws of the clamping rail have to be
carefully tightened with zero torque using assembly tool with T25 insert P 9744.
2. Insert fastening screw -1- into the tension cable eyelet and guide in the convertible top covering. Tighten
Microsoft
fastening screw. Tightening torque --> Tightening torque: 5 (3.5 ftlb.) Nm See Fig. 221.
Fig. 222: Fastening clamping rail

4. Secure clamping rail -2- at the rear with the fastening screw -1- . Tightening torque --> Tightening torque: 5
(3.5 ftlb.) Nm See Fig. 222.
Fastening convertible top mechanism
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Microsoft

mechanism!
mechanism!
Fastening convertible-top covering on the tension bow
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Fig. 226: Fastening convertible-top covering on the tension bow

1. Position convertible top covering -1- , with the center coinciding with the marking on the tension bow -inset-
, in the groove of the tension bow -3- . Use a plastic wedge -4- to press in from the center outwards. See Fig.
226.
2. After pressing the convertible top covering -1- into the tension bow -3- , check the center position once more
and correct if necessary. See Fig. 226.
Fastening convertible-top covering on the inside
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1. Close convertible top.
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Fig. 228: Fastening convertible-top covering on the inside

2. Stretch convertible top covering -2- and fasten Velcro fastener -1- in groove at rear of roof frame . See Fig.
228.
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Fig. 229: Fastening tightening strip and inlet aid

3. Pull inlet aid -3A- inwards and, at dimension -X= 85 mm- , tighten the fastening screw -1- with washer -2- .
Tightening torque --> Tightening torque : 2.8 (2.0 ftlb.) Nm See Fig. 229.
4. Position tightening strip -3B- with the fourth full slit of the seam in the hole on the main folding top bow and
tighten the fastening screw -1- with washer -2- . --> Tightening bow: 1.8 (1.5 ftlb.) Nm See Fig. 229.
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Fig. 230: Fastening folding aid

NOTE: Make sure that the folding aid is routed under the corner bow.
5. Pull folding aid -2- forwards. Rivet folding aid -2- with rivet -1- and washer -3- to convertible top support.
See Fig. 230.
Connecting electric plug connection at rear window
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Fig. 231: Main illustration of convertible top covering

CAUTION: Material damage when connecting the electric plug connection at the rear
window.
become loosened
--> Connect the plug connection carefully.
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1. Carefully connect plug connection -2- on left and right to the connector -1- at the rear window. See Fig. 232.
Installing rear seal (tension bow)
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1. Position rear seal (tension bow) -1- on one side of tension bow -2- and tap gently into place with a plastic
hammer. See Fig. 234.
SUBSEQUENT WORK
Subsequent work
1. Install roof liner. --> 610919 Removing and installing roof liner - chapter on "Installing"
2. Install right and left side trim panels. Refer to 70 75 19 Removing and installing side trim panel - as of MY
3. Install seal for convertible-top compartment lid. --> 619319 Removing and installing seal for lid - chapter
on "Installing"
61 30 55 REPLACING CONVERTIBLE TOP FRAME - AS OF MY 2005

TOOLS

Assembly tool for commercially NR.131
Microsoft
Springfix System pin available tool

circlips
Retaining frame special tool P 9695
Support for roll-over bar special tool P 9695/3
and convertible top
Assembly tool with T15 special tool P 9744
insert
Transmission jack workshop WE1082
equipment
TOOLS AND MATERIALS
Tools and materials
1. Transmission jack WE1082
2. Retaining frame P 9695
3. Support for roll-over bar and convertible top P 9695/3
4. Assembly tool with T15 insert P 9744
5. Assembly tool for Springfix System pin circlips NR.131
ASSEMBLING CONVERTIBLE TOP FRAME
Assembling convertible-top frame
NOTE:  Only use blind rivets from the parts package.
NOTE:  This document describes how to re-assemble the convertible top frame on
a roll-over bar that has been removed.
 All convertible-top components described here can also be removed and
installed on the vehicle except for the main folding top bow and the
convertible top support.
Microsoft
Fig. 235: Diagram of convertible top frame

1 - Roll-over bar
2 - Convertible top support
3 - B-pillar
4 - Roof frame
5 - Main bow
6 - Tension strap
7 - Corner bow
8 - Tension bow
9 - Tension cable
10 - Water drip pan
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Fig. 236: Assembly fixture for convertible top

CAUTION: Danger of injury if roll-over bar is not secured properly to the convertible
top frame
 Danger of injury
 Risk of damage to convertible-top components
--> Secure roll-over bar to convertible top frame on assembly fixture
1. Position and secure roll-over bar -1- on support for roll-over bar and convertible top -2- support for roll-
over bar and convertible top P 9695/3. A retaining frame -3- retaining frame P 9695 and transmission jack -
4- transmission jack WE1082 are also required for assembly. See Fig. 236.
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Fig. 237: Affixing double-sided adhesive tape

NOTE:  The double-sided adhesive tape is used to make the water drip pan more
secure.
2. In the area of the convertible-top support fastening point on the roll-over bar -1- , affix two strips of double-
sided adhesive tape -2- . See Fig. 237.
Installing wiring harness for rear window heating on the roll-over bar
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Fig. 238: Installing wiring harness

1. Insert upper central plug with retaining clip -1- and wiring harness on roll-over bar -2- from inside -arrow A-
and lock into place by turning to the right -arrow B- . See Fig. 238.
2. Press in retaining clip -3- for wiring harness on roll-over bar -arrow C- . See Fig. 238.
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Fig. 239: Installing wiring harness

3. Insert lower central plug with retaining clip -1- and wiring harness on roll-over bar -2- from outside -arrow
A- and lock into place by turning to the right -arrow B- . See Fig. 239.
Installing seat belt
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Fig. 240: Installing seat belt

1. Place belt reel -1- and top deflector -2- with cap -3- on the roll-over bar -4- ( -arrows- ), position them
correctly and secure with fastening screws Fig. 240 -5- . Tightening torque --> Tightening torque: 50 (37 ftlb.)
Nm See Fig. 240.
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Fig. 241: Closing cap

2. Close cap -arrow- until the latches engage securely. See Fig. 241.
Installing rubber stop and latches
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Fig. 242: Securing lower part of rubber stop

1. Place lower part of rubber stop -1- on roll-over bar from behind -2- , position it correctly and secure with a
steel blind rivet -3- . See Fig. 242.
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Fig. 243: Inserting rubber buffer

2. Insert rubber buffer -1- on lower part of rubber stop -2- . See Fig. 243.
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Fig. 244: Securing the cover

3. Attach cover -1- to lower part of rubber stop -2- ( -arrow- ) until the latches engage securely. See Fig. 244.
4. Position cover -1- and secure with a steel blind rivet -3- . See Fig. 244.
Fig. 245: Securing latch


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5. Place latch for center part of wind deflector -1- on roll-over bar -2- , position it correctly and secure with a
steel blind rivet -3- . See Fig. 245.
Installing water drip pan
Fig. 246: Installing water drip pan

1. Insert water drip pan -1- at roll-over bar -2- ( -arrows- ) and position on hole pattern for convertible-top
support fastening point. See Fig. 246.
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Fig. 247: Securing water drip pan

2. Press water drip pan onto the two strips of double-sided adhesive tape in the area of the convertible-top
support fastening point -arrows- . See Fig. 247.
Installing convertible top support
Microsoft
Fig. 248: Installing convertible top support

1. Place convertible top support -1- on roll-over bar from outside -2- , position it correctly and screw down with
the three fastening screws -3- . Tightening torque --> Tightening torque: 23 (17 ftlb.) Nm See Fig. 248.
Installing main folding top bow
Microsoft
Fig. 249: Installing main folding top bow

1. Press Teflon sleeves -1- at both sides into the bores on the main folding top bow -2- . See Fig. 249.
2. Position main folding top bow on convertible top support -3- and join with the pin -4- (8 x 70 mm) -arrow- .
See Fig. 249.
3. Press retaining clip -5- into the pin. See Fig. 249.
Connecting control arm and lower lever with B-pillar
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Fig. 250: Connecting control arm and lever

1. Press Teflon sleeves -1- at both sides into the bore on the control arm -2- . See Fig. 250.
2. Position control arm -2- on lever -3- and join with the pin -4- (8 x 25 mm) -arrow- . See Fig. 250.
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Fig. 251: Connecting control arm and lower lever with B-pillar
4. Press Teflon sleeves -1- at both sides into the bores on the lower lever -2- . See Fig. 251.
5. Position control arm and lower lever on B-pillar -3- and join with the pin -4- (8 x 30 mm) -arrow- . See Fig.
251, Fig. 250.
Installing B-pillar with control arm and lower lever
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Fig. 252: Installing B-pillar

1. Press Teflon sleeves -1- at both sides into the bore on the convertible top support -2- . See Fig. 252.
2. Position B-pillar -3- with control arm and lever on convertible top support and join with the pin -4- (8 x 53
mm) -arrow- . See Fig. 252.
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Fig. 253: Connecting lower lever to main folding top bow

4. Place main folding top bow -1- in a vertical position. Position lower lever -2- on main folding top bow and
join with the pin -3- (8 x 25 mm) -arrow- . See Fig. 253.
Installing B-pillar seal
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Fig. 254: Installing B-pillar seal

1. Place seal -1- on B-pillar -2- ( -arrows A- ) and position it correctly. See Fig. 254.
2. Pull seal receiver -3- in at the bore -4- on the B-pillar -arrow B- . See Fig. 254.
3. Screw down B-pillar seal on the door window aperture with the five fastening screws -5- . See Fig. 254.
4. Screw down B-pillar seal at the bottom of the B-pillar with the two fastening screws -6- ( assembly tool with
T15 insert P 9744 ). See Fig. 254.
Installing front roof frame
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Fig. 255: Inserting Teflon sleeves

1. Press Teflon sleeves -1- at both sides into the bores on the front B-pillar -2- and on the control arm -3- . See
Fig. 255.
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Fig. 256: Inserting Teflon sleeves on roof frame (view from inside)
2. Press Teflon sleeves -1- at both sides into the bores on the roof frame -2- . See Fig. 256.
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Fig. 257: Installing roof frame

3. Position front roof frame -1- on B-pillar -2- and on control arm -3- and join with the pins -4- (8 x 32 mm) -
arrow- . See Fig. 257.
4. Press retaining clips -5- into the pins. See Fig. 257.
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Fig. 258: Fitting cap

5. Place cap -1- on the bore on the roof frame -2- ( -arrow- ) and screw down with the fastening screw -3- . See
Fig. 258.
Installing corner bow
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Fig. 259: Installing Teflon sleeves

1. Press Teflon sleeves -1- at both sides into the bore on the corner bow -2- . See Fig. 259.
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Fig. 260: Installing corner bow

NOTE: The pin for joining the corner bow to the convertible top support is also used
for the tension bow receiver. For this reason, the pin should only be pressed
around half-way into the receiver on the convertible top support when
assembling the corner bow.
2. Position corner bow -1- on convertible top support -2- and join with the pin -3- (8 x 75 mm) -arrow- . See
Fig. 260.
Installing tension bow
Fig. 261: Fitting Teflon sleeves

1. Press Teflon sleeves -1- at both sides into the bore on the inside of the tension bow -2- . See Fig. 261.
2. Press Teflon sleeve -3- into the bore on the outside of the tension bow -4- from inside. See Fig. 261.
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Fig. 262: Installing tension bow

3. Position tension bow -1- on convertible top support -2- and join with the pin -3- (8 x 75 mm) -arrow- . See
Fig. 262.
Installing tensioning straps
CAUTION: Observe drill-bit diameter and drill depth of aluminum rivets on main
folding top bow and corner bow
 The main folding top bow and corner bow can be damaged if the drill
holes for the aluminum rivets for securing the tensioning straps are
too big and/or too deep.
--> Observe drill-bit diameter and drill depth for the relevant rivets in the scope of parts (rivets: Ø 4 mm, length:
12 mm)
NOTE:  During repair work, drilling chips can fall into the inside of the tension bow
when boring out blind rivets.
 For corrosion protection reasons, the tension bow must be cleared using
compressed air. The tension bow must then be treated with cavity
preservation.
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Fig. 263: Installing tensioning straps

NOTE:  Only use aluminum rivets from the parts package.
1. Place short tensioning strap -1- on main folding top bow -2- from inside, position it correctly and secure with
a blind rivet -3- . See Fig. 263.
2 - Main folding top bow (detailed view is shown from below)
5 - Tension bow (detailed view is shown from above)
7 - Corner bow (detailed view is shown from below)
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2. Place long tensioning strap -4- on tension bow -5- from outside, position it correctly and secure with a blind
rivet -6- . See Fig. 263.
3. Place corner bow -7- in a vertical position and raise tension bow -5- in accordance with strap length -arrow- .
Place short and long tensioning strap -1, 4- together on the corner bow from inside, position them correctly and
secure with a blind rivet -8- . See Fig. 263.
SUBSEQUENT WORK
Subsequent work
1. Install convertible top lock. --> 611919 Removing and installing convertible top lock - section on
"Installing"
2. Install front convertible-top mount. --> 611019 Removing and installing front convertible-top mount -
section on "Installing"
61 39 19 REMOVING AND INSTALLING SEAL FOR CONVERTIBLE-TOP TIP -

RHD)
PRELIMINARY WORK
Preliminary work
REMOVING SEAL FOR CONVERTIBLE-TOP TIP
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Microsoft

Removing seal for convertible-top tip
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The seal on the roof frame is in two parts.
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Fig. 267: Pulling off seal

1. Pull off lower lateral seal -1- out of the profile of the retaining strip -2- . See Fig. 267.
2. Unscrew fastening screws -3- at front of roof frame. See Fig. 267.
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3. Unscrew fastening screws -1- from the retaining strip -2- . Pull off seal for convertible-top tip -3- . See Fig.
268.
4. Remove additional seal -4- . See Fig. 268.
INSTALLING SEAL FOR CONVERTIBLE-TOP TIP
Installing seal for convertible-top tip
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The seal for the convertible-top tip on the roof frame is in two parts.
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Fig. 270: Installing seal for convertible-top tip

1. Remove protective film and fit additional seal -4- flush with the roof frame. See Fig. 270.
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Fig. 271: Fastening seal for convertible-top tip

NOTE: Make sure the additional seal is clamped under the retaining strip.
2. Insert seal for convertible top tip -3- into roof frame at front corners, position retaining strip -2- on the side of
the roof frame and tighten with the fastening screws -1- . Tightening torque --> Tightening torque: 2.8 (2.0
NOTE: Seal for convertible-top tip must not protrude downwards in the corner area.
Make sure it is positioned correctly.
3. Screw down seal for convertible-top tip at the front corners with fastening screws -3- . Tightening torque -->
4. Press lower seal -1- into profile of retaining strip -2- . See Fig. 271.

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SUBSEQUENT WORK
Subsequent work
End service position. --> 6101IN IN - convertible top service position
61 60 19 REMOVING AND INSTALLING SWITCH FOR ROOF - AS OF MY

PRELIMINARY WORK
Preliminary work
Microsoft
Remove center console. Refer to 68 17 19 Removing and installing center console - as of MY 2005 (All
Models) .
REMOVING SWITCH FOR ROOF
Removing switch for roof
Fig. 274: Overview of removing and installing switch for roof

1. Turn over center console.
2. Release connector -1- and remove it -arrow a- . See Fig. 275.
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Fig. 275: Removing switch for roof

3. Press locking lugs on switch for roof outwards -2- ( -arrows b- ) and push switch for roof up and out of the
center console. See Fig. 275.
INSTALLING SWITCH FOR ROOF
Installing switch for roof
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Fig. 276: Installing switch for roof

1. Insert switch for roof -1- into the center console from above -2- until the locking lugs are felt to engage. See
Fig. 276.
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Fig. 277: Pushing connector onto switch for roof

3. Push connector -1- onto switch for roof -2- until it is felt to engage. See Fig. 277.
SUBSEQUENT WORK
Subsequent work
Install center console. Refer to 68 17 19 Removing and installing center console - as of MY 2005 (All
Models) .
61 64 19 REMOVING AND INSTALLING MICROSWITCH FOR ROOF - AS OF

Microsoft
PRELIMINARY WORK
Preliminary work
1. Open convertible top.
4. Remove front lock. --> 610519 Removing and installing front lock - section on "Removing"
REMOVING MICROSWITCH FOR ROOF
Removing microswitch for roof
Fig. 278: Installation position of microswitch for roof

Microsoft
Fig. 279: Removing microswitch

1. Loosen circlips -1- (by turning them -arrow a- with a small screwdriver -2- ) at the front lock -4- and lift
them up and off -arrow A- . See Fig. 279.
2. Remove microswitch for roof -3- from front lock -4- by pulling it upwards -arrow B- . See Fig. 279.
INSTALLING MICROSWITCH FOR ROOF
Installing microswitch for roof
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Fig. 280: Installing microswitch

1. Insert microswitch for roof -1- from above -arrow A- into the front lock -2- . See Fig. 280.
NOTE: New circlips must always be used when securing the microswitch.
2. Fit circlips -3- from above -arrow B- and press in until they connect fully with the microswitch for roof -1- .
See Fig. 280.
SUBSEQUENT WORK
Subsequent work
Microsoft
1. Install front lock. --> 610519 Removing and installing front lock - section on "Installing"
61 70 19 REMOVING AND INSTALLING MOTOR FOR DRIVE MECHANISM -

RHD)
PRELIMINARY WORK
Preliminary work
REMOVING MOTOR FOR DRIVE MECHANISM
Removing motor for drive mechanism
Fig. 281: Installation position of motor for convertible top operation

Microsoft
Fig. 282: Releasing electric connector

1. Release -arrows a- and remove connector. See Fig. 282.
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Fig. 283: Removing motor for convertible top operation

2. Loosen lock washers -1- and lift up and out -arrows A- . See Fig. 283.
3. Remove pliable shafts -2- from the motor for convertible top operation and lay them aside -arrows B- . See
Fig. 283.
4. Loosen the three fastening nuts -3- and remove motor for convertible top operation by pulling it forwards -
arrow C- . See Fig. 283.
INSTALLING MOTOR FOR DRIVE MECHANISM
Installing motor for drive mechanism
Fig. 284: Installing motor for convertible top operation

1. Insert motor for convertible top operation into the studs -arrow A- . See Fig. 284.
2. Secure motor for convertible top operation with the three fastening nuts -1- . --> Tightening torque: 3.5 ftlb.
See Fig. 284.
3. Adjust convertible top gear. --> 61 72 Adjusting convertible top mechanism - as of MY 2005 (Boxster,
Microsoft
4. Insert pliable shafts -2- into the motor for convertible top operation -arrows B- and secure with lock washers
-3- (-arrows C- ). See Fig. 284.
Fig. 285: Connecting connector

5. Push connector onto motor for convertible top operation until it clicks into place.
SUBSEQUENT WORK
Subsequent work
Move convertible top out of service position.
61 72 19 REMOVING AND INSTALLING CONVERTIBLE TOP GEAR - AS OF

PRELIMINARY WORK
--> 6101IN IN - convertible top service position
Microsoft

1. Pressing out the push rod
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2. Press left and right push rod springs 8 out of the ball head of the lever.
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3. Unscrew the fastening screw 1 out of the lever 2 and remove the cover 3 and lever 2 from the convertible top
gear 4 .
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Fig. 289: Disengaging flexible shaft

4. Unclip clip 6 from the flexible shaft 5 and disengage the shaft from the drive motor 7 .
REMOVING CONVERTIBLE TOP GEAR
Removing convertible top gear
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Fig. 290: Removing convertible top gear

1. Unscrew fastening nuts 9 . Take off convertible top gear 10 from the studs 11 .
Removing studs
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Fig. 291: Removing studs

1. Unscrew studs 12 from the body.
Installing studs
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Fig. 292: Installing studs

1. Screw in the studs in the body and screw down. --> Tightening torque: 13 ftlb.
INSTALLING CONVERTIBLE TOP GEAR
Installing convertible top gear
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Fig. 293: Installing convertible top gear

1. Position the convertible top gear 10 on the studs 11 and screw down the fastening nuts 9 . --> Tightening
torque: 16 ftlb.
Subsequent work
1. --> 610115 Adjusting Cabriolet convertible top - chapter on "Adjusting"
Microsoft

2. Engage push rod.
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3. Press left and right push rod springs 8 into the ball head of the lever.
5. Functional test: open and close convertible top with the rocker switch. When opening and closing the
convertible top, the gap dimension between the --> dimension: 5 mm must be observed. If necessary, correct
by screwing the ball socket 6 in or out.
61 90 37 DISASSEMBLING AND ASSEMBLING CONVERTIBLE TOP

COMPARTMENT LID - AS OF MY 2005 (BOXSTER, BOXSTER RHD,
BOXSTER S, BOXSTER S RHD)
PRELIMINARY WORK
--> 6101IN Convertible top service position
DISASSEMBLING CONVERTIBLE TOP COMPARTMENT LID
Disassembling convertible-top compartment lid
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Fig. 296: Pulling off foam pads

1. Pull off foam pads 1 .
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Fig. 297: Removing locating peg

2. Unscrew locating peg 2 from the convertible top compartment lid.
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Fig. 298: Removing protective edging

3. Unscrew fastening screws 3 from the convertible top compartment lid and remove the inner protective edging
4.
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Fig. 299: Removing protective edging

4. Remove outer protective edging 5 from the convertible top compartment lid.
ASSEMBLING CONVERTIBLE TOP COMPARTMENT LID
Assembling convertible-top compartment lid
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Fig. 300: Installing protective edging

1. Position outer protective edging 5 on convertible top compartment lid and push into place.
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Fig. 301: Inner protective edging

2. Position and push inner protective edging 4 onto convertible top compartment lid, and tighten with the
fastening screws 3 . --> Tightening torque: 2.8 (2.0 ftlb.) Nm
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Fig. 302: Installing locating peg

3. Screw locating peg 2 into the convertible top compartment lid. --> Tightening torque: 9.7 (7.0 ftlb.) Nm
Microsoft
Fig. 303: Installing foam pad

4. Remove protective paper from foam pad 1 and stick pad onto the convertible top compartment lid at the
places specified.
Subsequent work
End service position. --> 6101IN Convertible top service position
61 92 REMOVING AND INSTALLING HINGE FOR TOP BOX COVER - AS OF

TOOLS

Assembly tool for commercially NR.131
Springfix System pin available tool
circlips
REMOVING HINGE FOR TOP BOX COVER
Removing hinge for top box cover
Microsoft
Fig. 304: Installation position of hinge for top box cover

1. Press lock 1 out of the push rod spring 2 at the left and right. Assembly tool for Springfix System pin
circlips NR.131
Microsoft
Fig. 305: Removing hinge for top box cover

2. Unscrew fastening nuts 3 from the hinge for top box cover 4 .
Removing guide rail
Microsoft
Fig. 306: Installation position of guide rail

Fig. 307: Removing guide rail

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1. Unscrew fastening screws 5 on the guide rail 6 .
INSTALLING HINGE FOR TOP BOX COVER
Installing guide rail
Fig. 308: Securing guide rail

1. Pull protective film off the guide rail 6 , position on inner side section and secure with the fastening screws
5 . --> Tightening torque: 7.2 ftlb.
Microsoft
Fig. 309: Bending tabs

2. Bend tabs arrows around the joint flange.
Installing hinge for top box cover
Microsoft
Fig. 310: Installing hinge for top box cover

1. Position hinge for top box cover 4 on the body and secure with the fastening nuts 3 . --> Tightening torque:
7.2 ftlb.
2. Fit lock 1 into the push rod spring 2 at the left and right. Assembly tool for Springfix System pin circlips
NR.131
61 93 19 REMOVING AND INSTALLING SEAL FOR CONVERTIBLE TOP

COMPARTMENT LID - AS OF MY 2005 (BOXSTER, BOXSTER RHD,
PRELIMINARY WORK
Preliminary work
Remove right and left side trim panels. Refer to 70 75 19 Removing and installing side trim panel - as of MY
REMOVING SEAL FOR CONVERTIBLE-TOP COMPARTMENT LID
Removing seal for convertible-top compartment lid
Microsoft

1. Move convertible top to position shown in the illustration.
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Fig. 312: Loosening rubber seal

2. Unscrew fixing clip -1- and slightly pull out rubber seal for door -2- . See Fig. 312.
Fig. 313: Loosening seal

3. Unscrew fastening screws -1- in area of B-pillar on right and left and gently lift seal for convertible top
compartment lid -2- . See Fig. 313.
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4. Remove seal for convertible top compartment lid from the flanges -1- at the side panels -Arrow A- , at the
corner pieces -Arrow B- and with the engine compartment bulkhead -Arrow C- . See Fig. 314.
REMOVING SEAL FOR CONVERTIBLE-TOP COMPARTMENT LID
Installing seal for convertible-top compartment lid
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Fig. 315: Installing seal

NOTE:  Before replacing, check the existing seal for signs of damage (areas torn,
crushed, etc.). If there are signs of damage, the seal must be replaced.
 The seal is pressed onto the flange without any additional sealants.
1. Lay seal for convertible top compartment lid -1- evenly along the flange. Position and press the seal without
any tension on the flanges to the side panel -Arrow A- , corner pieces -Arrow B- and to the engine
compartment bulkhead -Arrow C- . See Fig. 315.
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Fig. 316: Fastening seal

2. Position seal for convertible top compartment lid -2- in area of B-pillar and secure with fastening screws -1- .
See Fig. 316.
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Fig. 317: Fasten rubber seal.

3. Stick rubber seal for door -2- on the B-pillar and press in fixing clip -1- through both seals. See Fig. 317.
NOTE:  Pay particular attention to the areas near the tight roundings for correct
installation; there must be no deformation or stretching.
4. Check installation is correct. .
SUBSEQUENT WORK
Subsequent work
Install right and left side trim panels. Refer to 70 75 19 Removing and installing side trim panel - as of MY
61 96 19 REMOVING AND INSTALLING CONTROL UNIT FOR CONVERTIBLE

TOP - AS OF MY 2005 (BOXSTER, BOXSTER RHD, BOXSTER S, BOXSTER
S RHD)
REMOVING CONTROL UNIT FOR CONVERTIBLE TOP
Microsoft
Removing control unit for convertible top
NOTE: There are two relays on the 987 - one for opening the convertible top and the
other for closing it.
The relays are installed in the relay carrier on the driver's side, under the
dashboard.
1. Remove relay carrier. Refer to 97 83 19 Removing and installing relay carrier 1 - as of MY 2005 (All
Models) .
2. Read off the relay assignment from the wiring diagram for the relevant model and model year and remove the
required relay.
INSTALLING CONTROL UNIT FOR CONVERTIBLE TOP
Installing control unit for convertible top
1. Read off the relay assignment from the wiring diagram for the relevant model and model year and insert the
required relay in the relay carrier.
2. Install relay carrier. Refer to 97 83 19 Removing and installing relay carrier 1 - as of MY 2005 (All
Models) .
Microsoft
ACCESSORIES & EQUIPMENT Door front, central locking system
Door front, central locking system
57 08 37 DISASSEMBLING AND ASSEMBLING KEY - AS OF MY 2005 (ALL

MODELS)
DISASSEMBLING KEY
Removing cover of hand-held transmitter
Fig. 1: Removing cover of hand-held transmitter

1. Insert a small screwdriver between the cover and the bottom part of the hand-held transmitter -arrow- and
carefully lift off the cover. See Fig. 1.
Removing hand-held transmitter key
Microsoft
Fig. 2: Removing hand-held transmitter key

1. Push the sliding latch back using a small screwdriver -arrow A- and pull the key out of the bottom part. See
Fig. 2.
ASSEMBLING KEY
Installing hand-held transmitter key
NOTE: The lock code from IPAS must be specified when ordering a new key.
Microsoft
Fig. 3: Installing hand-held transmitter key

1. Push the key into the bottom part until the sliding latch -arrow- engages perceptibly. See Fig. 3.
Installing cover of hand-held transmitter
Microsoft
Fig. 4: Installing cover of hand-held transmitter

1. Position the cover on the bottom part of the hand-held transmitter and press together until the cover clicks
into place.
57 11 19 REMOVING AND INSTALLING DOOR HANDLE - AS OF MY 2005

(ALL MODELS)
TOOLS

PRELIMINARY WORK
Preliminary work
1. Remove door unit carrier. --> 573019 Removing and installing door unit carrier - chapter on "removing"
REMOVING DOOR HANDLE

Microsoft
Unclipping electric wire for micro switches
Fig. 5: Installation location for door handle

Fig. 6: Unclipping wire

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1. Unclip electric wire for microswitch -1- from the bottom part of door handle -2- . See Fig. 6.
Disconnect connection piece

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Fig. 8: Disconnect connection piece

1. Press locking tabs -arrow A- and move sliding part -1- -arrow B- . See Fig. 8.
2. Unclip the connection piece -2- from the actuating shaft -3- . See Fig. 8.
Removing door handle and bottom part of door handle
Microsoft

Microsoft
Fig. 10: Releasing the door handle

1. Unscrew fastening nuts -1- . See Fig. 10.
2. Separate bottom part of door handle -2- from door handle -3- . See Fig. 10.
Microsoft
Fig. 11: Removing door handle

3. Pull door handle downward at an angle.
Microsoft
Fig. 12: Unclipping support

4. Unclip support.
ADDITIONAL ASSEMBLY INSTRUCTIONS
Locking lock actuation

NOTE:  To fit the lock actuation correctly, the securing spring must be hooked into
the lock actuation lever before the door lock is installed.
 The secured position of the lock actuation is released automatically when
the door handle is first pressed. A clear clicking sound can be heard when
the door handle is first pressed.
1. Light up inside of door with a lamp.
Microsoft
Fig. 14: Locking lock actuation

2. Guide the assembly tool T10118 -1- between the securing spring -2- and the lever -3- . See Fig. 14.
3. The securing spring -2- hooks on to the tool with a rotary movement. See Fig. 14.
Microsoft
Fig. 15: Lock actuation locked

4. Pull the securing spring -2- towards the outside of the door -arrow A- until the spring engages audibly in the
locking lug of the lever -3- . See Fig. 14, Fig. 15.
5. Unhook the tool -1- and remove it. See Fig. 14.
NOTE:  Pull carefully on the lock actuation to check that it is secured in

installation position. Repeat the steps listed above if necessary.
INSTALLING DOOR HANDLE
Fitting door handle and bottom part of door handle

Microsoft

Fig. 17: Clipping in support

1. Clip in support.
Microsoft
Fig. 18: Installing door handle

2. Insert door handle carefully.
Microsoft
Fig. 19: Fastening the door handle

NOTE:  Make sure the electrical lead is routed correctly.

 To prevent a malfunction in the closing system, make sure that the closing
cylinder shaft is fitted correctly in the door lock.
3. Position bottom part of door handle -2- from the inside on the door handle -3- . See Fig. 19.
4. Tighten fastening nuts -1- . Tightening torque --> Final tightening: 7 ftlb. See Fig. 19.
Fit connection piece
Microsoft

Microsoft
Fig. 21: Fitting connection piece

1. Insert the connection piece -1- into the actuating shaft -2- without play. See Fig. 21.
2. Push out the sliding piece -3- until it can be heard to engage. See Fig. 21.
3. Actuate the handle to ensure that the handle and door lock function without play.
Clipping in the electric wire for micro switches
Microsoft

Fig. 23: Clipping in wire

1. On the bottom part of door handle -2- clip in the electrical wire -1- . See Fig. 23.
SUBSEQUENT WORK
Microsoft
Subsequent work
1. Install door unit carrier. --> 573019 Removing and installing door unit carrier - chapter on "installing"
Function test following assembly work

NOTE:  A malfunction occurs only after the vehicle is locked for the first time. In
other words: if a door handle was fitted incorrectly, the affected door can
be opened and closed without difficulty until the vehicle is locked for the
first time. After that, the door cannot be opened either from inside or
outside. Given this, it is important to perform a function test before the
door is closed.
1. Do not close vehicle door after installing door handle.
Microsoft
Fig. 25: Engaging the bolt

2. With the door open -2- , use a screwdriver to engage the bolt in the door lock -1- fully in the second notch.
See Fig. 25.
3. Lock vehicle with the remote control.
4. Unlock vehicle with the remote control.
5. Press door handle on open door.
NOTE:  If the bolt in the door lock does not open, press the door button to make
sure that the individual door opening function is deactivated. If the door
lock still does not open, the door lock was assembled incorrectly.
57 11 37 DISASSEMBLING AND ASSEMBLING DOOR HANDLE - AS OF MY

2005 (ALL MODELS)
PRELIMINARY WORK
Preliminary work
1. Remove door handle. --> 571119 Removing and installing door handle - chapter on "Removing"
Microsoft
2. Remove microswitch for window opening controls. Refer to 64 37 19 Removing and installing microswitch
for window opening controls - as of MY 2005 (All Models) .
DISASSEMBLING DOOR HANDLE
Disassembling door handle
Fig. 26: Disassembling door handle

1. Press out circlip -1- , pull pin -2- out of the handle and remove actuating shaft -3- . See Fig. 26.
2. Pull pin rod -4- out of the handle liner -9- and separate handle -8- from the handle liner. See Fig. 26.
Microsoft
3. Remove return spring -6- , eccentric -5- and sleeve -7- . See Fig. 26.
4. Pull buffer -10- out of the handle -8- , check it and replace if necessary. See Fig. 26.
ASSEMBLING DOOR HANDLE
Assembling door handle
Fig. 27: Assembling door handle

1. Fasten buffer -10- to handle -8- . See Fig. 27.
2. Position return spring -6- , eccentric -5- , sleeve -7- and handle -8- on the handle liner -9- and press in pin rod
Microsoft
Fig. 27 -4- . See Fig. 27.
3. Position actuating shaft -3- on handle. Insert pin -2- and secure pin with the circlip -1- . See Fig. 27.
SUBSEQUENT WORK
Subsequent work
1. Install microswitch for window opening controls. Refer to 64 37 19 Removing and installing microswitch
for window opening controls - as of MY 2005 (All Models) .
2. Install door handle. --> 571119 Removing and installing door handle - chapter on "Installing"
57 17 19 REMOVING AND INSTALLING DOOR LOCK - AS OF MY 2005 (ALL

MODELS)
TOOLS

PRELIMINARY WORK
Preliminary work
REMOVING DOOR LOCK
Disconnect connection piece
Microsoft

Microsoft
Fig. 29: Disconnect connection piece

1. Press locking tabs -arrow A- and move sliding part -1- -arrow B- . See Fig. 29.
2. Unclip the connection piece -2- from the actuating shaft -3- . See Fig. 29.
Installing door lock
Microsoft
Fig. 30: Installation location of door lock

Fig. 31: Removing door lock

2. Pull door lock with actuating motor unit -2- out of the door. See Fig. 31.
Microsoft
Unclipping and disengaging the bowden cable

Fig. 33: Unclipping and disengaging the bowden cable

Microsoft
1. Unclip bowden cable from the door lock -arrow A- . See Fig. 33.
2. Swivel bowden cable by 90° -arrow B- and pull it out of the actuating lever -arrow C- . See Fig. 33.
ADDITIONAL ASSEMBLY INSTRUCTIONS
Locking lock actuation

NOTE:  To fit the lock actuation correctly, the securing spring must be hooked into
the lock actuation lever before the door lock is installed.
 The secured position of the lock actuation is released automatically when
the door handle is first pressed. A clear clicking sound can be heard when
the door handle is first pressed.
1. Light up inside of door with a lamp.
Microsoft
Fig. 35: Locking lock actuation

2. Guide the assembly tool T10118 -1- between the securing spring -2- and the lever -3- . See Fig. 35.
3. The securing spring -2- hooks on to the tool with a rotary movement. See Fig. 35.
Microsoft
Fig. 36: Lock actuation locked

4. Pull the securing spring -2- towards the outside of the door -arrow A- until the spring engages audibly in the
locking lug of the lever -3- . See Fig. 35, Fig. 36.
5. Unhook the tool -1- and remove it. See Fig. 35.
NOTE:  Pull carefully on the lock actuation to check that it is secured in

installation position. Repeat the steps listed above if necessary.
INSTALLING DOOR LOCK
Fitting the bowden cable

Microsoft

Fig. 38: Fitting the bowden cable

1. Insert bowden cable into the actuating lever -arrow C- and swivel by 90° -arrow B- . See Fig. 38.
Microsoft
2. Clip bowden cable into the door lock -arrow A- . See Fig. 38.
Installing door lock

NOTE:  To prevent a malfunction in the closing system, make sure that the closing
cylinder shaft is fitted correctly in the door lock.
Microsoft
Fig. 40: Installing door lock

1. Insert door lock -2- into the door and secure with the fastening screws -1- . Tightening torque --> Final
tightening: 13 ftlb. +1.5 ftlb. See Fig. 40.
Fit connection piece
Microsoft

Microsoft
Fig. 42: Fitting connection piece

1. Insert the connection piece -1- into the actuating shaft -2- without play. See Fig. 42.
2. Push out the sliding piece -3- until it can be heard to engage. See Fig. 42.
3. Actuate the handle to ensure that the handle and door lock function without play.
SUBSEQUENT WORK
Subsequent work
1. Install door unit carrier. --> 573019 Removing and installing door unit carrier - chapter on "installing"
Microsoft
Function test following assembly work

NOTE:  A malfunction occurs only after the vehicle is locked for the first time. In
other words: if a door lock was fitted incorrectly, the affected door can be
opened and closed without difficulty until the vehicle is locked for the first
time. After that, the door cannot be opened either from inside or outside.
Given this, it is important to perform a function test before the door is
closed.
1. Do not close vehicle door after fitting the door lock.
Microsoft
Fig. 44: Engaging the bolt

2. With the door open -2- , use a screwdriver to engage the bolt in the door lock -1- fully in the second notch.
See Fig. 44.
3. Lock vehicle with the remote control.
4. Unlock vehicle with the remote control.
NOTE:  If the bolt in the door lock does not open, press the door button to make
sure that the individual door opening function is deactivated. If the door
lock still does not open, the door lock was assembled incorrectly.
5. Press door handle on open door.
57 26 19 REMOVING AND INSTALLING STRIKER PIN - AS OF MY 2005 (ALL

MODELS)
REMOVING STRIKER PIN
Removing striker pin
NOTE: The striker pin counterplate is permanently fixed to the B-pillar structure. After
Microsoft
the striker pin has been removed, the counterplate remains in the lower end
position on the B-pillar.
1. Open door.
Fig. 45: Striker pin position

2. Determine the position of the striker pin in relation to the B-pillar according to the impression made at the
factory -arrows- and note it down. See Fig. 45.
Microsoft
Fig. 46: Removing striker pin

3. Remove fastening screws -2- from striker pin -1- . See Fig. 46.
4. Remove striker pin -1- . See Fig. 46.
INSTALLING STRIKER PIN
Installing striker pin
Microsoft
Fig. 47: Striker pin position

1. Position striker pin in line with the markings.
Microsoft
Fig. 48: Installing striker pin

2. Screw in fastening screws -2- for the striker pin -1- and tighten slightly. See Fig. 48.
3. Carefully close door and check that the striker pin is correctly positioned with respect to the lock.
4. If necessary, adjust the striker pin accordingly.
5. Tighten fastening screws -2- . Tightening torque --> Final tightening: 17 ftlb. . See Fig. 48.
6. Remove the markings with a suitable cleaning product.
7. Close the door.
57 30 19 REMOVING AND INSTALLING DOOR UNIT CARRIER - AS OF MY

2005 (ALL MODELS)
PRELIMINARY WORK
Preliminary work
1. Disconnect electric lead for door. Refer to 97 32 19 Removing and installing wire harness for door - as of
2. Remove door trim panel. Refer to 70 59 19 Removing and installing door trim panel - as of MY 2005 (All
Models) .
3. Remove power window motor. Refer to 64 52 19 Removing and installing front power windows - as of
MY 2005 (Cayman S, Cayman S RHD) . Refer to 64 52 19 Removing and installing front power windows -
as of MY 2005 (Boxster, Boxster RHD, Boxster S, Boxster S RHD) .
4. Remove head airbag. Refer to 69 66 19 Removing and installing the head airbag unit - as of MY 2005
(All Models) .
REMOVING DOOR UNIT CARRIER
Covering door with adhesive tape
Microsoft
Fig. 49: Overview, door unit carrier

NOTE:  Adhesive tape protects the door from paint damage when removing the
door unit carrier.
Fig. 50: Covering door with adhesive tape

Microsoft
1. Cover door in marked area with adhesive tape.
Removing seal for mirror triangle
Fig. 51: Installation position of rear-view mirror

Microsoft
Fig. 52: Seal for mirror triangle

1. Pull out seal for mirror triangle from cable cutout opening for door mirror.

Microsoft

1. Disconnect the plug connection of the mirror housing -3- . See Fig. 54.
Releasing door unit carrier
Microsoft

NOTE:  A second person is required for removing the door unit carrier to avoid
damage.
Fig. 56: Pressing in rubber grommets

1. Press rubber grommet for electrical wire -1- and bowden cable -2- inwards. See Fig. 56.
Microsoft
Fig. 57: Releasing power windows

2. Release power windows -1- from door unit carrier -2- -arrows- . See Fig. 57.
Microsoft
Fig. 58: Releasing door unit carrier

3. Unscrew fastening screws -2- for the door unit carrier -1- . See Fig. 58.
Fig. 59: Pulling out the wiring harness

4. Press the rubber grommet on the wiring harness inwards and pull the wiring harness through the door
aperture.
Microsoft
Fig. 60: Pulling out the Bowden cable

5. Pull out the bowden cable -2- from the unit carrier -1- . See Fig. 60.
Disconnecting electrical plug connection on microswitch
Microsoft

damage.
Fig. 62: Disconnecting the microswitch plug connection

1. Unlock the electrical plug connection for the microswitch -1- by pressing the locking tab -arrow A- and
remove -arrow B- . See Fig. 62.
Disconnecting the door lock electrical plug connection
Microsoft

damage.
Fig. 64: Disconnecting the door lock plug connection

Microsoft
1. Unlock the electrical plug connection for the door lock -1- by pressing the locking tab -arrow A- and remove
-arrow B- . See Fig. 64.
2. Remove door unit carrier.
INSTALLING DOOR UNIT CARRIER
Locking electrical plug connection for door lock

damage.
Microsoft
Fig. 66: Locking plug connection for door lock

1. Lock electrical plug connection for door lock -1- until the plug audibly engages. See Fig. 66.
Locking electrical plug connection for microswitch
Microsoft

damage.
Fig. 68: Locking plug connection for microswitch

1. Lock electrical plug connection for microswitch -1- until the plug audibly engages. See Fig. 68.
Fastening door unit carrier
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damage.
Fig. 70: Pushing bowden cable through

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1. Push the bowden cable -2- through the unit carrier -1- . See Fig. 70.
Fig. 71: Pushing wiring harness through

NOTE:  Make sure that the wiring harness is not twisted through the door opening
when fitted.
2. Push the wiring harness from the inside through the door aperture and press in the rubber grommet on the
wiring harness from inside into the door aperture.
Microsoft
Fig. 72: Installing rubber grommets

3. Install the rubber grommet for electric lead -1- and bowden cable -2- in the unit carrier until this engages all
the way around. See Fig. 72.
Microsoft
Fig. 73: Fastening door unit carrier

4. Screw down fastening screws -2- for the door unit carrier -1- . Tightening torque --> Final tightening: 7.2
ftlb. See Fig. 73.
Microsoft
Fig. 74: Clipping in power windows

5. Press in power windows -1- on door unit carrier -2- -arrows- . See Fig. 74.
Locking electrical plug connection
Microsoft

1. Connect the plug connection of the mirror housing -3- . See Fig. 76.
Fig. 76: Locking plug connection

Fitting seal for mirror triangle
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1. Stick seal for mirror triangle at cable cutout opening on door mirror to the basic door frame.
Removing adhesive tape

Microsoft

Fig. 80: Remove adhesive tape.

1. Remove adhesive tape, clean marked area if necessary.

Microsoft
SUBSEQUENT WORK
Subsequent work
1. Install head airbag. Refer to 69 66 19 Removing and installing the head airbag unit - as of MY 2005 (All
Models) .
2. Install power window motor. Refer to 64 52 19 Removing and installing front power windows - as of MY
2005 (Cayman S, Cayman S RHD) . Refer to 64 52 19 Removing and installing front power windows - as
of MY 2005 (Boxster, Boxster RHD, Boxster S, Boxster S RHD) .
3. Install door trim panel. Refer to 70 59 19 Removing and installing door trim panel - as of MY 2005 (All
Models) .
4. Lock electric lead for door. Refer to 97 32 19 Removing and installing wire harness for door - as of MY
2005 (All Models) .
57 30 37 DISASSEMBLING AND ASSEMBLING DOOR UNIT CARRIER - AS

PRELIMINARY WORK
Preliminary work
1. Remove door sub-frame. --> 573019 Removing and installing door sub-frame - chapter on "removing"
2. Remove front loudspeaker from door. Refer to 91 40 19 Removing and installing front loudspeakers - as
3. Remove wiring harness for door. Refer to 97 32 19 Removing and installing wire harness for door - as of
DISASSEMBLING DOOR UNIT CARRIER
Disassembling door sub-frame
Microsoft
Fig. 81: Overview of door sub-frame

Fig. 82: Removing rubber sleeve

1. Remove rubber sleeve -2- from door sub-frame -1- . See Fig. 82.
ASSEMBLING DOOR UNIT CARRIER

Microsoft
Assembling door sub-frame
Fig. 83: Overview of door sub-frame

Fig. 84: Installing rubber sleeve

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1. Position rubber sleeve -2- on door sub-frame -1- and install so that it engages all the way round. See Fig. 84.
SUBSEQUENT WORK
Subsequent work
1. Install wiring harness for door. Refer to 97 32 19 Removing and installing wire harness for door - as of
2. Install front loudspeaker in door. Refer to 91 40 19 Removing and installing front loudspeakers - as of
3. Install door sub-frame. --> 573019 Removing and installing door sub-frame - chapter on "installing"
57 45 19 REMOVING AND INSTALLING DOOR HANDLE - AS OF MY 2005

(ALL MODELS)
PRELIMINARY WORK
Preliminary work
Models) .
REMOVING DOOR HANDLE
Removing door handle
Microsoft
Fig. 85: Installation position of door handle

Fig. 86: Removing door handle

NOTE:  Make sure that the return spring does not pop out.
2. Insert a screwdriver between the door trim panel and the door handle -2- . Press door handle down -arrow A-
and remove from the door trim panel -arrow B- . See Fig. 86.
INSTALLING DOOR HANDLE
Installing door handle
Microsoft
Fig. 87: Installation position of door handle

NOTE:  To fit the door handle correctly, the return spring must be hooked into
place prior to installation.
Fig. 88: Installing door handle

Microsoft
1. Position door handle -2- on door trim panel and secure with fastening screws -1- . Tightening torque -->
Final tightening: 1.5 ftlb. +0.1 ftlb. See Fig. 88.
NOTE:  Pull the door handle carefully to check that the return spring is fixed
correctly.
SUBSEQUENT WORK
Subsequent work
Models) .
57 48 19 REMOVING AND INSTALLING CRASH SUPPORT - AS OF MY 2005

(ALL MODELS)
REMOVING CRASH SUPPORT
Removing crash support
Fig. 89: Installation position of crash support

Microsoft
Fig. 90: Removing crash support

1. Carefully insert a plastic wedge between basic door frame -2- and crash support -1- -Arrow A- and lever out
in an inward direction -Arrow B- . See Fig. 90.
INSTALLING CRASH SUPPORT
Installing crash support
Microsoft
Fig. 91: Installation position of crash support

Fig. 92: Installing crash support

1. Position crash support -1- on basic door frame -2- -Arrow A- and press in until it can be felt to engage -
Arrow B- . See Fig. 92.
Microsoft
57 51 15 ADJUSTING FRONT DOOR - AS OF MY 2005 (ALL MODELS)

TOOLS

Wheel mounting trolley workshop 00000
Master Wheel 50 with equipment
optional door mount, see
Gr. 4; Workshop
Equipment Manual
Key for door adjustment VW-tool 3320
TOOLS AND MATERIALS
Tools and materials
Microsoft
Fig. 93: Wheel mounting trolley with optional door mount

Wheel mounting trolley Master Wheel 50 with optional door mount, see Gr. 4; Workshop Equipment Manual
00000 (Tools).
ADJUSTING FRONT DOOR
Adjusting the front doors
Microsoft
Fig. 94: Main illustration for adjusting front door

NOTE:  To adjust front doors, use special tool Key for door adjustment 3320
NOTE: To ensure that the tapered seat of the hinge is positioned without tension, it
may be necessary to take the door hinges off the door if:
 A new bare door shell is installed.

 The bare door shell was or is damaged.
 The bare door shell has no seam joining line.
Microsoft
Fig. 95: Adjusting the front doors

1. Loosen the fastening screw -1- so that the hinge pins are not strained. Support the doors if necessary to
prevent damage. --> Master Wheel 50 T wheel mounting trolley with door removal device (Tools) can be used
to do this.
Microsoft
Fig. 96: Fastening the hinge joint

2. Tighten fastening screws M6 x 12 -1- on the hinge joints -2- . Tightening torque --> : 13 (9.5 ftlb.) Nm . See
Fig. 96.
Microsoft
Fig. 97: Adjusting the front doors

3. Loosen fastening screw -1- . Set the contour with respect to the wing and side member by moving the angle
pieces -2- both vertically and horizontally. Refer to 50 IN Processing structural body adhesive - as of MY
2005 (All Models) . The dowel sleeves may have to be removed for subsequent assembly. Tightening torque: --
> Final tightening: 23 (17 ftlb.) Nm See Fig. 97.
Adjusting rear door
Microsoft
Fig. 98: Main illustration for adjusting front door

Fig. 99: Adjusting rear door

1. Loosen fastening screw -2- . By shifting the door lock striker -1- in vertical and horizontal position, adjust
contour to the rear wing and door sill. --> 50 IN DIAGRAM - BODY GAP DIMENSIONS - AS OF MY
2005 (CAYMAN S, CAYMAN S RHD) or 50 IN DIAGRAM - BODY GAP DIMENSIONS - AS OF MY
Microsoft
2005 (BOXSTER, BOXSTER RHD, BOXSTER S, BOXSTER S RHD) . Tightening torque: Tightening
torque --> Final tightening: 17 ftlb. See Fig. 99.
57 51 19 REMOVING AND INSTALLING FRONT DOOR - AS OF MY 2005

(ALL MODELS)
TOOLS

optional door mount, see
Gr. 4; Workshop
Equipment Manual
PRELIMINARY WORK
Preliminary work
Disconnect electric line for door. Refer to 97 32 19 Removing and installing wire harness for door - as of
Safety instructions for door. "Manufacturer does not provide specific Safety Instructions". .
TOOLS AND MATERIALS
Tools and materials
Microsoft
Fig. 100: Wheel mounting trolley with optional door mount

Wheel mounting trolley Master Wheel 50 with optional door mount, see Gr. 4; Workshop Equipment Manual
00000 (Tools).
REMOVING DOOR
Releasing hinge joint
Microsoft
Fig. 101: Main illustration for removing and installing door

Fig. 102: Releasing hinge joint

1. Unscrew fastening screws -1- on hinge joint -2- . Support the doors if necessary to prevent damage. -->
Master Wheel 50 T wheel mounting trolley with door removal device (Tools) can be used to do this. See Fig.
102.
Microsoft
Releasing door arrester on body side
Fig. 103: Installation position of door arrester

Fig. 104: Releasing door arrester on body side

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1. Unscrew fastening screw -1- from door arrester -2- at the A-pillar. See Fig. 104.
Removing door

Microsoft
Fig. 106: Removing door

1. Lift the door -5- up slightly until the hinge bolts -6- are extended out of the hinge halves on the door side. See
Fig. 106.
2. Take off the door -5- . See Fig. 106.
INSTALLING DOOR
Installing door

NOTE:  Before inserting the door, the upper and lower hinge joint must be
lubricated.
Microsoft
Fig. 108: Installing door

1. Engage the door -5- in the hinge bolts -6- from above. Support the doors if necessary to prevent damage. -->
Master Wheel 50 T wheel mounting trolley with door removal device (Tools). See Fig. 108.
Fastening the hinge joint
Microsoft

Fig. 110: Fastening the hinge joint

NOTE: To ensure that the tapered seat of the hinge is positioned without tension, it
may be necessary to take the door hinges off the door if:
Microsoft
 A new bare door shell is installed.

 The bare door shell was or is damaged.
 The bare door shell has no seam joining line.
1. See --> 575115 Adjusting front doorif necessary
Screw down fastening screws -1- on hinge joints -2- . Tightening torque --> Final tightening: 13 (9.5 ftlb.) Nm
See Fig. 110.
Fastening door arrester on body side

Microsoft

1. Screw door arrester -2- to A-pillar with fastening screw -1- . Tightening torque --> Final tightening: 22 ftlb.
See Fig. 112.
SUBSEQUENT WORK
Subsequent work
Lock electric line for door. Refer to 97 32 19 Removing and installing wire harness for door - as of MY
2005 (All Models) .
Adjust front door. --> 575115 Adjusting front door - chapter on "adjusting"
Teach power windows. --> 27 06 IN WORK INSTRUCTIONS AFTER DISCONNECTING THE

BATTERY - AS OF MY 2005 (ALL MODELS) .
57 51 37 DISASSEMBLING AND ASSEMBLING FRONT DOOR - AS OF MY

2005 (ALL MODELS)
TOOLS

Microsoft

optional door fixture
PRELIMINARY WORK
Preliminary work
1. Remove front door --> 575119 Removing and installing front door - chapter on "removing"
2. Position door on assembly fixture, Wheel mounting trolley Master Wheel 50 with optional door fixture 00000
(Tools).
Models) .
4. Remove rear-view mirror. Refer to 66 89 19 Removing and installing rear-view mirror - as of MY 2005
(All Models) .
5. Remove door sub-frame. --> 573019 Removing and installing door sub-frame - chapter on "removing"
6. Remove door handle. --> 571119 Removing and installing door handle - chapter on "removing"
7. Remove door lock. --> 571719 Removing and installing door lock - chapter on "removing"
8. Remove front door window. Refer to 64 40 19 Removing and installing front door window - as of MY
2005 (All Models) .
9. Remove front power windows. Refer to 64 52 19 Removing and installing front power windows - as of
MY 2005 (Cayman S, Cayman S RHD) . Refer to 64 52 19 Removing and installing front power windows -
10. Remove door arrester. --> 575919 Removing and installing door arrester - chapter on "removing"
11. Remove rubber seal for door. --> 576519 Removing and installing rubber seal for door (door side) -
chapter on "removing"
12. Remove window channel seal. Refer to 64 48 19 Removing and installing front window shaft seal - as of
13. Remove crash support. --> 574819 Removing and installing crash support
TOOLS AND MATERIALS
Tools and materials
Microsoft
Fig. 113: Wheel mounting trolley with optional door fixture

Wheel mounting trolley Master Wheel 50 with optional door fixture, see Gr. 4; Workshop Equipment Manual
00000 (Tools).
DISASSEMBLING DOOR
Removing lid and rubber sleeves
Microsoft
Fig. 114: Installation position of lid and rubber sleeves

Microsoft
Fig. 115: Removing lid and rubber sleeves

1. Press out lid -1- and rubber sleeve -2- using a plastic spatula. See Fig. 115.
Removing retaining clips
Microsoft
Fig. 116: Installation position of retaining clips

Microsoft
Fig. 117: Removing retaining clips

1. Unclip and check retaining clip for electric plug connection -1- ; replace if necessary. See Fig. 117.
2. Unclip and check retaining clip for bowden cable to window lifter -2- ; replace if necessary. See Fig. 117.
Removing rubber buffer
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Fig. 118: Installation position of rubber buffer

NOTE:  Note that removal of the rubber buffer will damage it. It must not be
reused.
Fig. 119: Removing rubber buffer

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1. Using a plastic wedge, lever out rubber buffer -1- from the door in white -2- and remove -arrow- . Clean
adhesive residues -3- from the door in white using a cleaning agent. See Fig. 119.
ASSEMBLING DOOR
Installing rubber buffer
Fig. 120: Installation position of rubber buffer

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Fig. 121: Installing rubber buffer

1. Remove protective film -3- from rubber buffer -1- , clip rubber buffer to the door in white -1- and press on -
Installing retaining clips
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Fig. 122: Installation position of retaining clips

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Fig. 123: Installing retaining clips

1. Clip in retaining clip for electric plug connection -1- ( -arrow- ). See Fig. 123.
2. Clip in retaining clip for bowden cable to window lifter -2- ( -arrow- ). See Fig. 123.
Fit lid and rubber sleeves
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Fig. 124: Installation position of lid and rubber sleeves

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Fig. 125: Installing lid and rubber sleeves

1. Position lid -1- and rubber sleeves -2- on door in white and press in until it engages all round. See Fig. 125.
SUBSEQUENT WORK
Subsequent work
1. Install crash support. --> 574819 Removing and installing crash support - chapter on "installing"
2. Install window channel seal. Refer to 64 48 19 Removing and installing front window shaft seal - as of
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3. Install rubber seal for door --> 576519 Removing and installing rubber seal for door (door side) - chapter
on "installing"
4. Install door arrester. --> 575919 Removing and installing door arrester - chapter on "installing"
5. Install front power windows. Refer to 64 52 19 Removing and installing front power windows - as of MY
2005 (Cayman S, Cayman S RHD) . Refer to 64 52 19 Removing and installing front power windows - as
6. Install front door window. Refer to 64 40 19 Removing and installing front door window - as of MY 2005
(All Models) .
7. Install door lock. --> 571719 Removing and door lock - chapter on "installing"
8. Install door handle. --> 571119 Removing and installing door handle - chapter on "installing"
10. Install rear-view mirror. Refer to 66 89 19 Removing and installing rear-view mirror - as of MY 2005
(All Models) .
Models) .
12. Install front door. --> 575119 Removing and installing front door- chapter on "installing"
57 53 55 REPLACING DOOR HINGE (ON BODY SIDE) - AS OF MY 2005 (ALL

MODELS)
TOOLS

Pneumatic body saw No. special tool 00000
PS1, see Gr. 3.5; Workshop
Equipment Manual
Press-out tool special tool 97290
dimensions
Spotweld drill special tool NR.129
Inverter welding equipment workshop WE1194

ATL Inverterspot equipment
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Safety instructions for body repairs
Safety instructions for door. "Manufacturer does not provide specific Safety Instructions". .
TOOLS AND MATERIALS
Tools and materials
Spotweld drill NR.129, Star gauges for body gap dimensions NR.127-1, Press-out tool 97290 Pneumatic
body saw No. PS1, see Gr. 3.5; Workshop Equipment Manual 00000. Angle grinder, see Gr. 3.5; see
Workshop Equipment Manual 00000. Oscillating body saw (special electrical cutter), see Gr. 3.5;
Workshop Equipment Manual 00000. Rotary brush, see Gr. 3.5; Workshop Equipment Manual 00000.
Hole punch, see Gr. 3.5; Workshop Equipment Manual 00000. Leister Elektron hot-air gun, see Gr. 3.5;
Workshop Equipment Manual 00000. Inverter welding equipment ATL Inverterspot WE1194, Basic
straightening attachments for 911 Carrera (996), see Gr. 3.5; Workshop Equipment Manual 00000.
Additional straightening attachments for 911 Carrera (997), see Gr. 3.5; Workshop Equipment Manual
00000. Pneumatic spotweld remover, Vario Drill No. WS 90, see Gr. 3.5; Workshop Equipment Manual
00000.
PRELIMINARY WORK FOR BODY REPAIRS WITH ALIGNMENT BENCH
Preliminary work for body repairs
NOTE:  If it can be ensured there has been no deformation of the vehicle structure,
the following repair can be carried out without the need of a straightening
bench. In this case, the vehicle must not be raised when welding the
component; it must stand on its wheels on an even surface.
1. Removing add-on parts in the repair area
1.1. Remove add-on parts in the repair area according to the extent of damage to the vehicle.
2. Equipping straightening bench with straightening attachments
2.1. Equip straightening bench with the straightening attachments according to the plans included with the
straightening attachments.
3. Placing vehicle on the straightening bench
3.1. Position vehicle on the straightening bench, align according to the reference holes and bolt firmly to the
attachment set.
4. Covering add-on parts adjacent to the vehicle repair area
4.1. Cover all add-on parts remaining on the vehicle and the neighboring areas with fire-proof, protective
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covers.
5. Reshaping connection area of the sheetmetal parts to be replaced
6. Exposing welding areas
6.1. Remove undersealing, paint, etc. from the welding areas of the body with a hot-air gun or rotary brush.
REMOVING DOOR HINGE (ON BODY SIDE)
Removing door hinge (on body side)
Fig. 126: Installation position of door hinge

1. Remove the wing. Refer to 50 55 19 Removing and installing front wing - as of MY 2005 (All Models) .
2. Remove door. --> 575119 Removing and installing door - section on "Removing"
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Fig. 127: Separating inert-gas welded seams

3. Separating inert-gas welded seams
3.1. Separate inert-gas welded seams in areas -A- and -B- using a parting grinder or spherical cutter. See Fig.
127.

4.1. Separate inert-gas welded seams in areas -A- and -B- using a parting grinder. See Fig. 128.
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PREPARING CONNECTION AREAS OF THE BODY FOR INSTALLING THE DOOR HINGE (ON
BODY SIDE)
Safety instructions for flying sparks during grinding and welding work
CAUTION: Danger of explosion and fire from flying sparks during grinding and
welding work!
 Danger of injury and danger of damage to vehicle parts and other

vehicles due to flying sparks
--> Cover vehicle parts such as battery, fuel system, paintwork, glass and passenger compartment parts with
fire-proof covers and, if necessary, remove batteries and fuel-carrying components.
--> No other vehicles may be left unprotected in areas used for body repair!
Preparing connection areas of the body for installing the door hinge (on body side)
Fig. 129: Preparing connecting flanges

1. Clean undersealing, adhesive residue and paint off the body connecting flanges from inside in the marked
areas -A- and -B- using a hot-air gun or rotary brush. Grind the connecting flanges until bare. See Fig. 129.
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2. Clean undersealing, adhesive residue and paint off the body connecting flanges in the marked areas -A- and -
B- using a hot-air gun or rotary brush. Grind the connecting flanges until bare. See Fig. 130.
PREPARING DOOR HINGE (ON BODY SIDE) FOR INSTALLATION
Safety instructions for sharp-edged body and unit parts
CAUTION: Danger of injury! Sharp-edge burrs on body and unit parts!
 Injuries from sharp edges on body and unit parts.
--> Wear protective gloves when working in the area of sharp-edged body and unit parts!
Preparing door hinge (on body side) for installation
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Fig. 131: Cleaning the welding areas

1. Cleaning the welding areas
1.1. Grind both sides of the connecting flanges of the door hinge in the marked areas -A, B, C, D- until bare
using a rotary brush. See Fig. 131.
INSTALLING DOOR HINGE (ON BODY SIDE)
Danger of injury when welding
WARNING: Risk of fatal injury from high voltage during electric welding!
 Danger of explosion and fire when welding in the area of highly

inflammable materials.
 Irritation to respiratory tracts from toxic zinc oxide emitted when
welding galvanised steel!
 Danger of injury from unintentional triggering of pyrotechnical
safety components!
 Danger of injury from weld spatters and UV light when welding!
--> Do not perform welding work in a damp environment or on wet ground; there is a risk of fatal injury from
the voltage being conducted through the human body. Persons with heart pacemakers should not perform
welding work. Use insulating underlays.
--> Remove highly flammable materials from the work area; if necessary, remove units with fuel-carrying parts
and protect work areas in the vehicle that are at risk of catching fire using fire-proof covers.
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--> Ventilate the work area well.
--> Remove smoke gases with a suitable extraction system (refer to Workshop Equipment Manual).
--> Wear suitable protective equipment, such as protective clothing, gloves, a welding shield and, if necessary, a
protective mask.
--> For welding work, always disconnect both terminals on the battery. In the case of welding work in the
immediate vicinity of the control modules for pyrotechnical safety systems, remove the control modules before
beginning work.
--> In addition, the guidelines of the welding equipment manufacturer and the legal accident prevention
regulations and those of the mutual indemnity association (BGV D1) must be observed.
Installing door hinge (on body side)
1. Fitting door hinge to the body
Fig. 132: Installing door hinge

1.1. Position door hinge on the body, align it and screw down securely.
1.2. Install wing, door lock and striker pin before fitting.
1.2.1. --> 50 55 19 REMOVING AND INSTALLING FRONT WING - AS OF MY 2005 (ALL

MODELS) .
1.2.2. --> 571719 Removing and installing door lock - section on "Installing"
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1.2.3. --> 572619 Removing and installing striker pin - section on "Installing"
NOTE: Two persons are needed to install the door hinges!
2. Fitting door to the body
Fig. 133: Adjusting the door hinge

2.1. Fit the door to the body and adjust gaps between the door, wing and outer side member according to the
adjustment values --> 50 IN DIAGRAM - BODY GAP DIMENSIONS - AS OF MY 2005 (CAYMAN S,
CAYMAN S RHD) or 50 IN DIAGRAM - BODY GAP DIMENSIONS - AS OF MY 2005 (BOXSTER,
BOXSTER RHD, BOXSTER S, BOXSTER S RHD) .
2.2. Fix the door in place.
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Fig. 134: Welding in the door hinge

3. Welding in the door hinge
3.1. Apply a full weld to door hinge in areas -A- and -B- from the inside using inert gas. See Fig. 134.

4.1. Secure the door hinge in area -A- by tack welding it using inert gas. See Fig. 135.
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Fig. 136: Adjusting the door hinge

4.2. Check position and gap dimensions of door and adjust them if necessary.
4.3. Lift the door and remove it.

5.1. Apply a full weld to the door hinge in areas -A- and -B- using inert gas. See Fig. 137.
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NOTE: After the required hardening time has elapsed, cut off excess expanded sealant
to a height of more than 25 mm using a knife.
Fig. 138: Applying expanded sealant

6. Applying expanded sealant
6.1. Seal inside of A-pillar in area -A- with --> AFS Vario. See:. Refer to 50 IN Processing structural body
adhesive - as of MY 2005 (All Models) . See Fig. 138.
6.2. Apply expanded sealant using a spatula.
SUBSEQUENT WORK
Subsequent work for body repairs
1. Remove vehicle from the alignment bench.
2. Clean welded joints and sheetmetal flanges with a wire brush.
3. Prime flange areas with 2K primer.
4. Restore standard sealing with body sealant. Refer to 50 IN Processing structural body adhesive - as of MY
2005 (All Models) .
5. Restore standard undersealing with underbody sealant. Refer to 50 IN Processing structural body adhesive
- as of MY 2005 (All Models) .
6. Paint repair area and adjacent surfaces, if necessary.

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7. Install removed accessories in the repair area.
8. Apply cavity preservation.
57 59 19 REMOVING AND INSTALLING DOOR LATCH SNIB - AS OF MY

2005 (ALL MODELS)
PRELIMINARY WORK
Subsequent work
1. Remove loudspeaker for front door. Refer to 91 41 19 Removing and installing front loudspeakers - as of
REMOVING DOOR LATCH SNIB
Releasing door arrester on body side

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1. Unscrew fastening screw -1- from door arrester -2- at the A-pillar. See Fig. 140.
Removing door arrester
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Fig. 142: Removing door arrester

1. Unscrew fastening nuts -1- from door arrester -2- . See Fig. 142.
2. Swivel door arrester -2- by 90° -Arrow A- and pull it inwards -Arrow B- . See Fig. 142.
3. Remove door arrester -2- through opening for loudspeaker. See Fig. 142.
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Fig. 143: Removing the seal

4. Remove the seal.
INSTALLING DOOR LATCH SNIB
Installing door arrester
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Fig. 145: Fitting the seal

1. Position the seal.
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Fig. 146: Installing door arrester

2. Insert door arrester -2- through opening for loudspeaker from inside -Arrow A- and swivel it by 90° -Arrow
B- . See Fig. 146.
3. Secure door arrester -2- with the fastening nuts -1- . Tightening torque --> Final tightening: 7.2 ftlb. See
Fig. 146.
Fastening door arrester on body side
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1. Screw door arrester -2- to A-pillar with fastening screw -1- . Tightening torque --> Final tightening: 22 ftlb.
See Fig. 148.
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SUBSEQUENT WORK
Subsequent work
1. Install loudspeaker for front door. Refer to 91 41 19 Removing and installing front loudspeakers - as of
57 63 19 REMOVING AND INSTALLING RUBBER SEAL FOR DOOR - AS OF

PRELIMINARY WORK
Preliminary work
1. Remove A-pillar trim panel. Refer to 70 57 19 Removing and installing A-pillar trim - as of MY 2005
2. Remove inner door sill trim. Refer to 68 05 19 Removing and installing inner door sill trim - as of MY
2005 (All Models) .
3. Remove side trim panel. Refer to 70 75 19 Removing and installing side trim panel - as of MY 2005
REMOVING RUBBER SEAL FOR DOOR
Removing rubber seal for door
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Fig. 149: Loosening rubber seal

1. Unscrew fixing clip -1- and gently pull out rubber seal for door -2- . See Fig. 149.
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Fig. 150: Removing rubber seal for door

2. Unscrew fastening screw -2- at A-pillar and pull out rubber seal for door -1- under the cover strip -3- -Arrow
A- . See Fig. 150.
3. Remove rubber seal for door -1- from all around the sheetmetal flange. See Fig. 150.
INSTALLING RUBBER SEAL FOR DOOR
Installing rubber seal for door
NOTE:  The rubber seal for the door must be fitted by hand.
 Pay particular attention to the areas near the tight roundings for correct
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 Check the air vents; they must not be closed or covered.
Fig. 151: Installing rubber seal for door

1. Fit rubber seal for door -1- all around the sheetmetal flange. See Fig. 151.
2. Push rubber seal for door -1- under the cover strip -3- -Arrow A- and screw down with fastening screw -2- .
Tightening torque --> Tightening torque : 6 (4.5 ftlb.) Nm See Fig. 151.
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3. Stick rubber seal for door -2- on the B-pillar and press in fixing clip -1- through both seals. See Fig. 152.
SUBSEQUENT WORK
Subsequent work
1. Install side-panel lining. Refer to 70 75 19 Removing and installing side trim panel - as of MY 2005
2. Install scuff plate. Refer to 68 05 19 Removing and installing inner door sill trim - as of MY 2005 (All
Models) .
3. Install A-pillar trim panel. Refer to 70 57 19 Removing and installing A-pillar trim - as of MY 2005
57 63 19 REMOVING AND INSTALLING RUBBER SEAL FOR DOOR - AS OF

PRELIMINARY WORK
Preliminary work
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1. Remove inner sill. Refer to 68 05 19 Removing and installing inner door sill trim - as of MY 2005 (All
Models) .
Fig. 153: Installation position of rubber seal for door

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Fig. 154: Removing rubber seal for door

1. Remove rubber seal for door -1- from around the sheetmetal flange. See Fig. 154.
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NOTE:  The rubber seal for the door must be fitted by hand.
 Pay particular attention to the areas near the tight roundings for correct
 Check the air vents; they must not be closed or covered.
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Fig. 156: Installing rubber seal for door

1. Position rubber seal for door -1- in upper area of B-pillar on the sheetmetal flange ( -Section A-A- ) and press
in -direction of arrow- . See Fig. 156.
SUBSEQUENT WORK
Subsequent work
1. Install inner sill. Refer to 68 05 19 Removing and installing inner door sill trim - as of MY 2005 (All
Models) .
57 65 19 REMOVING AND INSTALLING RUBBER SEAL FOR DOOR (DOOR

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SIDE) - AS OF MY 2005 (ALL MODELS)

PRELIMINARY WORK
Preliminary work
2. Remove rear-view mirror. Refer to 66 89 19 Removing and installing rear-view mirror - as of MY 2005
(All Models) .

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Fig. 158: Boring out tubular rivet

1. Bore out tubular rivet -1- . See Fig. 158.
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Fig. 159: Unclipping rubber seal

2. Carefully pull the rubber seal out of the clips along the door contour.
Fig. 160: Pulling off rubber seal

3. Pull the rubber seal off the bead of the door channel.
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Fig. 162: Pressing in rubber seal

NOTE:  Pay attention to correct assembly (water drain).
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1. Position the rubber seal in the bead of the door channel and press it on.
Fig. 163: Clipping in rubber seal

2. Position rubber seal at the top edge of the door and push it on.
3. Clip in the rubber seal along the door contour.
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4. Fasten rubber seal -1- with the tubular rivet -2- . See Fig. 164.
Subsequent work
1. Install rear-view mirror. Refer to 66 89 19 Removing and installing rear-view mirror - as of MY 2005 (All
Models) .
57 78 19 REMOVING AND INSTALLING CENTRAL LOCKING SWITCH - AS

PRELIMINARY WORK
Preliminary work - switch for central locking
Remove moulding for center of dashboard.
REMOVING CENTRAL LOCKING SWITCH
Removing central locking switch
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Fig. 165: Installation position

2. Unclip center moulding and switch -1- . Release and pull off electric plug. See Fig. 166.
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Fig. 166: Retaining lugs for moulding

3. Hold the moulding and pull the switch downwards in a circular motion, the switch is released from the two
retaining lugs -2- . See Fig. 166.
INSTALLING CENTRAL LOCKING SWITCH
Installing central locking switch
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Fig. 167: Moulding retaining tabs

1. Engage bottom of switch in the moulding and swivel upwards in a circle until both retaining tabs -2- latch
into the switch. See Fig. 167.
2. Insert electrical plug into switch until it clicks into place.
3. Installing moulding -1- for center of dashboard. See Fig. 167.
SUBSEQUENT WORK
Subsequent work - switch for central locking
Install moulding for center of dashboard.
57 89 19 REMOVING AND INSTALLING CONTROL UNIT FOR REAR

CONVENIENCE SYSTEMS - AS OF MY 2005 (ALL MODELS)
TOOLS

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PROGRAMMING CONTROL UNIT FOR REAR CONVENIENCE SYSTEMS
Reading from and writing to the rear convenience system control unit
WARNING: Sudden voltage interruption of the power supply to the control module.
 Destruction of the control module.
--> During programming, it is essential to guarantee the power supply for the Porsche System tester. It is
essential to connect a battery charger with a current rating of at least 40 A to the vehicle battery.
--> Prior to disconnecting the control module, switch off the ignition and remove the ignition key.
NOTE: The PIWIS tester P 9718 instructions take precedence and in the event of a
discrepancy these are the instructions that must be followed. Deviations may
occur with later software versions.
The procedure described here has been structured in general terms; different
text or additions may appear in the PIWIS tester P 9718.
1. Connect the Porsche System Tester to the vehicle and start the System Tester. Switch on ignition. >>
Continue.
2. Select the vehicle type.
3. Switch from the vehicle type to the list of control units.
4. Select Rear with the cursor keys and press the >> key.
5. Select Control unit replacement with the cursor keys and press the >> key.
6. Select Read out values (codings) with the cursor keys and press >>.
7. The message Codes successfully read out appears on the screen of the Porsche System Tester. Press >>.
8. Switch off ignition and replace control unit --> 21 Removing and installing control unit for rear convenience
systems - removing.
9. Switch to the Special functions menu and perform vehicle handover by pressing F8.
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10. Erase all fault memories in the Special functions menu and press >>.
11. Carry out automatic search of control units.
12. Switch to the Write in data menu and press >> to load the data that was read out.
13. System Tester displays Coding write-in complete >>.
14. Change to the Coding menu and compare the coding with the vehicle equipment. Recode if necessary.
15. Exit the menu, carry out a test drive and read out the fault memory.
CODING CONTROL UNIT FOR REAR CONVENIENCE SYSTEMS
Coding the control unit for rear convenience systems
NOTE: The procedure described must be applied when a control unit has to be
replaced and the tester function Control unit replacement cannot be used.
1. Connect the PIWIS tester P 9718 to the vehicle and start it. Switch on the ignition. >> Continue.
2. Select the vehicle type .
3. Switch to the Special functions menu and perform vehicle handover by pressing F8.
4. Erase all fault memories in the Special functions menu and press >>.
6. Using the >> key, move from the vehicle type to the list of control units.
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7. Select Rear end and press the >>.
8. Select Coding and press the >>.
9. Select Automatic transmission and code with F8.
Automatic transmission
Installed
Not installed
10. Select Vehicle type and code with F8.
Vehicle type
Boxster (987)
911 (997)
11. Select Rear wiper and code with F8.
Rear wiper
Installed
Not installed
12. Select Targa roof and code with F8.
Targa roof
Installed
Not installed
13. Select Convertible top and code with F8.
Convertible Top
Installed
Not installed
14. Select Steel tilt/slide sunroof and code with F8.
Steel tilt/slide sunroof

Installed
Not installed
15. Select Spoiler function and code with F8.
Spoiler function
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No
Yes
16. Select Country coding and code with F8.
Country coding
GB/Netherlands/Malta/Cyprus
USA/Mexico/Canada
Australia/New Zealand/Brazil
Belgium
RoW
17. Take a test drive, read out the fault memory and erase it if necessary.
18. Rear control unit is now taught.
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ACCESSORIES & EQUIPMENT Exterior equipment
Exterior equipment
66 04 19 REMOVING AND INSTALLING FRONT AIR GRILLE - AS OF MY

PRELIMINARY WORK
Preliminary work
1. Remove the front apron. Refer to 63 15 19 Removing and installing front spoiler - as of MY 2005 (All
Models) .
2. Remove spray nozzle for headlight washer system and set it aside. Refer to 92 72 19 Removing and
installing spray nozzle for headlight washer system - as of MY 2005 (All Models) .
REMOVING FRONT AIR GRILLE
Removing front outer air grille
Fig. 1: Loosening wire harness

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1. Press electric plug connection -1- up and out -Arrow A- . See Fig. 1.
2. Unclip wire harness -2- from air grille -3- -Arrow B- . See Fig. 1.
Fig. 2: Removing outer air grille

3. Insert a screwdriver between front apron -1- and air grille -2- at the same time releasing the locking tabs and
remove air grille -2- . See Fig. 2.
4. Disengage wire harness at bottom -3- of air grille -inset- . See Fig. 2.
Removing front center air grille
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Fig. 3: Removing center air grille

2. Disengage wire harness -3- from air grille -inset- . See Fig. 3.
INSTALLING FRONT AIR GRILLE
Installing front center air grille
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Fig. 4: Installing center air grille

1. Engage wire harness -3- on air grille -2- -inset- . See Fig. 4.
2. Position air grille -2- all the way round in the pegs of the front apron -1- . See Fig. 4.
3. Press air grille -2- into the front apron -1- until the locking tabs are felt to engage. See Fig. 4.
Installing front outer air grille
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Fig. 5: Installing air grille

1. Engage wire harness -3- at bottom of air grille -2- -inset- . See Fig. 5.
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Fig. 6: Securing wiring harness

4. Clip in wire harness -2- on air grille -3- -Arrow A- . See Fig. 6.
5. Fasten electric plug connection -1- to air grille -3- -Arrow B- . See Fig. 6.
SUBSEQUENT WORK
Subsequent work
1. Install spray nozzle for headlight washing system. Refer to 92 72 19 Removing and installing spray nozzle
2. Install front apron. Refer to 63 15 19 Removing and installing front spoiler - as of MY 2005 (All Models) .
66 04 19 REMOVING AND INSTALLING FRONT AIR GRILLE - AS OF MY

PRELIMINARY WORK
Preliminary work
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Models) .
2. Remove spray nozzle for headlight washer system and set it aside. Refer to 92 72 19 Removing and
installing spray nozzle for headlight washer system - as of MY 2005 (All Models) .
REMOVING FRONT AIR GRILLE
Removing front outer air grille
Fig. 7: Removing outer air grille

1. Press out retaining pins -1- with a screwdriver. See Fig. 7.
3. Disengage wire harness -4- from air grille. See Fig. 7.
Removing front center air grille
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Fig. 8: Removing center air grille

2. Disengage wire harness -3- from air grille -inset- . See Fig. 8.
INSTALLING FRONT AIR GRILLE
Installing front center air grille
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Fig. 9: Installing center air grille

1. Engage wire harness -3- on air grille -2- -inset- . See Fig. 9.
Installing front outer air grille
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Fig. 10: Installing outer air grille

1. Engage wire harness -4- on air grille -3- . See Fig. 10.
4. Press in new retaining pins -1- . See Fig. 10.
SUBSEQUENT WORK
Subsequent work
1. Install spray nozzle for headlight washing system. Refer to 92 72 19 Removing and installing spray nozzle
66 07 19 REMOVING AND INSTALLING FRONT LOGO - AS OF MY 2005

(ALL MODELS)
Microsoft
REMOVING FRONT LOGO
Removing front logo
1. Open front lid.
Fig. 11: Removing front logo

3. Remove logo -1- and washer -2- . See Fig. 11.
INSTALLING FRONT LOGO
Installing front logo
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Fig. 12: Installing front logo

1. Insert washer -2- and logo -1- into lid and secure with new fastening nuts -3- . See Fig. 12.
2. Close front lid.
66 34 19 REMOVING AND INSTALLING SIDE-SECTION TRIM - AS OF MY

2005 (ALL MODELS)
PRELIMINARY WORK
Preliminary work
Remove rear wheel. Refer to 44 05 19 Removing and installing wheel - as of MY 2005 (All Models) .
REMOVING SIDE-SECTION TRIM
Removing side-section trim
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Fig. 13: Installation location for side trim panel

Fig. 14: Removing side-section trim

1. Unscrew fastening screws -1- and remove side-section trim -2- . See Fig. 14.
INSTALLING SIDE-SECTION TRIM

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Installing side-section trim
Fig. 15: Installation location for side trim panel

Fig. 16: Installing side-section trim

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1. Check speed nuts -3- for deformation; replace speed nuts -3- if necessary. See Fig. 16.
2. Insert side-section trim -2- and push retaining clip -4- into side panel. See Fig. 16.
3. Screw in fastening screws -1- and tighten to tightening torque --> : 1.5 ftlb. . See Fig. 16.
SUBSEQUENT WORK
Subsequent work
Install rear wheel. Refer to 44 05 19 Removing and installing wheel - as of MY 2005 (All Models) .
66 36 19 REMOVING AND INSTALLING ROOF JOINT STRIP - AS OF MY

TOOLS

Loctite 241 workshop
equipment
PRELIMINARY WORK
Preliminary work
1. Remove trim panel for rear lid hinge. Refer to 70 91 19 Removing and installing rear lid hinge trim - as of
MY 2006 (Cayman S, Cayman S RHD) .
REMOVING ROOF JOINT STRIP
Removing roof joint cover strip
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Fig. 17: Installation position of roof joint cover strip

Fig. 18: Loosening roof joint cover strip

1. Press out retaining pin using a narrow screwdriver and remove expanding clip -1- . See Fig. 18.
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Fig. 19: Removing roof joint cover strip

2. Lift roof joint cover strip -1- using a plastic spatula -2 - and unclip all the way along. See Fig. 19.
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Fig. 20: Detaching spreader

3. Move wedge piece of spreader -1- with a plastic wedge. Remove spreader. See Fig. 20.
Fig. 21: Removing retaining pin

4. Insert a narrow screwdriver -1- in the hole in the body and remove the retaining pin -2- . See Fig. 21.
DISASSEMBLING ROOF JOINT COVER STRIP
Disassembling roof joint cover strip
Microsoft

Fig. 23: Removing fold-out element

1. Insert a screwdriver -1- beneath both ends of the fold-out element -2- and press out. See Fig. 23.
Microsoft
Fig. 24: Pulling off roof joint seal

2. Pull roof frame seal -1- from the roof joint cover strip -2- . See Fig. 24.
Microsoft
Fig. 25: Removing roof joint clips

3. Between the roof joint clip -1- and the roof joint cover strip -2- insert a narrow screwdriver -3- and press
outwards until the roof joint clip disengages. See Fig. 25.
ASSEMBLING ROOF JOINT COVER STRIP
Assembling roof joint cover strip
Microsoft

Fig. 27: Fitting roof joint clips

1. Insert roof joint clips -1- narrow side first, and press in until the locking tab in the roof joint cover strip -2-
engages. See Fig. 27.
Microsoft
Fig. 28: Fitting roof joint seal

2. Push the roof joint seal -1- onto the roof joint strip -2- all the way round. See Fig. 28.
3. Stick in the roof frame seal -1- at the ends of the roof joint cover strip -2- using Loctite 241. See Fig. 28.
Microsoft
Fig. 29: Fitting fold-out element

4. Position the fold-out element -1- in the cut-out of the roof joint strip -2- , and press in the locking tabs at the
ends until they engage. See Fig. 29.
INSTALLING ROOF JOINT STRIP
Installing roof joint cover strip
Microsoft

Fig. 31: Fitting spreader

1. Position spreaders -1- (3 per roof channel) in the recesses, beginning at the front. Press the spreader right
down into the roof channel. See Fig. 31.
Microsoft
2. Push wedge piece into the spreader -1- until the spreader is braced in the roof channel. See Fig. 31.
Fig. 32: Installing roof joint cover strip

3. Position the roof joint strip -1- on the roof channel, and align the roof joint clips -2- in the roof joint cover
strip with the spreaders -3- so that they lie directly above one another. See Fig. 33.
4. Press in roof joint cover strip -1- until it audibly engages. See Fig. 33.
Microsoft
Fig. 33: Fastening roof joint cover strip

5. Fasten roof joint cover strip -1- with the expanding clip -2- by pressing in the retaining pins. See Fig. 33.
SUBSEQUENT WORK
Subsequent work
1. Install lid hinge trim panel Refer to 70 91 19 Removing and installing rear lid hinge trim - as of MY 2006
66 50 19 REMOVING AND INSTALLING THE REAR LOGO - AS OF MY 2005

TOOLS

hot-air gun commercially v. a. g 1416
available tool
REMOVING THE REAR LOGO
Removing the rear logo
Microsoft
Fig. 34: Heating logo

1. Heat the rear lid
1.1. Heat the rear lid -1- in the area of the logo -2- using the hot-air gun v. a. g 1416 -3- . See Fig. 34.
Microsoft
Fig. 35: Lifting up logo

2. Lifting up the logo using a plastic wedge
2.1. Move a plastic spatula -1- under the logo -2- and lift it up. See Fig. 35.
Microsoft
Fig. 36: Cleaning the cover

3. Clean the cover
3.1. Loosen the adhesive residue -1- on the cover -2- using a silicone remover and remove it. See Fig. 36.
REPLACING MODEL LOGO
Replacing the model logo Boxster
1. Find the center of the lid.
Microsoft
Fig. 37: Logo Boxster

2. Position and affix logo on lid -Boxster- with dimensions -A and B- --> Dimension: 140.3 mm +/-1 mm and
-C- --> Dimension: 55.9 mm +/-1 mm . See Fig. 37.
Replacing the model logo Boxster S
Fig. 38: Logo Boxster S

Microsoft
2. Position and affix logo on lid -Boxster S- with dimensions -A - --> Dimension: 174.1 mm +/-1 mm and -C-
--> Dimension: 55.9 mm +/-1 mm . See Fig. 38.
3. Position and affix logo on lid -S- with dimensions -B- --> Dimension: 174.1 mm +/-1 mm and -D- -->
Dimension: 50.4 mm +/-1 mm . See Fig. 38.
66 50 19 REMOVING AND INSTALLING THE REAR LOGO - AS OF MY 2006

TOOLS

hot-air blower commercially v. a. g 1416
available tool
REMOVING THE REAR LOGO
Removing rear logo
Fig. 39: Heating logo

1. Heating the rear lid
1.1. Heat the rear lid -1- in the area of the logo -2- using the hot-air blower v. a. g 1416 -3- . See Fig. 39.
Microsoft
Fig. 40: Levering off logo

2. Levering off the logo using a plastic spatula
2.1. Slide a plastic spatula -1- under the logo -2- and lever off the logo. See Fig. 40.
Microsoft
Fig. 41: Cleaning the lid

3. Cleaning the lid
3.1. Loosen the adhesive residue -1- on the lid -2- using a silicone remover and remove it. See Fig. 41.
REPLACING MODEL LOGO
Replacing the model logo Cayman S
Microsoft
Fig. 42: Logo Cayman S

2. Position logo -Cayman S- with the dimensions -A- --> dimension: 179.2 mm +/-1 mm and -C- -->
dimension: 66.1 mm +/-1 mm and stick on lid. See Fig. 42.
3. Position logo -S- with the dimensions -B- --> dimension: 179.2 mm +/-1 mm and -D- --> dimension: 60.1
mm +/-1 mm and stick on rear lid. See Fig. 42.
66 54 19 REMOVING AND INSTALLING SWITCH FOR REARVIEW MIRROR -

REMOVING SWITCH FOR REARVIEW MIRROR
Removing switch for rear-view mirror
1. Remove ignition key.
Microsoft
Fig. 43: Unclipping switch

2. Use a plastic spatula to carefully lever the switch for the rear-view mirror out of the mount on the door panel.
Microsoft
Fig. 44: Removing plug

3. Pull off electrical plug on switch.
INSTALLING SWITCH FOR REARVIEW MIRROR
Installing switch for rear-view mirror
Microsoft
Fig. 45: Connecting plug

1. Push electric plug on to switch until it clicks into place.
Microsoft
Fig. 46: Clipping in switch

2. Push electric wire into the mount for the rear-view mirror switch and clip the switch into the mount.
66 56 19 REMOVING AND INSTALLING SIDE AIR INLET - AS OF MY 2005

REMOVING INLET GRILLE
Removing right air inlet grille
Microsoft
Fig. 47: Installation position of air inlet at the side

Microsoft
Fig. 48: Removing air-inlet slat

1. Remove air-inlet slat.
1.1. Release air-inlet slat -1- in the middle by hand -arrow A- . See Fig. 48.
1.2. Release air-inlet slat -1- using a screwdriver -2- ( -arrow B- ) and remove it -arrow C- . See Fig. 48.
Microsoft
Fig. 49: Removing air inlet grille

2. Remove air inlet grille.
2.1. Release locking tabs with a screwdriver -arrow A- and remove air inlet grille -1- ( -arrow B- ). See Fig.
49.
Microsoft
Fig. 50: Checking fixing clip

3. Check fixing clip.
3.1. Check fixing clip and replace if necessary.
Removing left air inlet grille
Microsoft

Microsoft
Fig. 52: Removing air-inlet slat

1. Remove air-inlet slat.
1.1. Release air-inlet slat -1- in the middle by hand -arrow A- . See Fig. 52.
1.2. Release air-inlet slat using a screwdriver -2- ( -arrow B- ) and remove it -arrow C- . See Fig. 52.
Microsoft
Fig. 53: Removing air inlet grille

2. Remove air inlet grille.
2.1. Release locking tabs with a screwdriver -2- ( -arrow A- ) and remove air inlet grille -1- ( -arrow B- ). See
Fig. 53.
Microsoft
Fig. 54: Checking fixing clip

3. Check fixing clip.
3.1. Check fixing clip and replace if necessary.
REMOVING INNER AIR GUIDE
Removing flow duct on the right
Microsoft

1. Remove electric fan. Manufacturer does not provide specific instructions.
2. Loosen right-hand fuel collection pipe and lay it to one side. Refer to 24 40 20 Removing and installing fuel
injector - as of MY 2005 (All Models) .
Microsoft
Fig. 56: Removing air guide and connecting dome

3. Remove air guide and connecting dome.
3.1. Unscrew fastening screws -1- and remove air guide -2- . See Fig. 56.
3.2. Unscrew fastening screws -1- and remove connecting dome -3- . See Fig. 56.
3.3. Check fastening nut -4- and replace if necessary. See Fig. 56.
Microsoft
Fig. 57: Releasing plug connections

4. Disconnect plug connections.
4.1. Pull off temperature sensor -1- and set it aside. See Fig. 57.
4.2. Pull off plug connection for oil pressure switch -2- . See Fig. 57.
Microsoft
Fig. 58: Removing flow duct

5. Remove flow duct.
5.1. Pull flow duct up and off.
Removing inner left air guide
Microsoft

Fig. 60: Removing impact protection element

1. Remove impact protection element.
1.1. Release locking tab with a screwdriver -arrow A- and remove impact protection element -arrow B- . See
Microsoft
Fig. 60.
Fig. 61: Removing reinforcement

2. Remove reinforcement.
2.1. Pull out reinforcement.
Microsoft
Fig. 62: Removing intake-air pipe

3. Remove intake-air pipe.
3.1. Press intake-air pipe together slightly -arrow A- and remove it -arrow B- . See Fig. 62.
4. Remove air-cleaner element. Refer to 24 24 19 Removing and installing air cleaner element - as of MY
2005 (All Models) .
5. Remove left intake-air distributor. Refer to 24 46 20 Removing and installing intake-air distributor - as of
6. Remove air flow sensor. Refer to 24 45 19 Removing and installing air flow sensor - as of MY 2005 (All
Models) .
Microsoft
Fig. 63: Loosening air cleaner housing at the bottom

7. Loosen air cleaner housing at the bottom.
7.1. Lift the vehicle. --> 40 LIFTING THE VEHICLE - AS OF MY 2005 (ALL MODELS) .
7.2. Unscrew fastening screw -2- at the bottom of air cleaner housing -1- . See Fig. 63.
7.3. Unscrew fastening screw -3- at the bottom of support frame -4- . See Fig. 63.
7.4. Lower the vehicle.
Microsoft
Fig. 64: Loosening air cleaner housing at the top

8. Loosen air cleaner housing at the top.
8.1. Unscrew fastening screw -2- . See Fig. 64.
8.2. Press fixing clip -3- together -arrow A- and swivel air cleaner housing -1- out of its position -arrow B- .
See Fig. 64.
Microsoft
Fig. 65: Loosening support frame

9. Loosen support frame at the top
9.1. Press the air cleaner housing -1- inwards until the fastening screw -2- is easily accessible. See Fig. 65.
9.2. Unscrew fastening screw -2- . See Fig. 65.
Microsoft
Fig. 66: Removing inner air guide

10. Remove inner left air guide.
10.1. Press support frame -1- inwards. See Fig. 66.
10.2. Pull out inner air guide -2- ( -arrow A- ). See Fig. 66.
10.3. Loosen inner air guide -2- and remove it -arrow B- . See Fig. 66.
INSTALLING INNER AIR GUIDE
Installing inner left air guide
Microsoft

Fig. 68: Installing inner air guide

1. Install inner left air guide.
1.1. Position inner air guide -2- between the support frame -1- and body -arrow A- . See Fig. 68.
Microsoft
1.2. Secure inner air guide -2- ( -arrow B- ) and check that it is seated properly (water drain). See Fig. 68.
Fig. 69: Securing support frame

2. Secure support frame at the top.
2.1. Tighten support frame with the fastening screw -2- . Tightening torque --> Tightening torque: 7.2 ftlb.
See Fig. 69.
Microsoft
Fig. 70: Securing air cleaner housing at the top

3. Secure air cleaner housing at the top.
3.1. Position air cleaner housing -1- on the body -arrow A- until the fixing clip -3- engages -arrow B- . See
Fig. 70.
3.2. Secure air cleaner housing -1- with the fastening screw -2- . Tightening torque --> Tightening torque: 7.2
ftlb. See Fig. 70.
Microsoft
Fig. 71: Securing air cleaner housing at the bottom

4. Secure air cleaner housing at the bottom.
4.1. Lift the vehicle.
4.2. Secure air cleaner housing -1- at the bottom with the fastening screw -2- . Tightening torque -->
Tightening torque: 7.2 ftlb. See Fig. 71.
4.3. Secure support frame -4- at the bottom with the fastening screw -3- . Tightening torque --> Tightening
torque: 7.2 ftlb. See Fig. 71.
4.4. Lower the vehicle.
5. Install air flow sensor. Refer to 24 45 19 Removing and installing air flow sensor - as of MY 2005 (All
Models) .
6. Install left intake-air distributor. Refer to 24 46 20 Removing and installing intake-air distributor - as of
7. Install air-cleaner element. Refer to 24 24 19 Removing and installing air cleaner element - as of MY 2005
(All Models) .
Microsoft
Fig. 72: Installing intake-air pipe

8. Install intake-air pipe.
8.1. Position intake-air pipe -1- on the air cleaner housing and press in until it clicks into place. See Fig. 72.
Microsoft
Fig. 73: Installing reinforcement

9. Install reinforcement.
9.1. Press reinforcement in.
Microsoft
Fig. 74: Installing impact protection element

10. Install impact protection element.
10.1. Position impact protection element until the locking tabs engage.
Installing flow duct on the right
Microsoft

Microsoft
Fig. 76: Installing flow duct

1. Install the flow duct.
NOTE: Stick commercially available body sealing strip in the marked area when
replacing the flow duct.
1.1. Position the flow duct on the body and press in.
Microsoft
Fig. 77: Installing connecting dome and air guide

2. Install connecting dome and air guide.
2.1. Position connecting dome -3- and screw down using the fastening screws -1- . Tightening torque -->
2.2. Position air guide -2- and screw down using the fastening screws -1- . Tightening torque --> Tightening
Microsoft
Fig. 78: Connecting plug connections

3. Connect electrical plug connections.
3.1. Insert temperature sensor -1- into the rubber sleeve. See Fig. 78.
3.2. Connect plug connection for oil pressure switch -2- . See Fig. 78.
4. Install electric fan. Manufacturer does not provide specific instructions.
5. Install right fuel collection pipe. Refer to 24 40 20 Removing and installing fuel injector - as of MY 2005
(All Models) .
INSTALLING INLET GRILLE
Installing left air inlet grille
Microsoft

Fig. 80: Installing air inlet grille

1. Install air inlet grille.
1.1. Press air inlet grille in until you feel the locking tabs engage.
Microsoft
Fig. 81: Installing air inlet slat

2. Install air inlet slat.
2.1. Press air inlet slat in until it clicks into place.
Installing right air inlet grille
Microsoft

Fig. 83: Install air inlet grille.

1. Install air inlet grille.
1.1. Press air inlet grille in until you feel the locking tabs engage.
Microsoft
Fig. 84: Installing air inlet slat

2. Install air inlet slat.
2.1. Press air inlet slat in until it clicks into place.

Safety instructions for rear spoiler
WARNING: Impairment of driving stability when the rear spoiler does not extend.
 Danger of accident due to the higher rear axle lift-off.
--> Adapt your driving style and speed to the different vehicle handling.
CAUTION: Danger of injury when manually retracting or extending the rear spoiler on
a stationary vehicle.
--> Make sure that no person or objects are in the range of motion of the rear spoiler.
Microsoft
CAUTION: Danger of damage, if the vehicle is pushed using the spoiler.
--> Do not push vehicle using rear spoiler.
Removing top section of the rear spoiler
Fig. 85: Installation location for rear spoiler

NOTE:  The rear spoiler extends at speeds of approximately 120 km/h and retracts
again at approx. 80 km/h.
 The rear spoiler decreases drag and reduces rear-axle lift especially at
higher speeds.
 The warning lights illuminate for a lamp check when the ignition is
switched on. The warning lights in the instrument panel and the on-board
computer light up if the rear spoiler does not extend or reach its end
position.
1. To remove the rear spoiler drive, the rear spoiler must be manually extended with the ignition switched on,
using the rocker switch in the passenger compartment.
Microsoft
Fig. 86: Removing top section of the rear spoiler

2. Press out the pin from the plastic body-bound rivet -1- . See Fig. 86.
3. Press down and hold top section of the rear spoiler -2- -arrow A- and take out upwards from the bottom
section of the rear spoiler -3- -arrow B- See Fig. 86.
Removing bottom section of the rear spoiler
Microsoft

Fig. 88: Removing bottom section of the rear spoiler

1. Unclip covers laterally -1- . See Fig. 88.
2. Unscrew fastening nuts -2- and take off heat protection shield upwards -3- . See Fig. 88.
Microsoft
Installing bottom section of the rear spoiler

Microsoft
Fig. 90: Installing bottom section of the rear spoiler

1. Position bottom section of the rear spoiler -3- on the rear spoiler drive -4- and screw down the fastening nuts
-2- . Tightening torque --> Tightening torque: 17 ftlb. See Fig. 90.
2. Clip in covers laterally -1- . See Fig. 90.
Installing top section of the rear spoiler

Microsoft
Fig. 92: Installing top section of the rear spoiler

NOTE: Make sure the centering on the top section of the rear spoiler is inserted
correctly in the groove.
1. Position top section of the rear spoiler -2- on the bottom section of the rear spoiler -3- -arrow A- and press
down -arrow B- . See Fig. 92.
2. Press in plastic body-bound rivet -1- and secure with the pin. See Fig. 92.
3. Check gap dimensions on rear spoiler. Refer to 50 IN Processing structural body adhesive - as of MY
2005 (All Models) .

Safety instructions for rear spoiler
WARNING: Impairment of driving stability when the rear spoiler does not extend.
 Danger of accident due to the higher rear axle lift-off.
Microsoft
--> Adapt your driving style and speed to the different vehicle handling.
CAUTION: Danger of injury when manually retracting or extending the rear spoiler on
a stationary vehicle.
--> Make sure that no person or objects are in the range of motion of the rear spoiler.
CAUTION: Danger of damage, if the vehicle is pushed using the spoiler.
--> Do not push vehicle using rear spoiler.
Removing upper part of the rear spoiler
Fig. 93: Installation position for rear spoiler

NOTE:  The rear spoiler extends at speeds of approximately 120 km/h and retracts
again at approx. 80 km/h.
 The rear spoiler decreases drag and reduces rear-axle lift especially at
higher speeds.
 The warning lights illuminate for a lamp check when the ignition is
switched on. The warning lights in the instrument panel and the on-board
Microsoft
computer light up if the rear spoiler does not extend or reach its end
position.
1. To remove the rear spoiler drive, the rear spoiler must be manually extended with the ignition switched on,
using the rocker switch in the passenger compartment.
Fig. 94: Removing upper part of the rear spoiler

2. Unscrew fastening screws -1- and separate rear spoiler upper part -2- from rear spoiler lower part -3- by
removing to the rear. See Fig. 94.
Removing lower part of the rear spoiler
Microsoft

Fig. 96: Removing lower part of the rear spoiler

1. Unscrew fastening nuts -1- and remove rear spoiler lower part upwards -2- . See Fig. 96.

Microsoft
Installing lower part of the rear spoiler

Fig. 98: Installing lower part of the rear spoiler

Microsoft
1. Position rear spoiler lower part -2- on the rear spoiler drive -3- , align and tighten with the fastening nuts -1- .
Tightening torque --> Tightening torque: 23 (17 ftlb.) Nm See Fig. 98.
Installing upper part of the rear spoiler

Microsoft
Fig. 100: Installing upper part of the rear spoiler

1. Position rear spoiler upper part -2- on rear spoiler lower part -3- and screw down with the fastening screws -
1- . See Fig. 100.
2. Check gap dimensions on rear spoiler. Refer to 50 IN Processing structural body adhesive - as of MY
2005 (All Models) .
66 71 19 REMOVING AND INSTALLING ENGINE FOR REAR SPOILER - AS

TOOLS

repair kit for wiring commercially NR.155-1
harnesses available tool
PRELIMINARY WORK
Preliminary work
Remove spoiler drive. --> 667219 Removing and installing spoiler drive - chapter on "Removing"
REMOVING ENGINE FOR REAR SPOILER

Microsoft
Removing engine for rear spoiler
Fig. 101: Installation position of spoiler drive

Fig. 102: Removing engine for rear spoiler

Microsoft
1. Unscrew the three fastening screws -1- on the engine for the spoiler drive -2- . See Fig. 102.
NOTE:  If the engine is replaced, the lines from the engine to the microswitch must
be pinched off and crimped on with the lines from the new engine.
2. Cut off the lines between the engine and the microswitch to a suitable length.
Fig. 103: Removing spur gear and axle

3. Pull out axle -A- and remove spur gear -B- . See Fig. 103.
INSTALLING ENGINE FOR REAR SPOILER
Installing motor for rear spoiler
Microsoft
Fig. 104: Fitting spur gear and axle

1. Insert spur gear -B- and push in axle -A- . See Fig. 104.
Microsoft
Fig. 105: Installing motor for rear spoiler

2. Position motor for spoiler drive -2- and screw down using the three fastening screws -1- . --> Tightening
torque: 6 (4.5 ftlb.) Nm See Fig. 105.
3. Connect wires using repair kit for wiring harnesses NR.155-1.
3.1. Cut wires for subsequent shrink connections to various lengths.
3.2. Slide shrink-fit hose onto the wires.
3.3. Strip 10 mm of insulation off the wires.
3.4. Join wires using crimp connectors. Make sure not to confuse the wire colors.
3.5. Shrink shrink-fit hoses with a hot-air gun so that wires are watertight.
3.6. Wrap commercially available PVC adhesive tape all around the area of the connection points.
SUBSEQUENT WORK
Subsequent work
Install spoiler drive. --> 667219 Removing and installing spoiler drive - chapter on "Installing"
66 71 19 REMOVING AND INSTALLING MOTOR FOR REAR SPOILER - AS

TOOLS

repair kit for wiring commercially NR.155-1
harnesses available tool
PRELIMINARY WORK
Preliminary work
Remove spoiler drive. --> 667219 Removing and installing spoiler drive - chapter on "Removing"
REMOVING MOTOR FOR REAR SPOILER
Removing motor for rear spoiler
Microsoft
Fig. 106: Installation position of motor for rear spoiler

Fig. 107: Removing motor for rear spoiler

1. Unscrew the three fastening screws -1- on the motor for the spoiler drive -2- . See Fig. 107.
Microsoft
NOTE:  If the engine is replaced, the lines from the engine to the microswitch must
be pinched off and crimped on with the lines from the new engine.
2. Cut off the lines between the motor and the microswitch to a suitable length.
Fig. 108: Removing spur gear and axle

3. Pull out axle -A- and remove spur gear -B- . See Fig. 108.
INSTALLING MOTOR FOR REAR SPOILER
Installing motor for rear spoiler
Microsoft
Fig. 109: Fitting spur gear and axle

1. Insert spur gear -B- and push in axle -A- . See Fig. 109.
Microsoft
Fig. 110: Installing motor for rear spoiler

2. Position motor for spoiler drive -2- and screw down using the three fastening screws -1- . --> Tightening
3. Connect wires using repair kit for wiring harnesses NR.155-1.
3.1. Cut wires for subsequent shrink connections to various lengths.
3.2. Slide shrink-fit hose onto the wires.
3.4. Join wires using crimp connectors. Make sure not to confuse the wire colors.
3.5. Shrink shrink-fit hoses with a hot-air gun so that wires are watertight.
3.6. Wrap commercially available PVC adhesive tape all around the area of the connection points.
SUBSEQUENT WORK
Subsequent work
Install spoiler drive. --> 667219 Removing and installing spoiler drive - chapter on "Installing"
66 72 19 REMOVING AND INSTALLING SPOILER DRIVE - AS OF MY 2005

PRELIMINARY WORK
Preliminary work
1. Remove rear luggage-compartment lining. Refer to 70 06 19 Removing and installing rear luggage-
compartment trim panel - as of MY 2005 (Boxster, Boxster RHD, Boxster S, Boxster S RHD) .
2. Remove the rear spoiler. --> 665819 Removing and installing rear spoiler - "Removing" section
REMOVING SPOILER DRIVE
Removing spoiler drive
Microsoft
Fig. 111: Installation position for spoiler drive

Microsoft
Fig. 112: Removing spoiler drive

1. Unscrew the three fastening nuts -2- and remove the three washers -3- . See Fig. 112.
2. Unscrew the fastening screw -4- and remove the washer -5- . See Fig. 112.
3. Unscrew the four fastening screws -6- on both sides and remove the mounting plates -7- . See Fig. 112.
4. Disconnect plug connection -8- and lift up and remove spoiler drive -1- . See Fig. 112.
INSTALLING SPOILER DRIVE
Installing spoiler drive
Microsoft
Fig. 113: Installing spoiler drive

1. Insert and position spoiler drive -1- . See Fig. 113.
2. Connect plug connection -8- . See Fig. 113.
3. Position the two mounting plates -7- and screw down with the four fastening screws -6- . --> Tightening
4. Tighten fastening screw -4- with washer -5- . --> Tightening torque: 10 (7.5 ftlb.) Nm See Fig. 113.
5. Tighten the three fastening nuts -2- with washers -3- . --> Tightening torque : 6 (4.5 ftlb.) Nm See Fig. 113.
Microsoft
SUBSEQUENT WORK
Subsequent work
1. Install rear spoiler. --> 665819 Removing and installing rear spoiler - chapter on "Installing"
2. Install rear luggage-compartment lining. Refer to 70 06 19 Removing and installing rear luggage-
66 72 19 REMOVING AND INSTALLING SPOILER DRIVE - AS OF MY 2005

PRELIMINARY WORK
Preliminary work
1. Remove rear luggage-compartment lining. Refer to 70 06 19 Removing and installing rear luggage
compartment trim (carpet lining) - as of MY 2006 (Cayman S, Cayman S RHD) .
2. Remove cover for rear lock carrier Refer to 70 39 19 Removing and installing cover for rear lock carrier -
as of MY 2006 (Cayman S, Cayman S RHD) .
3. Remove the rear spoiler. --> 665819 Removing and installing rear spoiler - "Removing" section
REMOVING SPOILER DRIVE
Removing spoiler drive
Microsoft
Fig. 114: Installation position for spoiler drive

Fig. 115: Removing spoiler drive

1. Unscrew the three fastening nuts -2- and remove the three washers -3- . See Fig. 115.
2. Unscrew the fastening screw -4- and remove the washer -5- . See Fig. 115.
3. Unscrew the four fastening screws -6- on both sides and remove the mounting plates -7- . See Fig. 115.
4. Disconnect plug connection -8- and lift up and remove spoiler drive -1- . See Fig. 115.
Microsoft
INSTALLING SPOILER DRIVE
Installing spoiler drive
Fig. 116: Installing spoiler drive

1. Insert and position spoiler drive -1- . See Fig. 116.
2. Connect plug connection -8- . See Fig. 116.
3. Position the two mounting plates -7- and screw down with the four fastening screws -6- . --> Tightening
Microsoft
4. Tighten fastening screw -4- with washer -5- . --> Tightening torque: 10 (7.5 ftlb.) Nm See Fig. 116.
5. Tighten the three fastening nuts -2- with washers -3- . --> Tightening torque : 6 (4.5 ftlb.) Nm See Fig. 116.
SUBSEQUENT WORK
Subsequent work
1. Install rear spoiler. --> 665819 Removing and installing rear spoiler - chapter on "Installing"
2. Install rear luggage-compartment lining. Refer to 70 06 19 Removing and installing rear luggage
3. Install cover for rear lock support. Refer to 70 39 19 Removing and installing cover for rear lock carrier -
66 77 55 REPLACING STONE GUARD FILM - AS OF MY 2005 (ALL

MODELS)
REPLACING STONE GUARD FILM
General affixing regulations for the stone guard film
NOTE: Affixing space:
 Room temperature 18 - 30°C.

 Humidity 40% - 60% rel. humidity.
NOTE: Vehicle for affixing:
 Acclimated to room conditions.

 Wear clean gloves when affixing so that there will not be any visible finger
prints on the film.
NOTE: Application fluid:
 3 drops of non-lubricating washing-up liquid (e. g., Pril) in 1000 ml distilled

water.
Affixing the stone guard film
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Fig. 117: Cleaning paint surface

NOTE:  The surface must be free from dirt, oil, and wax residues.
1. Clean the paint surface for the stone guard film and rub it dry using a lint-free, moisture absorbing cloth.
2. Wet the surface to be affixed with application fluid after cleaning.
NOTE:  The film must be affixed immediately after spraying.
3. Pull off film for stickers, and wet the bonding surface of the film with the application fluid.
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Fig. 118: Affixing the stone guard film

4. Affix film to vehicle to the dimension -X= 0.5 + 1.5 mm- and press lightly. Slight adjustments to the position
can still be made. See Fig. 118.
NOTE:  The film must be applied without bubbles, and no water may remain
between the paint surface and adhesive.
5. Press on the film with a plastic spatula from the inside to the outside to squeeze out water.
6. The adhesive is activated by the pressure of the spatula. The contact pressure should be at least 2 kg.
7. After affixing, pull off the thin protective film.
8. Dry off the entire surface with a lint-free, moisture-absorbing, non-scratching cloth.
9. Check the affixed film for bubbles and faults. The film must bond permanently to the vehicle. Check corners
again for correct bonding (press on again if necessary).
66 82 19 REMOVING AND INSTALLING MIRROR ADJUSTING MOTOR - AS

PRELIMINARY WORK
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Preliminary work
Remove mirror glass. Manufacturer does not provide specific instructions.
REMOVING MIRROR ADJUSTING MOTOR
Removing mirror adjusting motor
Fig. 119: Overview of mirror adjusting motor

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Fig. 120: Unscrewing fastening screws from mirror adjusting motor

2. Unscrew the three fastening screws -1- from mirror adjusting motor. See Fig. 120.
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Fig. 121: Pulling off connector from mirror adjusting motor

3. Pull off connector on mirror adjuster motor take off mirror adjusting motor.
INSTALLING MIRROR ADJUSTING MOTOR
Installing mirror adjuster motor
Fig. 122: Pushing connector onto the mirror adjusting motor

1. Push connector onto mirror adjusting motor until it is felt to engage.
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Fig. 123: Screwing down fastening screws on the mirror adjusting motor
2. Insert mirror adjusting motor and screw down the three fastening screws -1- . See Fig. 123.
3. Switch on ignition and check function of the mirror adjusting motor.
SUBSEQUENT WORK
Subsequent work
Install mirror glass. Manufacturer does not provide specific instructions.
66 89 19 REMOVING AND INSTALLING REAR-VIEW MIRROR - AS OF MY

2005 (ALL MODELS)
REMOVING REAR-VIEW MIRROR
Removing trim panel for mirror triangle
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Fig. 124: Installation position for mirror triangle trim panel

Fig. 125: Removing trim panel for mirror triangle

1. Carefully lever out trim panel for mirror triangle -1- using plastic wedge -Arrow A- and pull upwards -
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2. Press -2- electrical plug connection -Arrow C- and pull off -2- the plug -Arrow D- . See Fig. 125.
3. Remove trim panel for mirror triangle -1- . See Fig. 125.
Removing seal for mirror triangle

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1. Pull out seal for mirror triangle from cable cutout opening for door mirror.
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1. Disconnect the plug connection of the mirror housing -3- . See Fig. 129.
Removing rear-view mirror
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Fig. 131: Removing rear-view mirror

1. Unscrew fastening screws -4- and remove mirror housing -5- . See Fig. 131.
INSTALLING REAR-VIEW MIRROR

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Installing rear-view mirror

Fig. 133: Installing rear-view mirror

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1. Position mirror housing -5- and tighten with M6 fastening screws -4- . Tightening torque --> Final
tightening: 4 ftlb. See Fig. 133.

1. Connect the plug connection of the mirror housing -3- . See Fig. 135.
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Fitting seal for mirror triangle

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1. Stick seal for mirror triangle at cable cutout opening on door mirror to the basic door frame.
Installing trim panel for mirror triangle
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Fig. 139: Installing trim panel for mirror triangle

1. Lock electrical plug connection -2- until it audibly engages. See Fig. 139.
2. Hook cover -1- into the door triangle from above -Arrow E- and press into the fastening clips on the
underside until it engages audibly -Arrow F- . See Fig. 139.
66 92 19 REMOVING AND INSTALLING THE ROOF TRANSPORT SYSTEM -

AS OF MY 2006 (CAYMAN S, CAYMAN S RHD)
Warning notes
WARNING: Danger of accident (death/danger to yourself and/or other road users)
 as a result of losing the Roof Transport System and/or add-on

modules.
--> Check the Roof Transport System and add-on modules regularly before each journey and during an
extended journey to make sure it is seated correctly and securely on the vehicle.
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 as a result of changed vehicle handling (higher center of gravity and

larger area exposed to the wind) when the Roof Transport System is
fitted and especially when loaded.
--> Adapt driving style accordingly!
--> Observe the instructions about the "Roof Transport System" in the Driver's Manual!
--> If the Roof Transport System and add-on modules are not in use, they should be completely removed from
the vehicle in the interest of driving comfort (noise level) and fuel economy!
 due to improper loading of the Roof Transport System and/or add-on

modules.
--> Load the Roof Transport System and/or add-on modules so that the load does not project beyond the sides
of the roof surface!
--> Select the distances between several add-on modules fitted next to each other so that the transported items
cannot bump against each other during the journey!
--> Secure load adequately to prevent it from shifting during the journey!
CAUTION: Damage to the vehicle and/or Roof Transport System
 due to non-observance of the total height of the vehicle.
--> Observe total height of vehicle when entering car parks, underground car parks and tunnels etc.!
--> Completely remove load and Roof Transport System from the vehicle when not in use!
--> Completely remove the load and Roof Transport System from the vehicle roof before washing the vehicle in
automatic car washes!
CAUTION: Damage to the vehicle roof and/or Roof Transport System
 due to incorrect fitting and use
--> Always take care when fitting or removing both brackets for the adapter. If necessary, have a second person
help!
REMOVING THE ROOF TRANSPORT SYSTEM

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Removing the Roof Transport System
Fig. 140: Installation position of Roof Transport System

Fig. 141: Opening cover flaps

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1. Open cover flaps -1- on the lock handles -2- . See Fig. 141.
2. Unlock the lock handles -2- and pull out of the support tubes as far as the stop. See Fig. 141.
Fig. 142: Removing bracket

3. Unscrew fastening screw -1- and remove bracket -2- . See Fig. 142.
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Fig. 143: Removing adapter with base

4. Unscrew fastening screw -1- and remove adapter -2- together with base -3- . See Fig. 143.
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Fig. 144: Screw plug for base plate

5. Screw the screw plug -A- into the base plate to protect against corrosion. See Fig. 144.
6. Close flaps in the roof joint cover strips.
REMOVING BASE PLATE OF ROOF TRANSPORT SYSTEM
Removing base plate of Roof Transport System
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Fig. 145: Installation position of base plate for Roof Transport System
1. Remove roof joint cover strip. --> 663619 Removing and installing roof joint cover strip - section on
"Removing"
2. Remove A-pillar trim panel. Refer to 70 57 19 Removing and installing A-pillar trim - as of MY 2006
Microsoft
Fig. 146: Installing base plate of Roof Transport System

3. Unscrew fastening nut -1- from the inside and remove base plate -2- from roof channel. See Fig. 146.
4. Remove residual adhesive -3- and clean contact surface of base plate -2- . See Fig. 146.
INSTALLING BASE PLATE OF ROOF TRANSPORT SYSTEM
Installing base plate of Roof Transport System
Fig. 147: Installation position of base plate for Roof Transport System
NOTE: Contact surface of roof channel and base plate of Roof Transport System must
be free of dirt and grease.
1. Apply adhesive -3- --> SEALING MATERIAL on the underside of the base plate. See Fig. 148.
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Fig. 148: Installing base plate of Roof Transport System

2. Position base plate -2- of Roof Transport System in and parallel to the roof channel. Screw in fastening nut -
1- from inside and tighten. --> Tightening torque: 23 (17 ftlb.) Nm See Fig. 148.
3. Lightly spread adhesive -3- with a brush. See Fig. 148.
4. Patch new sealing face and damage to top-coat paint in area of base plate -2- with same color as the vehicle.
See Fig. 148.
6. Install roof joint cover strip. --> 663619 Removing and installing roof joint cover strip - section on
"Installing"
INSTALLING THE ROOF TRANSPORT SYSTEM
Installing the Roof Transport System
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Fig. 149: Installation position of Roof Transport System

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Fig. 150: Opening flaps of roof joint cover strip

1. Open flaps in the roof joint cover strips.
2. Unscrew the screw plug -A- from the base plate and keep in a safe place. See Fig. 150.
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Fig. 151: Installing adapter with base

3. Position base -3- in the cut-out of the roof joint cover strip. See Fig. 151.
4. Position adapter -2- , align with the base and secure to vehicle with the fastening screw -1- . See Fig. 151.
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Fig. 152: Installing bracket

NOTE: Observe marking (front/rear) on underside of support tube.
5. Carefully position bracket -2- on the adapter and tighten with fastening screw -1- . See Fig. 152.
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Fig. 153: Closing cover flap

6. Insert lock handles -2- into the support tube ends, lock them and push in caps -1 - of lock cylinder. See Fig.
153.
For further information on the Roof Transport System see: --> 66 92 19 Removing and installing the roof
transport system - as of MY 2006 (Cayman S, Cayman S RHD) .
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ACCESSORIES & EQUIPMENT Front
Front
50 IN DIAGRAM OF BODY BONDING POINTS AND SEALING ELEMENTS -

AS OF MY 2005 (CAYMAN S, CAYMAN S RHD)
DIAGRAM OF BODY BONDING POINTS AND SEALING ELEMENTS
Fig. 1: Diagram of body bonding points and sealing elements

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9:59:38 AM
AM Page 1 © 2005 Mitchell Repair Information Company, LLC.
A - Bonding area for cowl panel frame, roof frame. Refer to 51 03 55 Replacing roof - as of MY 2006
B - Spot welding/bonding procedure in area of wheel housing, inner side section and outer side section. Refer to
53 55 55 Replacing side section - as of MY 2006 (Cayman S, Cayman S RHD) .
C - Seal (moulded part) in area of inner side section and outer side section. Refer to 53 55 55 Replacing side
section - as of MY 2006 (Cayman S, Cayman S RHD) .
D - Bonding procedure in light housing area. Refer to 53 55 55 Replacing side section - as of MY 2006
E - Rivet-bonding procedure in roof frame reinforcement area. Refer to 51 08 55 Replacing roof

reinforcement - as of MY 2006 (Cayman S, Cayman S RHD) .
F - Resistance spot-welding/bonding procedure in cowl panel frame area. Manufacturer does not provide
specific Instructions.
G - Resistance spot-welding/bonding procedure in hinge pillar reinforcement area. Refer to 51 62 55 Replacing

hinge pillar reinforcement - as of MY 2006 (Cayman S, Cayman S RHD) .
H - Resistance spot-welding/bonding procedure in inner side member area. Manufacturer does not provide
specific Instructions.
I - Bonding procedure in the area. Refer to 51 03 55 Replacing roof - as of MY 2006 (Cayman S, Cayman S
RHD) .
J - Bonding procedure in the bulkhead panel area. Refer to 51 08 55 Replacing roof reinforcement - as of MY
K - Bonding procedure in the bulkhead panel area. Refer to 51 08 55 Replacing roof reinforcement - as of
L - Expanded sealant in the roof reinforcement is sealed using 2K acoustic filler foam when replacing the roof
reinforcement. Refer to 51 08 55 Replacing roof reinforcement - as of MY 2006 (Cayman S, Cayman S
RHD) .
The bonding and sealing elements must be replaced during repairs. The procedure is described in the relevant
chapter on body repairs.
50 IN DIAGRAM OF BODY BONDING POINTS AND SEALING ELEMENTS -

RHD)
DIAGRAM OF BODY BONDING POINTS AND SEALING ELEMENTS
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Fig. 2: Diagram of body bonding points and sealing elements

B - Spot welding/bonding method in area of wheel housing, inner side section and outer side section. Refer to
53 55 55 Replacing side section - as of MY 2005 (Boxster, Boxster RHD, Boxster S, Boxster S RHD) .
C - Seal (moulded part) in area of inner side section and outer side section. Refer to 53 55 55 Replacing side
section - as of MY 2005 (Boxster, Boxster RHD, Boxster S, Boxster S RHD) .
E - Spot welding/bonding method in area of inner lower side member and inside of A-pillar.
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The bonding and sealing elements must be replaced during repairs. The procedure is described in the relevant
chapter on body repairs.
50 IN GENERAL INFORMATION AND NOTES ON QUALITY - AS OF MY 2005

(ALL MODELS)
MEASURES FOR MAINTAINING LONG-TERM BODY PROTECTION
NOTE:  After repair work, the standard corrosion-inhibiting coating should only be
restored with the corrosion-inhibiting agents approved by the
manufacturer. The following points must be observed for body repairs.
 Always apply welding primer to both sides of the welding flange when resistance spot welding.
 Prime repair areas from outside. Prime on both sides in the accessible areas.
 Seal all sheetmetal overlaps, sheetmetal edges, butt joints, weld seams etc. with body sealant.
 When replacing structurally bonded body parts, proceed according to the information in the respective
repair instructions.
 Only apply body sealant to primed sheetmetal parts.
 Apply top coat paint to the inside of the outer sheetmetal shell before welding. See "Paint build-up": -->
"Paint Manual"
 Build up paint on bare sheetmetal panels according to the painting methods described in the --> "Paint
Manual".
 Repair or create standard undersealing by applying long-life undersealing material.
 Preserve cavities in the repair area with cavity preservative after applying a top coat paint.
 Check that the standard water drains (plugs) function correctly or clean them after the cavity preservation
material has dried.
Prerequisite for maintaining the long-life guarantee
All body repair work must be carried out correctly and according to the specific Porsche instructions for
sheetmetal, paint and corrosion protection/preservation work. To avoid jeopardising the long-life guarantee, a
Paint Condition Report is prepared two years after delivery of the vehicle. This condition report must be
updated annually by every Official Porsche center.
ELECTRONIC CONTROL MODULES
NOTE:  If electronic components, e. g. ABS control module, have been removed

for repair work and are then reused, they must undergo a functional check
after fitting in accordance with existing specifications.
Battery trickle charge
NOTE:
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 To prevent the vehicle battery from discharging while at the workshop, a

battery charging unit with a rated current of at least 40 A must be
connected as soon as the vehicle is unlocked.
Refer to 27 06 01 BATTERY TRICKLE CHARGE - AS OF MY 2005 (ALL MODELS) for instructions

about connecting the battery charging unit.
Protection against overvoltage when performing welding work
To protect electronic control units from overvoltage during electric arc welding, the following work regulations
must be observed:
 When welding work is extensive, the electronic control units must be removed. Ensure that there are no
electrically insulated parts between the ground connection and the welding point.
 Remove clamp from negative terminal of battery and cover negative terminal of battery.
 Connect the ground connection of the electric arc welding equipment as near as possible to the welding
point on the part to be welded.
 Do not touch electronic control units or electric cables with the ground connection or the welding
electrode.
Replacing control modules
The replacement of electronic control modules after an accident is necessary if at least one of the following
conditions is met:
The housing is noticeably deformed or damaged.
The supporting surface or bracket is deformed (the unit shows no external damage).
The plug connection is damaged or corroded by moisture.
Functional checks or self-diagnosis of the unit reveals the fault "Control module faulty".
50 IN BODY PARTS OF VARIOUS SHEETMETAL STRENGTHS - AS OF MY

2005 (ALL MODELS)
HIGH-STRENGTH STEEL PLATES
NOTE:  Only "Original Porsche parts" must be used for repair work!
Body parts of high-strength steel contribute to better protection of the passenger compartment and thus increase
protection of the passengers. In addition to improved crash safety, these parts also have a positive influence on
fatigue strength. In terms of crash behavior, body parts made from high-strength sheet steel are characterised by
their higher energy absorption. But this also means that higher reshaping force must be applied in reshaping
work.
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Fig. 3: High-strength steel plates

HIGHEST-STRENGTH STEEL PLATES
WARNING: This affects torsion resistance, resistance to bending and crash safety
 Danger of injury and material damage
--> Body parts made of highest-strength steel plate cannot be reshaped. Highest-strength body parts cannot be
straightened or reshaped!
Fig. 4: Highest-strength steel plates

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TAILORED BLANKS
The indicated body parts are made by welding together plates of different thicknesses and characteristics and
then deep-drawing these parts. In their crash behavior, these body parts are characterised by their high energy
absorption.
Fig. 5: Tailored blanks

BAKED HARDENING
WARNING: This affects torsion resistance, resistance to bending and crash safety
--> The spare parts are heat-treated. "Original Porsche parts" attain their final strength only after the production
stage of cathodic immersion painting and drying.
--> Only "Original Porsche parts" or sections of "Original Porsche parts" may be used for repair work!
ALUMINUM PARTS
The marked body parts are made of aluminum
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Fig. 6: aluminum parts

HIGH-STRENGTH STAINLESS STEEL
The marked body parts are made of high-strength stainless steel
Fig. 7: High-strength stainless steel

STRAIGHTENING BODY PARTS
NOTE: Only "Original Porsche parts" or sections of "Original Porsche parts" may be
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used!
The body and floor assembly are produced in series from deep-drawn panels. For this reason, accident damage
must be reshaped in the same way. Body repairs by reshaping are not possible if these body parts are
correspondingly deformed. Here, the repair must be carried out using new parts or by means of sectional
repairs. The separation of damaged body parts after reshaping against the accident direction should not take
place until after connection pieces have been straightened.
WELDING WORK
NOTE:  The use of the oxyacetylene welding process is not permissible for body
parts made of high-strength steel!
 Test welding must be carried out in the case of resistance spotwelding
(RP) of different panel strengths!
The body parts made from high-strength steel can be welded using the RP resistance spot-welding and MIG
welding processes that are customary in workshops.
RESHAPING
NOTE:  Only "Original Porsche parts" or sections of "Original Porsche parts" may
be used for repair work!
 The separation of damaged body parts should not take place until after
reshaping against the accident direction has taken place and connection
pieces have been straightened!
Body repairs by reshaping are not possible if these body parts are correspondingly deformed. Here, the repair
must be carried out using new parts or by means of sectional repairs.
SEPARATION POINTS
NOTE:  Separation points which influence the strength of the body, and thus also
the operating and traffic safety of the vehicle, must be carried out
according to the specifications of the relevant Technical Manual covering
body repair!
 Body reinforcements can be separated or joined together only if this is
specified in the method descriptions. Otherwise, a damaged reinforcement
must always be replaced with a new one!
50 IN WORK SEQUENCE FOR DETERMINING EXTENT OF DAMAGE TO

VEHICLES INVOLVED IN AN ACCIDENT - AS OF MY 2005 (ALL MODELS)
WORK SEQUENCE FOR DETERMINING EXTENT OF DAMAGE TO VEHICLES INVOLVED IN
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AN ACCIDENT
Notes
NOTE:  A body is constructed so that it has deformable zones in the front and rear
areas. These deformable zones enable absorption of impact energy
through their special design. The bearing structure in these areas is
adapted by a specific cross section reduction to provide optimum energy
reduction in the event of an impact.
 Due to the vehicle dimensions in the side area of the body, deformable
zones cannot be provided for absorbing energy. The impact energy can
only be absorbed to a lesser extent here through the deformation of doors
and pillars. This is also the case for the roof area where only the roof skin
can absorb impact energy to a very small extent. In these areas, passenger
protection is guaranteed by a rigid design of the passenger cell.
 The aim of this design is to absorb the impact energy in defined areas to
keep the passenger cell as free of damage as possible in the event of an
accident. If the passenger cell has been deformed in the event of an
accident, extremely large reshaping forces can be expected. Repair work
is often only possible in this case by replacing body parts.
 In general, an impact occurs diagonally or offset to the vehicle axle so that
mixed forms are usually the result of a front and side impact or a rear and
side impact. The deformation is not always restricted to the impact area.
Due to inertia forces of masses, such as running gear, drive line,
occupants of the vehicle and load or the body itself, deformation can also
occur in the opposite areas.
 The following work sequence should provide assistance to correctly
determine the scope of damage of vehicles damaged in an accident.
Work sequence for determining scope of damage to vehicles involved in an accident
1. Identify impact points on the outer shell or the wheels
2. Remove accessories which limit view of the impact area
3. Check unit mounts, running gear parts and steering parts for deformation and cracks
4. Determine scope of damage on the body
See Identifiable deformations on the body structure
See No identifiable deformations on the body structure
5. Repair vehicle, if necessary.
Identifiable deformations on the body structure

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1. Visual inspection of the structural parts for creasing and bending, starting from the point of impact toward the
center of the vehicle
2. Visual inspection of the structural parts at the joints for gaping panel joints (e. g. entry area at the side
member under the rubber seal of the door)
3. Drive vehicle onto a lifting platform and raise it. Measure the measuring points or reference points specified
in the repair check dimensions table diagonally, horizontally and vertically using a beam compass or an
electronic measuring system and compare with the specified values. 50 IN Diagram - body gap dimensions -
as of MY 2005 (Cayman S, Cayman S RHD) or 50 IN Diagram - body gap dimensions - as of MY 2005
(Boxster, Boxster RHD, Boxster S, Boxster S RHD).
4. Decide whether vehicle is technically repairable
5. Decide whether vehicle is economically repairable
Repair vehicle, if necessary.
No identifiable deformations on the body structure
1. Check seam joining line on the accessories . 50 IN Diagram - body gap dimensions - as of MY 2005
(Cayman S, Cayman S RHD) or 50 IN Diagram - body gap dimensions - as of MY 2005 (Boxster, Boxster
RHD, Boxster S, Boxster S RHD).
2. Check accessories for paint abrasion (accessories that were hit during impact)
3. Drive vehicle onto a lifting platform and raise it. Measure the measuring points or reference points specified
in the repair check dimensions table diagonally, horizontally and vertically using a beam compass or an
electronic measuring system and compare with the specified values. . 50 IN Diagram - body gap dimensions -
as of MY 2005 (Cayman S, Cayman S RHD) or 50 IN Diagram - body gap dimensions - as of MY 2005
(Boxster, Boxster RHD, Boxster S, Boxster S RHD).
4. Determine extent of any apparent damage to vehicle partsMeasure running gear electronically if necessary.
Refer to 44 95 03 Suspension alignment, complete - as of MY 2005 (All Models) .
5. Decide whether vehicle has to be repaired
Repair vehicle, if necessary.
50 IN WORK SEQUENCE FOR ACCIDENT REPAIR - AS OF MY 2005 (ALL

MODELS)
WORK SEQUENCE FOR ACCIDENT REPAIR
Procedure for accident repairs.
1. Determine scope of damage

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2. Expose the area to be repaired
3. Make an economic or technical decision: Should parts be repaired or replaced?
4. Determine the scope of replacement parts and order the partsSee Repair See Replacement
5. If necessary, prime and seal the seam areas
6. If necessary, renew the stone impact protection
7. Paint the repaired area
8. If necessary, touch up the undersealing
9. Seal cavities
10. Fit accessories
Repair
1. Cover undamaged areas of the vehicle
2. Reshape damaged areas
3. Fill or soak reshaped areas
4. Apply fine filler on repair areas
Replacement
1. Cover undamaged areas of the vehicle so that they are protected against fire
2. Disconnect battery
3. Pre-paint new parts from the inside
4. Reshape damaged area by straightening so that adjacent contours or gap dimensions correspond to the
standard condition
5. Roughly cut out damaged areas
6. Cut out remaining pieces
7. Fit new parts in, then check the gap dimensions with the accessories fitted
8. Protect spot-welded flanges against corrosion
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9. Observe safety and quality instructions for welding. Manufacturer does not provide specific Safety
Instructions.
10. Weld in new parts
11. Grind visible weld seams flat; if necessary apply body solder or filler
50 IN TOOLS AND METALWORKING TOOLS FOR BODY REPAIRS - AS OF

MY 2005 (ALL MODELS)
TOOLS

Celette type straightening commercially we1121
system available tool
Car Bench commercially we1122

available tool
STRAIGHTENING SYSTEMS
Straightening systems
NOTE:  Detailed and additional information about tools and equipment can be
found in the "Workshop Equipment" manual.
Shown on Celette type
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Fig. 8: Straightening systems

Celette type straightening system we1121
Car Bench we1122
METALWORKING TOOLS
Electrical equipment
Fig. 9: Electrical equipment

1 - Drill
2 - Angle grinder, large
3 - Angle grinder, small
4 - Sander
5 - Hot-air gun
Mechanical equipment
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Fig. 10: Mechanical equipment

6 - Hole punch
7 - Edge setter
Compressed-air equipment
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Fig. 11: Compressed-air equipment

8 - Air chisel
9 - Body saw
10 - Spot-weld remover
Welding equipment
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Fig. 12: Welding equipment

11 - Spotweld device and Multispot metalworking tool
12 - MIG welder
50 IN DIAGRAM - KEYS TO SYMBOLS FOR WELDING WORK - AS OF MY

2005 (ALL MODELS)
DIAGRAM - KEYS TO SYMBOLS FOR WELDING WORK
Resistance spot welding
A - Spot seam, single row
B - Spot seam, double row
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Fig. 13: Resistance spot welding

C - Spot seam, double row offset
Inert-gas arc welding (MAG procedure)
A - Plug weld
B - Stitch weld
C - Full weld
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Fig. 14: Inert-gas arc welding (MAG procedure)

D - Intermittent full weld
Gas welding
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Fig. 15: Gas welding

A - Brazing
50 IN CORROSION PROTECTION MEASURES DURING REPAIRS - AS OF

MEASURES FOR MAINTAINING LONG-TERM BODY PROTECTION
Measures for maintaining long-term body protection
NOTE:  After repair work, the standard corrosion-inhibiting coating should only be
restored with the corrosion-inhibiting agents approved by the
manufacturer. The following points must be observed for body repairs.
 Always apply welding primer to both sides of the welding flange when resistance spot welding.
 Prime repair areas from outside. Prime on both sides in the accessible areas.
 Seal all sheetmetal overlaps, sheetmetal edges, butt joints, weld seams etc. with body sealant.
 Only apply body sealant to primed sheetmetal parts.
 Apply top coat paint to the inside of the outer sheetmetal shell before welding. See "Paint build-up": -->
"Paint Manual"
 Build up paint on bright sheetmetal panels according to the painting methods described in the --> "Paint
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manual".
 Repair or create standard undersealing by applying long-life undersealing material.
 Preserve cavities in the repair area with cavity preservative after applying a top coat paint.
 Check that the standard water drains (plugs) function correctly or clean them after the cavity preservation
material has dried.
PREREQUISITE FOR ENSURING VALIDITY OF THE LONG-LIFE GUARANTEE
Prerequisite for ensuring validity of the long-life guarantee
Porsche long-life guarantee conditions
 All body repair work must be carried out correctly and according to the specific Porsche instructions for
sheetmetal, paint and corrosion protection/preservation work.
 To prevent jeopardising the long-life guarantee, a Paint Condition Report is made out 2 years after
delivery of the vehicle. This condition report must be drafted annually be every Official Porsche center.
50 IN VEHICLE IDENTIFICATION NUMBER - AS OF MY 2005 (ALL MODELS)

TOOLS

Handschlagstempel special tool 96930
8 mm letter/digit embossing special tool NR.128-1

tool with DIN 1451 closely
spaced lettering, letter set
RE-IMPRINTING NEW VEHICLE IDENTIFICATION NUMBER
Vehicle identification number
After replacing the body or the sheetmetal parts in the area of the vehicle identification number (firewall), the
original vehicle identification number must be reimprinted onto the new body or the new sheet metal part.
The documentation of the imprinted vehicle identification number in the vehicle supplementary document or
legally permissible treatment can be obtained from the importer of the respective country.
An incorrectly imprinted (stamped) vehicle identification number should be permanently crossed through with a
X so that it remains legible. The vehicle identification number to be newly imprinted should be imprinted above
the crossed through identification number.
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Spacer for replacing the vehicle identification number
The spacer for applying the vehicle identification number is in the front, right firewall. Two sections are
intended for use.
- Section 1 -A- is the standard spacer. See Fig. 16.
Fig. 16: Vehicle identification number

- Section 2 -B- is the spare spacer for a corrected vehicle identification number. See Fig. 16.
Re-imprinting new vehicle identification number
Microsoft
NOTE:  Only imprint vehicle identification number in a cathodic-dip coated

sheetmetal part.
 The area should be countered when imprinting the vehicle identification
number.
1. Stamp the vehicle identificaiton number to be replaced with 8 mm letter/digit embossing tool with DIN
1451 closely spaced lettering, letter set NR.128-1 and the Porsche star Handschlagstempel 96930 in den
Platzhalter einschlagen.
2. Mask imprinted vehicle identification number.
3. Apply exterior paintwork.
4. Remove the vehicle identification number mark.
5. Paint repair area with clear lacquer.
Cathodic-dip coating is the primer applied to the sheetmetal parts at the factory
50 IN CHANGE IDENTIFICATION DATA PLATE - AS OF MY 2005 (ALL

MODELS)
CHANGE IDENTIFICATION DATA PLATE
Installation location of identification data plate on the vehicle
A new type data plate must be affixed after replacing the side section or door sheetmetal parts.
The identification data plate must be ordered from the importer of the respective country.
Microsoft
Fig. 17: Installation location of identification data plate on the vehicle

When ordering the identification data plate, the item number and vehicle identification number must be
specified.
A - Right side section RoW
B - Left doors USA/Canada
Identification data plate RoW
1 - Item number
Microsoft
Fig. 18: Identification data plate RoW

2 - Vehicle identification number
Identification data plate USA
1 - Item number
Microsoft
Fig. 19: Identification data plate USA

Identification data plate Canada
1 - Item number
Microsoft
Fig. 20: Identification data plate Canada

50 IN DIAGRAM: PLUG PLAN - AS OF MY 2005 (CAYMAN S, CAYMAN S

RHD)
DIAGRAM: PLUG PLAN
Top of front of vehicle
Illustrated on the body of an all-wheel drive vehicle
Microsoft
Fig. 21: Top of front of vehicle

A - Rubber grommet hole Ø 20 mm
B - Rubber grommet hole Ø 30 mm
C - Plug hole Ø 35 mm
Bottom of front of vehicle
Fig. 22: Bottom of front of vehicle

Microsoft
Side of front of vehicle
Fig. 23: Side of front of vehicle

A1 - Rubber grommet hole (only when no sliding roof) Ø 20 mm
B - Plug hole Ø 10 mm
D - Rubber grommet hole Ø 30 mm
Bottom of lower side member and floor
Microsoft
Fig. 24: Bottom of lower side member and floor

A - Cap hole Ø 15 mm
B - Cap hole Ø 20 mm
C1 - Plug hole (only rear-wheel drive) Ø 10 mm
Top of lower side member and floor
Fig. 25: Top of lower side member and floor

Microsoft
C - Cap hole Ø 30 mm
D - Plug hole Ø 10 mm
E - Cap hole Ø 20 mm
Wheel housing and rear side section
Fig. 26: Wheel housing and rear side section

A1 - Rubber grommet hole (Cabriolet only) Ø 20 mm
Bottom of rear end
Microsoft
Fig. 27: Bottom of rear end

Bottom of engine compartment bulkhead
Fig. 28: Bottom of engine compartment bulkhead

Microsoft
Top of rear end
Fig. 29: Top of rear end

D - Plug hole Ø 20 mm x 25 mm
Microsoft

A1 - Rubber grommet hole Ø 20 mm to be set from underneath
Fig. 31: Sealing channel, upper rear

A - Plug hole Ø 15 mm
Microsoft
Side of rear end
Fig. 32: Side of rear end


A1 - Plug hole (right side only) Ø 10 mm

Microsoft
50 IN DIAGRAM: PLUG PLAN - AS OF MY 2005 (BOXSTER, BOXSTER RHD,

DIAGRAM: PLUG PLAN
Illustrated on the body of an all-wheel drive vehicle
Fig. 34: Top of front of vehicle

Microsoft
Fig. 35: Bottom of front of vehicle

Fig. 36: Side of front of vehicle

Microsoft
A1 - Rubber grommet hole (only when no sliding roof) Ø 20 mm
D - Rubber grommet hole Ø 30 mm
Fig. 37: Bottom of lower side member and floor

A - Cap hole Ø 15 mm
C1 - Plug hole (only rear-wheel drive) Ø 10 mm
Top of lower side member and floor
Microsoft
Fig. 38: Top of lower side member and floor

C - Cap hole Ø 30 mm
Wheel housing and rear side section
Microsoft
Fig. 39: Wheel housing and rear side section

A1 - Rubber grommet hole (Cabriolet only) Ø 20 mm
Bottom of rear end
Fig. 40: Bottom of rear end


Microsoft
Fig. 41: Bottom of engine compartment bulkhead

Top of rear end
Microsoft



Microsoft
Side of rear end


Microsoft
A1 - Plug hole (right side only) Ø 10 mm
50 IN UNDERSEALING - AS OF MY 2005 (ALL MODELS)

TOOLS

Multi-press telescopic spray special tool P 9320
gun
TOOLS AND MATERIALS
Tools
Recommendation Multi-press telescopic spray gun P 9320 For working with Terostat 9320
Manufacturer: Henkel Teroson GmbH Postfach 10 56 20 69046 Heidelberg www. teroson. com
Materials
Recommendation Terostat multi-functional sealant P 9320 Sprayable seam and compartment sealant
Manufacturer: Henkel Teroson GmbH Postfach 10 56 20 69046 Heidelberg www. teroson. com
DIAGRAM: UNDERSEALING
Overview, undersealing
NOTE:  In the case of repair work, the standard stone shield/undersealing of the
body structure must be restored before painting or unit assembly,
according to the following illustrations.
 The undersealing can only be applied to primed sheetmetal.
Microsoft
Fig. 46: Overview, undersealing

Bottom of front of vehicle, layout plan
Fig. 47: Bottom of front of vehicle, layout plan

A - 0.4 mm to 0.6 mm
B - 0.6 mm to 0.8 mm
C - 1 mm to 1.3 mm
Microsoft
Lower side member and floor, layout plan
Fig. 48: Lower side member and floor, layout plan

A - 0.4 mm to 0.6 mm
B - 0.6 mm to 0.8 mm
C - 1 mm to 1.3 mm
D - 0.2 mm to 0.4 mm
Bottom of rear end, layout plan
Microsoft
Fig. 49: Bottom of rear end, layout plan

A - 0.4 mm to 0.6 mm
B - 0.6 mm to 0.8 mm
C - 1 mm to 1.3 mm
50 IN SEAM SEALS - AS OF MY 2005 (BOXSTER, BOXSTER RHD,

ACCESSORIES
Note on seam seals
NOTE:  Due to modifications to the spare part range, in the case of repair work,
accessories must be sealed before assembly (painting) according to the
following illustrations.
 The sealing material --> SEALING MATERIAL can be applied directly to
accessories coated with KTL paint (cathodic dipbath coating).
 The seam seal can be painted over when it has reached approx. 70 %
hardness (approx. 4 - 5 h at 20 °C, 50 % relative air humidity. Higher air
humidity or dampening with water accelerates the hardening process).
 The hardening can be checked with a nail test. Press a finger nail gently
into the hardened sealing mass; if this causes no damage to the sealing
mass surface, the seam seal can be painted.
Microsoft
Door
Fig. 50: Door seam seal

Rear lid
Fig. 51: Rear lid seam seal

UNPAINTED BODYSHELL
Microsoft
Fig. 52: Seam seal, top of front of vehicle

Top of front of vehicle, front
Fig. 53: Seam seal, top of front of vehicle, front

Top of front of vehicle, (radiator tank)
NOTE:  The designated area -X- must be kept clear.
Microsoft
Fig. 54: Seam seal, top of front of vehicle, (radiator tank)

Front of vehicle and inside A-pillars
Fig. 55: Seam seal, front of vehicle and inside A-pillars

Front of vehicle and outside A-pillars
Microsoft
Fig. 56: Seam seal, front of vehicle and outside A-pillars

Fig. 57: Seam seal, side of front of vehicle

Top of inside front of vehicle and floor
Microsoft
Fig. 58: Seam seal, top of inside front of vehicle and floor
Bulkhead and center floor
Fig. 59: Seam seal, bulkhead and center floor

Wheel housing and upper rear side section
Microsoft
Fig. 60: Seam seal, wheel housing and upper rear side section
Fig. 61: Seam seal, bottom of front of vehicle

Microsoft
Fig. 62: Seam seal, bottom of lower side member and floor
Fig. 63: Seam seal, bottom of engine compartment bulkhead

Top of rear end
Microsoft
Fig. 64: Seam seal, top of rear end

Bottom of rear end
Fig. 65: Seam seal, bottom of rear end

Bottom of rear end at sides
Microsoft
Fig. 66: Seam seal, bottom of rear end at sides

Top of rear end at sides
Fig. 67: Seam seal, top of rear end at sides

Microsoft
Fig. 68: Seam seal, top of rear end at sides

50 IN SEAM SEALS - AS OF MY 2005 (CAYMAN S, CAYMAN S RHD)

ACCESSORIES
Note on seam seals
NOTE:  Due to modifications to the spare part range, in the case of repair work,
accessories must be sealed before assembly (painting) according to the
following illustrations.
 The sealing material --> SEALING MATERIAL can be applied directly to
accessories coated with KTL paint (cathodic dipbath coating).
 The seam seal can be painted over when it has reached approx. 70 %
hardness (approx. 4 - 5 h at 20 °C, 50 % relative air humidity. Higher air
humidity or dampening with water accelerates the hardening process).
 The hardening can be checked with a nail test. Press a finger nail gently
into the hardened sealing mass; if this causes no damage to the sealing
mass surface, the seam seal can be painted.
Door
Microsoft
Fig. 69: Door seam seal

UNPAINTED BODYSHELL
Fig. 70: Seam seal, top of front of vehicle

Top of front of vehicle, front
Microsoft
Fig. 71: Seam seal, top of front of vehicle, front

Top of front of vehicle, (radiator tank)
NOTE:  The designated area -X- must be kept clear.
Fig. 72: Seam seal, top of front of vehicle, (radiator tank)

Front of vehicle and inside A-pillars
Microsoft
Fig. 73: Seam seal, front of vehicle and inside A-pillars

Front of vehicle and outside A-pillars
Fig. 74: Seam seal, front of vehicle and outside A-pillars

Microsoft
Fig. 75: Seam seal, side of front of vehicle

Top of inside front of vehicle and floor
Fig. 76: Seam seal, top of inside front of vehicle and floor
Bulkhead and center floor
Microsoft
Fig. 77: Seam seal, bulkhead and center floor

Wheel housing and upper rear side section
Fig. 78: Seam seal, wheel housing and upper rear side section
Microsoft
Fig. 79: Seam seal, bottom of front of vehicle

Fig. 80: Seam seal, bottom of lower side member and floor
Microsoft
Fig. 81: Seam seal, bottom of engine compartment bulkhead

Top of rear end
Fig. 82: Seam seal, top of rear end

Bottom of rear end
Microsoft
Fig. 83: Seam seal, bottom of rear end

Bottom of rear end at sides
Fig. 84: Seam seal, bottom of rear end at sides

Upper side of rear end
Microsoft
Fig. 85: Seam seal on upper side of rear end

Fig. 86: Seam seal on upper side of rear end

50 IN DIAGRAM - BODY GAP DIMENSIONS - AS OF MY 2005 (CAYMAN S,

CAYMAN S RHD)
TOOLS

Microsoft

dimensions
DIAGRAM - BODY FRONT GAP DIMENSIONS
Gap dimensions, body front
NOTE:  Set gap dimensions on the lids, doors and covers, or accessories in
accordance with the gap specifications.
 Given a clearance in the opening that is too great or too small, the
movable body or the accessories must be centerd accordingly.
 Ensure that the gaps do not taper or do not narrow at local points.
 The given values are guidelines which should be observed as far as
possible.
 The guidelines apply to repair and assembly work.
 Use star gauges to measure the gap dimensions, Star gauges for body gap
dimensions NR.127-1
Microsoft
Fig. 87: Front lid to front apron

Location Explanation Type Basic value Tolerance 1 Tolerance 2

Front lid to front apron Gap dimension A 4.5 mm +/-1 mm
Front lid to front apron Lid only lowered Gap dimension B 2 mm
Microsoft
Fig. 88: Main headlight to inner wing

Location Explanation Type Basic Tolerance Tolerance

value 1 2
Main headlight to inner Determine left and right Gap dimension
4 mm +/-1 mm
wing gap A
Microsoft
Fig. 89: Main headlight to front apron


Main headlight to front apron Gap dimension A 4 mm +/-1.5 mm
Microsoft
Fig. 90: Main headlight to external wing


Main headlight to external wing Gap dimension A 4 mm +/-1 mm
Microsoft
Fig. 91: Main headlight to top wing


Main headlight to top wing Gap dimension A 4 mm +/-1 mm
Main headlight to top of wing Only lowered Gap dimension B 1.3 mm
Microsoft
Fig. 92: Front lid to wing


Front lid to wing Gap dimension A 4 mm +/-1 mm
Front lid to wing Only lowered Gap dimension B 0.5 mm
Microsoft
Fig. 93: Wing to front lid


Wing to front lid Determine left and right gap Gap dimension A 4 mm +1 mm
Wing to front lid Only lowered Gap dimension B 0.5 mm
Microsoft
Fig. 94: Filler flap to wing


Filler flap to wing All the way round Gap dimension A 3.5 mm +/-0.5 mm
Microsoft
Fig. 95: Front apron to side direction indicator


Front apron to side direction indicator Gap dimension A 1.5 mm
Wing to side direction indicator Gap dimension B 0.5 mm +0.5 mm
Microsoft
Fig. 96: Wing to outer side section


value 1 2
Wing to outer side Even transition from front to Gap dimension
4.5 mm +/-1 mm
section rear A
DIAGRAM - BODY CENTER GAP DIMENSIONS
Gap dimensions, body center
Microsoft

possible.
dimensions NR.127-1
Fig. 97: Door to wing

Microsoft

Door to wing gap dimension A 4 mm +/-0.5 mm
Fig. 98: Wing to outer side panel


Wing to outer side panel gap dimension A 4.5 mm +/-1 mm
Wing to outer side panel Only recessed gap dimension B 2 mm
Microsoft
Fig. 99: Door to outer side panel


Door to outer side panel gap dimension A 4.5 mm +/-1 mm
Door to outer side panel Door only recessed gap dimension B 2 mm
Microsoft
Fig. 100: Door to outer side panel


Door to outer side panel Door only raised gap dimension A 4 mm +/-0.8 mm
Microsoft
Fig. 101: Windscreen to windscreen frame


Windscreen to windscreen frame Only recessed gap dimension A 2 mm
Microsoft
Fig. 102: Roof joint strip to outer roof panel


Roof joint strip to outer roof panel gap dimension A 2.35 mm
Roof joint strip to outer roof panel gap dimension B 2.55 mm
Microsoft
Fig. 103: Cowl panel frame to wing


Cowl panel frame to wing Continuous transition gap dimension A 3 mm +/-1 mm
Microsoft
Fig. 104: Engine compartment vent to side panel


Engine compartment vent to side panel gap dimension A 1 mm +/-0.5 mm
Microsoft
Fig. 105: Door window to side window


Door window to side window gap dimension A 7 mm +/-1 Nm
DIAGRAM - BODY REAR GAP DIMENSIONS
Gap dimensions, body rear
Microsoft

possible.
dimensions NR.127-1
Fig. 106: Tail light to outer side panel


value 1 2
Microsoft
Tail light to outer side Tail light only gap dimension

4 mm +/-1.5 mm
panel recessed A
Tail light to outer side
gap dimension B 1 mm
panel
Fig. 107: Tail light to center side panel


value 1 2
Tail light to center side gap dimension
3 mm +/-0.8 mm
panel A
Tail light to center side Tail light only gap dimension 0.5 mm
Microsoft
panel recessed B
Fig. 108: Tail light to rear apron


Tail light to rear apron gap dimension A 4 mm +/-1.5 mm
Microsoft
Fig. 109: Tail light to inner rear apron


Tail light to inner rear apron center gap gap dimension A 4 mm +/-1.5 mm
Microsoft
Fig. 110: Rear spoiler to rear apron


Rear spoiler to rear apron gap dimension A 5 mm +/-1 mm
Microsoft
Fig. 111: Rear spoiler to rear lid


Rear spoiler to rear lid gap dimension A 6 mm +/-1 mm
Microsoft
Fig. 112: Inner rear apron to side panel


Inner rear apron to side panel Flush gap dimension
Microsoft
Fig. 113: Outer rear spoiler to rear apron


Outer rear spoiler to rear apron gap dimension A 4.5 mm +/-1 mm
Microsoft
Fig. 114: Rear lid to rear apron


Rear lid to rear apron Flush gap dimension A 4 mm +/-0.7 mm
Microsoft
Fig. 115: Rear lid to side panel


Rear lid to side panel Flush gap dimension A 4 mm +/-0.5 mm
Microsoft
Fig. 116: Rear lid to outer roof panel


Rear lid to outer roof panel Flush gap dimension A 4 mm +/-0.5 mm
Microsoft


Rear lid to side panel Rear lid only recessed gap dimension A 4 mm +/-0.5 mm
Rear lid to side panel gap dimension B 3.6 mm -1 mm
Microsoft
Fig. 118: Rear lid to rear window


value 1 2
Rear lid to rear Right and left gaps gap dimension
3 mm +/-0.5 mm
window uniform A
Rear lid to rear
On all sides gap dimension B 3 mm +/-0.5 mm
window
50 IN DIAGRAM - BODY GAP DIMENSIONS - AS OF MY 2005 (BOXSTER,

Microsoft
TOOLS

dimensions
DIAGRAM - BODY FRONT GAP DIMENSIONS
Gap dimensions, body front
possible.
dimensions NR.127-1
Microsoft
Fig. 119: Front lid to front apron


Front lid to front apron Gap dimension A 4.5 mm +/-1 mm
Front lid to front apron Lid only lowered Gap dimension B 2 mm
Microsoft
Fig. 120: Main headlight to inner wing


value 1 2
Main headlight to inner Determine left and right Gap dimension
4 mm +/-1 mm
wing gap A
Microsoft
Fig. 121: Main headlight to front apron


Main headlight to front apron Gap dimension A 4 mm +/-1.5 mm
Microsoft
Fig. 122: Main headlight to external wing


Main headlight to external wing Gap dimension A 4 mm +/-1 mm
Microsoft
Fig. 123: Main headlight to top wing


Main headlight to top wing Gap dimension A 4 mm +/-1 mm
Main headlight to top of wing Only lowered Gap dimension B 1.3 mm
Microsoft
Fig. 124: Front lid to wing


Front lid to wing Gap dimension A 4 mm +/-1 mm
Front lid to wing Only lowered Gap dimension B 0.5 mm
Microsoft
Fig. 125: Wing to front lid


Wing to front lid Determine left and right gap Gap dimension A 4 mm +1 mm
Wing to front lid Only lowered Gap dimension B 0.5 mm
Microsoft
Fig. 126: Filler flap to wing


Filler flap to wing All the way round Gap dimension A 3.5 mm +/-0.5 mm
Microsoft
Fig. 127: Front apron to side direction indicator


Front apron to side direction indicator Gap dimension A 1.5 mm
Wing to side direction indicator Gap dimension B 0.5 mm +0.5 mm
Microsoft


value 1 2
Wing to outer side Even transition from front to Gap dimension
4.5 mm +/-1 mm
section rear A
DIAGRAM - BODY CENTER GAP DIMENSIONS
Gap dimensions, body center
Microsoft

possible.
dimensions NR.127-1
Fig. 129: Door to wing

Microsoft

Door to wing Gap dimension A 4 mm +/-0.5 mm


Wing to outer side section Gap dimension A 4.5 mm +/-1 mm
Wing to outer side section Only lowered Gap dimension B 2 mm
Microsoft
Fig. 131: Door to outer side section


Door to outer side section Gap dimension A 4.5 mm +/-1 mm
Door to outer side section Doors only lowered Gap dimension B 2 mm
Microsoft
Fig. 132: Door to outer side section


Door to outer side section Doors only raised Gap dimension A 4 mm +/-0.8 mm
Microsoft
Fig. 133: Windscreen to windscreen frame


Windscreen to windscreen frame Only lowered Gap dimension A 2 mm
Microsoft
Fig. 134: Cowl panel frame to wing


Cowl panel frame to wing Continuous transition Gap dimension A 3 mm +/-1 mm
Microsoft
Fig. 135: Engine compartment vent to side panel


value 1 2
Engine compartment vent to side Gap dimension
1 mm +/-0.5 mm
panel A
DIAGRAM - BODY REAR GAP DIMENSIONS
Gap dimensions, body rear
Microsoft

possible.
dimensions NR.127-1
Fig. 136: Tail light to outer side section

Microsoft

value 1 2
Tail light to outer side Tail light only Gap dimension
4 mm +/-1.5 mm
section lowered A
Gap dimension
Tail light to outer side panel 1 mm
B
Fig. 137: Tail light to center side section


value 1 2
Tail light to center side Gap dimension 3 mm +/-0.8 mm

Microsoft
section A
Tail light to center of side Tail light only Gap dimension
0.5 mm
panel lowered B
Fig. 138: Rear apron to tail light


Rear apron to tail light Gap dimension A 4 mm +/-1.5 mm
Microsoft
Fig. 139: Tail light to inner rear apron


Tail light to inner rear apron Determine gap Gap dimension A 4 mm +/-1.5 mm
Microsoft
Fig. 140: Rear spoiler to rear apron


Rear spoiler to rear apron Gap dimension A 4 mm +/-1 mm
Microsoft
Fig. 141: Rear lid to rear spoiler


value 1 2
Rear lid to rear Rear lid only lowered (max. 1 Gap dimension
3.5 mm
spoiler mm) A
Rear lid to rear Gap dimension
0.5 mm
spoiler B
Microsoft
Fig. 142: Inner rear apron to side panel


Inner rear apron to side panel Flush
Microsoft
Fig. 143: Outer rear spoiler to rear apron


Outer rear spoiler to rear apron Gap dimension A 3 mm +/-0.5 mm
Microsoft
Fig. 144: Rear lid to rear apron


Rear lid to rear apron Only lowered Gap dimension A 4 mm +1 mm
Microsoft


Rear lid to side panel Only lowered Gap dimension A 4 mm +1 mm
Rear lid to side panel Gap dimension B 0.6 mm
Microsoft
Fig. 146: Rear lid to inner convertible-top compartment lid


value 1 2
Rear lid to inner convertible-top Gap dimension
1.4 mm
compartment lid A
Microsoft
Fig. 147: Rear lid to outer convertible-top compartment lid


value 1 2
Rear lid to outer convertible-top Gap dimension
5 mm +0.5 mm -1 mm
compartment lid A
Rear lid to outer convertible-top Gap dimension
1 mm
compartment lid B
Microsoft
Fig. 148: Side panel to convertible-top compartment lid


value 1 2
Side panel to convertible- Convertible-top compartment Gap
5 mm +0.5 mm -1 mm
top compartment lid lid only raised (max. 1 mm) dimension A
Side panel to convertible- Gap
0.8 mm
top compartment lid dimension B
Microsoft
Fig. 149: Side panel to convertible-top compartment lid


value 1 2
Side panel to Convertible-top compartment lid
Gap
convertible-top only raised (max. 1 mm). 4 mm +1 mm -0.5 mm
dimension A
compartment lid Determine gap
Side panel to
Gap
convertible-top Only lowered 0.6 mm
dimension B
compartment lid
Microsoft
Fig. 150: Outer side panel to convertible-top compartment lid


value 1 2
Outer side panel to convertible-top Gap dimension
4 mm +/-1 mm
compartment lid A
Outer side panel to convertible-top Only Gap dimension
1 mm
compartment lid lowered B
Microsoft


value 1 2
Rear lid to side Even transition from front to Gap dimension
4 mm +1 mm
panel rear A
ILLUSTRATION OF CONVERTIBLE-TOP GAP DIMENSIONS
Convertible-top gap dimensions
Microsoft

possible.
dimensions NR.127-1
Fig. 152: Windscreen frame to convertible top

Microsoft

value 1 2
Windscreen frame to Gap dimension
6.5 mm +/-1 mm
convertible top A
Windscreen frame to Convertible top only Gap dimension
1.5 mm
convertible top lowered B
Fig. 153: Windscreen frame to outer convertible top


value 1 2
Windscreen frame to outer Gap dimension 5.8 mm +/-3 mm

Microsoft
convertible top A
Windscreen frame to outer Convertible top only Gap dimension
1.5 mm
convertible top lowered B
Fig. 154: Convertible top to side window


Convertible top to side window Gap dimension A 6.7 mm
Convertible top to side window Gap dimension B 6.6 mm
Microsoft
Fig. 155: Convertible top to side panel


Convertible top to side panel Gap dimension A 5.9 mm +3.25 mm -2.9 mm
Microsoft
Fig. 156: Convertible top to side convertible-top compartment lid


value 1 2
Convertible top to side convertible-top Gap dimension
5 mm +2 mm -3 mm
compartment lid A
Microsoft
Fig. 157: Convertible top to convertible-top compartment lid


value 1 2
Convertible top to convertible-top Gap dimension
5 mm +2 mm -3 mm
compartment lid A
DIAGRAM - GAP DIMENSIONS, HARDTOP
Gap dimensions, hardtop
Microsoft

possible.
dimensions NR.127-1
Fig. 158: Windscreen frame to hardtop

Microsoft

value 1 2
Windscreen frame to Gap dimension
6.5 mm +/-1 mm
hardtop A
Windscreen frame to Convertible top only Gap dimension
1.5 mm
hardtop lowered B
Fig. 159: Windscreen frame to outer hardtop


value 1 2
Windscreen frame to outer Gap dimension 5.8 mm

Microsoft
hardtop A
Windscreen frame to outer Convertible top only Gap dimension
1.5 mm
hardtop lowered B
Fig. 160: Hardtop to side window


Hardtop to side window Gap dimension A 7.7 mm +/-3 mm
Hardtop to side window Gap dimension B 5.2 mm
Microsoft
Fig. 161: Roof joint strip to hardtop


Roof joint strip to hardtop Only lowered Gap dimension A 0.7 mm
Microsoft
Fig. 162: Hardtop body to cover


Hardtop body to cover Gap dimension A 5.5 mm +/-3.5 mm
Microsoft
Fig. 163: Hardtop to convertible top-compartment lid


value 1 2
Hardtop to side convertible-top Gap dimension
5.5 mm +/-3.5 mm
compartment lid A
Microsoft
Fig. 164: Hardtop to convertible-top compartment lid


value 1 2
Hardtop to convertible-top Gap dimension
5.5 mm +/-3.5 mm
compartment lid A
50 IN PROCESSING STRUCTURAL BODY ADHESIVE - AS OF MY 2005 (ALL

MODELS)
TOOLS
Microsoft

Primer commercially
available tool
TOOLS AND MATERIALS
Processing structural body adhesive
Fig. 165: Tools and materials for structural bonding

Item Designation Source Explanation

--> "See Parts Catalogue
-A- Primer
in Main Group 8 "
-B- Processing gun
in Main Group 8 "
-C- Betamate 2096 adhesive set
in Main Group 8 "
Item Designation Item Designation

-B1- Piston rod -C1- Double cartridge
-B2- Gun grip -C2- Processing nozzle
INFORMATION ON THE USE OF STRUCTURAL ADHESIVES IN VEHICLE CONSTRUCTION
General
Structural bonding in the body shell means that the adhesive assumes functions of stiffness, crash strength and
Microsoft
endurance strength, whereby the characteristics of the body shell are positively influenced in a significant way.
In a conventional steel body shell, use is made of a high-strength, heat-hardening single-component epoxy resin
adhesive that fully hardens in the cathodic immersion paint drying oven. In the case of a repair, this adhesive is
replaced by a cold-hardening two-component epoxy resin adhesive, since the hardening temperatures necessary
for the single-component epoxy resin adhesive are not conceivable on an assembled vehicle. For both series
production of bodies-in-white and repair, structural bonded joints are regularly used in combined jointing
processes.
Resistance spot-welding combined with adhesive bonding and mechanical jointing processes In the case of
spot weld bonding for repair and series production, the entire extent of adhesive surfaces and spot welds is
replaced. In this case, before actually spot weld bonding, the unhardened adhesive must be displaced from the
joint area by an appropriate squeeze time. In the case of two-component adhesives, the hardening reaction starts
immediately after mixing and application; this increases the viscosity and so there is only a certain time window
in which spot weld bonding can be performed if the process is to be reliable. For this reason, all time-intensive
preliminary work (drilling, cutting to size, fixing etc.) on the parts to be joined must be performed before
application of adhesive and jointing. This also applies to mechanical jointing processes where the adhesive has
to be displaced from the joint area.
Separating body components
Fig. 166: Separating body components

In the case of 3-layer spot-welded panel joints with a hardened bonded layer in which only the outer panel
needs to be replaced, drill the outer panel in the area of the spotwelds sufficiently well without damaging the
spotweld and bonded joint in the second component layer.
Microsoft
Fig. 167: Separating bonded body components

In the case of 3-layer spot-welded panel joints with a hardened bonded layer on the outer panel, drill the outer
panel in the area of the spotwelds sufficiently well without damaging the spotweld in the second component
layer. After removing the loosened body part, old adhesive must be removed and any uneven spots sanded
down. The flange area must then be pre-treated for bonding.
Welding in body components
Microsoft
Fig. 168: Spot-welding body components

NOTE:  In areas in which bonded flanges are spot-welded in an unhardened state,

suction devices must be used due to combustion products.
 Areas that can only be accessed from one side must be joined with MAG
plug-welds or MAG welded seams. In these cases, no adhesive can be
used in the vicinity of the welded seam because this would burn and
would have a negative effect on the joint.
 The areas without adhesive must be protected using appropriate anti-
corrosion and sealing measures.
Once the spare parts have been attached, repair spotwelds must be placed on the old spotwelds because there is
no current flow possible in areas with a hardened bonded layer. Welding procedures other than resistance spot-
welding are not permitted since the thermal effect would destroy the bonded joint over a wide area.
Microsoft
Fig. 169: Spot-welding body components

PROCESSING ADHESIVES
CAUTION: Danger of poisoning and injury when handling adhesive!
 Danger of poisoning from breathing in vapours or from swallowing

adhesive.
 Risk of injury due to contact with skin or eyes.
--> Do not eat, drink, or smoke while carrying out work.
--> Avoid direct contact with eyes and skin. Wear suitable protective equipment, such as protective clothing,
gloves, and if necessary, a protective mask.
--> If clothing is soiled with adhesive, change clothing immediately and only use again after they have been
cleaned.
--> Also observe the product-specific processing and safety instructions on the packing container and packing
container imprints.
--> In case of eye contact: Rinse eyes immediately and thoroughly with lukewarm running water and consult an
Microsoft
eye doctor.
--> In case of skin contact: Rinse contacted skin areas immediately with lukewarm running water and soap.
--> If adhesive is swallowed: Rinse mouth and consult a doctor.
NOTE:  Bonding surfaces must be free from oil, old adhesive, dirt, moisture, and
layers of paint and oxide.
 Body structural adhesive and primer must only be used on bare metal
parts.
 Ensure that clean gloves are worn when touching cleaned surfaces to
avoid transferring sweat from the hands and dirt onto the bonding area.
 The jointing operation must take place directly after application of the
adhesive in order to guarantee a high quality and reliable bond. Otherwise
the adhesive bead must be removed, with pre-treatment of the surface and
application of the adhesive being repeated.
 After adhesive has hardened, carefully prime accessible bonding areas
and seal with body sealant. Protect bonding areas in cavities with cavity
preservation against corrosion.
Preparing adhesive flanges
To improve adhesion, the bonding surfaces must be roughened using sandpaper with a grain of 100 to 150.
Remove paint layers (cathodic immersion painting) using dry sandpaper or fibre discs with a grain of 100 to
150. The bare bonding surface must then be cleaned with a lint-free cloth soaked in acetone. Leave cleaned
areas to dry for approx. 1 - 2 minutes; bonding surfaces must be completely dry. Apply primer to the cleaned
surfaces. --> 2-K-SIP
Bonding operation Minimum ambient and material temperature during working and hardening is 18° C. The
coating thickness of approx. 1 mm should not be exceeded; if necessary, spread the mixed adhesive on the
bonding surface with a spatula. Areas not covered by cathodic immersion painting and exposed body panels in
cavities must be brushed or filled with structural adhesive.
Jointing operation Join, fix and resistance spot-weld parts within the working time. The jointing operation
must take place directly after application of the adhesive in order to guarantee a high quality and reliable bond.
Otherwise the adhesive bead must be removed, with pre-treatment of the surface and application of the adhesive
being repeated.
Remove excess material Remove most of the excess material with paper or cloth. Finish cleaning visible
surfaces with a cloth soaked in acetone. Hardened material can only be removed mechanically.
Hardening The body structural adhesive used hardens at room temperature. Hardening can be accelerated by
heat (e. g. with an infra-red radiator in a painting booth). Do not load bonded parts until hardening is complete.
Betamate 2096 adhesive set

Microsoft
Initial strength at 23 °C Approx. 10 h ()

Initial strength at 60 °C Approx. 2 h ()
Hardening time at room temperature (23 °C) Approx. 170 h
() After this time assembly work is permitted
Corrosion protection After adhesive has hardened, carefully prime accessible bonding areas and seal with
body sealant. Protect bonding areas in cavities with cavity preservation against corrosion.
Further work on the vehicle The time from joining the repaired components to handing over the vehicle to the
customer must be at least 48 hours. After repairs with adhesive, allow at least ten hours before moving or
carrying out further work on the vehicle (leave standing overnight) to avoid damage to the bonded joint by
premature loading.
Disposal Small amounts remaining after mixing and complete hardening may be disposed of as industrial
waste. Dispose of used acetone-soaked cleaning cloths as special-category waste.
HANDLING PRIMER
General
For processing during body repairs, the following primer system is recommended by Porsche AG.
2-component SIP
CAUTION: Adhesion of the bonded joint will be impaired if the primer is not
processed correctly.
--> Process mixed primer within eight hours; do not keep any leftover primer.
--> The adhesive flange must be coated thinly and evenly with primer. Remove excess material.
--> Protect primed surfaces from soiling.
NOTE:  Primed surfaces can be stored in the open for a maximum of three days
before undergoing further processing. When doing so, make sure that the
surfaces are not soiled by the surrounding environment. After standing in
the open for more than three days, the primer must be removed and
reapplied. For this reason, body parts must be stuck immediately after the
primer has been applied.
1. Prepare adhesive flange for sticking. (see Processing adhesives)
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Fig. 170: Opening bottle

2. Open bottle for component A.
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Fig. 171: Filling with component B

3. Fill bottle completely with component B.
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Fig. 172: Screwing on spray head

4. Screw on spray head.
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Fig. 173: Mixing components

5. Mix components together by shaking vigorously.
6. Clean adhesive flange with isopropanol and allow it to flash off.
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Fig. 174: Applying primer

7. Spray on primer in the area around the adhesive flange.
7.1. Process mixed primer within eight hours; do not keep any leftover primer.
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Fig. 175: Working time of 2-component SIP

8. Check primer application.
Adhesive flanges are coated evenly with primer:
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Fig. 176: Primer application OK

result is OK.
Remove excess primer with a clean, dry cloth.
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Fig. 177: Removing excess primer

A thin, violet-colored coating of primer is sufficient for the adhesive flanges.
Adhesive flanges are not evenly coated (droplet formation):
result is not OK.
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Fig. 178: Primer application incorrect

Using wet sandpaper (approx. 200 grit) or a sanding fleece, rub the primer film, which is still damp, around the
flange area until an even application of primer is achieved. If an even application of primer is not obtained, the
adhesive flange must be completely cleaned, sanded and primed once again.
9. Dry primer.
9.1. Allow primer to flash off; it must be dust-dry before any adhesive is applied.

Primer Flash-off time 5 min
Microsoft
10. Process adhesive.
HANDLING PROCESSING DEVICES
Processing nozzle
CAUTION:
--> Observe the safety instructions of the individual adhesive set components.
NOTE:  Observe the relevant job descriptions for body repairs!
Fig. 179: Releasing holder

1. Open holder.
1.1. Release holder -arrow- and fold up. See Fig. 179.
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Fig. 180: Pressing sliding lock

2. Press sliding lock upwards
2.1. Press sliding lock upwards in direction of arrow -arrow- . See Fig. 180.
3. Insert piston rod.
3.1. Hold sliding lock pressed and insert piston rod -B1- completely into the gun grip -B1- . See Fig. 181.
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Fig. 181: Inserting piston rod

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Fig. 182: Inserting cartridge

4. Insert mixing cartridge.
4.1. Insert double cartridge -C1- into the gun -B- from above. Insert the cartridge until the muzzle of the gun
engages in the groove of the cartridge. See Fig. 182.
5. Engage holder.
5.1. Swivel holder downward and engage on handle of gun.
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Fig. 183: Engaging holder

Fig. 184: Opening cartridge

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6. Open cartridge.
6.1. Turn screw cap 90 ° counter-clockwise and remove.
7. Squeeze adhesive to the front.
7.1. By activating the valve of the gun grip, allow the piston rod to move out slowly until both components
emerge equally.
7.2. Wipe off any adhesive that emerges.
Fig. 185: Fitting processing nozzle

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8. Fit processing nozzle.
8.1. Before fitting the processing nozzle, ensure that the muzzle -A- and the mixing channels are aligned on one
level, if necessary turn the bayonet locking mechanism on the processing nozzle through 90°. See Fig. 185.
8.2. Position processing nozzle -C2- and turn clockwise 90°. See Fig. 185.
9. Mix adhesive components.
9.1. By activating the valve of the gun grip, allow the piston rod to move out slowly until the adhesive is visible
in the processing pipe.
Fig. 186: Working time of structural adhesive

10. Bond the body part.
NOTE:  In order to ensure that the substance is completely mixed, apply a 30 mm

long adhesive bead of fresh adhesive to a piece of cardboard before
processing.
 Process the adhesive within the processing period. The adhesive must be
applied and the body part must be jointed within this period. Any
resistance welding to be carried out in the area of the bonding must be
performed within this period as well. --> Working time: 60 min
Microsoft
 Do not load bonded parts until hardening is complete!

 If the contents of the cartridge are not used up completely, the processing
nozzle must be kept on the cartridge until the adhesive hardens. In the
event of later processing, a new processing nozzle must be used.
10.1.
50 10 55 REPLACING FRONT CLOSING PANEL - AS OF MY 2005 (ALL

MODELS)
TOOLS

PS 1, see Gr. 3.5;
Workshop Equipment
Manual
dimensions

Manufacturer does not provide specific Safety Instructions.
TOOLS AND MATERIALS
Tools and materials
Spotweld drill NR.129
Press-out tool 97290
Pneumatic body saw No. PS 1, see Gr. 3.5; Workshop Equipment Manual 00000
Microsoft
Angle grinder, see Gr. 3.5; see Workshop Equipment Manual 00000
Oscillating body saw (special electric cutter), see Gr. 3.5; Workshop Equipment Manual 00000
Rotary brush, see Gr. 3.5; Workshop Equipment Manual 00000
Hole punch, see Gr. 3.5; Workshop Equipment Manual 00000
Leister Elektron hot-air gun, see Gr. 3.5; Workshop Equipment Manual 00000
Inverter welding equipment ATL Inverterspot WE1194
00000
Straightening attachments for Boxster (986), see Gr. 3.5; Workshop Equipment Manual 00000
Pneumatic spotweld remover, Vario Drill No. WS 90, see Gr. 3.5; Workshop Equipment Manual 00000
Preliminary work for body repairs with alignment bench
1. Removing accessories in the repair area
1.1. Remove accessories in the repair area according to the extent of damage to the vehicle.
2. Equipping alignment bench with straightening kit
2.1. Equip alignment bench with the basic straightening attachments according to the plans included with the
3. Placing vehicle on the alignment bench
3.1. Position vehicle on alignment bench, align according to the reference holes and bolt firmly to the
attachment set.
4. Covering accessories adjacent to the vehicle repair area
4.1. Cover all accessories remaining on the vehicle and the neighboring areas with fire-proof, protective covers.
Microsoft
attachment set.
covers.
REMOVING FRONT CLOSING PANEL
Removing front closing panel
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Fig. 187: Installation position of front closing panel

Fig. 188: Milling off spotwelds

1. Milling off spotwelds
1.1. Mill off spotwelds in area -A- using a spotweld cutter. See Fig. 188.
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2.1. Mill off spotwelds in areas -A, B, C, D- using a spotweld cutter. See Fig. 189.

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Fig. 192: Separating spotwelds

5. Separating spotwelds
5.1. Separate spotwelds in areas -A- and -B- using a parting grinder. See Fig. 192.
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6.1. Mill off spotwelds in areas -A, B, C, D, E, F- using a spotweld cutter. See Fig. 193.
PREPARING CONNECTION AREAS OF THE BODY FOR INSTALLING THE FRONT CLOSING
PANEL
welding work!

Preparing connection areas of the body for installing the front closing panel
Microsoft
Fig. 194: Preparing connection areas of the body for installing the front closing panel
1. Clean undersealing, adhesive residue and paint off the body connecting flanges in the marked areas -A, B, C,
D, E- using a hot-air gun or rotary brush. Grind the connecting flanges until bare. See Fig. 194.
2. Coating spot-weld flange areas with zinc powder paint
2.1. Coat all spot-weld flange areas with zinc powder paint.
FITTING FRONT CLOSING PANEL AND PREPARING FOR INSTALLATION
Fitting front closing panel and preparing for installation
Microsoft
Fig. 195: Punching holes for plug welding using inert-gas welding
1. Punching holes for plug welding using inert-gas welding
1.1. Punch holes (Ø = 7 mm) in areas -A- and -B - for plug welding using inert-gas welding. Maintain spacing
between the holes as on the old part. See Fig. 195.
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2.1. Grind both sides of the connecting flanges of the closing panel in the marked areas -A, B, C, D, E, F, G-
until bare using a rotary brush. See Fig. 196.
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3.1. Grind both sides of the connecting flanges of the closing panel in the marked areas -A- and -B - until bare
INSTALLING FRONT CLOSING PANEL

safety components!
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protective mask.
beginning work.
Installing front closing panel
1. Fitting front closing panel to the body
1.1. Place the front closing panel against the body and secure to the straightening set.
1.2. Fix the front closing panel in place with tensioning clamps.
Fig. 198: Welding in front closing panel

2. Welding in front closing panel
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2.1. Resistance spot-weld the front closing panel in area -A- . See Fig. 198.

3.1. Resistance spot-weld the front closing panel in areas -A, B, C, D- . See Fig. 199.

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6.1. Plug-weld the front closing panel in areas -A, B, E, F- using inert-gas welding. See Fig. 203.
6.2. Plug-weld the front closing panel in areas -C- and -D- using inert-gas welding (2 panel thicknesses). See
Fig. 202.

7.1. Plug-weld the front closing panel in areas -A- and -B- using inert-gas welding. See Fig. 203.
SUBSEQUENT WORK
4. Restore standard sealing with body sealant. --> 5000IN Seam sealing
5. Restore standard undersealing with underbody sealant. --> 5000IN Underbody protection
Microsoft
50 14 55 REPLACING FRONT PANEL - AS OF MY 2005 (ALL MODELS)

TOOLS

Equipment Manual
dimensions

TOOLS AND MATERIALS
Tools and materials
Pneumatic body saw No. PS1, see Gr. 3.5; Workshop Equipment Manual 00000
Oscillating body saw (special electrical cutter), see Gr. 3.5; Workshop Equipment Manual 00000

Microsoft
Basic straightening attachments for 911 Carrera (996), see Gr. 3.5; Workshop Equipment Manual 00000
00000
attachment set.
Microsoft
attachment set.
covers.
REMOVING FRONT PANEL
Removing front panel
Microsoft
Fig. 204: Installation position of front panel

1. Remove end plate. --> 501055 Replacing end plate - section on "Removing"
2. Remove floor front section. --> 502055 Replacing floor front section - section on "Removing"

3.1. Mill off spotwelds in areas -A, B, C- using a spotweld cutter. See Fig. 205.
Microsoft

Microsoft

5.1. Mill off spotwelds in areas -A- and -B- using a spotweld cutter. See Fig. 207.
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6.1. Separate inert-gas welded seams in areas -A- and -B- using a parting grinder. See Fig. 208.
PREPARING CONNECTION AREAS OF THE BODY FOR INSTALLING THE FRONT PANEL
welding work!

Microsoft
Preparing connection areas of the body for installing the front panel

1. Clean undersealing, adhesive residue and paint off the body connecting flanges in the marked area -A- using
a hot-air gun or rotary brush. Grind the connecting flanges until bare. See Fig. 209.

Microsoft

Microsoft

D- using a hot-air gun or rotary brush. Grind the connecting flanges until bare. See Fig. 212.
5.1. Coat spot-weld flange areas with zinc powder paint.
PREPARING FRONT PANEL FOR INSTALLATION
Preparing front panel for installation
Microsoft
Fig. 213: Punching holes for plug welding using inert gas
1. Punching holes for plug welding using inert gas
1.1. Punch holes (Ø = 7 mm) in areas -A- and -B- for plug welding using inert gas. Maintain spacing between
the bores as on the old part. See Fig. 213.
Microsoft
Fig. 214: Punching holes for plug welding using inert gas
2. Punching holes for plug welding using inert gas
2.1. Punch holes (Ø = 7 mm) in areas -A- and -B- for plug welding using inert gas. Maintain spacing between
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3.1. Grind both sides of the connecting flanges of the front panel in the marked areas -A, B, C, D, E- until bare
Microsoft

4.1. Grind both sides of the connecting flanges of the front panel in the marked areas -A, B, C, D- until bare
INSTALLING FRONT PANEL

Microsoft

safety components!
protective mask.
beginning work.
Installing front panel
1. Fitting the front panel to the body
1.1. Fit the front panel to the side member and right and left wheel housings and fix in place with tensioning
clamps.
1.2. Fit floor front section and end plate to the body and fix in place with tensioning clamps.
1.3. Tack-weld the front panel.
1.4. Remove floor front section and end plate.
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Fig. 217: Welding in the front panel

2. Welding in the front panel
2.1. Resistance spot-weld the front panel in areas -A, B, C- . See Fig. 217.

3.1. Plug-weld the front panel in areas -A- and -B- using inert gas. See Fig. 218.
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4.1. Plug-weld the front panel in areas -A- and -B- using inert gas. See Fig. 219.
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5.1. Apply a full weld to the front panel in the marked areas using inert gas.
6. Install floor front section. --> 502055 Replacing floor front section - section on "Installing"
7. Install end plate. --> 501055 Replacing end plate - section on "Installing"
SUBSEQUENT WORK
Microsoft
50 20 55 REPLACING FRONT FLOOR PANEL - AS OF MY 2005 (ALL

MODELS)
TOOLS

PS 1, see Gr. 3.5;
Workshop Equipment
Manual
dimensions

TOOLS AND MATERIALS
Tools and materials

Microsoft
00000
PRELIMINARY WORK FOR BODY REPAIRS
attachment set.
Microsoft
attachment set.
covers.
REMOVING FLOOR FRONT SECTION
Removing floor front section
Microsoft
Fig. 221: Installation position of floor front section

Fig. 222: Cutting the spotwelds

1. Mill off spotwelds.
1.1. Mill off spotwelds applied to the front panel in area -A- (2 plate thicknesses). See Fig. 222.
1.2. Mill off spotwelds in area -B- (1 plate thickness). See Fig. 222.
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2. Separate spotwelds.
2.1. Separate spotwelds applied to the right side member in area -A- from below. See Fig. 223.

3. Separate spotwelds.
3.1. Separate spotwelds applied to the left side member in area -A- from below. See Fig. 224.
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4.1. Mill off spot welds applied to the front closing panel in area -A- . See Fig. 225.
PREPARING CONNECTION AREAS OF THE BODY FOR INSTALLING FRONT FLOOR PANEL
welding work!

Preparing connection areas of body for installing floor front section
Microsoft

2. Coat spot-weld flange areas with zinc powder paint.
FITTING FRONT FLOOR PANEL AT FRONT AND PREPARING FOR INSTALLATION
Adjusting floor front section and preparing for installation
Microsoft
Fig. 227: Drilling and punching holes for plug welding using inert gas
1. Drill and punch holes for plug welding using inert gas.
1.1. Drill holes (Ø = 7 mm) on the fastening flange in area -A- for plug welding using inert gas. See Fig. 227.
1.2. Punch holes (Ø = 7 mm) on the fastening flange in areas -B- and -C- for plug welding using inert gas. See
Fig. 227.


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2.1. Grind both sides of the connecting flanges of the floor front section in the marked areas -A, B, C, D- until
bare using a rotary brush. See Fig. 228.
INSTALLING FRONT FLOOR PANEL

safety components!
protective mask.
beginning work.
Installing floor front section
1. Fit the floor front section to the body.
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1.1. Place the floor front section against the body and secure to the straightening set.
Fig. 229: Welding in floor front section

NOTE: Determine the position of the new part and secure with tensioning clamps.
When butt welding body sheet panels with a sheet thickness of > 1.5 mm, there
must be a welding slit width s = 1 x sheet thickness to guarantee the required
welding quality (welding through).
2. Weld in floor front section.
2.1. Plug-weld the floor front section in area -A- to the right side member using inert gas. See Fig. 229.
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3.1. Plug-weld the floor front section in area -A- to the left side member using inert gas. See Fig. 230.

4.1. Plug-weld the floor front section in areas -A- and -B- to the front panel using inert gas. See Fig. 231.
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5.1. Resistance spot-weld floor front section in area -A- to the front closing panel. See Fig. 232.
SUBSEQUENT WORK
50 55 19 REMOVING AND INSTALLING FRONT WING - AS OF MY 2005 (ALL

MODELS)
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PRELIMINARY WORK
Preliminary work
1. Disconnect battery. Refer to 27 06 IN External power connection, jump lead starting - as of MY 2005
(All Models) .
2. Remove wheel . Refer to 44 05 19 Removing and installing wheel - as of MY 2005 (All Models) .
3. Remove front wheel housing liner. --> 505619 Removing and installing front wheel housing liner -
section on "Removing"
Models) .
5. Remove headlight. Refer to 94 15 19 Removing and installing main headlight - as of MY 2005 (All
Models) .
6. Remove headlight mounting. Refer to 94 14 19 Removing and installing headlight mounting - as of MY

2005 (All Models) .
7. Remove airbag sensor. Refer to 69 51 19 Removing and installing airbag sensor - as of MY 2005 (All
Models) .
NOTE: Only when removing the right wing.
8. Remove filler flap. Refer to 55 37 19 Removing and installing filler flap - as of MY 2005 (All Models) .
NOTE: Only when removing the right wing.
9. Remove carbon canister. Refer to 20 25 19 Removing and installing carbon canister - as of MY 2005
NOTE: Only when removing the left wing.
10. Install reservoir for windscreen washer system. Refer to 92 60 19 Removing and installing reservoir for
windscreen washer system - as of MY 2005 (All Models) .
REMOVING THE WING
Removing fuel tank cap
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Fig. 233: Installation location of wing

Fig. 234: Removing fuel tank cap

NOTE:  The following points apply only to the right wing.
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1. Press out plastic pin in center of rivet head -1- and remove fuel tank cap -2- . Then unclip rubber stop -3- and
rubber sleeve -4- . See Fig. 234.
Releasing tank filler neck

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Fig. 236: Releasing tank filler neck

1. Press locking tabs of sleeve -A- and unclip -5- . See Fig. 236.
2. Unscrew fastening screw -6- of tank filler neck -7- . See Fig. 236.
3. Remove angled pipe -8- . To do this, press apart locking tabs -B- of plastic clip -9- and remove. See Fig. 236.
Releasing bottom of wing
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Fig. 238: Releasing bottom of wing

1. Release fastening nut -10- from wing strut -11- and unscrew bracket -12- . See Fig. 238.
Releasing top of wing

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Fig. 240: Releasing top of wing

1. Undo fastening screws -13- on top flange. See Fig. 240.

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Removing retaining strip

Fig. 242: Removing retaining strip

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1. Unscrew fastening screw -14- from retaining strip -15- and remove retaining strip. See Fig. 242.
2. Unclip fastening nut -16- . See Fig. 242.
Removing protective film

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Fig. 244: Removing protective film

1. Remove protective film -17-
Releasing wing from A-pillar
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Fig. 246: Releasing wing from A-pillar

1. Unscrew fastening screws -18- at A-pillar and pull wing out -19- downwards -C- and forwards -D- . See Fig.
246.
2. Check fastening nut -20- , replacing if necessary. See Fig. 246.
3. Remove switching element for filler flap. Refer to 55 38 19 Removing and installing switching element for
filler flap - as of MY 2005 (All Models) .
Removing masking panel
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Fig. 248: Removing masking panel

1. Press out pin from plastic expansion rivet -1- and remove masking panel -2- from wing -3- . See Fig. 248.
INSTALLING THE WING

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Installing masking panel

Fig. 250: Installing masking panel

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1. Position masking panel -2- on wing -3- . See Fig. 250.
2. Press in plastic expansion rivet -1- and secure with pin. See Fig. 250.
Fastening wing to A-pillar

1. Install switching element for filler flap. Refer to 55 38 19 Removing and installing switching element for
filler flap - as of MY 2005 (All Models) .
Microsoft
Fig. 252: Fastening wing to A-pillar

2. Press in fastening nut -20- . See Fig. 252.
3. Position wing -19- on the body -C- and slide towards A-pillar -D- . Screw in fastening screws -18- into the
A-pillar and tighten lightly. See Fig. 252.
Fastening top of wing
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Fig. 254: Fastening top of wing

1. Screw in fastening screws -13- on top flange and tighten lightly. See Fig. 254.
2. Adjust the contour and gap dimensions relative to the front door and front lid. --> 5000IN Diagram - body
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gap dimensions
3. Tighten fastening screws -13- with specified tightening torque --> Tightening torque: 4.5 (3.5 ftlb.) Nm .
See Fig. 254.
4. Tighten fastening screws M6 -18- with tightening torque --> Tightening torque: 9.7 (7.0 ftlb.) Nm . See
Fig. 254.
Fastening bottom of wing

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Fig. 256: Fastening bottom of wing

1. Position wing strut -11- and bracket -12- on the body and tighten with fastening nuts -10- . Tightening torque
--> Tightening torque: 7.0 ftlb. See Fig. 256.
Sticking in the protective film
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Fig. 258: Sticking in the protective film

1. Stick in the protective film -17- . See Fig. 258.
Installing retaining strip

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Fig. 260: Installing retaining strip

1. Clip fastening nuts -16- into place. Fix retaining strip -15- on the wing up against the stop and tighten with
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the fastening nuts -14- . Tightening torque --> Tightening torque: 2.0 ftlb. See Fig. 260.
Fastening tank filler neck

Microsoft
Fig. 262: Fastening tank filler neck

1. Install angled pipe -8- . Press in the plastic clip -9- until the locking tabs -B- engage audibly. See Fig. 262.
2. Tighten fastening screw -6- on tank filler neck -7- . Tightening torque --> Tightening torque: 7.5 ftlb. See
Fig. 262.
3. Press in the locking tabs -A- of the sleeve -5- until they engage audibly. See Fig. 262.
Installing fuel tank cap

Microsoft
Fig. 264: Installing fuel tank cap

1. Press in plastic expansion rivet -1- on fuel tank cap -2- . Then clip in rubber stop -3- and rubber sleeve -4- .
See Fig. 264.
SUBSEQUENT WORK
Subsequent work
NOTE: Only when installing the left wing.
1. Install reservoir for windscreen washer system. Refer to 92 60 19 Removing and installing reservoir for
NOTE: Only when installing the right wing.
2. Install filler flap. Refer to 55 37 19 Removing and installing filler flap - as of MY 2005 (All Models) .
NOTE: Only when installing the right wing.
3. Install carbon canister. Refer to 20 25 19 Removing and installing carbon canister - as of MY 2005
Microsoft
4. Install airbag sensor. Refer to 69 51 19 Removing and installing airbag sensor - as of MY 2005 (All
Models) .
5. Install headlight mounting. Refer to 94 14 19 Removing and installing headlight mounting - as of MY

2005 (All Models) .
6. Install headlights. Refer to 94 15 19 Removing and installing main headlight - as of MY 2005 (All
Models) .
8. Install front wheel housing liner. --> 505619 Removing and installing front wheel housing liner - section
on "Installing"
9. Mount wheel. Refer to 44 05 19 Removing and installing wheel - as of MY 2005 (All Models) .
10. Connect the battery. Refer to 27 06 IN External power connection, jump lead starting - as of MY 2005
(All Models) .
50 56 19 REMOVING AND INSTALLING FRONT WHEEL HOUSING LINER -

PRELIMINARY WORK
Preliminary work
Remove front wheel. Refer to 44 05 19 Removing and installing wheel - as of MY 2005 (All Models) .
REMOVING FRONT WHEEL HOUSING LINER
Removing front wheel housing liner - rear section
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Fig. 265: Installation position of front wheel housing liner

Fig. 266: Releasing wheel housing liner part A

NOTE: Fastening nuts cannot be used again following removal.
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1. Unscrew fastening nuts -1- and fastening screws -2- . See Fig. 266.
2. Remove wheel housing liner -A- . See Fig. 266.
Remove front wheel housing liner - front section

NOTE: The front part of the wheel housing liner can also be removed without
disassembling the front wheels.
Microsoft
Fig. 268: Removing wheel housing liner part B

1. Unscrew fastening screws -2, 3- and remove wheel housing liner -B- . See Fig. 268.
INSTALLING FRONT WHEEL HOUSING LINER
Install front wheel housing liner - front section
Microsoft

Fig. 270: Fasten wheel housing liner part B

NOTE:  Push in wheel housing liner toward the outside up to contact in wing stop
position.
Microsoft
 Ensure that the right wheel housing liner is guided through the opening on
the wheel well.
1. Insert wheel housing liner -B- . See Fig. 270.
2. Screw in fastening screws -2- and tighten to the specified tightening torque --> Final tightening: 1.5 ftlb. .
See Fig. 270.
3. Screw in fastening screws -3- and tighten to the specified tightening torque --> Final tightening: 2 ftlb. . See
Fig. 270.
Installing front wheel housing liner - rear section

Microsoft
Fig. 272: Fasten wheel housing liner part A

NOTE:  Push in wheel housing liner toward the outside up to contact in wing stop
position.
 Ensure that the right wheel housing liner is guided through the opening on
the wheel well.
1. Insert wheel housing liner -A- . See Fig. 272.
2. Screw on fastening nuts -1- and tighten to the specified tightening torque --> Final tightening: 1 ftlb. . See
Fig. 272.
See Fig. 272.
SUBSEQUENT WORK
Subsequent work
Fit front wheel. Refer to 44 05 19 Removing and installing wheel - as of MY 2005 (All Models) .
50 74 55 REPLACING FRONT WHEEL HOUSING - AS OF MY 2005 (ALL

MODELS)
Microsoft
TOOLS

PS 1, see Gr. 3.5;
Workshop Equipment
Manual
dimensions

TOOLS AND MATERIALS
Tools and materials
Microsoft
00000
attachment set.
REMOVING FRONT WHEEL HOUSING
Removing reinforcement for front wheel housing
Microsoft
Fig. 273: Installation position of front wheel housing

1. Remove outer front side member. --> 507755 Replacing outer front side member - section on
"Removing"
Fig. 274: Removing reinforcement for front wheel housing

Microsoft
Removing front wheel housing

1.1. Mill off spotwelds in areas -A, B, C, D, E- using a spotweld cutter. See Fig. 275.

Microsoft

3.1. Mill off spotwelds in areas -A- and -B- using a spotweld cutter (2 plate thicknesses). See Fig. 277.

Microsoft
4.1. Mill off spotwelds on reinforcement for wheel housing in areas -A- and -B- using a spotweld cutter. See
Fig. 278.



Microsoft
6.1. Mill off spot welds in area -A- for the hinge pillar using a spotweld cutter. See Fig. 280.

7.1. Mill off spotwelds in area -A- using a spotweld cutter (1 plate thickness). See Fig. 281.
7.2. Mill off spotwelds in area -B- using a spotweld cutter (2 plate thicknesses). See Fig. 281.
PREPARING CONNECTION AREAS OF BODY FOR INSTALLATION OF FRONT WHEEL

HOUSING
welding work!

Microsoft
Preparing connection areas of body for installing front wheel housing
Fig. 282: Cleaning connection areas

1. Clean undersealing, adhesive residue and paint off the body connecting flanges in the marked areas -A, B, C-
using a hot-air gun or rotary brush. Grind the connecting flanges until bare. See Fig. 282.

Microsoft

FITTING FRONT WHEEL HOUSING AND PREPARING FOR INSTALLATION
Fitting front wheel housing and preparing for installation
Microsoft
Fig. 285: Drilling holes for plug welding using inert gas
1. Drill holes for plug welding using inert gas.
1.1. Drill holes (Ø = 7 mm) in areas -A- and -B- for plug welding using inert gas. Maintain spacing between the
bores as on the old part. See Fig. 285.

2. Clean the welding areas
2.1. Grind both sides of the connecting flanges of the front wheel housing in the marked areas -A, B, C, D, E,
Microsoft
F- until bare using a rotary brush. See Fig. 286.

3.1. Grind both sides of the connecting flanges of the front wheel housing in the marked areas -A, B, C, D ,E-
Preparing reinforcement for front wheel housing for installation
Microsoft
Fig. 288: Preparing reinforcement for front wheel housing

1. Prepare reinforcement for front wheel housing.
1.1. Drill holes (Ø = 7 mm) in area -A- for plug welding using inert gas. Maintain spacing between the bores as
on the old part. See Fig. 288.
1.2. Grind both sides of the connecting flanges of the front wheel housing in the marked areas -B- and -C- until
INSTALLING FRONT WHEEL HOUSING
Microsoft

safety components!
protective mask.
beginning work.
Installing front wheel housing
1. Fit the front wheel housing to the body.
1.1. Place the front wheel housing against the body and secure to the straightening set.
Microsoft
2. Drill hole for plug welding using inert gas.
2.1. After fitting in the new part, drill hole in area -A- by a further plate thickness. See Fig. 289.
Fig. 290: Welding in front wheel housing

Microsoft

3. Weld in front wheel housing.
3.1. Plug-weld front wheel housing in area -A- using inert gas. See Fig. 290.

4.1. Resistance spot-weld front wheel housing in areas -A, B, C, D- . See Fig. 291.
Microsoft

5.1. Resistance spot-weld front wheel housing in area -A- . See Fig. 292.
5.2. Plug-weld front wheel housing in area -B- using inert gas. See Fig. 292.

Microsoft
6.1. Plug-weld front wheel housing in area -A- using inert gas. See Fig. 293.

7.1. Resistance spot-weld front wheel housing in areas -A- and -B- . See Fig. 294.
Microsoft

8.1. Apply a full weld to the front wheel housing in areas -A, B, C- using inert gas. See Fig. 295.
Installing reinforcement for front wheel housing
Microsoft
Fig. 296: Welding in reinforcement for front wheel housing

1. Weld in reinforcement for front wheel housing.
1.1. Resistance spot-weld reinforcement for front wheel housing in areas -A, B, C, D- . See Fig. 296.
Microsoft
Fig. 297: Welding in reinforcement for front wheel housing

2. Weld in reinforcement for front wheel housing.
2.1. Plug-weld reinforcement for front wheel housing in area -A- using inert gas. See Fig. 297.
3. Install front outer side member. --> 507755 Replacing outer front side member - section on "Installing"
SUBSEQUENT WORK
1. Removing vehicle from straightening bench
2. Cleaning spot-welded joints and sheetmetal flanges with a wire brush
3. Priming flange areas with 2K primer
4. Restore standard sealing with body sealant --> 5000IN Seam sealing
5. Restore standard undersealing with underbody sealant --> 5000IN Underbody protection
6. Painting repair area and adjacent surfaces, if necessary
7. Install removed add-on parts in the repair area
50 74 55 REPLACING FRONT WHEEL HOUSING (SECTION) - AS OF MY

2005 (ALL MODELS)
TOOLS

PS 1, see Gr. 3.5;
Workshop Equipment
Manual
dimensions
Microsoft

TOOLS AND MATERIALS
Tools and materials
00000
Microsoft
attachment set.
REMOVING FRONT WHEEL HOUSING (SECTION)
Removing front wheel housing (section)
Microsoft
Fig. 298: Installation position of front wheel housing

1. Remove front side member (section). --> 507955 Replacing front side member (section) - section on
"Removing" [987321] --> 507955 Replacing front side member (section) - section on "Removing" [987120
987121 987310 987311 987320]
Fig. 299: Determining the cut

2. Determining the cut
2.1. Mark position of cut on front wheel housing at dimension -X= 140 mm- from cut on inner side member
Microsoft
against the direction of travel so that the outer side member is offset with respect to the front wheel housing.
See Fig. 299.
Fig. 300: Cutting through front wheel housing

3. Cutting through front wheel housing
3.1. Cut through the front wheel housing at the marked separation points -A- and -B- using the oscillating body
saw. Do not damage internal components when doing this. See Fig. 300.

Microsoft
PREPARING CONNECTION AREAS OF THE BODY FOR INSTALLING THE FRONT WHEEL
HOUSING (SECTION)
welding work!

Preparing connection areas of the body for installing the front wheel housing (section)

Microsoft
FITTING IN FRONT WHEEL HOUSING AND PREPARING FOR INSTALLATION
Fitting in front wheel housing and preparing for installation
NOTE: Maintain offset between the front wheel housing with respect to the outer side
member.
Fig. 303: Transfer cut for front wheel housing

1. Transfer cut for front wheel housing
1.1. Transfer cut from the old part and mark it.
1.2. Cut through the front wheel housing in area -A- . See Fig. 303.
Microsoft

2.1. Grind both sides of the connecting flanges of the front wheel housing in the marked areas -A, B, C- until
INSTALLING FRONT WHEEL HOUSING (SECTION)

safety components!
Microsoft
protective mask.
beginning work.
Installing front wheel housing (section)
NOTE: When butt welding body sheet panels with a sheet thickness of > 1.5 mm, there
1. Fitting in front wheel housing
1.1. Place the front wheel housing against the body and secure to the straightening set.
1.2. Fix the front wheel housing in place with tensioning clamps.

2. Welding in front wheel housing

Microsoft
2.1. Apply a full weld to the front wheel housing in areas -A- and -B- using inert gas. See Fig. 305.
3. Install front side member (section). --> 507955 Replacing front side member (section) - section on
"Installing" [987321] --> 507955 Replacing front side member (section) - section on "Installing" [987120
987121 987310 987311 987320]
SUBSEQUENT WORK
50 77 55 REPLACING OUTER FRONT SIDE MEMBER - AS OF MY 2005 (ALL

MODELS)
TOOLS

PS 1, see Gr. 3.5;
Workshop Equipment
Manual
dimensions
Microsoft
TOOLS AND MATERIALS
Tools and materials
00000
Microsoft
attachment set.
REMOVING OUTER FRONT SIDE MEMBER
Removing outer front side member
Fig. 306: Installation position of outer front side member

1. Remove the end plate. --> 501055 Replacing end plate - section on "Removing"
Microsoft
2. Remove floor front section. --> 502055 Replacing floor front section - section on "Removing"


Microsoft

5. Separate inert-gas welded seams.
5.1. Separate welded seams applied using inert gas in areas -A, B, C- using a parting grinder. See Fig. 309.

Microsoft
6.1. Separate welded seams applied using inert gas in areas -A, B, C, D- using a parting grinder. See Fig. 310.


Microsoft
8.1. Separate welded seams applied using inert gas in area -A- from below using a parting grinder. See Fig. 312.
PREPARING CONNECTION AREAS OF BODY FOR INSTALLATION OF OUTER FRONT SIDE

MEMBER
welding work!

Preparing connection areas of body for installing outer front side member
Fig. 313: Preparing connection areas of the body for installing the side members
Microsoft
FITTING OUTER FRONT SIDE MEMBER AND PREPARING FOR INSTALLATION
Fitting outer front side member and preparing for installation
Fig. 314: Punch holes for plug welding using inert gas.
1.1. Drill holes in area -A- for plug welding using inert gas. Maintain spacing between the bores as on the old
part. See Fig. 314.
Microsoft

2.1. Grind both sides of the connecting flanges of the outer side member in the marked areas -A, B, C, D- until
INSTALLING OUTER FRONT SIDE MEMBER

safety components!
Microsoft
protective mask.
beginning work.
Installing outer front side member
1. Fit outer front side member to the body.
1.1. Place the outer front side member on the body and secure to the straightening set.
Fig. 316: Welding in outer front side member

Microsoft
2. Weld in the outer front side member.
2.1. Plug-weld the outer front side member in area -A- using inert gas. See Fig. 316.

3.1. Apply a full weld to the outer front side member in area -A- using inert gas (interrupted). See Fig. 317.
3.2. Apply a full weld to the outer front side member in area -B- using inert gas. See Fig. 317.
Microsoft

4.1. Apply a full weld to the outer front side member in area -A, B, C- using inert gas (interrupted). See Fig.
318.

5.1. Plug-weld the outer front side member in areas -A- and -B- using inert gas (through existing slots). See Fig.
Microsoft
319.

6.1. Plug-weld the outer front side member in area -A- using inert gas. See Fig. 320.

Microsoft
7.1. Resistance spot-weld outer front side member in area -A, B, C- using inverter-welding equipment ATL
Inverterspot WE1194. See Fig. 321.

8. Weld in outer front side member.
8.1. Apply a full weld to the outer front side member in area -A- using inert gas (interrupted). See Fig. 322.
8.2. Plug-weld the outer front side member in area -B- using inert gas. See Fig. 322.
SUBSEQUENT WORK
1. Removing vehicle from straightening bench
4. Restore standard sealing with body sealant --> 5000IN Seam sealing
5. Restore standard undersealing with underbody sealant --> 5000IN Underbody protection
Microsoft
7. Install removed add-on parts in the repair area
50 79 55 REPLACING INNER FRONT SIDE MEMBER - AS OF MY 2005 (ALL

MODELS)
TOOLS

PS 1, see Gr. 3.5;
Workshop Equipment
Manual
dimensions

SAFETY INSTRUCTIONS FOR BODY REPAIRS
TOOLS AND MATERIALS
Tools and materials
Microsoft
00000
attachment set.
PREPARING CONNECTION AREAS OF BODY FOR INSTALLATION OF INNER FRONT SIDE

MEMBER
Microsoft
welding work!

Preparing connection areas of body for installing inner front side member

FITTING INNER FRONT SIDE MEMBER AND PREPARING FOR INSTALLATION

Microsoft
Fitting inner front side member and preparing for installation
1.1. Drill holes (Ø = 7 mm) in the area for plug welding using inert gas.
Microsoft

2.1. Grind both sides of the connecting flanges of the inner side member and the reinforcement plate in the
marked areas -A, B, C, D- until bare using a rotary brush. See Fig. 325.
INSTALLING INNER FRONT SIDE MEMBER

safety components!
protective mask.
beginning work.
Microsoft
Installing inner front side member
1. Fit outer front side member to the body.
1.1. Place the outer front side member on the body and secure to the straightening set.
Fig. 326: Welding in inner front side member

2. Weld in inner front side member.
2.1. Plug-weld the inner front side member in area -A- using inert gas. See Fig. 326.
Microsoft

3.1. Apply a full weld to the outer front side member in area -A- using inert gas. See Fig. 327.
Fig. 328: Welding in reinforcement plate

4. Weld in the reinforcement plate.
4.1. Resistance spot-weld the reinforcement plate in areas -A, C, D- . See Fig. 328.
Microsoft
4.2. Apply a full weld to the reinforcement plate in area -B- using inert gas. See Fig. 328.

5.1. Apply a full weld to the inner front side member in area -A, B- using inert gas. See Fig. 329.

Microsoft
6.1. Apply a full weld to the inner front side member in area -A- using inert gas. See Fig. 330.
6.2. Plug-weld the inner front side member in area -B- using inert gas. See Fig. 330.
6.3. Plug-weld the inner front side member in area -C- using inert gas (through existing slots). See Fig. 330.
7. Install front wheel housing. --> 507455 Replacing wheel housings and side members - section on
"Installing"
SUBSEQUENT WORK
50 79 55 REPLACING FRONT SIDE MEMBER (SECTION) - AS OF MY 2005

(BOXSTER S RHD)
TOOLS

PS 1, see Gr. 3.5;
Workshop Equipment
Manual
dimensions
Microsoft

TOOLS AND MATERIALS
Tools and materials
00000
Microsoft
attachment set.
REMOVING FRONT SIDE MEMBER (SECTION)
Removing front side member (section)
Fig. 331: Installation position of front side member

1. Remove front closing panel. --> 501055 Replacing end plate - section on "Removing"
Microsoft
NOTE: If you are sure there has been no deformation of the wheel housing and floor
front section structure, the cuts can be made without removing the wheel
housing and floor front section for the following repair work.
2. Remove front wheel housing (section). --> 507455 Replacing front wheel housing (section) - section on
"Removing"
3. Remove floor front section. --> 502055 Replacing floor front section - removing
WARNING: Possible separation points on inner front side member
 Danger of material damage and injury

 Cuts can only be made on the inner front side member at dimension
-X= 30 mm- , in the marked areas -A- and -B- in front of the tailored
blank (laser weld) -1, 2- against the direction of travel. See Fig. 332.
--> The possible separation points on the inner front side member are 30 mm in front of the tailored blanks
(laser weld) against the direction of travel.
NOTE: Possible separation points on inner front side member.
Fig. 332: Possible separation points

Microsoft

4.1. Determine possible cut on the inner front side member at dimension -X= 30 mm- in front of the tailored
blank (laser weld) -1- . Mark the cut. See Fig. 333.
Fig. 334: Cutting through inner front side member

5. Cutting through inner front side member
5.1. Cut through the inner front side member at the marked separation point -A- using the oscillating body saw.
Microsoft
Do not damage internal components when doing this. See Fig. 334.

NOTE: Ensure that the outer side member is offset by dimension X = min. 50 mm with
respect to the inner side member.

Microsoft
7.1. Mark cut on the outer front side member depending on the damage at dimension -X= min. 50 mm- in front
of the inner tailored blank (laser weld) against or in the direction of travel. See Fig. 336.
Fig. 337: Cutting through outer front side member

8. Cutting through outer front side member
8.1. Cut through the outer front side member at the marked separation point -A- using the oscillating body saw.
Microsoft

PREPARING CONNECTION AREAS OF THE BODY FOR INSTALLING THE FRONT SIDE
MEMBERS (SECTION)
welding work!

Preparing connection areas of the body for installing the front side members (section)
Microsoft

FITTING IN FRONT SIDE MEMBER AND PREPARING FOR INSTALLATION
Fitting in front side member and preparing for installation
Microsoft
Fig. 340: Transferring cut to the inner front side members

1. Transferring cut to the inner front side members
1.2. Cut through the inner front side member in area -A- . See Fig. 340.

Microsoft
2.1. Grind both sides of the connecting flanges of the inner front side member in the marked areas -A, B, C-
Fig. 342: Transferring cut to the outer front side members

3. Transferring cut to the outer front side members
3.2. Cut through the outer front side member in area -A- . See Fig. 342.

Microsoft
4.1. Grind both sides of the connecting flanges of the outer front side member in the marked areas -A, B, C-
INSTALLING FRONT SIDE MEMBER (SECTION)

safety components!
protective mask.
beginning work.
Installing front side member (section)
Microsoft
Only for vehicles on which the wheel housing and floor front section have been
removed.
1. Install front wheel housing (section). --> 507455 Replacing front wheel housing (section) - section on
"Removing"
2. Fitting in outer and inner front side members
2.1. Place the outer and inner front side members on the body and secure to the straightening set for the impact
absorbers.
2.2. Fix the outer and inner front side members in place with tensioning clamps.
Fig. 344: Welding in outer and inner front side members

3. Welding in outer and inner front side members
3.1. Resistance spot-weld the outer and inner front side members in areas -A, B, C, D, E- . See Fig. 344.
Microsoft

4. Welding in outer front side member

5. Welding in inner front side member
Microsoft
NOTE: Only for vehicles on which the wheel housing and floor front section have been
removed.
7. Install front closing panel. --> 501055 Replacing front end plate - section on "Installing"
SUBSEQUENT WORK
50 79 55 REPLACING FRONT SIDE MEMBER (SECTION) - AS OF MY 2005

(ALL EXCEPT BOXSTER S RHD)
TOOLS

PS 1, see Gr. 3.5;
Workshop Equipment
Manual
dimensions
Microsoft

TOOLS AND MATERIALS
Tools and materials
00000
Microsoft
attachment set.
REMOVING FRONT SIDE MEMBER (SECTION)
Removing front side member (section)
Fig. 347: Installation position of front side member

1. Remove front closing panel. --> 501055 Replacing end plate - section on "Removing"
Microsoft
NOTE: If you are sure there has been no deformation of the wheel housing and floor
front section structure, the cuts can be made without removing the wheel
housing and floor front section for the following repair work.
2. Remove front wheel housing (section). --> 507455 Replacing front wheel housing (section) - section on
"Removing"
3. Remove floor front section. --> 502055 Replacing floor front section - removing

 Cuts can only be made on the inner front side member at dimension
-X= 30 mm- , in the marked areas -A- and -B- in front of the tailored
blank (laser weld) -1, 2- against the direction of travel. See Fig. 348.
NOTE: Possible separation points on inner front side member.

Microsoft

4.1. Determine possible cut on the inner front side member at dimension -X= 30 mm- in front of the tailored
blank (laser weld) -1- . Mark the cut. See Fig. 349.
Fig. 350: Cutting through inner front side member

5. Cutting through inner front side member
5.1. Cut through the inner front side member at the marked separation point -A- using the oscillating body saw.
Microsoft


Microsoft
7.1. Mark cut on the outer front side member depending on the damage at dimension -X= min. 50 mm- in front
of the inner tailored blank (laser weld) against or in the direction of travel. See Fig. 352.
Fig. 353: Cutting through outer front side member

8. Cutting through outer front side member
8.1. Cut through the outer front side member at the marked separation point -A- using the oscillating body saw.
Microsoft

PREPARING CONNECTION AREAS OF THE BODY FOR INSTALLING THE FRONT SIDE
MEMBERS (SECTION)
welding work!

Preparing connection areas of the body for installing the front side members (section)
Microsoft

FITTING IN FRONT SIDE MEMBER AND PREPARING FOR INSTALLATION
Fitting in front side member and preparing for installation
Microsoft
Fig. 356: Transferring cut to the inner front side members

1. Transferring cut to the inner front side members
1.2. Cut through the inner front side member in area -A- . See Fig. 356.

Microsoft
2.1. Grind both sides of the connecting flanges of the inner front side member in the marked areas -A, B, C-
Fig. 358: Transferring cut to the outer front side members

3. Transferring cut to the outer front side members
3.2. Cut through the outer front side member in area -A- . See Fig. 358.

Microsoft
4.1. Grind both sides of the connecting flanges of the outer front side member in the marked areas -A, B, C-
INSTALLING FRONT SIDE MEMBER (SECTION)

safety components!
protective mask.
beginning work.
Installing front side member (section)
Microsoft
Only for vehicles on which the wheel housing and floor front section have been
removed.
1. Install front wheel housing (section). --> 507455 Replacing front wheel housing (section) - section on
"Removing"
2. Fitting in outer and inner front side members
2.1. Place the outer and inner front side members on the body and secure to the straightening set for the impact
absorbers.
2.2. Fix the outer and inner front side members in place with tensioning clamps.
Fig. 360: Welding in outer and inner front side members

3. Welding in outer and inner front side members
3.1. Resistance spot-weld the outer and inner front side members in areas -A, B, C, D, E- . See Fig. 360.
Microsoft

4. Welding in outer front side member

5. Welding in inner front side member
Microsoft
NOTE: Only for vehicles on which the wheel housing and floor front section have been
removed.
7. Install front closing panel. --> 501055 Replacing front end plate - section on "Installing"
SUBSEQUENT WORK
50 87 19 REMOVING AND INSTALLING COWL PANEL COVER - AS OF MY

2005 (ALL MODELS)
PRELIMINARY WORK
Preliminary work
1. Remove right and left wiper arm. Refer to 92 25 19 Removing and installing wiper arm - as of MY 2005
(All Models) .
2. Remove battery cover. Refer to 27 06 19 Removing and installing battery - as of MY 2005 (All Models) .
3. Remove left and right cover. Refer to 85 22 19 Removing and installing cover - as of MY 2005 (All
Models) .
REMOVING COWL PANEL COVER
Removing lateral cap
Microsoft
Fig. 363: Installation location of cowl panel cover

Microsoft

1. Unclip lateral cap.
Removing upper cowl panel cover
Microsoft

Microsoft
Fig. 366: Removing upper cowl panel cover

1. Unscrew fastening nuts -1- . Remove spacer sleeve -2- , spring element -3- and sliding plate -4- in upward
direction. See Fig. 366.
2. Unscrew fastening screw -5- in the center. See Fig. 366.
Removing upper cowl panel cover
Microsoft

Microsoft
Fig. 368: Removing upper cowl panel cover

1. Unscrew fastening nuts -1- . Remove clamping bush -2- , spring element -3- and sliding plate -4- in upward
direction. See Fig. 368.
2. Unscrew fastening screw -5- in the center. See Fig. 368.
Disconnecting plug connection of spray nozzle for windscreen washer system
Microsoft

Microsoft
Fig. 370: Disconnecting plug connection of spray nozzle

1. Release electric plug connection for right and left spray nozzle -Arrow A- and pull apart. See Fig. 370.
Disconnecting water line for windscreen washer system
Microsoft

Fig. 372: Disconnecting water line for windscreen washer system

1. Rotate water line in -direction of Arrow A- and pull off -Arrow B- . See Fig. 372.
Disconnecting plug connection for GPS antenna

Microsoft

Fig. 374: GPS plug connection.

Microsoft
NOTE: Only for vehicles with GPS antenna.
1. Under the cover for the cowl panel, release the electric plug connection -A- and remove. See Fig. 374.
Disconnecting plug connection for radio antenna

CAUTION: Voltage peaks can damage the audio system.
--> Before unplugging/removing audio components, remove ignition key and switch off audio system.
Microsoft
Fig. 376: Disconnecting plug connection for radio antenna

NOTE: Only for vehicles with radio antenna.
1. Unclip the retaining clamps for the antenna line. Disconnect antenna line and undo the fastening screws -1- .
See Fig. 376.
Removing lower cowl panel cover
Microsoft

Microsoft
Fig. 378: Removing lower cowl panel cover

NOTE: Two persons are needed to remove the cowl panel cover!
1. Unscrew fastening screws -1- and carefully remove cowl panel cover -2- upwards. See Fig. 378.
INSTALLING COWL PANEL COVER
Installing cowl panel cover
Microsoft

Microsoft
Fig. 380: Installing cowl panel cover

NOTE: Two persons are needed to remove the cowl panel cover!
1. Insert cowl panel cover -2- in the plenum panel and align. See Fig. 380.
2. Tighten fastening screws -1- . Tightening torque --> Tightening torque: 1.5 ftlb. See Fig. 380.
Locking plug connection for radio antenna
Microsoft

Microsoft
Fig. 382: Disconnecting plug connection for radio antenna

NOTE: Only for vehicles with radio antenna.
1. Connect the antenna line and clip on the fuse.
2. Slide antenna onto its support and screw it down with the fastening screws -1- . See Fig. 382.
Locking plug connection for GPS antenna
Microsoft

Fig. 384: Locking plug connection for GPS

NOTE: Only for vehicles with GPS antenna.
Microsoft
1. Push on the electric plug until it clicks into place.
Locking water line for windscreen washer system

Microsoft
Fig. 386: Locking water line for windscreen washer system

1. Connect water line -Arrow A- and rotate in -direction of Arrow B- . See Fig. 386.
Locking plug connection of spray nozzle for windscreen washer system

Microsoft
Fig. 388: Locking plug connection of spray nozzle for windscreen washer system
1. Push on electric connector for spray nozzle until it clicks into place.
Securing upper cowl panel cover
Microsoft

Microsoft
Fig. 390: Securing upper cowl panel cover

1. Insert sliding plate -4- , spring element -3- and clamping bush -2- . Tighten fastening nuts -1- . See Fig. 390.
2. Tighten fastening screw -5- . See Fig. 390.
Installing lateral cover cap
Microsoft


Microsoft
Fig. 393: Clipping lateral cap into place

1. Clip lateral cap into place.
SUBSEQUENT WORK
Subsequent work
1. Install right and left wiper arm. Refer to 92 25 19 Removing and installing wiper arm - as of MY 2005 (All
Models) .
2. Install right and left cover. Refer to 85 22 19 Removing and installing cover - as of MY 2005 (All
Models) .
Microsoft
3. Install battery cover. Refer to 27 06 19 Removing and installing battery - as of MY 2005 (All Models) .
Microsoft
ACCESSORIES & EQUIPMENT Glazing, window control
Glazing, window control
64 12 IN GENERAL INFORMATION ON INSTALLING AND REMOVING CAR

WINDOWS - AS OF MY 2005 (ALL MODELS)
TOOLS

Glass separating tool commercially VAG 1474 B
available tool
REMOVING GLASS WITH CUTTING WIRE SEPARATOR
Danger of injury when working on car windows
WARNING: Danger of cut injuries when removing and installing car windows!
 Cutting out glued car windows may lead to cut injuries to the skin
and eyes due to flying glass splinters and may result in cut injuries
from the knife of the cutter.
--> Always wear protective gloves when working on car windows.
--> Wear protective goggles when cutting out car windows.
--> Only replace the cutting knife with the power supply disconnected so that the cutter is not switched on
accidentally.
Material damage when removing the glass from car windows
CAUTION: Danger of damage to the label with the vehicle identification number!
 Danger of paint damage and damage to the label with the vehicle
identification number if windscreen is removed incorrectly!
--> When cutting out the windscreen, ensure that the label with the vehicle identification number is not
damaged!
Removing glass with cutting device - wire separator
Microsoft
NOTE:  The following instructions describe the general procedure for removing
car windows with the glass separating tool VAG 1474 B.
 Information on procedures relating to specific vehicles can be obtained from the instructions in the
corresponding chapters in the Technical Manual.
NOTE:  It is generally possible to remove the windscreen with the cutting wire and
the optional cutting thread contained in the tool set.
 In contrast to cutting threads, however, the cutting wire has the following disadvantages:
 Danger of injury when tearing off the cutting wire.
 Danger of damage to materials on paint surfaces and interior equipment parts.
 For the reasons outlined above we recommend using the cutting thread.
Fig. 1: Glass separating tool

A Glass separating tool VAG 1474 B
B Cutting thread
A1 Guide rail
A2 Cutting tool (wire holder)
Microsoft
A3 Spooling device
A4 Awl
A5 Guide rail
A6 Filler
A7 Steering roller with arm bracket
A8 Handle
A9 Square cutting wire
Contains component set A1-A9 and protective film for dashboard
Applying protective film to the dashboard
NOTE:  In order to guarantee an optimum fastening intake grip, it is advisable to

clean the inside of the glass before removal.
NOTE:  The film protects the damping mat against damage when removing the
glass.
1. Cleaning glass on the inside
Microsoft
Fig. 2: Applying protective film to the dashboard

2. Apply protective film to the dashboard. Select the appropriate film -1- and insert between windscreen and
damping mat. See Fig. 2.
Guiding cutting thread into the passenger compartment
NOTE:  In order to prevent damage, make sure that the vehicle identification
number is completely covered by the protective film when pushing
through the adhesive bead.
 Warm awl beforehand with the hot-air gun for pushing this through.
Microsoft
Fig. 3: Guiding cutting thread into the passenger compartment

1. Push through adhesive bead on the glass on the edge of the vehicle identification number -C- with the awl -
A4- from the inside to the outside. See Fig. 3.
2. Pass cutting thread -B- through the eyelet on the awl -A4- . See Fig. 3.
3. Pull cutting thread -B- into the passenger compartment. See Fig. 3.
4. Pull cutting thread -B- out of the awl -A4- . See Fig. 3.
5. Draw cutting thread -B- approx. 1m into the passenger compartment. See Fig. 3.
Guiding cutting thread into the gap in the glass
NOTE:  The cutting thread should be positioned under the rim as far as possible.
The sealing lip must be raised slightly in the upper part of the glass in
order to pull the cutting thread through.
Microsoft
Fig. 4: Guiding cutting thread into the gap in the glass

1. Pull cutting thread -B- in the direction of the arrow through the gap between the glass and the body. Use filler
if necessary. See Fig. 4.
Attaching cutting thread to the body
Microsoft
Fig. 5: Attaching cutting thread to the body

1. Attach the loose end of the cutting thread -B- firmly at a suitable point on the body with the fastening screw -
2- of a component (e.g. wiper motor fastening). To do this, unscrew the fastening screw, wind the cutting thread
-B- around the screw and tighten the fastening screw again. See Fig. 5.
Attaching cutting thread to the spooling device
Microsoft
Fig. 6: Attaching cutting thread to the spooling device

1. Undo clamping screw -3- . See Fig. 6.
2. Insert cutting thread -B- into the bore on the spooling device -A3- . See Fig. 6.
3. Attach cutting thread -B- firmly with the clamping screw -3- . See Fig. 6.
Installing spooling device and deflection rollers on the glass
Microsoft
Fig. 7: Installing spooling device and deflection rollers on the glass

1. Position spooling device -A3- diagonally in the center of the glass. See Fig. 7.
2. Press spooling device -A3- with the fastening intakes firmly against the glass. See Fig. 7.
3. Fix fastening intake onto the glass by moving the actuating lever.
Separating glass as far as P1
Microsoft
Fig. 8: Separating glass as far as P1

1. Separate glass by spooling the cutting thread on the spooling device as far as point -P1- . See Fig. 8.
Repositioning spooling device
Microsoft
Fig. 9: Repositioning spooling device

1. Release spooling device.
2. Release the lower fastening intake on the spooling device.
3. Pull cutting thread through onto the other side of the fastening intake.
NOTE:  The fastening force can be increased by moistening the fastening intake.
Microsoft

1. Position deflection roller in the lower right corner.
2. Press deflection roller with fastening intake firmly against the glass.
4. Pass cutting thread over the deflection roller onto the spooling device.
Microsoft

2. Position deflection roller in the upper right corner.
Repositioning spooling device
Microsoft
Fig. 12: Repositioning spooling device

2. Release the upper fastening intake on the spooling device.
3. Pull cutting thread through onto the other side of the fastening intake.
Microsoft

1. Position deflection roller in the upper left corner.
5. Separate glass by spooling the cutting thread on the spooling device as far as point -P4- using the guide rails.
See Fig. 13.
Microsoft

2. Position deflection roller in the lower left corner.
7. Remove the windscreen.
Cutting power when removing glass with cutting thread
Microsoft
Fig. 15: High cutting power

NOTE:  The power for separating the glass is weaker when the cutting thread is
deflected to its maximum point. An angle greater than 90° should be
avoided.
Microsoft
Fig. 16: Average cutting power

Unfavorable angle (strong traction required)
Microsoft
Fig. 17: Low cutting power

Favorable angle (average traction required)
Optimum angle (minimum traction required)
64 16 23 REMOVING AND INSTALLING SEAL FOR WINDSCREEN - AS OF

INSTALLING SEAL FOR WINDSCREEN
Fitting windscreen seal
NOTE: The bonding surfaces must be clean and free of grease.
Microsoft
Fig. 18: Fitting the windscreen seal

- Stick seal -1- to the windscreen -2- from one edge along the entire border. See Fig. 18.
64 40 49 REWORKING (COATING) FRONT DOOR WINDOW - AS OF MY 2005

(ALL MODELS)
Warning note on hydrophobic window
WARNING: Coating of windows
 Fogging, dazzling and danger of accident!
--> Hydrophobic coating is approved by the Porsche AG for the door windows only.
Checking front door window
Microsoft
Fig. 19: Installation position of door windows

NOTE:  The hydrophobic coating has a very long life. If the hydrophobic coating
deteriorates, the side window can be recoated without any special
measures being required.
 You can see if reworking (coating) is required by checking how droplets form.
Spray on water using a water spray bottle with an atomizer and check the hydrophobic layer from the droplet
formation.
Microsoft
Fig. 20: Droplet formation - hydrophobic door window OK

- Droplet formation - hydrophobic door window OK
Microsoft
Fig. 21: Droplet formation - hydrophobic door window coating worn

- Droplet formation - coating worn.
PRELIMINARY WORK
Mixing the components
NOTE: Once mixed, hydrophobic coating agent must be used within 24 hours!
1. Pour the entire contents of the Component 2 bottle into the Component 1 bottle.
2. Close the bottle tightly again and shake well immediately for at least three minutes.
Cleaning the surface
NOTE: Immediately after buffing, the side window should be coated.
1. Clean the side window with a commercially available glass cleaner
2. Shake the polish well before use.
3. Dampen polishing cloths with water, apply polish and buff for several minutes.
4. Allow polish film to dry and then remove completely.
Reworking (coating) front door window
NOTE:  Do not let the hydrophobic coating come into contact with water for at
least 30 minutes after applying the coating.
1. Apply hydrophobic coating agent as a liquid film extensively over the surface and immediately rub evenly
with a paper towel.
2. After buffing, a grey bloom forms over the treated surface. This grey bloom must be completely polished off
with a new, dry and clean paper towel.
3. Afterwards the coating should be kept free of water or other liquids for at least 30 minutes.
Coating agent that has begun to dry can be softened up by rubbing with the aid of the still soaking towel and
then rubbed off with a clean paper towel.
64 12 IN PROCESSING OF PORSCHE 2-COMPONENT WINDOW BONDING

AGENTS - AS OF MY 2005 (ALL MODELS)
Microsoft
TOOLS

2-component window commercially 000.043.300.94
bonding agent available tool
Flashing knife, U-type commercially 639.031.130.22
available tool
Pipette commercially vag 1344

available tool
Special electric cutter commercially vag 1561 a
(fine) available tool
Double cartridge gun commercially vas 5237
available tool
TOOLS AND MATERIALS
Tools and materials for installing car windows
Fig. 22: Tools and materials for installing car windows

Double cartridge gun vas --> "See Workshop

Microsoft
5237 Equipment Manual,

-A-
Chapter 3.5 "
--> "See Workshop
-B- Pipette vag 1344 Equipment Manual,
Chapter 3.5 "
--> "See Workshop
Special electric cutter (fine)
-C- Equipment Manual,
vag 1561 a
Chapter 3.5 "
--> "See Workshop
Flashing knife, U-type
-D- Equipment Manual,
639.031.130.22
Chapter 3.5 "
2-component window --> "See Parts Catalogue
-H- Contains set components H1-H8
bonding agent 000.043.300.94 in Main Group 8 "

-H1- Cleaning solution -H5- Cartridge, component A
-H2- Primer -H6- Cartridge, component B
-H3- Activator -H7- Mixing nozzle
-H4- Swab -H8- Processing nozzle
PRE-TREATMENT OF BONDING SURFACES
Pre-treating adhesive flanges on vehicle windows
NOTE:  The table below shows how to use cleaners, primers and activators when
preparing the adhesive surface.
Preparing the body glass for installation

Old glass New glass
(window removed) with preliminary coat (durable primer)
Cleaner ?
Cut back adhesive bead?
Clean rim (ceramic layer and durable primer)?
Activator ? Primer ?
Activate adhesive bead (only necessary after idle Apply primer from the adhesive kit over the
periods > 24 h) ? durable primer on the spare part?
Apply adhesive
Install glass
Pre-treating adhesive flanges on vehicle body
NOTE:  The table below shows how to use cleaners, primers and activators when
preparing the adhesive surface.
Microsoft
Preparing the window flange for installation

Old flange (old paint job) New flange (new paint job)
Cleaner ?
Cut back adhesive bead?
Clean flange surface ?
Activator ? Primer ?
Activate adhesive bead (only necessary after
Prime flange surface ?
idle periods > 24 h) ?
Apply adhesive
Install glass
HANDLING PROCESSING DEVICE
Double cartridge press
CAUTION: Danger of poisoning and injury when handling adhesive!
 Danger of poisoning from breathing in vapors or from swallowing

adhesive.
 Risk of injury due to contact with skin or eyes.
--> Do not eat, drink, or smoke while carrying out work.
--> Avoid direct contact with eyes and skin. Wear suitable protective equipment, such as protective clothing,
gloves, and if necessary, a protective mask.
--> If clothing is soiled with adhesive, change clothing immediately and only use again after they have been
cleaned.
--> Also observe the product-specific processing and safety instructions on the packing container and packing
container imprints.
--> In case of eye contact: Rinse eyes immediately and thoroughly with lukewarm running water and consult an
eye doctor.
--> In case of skin contact: Rinse contacted skin areas immediately with lukewarm running water and soap.
--> If adhesive is swallowed: Rinse mouth and consult a doctor.
NOTE:  In addition to this manual, observe the relevant job descriptions for
installing car windows!
Microsoft
Fig. 23: Piercing membrane in nozzle with screwdriver

1. Preparing cartridge components A and B
1.1. Pierce the membrane in the nozzle connection of components A and B (aluminum cartridge) -H5, H6- with
a screwdriver and extend the opening. See Fig. 23.
1.2. Remove flanged cover on end of cartridge.
Microsoft
Fig. 24: Screw on mixing nozzle

2. Screw on mixing nozzle.
2.1. Screw both cartridges -H5, H6- onto the mixing nozzle. See Fig. 24.
Microsoft
Fig. 25: Placing cartridges in the double cartridge gun

3. Placing cartridges in the double cartridge gun
3.1. Move pressure piston back fully.
3.2. Insert the double cartridges -H5, H6- into the bonding gun -A- . See Fig. 25.
Microsoft
Fig. 26: Press out the adhesive

4. Press out the adhesive
4.1. By activating the valve -arrow- allow the pressure piston to move out slowly until both components of the
adhesive are visible at the mixing nozzle. See Fig. 26.
4.2. Wipe off the emerging adhesive.
Microsoft
Fig. 27: Screwing on processing nozzle

5. Screwing on processing nozzle
5.1. Screw processing nozzle -H8- onto the mixing nozzle -H7- . See Fig. 27.
Microsoft
Fig. 28: Align processing nozzle

6. Align processing nozzle.
6.1. Turn the processing nozzle on the mixing nozzle until the illustrated position is reached.
7. Mixing adhesive components.
7.1. By activating the valve -arrow- allow the pressure piston to move out slowly until the adhesive is visible in
the processing pipe. See Fig. 29.
Microsoft
Fig. 29: Cartridge gun activation valve

NOTE: In this position, when the mixing nozzle is horizontal, the closed surfaces must
be visible on the processing nozzle from above and below and the mixer
insert's mixing plates must be visible from the sides.
8. Affixing car window.
Microsoft
Fig. 30: Adhesive has an open time

NOTE:  The bonding material has an open time of 15 min ,
which means that the bonding material must be applied and the car window must be assembled within this
period of time.
 In order to ensure that the substance is completely mixed, apply a 30 mm long adhesive bead of fresh
adhesive to a piece of cardboard before processing.
64 12 19 REMOVING AND INSTALLING WINDSCREEN - AS OF MY 2005

(ALL MODELS)
TOOLS

Cutting thread commercially
available tool
2-component window commercially 000.043.300.94
bonding agent available tool
Flashing knife, U-type commercially 639.031.130.22
available tool
Microsoft
Pipette commercially vag 1344

available tool
Glass separating tool commercially vag 1474 b
available tool
Special electric cutter commercially vag 1561 a
(fine) available tool
Double cartridge gun commercially vas 5237
available tool
PRELIMINARY WORK
Preliminary work
Remove cowl panel cover. Refer to 50 87 19 Removing and installing cowl panel cover - as of MY 2005 (All
Models) .
Remove A-pillar linings. Refer to 70 57 19 Removing and installing A-pillar trim - as of MY 2006 (Cayman
S, Cayman S RHD) . Refer to 70 57 19 Removing and installing A-pillar trim - as of MY 2005 (Boxster,
Remove dashboard cover (defroster trim). Refer to 70 20 19 Removing and installing cover for dashboard
(defroster trim) - as of MY 2005 (All Models) .
Remove interior rear-view mirror.
Disconnect plug connection for antenna amplifier. Refer to 91 84 19 Removing and installing antenna
amplifier - as of MY 2005 (All Models) .
--> 64 12 IN General information on installing and removing car windows - as of MY 2005 (All Models).
TOOLS AND MATERIALS
Tools and materials
The following tools and materials are required for removing and installing the windscreen with 2-component
adhesive:
Microsoft

Item. Designation Source Explanation

--> "See Workshop
Double cartridge gun vas
-A- Equipment Manual,
5237
Chapter 3.5"
--> "See Workshop
-B- Pipette vag 1344 Equipment Manual,
Chapter 3.5"
--> "See Workshop
Special electric cutter (fine)
-C- Equipment Manual,
vag 1561 a
Chapter 3.5"
Flashing knife, U-type
-D-
639.031.130.22
2-component window
-H- Contains set components H1-H8
bonding agent 000.043.300.94
Item. Designation Item. Designation

-H1- Cleaning solution -H5- Cartridge, component A
-H2- Primer -H6- Cartridge, component B
-H3- Activator -H7- Mixing nozzle
-H4- Swab -H8- Processing nozzle
Microsoft
Fig. 32: Glass separating tool


--> "See Workshop
Glass separating tool vag
-A- Equipment Manual, Contains set components A1-A9
1474 b
Chapter 3.5"
-B- Cutting thread See Fig. 148.
in Main Group 8"

-A1- Guide rails -A6- Filler
-A2- Cutting tool (wire holder) -A7- Steering roller with arm bracket
-A3- Spooling device -A8- Handle
-A4- Awl -A9- Square cutting wire
-A5- Guide rails
REMOVING WINDSCREEN
Removing spacer blocks
Microsoft
Fig. 33: Removing spacer blocks

1. Insert a spatula under the spacer blocks -1- and remove the expanding rivets. Spacer blocks -1- must be
replaced. See Fig. 33.
Removing windscreen
NOTE:  The door windows must not be closed until after the curing time has
elapsed.
1. Lower the door windows.
Microsoft
Fig. 34: Removing windscreen

2. Remove windscreen with the cutting wire separator. --> 64 12 IN General information on installing and
removing car windows - as of MY 2005 (All Models).
PREPARING WINDOW FRAME FOR INSTALLATION
Removing adhesive from the body
NOTE:  The surface coating of adhesive residue on the window aperture of the
body acts as an adhesive base for new bonding material. Keep cut
surfaces clean and free of grease and do not clean with cleaning solution.
Microsoft
Fig. 35: Removing adhesive from the body

1. When removing remaining adhesive -2- with the cutting tool -C- and the flashing knife -D- on the body,
ensure that a surface coating of adhesive remains -3- . See Fig. 35.
Cleaning and priming areas that are free of adhesive residue or have paint damage or where there is newly built-up
paint in the window aperture of the body
NOTE:  A flash-off time of at least 2 minutes must be observed between the

cleaning of the window aperture and the application of the primer! No
cleaning solution residues must remain on the body.
Microsoft
Fig. 36: Cleaning and priming the body

1. Clean areas that are free of adhesive residue or have new paint or where there is damage to the top coat paint
in the non-visible area of the window aperture in the body with cleaning solution -H1- and touch up with
primers -H2- . See Fig. 36.
PREPARING WINDSCREEN FOR INSTALLATION
Removing windscreen seal
NOTE:  Only if the windscreen is re-installed
Microsoft
Fig. 37: Pull off the seal

1. Pull off the seal -4- . Remove adhesive residues with cleaning solution -H1- . See Fig. 37.
Removing adhesive from the windscreen
NOTE:  The remaining adhesive helps new adhesive to stick. Keep cut surfaces
clean and free of grease and do not clean with cleaning solution.
Microsoft
Fig. 38: Removing adhesive from the windscreen

1. Equip cutting device -C- with the flashing knife -D- and remove the remaining adhesive from the
windscreen, ensuring that a surface coating of adhesive remains. See Fig. 38.
Fitting windscreen seal
Microsoft
Fig. 39: Fit the windscreen seal

1. Stick seal -4- to the windscreen -5- from one edge along the entire border. See Fig. 39.
Marking the bonding area
NOTE:  Only if the windscreen is new and does not have a preliminary coat
Microsoft
Fig. 40: Marking the bonding area

1. Before applying the adhesive, mark the course of the adhesive bead in accordance with the dimensions -E- =
160 mm, -F- = 30 mm on the left and right on the lower edge of the windscreen. See Fig. 40.
Activating the bonding section of the windscreen
Microsoft
Fig. 41: Activating the bonding section of the windscreen

1. During long idle periods (> 24 hours) apply activator -H3- to the remaining adhesive. See Fig. 41.
Priming the windscreen
NOTE:  Only with new windscreens
NOTE:  A ventilation period of at least 2 minutes must be observed between the

cleaning of the glass and the application of the primer! No cleaning
solution residues may remain on the body.
1. Clean the windscreen with cleaning solution -H1- . See Fig. 42.
Microsoft
Fig. 42: Priming the windscreen

2. Apply primer -H2- to the glass flange in the area of the marking. See Fig. 42.
INSTALLING WINDSCREEN
Preliminary work before windscreen installation
NOTE:  The removed windscreen can be reinstalled if there was no prior damage
to the windscreen and the windscreen was removed without damage.
1. Clip in spacer blocks and press in body-bound rivets.
2. Install dashboard cover (defroster trim). Refer to 70 20 19 Removing and installing cover for dashboard
(defroster trim) - as of MY 2005 (All Models) .
Fitting windscreen into the body
NOTE:  Two persons are needed to insert and adjust the windscreen.
NOTE:  Owing to the bonding section, the windscreen can no longer be aligned on
the seal because the section immediately adheres to the windscreen when
inserted.
Microsoft
Fig. 43: Fitting windscreen into the body

1. Apply suction cups -B- to the windscreen -5- and insert the windscreen into the window aperture. Press the
windscreen -5- up as far as it will go. When doing so, press the lower edge of the glass against the spacer
blocks. Mark the windscreen with adhesive tape -6- and remove. See Fig. 43.
Preparing 2-component adhesive for processing
NOTE:  The adhesive has an open time of -15 min- , which means that the bonding
material must be applied and the car window must be assembled within
this period of time. See Fig. 44.
Microsoft
Fig. 44: Preparing the adhesive

1. Prepare 2-component bonding material for processing. --> 6412IN IN Processing of Porsche 2-component
window bonding agents
Applying adhesive to the windscreen
NOTE:  When applying the adhesive, it is essential to ensure that the adhesive
bead overlaps by approx. 30 mm at the beginning and at the end.
Microsoft
Fig. 45: Apply adhesive

1. Using the bonding gun -A- , apply 2-component adhesive to the windscreen along the seal -4- in the form of a
triangular bead measuring -X= ca. 15 mm- -Y= ca. 8 mm- . See Fig. 45.
Pulling off protective film
NOTE:  Make sure that no further work is performed in the area of the seal once
the protective film has been removed.
1. Before bonding the windscreen, remove the protective film from the seal such that no residues remain.
Inserting windscreen into the body

observed!

Microsoft
NOTE:  Two persons are needed to insert and adjust the windscreen.
NOTE:  The rear window can no longer be aligned, because the bonding section
on the seal immediately sticks to the body when the rear window is
installed.
Fig. 46: Insert the windscreen

1. Guide the windscreen -5- into the window aperture and insert in the pre-marked positions. See Fig. 46.
Cleaning fields of vision
NOTE:  The door windows must not be closed until after the curing time has
elapsed.
1. Adhesive which has oozed out must be removed immediately and the affected fields of vision must be
cleaned using cleaning agent -H1- .
SUBSEQUENT WORK
Microsoft
Subsequent work
1. Install cowl panel cover. Refer to 50 87 19 Removing and installing cowl panel cover - as of MY 2005 (All
Models) .
2. Connect plug connection for antenna amplifier. Refer to 91 84 19 Removing and installing antenna
(Cayman S, Cayman S RHD) . Refer to 70 57 19 Removing and installing A-pillar trim - as of MY 2005
NOTE:  Only with new windscreens
4. Bond on interior rear-view mirror.
NOTE:  The interior rear-view mirror may only be installed after a curing time of
three hours!
5. Installing the interior rearview mirror.
6. Close door windows.
64 37 19 REMOVING AND INSTALLING MICROSWITCH FOR WINDOW

OPENING CONTROLS - AS OF MY 2005 (ALL MODELS)
PRELIMINARY WORK
Preliminary work
1. Remove door unit carrier. Refer to 57 30 19 Removing and installing door unit carrier - as of MY 2005
(All Models) .
REMOVING MICROSWITCH FOR WINDOW OPENING CONTROLS
Unclipping electric line for micro switches
Microsoft
Fig. 47: Install location for window opening microswitch

Fig. 48: Unclipping line

1. Unclip electric line for microswitch -1- from the bottom part of door opener -2- . See Fig. 48.
Removing microswitch for window opening controls

Microsoft

Microsoft
Fig. 50: Removing microswitch

2. Pull bottom section of door opener -2- slightly backwards. See Fig. 50.
NOTE:  Make sure that the locking tabs do not break when the microswitch is
removed.
3. Gently loosen the locking tab -Arrow A- and remove the microswitch -3- -Arrow B- . See Fig. 50.
INSTALLING MICROSWITCH FOR WINDOW OPENING CONTROLS
Microsoft
Installing microswitch for window opening controls

Microsoft
Fig. 52: Installing microswitch

1. Position microswitch -3- on the door opener -4- and press in until it can be felt to engage. See Fig. 52.
2. Position the lower part of the door opener -2- under the handle and screw down with fastening nuts -1- .
Tightening torque --> Final tightening: 7 ftlb. See Fig. 52.
Clipping in the electric line for micro switches
Microsoft

Fig. 54: Clipping in line

1. On the bottom part of door opener -2- clip in the electrical line -1- . See Fig. 54.
SUBSEQUENT WORK
Microsoft
Subsequent work
1. Install door unit carrier. Refer to 57 30 19 Removing and installing door unit carrier - as of MY 2005 (All
Models) .
64 40 19 REMOVING AND INSTALLING FRONT DOOR WINDOW - AS OF MY

2005 (ALL MODELS)
PRELIMINARY WORK
Preliminary work
Fig. 55: Raising front door window

1. Raise front door window -1- . See Fig. 55.
Models) .
REMOVING FRONT DOOR WINDOW
Removing front door window
Microsoft
Fig. 56: Installation position of front door window

Fig. 57: Removing plastic lid

1. Remove plastic lid. Fastening screws are then accessible.
Microsoft
Fig. 58: Detaching door window

2. Loosen fastening screw -1- of the clamping jaws at the front and rear by 2 turns. See Fig. 58.
Microsoft
Fig. 59: Removing door window

3. Pull front door window -1- upwards out of the door channel -arrow- . See Fig. 59.
INSTALLING FRONT DOOR WINDOW
Installing front door window
CAUTION: Door glass can become soiled during installation!
 Risk of irreparable damage to front window shaft seal!
--> During installation, make sure that no lubricant (grease) gets onto the door glass from the window guides.
Clean door glass if necessary and check front window shaft seal for soiling, and replace the seal if necessary.

Microsoft
Fig. 61: Installing front door window

1. Insert front door window -1- into the door channel -Arrows- and position in the clamping jaws -2- . See Fig.
61.
2. Press the door window down as far as it will go -Arrow- into the clamping jaws. See Fig. 61.
Securing front door window
Microsoft

Fig. 63: Securing front door window

1. Slide door window -1- all the way forward into the window channel -A - A- and screw down the fastening
screw -2- on the front clamping jaw. Tightening torque --> Final tightening: 6.25 ftlb. +/-1 ftlb. . See Fig. 63.
Microsoft
Fig. 64: Securing door window

2. Raise rear clamping jaw -2- approx. 4 mm -A- and screw down fastening screw -1- . Tightening torque -->
Final tightening: 6.25 ftlb. +/-1 ftlb. . See Fig. 64.
Inserting door trim panel
Microsoft

Fig. 66: Lock plug connection to control unit.

1. Connect electrical plug connection -1- to control unit -2- by operating locking lever -3- and lock. See Fig. 66.
Microsoft
Fig. 67: Locking electrical plug connection

2. Lock electrical plug connection -arrow- until it engages audibly. See Fig. 67.
Microsoft
Fig. 68: Hooking in door trim panel

3. Hook front door trim panel into sealing channel at the top.
Standardizing the power windows
The system must be re-standardized after an interruption in the power supply to the power window electronics
in the door. The position values for the short-stroke lowering function, position-controlled lowering function in
the case of convertible top actuation and enabling for "automatic start-up of window closing" (one-touch
function) are redefined. The standardization process is initiated by continuous actuation of the operating button
Raise window.
- Hold down the Raise window button until the window is closed and is switched off by the blockage detection
function of the power windows.
Blockage detection function
NOTE:  If the window drive encounters resistance during the door window
movement, the motor is switched off after a delay of 500 ms.
Precondition for operation of the power windows
Ignition switched on.
Ignition key should not be removed from the steering lock with the ignition switched off.
The door is opened for the first time after switching off the ignition.
Door opened.
Adjusting the door window angle in the vehicle's longitudinal direction
Microsoft

1. Raise door window. Fastening screws are accessible.
2. Release electrical plug connections for door trim panel and remove door trim panel.
Fig. 70: Adjusting the door window angle in the vehicle's longitudinal direction
Microsoft
3. Adjust to equalize the angle of the door window on the clamping jaws of the driver (upwards or downwards)
-A- . Adjustment range: 10 mm See Fig. 70.
4. Tighten the fastening screw -1- on the clamping jaw -2- after completing the adjustment. Tightening torque --
> Final tightening: 6.25 ftlb. +/-1 ftlb. See Fig. 70.
Adjusting the door window height

NOTE:  The wax marking along the door window should be uniformly approx. 4
mm.
Microsoft
Fig. 72: Adjusting the door window height

NOTE:  The adjusting screws of the drivers for the upper limit stops for the door
window height are accessible through 2 holes at the bottom of the door.
1. Adjust the upper limit stops of the drivers by screwing the fastening screw in or out using socket E6 in or
against the direction of travel. Adjustment range: approx. 15 mm
NOTE:  The adjusting screws of the drivers for the upper limit stops for the door
window height are accessible through 2 holes at the bottom of the door.
2. Adjust the drivers so that they meet the upper limit stops at the same time.
Adjustment procedure:
3. Open the door.
4. Lock door lock with a screwdriver.
5. Re-insert the door trim panel (see Inserting door trim panel).
6. Move the power window regulator into its upper position.
Microsoft
7. Adjust door window height at the drivers so that the door window evenly projects approx. 2 mm above the
roof strip.
Fig. 73: Overlapping of door window to roof

Checking the adjustment
8. Close the door.
9. Use a wax marker to mark the door window along the roof strip.
10. Actuate the door opener until the window lowering function is activated. Lowering function adjustment
value: approx. 11 mm
11. The wax marking along the door window must have the dimension -X = ca. 4 mm- . Correct adjustment if
Adjustment of pressing force of door window edge against seal of convertible top at top and sides
Microsoft

Fig. 75: Adjustment of pressing force

NOTE:  The adjusting nuts of the power window unit rails for the pressing force of
the door window upper edge against the convertible top are accessible
Microsoft
through two holes at the bottom of the door.
1. Move the power window unit rails outwards or inwards by approx. 10 mm.
Adjustment procedure:
2. Open the door.
NOTE:  The adjusting nuts of the power window unit rails for the pressing force of
the door window upper edge against the convertible top are accessible
through two holes at the bottom of the door.
3. Move the power window regulator into its upper position and undo the fastening nuts on the power window
rails.
4. Adjust the power window unit so that the upper edge of the door window is sufficiently pressed against the
door seal at the side. Tightening torque --> Final tightening: 7.2 ftlb.
Checking the adjustment:
NOTE:  It should not be possible to pull out the sheet of paper along the B-pillar
when the door is closed.
- clamp a sheet of paper between the door window and door seal.
SUBSEQUENT WORK
Subsequent work
Models) .
64 48 19 REMOVING AND INSTALLING FRONT WINDOW SHAFT SEAL - AS

REMOVING FRONT WINDOW SHAFT SEAL
Removing the front window bay seal
Microsoft
Fig. 76: Installation position of front window bay seal

Fig. 77: Opening the front door window

1. Open the front door window -1- fully. See Fig. 77.
Microsoft
Fig. 78: Removing the front window bay seal

2. Pull front window bay seal -1- - beginning at the rear end -Arrow A- - off the sheetmetal door flange -2- in
an upward direction -Arrow B- . See Fig. 78.
3. Remove the front window bay seal -1- . See Fig. 78.
INSTALLING FRONT WINDOW SHAFT SEAL
Installing the front window shaft seal
Microsoft
Fig. 79: Installation position of front window shaft seal

CAUTION: Door glass can become soiled during installation!
 Risk of irreparable damage to front window shaft seal!
--> During installation, make sure that no lubricant (grease) gets onto the door glass from the window guides.
Clean door glass if necessary and check front window shaft seal for soiling, and replace the seal if necessary.
Microsoft
Fig. 80: Installing the front window shaft seal

NOTE:  Make sure horizontal alignment is correct (Arrows C, D).
1. Attach front window shaft seal -1- - starting at the front end -Arrow A- - to the sheetmetal door flange -2-
from above -Arrow B- . See Fig. 80.
Microsoft
Fig. 81: Closing the front door window

2. Close the front door window -1- fully. See Fig. 81.
64 52 19 REMOVING AND INSTALLING FRONT POWER WINDOWS - AS OF

PRELIMINARY WORK
Preliminary work
1. Remove door sub-frame. Refer to 57 30 19 Removing and installing door unit carrier - as of MY 2005
(All Models) .
2. Remove front door window. --> 644019 Removing and installing front door window - chapter on
"removing"
REMOVING FRONT POWER WINDOWS
Removing front power windows
Microsoft
Fig. 82: Installation position of front power windows


1. Remove rubber sleeves -1- . See Fig. 83.
Microsoft
Fig. 84: Unclipping cable

2. Unclip cable at retaining clip -1- . See Fig. 84.
Microsoft

3. Unscrew fastening nuts -2- on power windows -1- . See Fig. 85.
Microsoft
Fig. 86: Removing power windows

4. Fold power windows -1- together and remove through the door opening -arrow- . See Fig. 86.
INSTALLING FRONT POWER WINDOWS
Adjusting the lower stop of the power window unit
Microsoft

NOTE:  When replacing the power window unit, make sure that the correct
position of the lower limit stop is selected for the relevant vehicle model.
 There are three bores lying one above the other with the screwed-on limit stop in the front power window
unit rail.
 The limit stop must be fitted in the top bore for the 987 C7 model.
Microsoft
Fig. 88: Limit stop for power window unit

Installing front power windows

Microsoft
Fig. 90: Installing power windows

1. Fold power windows -1- together and insert through the door opening -arrows- . See Fig. 90.
Microsoft
Fig. 91: Securing power windows

CAUTION: Noises on the power windows due to interfacing the window lifter rails!
--> When moving the window lifter rails, they must be adjusted in parallel both during the first installation as
well as during subsequent adjustment.
2. First position the lower fastening points of the power windows -1- to the dimension -X = 5 mm- and tighten
with fastening nuts - 2- . Tightening torque --> Final tightening : 7 ftlb. See Fig. 91.
Microsoft

3. Then screw down the upper fastening points of the power windows -1- with the fastening nuts -2- .
Tightening torque --> Final tightening: 7.2 ftlb. See Fig. 92.
Microsoft
Fig. 93: Clipping in cable

4. Clip in cable at retaining clip -1- . See Fig. 93.
Microsoft
Fig. 94: Fitting rubber sleeve

5. Fit rubber sleeves -1- . See Fig. 94.
SUBSEQUENT WORK
Subsequent work
1. Install door sub-frame. Refer to 57 30 19 Removing and installing door unit carrier - as of MY 2005 (All
Models) .
2. Install front door window. --> 644019 Removing and installing front door window - chapter on
"installing"
64 52 19 REMOVING AND INSTALLING FRONT POWER WINDOWS - AS OF

PRELIMINARY WORK
Preliminary work
(All Models) .
Microsoft
2. Remove front door window. --> 644019 Removing and installing front door window - chapter on
"removing"
REMOVING FRONT POWER WINDOWS
Removing front power windows

Microsoft

Microsoft
Fig. 97: Unclipping cable

2. Unclip cable at retaining clip -1- . See Fig. 97.
Microsoft

3. Unscrew fastening nuts -2- on power windows -1- . See Fig. 98.
Microsoft
Fig. 99: Removing power windows

4. Fold power windows -1- together and remove through the door opening -arrow- . See Fig. 99.
INSTALLING FRONT POWER WINDOWS
Adjusting the lower stop of the power window unit
Microsoft

NOTE:  When replacing the power window unit, make sure that the correct
position of the lower limit stop is selected for the relevant vehicle model.
 There are three bores lying one above the other with the screwed-on limit stop in the front power window
unit rail.
 The limit stop must be fitted in the top bore for the 987 model.
Microsoft
Fig. 101: Limit stop for power window unit

Installing front power windows

Microsoft
Fig. 103: Installing power windows

1. Fold power windows -1- together and insert through the door opening -arrows- . See Fig. 103.
Microsoft

CAUTION: Noises on the power windows due to interfacing the window lifter rails!
--> When moving the window lifter rails, they must be adjusted in parallel both during the first installation as
well as during subsequent adjustment.
2. First position the lower fastening points of the power windows -1- to the dimension -X = 5 mm- and tighten
with fastening nuts - 2- . Tightening torque --> Final tightening : 7 ftlb. See Fig. 104.
Microsoft

3. Then screw down the upper fastening points of the power windows -1- with the fastening nuts -2- .
Tightening torque --> Final tightening: 7.2 ftlb. See Fig. 105.
Microsoft
Fig. 106: Clipping in cable

4. Clip in cable at retaining clip -1- . See Fig. 106.
Microsoft

SUBSEQUENT WORK
Subsequent work
Models) .
2. Install front door window. --> 644019 Removing and installing front door window - chapter on
"installing"
64 54 19 REMOVING AND INSTALLING POWER WINDOW MOTOR - AS OF

TOOLS

Microsoft
PRELIMINARY WORK
Preliminary work for power window motor
Refer to 70 59 19 Removing and installing door trim panel - as of MY 2005 (All Models) .
REMOVING POWER WINDOW MOTOR
Removing power window motor
Fig. 108: Installation position shown on the 997

1. If a new power window motor is to be installed, read out the values first. --> 645419 Removing and
installing power window motor - chapter on "installing"
Switch off ignition and remove ignition key.
Microsoft
Fig. 109: Release connector -a- and remove.

2. Unlock electric connector -a- and disconnect from power window motor. See Fig. 109.
Microsoft
Fig. 110: Unscrew fastening screws -1-.

3. Unscrew the three fastening screws -1- . See Fig. 110.
4. Pull the power window motor out of the teeth.
INSTALLING POWER WINDOW MOTOR
Installing power window motor
1. Position power window motor and push into the teeth.
Microsoft
Fig. 111: Screwing in fastening screws -1-

2. Screw in the three fastening screws. --> Tightening torque: 2 ftlb.
Microsoft
Fig. 112: Plugging in connector

3. Press in electric connector on power window motor until it is felt to engage.
NOTE: The end positions of the power windows are deleted from the control unit when
the electric connectors are disconnected and connected.
4. Operate rocker switch and fully close window once.
5. Operate rocker switch to close again. The upper end position of the side window is stored.
6. Operate rocker switch and fully open window once.
7. Operate rocker switch to open again. The lower end position of the side window is stored.
8. If a new power window motor has been installed (door control unit), this must be programmed/coded. -->
645419 Removing and installing power window motor - chapter on "programming"; --> 645419
Removing and installing power window motor - chapter on "coding".
SUBSEQUENT WORK
Subsequent work for window power motor
Microsoft
PROGRAMMING POWER WINDOW MOTOR (DOOR CONTROL UNIT)
Reading from and writing to the power windows motor (door control unit)
text or additions may appear in the PIWIS tester P 9718 .
Continue.
2. Select vehicle type using the cursor keys.
4. Select Door and press the >> key.
5. Select Control unit replacement and press the >> key.
6. Select Read out values (codings) and press >>.
7. The message Coding read-out complete appears on the screen of the Porsche System Tester >>.
8. Switch off ignition and replace control unit .
9. Switch to the Special functions menu and perform the vehicle handover using the F8 key.
10. In the Special functions menu, erase All fault memories by pressing >>.
12. In the menu Write in data >> , the data read-out is installed.
13. System Tester displays Codes successfully written in . Press >>.

Microsoft
15. Read out fault memory and, if necessary, erase it.
CODING POWER WINDOW MOTOR (DOOR CONTROL UNIT)
Coding the power windows motor (door control unit)
text or additions may appear in the PIWIS tester P 9718 .
7. Select Door and press the >>.
9. Select Memory via radio and code with F8.
Microsoft
Memory via radio

No
Yes
10. Select Mirror memory function and code with F8.
Mirror memory function

Installed
Not installed
11. Select Lock with Safe function and code with F8.
Lock with Safe function

Installed
Not installed
12. Select Synchronous mirror adjustment and code with F8.
Synchronous mirror adjustment

Off
On
13. Select Mirror lowering and code with F8.
Mirror lowering
Off
On
14. Select Comfort closing and code with F8.
Comfort closing
Off
On
15. Select Comfort opening and code with F8.
Comfort opening
Off
On
16. Select Door inner handle in normal driving and code with F8.
Microsoft
Door inner handle in normal driving

Inactive
Active
17. Select Manual transmission and code with F8.
Manual transmission
No
Yes
18. Read out fault memory and erase if required.
19. Door control unit is taught.
64 58 19 REMOVING AND INSTALLING SWITCH FOR POWER WINDOWS -

PRELIMINARY WORK
Preliminary work
Remove door trim panel. Refer to 70 59 19 Removing and installing door trim panel - as of MY 2005 (All
Models) .
REMOVING SWITCH FOR POWER WINDOWS
Removing switch for power windows
Microsoft
Fig. 113: Overview of switch for power windows

Fig. 114: Pulling connector off switch for power windows

1. Release -arrow a- and pull off connector. See Fig. 114.
Microsoft
Fig. 115: Removing switch for power windows

2. Lever off switch for power windows at the locking tab -arrow- ( -arrow A- ) and remove it. See Fig. 115.
INSTALLING SWITCH FOR POWER WINDOWS
Installing switch for power windows
Microsoft
Fig. 116: Installing switch for power windows

1. Insert the switch for power windows into the mounting points at the door trim panel using the locking tabs.
Microsoft
Fig. 117: Installing switch for power windows

2. Press in switch for electric power windows until the locking tab -arrow- clicks into place. See Fig. 117.
Fig. 118: Connecting connector for switch for power windows

3. Press in the connector until it is felt to engage.
SUBSEQUENT WORK
Subsequent work
Install door trim panel. Refer to 70 59 19 Removing and installing door trim panel - as of MY 2005 (All
Models) .
64 75 19 REMOVING AND INSTALLING SIDE WINDOW - AS OF MY 2006

PRELIMINARY WORK
Preliminary work
1. Remove rubber seal for door. Refer to 57 63 19 Removing and installing rubber seal for door - as of MY
Microsoft
2. Remove oddments tray. Refer to 70 66 19 Removing and installing oddments tray - as of MY 2006
3. Remove deflector for front three-point belt. Refer to 69 11 19 Removing and installing front three-point
belt - as of MY 2006 (Cayman S, Cayman S RHD) .
4. Unclipping A-pillar trim panel in area of side window
REMOVING SIDE WINDOW
Removing side window
Fig. 119: Installation position of side window

Microsoft
Fig. 120: Drilling out rivet

1. Drill out rivet -2- from the side window seal -1- using a 4.1 mm drill bit. See Fig. 120.
Microsoft
Fig. 121: Loosening side window

Microsoft
Fig. 122: Removing side window

3. Remove side window -1- first at the top -Arrow A- and then at the bottom -Arrow B- . See Fig. 122.
INSTALLING SIDE WINDOW
Installing side window
Microsoft
Fig. 123: Installation position of side window

NOTE:  The removed side window can be reinstalled if:
 there is no prior damage to the side window.
 the side window was removed without being damaged.
Microsoft
Fig. 124: Pulling out seal for side window

1. Slightly pull out seal for side window -1- . See Fig. 124.
Microsoft
Fig. 125: Installing side window

2. Insert side window -1- into the side window seal -2- -Arrow A- and press them together into the side panel -
Microsoft
Fig. 126: Securing side window

3. Fit fastening nuts -1- top and bottom. See Fig. 126.
Microsoft
Fig. 127: Fastening side window seal

4. Rivet down seal for side window -1- with rivet -2- . See Fig. 127.
5. Press in rubber seal for door. Refer to 57 63 19 Removing and installing rubber seal for door - as of MY
Microsoft
Fig. 128: Adjusting side window

6. Adjust side window to door glass using the specified adjustment dimensions and tolerances. --> Gap
dimension A: 7 mm +/-1 mm
7. Tighten fastening nuts. --> Tightening torque: 4 mm +/-0.5 mm
SUBSEQUENT WORK
Subsequent work
1. Clip A-pillar trim panel into place in area of B-pillar trim panel.
Microsoft
2. Install deflector for front three-point belt. Refer to 69 11 19 Removing and installing front three-point belt
- as of MY 2006 (Cayman S, Cayman S RHD) .
3. Install oddments tray. Refer to 70 66 19 Removing and installing oddments tray - as of MY 2006
64 76 19 REMOVING AND INSTALLING SIDE WINDOW SEAL - AS OF MY

PRELIMINARY WORK
Preliminary work
1. Remove side window. --> 647519 Removing and installing side window - chapter on "removing"
REMOVING SIDE WINDOW SEAL
Removing side window seal
Microsoft
Fig. 129: Removing side window seal

1. Drill out rivets -2- from the integrated sheetmetal strip of the seal for the side window -1- using a 4.1 mm
drill bit. See Fig. 129.
2. Unclip side window seal -1- and remove. See Fig. 129.
INSTALLING SIDE WINDOW SEAL
Installing side window seal
Microsoft
Fig. 130: Installing side window seal

1. Position seal for side window -1- on the centering hole and rivet down with the rivets -2- , starting from the
top right. See Fig. 130.
2. Clip grommet -3- into the side panel and then press side window seal -3- into the side panel. See Fig. 130.
SUBSEQUENT WORK
Subsequent work
1. Install side window. --> 647519 Removing and installing side window - chapter on "installing"
Microsoft
64 86 19 REMOVING AND INSTALLING REAR WINDOW - AS OF MY 2005

--> 64 12 IN General information on installing and removing car windows - as of MY 2005 (All Models).
TOOLS AND MATERIALS
Tools and materials
The following tools and materials are required for removing and installing the windscreen with 2-component
adhesive:

A - Double cartridge gun VAS 5237 - see Workshop Equipment Manual, Chapter 3.5
B - Suction cups VAG 1344 - see Workshop Equipment Manual, Chapter 3.5
C - Special electric cutter (fine) VAG 1561 A - see Workshop Equipment Manual, Chapter 3.5
D - Flashing knife, U-type 639.031.130.22; see Parts Catalogue, Main Group 8
H - 2-component window adhesive 000.043.300.94, contains set components H1-H8; see Parts Catalogue, Main
Group 8
Microsoft
H1 - Cleaning solution
H2 - Primer
H3 - Activator
H4 - Swab
H5 - Cartridge, component A
H6 - Cartridge, component B
H7 - Mixing nozzle
H8 - Processing nozzle

A - Glass separating tool VAG 1474 B, contains set components A1-A9; see Workshop Equipment Manual,
Chapter 3.5
B - Cutting thread, see Parts Catalogue, Main Group 8
A1 - Guide rails
A2 - Cutting tool (wire holder)
A3 - Spooling device
Microsoft
A4 - Awl
A5 - Guide rails
A6 - Filler
A7 - Steering roller with arm bracket
A8 - Handle
A9 - Square cutting wire
REMOVING REAR WINDOW
Removing rear window (hardtop)
Microsoft
Fig. 133: Removing and installing rear window (hardtop)

1. Remove hardtop.
1.1. Unlock hardtop and take it off the car.
2. Position the hardtop.
2.1. Place outer side of the hardtop on the assembly fixture,. Refer to 61 02 IN Assembly instructions for
hardtop assembly fixture - as of MY 2005 (Boxster, Boxster RHD, Boxster S, Boxster S RHD) .
Microsoft
Fig. 134: Unclipping lining

3. Unclip lining.
3.1. Unclip lining -1- at the sides and at the front from the hardtop body -2- . See Fig. 134.
Microsoft
Fig. 135: Disengaging roof liner at rear

4. Disengage roof liner at rear.
4.1. Pull roof liner -3- backwards and detach it. See Fig. 135.
Microsoft
Fig. 136: Disconnecting the plug connection of the rear window heating
5. Disconnect the plug connection of the rear window heating.
NOTE:  To avoid damaging the electric line when cutting out the rear window, affix
this to the rear window with adhesive tape.
5.1. Disconnect electrical plug connection -4- at left and right of rear window. See Fig. 136.
Microsoft
Fig. 137: Turning hardtop

6. Turn hardtop.
6.1. Place hardtop on the assembly fixture and lock with the latching levers and the locking lever at front.
Microsoft
Fig. 138: Pulling off cover section

7. Pull off cover section.
NOTE:  If the cover section is removed undamaged, it can be re-used.
7.1. Loosen and pull off the cover section -5- . See Fig. 138.
Microsoft
Fig. 139: Removing rear window

8. Remove rear window.
NOTE:  When cutting out the rear window, take care not to damage the rivet
connections that are connecting the hardtop body parts.
 When cutting out the rear window, make sure to cut close to the rear window.
8.1. Fit a cutter -C- with a u-type cutter -E- . Set the vibration frequency controller to 5. Cut through the bond
between the body and the rear window at the top, bottom and sides. See Fig. 139.
9. Take off rear window.
PREPARING WINDOW FRAME FOR INSTALLATION
Preparing the window section (hardtop) for installation
Microsoft

Microsoft
Fig. 141: Removing adhesive on the hardtop body

1. Remove adhesive on the hardtop body.
NOTE:  The surface coating of adhesive residue helps new adhesive to stick. Keep
cut surfaces clean and free of grease and do not clean with cleaning
solution.
 Remove remaining adhesive between the riveted joints as much as possible without damaging the riveted
joints.
1.1. When removing remaining adhesive -6- with the cutting tool -C- and the flashing knife -D- on the hardtop
body, ensure that a surface coating of adhesive remains -7- . See Fig. 141.
Microsoft
Fig. 142: Removing rear window (hardtop), cleaning and priming the window aperture of the body
2. Clean and prime paint damage or newly built-up paint areas in the window aperture of the hardtop body.

cleaning of the glass section and the application of the primer!
 No cleaning solution residues may remain on the body.
2.1. Clean new paint areas or damage to the top coat paint in the non-visible area of the glass section in the
hardtop body with cleaning solution -H1- and patch with primer -H2- . See Fig. 142.
PREPARING REAR WINDOW FOR INSTALLATION
Preparing the rear window (hardtop) for installation
Microsoft

NOTE:  Only if the rear window is re-installed
Microsoft
Fig. 144: Removing adhesive from the windscreen

NOTE:  Only if the rear window is re-installed!
1. Remove adhesive from the rear window.
NOTE:  The remaining adhesive helps new adhesive to stick. Keep cut surfaces
clean and free of grease and do not clean with cleaning solution.
1.1. Equip cutter -C- with flashing knife -D- and remove remaining adhesive from the rear window, ensuring
that a surface coating of adhesive remains. See Fig. 144.
Microsoft
Fig. 145: Activating the bonding section of the windscreen

NOTE:  Only if the rear window is re-installed!
2. Apply activator to the bonding section of the rear window.
NOTE:  Only with new rear windows
2.1. During long idle periods apply activator to the remaining adhesive.
2.2. Clean glass with cleaning solution.

cleaning of the glass and the application of the primer! No cleaning
solution residues may remain on the body.
2.3. Apply primer to the window flange in the area of the marking.
INSTALLING REAR WINDOW
Installing rear window (hardtop)
Microsoft

Microsoft
Fig. 147: Fitting cover section

1. Fit the cover section.
NOTE:  The removed rear window can be reinstalled if there was no prior damage
to the rear window and the rear window was removed without damage.
NOTE:  If the cover section is removed from the rear window undamaged, it can be
re-used.
1.1. Attach cover section -8- to the rear window. See Fig. 147.
NOTE:  The adhesive has an open time of -15 min- , which means that the bonding
material must be applied and the car window must be assembled within
this period of time.
Microsoft
Fig. 148: Adhesive has an open time

2. Preparing 2-component adhesive for processing.
Microsoft
Fig. 149: Applying bonding material to the windscreen

3. Apply adhesive to the rear window.
NOTE:  When applying the adhesive, it is essential to ensure that the adhesive
bead overlaps by approx. 30 mm at the beginning and at the end.
3.1. Using bonding gun -A- apply 2-component adhesive to the rear window along the cover section in the form
of a triangular bead with the dimension -X = approx. 15 mm- . See Fig. 149.
Microsoft
Fig. 150: Installing rear window (hardtop), inserting rear window

NOTE:  Two persons are needed to insert and adjust the rear window.
4. Insert rear window into the hardtop body.
4.1. Affix suction cups -B- to the rear window. See Fig. 150.
4.2. Insert the rear window at the top of the window aperture and lay it down carefully into the aperture.
Microsoft
Fig. 151: Fixing rear window


observed!

5. Fix rear window.
5.1. Press the rear window fully upwards, pressing on the lower edge of the glass while doing so. Use adhesive
tape to prevent the rear window from slipping at the side and the top.
6. Clean the fields of vision.
6.1. Adhesive which has oozed out must be removed immediately and the affected fields of vision must be
Microsoft
cleaned using cleaning agent.
7. Turn hardtop.
7.1. Place outer side of the hardtop on the assembly fixture.
Fig. 152: Plugging in rear window heater

8. Plug in rear window heater.
8.1. Connect electrical plug connection -4- at left and right of rear window. See Fig. 152.
Microsoft
Fig. 153: Engaging roof liner to the rear

9. Engage roof liner to the rear.
9.1. Engage roof liner -3- at rear. See Fig. 153.
Microsoft
Fig. 154: Clipping in interior trim parts

10. Clip in lining.
10.1. Clip in lining -1- at the sides and at the front on the hardtop body -2- . See Fig. 154.
11. Install hardtop.
11.1. Place hardtop on the car and lock it.
Microsoft
ACCESSORIES & EQUIPMENT Instruments, alarm system
Instruments, alarm system
90 03 19 REMOVING AND INSTALLING DASHBOARD INSERT - AS OF MY

2005 (ALL MODELS)
PRELIMINARY WORK
Preliminary work for the dashboard insert
1. Remove instrument cluster. --> 902519 Removing and installing instrument cluster - chapter on
"removing"
REMOVING DASHBOARD INSERT
Removing dashboard insert
1. Adjust the steering wheel as far down and as far back as it will go (as seen from the direction of travel)

2. Unscrew fastening screw -2- . See Fig. 1.

Microsoft
3. Lift up the dashboard insert -1- and remove. See Fig. 1.
INSTALLING DASHBOARD INSERT
Installing dashboard insert
Fig. 2: Tightening fastening screws

1. Position dashboard insert -1- on the dashboard and screw into place with the seven fastening screws -2- . -->
SUBSEQUENT WORK
Subsequent work for dashboard insert
1. Remove instrument cluster. --> 902519 Removing and installing instrument cluster - chapter on
"installing"
90 22 19 REMOVING AND INSTALLING STOPWATCH - AS OF MY 2005 (ALL

MODELS)
TOOLS
Microsoft

REMOVING STOPWATCH
Removing stopwatch
Fig. 3: Installation position shown on the 911 Cockpit
Microsoft
Fig. 4: Plastic spatula

1. Insert a plastic spatula between the dashboard and the stopwatch. Lift up the stopwatch until its four clips
unclip from the dashboard.
Microsoft

2. Release electric connector -a- and pull away from the stopwatch. See Fig. 5.
Microsoft

3. Turn the stopwatch around, unscrew the four fastening screws, remove the cover and take the stopwatch out
of its holder.
INSTALLING STOPWATCH
Installing stopwatch
Microsoft
Fig. 7: Installing stopwatch

1. Insert the stopwatch into the holder and attach it.
2. Position the cover and screw down with the fastening screws.
Microsoft
Fig. 8: Inserting connector into stopwatch.

3. Insert electrical connector into stopwatch until it is felt to engage.
Microsoft
Fig. 9: Clipping in stopwatch.

4. Run electrical lead into the dashboard, position the stopwatch with its cover over the dashboard and clip in
the four clips.
PROGRAMMING STOPWATCH
Reading out and writing stopwatch values
Microsoft
1. Connect the Porsche System tester to the vehicle and start the System tester. Switch on ignition. >> Continue.
4. Select Stopwatch with the cursor keys and press the >> key.
7. The message Codes successfully read out appears on the screen of the Porsche System tester. Press >>.
8. Switch off ignition and replace control unit.
9. Switch on ignition, switch to the Special functions menu and perform the Vehicle handover using the F8
key.
12. In the menu Write in data >> , the data read-out is installed.
13. System tester displays Coding write-in complete >>.
14. Quit menu, check operation of stopwatch and read out fault memory.
Coding stopwatch
Microsoft
7. Select Stopwatch with the cursor keys and press the >>.
NOTE: The codings will be optimized with later versions of the tester software; the
coding scope documented here serves as a guide.
8. Select Stopwatch with the cursor keys and press the >>.
Default
Illumination settings:
Illumination off
Time constant brighter Reference value >> 3.2
Time constant darker Reference value >> 12.8
9. Quit menu, check operation of stopwatch and read out fault memory.
90 25 19 REMOVING AND INSTALLING INSTRUMENT CLUSTER - AS OF MY

2005 (ALL MODELS)
TOOLS

PIWIS Tester special tool P 9718
PRELIMINARY WORK
Preliminary work for instrument cluster
Microsoft
Remove trim for steering column.
REMOVING INSTRUMENT CLUSTER
Removing instrument cluster
CAUTION: Sudden voltage interruption of the power supply to the control module.
1. If a new instrument cluster is to be installed, read out the values if possible from the instrument cluster. -->
902519 Removing and installing instrument cluster - "Programming"
2. Loosen the steering wheel adjustment, put the steering wheel in the front-most and lowest position and lock
the steering wheel adjustment.

Microsoft
3. Unscrew the two fastening screws -1- . See Fig. 10.
4. Pull instrument cluster forward, push side panels -2- to the side. See Fig. 11.
Fig. 11: Releasing and unplugging electrical connectors

5. Release electrical connector -A- and unplug it. See Fig. 11.
INSTALLING INSTRUMENT CLUSTER
Installing instrument cluster
Microsoft
Fig. 12: Plugging in the electrical connector and locking it

1. Position the instrument cluster, connect the electrical plug and lock.
Microsoft
Fig. 13: Tightening instrument cluster

2. Screw down instrument cluster with both fastening screws -1- . --> Tightening torque: 1.7 ftlb. See Fig. 13.
3. If a new instrument cluster was installed, --> 902519 Removing and installing instrument cluster -
"Programming"
SUBSEQUENT WORK
Reworking instrument cluster
Install trim for steering column.
PROGRAMMING INSTRUMENT CLUSTER
Reading and printing values
NOTE: If the instrument cluster is replaced or exchanged, the instrument cluster must
be programmed and coded using the PIWIS Tester P 9718. This is done to adapt
the instrument cluster to the vehicle and equipment.
If possible, before the instrument cluster is removed and replaced, a read-out of

the vehicle data should be obtained using the Porsche System Tester.
Microsoft
During coding, it is essential to guarantee the power supply for the Porsche
System Tester. It is essential to connect a battery charger with a current rating
of at least 40 A to the vehicle battery.
The Porsche System Tester instructions take precedence and in the event of a
text or additions may appear in the Porsche System Tester.
Continue.
2. Select vehicle type >>.
4. Select Instrument cluster and press the >> key.
6. Select Read out values (codings) with the cursor keys and press the >> key.
7. The message Coding read-out complete will appear on the screen of the Porsche System Tester. Press the >>
key.
8. Switch off ignition and replace instrument cluster. --> 902519 Removing and installing instrument cluster
- "Removing"
9. Switch on ignition. After replacement of the control unit, the vehicle data is installed under the menu Write
in data (see Point 6) > >.
10. System Tester displays Coding write-in complete. Press the >> key.
11. Go to the Special functions menu and start the Vehicle handover also; follow the instructions on the
Tester.
12. Erase all fault memories .
13. Go to the Instrument cluster Coding menu again and check the coding in accordance with the vehicle
equipment.
14. Carry out a test drive and read out fault memory again.
Microsoft
Programming the instrument cluster
NOTE: If the instrument cluster is replaced or exchanged, the instrument cluster must
be programmed and coded using the PIWIS Tester P 9718. This is done to adapt
the instrument cluster to the vehicle and equipment.
If the Control unit replacement function cannot be performed, proceed according to this variant.
Continue.
2. Select the vehicle type and press >>.
3. Switch to the Special functions menu and start Vehicle handover ; follow the instructions on the Tester.
4. Erase all fault memories .
5. Perform an automatic control unit search and switch to the Instrument cluster menu, then press >>.
7. Select the Write in data menu and press >>.
8. Select the Coding menu and press >>.
9. Enter the Vehicle ID No. if required and code the other codes according to the vehicle equipment.
10. Switch to the Special functions menu and enter total mileage in accordance with the specifications on the
Tester.
11. Select the type of oil level measurement .
12. Disconnect Tester from vehicle.
Microsoft
13. Carry out a test drive and read out the fault memory again.
90 35 19 REMOVING AND INSTALLING GATEWAY CONTROL UNIT - AS OF

TOOLS

PRELIMINARY WORK
Preliminary work for gateway control unit
Cover of driver's footwell: Refer to 70 22 19 Removing and installing cover (cold air bulkhead) - as of MY
2005 (All Models) .
Remove relay carrier 1 Refer to 97 83 19 Removing and installing relay carrier 1 - as of MY 2005 (All
Models) .
Remove vehicle electrical system control unit. Refer to 97 10 19 Removing and installing vehicle electrical
system control unit - as of MY 2005 (All Models) .
REMOVING GATEWAY CONTROL UNIT
Removing gateway control module
NOTE: The gateway control module is located under the radiator tank, accessible from
inside the vehicle near to the driver.
Microsoft
Fig. 14: Installation location for Gateway control module illustrated on 997
Fig. 15: Removing gateway control module

1. -A- Pull gateway control module downwards on the connector side (unclip) See Fig. 15.
Microsoft
2. -B- Pull gateway control module to the left out of the support. See Fig. 15.
Fig. 16: Unlocking the electrical plug

3. Release electric connector -A- and pull from the gateway control module. See Fig. 16.
INSTALLING GATEWAY CONTROL UNIT
Installing gateway control unit
Microsoft
Fig. 17: Connecting electric plug

1. Push on electric plug until it is felt to engage on gateway control unit.
Microsoft
Fig. 18: Installing gateway control unit

2. Push in gateway control unit into the support -A- and clip in -A- . See Fig. 18.
3. If a new gateway control unit has been installed, it must be coded on the vehicle. --> 903519 Removing and
installing gateway control unit - "Coding"
SUBSEQUENT WORK
Subsequent work for gateway control unit
Install relay carrier 1. Refer to 97 83 19 Removing and installing relay carrier 1 - as of MY 2005 (All
Models) .
Install vehicle electrical system control unit. Refer to 97 10 19 Removing and installing vehicle electrical
system control unit - as of MY 2005 (All Models) .
Cover of driver's footwell: Refer to 70 22 19 Removing and installing cover (cold air bulkhead) - as of MY
2005 (All Models) .
CODING GATEWAY CONTROL UNIT
Coding the gateway control unit

Microsoft
NOTE: If the gateway control module is replaced, the gateway control module must be
coded using the PIWIS tester P 9718. This is to adapt the Gateway control
module to the vehicle and equipment.
If possible, before the gateway control module is removed and replaced, a read-
out of the vehicle data should be obtained from the Porsche System Tester.
1. Connect the Porsche System Tester to the vehicle and start the System Tester. Switch on the ignition. >>
Continue.
3. Move from vehicle type to the list of control units >>.
4. Select Gateway with the cursor keys and press the >> key.
7. The message "Reading code" will appear on the screen of the Porsche System Tester. Press the >> key.
8. Switch off ignition and replace gateway control unit. --> 903519 Removing and installing gateway control
unit - "Removing"
10. Follow the instructions on the Tester.
11. Quit menu, switch off ignition, lock then unlock vehicle and read out fault memory once more.
If faults are present, proceed in accordance with the Diagnosis.
Microsoft
12. In the Gateway menu, select Required & actual configuration and press >>.
13. Check the list for both Required and Actual for the same + or - . If there are deviating specifications, first
check if the components are installed on this vehicle.
14. If necessary, change to the Coding menu, and select the non-matching components (e. g., Tire pressure
monitoring system) and code the components with F8.
15. In the Gateway menu, select Required & actual configuration and press >>. Then check the list once
again.
16. Read out and erase fault memory.
Manually coding with the tester
NOTE: If the "old" control module can no longer be read out, the coding must be
performed "manually" with the PIWIS tester P 9718. This is to adapt the
Gateway control module to the vehicle and equipment.
Continue.
3. Move from vehicle type to the list of control units >>.
4. Select Gateway with the cursor keys and press the >> key.
5. Select the Coding menu >>.
6. Select the individual systems/components in turn and code the vehicle-dependent equipment with F8.
7. In the Gateway menu, select Required & actual configuration >>.
Microsoft
8. Check the list for both Required and Actual for the same + or - . If there are deviating specifications, first
check if the components are installed on this vehicle.
9. If necessary, change to the Coding menu, and select the non-matching components (e. g., Tire pressure
monitoring system) and code the components with F8.
10. In the Gateway menu, select Required & actual configuration >> and check the list once again.
11. In the menu Vehicle type , select Control units and then select the menu Special functions .
12. PerformVehicle handover and follow the instructions of the tester.
90 50 19 REMOVING AND INSTALLING HORN - AS OF MY 2005 (ALL

MODELS)
PRELIMINARY WORK
Preliminary work for horn
Refer to 63 15 19 Removing and installing front spoiler - as of MY 2005 (All Models) .
REMOVING HORN
Removing horn
Microsoft
Fig. 19: Installation position for horn, shown on the 911
Fig. 20: Horn with holder

1. The horn must be removed with the holder.
Microsoft
Fig. 21: Fastening nut

2. Unscrew the fastening nut -2- and remove the holder with the horns. See Fig. 21.
Microsoft
Fig. 22: Installation of horn

3. Unlock the electric connector -a- and disconnect from the horns. See Fig. 22.
4. Unscrew the fastening nut -1- and remove the horn from the holder. See Fig. 22.
INSTALLING HORN
Installing horn
Microsoft
Fig. 23: Installation position of the horn

1. Push in the horn in the holder and position the horn in the same way as the figure.
Microsoft
Fig. 24: Installation of horn

2. Screw down the horns with the fastening nuts -1- . --> M6: 7.5 ftlb. See Fig. 24.
3. Insert both electrical connectors until they perceptibly engage.
Microsoft
Fig. 25: Installation of holder

4. Position the holder with the horns on the body and screw down with the fastening nuts -2- . --> M8: 17 ftlb.
See Fig. 25.
SUBSEQUENT WORK
Subsequent work on horn
90 58 19 INSTALLING AND REMOVING SOCKET - AS OF MY 2005 (ALL

MODELS)
PRELIMINARY WORK
Preliminary work for passenger's footwell socket
Remove right center console cover. Refer to 68 14 19 Removing and installing center console cover - as of
Preliminary work for center console socket
Refer to 68 17 19 Removing and installing center console - as of MY 2005 (All Models) .
Microsoft
REMOVING SOCKET
Removing passenger's footwell socket
Fig. 26: Overview of socket in passenger's footwell, shown on the 911
Microsoft
Fig. 27: Removing the passenger's footwell socket

1. Loosen the fastening nuts -1- and pull to the rear over the electric wire. See Fig. 27.
2. Unlock electrical plug -A- and pull from the socket. See Fig. 27.
Removing center console socket
Microsoft
Fig. 28: Overview of socket in center console, shown on the 911
Microsoft
Fig. 29: Removing the center console socket

1. Turn center console, unlock electric plug -A- and pull from the socket. See Fig. 29.
2. Unlock socket and pull out of the center console.
INSTALLING SOCKET
Installing passenger's footwell socket
1. Move the fastening nut through the electrical wire, move socket through the cover for the center console and
screw down with the fastening nut.
Microsoft
2. Push electrical plug onto socket until plug is felt to engage.
Installing the center console socket
Fig. 30: Installing the center console socket

1. Insert the socket into the center console until it clicks into place.
2. Push electrical plug onto socket until plug is felt to engage.
SUBSEQUENT WORK
Subsequent work for passenger's footwell socket
Microsoft
Install right center console cover. Refer to 68 14 19 Removing and installing center console cover - as of MY
2005 (All Models) .
Reworking the center console socket
90 62 19 REMOVING AND INSTALLING CIGAR LIGHTER - AS OF MY 2005

(ALL MODELS)
PRELIMINARY WORK
Preliminary work for cigar lighter
REMOVING CIGAR LIGHTER
Removing cigar lighter
Microsoft
Fig. 31: Overview
The cigar lighter is located in the center console behind the ashtray.
Fig. 32: Removing the cigar lighter

1. Disconnect the electrical plugs.
2. Press together the locks -A- and push out the cigar lighter out of the center console. See Fig. 32.
INSTALLING CIGAR LIGHTER
Installing cigar lighter
Microsoft
Fig. 33: Installing the cigar lighter

1. Push in the cigar lighter into the center console until the cigar lighter clicks into place in the center console.
2. Connect the electric plug.
SUBSEQUENT WORK
Reworking the cigar lighter
Microsoft
ACCESSORIES & EQUIPMENT Interior equipment
Interior equipment
68 05 19 REMOVING AND INSTALLING INNER DOOR SILL TRIM - AS OF MY

2005 (ALL MODELS)
REMOVING INNER DOOR SILL TRIM
Removing inner door sill trim (driver's side)
Fig. 1: Installation position of scuff plate

Microsoft
Fig. 2: Loosening scuff plate

1. Take off plastic caps -1- and loosen the fastening screws -2- of the scuff plate -3- . See Fig. 2.
Microsoft
Fig. 3: Removing scuff plate

2. Lift scuff plate -1- using a plastic wedge and pull off upwards. See Fig. 3.
3. Checking fixing clips -2- on the underside of the scuff plate -1- and replacing if necessary See Fig. 3, Fig. 4.
Microsoft

4. Releasing plug connection on actuating switch and take off scuff plate.
Removing inner door sill trim (passenger's side)
Microsoft

Fig. 6: Removing lining mat

1. Remove lining mat from shelf.
Microsoft
Fig. 7: Removing scuff plate

2. Unscrew fastening screw -1- from scuff plate -2- . See Fig. 7.
3. Lift scuff plate using a plastic wedge and pull off upwards and remove.
4. Checking fixing clips -3- on the underside of the scuff plate and replacing if necessary See Fig. 7.
INSTALLING INNER DOOR SILL TRIM
Installing inner door sill trim (driver's side)
Microsoft


1. Lock plug connection on actuating switch.
Microsoft
Fig. 10: Installing scuff plate

2. Checking fixing clips -2- on the underside of the scuff plate -1- and replacing if necessary See Fig. 10.
3. Position scuff plate -1- , press in and engage. See Fig. 10.
Microsoft
Fig. 11: Screwing down the scuff plate

4. Tighten fastening screws -2- . Tightening torque --> Tightening torque: 3.5 ftlb. +/-0.5 ftlb. See Fig. 11.
5. Seal bores of scuff plate -3- with plastic caps -1- . See Fig. 11.
Installing inner door sill trim (passenger's side)
Microsoft

1. Checking fixing clips -3- on the underside of the scuff plate -2- and replacing if necessary See Fig. 13.
Microsoft
Fig. 13: Installing scuff plate

2. Position scuff plate -2- , press in and engage. See Fig. 13.
3. Tighten fastening screw -1- . Tightening torque --> Tightening torque: 2 ftlb. +/-0.5 ftlb. See Fig. 13.
Microsoft
Fig. 14: Inserting lining mat

4. Insert lining mat in shelf.
68 07 19 REMOVING AND INSTALLING COVER STRIP - AS OF MY 2005

(ALL MODELS)
PRELIMINARY WORK
Preliminary work
1. Remove inner sill. --> 680519 Removing and installing inner sill - "Removing" section
2. Loosen rubber seal for door in area of cover strip. Refer to 57 63 19 Removing and installing rubber seal
for door - as of MY 2006 (Cayman S, Cayman S RHD) . Refer to 57 63 19 Removing and installing rubber
seal for door - as of MY 2005 (Boxster, Boxster RHD, Boxster S, Boxster S RHD) .
REMOVING COVER STRIP
Microsoft
Fig. 15: Main illustration of cover strip


1. Lift cover strip with plastic wedge and pull off cover strip.
2. Remove adhesive residues with cleaning solution.

Microsoft
INSTALLING COVER STRIP
Fig. 17: Main illustration of cover strip

NOTE:  The bonding surface must be free of dirt and grease. Clean with cleaning
solution if necessary.
Microsoft
Fig. 18: Pulling off protective film

1. Pull protective film off the bonding area of cover strip.
Microsoft
Fig. 19: Installing cover strip

2. Position cover strip and apply. center notch in cover strip at height of bead.
3. Press on cover strip firmly.
SUBSEQUENT WORK
Subsequent work
1. Connect rubber seal for door in area of cover strip. Refer to 57 63 19 Removing and installing rubber seal
for door - as of MY 2006 (Cayman S, Cayman S RHD) . Refer to 57 63 19 Removing and installing rubber
seal for door - as of MY 2005 (Boxster, Boxster RHD, Boxster S, Boxster S RHD) .
2. Install inner sill. --> 680519 Removing and installing inner sill - "Installing" section
68 11 19 REMOVING AND INSTALLING GLOVE COMPARTMENT LOCK - AS

REMOVING GLOVE COMPARTMENT LOCK
Removing and installing support for glove compartment lid
Fig. 20: Installation position of glove compartment lock

Microsoft
Fig. 21: Releasing support for glove compartment

1. Unscrew fastening screws at the side -1- . See Fig. 21.
Microsoft
Fig. 22: Removing support for glove compartment

2. Unscrew fastening screws at the front -1- and remove support for glove compartment lid -2- . See Fig. 22.
Removing glove compartment lid lock

NOTE:  The lock barrel for the glove compartment can only be removed when
replacing the handle.
 Removing the lock barrel can damage the handle.
Microsoft
Fig. 24: Removing glove compartment lock

1. Unscrew fastening screws -1- . See Fig. 24.
2. Loosen the locking tabs slightly -Arrow A- and remove the handle -3- with the glove compartment lock -2-
out of the support for the glove compartment -4- . See Fig. 24.
INSTALLING GLOVE COMPARTMENT LOCK
Installing glove compartment lock
Microsoft

Fig. 26: Installing glove compartment lock

1. Position the handle -3- with the glove compartment lock -2- in the support for the glove compartment lid -4-
( -arrow- ) and secure in position with the fastening screws -1- . See Fig. 26.
Microsoft
Installing support for glove compartment lid

Fig. 28: Installing support for glove compartment

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1. Position support for glove compartment lid -2- on the glove compartment lid -arrow- and screw in the
fastening screws at the front -1- . See Fig. 28.
Fig. 29: Securing support for glove compartment

2. Screw in fastening screws at the side -1- . See Fig. 29.
68 12 19 REMOVING AND INSTALLING LID FOR GLOVE COMPARTMENT -

PRELIMINARY WORK
Preliminary work
Remove glove compartment. --> 681519 Removing and installing glove compartment - chapter on
"removing"
REMOVING LID FOR GLOVE COMPARTMENT
Removing lid for glove compartment
Microsoft
Fig. 30: Installation position of glove compartment lid

1. Open the glove compartment.
Fig. 31: Pressing out shock absorber for glove compartment

2. Press shock absorber for glove compartment -1- carefully out of the fastening tab -2- . See Fig. 31.
Microsoft
Fig. 32: Removing stop

3. Turn stop -1- 45° in -direction of arrow- and remove it. See Fig. 32.
Microsoft
Fig. 33: Removing lid for glove compartment

4. Drive out pin rod -3- , remove washer -4- and then detach the lid -1- from the glove compartment -2- ( -
direction of arrow- ). See Fig. 33.
INSTALLING LID FOR GLOVE COMPARTMENT
Installing lid for glove compartment
Fig. 34: Installation position of glove compartment lid

Microsoft
Fig. 35: Checking rubber stops

1. Check rubber stops to the left and right -2- before installing the glove compartment lid -1- and replace them if
Microsoft
Fig. 36: Installing lid for glove compartment

2. Position lid -1- and washer -4- on the glove compartment -2- and press in the pin rods -3- ( -arrows- ). See
Fig. 36.
Microsoft
Fig. 37: Installing stop

3. Close the glove compartment slightly, position stop -1- on the lid and turn 45° in -direction of arrow- . See
Fig. 37.
Microsoft
Fig. 38: Pressing in shock absorber for glove compartment

4. Press shock absorber for glove compartment -1- into the fastening tab -2- . See Fig. 38.
5. Close glove compartment.
SUBSEQUENT WORK
Subsequent work
Install glove compartment. --> 681519 Removing and installing glove compartment - chapter on
"installing"
68 14 19 REMOVING AND INSTALLING CENTER CONSOLE COVER - AS OF

PRELIMINARY WORK
Preliminary work
NOTE: Only for vehicles with additional receiver for telephone.
1. Remove bracket for telephone. Refer to 91 88 19 Removing and installing console for telephone - as of
Microsoft
REMOVING CENTER CONSOLE COVER
Removing footwell outlet vent cover
Fig. 39: Installation location of footwell outlet vent cover

Microsoft
Fig. 40: Removing footwell outlet vent cover

1. Unscrew fastening screw -1- and take out footwell outlet vent cover -2- . See Fig. 40.
NOTE: Only passenger's side.
2. Release electric connector -arrow A- and pull off from the socket. See Fig. 40.
3. Check fastening nut -3- , replace if necessary. See Fig. 40.
Removing center console cover
Microsoft
Fig. 41: Installation location for center console cover

Fig. 42: Removing center console cover

1. Unscrew fastening screws -1- and take off cover for center console -2- . See Fig. 42.
2. Check fastening nut -3- , replace if necessary. See Fig. 42.

Microsoft
INSTALLING CENTER CONSOLE COVER
Installing center console cover

Microsoft
Fig. 44: Installing center console cover

1. Position cover for center console -2- and screw down using the fastening screws -1- . Tightening torque -->
Tightening torque: 1.5 ftlb. +/-0.15 ftlb. . See Fig. 44.
Installing footwell outlet vent cover
Fig. 45: Installation location of footwell outlet vent cover

Microsoft
Fig. 46: Installing footwell outlet vent cover

NOTE: Only passenger's side.
1. Push electric connector onto socket -arrow- until connector is felt to engage. See Fig. 46.
2. Insert footwell outlet vent cover -2- into center console cover -3- and screw down the fastening screw -1- .
Tightening torque --> Tightening torque: 7.5 ftlb. See Fig. 46.
SUBSEQUENT WORK
Subsequent work
Microsoft
NOTE: Only for vehicles with additional receiver for telephone.
1. Install bracket for telephone. Refer to 91 88 19 Removing and installing console for telephone - as of MY
2005 (All Models) .
68 15 19 REMOVING AND INSTALLING GLOVE COMPARTMENT - AS OF MY

2005 (ALL MODELS)
PRELIMINARY WORK
Preliminary work
1. Remove right dashboard cover. Refer to 70 16 19 Removing and installing dashboard cover - as of MY
2005 (All Models) .
2. Remove trim panel under dashboard on passenger's side. Refer to 70 19 19 Removing and installing trim
under dashboard - as of MY 2005 (All Models) .
3. Remove right footwell light. Refer to 96 15 19 Removing and installing footwell light - as of MY 2005 (All
Models) .
4. Remove cover (cold air bulkhead). Refer to 70 22 19 Removing and installing cover (cold air bulkhead) -
5. Remove right center console cover. --> 681419 Removing and installing center console cover - chapter on
"removing"
6. Remove cup holder. --> 683019 Removing and installing cup holder - chapter on "removing"
REMOVING GLOVE COMPARTMENT
Removing glove compartment
Microsoft
Fig. 47: Installation position of glove compartment

Fig. 48: Releasing glove compartment, right

1. Unscrew right fastening screws -2- from the glove compartment -1- . See Fig. 48.
2. Pull electrical line out of glove compartment -arrow- . See Fig. 48.
Microsoft
Fig. 49: Releasing glove compartment, left

3. Unscrew left fastening screws -2- from the glove compartment -1- . See Fig. 49.
Microsoft
Fig. 50: Releasing glove compartment, top

4. Unscrew top fastening screws -2- from the glove compartment -1- . See Fig. 50.
5. Carefully pull out glove compartment -1- ( -arrow- ) until the electrical plug connection can be removed. See
Fig. 50.
Microsoft

6. Pull off electrical plug connection -2- ( -arrow- ) and remove glove compartment -1- to the rear. See Fig. 51.
INSTALLING GLOVE COMPARTMENT
Installing glove compartment
Microsoft
Fig. 52: Installation position of glove compartment


1. Swivel in glove compartment -1- at the bottom until the electrical plug connection -2- can be connected. See
Fig. 53.
Microsoft
2. Plug in electrical plug connection -2- ( -arrow- ). See Fig. 53.
Fig. 54: Installing glove compartment

3. Swivel glove compartment -1- into the dashboard -arrow- and secure with the top fastening screws -2- .
Tightening torque --> Final tightening: 2 ftlb. See Fig. 54.
Fig. 55: Securing the glove compartment

Microsoft
4. Screw right fastening screws -2- into the glove compartment -1- . Tightening torque --> Final tightening: 2
ftlb. See Fig. 55.
5. Attach electrical line to glove compartment -arrow- . See Fig. 55.
Fig. 56: Securing glove compartment, left

6. Screw left fastening screws -2- into the glove compartment -1- . Tightening torque --> Final tightening: 2
ftlb. See Fig. 56.
SUBSEQUENT WORK
Microsoft
Subsequent work
1. Install cup holder. --> 683019 Removing and installing cup holder - chapter on "removing"
2. Install right center console cover. --> 681419 Removing and installing center console cover - chapter on
"installing"
3. Install cover (cold air bulkhead). Refer to 70 22 19 Removing and installing cover (cold air bulkhead) - as
4. Install right footwell light. Refer to 96 15 19 Removing and installing footwell light - as of MY 2005 (All
Models) .
5. Install trim panel under dashboard on passenger's side. Refer to 70 19 19 Removing and installing trim
6. Install right dashboard cover. Refer to 70 16 19 Removing and installing dashboard cover - as of MY 2005
(All Models) .
68 16 19 REMOVING AND INSTALLING SHELF - AS OF MY 2005 (ALL

MODELS)
PRELIMINARY WORK
Preliminary work
1. Remove center console cover. --> 681919 Removing and installing center console cover - chapter on
"removing"
REMOVING SHELF
Removing shelf
Microsoft
Fig. 57: Installation location for shelf

Fig. 58: Removing shelf

1. Unscrew fastening screws -1- and take off shelf -2- with mat -3- . See Fig. 58.
INSTALLING SHELF
Microsoft
Installing shelf
Fig. 59: Installation location for shelf

Fig. 60: Installing shelf

Microsoft
1. Position shelf -2- and screw down using the fastening screws -1- . See Fig. 60.
2. Insert the mat -3- . See Fig. 60.
SUBSEQUENT WORK
Subsequent work
1. Install center console cover. --> 681919 Removing and installing center console cover - chapter on
"installing"
68 17 19 REMOVING AND INSTALLING CENTER CONSOLE - AS OF MY

2005 (ALL MODELS)
PRELIMINARY WORK
Preliminary work
Remove shelf. --> 681619 Removing and installing shelf - chapter on "Removing"
REMOVING CENTER CONSOLE
Removing cover for parking-brake lever
Fig. 61: Main illustration for removing and installing center console
Microsoft
Fig. 62: Removing cover for parking-brake lever

1. Pull parking-brake lever.
2. Unclip cover for parking-brake lever -1- using a plastic wedge -2- . See Fig. 62.
Disconnecting wire harness plug connection for center console
Microsoft

1. Release wire harness electric plug connection for center console -1- on right and left -Arrows A- and pull
apart -Arrow B- . See Fig. 64.
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Removing center console
1. Open lid of oddments tray.
Microsoft
Fig. 66: Removing center console insert

2. Remove insert at rear of center console -1- . See Fig. 66.
Fig. 67: Removing floor at rear of center console

3. Unscrew fastening screws -1- and remove floor at rear of center console -2- . See Fig. 67.
4. Close lid of oddments tray.
Microsoft
Fig. 68: Releasing center console

Microsoft
Fig. 69: Removing center console

6. Swivel center console -1- upward -Arrow A- and remove -Arrow B- . See Fig. 69.
INSTALLING CENTER CONSOLE
Installing center console
Microsoft
Fig. 71: Installing center console

1. Position and align the center console -1- See Fig. 71.
Microsoft
Fig. 72: Fastening center console

2. Tighten fastening screws -1- . See Fig. 72.
3. Open lid of oddments tray.
Microsoft
Fig. 73: Installing floor at rear of center console

4. Insert floor at rear of center console -2- and screw down with fastening screw -1- . See Fig. 73.
Microsoft
Fig. 74: Installing insert of center console

5. Position insert at rear of center console -1- and close lid of oddments tray. See Fig. 74.
Locking wire harness plug connection for center console
Microsoft

1. Push together electric plug connection of wire harness for center console -1- until it audibly engages. See Fig.
76.
Installing cover for parking-brake lever
Microsoft
Fig. 78: Installing cover for parking-brake lever

1. Press in cover of parking-brake lever -1- until it engages. See Fig. 78.
SUBSEQUENT WORK
Microsoft
Subsequent work
Install shelf. --> 681619 Removing and installing oddments tray - chapter on "Installing"
68 17 37 DISASSEMBLING AND ASSEMBLING THE CENTER CONSOLE -

PRELIMINARY WORK
Preliminary work
1. Remove center console. --> 681719 Removing and installing center console - chapter on "Removing"
2. Remove front ashtray. --> 682019 Removing and installing front ashtray - chapter on "Removing"
3. Remove lid for rear tray.
4. Remove cigarette lighter. Refer to 90 62 19 Removing and installing cigar lighter - as of MY 2005 (All
Models) .
5. Remove center console socket. Refer to 90 58 19 Installing and removing socket - as of MY 2005 (All
Models) .
6. Remove interior monitoring sensor. Refer to 96 85 19 Removing and installing interior monitoring sensor
7. Removing switch for convertible top operation Refer to 61 60 19 Removing and installing switch for roof -
8. Remove wire harness for center console. Refer to 97 20 19 Removing and installing wiring harness for
center console - as of MY 2005 (All Models) .
DISASSEMBLING THE CENTER CONSOLE
Disassembling center console
Microsoft
Fig. 79: Unclipping fastening nut

1. Unclip fastening nut, check and replace if necessary.
Microsoft
Fig. 80: Removing locking mechanism insert

3. Unscrew fastening screw -1- . Press in locking tabs -Arrow A- and remove insert of locking mechanism -2- .
See Fig. 80.
Microsoft
Fig. 81: Removing filler piece

4. Loosen adhesive tape -2- and remove filler piece (sound absorber) -1- . See Fig. 81.
ASSEMBLING THE CENTER CONSOLE
Assembling center console
Microsoft
Fig. 82: Sticking in sound absorbent film.

NOTE: Only if replacing the center console.
1. Remove protective film -1- from bonding point and stick sound absorbent film -2- inside the center console -
3- . See Fig. 82.
Microsoft
Fig. 83: Sticking in a filler piece

2. Position filler piece (sound absorber) -1- and use commercially available adhesive tape -2- to fix it to the
center console. See Fig. 83.
Microsoft
Fig. 84: Installing locking mechanism insert

3. Press in locking mechanism insert -2- until it clicks into place and tighten with fastening screw -1- . See Fig.
84.
Microsoft
Fig. 85: Unclipping fastening nut

4. Press in fastening nut.
SUBSEQUENT WORK
Subsequent work
1. Install wire harness for center console. Refer to 97 20 19 Removing and installing wiring harness for
center console - as of MY 2005 (All Models) .
2. Install switch for convertible top operation. Refer to 61 60 19 Removing and installing switch for roof - as
3. Install interior monitoring sensor. Refer to 96 85 19 Removing and installing interior monitoring sensor -
4. Install center console socket. Refer to 90 58 19 Installing and removing socket - as of MY 2005 (All
Models) .
5. Install cigarette lighter. Refer to 90 62 19 Removing and installing cigar lighter - as of MY 2005 (All
Models) .
6. Install lid for rear tray.
Microsoft
7. Installing front ashtray. --> 682019 Removing and installing front ashtray - chapter on "Installing"
8. Install center console. --> 681719 Removing and installing center console - chapter on "Installing"
68 19 19 REMOVING AND INSTALLING COVER FOR CENTER CONSOLE -

PRELIMINARY WORK
Preliminary work
NOTE: For vehicles with manual transmission.
1. Remove shift lever knob. Refer to 34 04 19 Removing and installing shift lever knob - as of MY 2005 (All
Models) .
NOTE: For vehicles with automatic transmission.
2. Remove selector knob. Refer to 37 04 19 Removing and installing selector knob - as of MY 2005 (All
Models) .
3. Remove cover for center console on the left and right. --> 681419 Removing and installing cover for center
console - Chapter "Removing"
REMOVING COVER FOR CENTER CONSOLE
Removing cover for support frame
Microsoft

Fig. 87: Unclipping cover for support frame

1. Move in with a plastic wedge -3- between cover for support frame -1- and frame -2- and unclip cover -1- -
arrow A- . See Fig. 87.
Microsoft
2. Shift gearshift lever to the rear (4th gear) and take out cover -1- toward the top -arrow B- . See Fig. 87.
3. Check clamp -4- , replace if necessary. See Fig. 87.
Removing frame

Microsoft

1. Loosen fastening screws -1- and take out frame -2- upwards. See Fig. 89.
2. Check clamp, replace if necessary.
Removing Tiptronic cover
Microsoft

Fig. 91: Unclipping Tiptronic cover

1. Put selector lever -1- in position "R" . See Fig. 91.
2. Unclip cover -2- with a plastic wedge and pull upwards slightly. See Fig. 91.
Microsoft
Fig. 92: Removing Tiptronic cover

3. Put selector lever -1- in position "D" and take out cover -2- toward the top. See Fig. 92.
INSTALLING COVER FOR CENTER CONSOLE
Installing Tiptronic cover
Microsoft

Fig. 94: Installing Tiptronic cover

NOTE: Make sure that the rotary slide is positioned correctly.
Microsoft
1. Put selector lever -1- in position "D" and move in cover -2- . See Fig. 94.
Fig. 95: Clipping in the Tiptronic cover

2. Put selector lever -1- in position "R" . See Fig. 95.
3. Move in cover -2- at the front into the guide on the right and left -inset- , clip in cover completely. See Fig.
95.
Installing frame
Microsoft

Fig. 97: Installing frame

1. Move in cover -2- at the front into the guide on the right and left -inset- . See Fig. 97.
2. Tighten fastening screws -1- . Tightening torque [Nm] (ftlb.) --> Tightening torque: 1.5 ftlb. +/-0.15 ftlb.
Microsoft
See Fig. 97.
Installing cover for support frame

Microsoft
Fig. 99: Clipping in support frame cover

1. Shift gearshift lever to the rear (4th gear).
2. Position the cover -1- and clip completely into place. See Fig. 99.
SUBSEQUENT WORK
Subsequent work
1. Install cover for center console on the left and right. --> 681419 Removing and installing cover for center
console - Chapter "Installing"
2. Install selector knob. Refer to 37 04 19 Removing and installing selector knob - as of MY 2005 (All
Models) .
3. Install shift lever knob. Refer to 34 04 19 Removing and installing shift lever knob - as of MY 2005 (All
Models) .
68 20 19 REMOVING AND INSTALLING FRONT ASHTRAY - AS OF MY 2005

(ALL MODELS)
REMOVING FRONT ASHTRAY
Removing front ashtray
Microsoft
Fig. 100: Removing front ashtray

1. Open ashtray -1- -Arrow A- and pull it upwards -Arrow B- . See Fig. 100.
INSTALLING FRONT ASHTRAY
Installing front ashtray
Microsoft
Fig. 101: Installing front ashtray

1. Insert opened ashtray -1- -Arrow A- and close lid -Arrow B- . See Fig. 101.
68 23 19 REMOVING AND INSTALLING SUN VISOR - AS OF MY 2005

REMOVING SUN VISOR
Removing sun visor
Microsoft
Fig. 102: Installation position of sun visor

1. Unclip cover -1- with a screwdriver and unscrew the fastening screw -2- . See Fig. 103.
Fig. 103: Removing sun visor

2. Pull off the sun visor -3- from the mounting saddle towards the center of the car. See Fig. 103.
Microsoft
INSTALLING SUN VISOR
Installing sun visor

1. Insert sun visor -3- into the mounting saddle. See Fig. 105.
2. Position sun visor -3- and screw down using the fastening screw -2- . See Fig. 105.
Microsoft
Fig. 105: Installing sun visor

3. Press in cover -1- until it engages. See Fig. 105.
68 23 19 REMOVING AND INSTALLING SUN VISOR - AS OF MY 2005

REMOVING SUN VISOR
Removing sun visor
Microsoft

Fig. 107: Removing sun visor

1. Detach the sun visor -1- from the support -2- and pull it out of the mounting saddle -3- towards the center of
the vehicle. See Fig. 107.
Microsoft
INSTALLING SUN VISOR
Installing sun visor

Microsoft
Fig. 109: Fitting sun visor

1. Insert sun visor -1- into the mounting saddle -3- and then push it into the support -2- . See Fig. 109.
68 23 37 DISASSEMBLING AND ASSEMBLING SUN VISOR - AS OF MY 2005

(ALL MODELS)
PRELIMINARY WORK
Preliminary work
Remove sun visor. --> 682319 Removing and installing sun visor - chapter on "removing" [987310 987311
987320 987321] --> 682319 Removing and installing sun visor - chapter on "removing" [987120 987121]
DISASSEMBLING SUN VISOR
Removing mirror insert
Fig. 110: Unclipping mirror insert

1. Insert a narrow screwdriver between the mirror insert -3- and mirror housing -2- at the bottom center, and
unclip the mirror insert. See Fig. 110.
Microsoft
Fig. 111: Removing mirror insert

2. Pull the mirror insert -3- upwards and remove from the mirror housing -2- . See Fig. 111.
Removing bulb and contact clips
Microsoft
Fig. 112: Removing bulb and contact clips

1. Remove bulb -5- from contact clips -4- . Take the contact clips upwards out of the holder. See Fig. 112.
Removing mirror housing
Microsoft
Fig. 113: Unclipping mirror housing

1. Insert a narrow plastic spatula between the mirror housing -2- and the sun visor -1- on the left and right and
unclip the mirror housing. See Fig. 113.
Microsoft
Fig. 114: Removing mirror housing

2. Take the electric lead out of the mirror housing -2- and detach the mirror housing from the sun visor. See Fig.
114.
ASSEMBLING SUN VISOR
Installing mirror housing
Microsoft
Fig. 115: Positioning the mirror housing

1. Insert electric lead into the mirror housing -2- . Position the mirror housing in the sun visor. See Fig. 115.
Microsoft
Fig. 116: Press in mirror housing

2. Press the mirror housing -2- at all four corners until it locks into place. See Fig. 116.
Inserting contact clips and bulb
Fig. 117: Inserting contact clips and bulb

1. Position the contact clips -4- in the mirror housing and fit under the lug. Insert bulb -5- . See Fig. 117.
Installing mirror insert
Microsoft
Fig. 118: Positioning mirror insert

1. Position the lugs on the right and left of the mirror insert -3- in the mirror housing. See Fig. 118.
Microsoft
Fig. 119: Clipping in mirror insert

2. Clip the mirror insert -3- into the mirror housing -2- on the left, right and in the middle. See Fig. 119.
SUBSEQUENT WORK
Subsequent work
Install sun visor. --> 682319 Removing and installing rear window - chapter on "installing" [987310
987311 987320 987321] --> 682319 Removing and installing rear window - chapter on
"installing" [987120 987121]
68 30 19 REMOVING AND INSTALLING CUP HOLDER - AS OF MY 2005

(ALL MODELS)
REMOVING CUP HOLDER
Removing cup holder
Fig. 120: Removing cup holder

1. Open the glove compartment.
Microsoft
2. Unscrew fastening screws -2- from cupholder -1- . See Fig. 120.
3. Take off the cup holder -1- . See Fig. 120.
INSTALLING CUP HOLDER
Installing cup holder
Fig. 121: Installing cup holder

1. Push cup holder -1- into the shaft of the glove compartment. See Fig. 121.
2. Tighten fastening screws -2- . Tightening torque --> Final tightening: 7.2 ftlb. See Fig. 121.
68 31 19 REMOVING AND INSTALLING CASSETTE/CD BOX - AS OF MY

2005 (ALL MODELS)
PRELIMINARY WORK
Preliminary work
Remove glove compartment. --> 681519 Removing and installing glove compartment - chapter on
"removing"
Microsoft
REMOVING CD BOX
Removing CD holder.
Fig. 122: Installation location for CD holder

Microsoft
Fig. 123: Removing CD holder.

1. Unscrew fastening screws -1- and remove CD holder -2- . See Fig. 123.
INSTALLING CD BOX
Installing CD holder
Fig. 124: Installation location for CD holder

Microsoft
Fig. 125: Installing CD holder

1. Position CD holder -2- at glove compartment -3- and secure using the fastening screws -1- . See Fig. 125.
SUBSEQUENT WORK
Subsequent work
Install glove compartment. --> 681519 Removing and installing glove compartment - chapter on
"installing"
68 47 19 REMOVING AND INSTALLING WINDSTOP - AS OF MY 2005

REMOVING WINDSTOP
Removing windstop
Microsoft
Fig. 126: Installation position of windstop

Microsoft
Fig. 127: Removing outer windstop

1. Press outer windstop to the rear out of the roll-over bar.
Microsoft
Fig. 128: Removing center windstop

2. Disengage center windstop at the latches -A- on the left and right, tilt to the rear -B- and remove. See Fig.
128.
INSTALLING WINDSTOP
Fitting fastening parts
Microsoft

NOTE: If the windstop is retrofitted, three fastening parts must be fitted for the center
windstop.
1. Remove trim for roll-over bar. Refer to 70 81 19 Removing and installing trim for roll-over bar - as of
Microsoft
Fig. 130: Riveting the fastening parts

2. Position the two fastening parts in the upper area of the roll-over bar -1- at the existing holes and rivet them
in place -2- . See Fig. 130.
Microsoft
Fig. 131: Fit fastening part to trim

3. Mark the fastening part -1- centrally on the back of the trim for the roll-over bar, drill and rivet in place -2- .
See Fig. 131.
4. Install trim for roll-over bar. Refer to 70 81 19 Removing and installing trim for roll-over bar - as of MY
Installing windstop
Microsoft

Microsoft
Fig. 133: Installing outer windstop

1. Position outer windstop from the rear on the roll-over bar with the plastic tabs and press in.
Microsoft
Fig. 134: Installing center windstop

2. Install center windstop.
2.1. Mount windstop on the lower fastening part.
2.2. Tilt windstop forwards and engage at the two upper fastening parts.
68 54 19 REMOVING AND INSTALLING LUGGAGE NET/MESH - AS OF MY

REMOVING LUGGAGE NET/MESH
Microsoft
Removing luggage net
Fig. 135: Installation position for luggage net/mesh

1. Open the rear lid.
Microsoft
Fig. 136: Removing luggage net

2. Disengage luggage net -1- from the tie-down rings -2- and remove. See Fig. 136.
Removing luggage mesh
Microsoft

1. Fold front seat forwards.
Fig. 138: Releasing locking mechanism

Microsoft
3. Release locking mechanism of luggage mesh right and left in -direction of arrow- . See Fig. 138.
Fig. 139: Removing luggage mesh

4. Disengage luggage mesh -1- right and left from the bodyshell hooks -2- -Arrow A- and then remove from
mounting saddle -3- -Arrow B- . See Fig. 139.
INSTALLING LUGGAGE NET/MESH
Fitting fastening parts
Microsoft

NOTE: If the luggage mesh is retrofitted, the following spare parts must be fitted for the
luggage mesh.
Fig. 141: Removing lining for engine compartment lid

Microsoft
1. Lift lining of engine compartment lid at the front -1- with a plastic wedge -2- -Arrow A- and pull out to the
front -Arrows B- . See Fig. 141.
Fig. 142: Removing tie-down ring

2. Unscrew fastening screw -2- and remove tie-down ring -1- right and left. See Fig. 142.
Microsoft
Fig. 143: Installing bearing pedestal

3. Position mounting saddle -1- right and left on the body and screw down with fastening screw -2- . -->
Tightening torque: 10 (7.5 ftlb.) Nm +0.5 (0.5 ftlb.) Nm See Fig. 143.
Microsoft
Fig. 144: Installing lining for engine compartment lid

4. Insert lining for engine compartment lid -1- with the clips -arrows- in the mounting points and press
downwards. See Fig. 144.
Microsoft
Fig. 145: Removing lid

5. Unclip lid -1- right and left from the C-pillar trim panel -2- . See Fig. 145.
Fig. 146: Installing cover and trim

Microsoft
6. Push cover -2- right and left fully onto the bodyshell hooks -1- . See Fig. 146.
7. Clip trim -3- right and left into the C-pillar trim panel -4- . See Fig. 146.
Installing luggage mesh

Microsoft
Fig. 148: Installing luggage mesh

1. Insert luggage mesh -1- right and left in the mounting saddle -3- -Arrow A- and then engage in the bodyshell
hooks -2- -Arrow B- . See Fig. 148.
Microsoft
Fig. 149: Locking luggage mesh

2. Lock the locking mechanism of the luggage mesh right and left in -direction of arrow- . See Fig. 149.
3. Close rear lid.
4. Fold back front seat.
Installing luggage net
Microsoft

Microsoft
Fig. 151: Installing luggage net

1. Position luggage net -1- and engage in the tie-down eyes -2- . See Fig. 151.
2. Close rear lid.
68 57 19 REMOVING AND INSTALLING STORAGE POCKET/BOX - AS OF

PRELIMINARY WORK
Preliminary work
Move convertible top to service position. Refer to 61 01 IN Diagram of convertible top - as of MY 2005
Microsoft
REMOVING STORAGE POCKET/BOX
Removing storage pocket/box
Fig. 152: Removing storage pocket/box

1. Twist the turn-lock fasteners -1- in -direction of arrow- and lift storage pocket/box -2- up and off. See Fig.
152.
INSTALLING STORAGE POCKET/BOX
Installing storage pocket/box
Microsoft
Fig. 153: Installing storage pocket/box

1. Position storage pocket/box -2- and fasten with the turn-locks -1- by turning in -direction of arrow- . See
Fig. 153.
SUBSEQUENT WORK
Subsequent work
End service position. Refer to 61 01 IN Diagram of convertible top - as of MY 2005 (Boxster, Boxster RHD,
Boxster S, Boxster S RHD) .
Microsoft
ACCESSORIES & EQUIPMENT Lights, lamps, switches exterior
Lights, lamps, switches exterior
94 05 19 REMOVING AND INSTALLING MAIN LIGHT SWITCH - AS OF MY

2005 (ALL MODELS)
REMOVING MAIN LIGHT SWITCH
Removing main light switch
Fig. 1: Install location

Microsoft
Fig. 2: Removing main light switch

1. Press in rotary knob on the light switch (but not to the limit) and turn the switch to the right.
2. Pull the light switch out.
Microsoft
Fig. 3: Releasing electrical connector

3. Release -A- and remove -B- electrical connector. See Fig. 3.
INSTALLING MAIN LIGHT SWITCH
Installing main light switch
Microsoft

1. -A- Insert the light switch connector until it is felt to engage. See Fig. 4.
2. -B- Push in the light switch to its limit and turn the rotary knob anti-clockwise. See Fig. 4.
94 14 19 REMOVING AND INSTALLING HEADLIGHT MOUNTING - AS OF MY

2005 (ALL MODELS)
PRELIMINARY WORK
Preliminary work - headlight mounts
Microsoft
Remove the headlights. --> 941519 Removing and installing headlights - removing
Remove the front spoiler. Refer to 63 15 19 Removing and installing front spoiler - as of MY 2005 (All
Models) .
Remove front wheel housing liner. Refer to 50 56 19 Removing and installing front wheel housing liner - as
REMOVING HEADLIGHT MOUNTING
Removing headlight mount
NOTE: The main headlights are fitted into the body at the factory.
A new adjustment may only be made in the case of accident repairs or

replacement of the main headlights.
The headlight mount is secured to the body by 3 knurled nuts.
Fig. 5: Adjusting element

1. Unscrew the 3 knurled nuts from the adjusting elements.
Microsoft
Fig. 6: Mount installation

2. Pull mount forwards out of the body.
INSTALLING HEADLIGHT MOUNTING
Installing headlight mount
NOTE: The main headlights are fitted into the body at the factory.
A new adjustment may only be made in the case of accident repairs or

replacement of the main headlights.
The headlight mount is secured to the body by 3 knurled nuts.
Microsoft
Fig. 7: Adjusting element

1. Push the mount into the body and screw down with three knurled nuts. --> Tightening torque: 6 ftlb. +/-1.5
ftlb.
2. Check that the gaps match the specified gap dimensions --> 50 IN DIAGRAM - BODY GAP
DIMENSIONS - AS OF MY 2005 (CAYMAN S, CAYMAN S RHD) or 50 IN DIAGRAM - BODY GAP
DIMENSIONS - AS OF MY 2005 (BOXSTER, BOXSTER RHD, BOXSTER S, BOXSTER S RHD) .
Adjust the headlight mount if necessary. --> 941419 Removing and installing headlight mount - testing and
adjusting.
TESTING AND ADJUSTING HEADLIGHT MOUNTING
Testing and adjusting headlight mount
Microsoft
Fig. 8: Edge of body

NOTE: The headlight cover lens should lie approximately 2 mm below the body edge.
Microsoft
Fig. 9: Factory fitting of the adjusting element fastening nuts

Where the headlight housing joins the body, both should be in the same plane (flush).
Microsoft
Fig. 10: Fitting of the fastening nuts in the case of accident repairs or replacement of the main headlights
Adjust fastening nuts to the same height as the old unit and tighten gently by hand.
Microsoft
Fig. 11: Mounting plate removed

1. Adjust fastening nuts to the same height as the old unit and tighten gently by hand.
2. Press headlight housing firmly into the body and lock.
3. After adjustment, tighten the fastening nuts. --> Tightening torque: 6 ftlb. +/-1.5 ftlb.
SUBSEQUENT WORK
Subsequent work - headlight mounts
Install front wheel housing liner. Refer to 50 56 19 Removing and installing front wheel housing liner - as of
Install the front spoiler. Refer to 63 15 19 Removing and installing front spoiler - as of MY 2005 (All
Models) .
Installing headlights. --> 941519 Removing and installing headlights - installing
94 15 19 REMOVING AND INSTALLING MAIN HEADLIGHT - AS OF MY 2005

(ALL MODELS)
REMOVING MAIN HEADLIGHT
Microsoft
Removing main headlight
NOTE: Risk of damage to headlights due to chafing and excessive temperatures.
Headlights must not be covered when they are switched on, e. g. wing protector
or film.
Switch off the ignition.
Fig. 12: Releasing carpet at the sides.

1. Release carpet at the side by unscrewing plastic nut -A, arrow- . See Fig. 12.
Microsoft
Fig. 13: Rubber stopper

2. Pull rubber stopper -B- out of the release opening. See Fig. 13.
Microsoft
Fig. 14: Release the headlight.

3. Place the socket wrench from the tool kit on the release axle.
4. The toggle of the socket wrench should point horizontally to the rear.
5. Turn the socket wrench through approx. 180° -A- and leave it in position. See Fig. 14.
6. The headlight is now unlocked and can be pulled forwards out of the wing.
7. Turn the socket wrench back until it points vertically -B- downwards. See Fig. 14.
INSTALLING MAIN HEADLIGHT
Installing main headlight
NOTE: Risk of damage to headlights due to chafing and excessive temperatures.
Headlights must not be covered when they are switched on, e. g. wing protector
or film.
Switch off the ignition.
Microsoft
Fig. 15: Lock headlight.

1. Insert headlight into guide rails and push fully home into wing -arrow- .
2. Press the headlight to the rear, turning the socket wrench at the same time until the wrench points
horizontally to the rear -arrow C- . In the process, the headlight lock must engage with an audible and
perceptible click.
Microsoft
Fig. 16: Rubber stopper

3. Check the correct seating of the headlight, e. g. by pulling gently in the area of the fog light.
4. Insert rubber stopper -B- in the release opening.
Microsoft
Fig. 17: Fastening carpet at the sides.

5. Screw the carpeting at the side tight with the plastic screw -A- .
94 15 IN CONVERTING HEADLIGHTS FOR LEFT/RIGHT-HAND DRIVING - AS

CONVERTING HALOGEN HEADLIGHTS FOR LEFT/RIGHT-HAND DRIVING
NOTE: For driving in countries in which vehicles drive on the other side of the road, it
is important to convert the headlights as soon as you cross the border.
The dipped beam headlight then lights symmetrically so that oncoming traffic is
not dazzled.
When you return to your own country, reset the headlights to 0 .
Microsoft
Fig. 18: Halogen headlight

1. Remove the headlight. --> 9415IN - Converting headlights for left/right-hand driving - section on
"Removing"
2. Open the housing cover.
3. Set lever to position -T- . See Fig. 18.
4. Close headlight housing cover and install headlight. --> 941519 Removing and installing headlights -
5. Repeat conversion for other headlight.
CONVERTING BI-XENON HEADLIGHTS FOR LEFT/RIGHT-HAND DRIVING
NOTE: For driving in countries in which vehicles drive on the other side of the road, it
is important to convert the headlights as soon as you cross the border.
The dipped beam headlight then lights symmetrically so that oncoming traffic is
not dazzled.
When you return to your own country, reset the headlights to 0 .
Microsoft
Fig. 19: Bi-Xenon headlight

1. Remove the headlight. --> 9415IN IN - Converting headlights for left/right-hand driving - section on
"Removing"
2. Open the housing cover.
3. Set lever to position -T- . See Fig. 19.
4. Close headlight housing cover and install headlight. --> 941519 Removing and installing headlights -
5. Repeat conversion for other headlight.
94 23 19 REMOVING AND INSTALLING HALOGEN BULB - AS OF MY 2005

(ALL MODELS)
PRELIMINARY WORK
Preliminary work
Remove main headlight. --> 941519 Removing and installing headlight - section on "Removing"
Microsoft
REMOVING HALOGEN BULB
Removing cap of main headlight
Fig. 20: Fastening screws for cap

1. Unscrew four fastening screws -1- from the cap. See Fig. 20.
Microsoft
Fig. 21: Releasing cap

2. Release cap once at the top and twice at the bottom -a- and remove from the main headlight. See Fig. 21.
Removing halogen bulb
Microsoft
Fig. 22: Installation position shown on the 911 headlight

A - Halogen bulb
B - High beam bulb
Microsoft
Fig. 23: Disengaging securing clip

1. Disengage securing clip.
Microsoft
Fig. 24: Pulling off electrical connector

2. Pull electrical connector off bulb and remove bulb.
Removing high beam halogen bulb
Microsoft
Fig. 25: Installation position shown on the 911 headlight

A - Halogen bulb
B - High beam bulb
Microsoft
Fig. 26: Unscrewing bayonet lock

1. Unscrew high beam bulb, bayonet lock counter-clockwise.
Microsoft
Fig. 27: Unplugging electrical connector

2. Unclip electric connector -a- and unplug. See Fig. 27.
INSTALLING HALOGEN BULB
Installing halogen bulb
CAUTION: Danger of injury! Danger of material damage if bulbs are used or handled
incorrectly!
--> When installed, the headlight has a high voltage.
--> Only bulbs specified in the bulb table may be used!
--> Bulbs with a higher wattage may damage the bulb housing!
--> To prevent short circuits, the load in question must be switched off when changing bulbs!
--> New bulbs must be clean and free of grease. Therefore, never touch bulbs with your bare hands! To change
the bulbs, use a cloth or soft paper.
--> Observe the safety instructions when replacing a bulb in a Bi-Xenon headlight.
Microsoft
--> In certain states, it is compulsory to carry spare light bulbs.
Fig. 28: Pushing connector onto bulb

1. Push the electrical connector fully onto the bulb.
2. Engage locking clip.
Installing high beam halogen bulb
incorrectly!
Microsoft
Fig. 29: Pushing on electric connector

1. Push electric connector onto bulb until it clicks into place.
Microsoft
Fig. 30: Installing high beam bulb

2. Insert high beam bulb into headlight and lock with bayonet lock.
Installing main headlight cap
Microsoft
Fig. 31: Positioning cap

1. Position cap on main headlight and press into place, making sure that the cap engages once at the top and
twice at the bottom.
Microsoft
Fig. 32: Screwing in the fastening screws

2. Screw in four fastening screws -1- for the cap. See Fig. 32.
SUBSEQUENT WORK
Subsequent work
Install main headlight. --> 941519 Removing and installing headlight - section on "Installing"
Carry out functional check of headlights.
94 23 IN BULB TABLE AND INSTALLATION INSTRUCTIONS - AS OF MY

2005 (ALL MODELS)
BULB TABLE
Bulb table
Shape, wattage
Dipped beam, halogen H7, 55 W
Dipped beam for Bi-Xenon headlight Philips, D2S, 35 W
High beam, halogen H9, 65 W
Microsoft
Auxiliary main beam for Bi-Xenon headlight H11, 55 W

Fog light H8, 55 W
Parking light, front W, 5 W
Right tail light, rear fog light P, 21/4 W

Brake/tail light. P, 21/4 W BV
Rear tail light, reflector P, 21/5 W
Reverse light P, 21 W
Number plate light C, 5 W
Direction indicator, front and rear PY, 21 W

Direction indicator light, side WY, 5 W
Door warning light W, 5 W

Luggage compartment light K, 10 W
Engine compartment light K, 10 W
Interior light K, 10 W
Footwell light K, 10 W
Glove compartment light K, 10 W
Reading light 6 W Xenon
INSTALLATION INSTRUCTIONS
Installation instructions for bulbs
WARNING: Risk of injury due to high voltage to built-in Bi-Xenon headlights.
--> Switch ignition off, remove ignition key and turn off light switch.
CAUTION: Danger of damage to property if bulbs are used or handled incorrectly!
 Risk of damage to bulbs and bulb housing.
--> Switch off ignition and remove ignition key.
--> To prevent short circuits, the load in question must be switched off while changing bulbs.
--> Only bulbs specified in the bulb table may be used.
--> Bulbs with a higher wattage may damage the bulb housing.
--> New bulbs must be clean and free of grease. Therefore, never touch the bulbs with your bare hands. Use a
Microsoft
cloth or soft paper when changing bulbs.
94 27 19 REMOVING AND INSTALLING BULB FOR PARKING LIGHT - AS OF

PRELIMINARY WORK
Preliminary work for parking light bulb
Remove auxiliary headlight. --> 947119 Removing and installing auxiliary headlight - section on
"Removing"
REMOVING BULB FOR PARKING LIGHT
Removing parking light bulb
Fig. 33: Unlocking bulb holder

1. Pull out mounting for parking light bulb from fog light.
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Fig. 34: Removing bulb from holder

2. Unscrew parking light bulb from bulb holder.
INSTALLING BULB FOR PARKING LIGHT
Installing parking light bulb
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Fig. 35: Pushing bulb into holder

1. Insert bulb into holder.
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Fig. 36: Locking bulb holder

2. Insert and lock bulb holder.
SUBSEQUENT WORK
Subsequent work for parking light bulb
Install auxiliary headlight. --> 947119 Removing and installing auxiliary headlight - section on "Installing"
94 27 19 REMOVING AND INSTALLING BULB FOR PARKING LIGHT - AS OF

PRELIMINARY WORK
Preliminary work for parking-light bulb
"Removing"
REMOVING BULB FOR PARKING LIGHT
Removing parking light bulb
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Fig. 37: Removing bulb

1. Press the bulb into the holder, turn (bayonet lock) and remove from the holder.
INSTALLING BULB FOR PARKING LIGHT
Installing parking light bulb
1. Observe bulb table and installation instructions. --> 9423IN Bulb table
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Fig. 38: Installing bulb

2. Press bulb into holder and turn (bayonet lock). Check that it is secure.
SUBSEQUENT WORK
Subsequent work for parking-light bulb
94 31 19 REMOVING AND INSTALLING TAIL LIGHT - AS OF MY 2005 (ALL

MODELS)
REMOVING TAIL LIGHT
Removing tail light
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Fig. 40: Unscrew fastening screw.

1. Unscrew the three fastening nuts -1- for the tail light. See Fig. 40.
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Fig. 41: Releasing and pulling off connector

2. Pull out rear light, release the electric central connector for the rear light -A- and pull it off. See Fig. 41.
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Fig. 42: Releasing the plate for the bulbs

3. Take out rear light and release the plate for the bulbs -A- and remove. See Fig. 42.
INSTALLING TAIL LIGHT
Installing tail light
1. Push on the plate for the bulbs on the rear light until the plate clicks into place.
2. Check the seal for the rear light and if in doubt, replace.
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3. Push the central connector for the tail light together until the connector is felt to engage.
4. Push the electric lead into the rear wing and insert the tail light into the mounting.
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Fig. 44: Screwing down the tail light

5. Screw down the rear light with the three fastening nuts -1- . --> Tightening torque: 2 ftlb. See Fig. 44.
INFORMATION
Lamp overview: tail light
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Fig. 45: Lamp overview: tail light

A - P21 W, reverse light
B - PY21 W, direction indicator light
C - P21/4 W, brake light/tail light
D - P21/5 W, rear fog light/tail light
E - P21/4 W, rear fog light/tail light
94 36 19 REMOVING AND INSTALLING BRAKE LIGHT SWITCH - AS OF MY

2005 (ALL MODELS)
REMOVING BRAKE LIGHT SWITCH
Removing brake light switch
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Fig. 46: Overview of stop light switch, shown on the 911

Fig. 47: Disconnecting plug for stop light switch

2. Disengage plug from stop light switch on both sides (Arrows a) and remove.
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Fig. 48: Removing stop light switch

3. Turn brake light switch 90° counter-clockwise and remove it.
INSTALLING BRAKE LIGHT SWITCH
Installing stop light switch
NOTE:  The brake light switch setting is firmly fixed and is not adjustable!
 The brake light switch may be fitted only once in order to ensure that it fits
tightly!
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Fig. 49: Installing stop light switch

1. Before fitting the stop light switch, pull out the plunger (arrow) out of the stop light switch until the stop.
2. Insert stop light switch with the bayonet lock take-up bore, press in, and turn clockwise by 90°. This sets the
tappet push rod to the exact length.
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Fig. 50: Connecting stop light switch plug

3. Position and insert the plug until it is felt to engage.
94 44 19 REMOVING AND INSTALLING BULB FOR NUMBER PLATE LIGHT -

REMOVING BULB FOR NUMBER PLATE LIGHT
Removing number plate light
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Fig. 51: Overview of number plate light, shown on the 911

G - Number plate lights
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Fig. 52: Removing number plate light, shown on the 911

1. Unscrew the two fastening screws and remove the number plate light.
Removing bulb for number plate light
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Fig. 53: Removing bulb for number plate light

1. Remove defective bulb from between the contact springs.
INSTALLING BULB FOR NUMBER PLATE LIGHT
Installing bulb for number plate light
NOTE: Only use the relevant bulb specified in the bulb table --> 94 23 IN Bulb table and
installation instructions.
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Fig. 54: Installing bulb for number plate light

1. Insert new bulb into the contact springs.
Installing number plate light
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Fig. 55: Number plate light overview

G - Number plate lights
Fig. 56: Installing number plate light

1. Insert number plate lights and tighten with the two fastening screws.
94 47 19 REMOVING AND INSTALLING HAZARD WARNING LIGHT SWITCH

- AS OF MY 2005 (ALL MODELS)
PRELIMINARY WORK
Preliminary work for hazard warning light switch
Remove middle fresh-air vent. Refer to 85 53 19 Removing and installing middle air vent - as of MY 2005
(All Models) .
REMOVING HAZARD WARNING LIGHT SWITCH
Removing hazard warning light switch
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Fig. 58: Releasing hazard warning light switch at left and right
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1. Reach in through the openings of the removed middle air vent and release the hazard warning light switch at
the left and right.
Fig. 59: Unlocking the electric connector

2. Take the hazard warning light switch out sideways through the dashboard, release the electric connector and
pull it off.
INSTALLING HAZARD WARNING LIGHT SWITCH
Installing hazard warning light switch

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Fig. 60: Connecting electric connector to hazard warning light switch

1. Push the electric connector into the hazard warning light switch until the connector clicks into place.
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Fig. 61: Pushing hazard warning light switch into the mounting point
2. Push the hazard warning light switch at both sides into the mounting point in the dashboard until it clicks into
place.
SUBSEQUENT WORK
Subsequent work for hazard warning light switch
Install middle fresh-air vent. Refer to 85 53 19 Removing and installing middle air vent - as of MY 2005 (All
Models) .
94 49 19 REMOVING AND INSTALLING FRONT CONTROL UNIT - AS OF MY

2005 (ALL MODELS)
TOOLS

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PRELIMINARY WORK
Preliminary work - front control unit
Remove luggage compartment lining in the area around the front control unit.
Refer to 70 30 19 Removing and installing front luggage compartment cover - as of MY 2005 (All
Models) . Refer to 70 30 19 Removing and installing rear luggage compartment cover - as of MY 2006
REMOVING FRONT CONTROL UNIT
Removing front control unit
Fig. 62: Installation position diagram for the 997

If a new control unit has to be installed, read out as much of the data from the old control unit as possible using
the PIWIS Tester P 9718. --> 944919 Removing and installing front control unit - chapter on "Coding"
WARNING: Risk of damage to electronic control modules.
 If care is not taken, electrical and electronic components may be

destroyed.
--> Before removing the control module, switch off the ignition and remove the ignition key.
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Fig. 63: Removing the cover

2. Push a screwdriver into the openings -A- and unclip the four clips holding the cover -1- . See Fig. 63.
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Fig. 64: Electric plug

3. Release and unplug both electric connectors -A- and disengage the left and right electric lines on the control
unit. See Fig. 64.
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Fig. 65: Detaching control unit

4. Unscrew the fastening nuts -2- , lift up the control unit and detach it. See Fig. 65.
INSTALLING FRONT CONTROL UNIT
Installing front control unit

destroyed.
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Fig. 66: Attaching control unit.

1. Engage the front control unit in the body and screw down with the fastening nut -2- . --> M6: 7.2 ftlb. See
Fig. 66.
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Fig. 67: Plugging in and locking electric plug

2. Push in the electric plug and lock it so that it is felt to engage.
3. Clip in left and right electric lines to the control unit.
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Fig. 68: Positioning the cover.

4. Position the cover -1- and push it in until it snaps into place in the four clips. See Fig. 68.
5. Screw down cover with the fastening screw -3- . See Fig. 68.
6. If a new control unit has been installed, it must be programmed in the vehicle. --> 944919 Removing and
installing front control unit - chapter on "Coding"
SUBSEQUENT WORK
Subsequent work - front control unit
Secure luggage compartment lining in the area around the front control module.
PROGRAMMING FRONT CONTROL UNIT
Reading out and printing out values
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NOTE: Follow the instructions on the Tester.
Later versions of the software may display slightly different text or require a
slightly different procedure. The instructions you receive from the tester itself
take precedence over this description.
Continue.
2. Select Vehicle type .
3. Move from Vehicle type to Control units >> .
4. Select the required Control unit with the cursor keys and press the >> key.
7. The message Codes successfully read out appears on the screen of the Porsche System Tester. Press >> .
9. Switch on ignition. After replacement of the control unit, the data previously read out (see Item 6) is reloaded
under the menu Write in codes . Press >> .
10. System Tester displays Coding write-in complete . Press the >> key.
11. Quit menu, read out all control units and erase fault memory.
12. In the control unit Front end , perform the menu Calibration .
13. Check adjustment of headlights and adjust if necessary.
Coding (programming) the control unit
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Continue.
2. Select Vehicle type, select the menu Special functions , start Vehicle handover and follow the instructions
on the Tester.
3. Erase All fault memories .
4. Using the >> key, move from the vehicle type to the list of control units. Perform the automatic control unit
search.
5. Select the Front end control unit with the cursor keys and press the >> key.
6. Select Coding with the cursor keys and press >> .
7. Select the version required for the vehicle in question and follow the instructions on the Tester.
9. In the control unit Front end , perform the menu Calibration .
10. Check adjustment of headlights and adjust if necessary.
94 50 19 REMOVING AND INSTALLING STEERING-COLUMN SWITCH - AS

PRELIMINARY WORK
Preliminary work - steering column switch
Refer to 69 58 19 Removing and installing driver's airbag unit - as of MY 2005 (All Models) .
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Refer to 48 10 19 Removing and installing steering wheel - as of MY 2005 (All Models) .
Removing and installing trim
TECHNICAL VALUES
Technical values - steering column switch
--> Tightening torque: 4.5 ftlb.
REMOVING STEERING-COLUMN SWITCH
Removing steering column switch

WARNING: Incorrect adjustment of the contact unit may cause the airbag contact unit
to be destroyed when the steering wheel is turned all the way.
 Risk of destroying airbag contact unit.
--> When removing and installing steering column switch, the steering wheel must be pulled off in the straight-
ahead position. This ensures that the airbag contact unit is locked in the central position.
--> If the setting has accidently changed (locking element released, airbag contact unit out of adjustment), the
airbag contact unit must be adjusted as follows.
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--> To position the airbag contact unit in the central position, press the locking element and turn the rotor
carefully to the left as far as it will go.
--> Then turn the rotor carefully to the right, approx. 3.5 to 3.75 revolutions, until the locking element engages.
The rotor arrow marking must be positioned between the arrow markings of the contact unit.

destroyed.
Fig. 70: Releasing electrical plug

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1. Press locking element for the electrical plug and pull off the plug.
Fig. 71: Undoing fastening screw

2. Loosen fastening screw and pull steering column switch downwards from the steering column.
INSTALLING STEERING-COLUMN SWITCH
Installing steering-column switch
WARNING: Incorrect adjustment of the contact unit may cause the airbag contact unit
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to be destroyed when the steering wheel is turned all the way.
 Risk of destroying airbag contact unit.
--> When removing and installing steering column switch, the steering wheel must be pulled off in the straight-
ahead position. This ensures that the airbag contact unit is locked in the central position.
--> If the setting has accidently changed (locking element released, airbag contact unit out of adjustment), the
airbag contact unit must be adjusted as follows.
The rotor arrow marking must be positioned between the arrow markings of the contact unit.
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Fig. 72: Installation of steering column switch

1. Slide steering column switch onto steering column to the stop and secure with fastening screw. -->
Tightening torque: 4.5 ftlb.
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2. Push on connector plugs of steering column switch until they are felt to engage.
SUBSEQUENT WORK
Subsequent work - steering column switch
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94 50 37 DISASSEMBLING AND ASSEMBLING STEERING-COLUMN

SWITCH - AS OF MY 2005 (ALL MODELS)
PRELIMINARY WORK - STEERING-COLUMN SWITCH
Preliminary work - steering column switch
DISASSEMBLING AND ASSEMBLING STEERING-COLUMN SWITCH
Disassembling steering column switch
Fig. 74: Diagram of steering column switch

-A- - Direction indicator switch See Fig. 74.
-B- - GRA switch See Fig. 74.
-C- - Contact unit for airbag See Fig. 74.
-D- - Switch for wiper and washer system See Fig. 74.
-E- - Electronic unit See Fig. 74.
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Fig. 75: Airbag contact unit marking

NOTE: Ensure that arrow -A- on the rotor is positioned between the markings -B- of the
arrows -C- on the airbag contact unit and that the locking element -D- is
engaged.
Fig. 76: Airbag contact unit locking tabs

1. Carefully lift up the three retaining tabs and remove airbag contact unit -C- . See Fig. 74.
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Fig. 77: Fastening screws

2. Unscrew the six fastening screws.
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Fig. 78: Electronic unit

3. Turn the steering column switch round and remove the electronic unit -E- . See Fig. 74.
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Fig. 79: GRA switch

4. Pull the GRA switch -B- downward and disengage. See Fig. 74.
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Fig. 80: Switch for wiper and washer system

5. Pull switch for wiper and washer system -D- up and out of the mount. See Fig. 74.
Assembling steering column switch
WARNING: Risk of damage to airbag contact unit!
 If the contact unit has been adjusted, proceed in accordance with

the following work instruction:
The rotor arrow marking must be positioned between the arrow markings of the contact unit
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Fig. 81: Switch for wiper and washer system

1. Insert switch for wiper and washer system -D- into the mount. See Fig. 81.
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Fig. 82: GRA switch

2. Attach the GRA switch -B- and fold it upwards. See Fig. 82.
3. Turn the steering column switch and position the electronic unit.
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Fig. 83: Screw in 6 fastening screws.

4. Turn the steering column switch round again and screw in the six fastening screws.
Fig. 84: Position airbag contact unit

5. Position airbag contact unit and press onto the steering column switch until the three tabs engage -arrows- .
See Fig. 84.
SUBSEQUENT WORK - STEERING-COLUMN SWITCH
Subsequent work - steering column switch
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94 53 19 REMOVING AND INSTALLING SIDE DIRECTION INDICATOR LIGHT

REMOVING SIDE DIRECTION INDICATOR LIGHT
Removing side direction indicator light
Fig. 85: Removing direction indicator light

1. Insert a screwdriver through the opening in the wheel housing liner, press on the spring clamp at the direction
indicator light and remove the direction indicator light.
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Fig. 86: Disconnecting electric plug connection

2. Release the electric plug connection and disconnect it from the direction indicator light.
3. Remove the direction indicator light.
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4. Unscrew the bulb holder.
5. Remove the bulb from the holder.
INSTALLING SIDE DIRECTION INDICATOR LIGHT
Installing side direction indicator light
Observe instructions in Bulb table and installation instructions. --> 9423IN Bulb table and installation
instructions
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1. Insert the new bulb into the holder.
2. Screw the holder with the bulb into the direction indicator light.
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3. Insert the electric plug connection into the direction indicator light until the connector can be felt to engage.
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Fig. 90: Installing direction indicator light

4. Engage the direction indicator light in the front apron -A- and clip it in -B- . See Fig. 90.
5. Check operation of direction indicator light.
94 56 19 REMOVING AND INSTALLING BULB FOR FRONT DIRECTION

INDICATOR - AS OF MY 2005 (ALL MODELS)
PRELIMINARY WORK
Preliminary work - bulb for front direction indicator light
--> 941519 Removing and installing main headlight - section on "Removing"
REMOVING BULB FOR FRONT DIRECTION INDICATOR
Removing bulb for front direction indicator light
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Fig. 91: Opening the cap

1. Open cap on headlight.
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Fig. 92: Removing holder from headlight

2. Turn bulb holder to the right (bayonet lock) and pull it out of the headlight mounting point.
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3. Slide in, turn and pull out bulb.
INSTALLING BULB FOR FRONT DIRECTION INDICATOR
Installing bulb for front direction indicator light
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1. Slide bulb into holder and turn (bayonet lock).
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Fig. 95: Installing holder

2. Screw in holder and bulb into headlight (bayonet lock).
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Fig. 96: Installing cap

3. Position and close cap.
SUBSEQUENT WORK
Subsequent work - bulb for front direction indicator light
--> 941519 Removing and installing main headlight - section on "Installing"
94 57 19 REMOVING AND INSTALLING CONTROL UNIT FOR GAS

DISCHARGE - AS OF MY 2005 (ALL MODELS)
PRELIMINARY WORK
Preliminary work on control unit for gas discharge
--> 941519 Removing and installing headlights - "Removing" section
REMOVING CONTROL UNIT FOR GAS DISCHARGE
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Microsoft

Removing control unit for gas discharge
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Fig. 99: Unscrewing fastening screws and pulling out coil

1. Unscrew the fastening screw -2- for the coil and pull the coil -3- out of the cap. See Fig. 99.
2. Unscrew the two fastening screws -1- and remove the control unit. See Fig. 99.
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Fig. 100: Releasing electrical connector with screwdriver

3. Using a screwdriver, carefully release the electrical connector on the screwdriver and lever it out.
INSTALLING CONTROL UNIT FOR GAS DISCHARGE
Installing control unit for gas discharge
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1. Press in the electrical connector for the gas-discharge control unit until it clicks into place.
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Fig. 102: Screwing down the fastening screws and the coil
2. Insert the control unit in the headlight cap and screw down with both fastening screws -1- . See Fig. 102.
3. Push on the coil and screw it down with the fastening screw.
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Microsoft

SUBSEQUENT WORK
Subsequent work on control unit for gas discharge
--> 941519 Removing and installing headlights - "Installing" section
94 59 19 REMOVING AND INSTALLING GAS DISCHARGE LAMP - AS OF MY

2005 (ALL MODELS)
PRELIMINARY WORK
Preliminary work
Remove main headlight. --> 941519 Removing and installing headlight - section on "Removing"
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Microsoft

REMOVING GAS DISCHARGE LAMP
Removing gas discharge lamp
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1. Turn connector to the left (bayonet lock) and pull it off.
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Fig. 108: Disengaging retaining bows

2. Disengage both retaining bows and pull out lamp.
INSTALLING GAS DISCHARGE LAMP
Installing gas discharge lamp
incorrectly!
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1. Replace faulty lamp. Ensure that the lamp is seated correctly when doing so.
Fig. 109: Inserting retaining bows

2. Insert both retainng bows.
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Fig. 110: Positioning electric connector

3. Position electric connector and turn to the right as far as it will go (bayonet lock).
SUBSEQUENT WORK
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Microsoft

Subsequent work
Install main headlight. --> 941519 Removing and installing headlight - section on "Installing"
Carry out functional check of headlights.
94 67 19 REMOVING AND INSTALLING BULB FOR FOG LIGHT - AS OF MY

PRELIMINARY WORK
Preliminary work
"Removing"
REMOVING BULB FOR FOG LIGHT
Removing bulb for fog light
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Fig. 113: Releasing lamp (yellow connector)

1. Turn faulty lamp in left fog light to the left or turn lamp in right fog light to the right (bayonet lock) and
replace.
INSTALLING BULB FOR FOG LIGHT
Installing bulb for fog light
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Fig. 114: Locking lamp

1. Insert new lamp in headlight and turn lamp in left fog light to the right or turn lamp in right fog light to the
left (bayonet lock).
SUBSEQUENT WORK
Subsequent work
94 67 19 REMOVING AND INSTALLING BULB FOR FOG LIGHT - AS OF MY

PRELIMINARY WORK
Preliminary work for fog-light bulb
"Removing"
REMOVING BULB FOR FOG LIGHT
Removing bulb for fog light
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Fig. 115: Releasing bulb

1. Turn fog-light bulb (bayonet lock) and replace.
INSTALLING BULB FOR FOG LIGHT
Installing bulb for fog light
1. Observe bulb table and installation instructions. --> 9423IN Bulb table
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Fig. 116: Locking lamp

2. Insert new bulb in headlight and turn (bayonet lock).
SUBSEQUENT WORK
Subsequent work for fog-light bulb
94 70 19 REMOVING AND INSTALLING AUXILIARY BRAKE LIGHT - AS OF

REMOVING AUXILIARY BRAKE LIGHT
Removing auxiliary brake light
1. Open the convertible top compartment lid using the convertible top release and remove ignition key.
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2. Unscrew the two fastening screws -1- for the auxiliary brake light and turn the light 90°. See Fig. 117.
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3. Release electric connector -A- and pull it off the light. See Fig. 118.
INSTALLING AUXILIARY BRAKE LIGHT
Installing auxiliary brake light
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Fig. 119: Screwing down the auxiliary brake light

1. Push electric connector onto the auxiliary brake light until the connector is felt to engage.
2. Fit auxiliary brake light and screw down with the two fastening screws -1- . See Fig. 119.
3. Check operation of auxiliary brake light.
94 70 19 REMOVING AND INSTALLING AUXILIARY BRAKE LIGHT - AS OF

PRELIMINARY WORK
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Preliminary work for auxiliary brake light
Remove cover for rear luggage-compartment lid. Refer to 70 87 19 Removing and installing trim panel for
rear lid - as of MY 2006 (Cayman S, Cayman S RHD) .
REMOVING AUXILIARY BRAKE LIGHT
Removing auxiliary brake light
Fig. 120: Loosening fastening screws

1. Loosen the two fastening screws -1- for the auxiliary brake light and pull the auxiliary brake light downwards
out of the mounting point on the rear lid. See Fig. 120.
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Fig. 121: Pulling off connector

2. Pull off electric connector on the auxiliary brake light.
INSTALLING AUXILIARY BRAKE LIGHT
Installing auxiliary brake light
1. Connect electric connector to the auxiliary brake light until the connector is felt to engage.
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Fig. 122: Screwing down the auxiliary brake light

2. Position auxiliary brake light in rear lid and screw down with the two fastening screws -1- . --> Tightening
torque: 1.5 (1 ftlb.) Nm See Fig. 122.
3. Check operation of auxiliary brake light.
SUBSEQUENT WORK
Subsequent work for auxiliary brake light
Install cover for rear luggage-compartment lid. Refer to 70 87 19 Removing and installing trim panel for rear
lid - as of MY 2006 (Cayman S, Cayman S RHD) .
94 71 19 REMOVING AND INSTALLING AUXILIARY HEADLIGHT - AS OF MY

REMOVING AUXILIARY HEADLIGHT
Removing auxiliary headlamp
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Fig. 123: Installation location


1. Unscrew both fastening screws -1- . See Fig. 124.
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Fig. 125: Pulling out headlight

2. Pull down headlight at the side -A- and remove it from front apron. See Fig. 125.
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Fig. 126: Unplugging electric connectors

3. Release electric connectors -1, 2- -A- and remove from auxiliary headlight. See Fig. 126.
INSTALLING AUXILIARY HEADLIGHT
Installing auxiliary headlamp
CAUTION: Auxiliary headlamp is inserted into the front spoiler at a tilt.
 Paint damage on the front spoiler.
--> Carefully insert auxiliary headlamp into the guides of the front apron.
--> Make sure that the guide of the housing is inserted into the guide of the front spoiler.
1. Make sure that the ventilation connection piece is correctly seated on the auxiliary headlamp.
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Fig. 127: Pushing on electric connectors

2. Connect the electric connectors -1, 2- until they are felt to engage. See Fig. 127.
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Fig. 128: Engaging locking tab in front apron

3. Push auxiliary headlight into front apron, ensuring that the locking tab -A- is engaged in the front apron. See
Fig. 128.
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Fig. 129: Screwing down auxiliary headlight

4. Push auxiliary headlight on locking tab side -A- upwards and secure using both fastening screws -1- . See
Fig. 129.
SUBSEQUENT WORK
Subsequent work for auxiliary headlight
NOTE: On installing a new auxiliary headlight, the adjustment must be checked with a
headlight adjustment unit and adjusted if necessary.
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Fig. 130: Adjusting auxiliary headlight

Adjust the auxiliary headlight using a size 30 Torx socket wrench.
94 71 19 REMOVING AND INSTALLING AUXILIARY HEADLIGHT - AS OF MY

REMOVING AUXILIARY HEADLIGHT
Removing auxiliary headlamp
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Fig. 131: Main illustration

Fig. 132: Unclipping cover for auxiliary headlight

1. Lift up cover for auxiliary headlight from below and unclip it from the front apron.
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2. Unscrew the three fastening screws -1- and remove the headlights from the front apron. See Fig. 133.
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Fig. 134: Screwing down auxiliary headlight

3. Release the electric connector from the fog-light bulb -1- -A- and disconnect it, turn the holder for the
parking light -2- (bayonet lock) and remove from the headlight. See Fig. 134.
INSTALLING AUXILIARY HEADLIGHT
Installing auxiliary headlamp
1. Insert parking light holder in the auxiliary headlight and lock it (bayonet lock). Push electric connector onto
fog-light bulb until it clicks into place.
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Fig. 135: Tightening auxiliary headlight

2. Position the auxiliary headlight in the front apron and secure it with the three fastening screws.
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Fig. 136: Clipping in cover for auxiliary headlight

3. First, insert cover laterally -A- , then -B- in the front apron and clip it in. See Fig. 136.
SUBSEQUENT WORK
Subsequent work for auxiliary headlight
NOTE: On installing a new auxiliary headlight, the adjustment must be checked with a
headlight adjustment unit and adjusted if necessary.
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Fig. 137: Tightening auxiliary headlight

Using a Torx socket wrench (size 30), adjust the auxiliary headlight through the cover on the adjusting screw -
2- . See Fig. 137.
94 72 19 REMOVING AND INSTALLING SWITCH FOR REVERSING LIGHT -

AS OF MY 2005 (BOXSTER S, BOXSTER S RHD, CAYMAN S, CAYMAN S
RHD)
PRELIMINARY WORK
Preliminary work
Remove rear underbody cover. Refer to 51 94 19 Removing and installing cover for rear underbody - as of
REMOVING SWITCH FOR REVERSING LIGHT
Removing switch for reversing light (6-speed transmission)
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Fig. 138: Overview of switch for reversing light (6-speed transmission)

Fig. 139: Pulling plug off switch for reversing light

1. Release connector on switch for reversing light -Arrow a- and pull it off. See Fig. 139.
Microsoft
Fig. 140: Removing switch for reversing light

2. Unscrew and remove switch for reversing light.
INSTALLING SWITCH FOR REVERSING LIGHT
Installing switch for reversing light (6-speed transmission)
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Fig. 141: Installing switch for reversing light

1. Install switch for reversing light. --> Tightening torque: 15 ftlb.
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Fig. 142: Pushing connector onto switch for reversing light

2. Push connector onto switch for reversing light until it is felt to engage.
3. Check operation of switch for reversing light.
SUBSEQUENT WORK
Subsequent work
Install rear underbody cover. Refer to 51 94 19 Removing and installing cover for rear underbody - as of
94 72 19 REMOVING AND INSTALLING SWITCH FOR REVERSING LIGHT -

AS OF MY 2005 (BOXSTER, BOXSTER RHD)
PRELIMINARY WORK
Preliminary work
Remove rear underbody cover. Refer to 51 94 19 Removing and installing cover for rear underbody - as of
REMOVING SWITCH FOR REVERSING LIGHT
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2. Unscrew the two fastening screws -1- on the holder -2- . See Fig. 144.
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3. Unscrew fastening screw -1- and remove holder -2- . See Fig. 145.
4. Remove switch for reversing light from the transmission.
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Microsoft

2. Unscrew and remove switch for reversing light.
INSTALLING SWITCH FOR REVERSING LIGHT
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Fig. 149: Replacing sealing ring on switch for reversing light

1. Replace sealing ring -1- on switch for reversing light. See Fig. 149.
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2. Insert switch for reversing light in the transmission.
3. Position holder -2- and screw down with the fastening screw -1- . --> Tightening torque: 19 ftlb. See Fig.
150.

4. Position holder -2- on transmission and screw down with the two fastening screws -1- . --> Tightening
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1. Install switch for reversing light. --> Tightening torque: 15 ftlb.
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SUBSEQUENT WORK
Subsequent work
Install rear underbody cover. Refer to 51 94 19 Removing and installing cover for rear underbody - as of
94 78 19 REMOVING AND INSTALLING FRONT ANGLE SENSOR FOR

HEADLIGHT LEVELLING SYSTEM - AS OF MY 2005 (ALL MODELS)
TOOLS

PRELIMINARY WORK
Preliminary work - front angle sensor for headlight levelling system
Remove front underbody panel. Refer to 51 92 19 Removing and installing cover for front underbody - as of
REMOVING FRONT ANGLE SENSOR FOR HEADLIGHT LEVELLING SYSTEM
Removing front angle sensor for headlight levelling system
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Fig. 154: Unscrewing fastening nut

1. Hold intermediate link on rotary lever with second open-ended wrench and screw off fastening nut -2- . See
Fig. 154.
2. Push back rubber cover -1- over the electrical plug connection, release electrical plug connection -A- and
remove connector from angle sensor. See Fig. 154.
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Fig. 155: Unscrewing fastening screw for angle sensor retaining bracket
3. Unscrew fastening screw -3- for angle sensor retaining bracket on side member from below. See Fig. 155.
4. Remove angle sensor from retaining bracket.
INSTALLING FRONT ANGLE SENSOR FOR HEADLIGHT LEVELLING SYSTEM
Installing front angle sensor for headlight levelling system
NOTE: If the angle sensor has been replaced, the front end control unit must be
calibrated; afterwards the headlight setting must be checked and adjusted if
necessary.
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Fig. 156: Securing angle sensor and bracket

1. Fasten angle sensor to retaining bracket and secure with fastening screw -3- to the side member. See Fig.
156.
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Fig. 157: Engaging electrical plug connection

2. Engage electrical plug connection and pull rubber cover -1- carefully over the plug connection (protects
against ingress of water). See Fig. 157.
3. Engage intermediate link on rotary lever and secure with fastening nut -2- . --> Tightening torque: 7 (5
SUBSEQUENT WORK
Subsequent work - front angle sensor for headlight levelling system
necessary.
1. Install front underbody panel. Refer to 51 92 19 Removing and installing cover for front underbody - as
2. Connect the Porsche System Tester PIWIS Tester P 9718 to the vehicle and start the System Tester. Switch
on ignition. >> to continue.
3. Select front end on the control unit, carry out calibration menu.
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4. Check headlight setting and adjust if necessary.
94 79 19 REMOVING AND INSTALLING REAR ANGLE SENSOR FOR

HEADLIGHT LEVELLING SYSTEM - AS OF MY 2005 (ALL MODELS)
TOOLS

REMOVING REAR ANGLE SENSOR FOR HEADLIGHT LEVELLING SYSTEM
Removing rear angle sensor for headlight levelling system
Fig. 158: Removing rear angle sensor for headlight levelling system
1. Hold intermediate link on rotary lever with second open-ended wrench and screw off fastening nut.
2. Push back rubber cover -1- over the electrical plug connection, release electrical plug connection and remove
connector from angle sensor. See Fig. 158.
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3. Unscrew fastening screw -3- for securing retaining bracket for angle sensor, combination wire and brake line
to the body. See Fig. 158.
4. Unscrew the two fastening screws -2- and remove angle sensor from bracket. See Fig. 158.
INSTALLING REAR ANGLE SENSOR FOR HEADLIGHT LEVELLING SYSTEM
Installing rear angle sensor for headlight levelling system
necessary.
Fig. 159: Installing rear angle sensor for headlight levelling system
1. Secure angle sensor to retaining bracket with the two fastening screws -2- . See Fig. 159.
2. Position retaining bracket with angle sensor on the body and screw down with the fastening screw -3- . See
Fig. 159.
3. Engage electrical plug connection and pull rubber cover carefully over the plug connection (protects against
water leaking in).
4. Engage intermediate link on rotary lever and secure with fastening nut. --> Tightening torque: 7 (5 ftlb.)
Microsoft
Nm
SUBSEQUENT WORK
Subsequent work - rear angle sensor for headlight levelling system
necessary.
94 94 19 REMOVING AND INSTALLING SERVO MOTOR FOR HEADLIGHT

LEVELLING SYSTEM - AS OF MY 2005 (ALL MODELS)
TOOLS

PRELIMINARY WORK
Preliminary work - servo motor for headlight levelling system
1. Remove main headlight. --> 941519 Removing and installing headlight - chapter on "Removing"
Microsoft

Microsoft

REMOVING SERVO MOTOR FOR HEADLIGHT LEVELLING SYSTEM
Removing servo motor for headlight levelling system
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Fig. 162: Unscrewing the two fastening screws

1. Unscrew the two fastening screws -1- for the servo motor. See Fig. 162.
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Fig. 163: Disengaging ball head from servo motor for headlight
2. Slide servo motor vertically downwards and remove.
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Fig. 164: Disconnecting electric plug connection

3. Disconnect electrical plug connection from servo motor and remove the servo motor.
INSTALLING SERVO MOTOR FOR HEADLIGHT LEVELLING SYSTEM
Installing servo motor for headlight levelling system
NOTE: After reinstallation or installation of a new servo motor for the headlight
levelling system, the headlight must be calibrated.
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Fig. 165: Connecting the electrical plug connection

1. Push electric plug onto the servo motor until it is felt to engage.
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Fig. 166: Engaging ball head

2. Engage servo motor in the actuator for the main headlight and push servo motor upwards.
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Fig. 167: Tightening the two fastening screws

3. Screw down the servo motor with the two fastening screws.
SUBSEQUENT WORK
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Microsoft

Subsequent work - servo motor for headlight levelling system
NOTE: After reinstallation or installation of a new servo motor for the headlight
levelling system, the headlight must be calibrated.
1. Install main headlight. --> 941519 Removing and installing headlight - chapter on "Installing"
Microsoft
ACCESSORIES & EQUIPMENT Lights, lamps, switches interior, theft protection
Lights, lamps, switches interior, theft protection
96 07 19 REMOVING AND INSTALLING CONTACT SWITCH FOR GLOVE

COMPARTMENT LIGHT - AS OF MY 2005 (ALL MODELS)
PRELIMINARY WORK
Preliminary work
Remove glove compartment. Refer to 68 15 19 Removing and installing glove compartment - as of MY 2005
(All Models) .
REMOVING CONTACT SWITCH FOR GLOVE COMPARTMENT LIGHT
Removing contact switch for glove compartment light
NOTE: The door switch for the glove compartment light is located on the rear of the
glove compartment.
Fig. 1: Overview of contact switch for glove compartment light, shown on the 911 cockpit
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Fig. 2: Unclipping wiring harness

1. Release glove compartment light connector -arrows a- and unplug. See Fig. 2.
2. Remove wire harness on the mounting points on the glove compartment -arrows- . See Fig. 2.
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Fig. 3: Unclipping contact switch for glove compartment light

3. Release mounting points -arrows a- and take out the door switch for the glove compartment light -1- and the
connector socket -2- . See Fig. 3.
INSTALLING CONTACT SWITCH FOR GLOVE COMPARTMENT LIGHT
Installing contact switch for glove compartment light
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Fig. 4: Clipping in contact switch for glove compartment light

1. Press the door switch for the glove compartment light -1- and the connector socket -2- in the mounting
points, until they can be felt to engage. See Fig. 4.
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Fig. 5: Clipping in wiring harness

2. Lay the wiring harness and press in the mounting points on the glove compartment -Arrows- See Fig. 5.
3. Insert the glove compartment light plug until it is felt to engage.
SUBSEQUENT WORK
Subsequent work
Install glove compartment. Refer to 68 15 19 Removing and installing glove compartment - as of MY 2005
(All Models) .
96 15 19 REMOVING AND INSTALLING FOOTWELL LIGHT - AS OF MY 2005

(ALL MODELS)
REMOVING FOOTWELL LIGHT
Removing footwell light
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Fig. 6: Footwell light overview

E - Floor light shown on the 911
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Fig. 7: Removing footwell light

1. Press footwell light carefully out of the trim panel at the cutout -arrow- using a screwdriver. See Fig. 7.
2. Release plug on footwell light -arrows a- and pull it off. See Fig. 7.
3. Remove footwell light.
INSTALLING FOOTWELL LIGHT
Installing footwell light
NOTE: Only use the relevant bulb specified in the bulb table --> 94 23 IN BULB TABLE
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AND INSTALLATION INSTRUCTIONS - AS OF MY 2005 (ALL MODELS) .
Fig. 8: Overview of floor light, shown on the 911

E - Footwell light
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Fig. 9: Installing footwell light

1. Push plug on to footwell light until the plug is felt to engage.
2. Press footwell light into trim panel.
96 16 19 REMOVING AND INSTALLING DOOR WARNING LIGHT - AS OF MY

2005 (ALL MODELS)
REMOVING BULB FOR DOOR WARNING LIGHT
Removing door warning light
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Fig. 10: Overview of door warning light, shown on the 911

F - Door warning light, left and right
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Fig. 11: Removing door warning light

1. Push door warning light carefully out of the door trim via the cutaway -arrow- using a screwdriver. See Fig.
11.
2. Pull off door warning light connector and remove light.
Removing bulb for door warning light
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Fig. 12: Removing bulb for door warning light

1. Remove bulb socket from the door warning light and remove defective bulb.
INSTALLING BULB FOR DOOR WARNING LIGHT
Installing bulb for door warning light
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Fig. 13: Installing bulb for door warning light

1. Insert new bulb in the bulb socket and insert the socket into the door warning light opening.
Installing door warning light
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Fig. 14: Overview of door warning light, shown on the 911

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Fig. 15: Installing door warning light

1. Push connector on to door warning light.
2. Press door warning light into door trim panel.
96 22 19 REMOVING AND INSTALLING BULB FOR INTERIOR LIGHT - AS

REMOVING BULB FOR INTERIOR LIGHT
Removing bulb for interior light
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Fig. 16: Installation position of interior light, front and rear

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Fig. 17: Unclipping cover

1. Carefully unclip cover for the interior light top and bottom using a small screwdriver.
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2. Remove defective bulb from the mounting.
Removing bulb for rear interior light
CAUTION: Danger of material damage if bulbs are used or handled incorrectly.
 Danger of damage from bulbs and bulb housing.
--> To prevent short circuits, the load in question must be switched off when a bulb is changed.
--> Bulbs with a higher wattage may cause damage to the bulb housing.
--> New bulbs must be clean and free of grease. Therefore never touch bulbs with your bare hands. Use a cloth
or soft paper when changing bulbs.
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Fig. 19: Removing interior light

1. Carefully loosen interior light with a small screwdriver and pull out of the trim panel.
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Fig. 20: Pulling off connector on interior light

2. Pull off connector from the interior light.
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3. Remove bulb from holder.
INSTALLING BULB FOR INTERIOR LIGHT
Installing bulb for front interior light
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Fig. 22: Installing cover

1. Insert new bulb into the bulb holder.
2. Position the cover and clip in place.
Installing bulb for rear interior light
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Fig. 23: Clipping light into the trim panel

2. Insert bulb holder into the light and clip light into the trim panel.
96 22 19 REMOVING AND INSTALLING BULB FOR INTERIOR LIGHT - AS

REMOVING BULB FOR INTERIOR LIGHT
Removing interior light
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Fig. 24: Installation position for interior light

A - Interior light
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Fig. 25: Removing interior light

1. Carefully loosen interior light -1- with a small screwdriver -Arrows A and B- and pull downwards out of the
front lock -Arrow C- . See Fig. 25.
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Fig. 26: Pulling off connector on interior light

2. Release connector -1- on interior light -Arrow a- and pull it off. -arrow- . See Fig. 26.
Removing bulb for interior light
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1. Loosen bulb holder with bayonet lock -1- from the interior light -direction of arrow- and remove it. See Fig.
27.
2. Take defective bulb out of the bulb socket.
INSTALLING BULB FOR INTERIOR LIGHT
Installing bulb for interior light
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1. Insert new bulb into the bulb socket.
2. Insert bulb holder with bayonet lock -1- in the interior light and lock it -direction of arrow- . See Fig. 28.
Installing interior light
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Fig. 29: Pushing on connector of interior light

1. Push connector -1- onto the interior light until it is felt to engage -arrow- . See Fig. 29.
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Fig. 30: Installing interior light

2. Insert interior light -1- into the front lock -Arrow A- and press in and up -Arrow B- . See Fig. 30.
96 27 19 REMOVING AND INSTALLING SWITCH CONSOLE - AS OF MY

2005 (ALL MODELS)
PRELIMINARY WORK
Preliminary work for switch console
Remove air-conditioning control. Refer to 87 02 19 Removing and installing air-conditioning system

regulator - as of MY 2005 (All Models) .
REMOVING SWITCH CONSOLE
Removing switch console
Fig. 31: Installation diagram for the 911

1. Switch off ignition and pull gearshift lever back.
NOTE: The switch console is clipped into the center console.
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Fig. 32: Removing switch console

2. Lift the switch console out of the center console mounting using a screwdriver and pull it out.
3. Release electric plugs and disconnect from the switch console.
INSTALLING SWITCH CONSOLE
Installing switch console
1. Insert electric plugs into the switch console until they click into place.
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Fig. 33: Inserting switch console

2. Slide switch console into the center console and press until the switch console clips into place.
SUBSEQUENT WORK
Subsequent work for switch console
Install air-conditioning control. Refer to 87 02 19 Removing and installing air-conditioning system regulator
96 40 19 REMOVING AND INSTALLING LUGGAGE COMPARTMENT LIGHT

IN REAR LID - AS OF MY 2006 (CAYMAN S, CAYMAN S RHD)
REMOVING LUGGAGE COMPARTMENT LIGHT IN REAR LID
Removing luggage compartment light in rear lid
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Fig. 34: Unclipping light

2. Use a plastic spatula or screwdriver to press out the light in the trim panel of the rear lid.
3. Pull out light, then release and remove connector -A- . See Fig. 34.
INSTALLING LUGGAGE COMPARTMENT LIGHT IN REAR LID
Installing luggage compartment light in rear lid
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Fig. 35: Connecting plug connection for light

1. Push in plug until it is felt to engage.
2. Insert light into opening and clip it into the trim panel. Check that light is fitted securely.
96 41 19 REPLACING BULB FOR LUGGAGE COMPARTMENT LIGHT - AS

REMOVING BULB FOR LUGGAGE COMPARTMENT LIGHT
Removing luggage compartment light
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Fig. 36: Overview of luggage compartment light, shown on the 911

D - Luggage compartment light
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Fig. 37: Removing luggage compartment light

1. Press luggage compartment light carefully out of the luggage compartment trim at the cutout -arrow- using a
screwdriver. See Fig. 37.
2. Pull off plug on luggage compartment light and remove luggage compartment light.
Removing bulb for light
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Fig. 38: Removing bulb for light

INSTALLING BULB FOR LUGGAGE COMPARTMENT LIGHT
Installing bulb for light
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Fig. 39: Installing bulb for light

Installing luggage compartment light
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Fig. 40: Overview of luggage compartment light, shown on the 911

D - Luggage compartment light
Fig. 41: Installing luggage compartment light

1. Attach plug on luggage compartment light.
2. Press luggage compartment light into the luggage compartment lining.
96 41 55 REPLACING BULB FOR LUGGAGE COMPARTMENT LIGHT - AS

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REPLACING BULB FOR LUGGAGE COMPARTMENT LIGHT
Fig. 42: Removing bulb for light

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Fig. 43: Installing bulb for light

96 44 19 REMOVING AND INSTALLING GLOVE COMPARTMENT LIGHT - AS

REMOVING GLOVE COMPARTMENT LIGHT
Removing glove compartment light
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Fig. 44: Overview of glove compartment light, shown on the 911

C - Glove compartment light
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Fig. 45: Removing glove compartment light

1. Press glove compartment light carefully out of the glove compartment at the cutout -arrow- using a
2. Release connector on glove compartment light -arrows a- and pull it off. See Fig. 45.
3. Remove glove compartment light.
INSTALLING GLOVE COMPARTMENT LIGHT
Installing glove compartment light
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Fig. 46: Overview of glove compartment light, shown on the 911

C - Glove compartment light
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Fig. 47: Installing glove compartment light

1. Push plug on to glove compartment light until the plug is felt to engage.
2. Press glove compartment light into the glove compartment.
96 47 55 REPLACING BULB FOR READING LIGHT - AS OF MY 2005

REPLACING BULB FOR READING LIGHT
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Microsoft
Fig. 48: Removing interior light >> shown on the 911

1. Pull the interior light out of the trim panel carefully from the front.
2. Release plug on interior light -arrow a- and pull it off. See Fig. 48.
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Fig. 49: Removing bulb for reading light

3. Loosen bulb holder with bayonet lock -direction of arrow- and remove it. See Fig. 49.
4. Take defective bulb out of the bulb holder.
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Fig. 50: Installing bulb for reading light

6. Insert bulb holder with bayonet lock into the interior light and lock it -direction of arrow- . See Fig. 50.
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Fig. 51: Installing interior light

7. Connect plug for interior light until the plug engages securely.
8. Insert interior light into the trim panel at the rear, then press it into the trim panel at the front.
96 47 55 REPLACING BULB FOR READING LIGHT - AS OF MY 2006

REMOVING BULB FOR READING LIGHT
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Fig. 52: Installation position of interior light, front and rear

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1. Carefully unclip cover for the interior light at top and bottom using a small screwdriver.
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2. Remove defective bulb from the mounting.
INSTALLING BULB FOR READING LIGHT
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Fig. 55: Clipping cover into place

2. Position the cover and clip into place.
96 60 21 REMOVING MAIN SWITCH FOR POWER SUPPLY - AS OF MY 2005

(ALL MODELS)
REMOVING MAIN SWITCH FOR POWER SUPPLY
Main switch for power supply
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Fig. 57: Plug for main switch

1. Pull off the B+ plug -1- for the main switch (battery disconnect switch) on the battery positive terminal. See
Fig. 57.
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Fig. 58: Unscrewing the ground point

2. Unscrew the fastening nut -2- for the ground point on the body and disconnect the negative terminal -3- at the
battery. See Fig. 58.
3. Cover the negative terminal on the battery with a soft, dry cloth.
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Fig. 59: Removing the battery disconnect switch

4. Remove battery disconnect switch together with the lead for the negative terminal and unscrew the fastening
nut -4- . Remove lead for the negative terminal. See Fig. 59.
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Fig. 60: Routing and securing lead for negative terminal

5. Position lead for the negative terminal on the battery again and screw it firmly into place -3- . --> Tightening
torque: 4.7 (3.5 ftlb.) Nm See Fig. 60.
6. Position lead for the negative terminal on the bulkhead and secure with the fastening nut -2- . --> Tightening
torque: 15 (11 ftlb.) Nm See Fig. 60.
7. Place and fit the battery cover included with the vehicle.
8. Refer to 27 06 IN External power connection, jump lead starting - as of MY 2005 (All Models) . must
then be carried out.
INFORMATION
Vehicle electrical system - switching on
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Fig. 61: Battery disconnect switch with external switch lever

The battery disconnect switch, which is supplied via the positive terminal, is closed manually using the external
switch lever and locked electromagnetically. The luggage compartment lid must not be open when doing this.
Vehicle electrical system - switching off
The vehicle electrical system switches off:
If the battery voltage falls below 12.6 V for approx. 10 min.
Immediately, if the voltage supply of the main power supply switch (battery disconnect switch) is disconnected
from the positive terminal.
Microsoft
Fig. 62: Vehicle electrical system - switching off

Immediately, if the main power supply switch (battery disconnect switch) is mechanically released.
96 62 55 REPLACING REMOTE CONTROL - AS OF MY 2005 (ALL MODELS)

DISASSEMBLING REMOTE CONTROL
Removing cover of hand-held transmitter
Microsoft
Fig. 63: Removing cover of hand-held transmitter

1. Insert a small screwdriver between the cover and the bottom part of the hand-held transmitter -arrow- and
carefully lift off the cover. See Fig. 63.
Removing hand-held transmitter key
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Fig. 64: Removing hand-held transmitter key

1. Push the sliding latch back using a small screwdriver -arrow A- and pull the key out of the bottom part. See
Fig. 64.
Removing battery for hand-held transmitter
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Fig. 65: Removing battery for hand-held transmitter

1. Loosen the locking tab -arrow a- and remove the battery. See Fig. 65.
ASSEMBLING REMOTE CONTROL
Installing battery for hand-held transmitter
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Fig. 66: Installing battery for hand-held transmitter

1. Insert battery and press it in until the locking tab clicks into place.
Installing hand-held transmitter key
NOTE: The lock code from IPAS must be specified when ordering a new key.
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Fig. 67: Installing hand-held transmitter key

1. Push the key into the bottom part until the sliding latch -arrow- engages perceptibly. See Fig. 67.
Installing cover of hand-held transmitter
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Fig. 68: Installing cover of hand-held transmitter

1. Position the cover on the bottom part of the hand-held transmitter and press together until the cover clicks
into place.
96 62 25 TEACHING HAND-HELD TRANSMITTER - AS OF MY 2005 (ALL

MODELS)
TEACHING HAND-HELD TRANSMITTER
NOTE: If an additional hand-held transmitter is to be taught, for example, all original

keys/remote controls must also be used and taught.
If a new hand-held transmitter is taught for a vehicle, the Teach Enable Code
(TEC), Transponder password and Transponder Secret Key specified in IPAS
must be entered.
You can get the codes from IPAS or from your importer by specifying the
vehicle identification number.
During programming, it is essential to guarantee the power supply for the

Porsche System tester. It is essential to connect a battery charger with a
current rating of at least 40 A to the vehicle battery.
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The procedure described here has been structured generally, different text or
additions may appear in the Porsche System Tester.
NOTE:  Only new hand-held transmitters or those already adapted to the

immobilizer system on the vehicle can be taught.
 Hand-held transmitters that are already adapted are overwritten, and so all
hand-held transmitters that will later be used on the vehicle must be
taught.
 Teaching of keys is protected over a time period. Once this time has
elapsed, teaching is aborted.
1. Ignition off. Connect the Porsche System Tester to the vehicle and start the System Tester. Select vehicle
type.
2. Switch on warning indicator light; this will activate CAN and ensure that the KESSY control unit is
identified.
3. Select PAS control unit and press >>.
4. Select the Teaching function menu >>.
5. Select the Teach keys menu >>.
6. Enter the Teach Enable Code TEC from IPAS >> and confirm by pressing F7.
7. Enter the Number of keys >> and confirm by pressing F7.
8. Enter the Transponder password >> and confirm by pressing F7.
9. Enter the Transponder Secret Key >> and confirm by pressing F7.
10. Tester requests: Insert key 1 >> , Insert key 2 >> etc., until the relevant number of keys is reached.
11. Tester information regarding Synchronization of keys is no longer necessary.
12. Switch on the ignition, read out the fault memory of all control units, and erase if necessary.
13. Start engine with all keys, one after the other. The hand-held transmitters have now been taught.
Microsoft
96 63 19 REMOVING AND INSTALLING TILT SENSOR CONTROL UNIT - AS

PRELIMINARY WORK
Preliminary work
Remove center console cover. --> 68 14 19 REMOVING AND INSTALLING CENTER CONSOLE
COVER - AS OF MY 2005 (ALL MODELS) .
REMOVING TILT SENSOR CONTROL UNIT
Removing tilt sensor control unit
NOTE:  The tilt sensor is integrated into the tilt control unit and cannot be
separately replaced.
Fig. 69: Overview of tilt sensor control unit

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destroyed.
Fig. 70: Unscrewing fastening screws for tilt sensor control unit
2. Unscrew the two fastening nuts -1- and remove the tilt sensor control unit. See Fig. 70.
3. Remove the two sheetmetal nuts -2- from the tilt sensor control unit. See Fig. 70.
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Fig. 71: Removing plug for tilt sensor control unit

4. Unlock plug for tilt sensor control unit -Arrow a- and remove. See Fig. 71.
INSTALLING TILT SENSOR CONTROL UNIT
Installing tilt sensor control unit
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Fig. 72: Connect plug to tilt sensor control unit.

1. Push plug onto tilt sensor control unit until it is felt to engage.
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Fig. 73: Tightening fastening screws for tilt sensor control unit
2. Check sheetmetal nuts for deformation, replacing if necessary. Push the two sheetmetal nuts -2- onto the tilt
sensor control unit. See Fig. 73.
3. Position tilt sensor control unit -1- and secure with both fastening nuts. --> Tightening torque: 3 ftlb. See
Fig. 73.
SUBSEQUENT WORK
Subsequent work
Install center console cover. --> 68 14 19 REMOVING AND INSTALLING CENTER CONSOLE COVER
- AS OF MY 2005 (ALL MODELS) .
96 65 19 REMOVING AND INSTALLING THE ALARM SIREN - AS OF MY

2005 (ALL MODELS)
PRELIMINARY WORK
Preliminary work
1. Remove battery cover. Refer to 27 12 19 Removing and installing battery cover - as of MY 2005 (All
Models) .
(All Models) .
REMOVING THE ALARM SIREN
Removing alarm horn
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Fig. 74: Installation position for alarm horn

Fig. 75: Removing alarm horn

1. Release connector -2- and remove it -Arrows a- . See Fig. 75.
2. Counter fastening screw -4- and unscrew fastening nut -3- . See Fig. 75.
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3. Remove alarm horn -1- . See Fig. 75.
Removing alarm siren
Fig. 76: Removing alarm siren

1. Release connector -2- and remove it -Arrows a- . See Fig. 76.
2. Counter fastening screw -4- and unscrew fastening nut -3- . See Fig. 76.
3. Remove alarm siren -1- . See Fig. 76.
INSTALLING THE ALARM SIREN
Installing alarm horn.
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Fig. 77: Installing alarm horn

1. Position alarm horn -1- . Insert and counter fastening screw -4- and tighten fastening nut -3- . --> Tightening
2. Push on connector -2- until it is felt to engage. See Fig. 77.
Installing alarm siren
Microsoft
Fig. 78: Installing alarm siren

1. Position alarm siren -1- . Insert and counter fastening screw -4- and tighten fastening nut -3- . --> Tightening
2. Push on connector -2- until it is felt to engage. See Fig. 78.
SUBSEQUENT WORK
Subsequent work
(All Models) .
2. Remove battery cover. Refer to 27 12 19 Removing and installing battery cover - as of MY 2005 (All
Models) .
96 66 19 REMOVING AND INSTALLING KESSY/PAS CONTROL UNIT - AS

TOOLS

Microsoft
INFORMATION
Control unit information for KESSY/PAS
NOTE: If the KESSY/PAS control unit is replaced, it must be programmed using the
Porsche System Tester. This will ensure that the control module is taught for
the relevant vehicle, country version and equipment.
If possible, before the control unit is removed and replaced, a read-out of the
vehicle data should be obtained from the Porsche PIWIS Tester P 9718 System
Tester.
 Follow the instructions for the Porsche System Tester.
The KESSY/PAS control unit can only be taught once for one vehicle. Switching is not possible.
PROGRAMMING KESSY/PAS CONTROL UNIT
Obtaining read-out and saving vehicle data from control unit
1. Connect the PIWIS Tester P 9718 to the vehicle and start the System Tester. Switch on ignition. Press >> to
continue.
3. Switch to Control units.
NOTE: In order to guarantee the function of the control unit after teaching, the coding
value in the old control unit must be read out or determined again. This value
must be written into the new control unit after teaching.
If the control unit cannot be read out again, it must be coded according to the
vehicle equipment after the control unit has been replaced manually. PAS menu
- Coding .
4. Select PAS with the cursor keys and press the >> key.
6. Select Read-out values (vehicle data) with the cursor keys and press the >> key.
Microsoft
7. The note Coding read-out complete will appear on the screen of the Porsche System Tester.
8. After the PAS/KESSY/Immobilizer control unit has been replaced, the data that is read out is loaded in via
the Control unit replacement - Write in data menu (see Item 6).
9. The KESSY/PAS control unit and vehicle keys must then be taught. --> 966619 Removing and installing
KESSY control unit - "Programming" section
REMOVING KESSY/PAS CONTROL UNIT
Removing KESSY/PAS control unit

To provide a clearer picture, the illustrations are shown from the bulkhead view.
Microsoft
Fig. 80: Pivoting out securing bolt and unclipping control unit
1. Release and open the locking lever located "in the forward direction of travel".
2. Lift control unit at front out of the support for the steering wiring.
Microsoft
Fig. 81: Disengaging control unit at both plates

3. Push control unit forward in "direction of travel" and disengage it from the support for the steering wiring.

destroyed.
NOTE: Depending on the vehicle equipment, the control unit has one or two
connectors.
Microsoft
Fig. 82: Releasing and unplugging connectors

4. Release both electrical connectors -1, 2- -A- and unplug them from the control unit. See Fig. 82.
5. Take out the control unit.
INSTALLING KESSY/PAS CONTROL UNIT
Installing KESSY/PAS control unit

destroyed.
NOTE: Depending on the vehicle equipment, the control unit has one or two
connectors.
Microsoft
Fig. 83: Inserting the connectors

1. Press both electrical connectors -1, 2- into control unit and lock them until they are felt to engage. See Fig.
83.
Microsoft
Fig. 84: Engaging control units at both retaining lugs

2. Engage control unit in support for wiring harness with both retaining lugs.
Microsoft
Fig. 85: Clipping in control unit + pivoting out securing bolt

3. Clip in control unit on the support for the steering wiring and engage the locking mechanism for the lock.
PROGRAMMING KESSY/PAS CONTROL UNIT
Programming new KESSY/PAS control unit
NOTE: All original keys are required for teaching.
NOTE: If a new KESSY/PAS control unit is installed in a vehicle, the immobilizer code,
Teach Enable Code (TEC), ELV Secret Key, Transponder password and
Transponder Secret Key specified in IPAS must be entered.
You can get the codes from IPAS or from your importer by specifying the
During programming, it is essential to guarantee the power supply for the

Porsche System tester. It is essential to connect a battery charger with a
Microsoft
The procedure described here has been structured generally, different text or
additions may appear in the Porsche System Tester.
In order to guarantee the function of the control unit after teaching, the coding
must be written into the new control unit after teaching. --> Removing and
installing KESSY control unit - "Reading out" Control unit information for
KESSY/PAS.
1. Ignition off.
2. Replace control unit. --> 96 66 19 Removing and installing KESSY/PAS control unit - as of MY 2005
(All Models).
NOTE: Once a new KESSY/PAS control unit has been installed, the ignition can no
longer be switched on. In order for the Tester to be able to identify the new
control unit, the warning indicator light must remain switched on during the
teaching procedure. This will activate CAN.
3. Insert ignition key and switch on hazard warning light switch.
4. Select vehicle type.
5. Switch to the control units and press >>.
6. Select PAS with the cursor keys and press the >> key.
7. Switch to the Teaching functions menu and select Teach control unit . Press >> to continue.
8. Enter the Teach Enable Code TEC from IPAS, press >> and confirm by pressing F7.
9. Vehicle identification number must be entered using >>. Then confirm your entry by pressing F7.
10. Enter the ELV Secret Key from IPAS >> and confirm by pressing F7.
11. Immobilizer code from IPAS must be entered using >>. Then confirm your entry by pressing F7.
12. Enter the Transponder password using >> and confirm by pressing F7.
13. Enter the Transponder Secret Key using >> and confirm by pressing F7.
Microsoft
14. The Tester displays the message: Control unit taught, Teach keys . Select the menu Teach keys >>.
15. Enter the Teach Enable Code TEC from IPAS >> and confirm by pressing F7.
16. Enter the Number of keys using >> and confirm by pressing F7.
17. Enter the Transponder password using >> and confirm by pressing F7.
18. Enter the Transponder Secret Key using >> and confirm by pressing F7.
19. The Tester displays the prompt: Insert key 1 >> , Insert key 2 >> etc., until the relevant number of keys is
reached.
20. Observe Tester information regarding Synchronization of keys , insert key and press the Lock button on
the Tester for at least 5 seconds when instructed by the Tester.
21. Switch on the ignition, read out the fault memory of all control units, and erase if necessary.
22. << Return to vehicle type, select the Special functions on the control unit side, and carry out a vehicle
handover .
23. Then read out the fault memory again, and erase the fault memory for each faulty control unit.
24. Start engine with all keys, one after the other.
NOTE: In order to guarantee the function of the control unit after teaching, the coding
must be written into the new control unit after teaching.
If the control unit cannot be read out again, it must be coded according to the
vehicle equipment after the control unit has been replaced manually. PAS menu
- Coding .
25. In the menu PAS codings select the coding desired by the customer and code with F8.
26. The Kessy/PAS has been taught. Check the remote controls on the vehicle for proper function.
96 78 19 REMOVING AND INSTALLING CONTROL UNIT FOR GARAGE

DOOR OPENER - AS OF MY 2005 (BOXSTER, BOXSTER RHD, BOXSTER S,
BOXSTER S RHD)
REMOVING CONTROL UNIT FOR GARAGE DOOR OPENER
Removing control unit for garage door opener
Microsoft
Fig. 86: Installation position for garage door opener

Fig. 87: Removing control units

1. Lever the control units -1- out of the front lock with a small screwdriver at the openings provided -2- -
Arrows a- . See Fig. 87.
Microsoft
2. Pull control units -1- down and out of the assembly openings of the front lock -2- -Arrows B- . See Fig. 87.
Fig. 88: Pulling off connector for control units.

3. Pull off connector -1- for control units -2- -arrows- . See Fig. 88.
Installing control unit for garage door opener
Microsoft
Fig. 89: Pushing on connector for control units

1. Push on connector -1- for control units -2- -Arrows A- . See Fig. 89.
2. Insert control units -2- with electric connecting lines into the assembly openings of the front lock -3- in an
upwards direction -Arrows B- . See Fig. 89.
Microsoft
Fig. 90: Installing control units

3. Press in control units -1- on front lock -2- until latches are felt to engage. See Fig. 90.
96 78 19 REMOVING AND INSTALLING CONTROL UNIT FOR GARAGE

DOOR OPENER - AS OF MY 2005 (CAYMAN S, CAYMAN S RHD)
REMOVING CONTROL UNIT FOR GARAGE DOOR OPENER
Removing control unit for garage door opener
Microsoft
Fig. 91: Removing control unit

1. Lever out the control unit from the headliner with a plastic spatula.
Microsoft
Fig. 92: Unplugging electrical connector

2. Disconnect electric plug connection from control unit.
Installing control unit for garage door opener
Microsoft
Fig. 93: Installing control unit

1. Connect electric connector to control unit.
2. Clip control unit into headliner.
96 79 19 REMOVING AND INSTALLING GARAGE DOOR OPENER

CONTROL UNIT - AS OF MY 2005 (ALL MODELS)
PRELIMINARY WORK
Preliminary work for control unit for garage door opener/HomeLink
Removing front apron. Refer to 63 15 19 Removing and installing front spoiler - as of MY 2005 (All
Models) .
REMOVING CONTROL UNIT FOR GARAGE DOOR OPENER/HOMELINK
Removing control unit for garage door opener/HomeLink
Microsoft

Fig. 95: Unclipping control unit

Microsoft
1. Unclip control unit from the holder -A- . See Fig. 95.

2. Release electric connector -A- and remove it from control unit. See Fig. 96.
INSTALLING CONTROL UNIT FOR GARAGE DOOR OPENER/HOMELINK
Installing control unit for garage door opener/HomeLink
1. Push electric connector onto control unit until it is felt to engage.
Microsoft
Fig. 97: Engaging and clipping in control unit

2. Engage and clip control unit into holder.
SUBSEQUENT WORK
Subsequent work for control unit for garage door opener/HomeLink
Installing front apron. Refer to 63 15 19 Removing and installing front spoiler - as of MY 2005 (All
Models) .
TEACHING CONTROL UNIT FOR GARAGE DOOR OPENER/HOMELINK
HomeLink
WARNING: Danger of accidents if persons, animals or objects lie in the swinging

range of the controlled mechanism during operation of the garage door
opener.
--> Ensure that there are no persons, animals or objects in the swinging range of the controlled mechanism
during operation of the garage door opener.
--> Observe the safety instructions for the original hand-held transmitter.
Microsoft
The programmable HomeLink replaces up to three original remote controls for operating various equipment (e.
g. garage door, gate to property, alarm system).
Fig. 98: Overview of button assignment for garage door opener

The buttons -1 to 3- can be programmed with a frequency of an original remote control. See Fig. 98.
Prerequisites for operating and programming the HomeLink:
- The ignition is switched on.
- The fog lights are switched off.
To activate the required equipment:
Press the relevant button -1, 2 or 3- . The LED -A- lights up during signal transmission. See Fig. 98.
Operating instructions:
Always use the garage door opener in the direction of travel. Otherwise range limitations cannot be ruled out.
Before selling the vehicle, erase the programmed garage door opener signals on the keypad.
To determine whether the original remote control has a fixed or variable code, please read the instructions for
Microsoft
the original remote control.
In the case of a standard fixed code, the LED in the roof console is permanently lit during the transmission
process. No further steps are necessary for the operation of compatible systems.
If the system set is not activated by the garage door opener control unit, this may be because the original remote
control has a variable code.
ASSIGNING GARAGE DOOR OPENER/HOMELINK SIGNALS TO BUTTONS
Garage door opener/HomeLink with fixed code system

NOTE:  This operation erases the standard codes set in the factory. Do not repeat
this operation if additional buttons are to be programmed.
 Hold the two outer buttons -1 and 3- down for around 20 seconds until the
LED -A- starts to flash quickly. All programmed signals for the buttons -1
to 3- are erased. See Fig. 99.
Microsoft

1. Press the required button until the LED flashes slowly. You then have around 5 minutes to complete steps 2
and 3.
Microsoft
Fig. 101: Teaching position for remote control

2. Hold the original remote control approx. 0 - 30 cm in front of the marked position on the vehicle.
3. Press the Send button on the original remote control until the fog lights flash three times (up to approx. 45
seconds).
4. Repeat steps 1 to 3 to assign further buttons.
NOTE: A number of attempts may be necessary at different distances between the

vehicle and original remote control.
The fog lights flash once after 5 minutes. The programming operation must then
be started from scratch.
Garage door opener/HomeLink with variable code system
Check operating instructions for the garage door drive (or other system) for specification of a variable code.
If the garage door opener control unit has been programmed to a variable code system, it will still have to be
synchronized with this system on completion of programming before it will work correctly.
Microsoft
Fig. 102: Button assignment for garage door opener

1. Press the required button until the LED flashes slowly. You then have around 5 minutes to complete steps 2
and 3.
Microsoft

seconds).
4. To synchronize the system: press the programming button on the garage door drive receiver. You then have
30 seconds to initiate step 5.
5. Press assigned button on the HomeLink twice. (You may have to press the button to be assigned a third time
on some equipment in order to complete the setting.)
6. Repeat the programming steps to assign further buttons.
Re-programming an individual button
Microsoft

1. Press the required button until the LED flashes slowly (approx. 20 seconds). You then have around 5 minutes
to complete steps 2 and 3.
Microsoft

seconds).
4. Repeat steps 1 to 3 to assign further buttons.
NOTE: A number of attempts may be necessary at different distances between the

vehicle and original remote control.
The fog lights flash once after 5 minutes. The programming operation must then
be started from scratch.
Erasing programmed signals on the HomeLink
Microsoft

NOTE: This operation erases the standard codes set in the factory. Do not repeat this
operation if additional buttons are to be programmed.
Hold the two outer buttons -1 and 3- down for around 20 seconds until the LED -A- starts to flash quickly. All
programmed signals for the buttons -1 to 3- are erased. See Fig. 106.
Do this before selling the vehicle, for example.
96 85 19 REMOVING AND INSTALLING INTERIOR MONITORING SENSOR -

PRELIMINARY WORK
Preliminary work for interior monitoring sensor
Models) .
REMOVING INTERIOR MONITORING SENSOR
Removing interior monitoring sensor
Microsoft
1. To protect it, set the center console down on a suitable base.
Fig. 107: Disengaging sensor

2. Lift the two retaining tabs aside and pull out the sensor.
3. Unplug electric plug connection and remove sensor.
INSTALLING INTERIOR MONITORING SENSOR
Installing interior monitoring sensor
Microsoft
Fig. 108: Inserting sensor

1. Insert sensor into the center console until it clicks into place.
2. Plug electric connector into sensor.
SUBSEQUENT WORK
Subsequent work for interior monitoring sensor
Models) .
Microsoft
ACCESSORIES & EQUIPMENT Linings, insulation
Linings, insulation
70 IN NOTES FOR THE CARE OF SOFT-LOOK PAINT SURFACES - AS OF

CAUTION: Risk of damage to the soft-look paint coat if the cleaning agents or
solvents available as accessories for cleaning the vehicle interior are
used. This also applies to the use of plastic polish from the Tequipment
care set. The contents of these agents etch the paint coat (paint swells,
rubber-like texture).
 Consequently, the paint coat can separate from the substrate when a
mechanical load is applied. Furthermore, the surface may shine
brightly after using the cleaning agents.
--> The following procedure is recommended for the care or cleaning of soft-look paint surfaces.
LIGHT SOILING (E. G. DUST)
It is possible to clean light soiling by selecting an option from the following cleaning tools and cleaning fluids:
Cleaning tools Cleaning fluid Cleaning procedure

Soft household
Clear water
sponge
Water with small amount of commercially available
Gentle wiping movements,
washing-up liquid added
Soft, lint-free do not apply pressure
cloth Interior window cleaner (from Porsche care set) Note
Observe cleaning instructions, wipe down with clear water if
necessary
INFORMATION
It is possible to clean heavy soiling by selecting an option from the following cleaning tools and cleaning fluids:
Cleaning tools Cleaning fluid Cleaning procedure

Soft household Water with small amount of commercially available
sponge washing-up liquid added
Interior window cleaner (from Porsche care set) Note
Gentle wiping movements,
Observe cleaning instructions, wipe down with clear water if
Soft, lint-free necessary do not apply pressure
cloth
Solvent naphtha Note: Use solvent naphtha only, other
solvents are not permissible!
Microsoft
70 02 19 REMOVING AND INSTALLING FRONT TRIM (WING FLANGE) - AS

REMOVING WING FLANGE COVER
Removing cover for wing flange
1. Open front lid.
Fig. 1: Removing cover for wing flange

2. Loosen cover for wing flange -2- at the Velcro fasteners -3- . See Fig. 1.
3. Lift cover for wing flange up slightly -2- , release the locking tab at the side from below -arrow A- and pull
it out of the cover for the lock support -1- ( -arrows B- ). See Fig. 1.
INSTALLING WING FLANGE COVER
Installing cover for wing flange
NOTE:  The Velcro fasteners must be removed and replaced when replacing the
wing and cover for wing flange.
1. Check Velcro fasteners on wing and cover for wing flange and replace if necessary. See: Additional assembly
Microsoft
instructions for replacing Velcro fasteners
Fig. 2: Installing cover for wing flange

2. Insert cover for wing flange -2- sideways into the trim panel for the lock support -1- ( -arrows A- ). See Fig.
3.
3. Slide cover for wing flange -2- with the soft lip under the luggage compartment seal and press on Velcro
fasteners -3- . See Fig. 3.
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Fig. 3: Locking cover for wing flange into place

4. Lock cover for wing flange into place in plenum panel.
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Fig. 4: Securing trim panel

5. Insert locking lug for trim panel for lock support -1- into the wing at the side -2- .
6. Close front lid.
Additional assembly instructions for replacing Velcro fasteners

1. Remove protective paper on the underside, push locking lug into the cover for lock support and press cover
down onto the wing flange.
Microsoft
Fig. 6: Pressing on Velcro fasteners

2. Press Velcro fasteners on at the positions indicated.
Microsoft
Fig. 7: Securing Velcro fasteners

3. Lift off cover and press Velcro fasteners securely onto the wing flange again using a suitable tool.
70 03 19 REMOVING AND INSTALLING REAR LUGGAGE COMPARTMENT

SIDE-TRIM PANEL - AS OF MY 2006 (CAYMAN S, CAYMAN S RHD)
PRELIMINARY WORK
Preliminary work
1. Remove rear light cover. --> 709419 Removing and installing rear light cover - chapter on "Removing"
2. Remove rear luggage-compartment carpet lining at the sides. --> 700619 Removing and installing trim
panel of rear luggage compartment - chapter on "Removing"
3. Remove trim panel for spring strut mount. --> 702319 Removing and installing trim panel for spring strut
mount - chapter on "Removing"
REMOVING REAR LUGGAGE COMPARTMENT SIDE-TRIM PANEL
Removing rear luggage compartment side trim panel
Fig. 8: Installation position of side trim panel for rear luggage compartment
Microsoft
NOTE:  In order to reduce the unclipping forces and thereby the risk of damage
during removal, the process must take place at the accessible connection
points using a suitable tool.
Fig. 9: Removing side trim panel for rear luggage compartment

1. Unclip side trim panel for rear luggage compartment -2- in area of lock trim -1- -Arrow A- . See Fig. 9.
2. Unclip side trim panel for rear luggage compartment -2- completely in -direction of Arrow B- . See Fig. 9.
3. Check clamps -3- , and replace if necessary. See Fig. 9.
INSTALLING REAR LUGGAGE COMPARTMENT SIDE-TRIM PANEL
Installing rear luggage compartment side trim panel
Microsoft
Fig. 10: Installation position of side trim panel for rear luggage compartment
Fig. 11: Installing side trim panel for rear luggage compartment
1. Position side trim panel for rear luggage compartment -2- on the body and press in -Arrows A - until the
clamps -3- engage. See Fig. 11.
Microsoft
2. Clip in side trim panel for rear luggage compartment -2- in area of lock trim -1- -Arrow B- . See Fig. 11.
SUBSEQUENT WORK
Subsequent work
1. Install trim panel for spring strut mount --> 702319 Removing and installing trim panel for spring strut
mount - chapter on "Installing"
2. Install rear luggage-compartment carpet lining at the sides. --> 700619 Removing and installing trim panel
of rear luggage compartment - chapter on "Installing"
3. Install rear light cover. --> 709419 Removing and installing rear light cover - chapter on "Installing"
70 05 19 REMOVING AND INSTALLING FRONT LUGGAGE COMPARTMENT

TRIM PANEL - AS OF MY 2005 (ALL MODELS)
REMOVING FRONT LUGGAGE COMPARTMENT TRIM PANEL
Removing front luggage compartment trim panel (luggage compartment pan)
Fig. 12: Installation position of front luggage compartment trim panel

1. Remove front emergency release. Refer to 55 62 19 Removing and installing front emergency release - as
Microsoft
of MY 2005 (Cayman S) .
Fig. 13: Removing trim panel for warning triangle

2. Release twist locks -1- , open up tool box -2- and remove it in an upward direction. See Fig. 13.
Microsoft
Fig. 14: Loosening luggage compartment pan

3. Unclip fixing clip -1- and screw off plastic nut -2- at the right and left. See Fig. 14.
Microsoft
Fig. 15: Loosening luggage compartment pan

4. Screw off plastic nut -1- at the right and left in direction of arrow. See Fig. 15.
Fig. 16: Removing luggage compartment pan

5. Lift up the luggage compartment pan -1- and remove it. See Fig. 16.
Removing front luggage compartment trim panel (bulkhead)
Microsoft
Fig. 17: Installation position of front luggage compartment trim panel

1. Remove luggage compartment cover. --> 703019 Removing and installing front luggage compartment
cover - section on "Removing" [987310 987311 987320 987321] --> 703019 Removing and installing front
luggage compartment cover - section on "Removing" [987120 987121]
2. Release and remove electric plug connections on the navigation unit. Refer to 91 12 19 Removing and
installing navigation unit - as of MY 2005 (All Models) .
3. Release and remove electric connector for loudspeaker amplifier. Refer to 91 44 19 Removing and installing
loudspeaker amplifier - as of MY 2005 (All Models) .
NOTE: When removing the bulkhead trim panel, make sure not to damage any wires or
plug connections.
Microsoft
Fig. 18: Removing bulkhead trim panel

5. Loosen bulkhead trim panel -1- in -direction of arrow A- and lift it up and off -Arrow B- . See Fig. 18.
INSTALLING FRONT LUGGAGE COMPARTMENT TRIM PANEL
Installing front luggage compartment trim panel (bulkhead)
Microsoft
Fig. 19: Installing bulkhead trim panel

1. Insert bulkhead trim panel -1- ( -Arrow A- ) and align it -Arrow B- . See Fig. 19.
2. Route electric lines and plug connections.
3. Lock electric plug connections on the navigation unit. Refer to 91 12 19 Removing and installing
navigation unit - as of MY 2005 (All Models) .
4. Lock electric connector on loudspeaker amplifier. Refer to 91 44 19 Removing and installing loudspeaker
6. Install luggage compartment cover. --> 703019 Removing and installing front luggage compartment
cover - section on "Installing" [987310 987311 987320 987321], --> 703019 Removing and installing front
luggage compartment cover - section on "Installing" [987120 987121].
Installing front luggage compartment trim panel (luggage compartment pan)
Microsoft
Fig. 20: Installing luggage compartment pan

1. Insert and align luggage compartment pan -1- . See Fig. 20.
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Fig. 21: Securing luggage compartment pan

2. Screw on plastic nut -1- at the right and left in direction of arrow. See Fig. 21.
Fig. 22: Securing luggage compartment pan

3. Press in fixing clip -1- and screw on plastic nut -2- at the right and left. See Fig. 22.
Microsoft
Fig. 23: Installing trim panel for warning triangle

4. Insert tool box -2- into the guide pins in the luggage compartment floor, close the tool box and lock the twist
locks -1- . See Fig. 23.
5. Install front emergency release. Refer to 55 62 19 Removing and installing front emergency release - as of
MY 2005 (Cayman S) .
70 06 19 REMOVING AND INSTALLING REAR LUGGAGE-COMPARTMENT

TRIM PANEL - AS OF MY 2005 (BOXSTER, BOXSTER RHD, BOXSTER S,
Microsoft
BOXSTER S RHD)
PRELIMINARY WORK
Preliminary work
Remove emergency release for rear lid. --> 55 57 19 REMOVING AND INSTALLING RELEASE FOR
REAR LID - AS OF MY 2005 (ALL MODELS) .
REMOVING REAR LUGGAGE-COMPARTMENT TRIM PANEL
Removing cover for rear lock lower part
Fig. 24: Installation position of rear lock lower part

Microsoft
Fig. 25: Removing cover for rear lock lower part

1. Unclip cover -1- -Arrow A- and lift up and off -Arrow B- . See Fig. 25.
Removing trim panel of rear luggage compartment pan
Microsoft
Fig. 26: Installation position of rear luggage compartment trim panel

Fig. 27: Releasing fixing clips

1. Turn fixing clips -1- 1/4 turn to release. See Fig. 27.
2. Loosen fixing clips -2- and remove. See Fig. 27.
3. Pull out trim panel of luggage compartment pan from under the lid seal and remove.
Removing trim panel of rear luggage-compartment (bulkhead)
Microsoft

1. Remove luggage compartment light. --> 96 40 19 REMOVING AND INSTALLING LUGGAGE

COMPARTMENT LIGHT IN REAR LID - AS OF MY 2006 (CAYMAN S, CAYMAN S RHD) .
Fig. 29: Loosening fixing clips

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2. Loosen fixing clips and remove.

3. Loosen luggage compartment trim panel in the area around the coolant reservoir -A- . See Fig. 30.
4. Pull out luggage compartment trim panel in the lower area -B- and remove. See Fig. 30.
Removing support for rear luggage-compartment trim panel
Microsoft

Fig. 32: Removing support for trim panel

1. Disengage left support -1- at joint with right support, lift up and remove. See Fig. 32.
2. Remove right support -2- . See Fig. 32.

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Removing trim panel for tail light


Microsoft
2. Remove trim panel for tail light -2- . See Fig. 34.
INSTALLING REAR LUGGAGE-COMPARTMENT TRIM PANEL
Installing trim panel for tail light

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1. Install trim panel for tail light -2- . See Fig. 36.
2. Screw in fastening nuts -1- hand-tight. See Fig. 36.
Installing support for rear luggage-compartment trim panel
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Fig. 38: Installing support for trim panel

1. Install right support -2- . See Fig. 38.
2. Install left support -1- and engage at joint with right support. See Fig. 38.
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Installing trim panel of rear luggage-compartment (bulkhead)

Microsoft

1. Insert luggage compartment trim panel in the area around the coolant reservoir -B- under the lid. See Fig. 40.
2. Place luggage compartment trim panel in its installation position -A- , align it and push it under the lid seal.
See Fig. 40.
Microsoft
Fig. 41: Pressing in fixing clips

3. Press in fixing clips.
4. Install luggage compartment light. --> 96 40 19 REMOVING AND INSTALLING LUGGAGE

COMPARTMENT LIGHT IN REAR LID - AS OF MY 2006 (CAYMAN S, CAYMAN S RHD) .
Installing trim panel of rear luggage compartment pan
Microsoft

1. Insert trim panel of luggage compartment pan, align it and push it under the lid seal.

2. Press in fixing clips -1 and 2- . See Fig. 43.

Microsoft
Installing cover for lock lower part
Fig. 44: Installation position of rear lock lower part

Fig. 45: Installing cover for lock lower part

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1. Position cover -1- -Arrow A- and press in until it can be felt to engage -Arrow B- . See Fig. 45.
SUBSEQUENT WORK
Subsequent work
Install emergency release for rear lid. --> 55 57 19 REMOVING AND INSTALLING RELEASE FOR
REAR LID - AS OF MY 2005 (ALL MODELS) .

TRIM (CARPET LINING) - AS OF MY 2006 (CAYMAN S, CAYMAN S RHD)
PRELIMINARY WORK
Preliminary work
1. Remove rear light cover, left and right. --> 709419 Removing and installing rear light cover - chapter on
"Removing"
2. Remove rear luggage net. Refer to 68 54 19 Removing and installing luggage net/mesh - as of MY 2005
REMOVING REAR LUGGAGE-COMPARTMENT TRIM PANEL (CARPET LINING)
Remove luggage-compartment carpet lining at the sides.
Microsoft
Fig. 46: Installation position of luggage compartment carpet lining at the sides
Fig. 47: Removing luggage-compartment carpet lining at the sides

1. Lift luggage compartment carpet lining at the sides -1- from the groove in the direction of the arrow. See Fig.
47.
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Removing carpet lining for cross member rear wall
Fig. 48: Installation position for carpet lining for cross member rear wall
Fig. 49: Removing carpet lining for cross member rear wall
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1. Lift carpet lining for cross member rear wall -1- from the groove and remove from under the rear cover -2- .
See Fig. 49.
Removing carpet lining for rear spoiler
Fig. 50: Installation position of carpet lining for rear spoiler

Microsoft
Fig. 51: Removing carpet lining for rear spoiler

1. Lift carpet lining for rear spoiler -1- from the groove and remove from under the cover for lock carrier -2- .
See Fig. 51.
Removing carpet lining for rear luggage-compartment pan
Microsoft
Fig. 52: Installation position of carpet lining for rear luggage-compartment pan
Fig. 53: Removing carpet lining for rear luggage-compartment pan

1. Fold up carpet lining for rear luggage-compartment pan -1- at the sides -Arrow A- and remove upwards -
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INSTALLING REAR LUGGAGE-COMPARTMENT TRIM PANEL (CARPET LINING)
Installing carpet lining for rear luggage-compartment pan
Fig. 54: Installation position of carpet lining for rear luggage-compartment pan
Microsoft
Fig. 55: Installing carpet lining for rear luggage-compartment pan

1. Insert carpet lining for rear luggage-compartment pan -1- in the luggage compartment -Arrow A- and align -
2. Pull rear tie-down rings -2- upwards through the cover -3- . See Fig. 55.
3. Align front tie-down rings -4- upwards. See Fig. 55.
Installing carpet lining for rear spoiler
Microsoft
Fig. 56: Installation position of carpet lining for rear spoiler

Fig. 57: Installing carpet lining for rear spoiler

1. Insert carpet lining for rear spoiler -1- under the cover for lock carrier -2- and press into the groove. See Fig.
57.
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Installing carpet lining for cross member rear wall
Fig. 58: Installation position for carpet lining for cross member rear wall
Microsoft
Fig. 59: Installing carpet lining for cross member rear wall
1. Insert carpet lining for cross member rear wall -1- under the cover for rear -2- and press into the groove. See
Fig. 59.
2. Open service tray -3- . See Fig. 59.
3. Align carpet lining for cross member rear wall -1- in area of service tray -3- . See Fig. 59.
Installing luggage-compartment carpet lining at the sides
Microsoft
Fig. 60: Installation position of luggage compartment carpet lining at the sides
Fig. 61: Installing luggage-compartment carpet lining at the sides

1. Position luggage compartment carpet lining at the sides -1- in direction of arrow and press into the groove.
See Fig. 61.
Microsoft
SUBSEQUENT WORK
Subsequent work
1. Install luggage net. Refer to 68 54 19 Removing and installing luggage net/mesh - as of MY 2005
2. Install rear light cover, left and right. --> 709419 Removing and installing rear light cover - chapter on
"Installing"
70 08 19 REMOVING AND INSTALLING TRIM PANEL FOR CONVERTIBLE

TOP REST/ENGINE COMPARTMENT LID - AS OF MY 2005 (CAYMAN S,
CAYMAN S RHD)
PRELIMINARY WORK
Preliminary work
NOTE:  Only for vehicles with luggage net.
Remove luggage net and luggage mesh. Refer to 68 54 19 Removing and installing luggage net/mesh - as of
REMOVING TRIM PANEL FOR CONVERTIBLE TOP REST/ENGINE COMPARTMENT LID
Removing lining for engine compartment lid
Microsoft
Fig. 62: Removing lining for engine compartment lid

1. Lift lining of engine compartment lid at the front -1- with a plastic wedge -2- -Arrow A- and pull out to the
front -Arrows B- . See Fig. 62.
INSTALLING TRIM PANEL FOR CONVERTIBLE TOP REST/ENGINE COMPARTMENT LID
Installing lining for engine compartment lid
Microsoft
Fig. 63: Installing lining for engine compartment lid

Microsoft
Fig. 64: Position of tie-down rings

NOTE: During installation of the engine compartment lid lining, observe the position of
the tie-down rings.
1. Insert lining for engine compartment lid -1- with the clips in the mounting points and press downwards. See
Fig. 63.
SUBSEQUENT WORK
Subsequent work

Microsoft
Install luggage net and luggage mesh. Refer to 68 54 19 Removing and installing luggage net/mesh - as of
70 08 19 REMOVING AND INSTALLING TRIM PANEL FOR CONVERTIBLE

TOP REST/ENGINE COMPARTMENT LID - AS OF MY 2005 (BOXSTER,
PRELIMINARY WORK
Preliminary work
NOTE:  Only for vehicles with subwoofer.
1. Remove subwoofer. Refer to 91 36 19 Removing and installing subwoofer - as of MY 2005 (Boxster,

NOTE:  Only for vehicles with storage pocket/box.
2. Remove storage pocket/box. Refer to 68 57 19 Removing and installing storage pocket/box - as of MY

3. Remove luggage net. --> 68 54 19 REMOVING AND INSTALLING LUGGAGE NET/MESH - AS OF

MY 2005 (CAYMAN S, CAYMAN S RHD) .
REMOVING TRIM PANEL FOR CONVERTIBLE TOP REST/ENGINE COMPARTMENT LID
Removing trim panel for convertible top rest
Microsoft
Fig. 65: Removing trim panel for convertible top rest

1. Twist the turn-lock fasteners -1- in -direction of arrow- and lift trim panel for convertible top rest -2- up and
off. See Fig. 65.
INSTALLING TRIM PANEL FOR CONVERTIBLE TOP REST/ENGINE COMPARTMENT LID
Installing trim panel for convertible top rest
Microsoft
Fig. 66: Installing trim panel for convertible top rest

1. Position trim panel for convertible top rest -2- and fasten with the turn-locks -1- by turning in -direction of
SUBSEQUENT WORK
Subsequent work
1. Install luggage net. --> 68 54 19 REMOVING AND INSTALLING LUGGAGE NET/MESH - AS OF

NOTE:  Only for vehicles with storage pocket/box.
2. Install storage pocket/box. Refer to 68 57 19 Removing and installing storage pocket/box - as of MY 2005
NOTE:  Only for vehicles with subwoofer.
3. Install subwoofer. Refer to 91 36 19 Removing and installing subwoofer - as of MY 2005 (Boxster,

Microsoft
70 16 19 REMOVING AND INSTALLING DASHBOARD COVER - AS OF MY

2005 (ALL MODELS)
REMOVING DASHBOARD COVER
Removing dashboard cover
Fig. 67: Removing cover

1. Unclip cover -1- using a plastic wedge on the retaining clips -2- and swivel it outwards -Arrow A- . See Fig.
67.
2. Remove the cover -1- to the rear -Arrow B- . See Fig. 67.
INSTALLING THE DASHBOARD COVER
Installing dashboard cover
Microsoft

1. Insert cover -1- at the front -Arrow E- . See Fig. 68.
2. Swivel cover -1- inward and push it in -Arrow F- until the retaining clips -2- click into place. See Fig. 68.
70 19 19 REMOVING AND INSTALLING TRIM UNDER DASHBOARD - AS OF

PRELIMINARY WORK
Preliminary work
Remove main headlight switch. Refer to 94 05 19 Removing and installing main light switch - as of MY
2005 (All Models) .
Remove left dashboard cover --> 701619 Removing and installing dashboard cover - chapter on
"removing"
Remove top steering-column trim.
Remove left center console cover. Refer to 68 14 19 Removing and installing center console cover - as of
Microsoft
REMOVING TRIM UNDER DASHBOARD ON DRIVER'S SIDE
Removing trim panel under the dashboard on the driver's side
Fig. 69: Installation position of trim panel under dashboard on driver's side
Microsoft

1. Unscrew the fastening screws -1- and swivel the cover under the dashboard on the driver's side -2-
downwards -Arrow A- . See Fig. 70.
Disconnecting the electrical plug connections
Microsoft
Fig. 72: Disconnecting the electrical plug connections

1. Release plug connections -1, 2, 3- and remove -Arrow A- . See Fig. 72.
INSTALLING TRIM UNDER DASHBOARD ON DRIVER'S SIDE
Locking electrical plug connections
Microsoft
Fig. 74: Locking electrical plug connections

1. Push on plug connections -1, 2, 3- -Arrows A- , until the locking tabs engage audibly. See Fig. 74.
Installing trim panel under dashboard on the driver's side

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1. Insert trim panel under the dashboard -2- on the guides. See Fig. 76.
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2. Swivel trim panel under the dashboard -2- upwards -Arrow A- . See Fig. 76.
3. Screw in -1- fastening screws. Tightening torque --> : 1.5 ftlb. See Fig. 76.
REMOVING AND INSTALLING COVER UNDER DASHBOARD ON PASSENGER'S SIDE
Removing the trim panel under the dashboard on the passenger's side
Fig. 77: Installation position of trim panel under dashboard on passenger's side
Microsoft

1. Unclip trim panel under dashboard on passenger's side -1- using a plastic wedge on the retaining clips -2- and
swivel outwards -Arrow A- . See Fig. 78.
2. Take off the trim panel under the dashboard on the passenger's side -1- to the rear -Arrow B- . See Fig. 78.
Installing the trim panel under the dashboard on the passenger's side
Microsoft
Fig. 79: Installation position of trim panel under dashboard on passenger's side

1. Insert the trim panel under the dashboard on the passenger's side -1- from above -Arrow A- . See Fig. 80.
2. Swivel trim panel under the dashboard on the passenger's side -1- downwards and press in -Arrow B- , until
Microsoft
the retaining clips -2- engage audibly. See Fig. 80.
SUBSEQUENT WORK
Subsequent work
Install left center console cover. Refer to 68 14 19 Removing and installing center console cover - as of MY
2005 (All Models) .
Install top steering-column trim.
Install left dashboard cover. --> 701619 Removing and installing dashboard cover - chapter on "installing"
Install main headlight switch. Refer to 94 05 19 Removing and installing main light switch - as of MY 2005
(All Models) .
70 18 19 REMOVING AND INSTALLING INSTRUMENT PANEL - AS OF MY

2005 (ALL MODELS)
PRELIMINARY WORK
Preliminary work
1. Remove steering wheel. Refer to 48 10 19 Removing and installing steering wheel - as of MY 2005 (All
Models) .
2. Remove trim panel under dashboard. --> 701919 Removing and installing dashboard trim panel - chapter
on "Removing"
3. Remove dashboard insert. Refer to 90 03 19 Removing and installing dashboard insert - as of MY 2005
(All Models) .
4. Remove passenger's airbag unit. Refer to 69 59 19 Removing and installing passenger's airbag unit - as of
NOTE: Only for vehicles with stopwatch.
5. Remove stopwatch. Refer to 90 22 19 Removing and installing stopwatch - as of MY 2005 (All Models) .
6. Remove front loudspeakers. Refer to 91 40 19 Removing and installing front loudspeakers - as of MY

2005 (All Models) .
7. Remove oddments tray. Refer to 68 16 19 Removing and installing shelf - as of MY 2005 (All Models) .
8. Remove switch console. Refer to 96 27 19 Removing and installing switch console - as of MY 2005 (All
Models) .
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9. Remove display and PCM operator control unit. Refer to 91 10 19 Removing and installing PCM display
and control unit - as of MY 2005 (All Models) .
10. Remove dashboard moldings.
11. Remove central locking switch. Refer to 57 78 19 Removing and installing central locking switch - as of
12. Remove middle air vent. Refer to 85 53 19 Removing and installing middle air vent - as of MY 2005 (All
Models) .
13. Remove air vent at door. Refer to 85 59 19 Removing and installing air vent at door - as of MY 2005
(All Models) .
14. Remove warning light switch. Refer to 94 47 19 Removing and installing hazard warning light switch -
REMOVING INSTRUMENT PANEL
Removing the device carrier
Fig. 81: Installation location of dashboard

Microsoft
Fig. 82: Removing the device carrier

NOTE:  Unclip electrical lead in vehicles with a telephone handset.
2. Pull device carrier -2- to the rear. See Fig. 82.
Undoing intermediate piece for defroster cover

Microsoft
Fig. 84: Undoing intermediate piece for defroster cover

1. Unscrew fastening screws -1- on defroster intermediate piece -2- . See Fig. 84.
2. Remove defroster cover lid -3- . See Fig. 84.
Removing dashboard
Microsoft

Microsoft
Fig. 86: Detaching dashboard

1. Unscrew fastening screws -1- from dashboard -2- at the lower front passenger side. See Fig. 86.
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Fig. 87: Detaching outer dashboard

2. Press outer air guides -3- slightly downwards and unscrew fastening screws -1- from dashboard -2- . See Fig.
87.
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Fig. 88: Removing instrument panel

3. Unscrew fastening screws -1- near instrument cluster and center air guides -3- from dashboard -2- . See Fig.
88.
NOTE:  When removing the instrument panel, make sure that no wires or plug
connections are damaged.
4. With the help of a second person, carefully remove dashboard to the rear.
INSTALLING INSTRUMENT PANEL
Checking dashboard clamps

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Fig. 90: Dashboard clamps

1. Check dashboard clamps and replace if necessary.

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Installing dashboard

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Fig. 92: Installing dashboard

NOTE:  When installing the instrument panel, make sure that no wires or plug
connections are trapped.
1. With the help of a second person, carefully fit dashboard over the dashboard bracket.
NOTE:  Before securing the instrument panel, make sure that all wires and plug
connections are routed correctly.
2. Screw in dashboard -2- near instrument cluster and center air guide -3- with the fastening screws -1- . See
Fig. 92.
Microsoft
Fig. 93: Fastening the dashboard

NOTE:  Before securing the instrument panel, make sure that all wires and plug
connections are routed correctly.
3. Screw in dashboard -2- at the lower front passenger side with the fastening screws -1- . See Fig. 93.
Microsoft
Fig. 94: Fastening outer dashboard

4. Screw in dashboard -2- near outer air guides -3- with the fastening screws -1- . See Fig. 94.
Securing intermediate piece for defroster cover
Microsoft

Fig. 96: Securing intermediate piece for defroster cover

1. Position fastening screws -1- with the defroster cover lid -3- on the intermediate piece for the defroster cover
-2- and tighten as required. Tightening torque --> Final tightening: 2.0 ftlb. See Fig. 96.
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Installing the device carrier

Fig. 98: Installing the device carrier

1. Position device carrier -2- and screw down with the fastening screws -1- . Tightening torque --> Final
tightening: 2.0 ftlb. See Fig. 98.
SUBSEQUENT WORK
Subsequent work
1. Install warning-light switch. Refer to 94 47 19 Removing and installing hazard warning light switch - as
Microsoft
2. Install middle air vent. Refer to 85 53 19 Removing and installing middle air vent - as of MY 2005 (All
Models) .
3. Install air vent at door. Refer to 85 59 19 Removing and installing air vent at door - as of MY 2005 (All
Models) .
4. Install central locking switch. Refer to 57 78 19 Removing and installing central locking switch - as of
5. Install dashboard molding.
6. Install display and PCM operator control unit. Refer to 91 10 19 Removing and installing PCM display and
7. Install switch console. Refer to 96 27 19 Removing and installing switch console - as of MY 2005 (All
Models) .
8. Install oddments tray. Refer to 68 16 19 Removing and installing shelf - as of MY 2005 (All Models) .
9. Install front loudspeakers. Refer to 91 40 19 Removing and installing front loudspeakers - as of MY 2005
(All Models) .
NOTE: Only for vehicles with stopwatch.
10. Install stopwatch. Refer to 90 22 19 Removing and installing stopwatch - as of MY 2005 (All Models) .
11. Install passenger's airbag unit. Refer to 69 59 19 Removing and installing passenger's airbag unit - as of
12. Install dashboard insert. Refer to 90 03 19 Removing and installing dashboard insert - as of MY 2005
(All Models) .
13. Install trim panel under dashboard. --> 701919 Removing and installing dashboard trim panel - chapter
on "Installing"
14. Install steering wheel. Refer to 48 10 19 Removing and installing steering wheel - as of MY 2005 (All
Models) .
70 20 19 REMOVING AND INSTALLING COVER FOR DASHBOARD

(DEFROSTER TRIM) - AS OF MY 2005 (ALL MODELS)
PRELIMINARY WORK
Preliminary work
Remove A-pillar trim panel. --> 705719 Removing and installing A-pillar trim panel - chapter on
Microsoft
"removing" [987120 987121] --> 705719 Removing and installing A-pillar trim panel - chapter on
"removing" [987310 987311 987320 987321]
REMOVING COVER FOR DASHBOARD (DEFROSTER TRIM)
Removing cover for center dashboard (defroster trim)
Fig. 99: Installation position for center dashboard cover (defroster trim)
Microsoft
Fig. 100: Removing center cover

1. Insert plastic wedge under dashboard cover (defroster trim) center -1- and lever out in upward direction -
2. Disconnect plug connection for sun sensor.
Removing cover for dashboard (defroster trim) on right and left
Microsoft
Fig. 101: Installation position for dashboard cover (defroster trim)

Fig. 102: Removing side cover

1. Insert plastic wedge under dashboard cover (defroster trim) left and right -4- and lever out of sheetmetal clips
-5- . See Fig. 102.
Microsoft
INSTALLING COVER FOR DASHBOARD (DEFROSTER TRIM)
Installing cover for dashboard (defroster trim) on right and left
Fig. 103: Installation position for dashboard cover (defroster trim)

Microsoft
Fig. 104: Installing side cover

1. Check sheetmetal clips -5- for deformation; replace if necessary. See Fig. 104.
2. Clip cover for dashboard (defroster trim) into place on left and right -4- . See Fig. 104.
Installing center dashboard cover (defroster trim)
Fig. 105: Installation position for center dashboard cover (defroster trim)
1. Lock plug connection for sun sensor.
Microsoft
Fig. 106: Install center cover

2. Position center dashboard cover (defroster trim) -1- and clip in -arrow- . See Fig. 106.
SUBSEQUENT WORK
Subsequent work
Install A-pillar trim panel. --> 705719 Removing and installing A-pillar trim panel - chapter on
"installing" [987120 987121] --> 705719 Removing and installing A-pillar trim panel - chapter on
"installing" [987310 987311 987320 987321]
70 22 19 REMOVING AND INSTALLING COVER (COLD AIR BULKHEAD) -

REMOVING COVER (COLD AIR BULKHEAD)
Removing cover (cold air bulkhead)
Microsoft

1. Unscrew both plastic screws -1- and remove the cover downwards -arrows- . See Fig. 107.
INSTALLING COVER (COLD AIR BULKHEAD)
Installing cover (cold air bulkhead)
Microsoft

1. Position the cover from below -arrows- and screw in with the two fastening screws -1- . See Fig. 108.
70 23 19 REMOVING AND INSTALLING TRIM PANEL FOR SPRING STRUT

MOUNT - AS OF MY 2006 (CAYMAN S, CAYMAN S RHD)
PRELIMINARY WORK
Preliminary work
1. Remove cover for rear. --> 705319 Removing and installing cover for rear - chapter on "Removing"
2. Remove C-pillar trim panel. --> 706819 Removing and installing C-pillar trim panel - chapter on
"Removing"
REMOVING TRIM PANEL FOR SPRING STRUT MOUNT
Removing trim panel for spring strut mount
Microsoft
Fig. 109: Installation position of trim panel for spring strut mount
Microsoft
Fig. 110: Removing trim panel for spring strut mount

2. Unclip trim panel for spring strut mount -2- first upwards -Arrows A- and then pull out slightly in -direction
of Arrow B- . See Fig. 110.
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Fig. 111: Disconnecting connector for loudspeaker

3. Press locking tabs together -Arrows a- and disconnect connector for loudspeaker -1- . See Fig. 111.
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Fig. 112: Checking fastening nut and clamps

4. Check fastening nuts -1- and clamps -2, 3- , and replace if necessary. See Fig. 112.
INSTALLING TRIM PANEL FOR SPRING STRUT MOUNT
Installing trim panel for spring strut mounts
Microsoft
Fig. 114: Pushing in connector for loudspeaker

1. Push in connector for loudspeaker -1- until the locking tabs engage. See Fig. 114.
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Fig. 115: Installing trim panel for spring strut mount

NOTE: Make sure that the tie-down rings are not pinched.
2. Insert trim panel for spring strut mount -2- in the side trim panel -Arrows A- and press down until the clamps
engage -Arrows B- . See Fig. 115.
3. Align gap of trim panel for spring strut mount -2- to shelf and tighten fastening screws -1- . --> Tightening
torque: 1.5 (1.0 ftlb.) Nm See Fig. 115.
SUBSEQUENT WORK
Subsequent work
Microsoft
1. Install C-pillar trim. --> 706819 Removing and installing C-pillar trim - section on "Installing"
2. Install cover for rear. --> 705319 Removing and installing cover for rear - chapter on "Installing"
70 24 19 REMOVING AND INSTALLING FRONT SIDE SECTION TRIM - AS

REMOVING FRONT SIDE SECTION TRIM
Removing front side section trim panel (driver's side)
Fig. 116: Removing front side section trim panel (driver's side).
1. Remove fuse carrier cover -1- -Arrow A- . See Fig. 116.
2. Unscrew fastening screws -2- and remove side section trim panel -3- -Arrow B- . See Fig. 116.
Removing front side section trim panel (passenger's side).
Microsoft
Fig. 117: Removing front side section trim panel (passenger's side)
1. Partly loosen carpet -1- at the bottom in the area of the A-pillar -Arrow A- . See Fig. 117.
2. Unscrew plastic nuts -2- and remove side section trim panel -3- -Arrow B- . See Fig. 117.
INSTALLING FRONT SIDE SECTION TRIM
Installing front side section trim panel (passenger's side)
Microsoft
Fig. 118: Installing front side section trim panel (passenger's side)
1. Position side section trim panel -3- -Arrow A- and screw down with the plastic nuts -2- . See Fig. 118.
2. Fasten carpet -1- at the bottom in the area of the A-pillar -Arrow B- Double-sided adhesive tape or suitable
adhesive . See Fig. 118.
Installing front side section trim panel (driver's side)
Microsoft
Fig. 119: Installing front side section trim panel (driver's side)
1. Insert side section trim panel -3- insert -Arrow A- and screw down with the fastening screws -2- . -->
2. Insert the fuse carrier cover -1- with both clips -4- into the lateral side section trim panel -2- and clip in -
70 30 19 REMOVING AND INSTALLING FRONT LUGGAGE COMPARTMENT

COVER - AS OF MY 2005 (ALL MODELS)
PRELIMINARY WORK
Preliminary work
Remove luggage compartment light. Refer to 96 40 19 Removing and installing luggage compartment light
in rear lid - as of MY 2006 (Cayman S, Cayman S RHD) .
REMOVING FRONT LUGGAGE COMPARTMENT COVER
Removing luggage compartment cover
Microsoft
Fig. 120: Installation position of luggage compartment cover

Fig. 121: Loosening luggage-compartment lining

1. Unscrew plastic nut -1- ( -Arrow A- ) and loosen luggage-compartment lining on the left-hand side -2- ( -
Arrow B- ). See Fig. 121.
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Fig. 122: Loosening luggage compartment cover

2. Unscrew fastening screws -1- from the luggage compartment cover -2- . See Fig. 122.
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Fig. 123: Removing luggage compartment cover

3. Remove luggage compartment cover -1- to the front. See Fig. 123.
Fig. 124: Checking support

4. Check support -1- and replace if necessary. See Fig. 124.
Microsoft

Fig. 126: Loosening luggage-compartment lining

1. Unscrew plastic nut -1- ( -Arrow A- ) and loosen luggage-compartment lining on the left-hand side -2- ( -
Arrow B- ). See Fig. 126.
Microsoft

2. Unscrew fastening screws -1- from the luggage compartment cover -2- . See Fig. 127.
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3. Remove luggage compartment cover -1- to the front. See Fig. 128.
Fig. 129: Checking support

4. Check support -1- and replace if necessary. See Fig. 129.
INSTALLING FRONT LUGGAGE COMPARTMENT COVER
Installing luggage compartment cover
Microsoft
Fig. 130: Installing luggage compartment cover

1. Position luggage compartment cover -1- in the luggage compartment. See Fig. 130.
Microsoft
Fig. 131: Fastening luggage compartment cover

2. Screw down luggage compartment cover -2- using the fastening screws -1- . See Fig. 131.
Fig. 132: Fastening luggage compartment lining

3. Run in luggage-compartment lining -2- -arrow A- and fasten with the plastic nut -1- -arrow B- . See Fig.
132.
4. Check to ensure that lid seal is installed correctly.
Installing luggage compartment cover
Microsoft

1. Position luggage compartment cover -1- in the luggage compartment. See Fig. 133.
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2. Screw down luggage compartment cover -2- using the fastening screws -1- . See Fig. 134.
Fig. 135: Fastening luggage compartment lining

3. Run in luggage-compartment lining -2- -arrow A- and fasten with the plastic nut -1- -arrow B- . See Fig.
135.
4. Check to ensure that lid seal is installed correctly.
SUBSEQUENT WORK
Subsequent work
Install luggage compartment light. Refer to 96 40 19 Removing and installing luggage compartment light in
rear lid - as of MY 2006 (Cayman S, Cayman S RHD) .

COVER - AS OF MY 2006 (CAYMAN S, CAYMAN S RHD)
REMOVING REAR LUGGAGE COMPARTMENT COVER
Microsoft

Microsoft
Fig. 137: Removing rear luggage compartment cover

2. Release locking mechanism -1- right and left in -direction of Arrow A- , and remove rear luggage
compartment cover -2- -Arrow B- . See Fig. 137.
INSTALLING REAR LUGGAGE COMPARTMENT COVER
Installing rear luggage compartment cover
Microsoft

Microsoft
Fig. 139: Installing rear luggage compartment cover

1. Position rear luggage compartment cover -2- on the rear lid lining -3- -Arrow A- , and lock the locking
mechanism -1- right and left in -direction of Arrow B- . See Fig. 139.
2. Close rear lid.
70 31 19 REMOVING AND INSTALLING REAR WALL TRIM PANEL - AS OF

PRELIMINARY WORK
Preliminary work
Remove trim panel for convertible top rest/engine compartment lid. --> 700819 Removing and installing trim
Microsoft
panel for convertible top rest - chapter on "Removing"
REMOVING REAR WALL TRIM PANEL
Removing rear wall trim panel
1. Move front seat all the way forward.
Fig. 140: Removing rear wall trim panel

3. Loosen rear wall trim panel -2- at the sides from the side trim panel -Arrow A- and lift up and out -Arrow B-
. See Fig. 140.
INSTALLING REAR WALL TRIM PANEL
Installing rear wall trim panel
Microsoft
Fig. 141: Installing rear wall trim panel

1. Position rear wall trim panel -2- -Arrow A- and insert sides between the body and side trim panel -Arrow B-
. See Fig. 141.
2. Screw in -1- fastening nuts. See Fig. 141.
3. Move front seat back to the initial position.
SUBSEQUENT WORK
Subsequent work
Install trim panel for convertible top rest/engine compartment lid. --> 700819 Removing and installing trim
panel for convertible top rest - chapter on "Installing"
70 31 19 REMOVING AND INSTALLING REAR WALL TRIM PANEL - AS OF

PRELIMINARY WORK
Preliminary work
Microsoft
REMOVING REAR WALL TRIM PANEL
Removing retaining strip for securing luggage
Fig. 142: Installation position of retaining strip for securing luggage

1. Move front seat fully forward.
Microsoft
Fig. 143: Removing clip

2. Remove covers -1- and push them inwards. See Fig. 143.
3. Unscrew fastening screws -2- and remove clip -3- . See Fig. 143.
Microsoft
Fig. 144: Removing retaining strip

4. Unscrew fastening screw -1- and remove retaining strip for securing luggage -2- upwards. See Fig. 144.
5. Check clamp -3- , replace if necessary. See Fig. 144.
Removing rear wall trim panel
Microsoft
Fig. 145: Installation position for rear wall trim panel

Fig. 146: Removing rear wall trim panel

1. Loosen rear wall trim panel -1- at the sides from the side trim panel -Arrow A- and lift up and out -Arrow B-
. See Fig. 146.
Microsoft
INSTALLING REAR WALL TRIM PANEL
Installing rear wall trim panel
Fig. 147: Installation position for rear wall trim panel

Microsoft
Fig. 148: Installing rear wall trim panel

1. Position rear wall trim panel -1- -Arrow A- and insert sides between the body and side trim panel -Arrow B-
. See Fig. 148.
Installing retaining strip for securing luggage
Fig. 149: Installation position of retaining strip for securing luggage

Microsoft
Fig. 150: Installing retaining strip

1. Position retaining strip for securing luggage -2- on the body and press in until the clamps engage. See Fig.
150.
2. Tighten fastening screw -1- . --> Tightening torque: 1.5 (1.0 ftlb.) Nm See Fig. 150.
Microsoft
Fig. 151: Installing clip

3. Position clip -1- and screw down with the fastening screws -2- . torque --> Tightening torque: 23 (17 ftlb.)
Nm See Fig. 151.
4. Press in covers -3- . See Fig. 151.
SUBSEQUENT WORK
Subsequent work
Microsoft
70 35 19 REMOVING AND INSTALLING FOOTREST - AS OF MY 2005 (ALL

MODELS)
REMOVING FOOTREST
Removing footrest
Fig. 152: Installation position for footrest

Microsoft
Fig. 153: Removing footrest

1. Carefully pull out footrest by hand from above and remove.
INSTALLING FOOTREST
Installing footrest
Microsoft
Fig. 154: Installation position for footrest

Fig. 155: Installing footrest

1. Position footrest with the three locking tabs and carefully engage.
Microsoft
70 39 19 REMOVING AND INSTALLING COVER FOR FRONT LOCK MOUNT -

REMOVING COVER FOR FRONT LOCK MOUNT
Removing cover for lock support
1. Open front lid.
Fig. 156: Loosening trim panel

2. Loosen cover for lock support -1- at the Velcro fasteners -2- . See Fig. 156.
3. Actuate lid-release lever -3- in -direction of arrow A- and remove cover for lock support -1- ( -arrow B- ).
See Fig. 156.
Microsoft
Fig. 157: Unclipping trim panel

4. Lift cover for lock support up slightly -1- , release the locking tab at the side from below -arrow A- and pull
it out of the cover for the wing flange -2- ( -arrows B- ). See Fig. 157.
INSTALLING COVER FOR FRONT LOCK MOUNT
Installing cover for lock support
NOTE:  The Velcro fasteners must be removed and replaced when replacing the
front apron and cover for lock support.
1. Check Velcro fasteners on front apron and cover for lock support and replace if necessary. See: Additional
assembly instructions for replacing Velcro fasteners
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Fig. 158: Inserting trim panel

2. Insert trim panel for lock support -1- sideways into the cover for the wing flange -2- ( -arrows A- ). See Fig.
158.
Microsoft
Fig. 159: Installing lining

3. Actuate lid-release lever -3- in -direction of arrow A- and fit trim panel for lock support -1- ( -arrow B- ).
See Fig. 159.
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4. Insert locking lug for trim panel for lock support -1- into the wing at the side -2- . See Fig. 160.
5. Slide trim panel for lock support -1- with the soft lip under the luggage compartment seal and press on Velcro
fasteners. See Fig. 160.
6. Close front lid.
Additional assembly instructions for replacing Velcro fasteners
Microsoft
Fig. 161: Checking Velcro fasteners

1. Remove protective paper on the underside, push locking lug into the cover for the wing flange and press trim
panel for lock support -1- down onto the front apron. See Fig. 161.
2. Press Velcro fasteners -2- on at the positions indicated. See Fig. 161.
3. Lift off trim panel for lock support -1- and press Velcro fasteners -2- securely onto the front apron again
using a suitable tool. See Fig. 161.
70 39 19 REMOVING AND INSTALLING COVER FOR REAR LOCK CARRIER

- AS OF MY 2006 (CAYMAN S, CAYMAN S RHD)
PRELIMINARY WORK
Preliminary work
1. Remove rear light cover, left and right. --> 709419 Removing and installing rear light cover - chapter on
"Removing"
REMOVING COVER FOR REAR LOCK CARRIER
Removing cover for rear lock carrier
Microsoft
Fig. 162: Installation position of cover for lock carrier

Microsoft
Fig. 163: Removing cover for rear lock carrier

1. Partly unclip side trim panels for rear luggage compartment -1- in area of cover for rear lock carrier -2- -
Arrow A- . See Fig. 163.
2. Unclip cover for rear lock carrier -2- -Arrow B- . See Fig. 163.
INSTALLING COVER FOR REAR LOCK CARRIER
Installing cover for rear lock carrier
Microsoft
Fig. 164: Installation position of cover for lock carrier

Microsoft
Fig. 165: Installing cover for rear lock carrier

1. Position cover for rear lock carrier -2- on the body and press in until the clamps -3- engage -Arrow A- . See
Fig. 165.
2. Clip in side trim panels for rear luggage compartment -1- in area of cover for rear lock carrier -2- -Arrow B-
. See Fig. 165.
Microsoft
Fig. 166: Lifting rubber seal for rear lid

3. Lift up rubber seal for rear lid -1- using a plastic wedge -2- along cover for rear lock carrier -3- . See Fig.
166.
SUBSEQUENT WORK
Subsequent work
1. Install rear light cover, left and right. --> 709419 Removing and installing rear light cover - chapter on
"Installing"
70 53 19 REMOVING AND INSTALLING REAR COVER. - AS OF MY 2006

PRELIMINARY WORK
Preliminary work
REMOVING REAR COVER
Microsoft
Removing trim for the rear.
Fig. 167: Installation position for rear cover

Microsoft
Fig. 168: Loosening cover

1. Open service tray -1- . See Fig. 168.
2. Unscrew fastening screws -2- in area of service tray -1- . See Fig. 168.
Microsoft

3. Unclip cover upwards -1- . See Fig. 169.
4. Check clamps -2- and fastening nuts -3- and replace if necessary. See Fig. 169.
INSTALLING REAR COVER
Installing cover for rear
Microsoft
Fig. 170: Installation position for rear cover


1. Position cover -1- on body and press in until clamps engage -2- . See Fig. 171.
Microsoft
Fig. 172: Fastening cover

2. Align cover -3- with service tray -1- and screw down with fastening screws -2- . See Fig. 172.
3. Close service tray -1- . See Fig. 172.
SUBSEQUENT WORK
Subsequent work
Microsoft
70 54 19 REMOVING AND INSTALLING SERVICE TRAY - AS OF MY 2006

PRELIMINARY WORK
Preliminary work
1. Remove carpet lining for cross member rear wall. --> 700619 Removing and installing rear luggage
compartment trim - section on "Removing"
2. Remove cover for rear. --> 705319 Removing and installing cover for rear - section on "Removing"
3. Drain coolant. Refer to 19 38 17 Draining and filling in coolant - as of MY 2005 (All Models) .
REMOVING SERVICE TRAY
Removing service tray
Fig. 173: Installation position of service tray

WARNING: Danger of scalding from hot oil!
--> Engine oil and components of the oil circuit can become very hot!
--> Allow engine and components to cool down.

Microsoft
--> Avoid contact with the skin and eyes.
--> Wear suitable protective clothing.
WARNING: Coolant is corrosive and hazardous to health.
 Skin and eye irritation
--> Wear protective gloves and goggles.
--> If you come into contact with coolant, wash off immediately with plenty of warm water.
Fig. 174: Pulling out hoses

Microsoft
1. Pull off spring band clamp -1- on oil hose -2- . Pull oil hose out of service tray -3- . See Fig. 174.
2. Pull spring band clamp off filler hose -4- . Pull filler hose out of service tray. See Fig. 174.
3. Pull spring band clamp off breather hose -5- . Pull breather hose out of service tray. See Fig. 174.
Fig. 175: Removing service tray

4. Open service tray cover -1- . See Fig. 175.
5. Press out cap -2- with a screwdriver. Unscrew fastening nut -3- . See Fig. 175.
6. Unclip locking lug at the bottom of the service tray -4- ( -Arrow A- ) and pull out service tray in -direction
Microsoft
of arrow B- . See Fig. 175.
Fig. 176: Removing service tray assembly frame

7. Unscrew fastening nuts -1- and remove service tray assembly frame -2- . See Fig. 176.
Microsoft
Fig. 177: Removing sealing frame

8. Remove and check service tray sealing frame -1- , and replace it if necessary. See Fig. 177.
INSTALLING SERVICE TRAY
Installing service tray
Microsoft
Fig. 178: Installing sealing frame

1. Position service tray sealing frame -1- on the body. See Fig. 178.
Microsoft
Fig. 179: Installing service tray assembly frame

2. Position service tray assembly frame -2- on the body and screw fastening nuts -1- on slightly. See Fig. 179.
Fig. 180: Installing service tray

3. Clip service tray -1- onto the assembly frame in direction of arrow and screw fastening nut -2- on slightly.
See Fig. 180.
Microsoft
Fig. 181: Fitting the hoses

4. Attach breather hose -5- to the service tray -3- and fit the spring band clamp -1- . See Fig. 181.
5. Attach filler hose -4- to the service tray and fit the spring band clamp. See Fig. 181.
6. Attach oil hose -2- to the service tray and fit the spring band clamp. See Fig. 181.
7. Check that the hoses are firmly in place.
8. Install carpet lining for cross member rear wall. --> 700619 Removing and installing rear luggage
compartment trim - section on "Installing"
Microsoft
9. Install cover for rear. --> 705319 Removing and installing cover for rear - section on "Installing"
Fig. 182: Securing service tray

10. Align service tray -1- with cover for the rear and carpet lining, and screw down the fastening nuts -2- . -->
Tightening torque: 6 (4.5 ftlb.) Nm See Fig. 182.
11. Press cap -3- onto the upper fastening nut -2- . See Fig. 182.
SUBSEQUENT WORK
Subsequent work
1. Fill coolant and bleed cooling system Refer to 19 38 17 Draining and filling in coolant - as of MY 2005
(All Models) .
70 57 19 REMOVING AND INSTALLING A-PILLAR TRIM - AS OF MY 2005

PRELIMINARY WORK
Preliminary work
1. Open convertible top.

Microsoft
2. Remove sun visor. Refer to 68 23 19 Removing and installing sun visor - as of MY 2005 (Boxster,
REMOVING A-PILLAR TRIM
Removing A-pillar trim
Fig. 183: Installation position for A-pillar trim

Microsoft
Fig. 184: Removing convertible-top peg housing

1. Unscrew fastening screws -1- from the convertible-top peg housing -2- . See Fig. 184.
Microsoft
Fig. 185: Removing A-pillar trim

2. Pull A-pillar trim -1- inwards along the windscreen frame -2- in -direction of arrow- . See Fig. 185.

3. Remove A-pillar trim -1- upwards in -direction of arrow- . See Fig. 186.
INSTALLING A-PILLAR TRIM
Installing A-pillar trim
Microsoft

NOTE:  Ensure that deformation element is seated correctly before installation.
Fig. 188: Installing A-pillar trim

Microsoft
1. Check sheetmetal clips -3- and replace if necessary. Position A-pillar trim panel -1- on windscreen frame -
direction of arrow- . See Fig. 188.
Fig. 189: Installing A-pillar trim

2. Insert A-pillar trim panel -1- laterally (transition point to dashboard) on windscreen frame -direction of
arrow- click into place. See Fig. 189.
Microsoft
Fig. 190: Installing convertible-top peg housing

3. In order to avoid rattling noises, each of the two convertible-top peg housings on the left and right -2- must
be facing outwards in relation to the centering pins fitted on the convertible top or hardtop when tightening. The
convertible top must be closed or the hardtop must be fitted to check the adjustment. Tighten fastening screws -
1- . Tightening torque --> Final tightening: 7.5 ftlb. See Fig. 190.
SUBSEQUENT WORK
Subsequent work
Install sun visor. Refer to 68 23 19 Removing and installing sun visor - as of MY 2005 (Boxster, Boxster
70 57 19 REMOVING AND INSTALLING A-PILLAR TRIM - AS OF MY 2006

REMOVING A-PILLAR TRIM
Removing A-pillar trim
Microsoft

Fig. 192: Unclipping C-pillar trim panel

Microsoft
1. Unclip C-pillar trim panel -1- in area of A-pillar trim panel -2- using a plastic wedge -3- . See Fig. 192.
Fig. 193: Unclipping A-pillar trim

2. Pull A-pillar trim panel -1- inwards along the roof frame and windscreen frame. See Fig. 193.
Microsoft

3. Remove A-pillar trim panel -1- upwards. See Fig. 194.
Microsoft
Fig. 195: Checking clamps

4. Check clamps -1, 2- , and replace if necessary. See Fig. 195.
INSTALLING A-PILLAR TRIM
Installing A-pillar trim

Microsoft
Fig. 197: Installing A-pillar trim panel

1. Insert A-pillar trim panel -1- at the side of the windscreen frame (transition point to dashboard). See Fig. 197.
Microsoft
Fig. 198: Clipping A-pillar trim panel into place

2. Press in A-pillar trim panel -1- along the roof frame until the clamps -2- engage. See Fig. 198.
Fig. 199: Installing C-pillar trim

3. Clip C-pillar trim panel into place -1- in area of A-pillar trim panel -2- . See Fig. 199.
Microsoft
Fig. 200: Lifting rubber seal for door.

4. Lift rubber seal for door -1- using a plastic wedge -2- along the A-pillar trim panel -3- . See Fig. 200.
70 59 19 REMOVING AND INSTALLING DOOR TRIM PANEL - AS OF MY

2005 (ALL MODELS)
REMOVING DOOR TRIM PANEL
Microsoft


Microsoft
Removing lever for door opener
Fig. 203: Main illustration for removing and installing door trim panel
Microsoft
Fig. 204: Removing lever for door opener

1. Unscrew fastening screw -1- and remove lever for door opener -2- . See Fig. 204.
Removing covers for door trim panel
Microsoft
Fig. 206: Removing covers for door trim panel

1. Carefully lever out covers -1, 2, 3- using a plastic wedge and remove. See Fig. 206.
Releasing door trim panel
Microsoft
Fig. 208: Releasing door trim panel

Microsoft
Fig. 209: Clipping out door trim panel

2. Unclip front door trim panel -1- at the bottom -arrow A- and unhook from the sealing channel at the top -
Disconnecting the electrical plug connections
Microsoft

1. Disconnect electrical plug connection -arrow- . See Fig. 211.
Microsoft
Fig. 212: Unlocking plug connection on control unit

2. Unlock electrical plug connection -2- by operating locking lever -1- and remove from control unit -3- . See
Fig. 212.
Removing actuating cable for door lock
Microsoft
Fig. 214: Disengaging actuating cable

1. Unlock fastening clip of actuating cable for door lock -1- by pressing the locking hook -A- and disengage
from the guide slot -B- . See Fig. 214.
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2. Swivel pin -2- of actuating cable to the right by 90° -C- and disengage. See Fig. 214.
3. Remove door trim panel.
INSTALLING DOOR TRIM PANEL
Checking fastening clips
NOTE:  The fastening clips have two settings. Before installing the front door trim
panel, the fastening clips must be loosened fully because otherwise the
door trim panel may not engage fully into the door unit carrier, possibly
resulting in noises. The fastening clips must be pulled to the front
position.
Microsoft
Fig. 216: Checking the fastening clips

1. Check fastening clips -1- for deformation; replace if necessary. See Fig. 216.
2. Pull fastening clips -1- to the front position so that they are fully loosened. See Fig. 216.
Installing actuating cable for door lock
Microsoft
Fig. 218: Engaging actuating cable

1. Engage pin -2- of the actuating cable and swivel to the left by 90° -Arrow A- . See Fig. 218.
2. Insert T-tread of fastening clip -1- into the square hole -Arrow B- . See Fig. 218.
Microsoft
3. Push fastening clip -1- forward and lock the locking hook. See Fig. 218.
Microsoft
Fig. 220: Lock plug connection to control unit.

1. Connect electrical plug connection -3- to control unit -2- by operating locking lever -1- and lock. See Fig.
220.

2. Lock electrical plug connection -arrow- until it engages audibly. See Fig. 221.
Installing door trim panel
Microsoft
Fig. 223: Clipping door trim panel into place

1. Hook front door trim panel into sealing channel at the top -Arrow A- and clip in at the bottom -Arrow B- .
Make sure that the guide fixing clips -1- engage in the sub-frame. See Fig. 223, Fig. 224.
Microsoft
Fig. 224: Fastening door trim panel

2. Tighten fastening screws -1- . Tightening torque --> Final tightening: 5.5 + 0.5 ftlb. See Fig. 224.
Installing covers for door trim panel
Microsoft
Fig. 226: Installing covers for door trim panel

1. Clip covers -1, 2, 3- into place on the door trim panel until they are felt to engage. See Fig. 226.
Installing lever for door opener
Microsoft
Fig. 228: Installing lever for door opener

1. Screw in fastening screw -1- and screw down lever for door opener -2- . Tightening torque --> Final
tightening: 1.5 + 0.15 ftlb. See Fig. 228.
Microsoft


Microsoft
70 61 19 REMOVING AND INSTALLING COVER FOR DOOR TRIM PANEL -

TOOLS

vice-grip wrench lowered commercially NR.127
available tool
TRIAC S plastic welder workshop WE1120
equipment
PRELIMINARY WORK
Preliminary work
1. Remove trim panel for mirror triangle. --> 707019 Removing and installing trim panel for mirror triangle
- section on "Removing"
2. Remove door trim panel. --> 705919 Removing and installing door trim panel - section on "Removing"
3. Remove door handle. Refer to 57 45 19 Removing and installing door handle - as of MY 2005 (All
Models) .
REMOVING COVER FOR DOOR TRIM PANEL
Removing cover for door trim panel
Microsoft
Fig. 231: Installation position of cover for door trim panel

Fig. 232: Drilling out pins

1. Drill out the nine fastening pins -arrows- on the cover with a 4.5-mm drill bit, starting at the back of the door
trim panel. See Fig. 232.
Microsoft

2. Remove cover -1- outwards from the door trim panel -2- ( -arrows- ). See Fig. 233.
INSTALLING COVER FOR DOOR TRIM PANEL
Installing cover for door trim panel
Microsoft
Fig. 234: Installation position of cover for door trim panel

NOTE: To ensure that the new cover fits correctly, the fastening holes on the inner
door trim panel must be countersunk from the inside using an 8-mm drill bit.
1. Countersink the nine fastening holes on the inner door trim panel with an 8-mm drill bit.
Microsoft
Fig. 235: Fitting the cover

2. Position cover -1- on the door trim panel -2- from outside ( -arrows- ). See Fig. 235.
Fig. 236: Attaching cover

NOTE: When attaching the cover with a screw clamp and vice-grip wrench, always
protect the outside of the door trim panel with fabric protection. A flat metal
piece (flat iron, etc.) must be placed on the inside of the door trim panel so that
the tools can be positioned better.
3. Position cover -1- and secure with a screw clamp -2- and vice-grip wrench -3- vice-grip wrench lowered
NR.127. Always use sufficiently thick fabric -4- to protect the door trim panel . See Fig. 236.
Microsoft
Fig. 237: Checking joint

4. Check that the joint between the cover -1- and door trim panel -2- is uniform all the way round and align the
cover as required -arrows- . See Fig. 237.
Microsoft
Fig. 238: Securing the cover

5. Use a plastic welder -1- TRIAC S plastic welder WE1120 to heat up the fastening pins -2- for the cover
until visco-elasticity is achieved. See Fig. 238.
Microsoft
Fig. 239: Pressing in fastening pins

6. Use an 8-mm round stock -1- to press the fastening pins -2- in evenly on the door trim panel. See Fig. 239.
SUBSEQUENT WORK
Subsequent work
1. Fit door handle. Refer to 57 45 19 Removing and installing door handle - as of MY 2005 (All Models) .
2. Install door trim panel. --> 705919 Removing and installing door trim panel - section on "Installing"
3. Install trim panel for mirror triangle. --> 707019 Removing and installing trim panel for mirror triangle -
70 63 19 REMOVING AND INSTALLING INNER DOOR OPENER - AS OF MY

2005 (ALL MODELS)
PRELIMINARY WORK
Preliminary work
1. Remove door trim panel. --> 705919 Removing and installing door trim panel - chapter on "removing"
Microsoft
REMOVING INNER DOOR OPENER
Removing inner door handle
Fig. 240: Installation position of inner door handle

Microsoft
Fig. 241: Removing inner door handle

2. Take off inner door handle -2- ( -arrow- ). See Fig. 241.
INSTALLING INNER DOOR OPENER
Installing inner door handle
Fig. 242: Installation position of inner door handle

Microsoft
Fig. 243: Installing inner door handle

1. Insert inner door handle -2- ( -arrow- ). See Fig. 243.
2. Screw in fastening screws -1- and tighten to required tightening torque --> Final tightening: 5 ftlb. . See Fig.
243.
SUBSEQUENT WORK
Subsequent work
1. Install door trim panel. --> 705919 Removing and installing door trim panel - chapter on "installing"
70 65 19 REMOVING AND INSTALLING ODDMENTS COMPARTMENT LID -

PRELIMINARY WORK
Preliminary work
1. Remove door trim panel. --> 705919 Removing and installing door trim panel - chapter on "removing"
REMOVING LID FOR ODDMENTS COMPARTMENT
Microsoft
Removing lid for oddments compartment
Fig. 244: Installation position of lid for oddments compartment

Fig. 245: Disengaging spring

Microsoft
1. Disengage spring -1- with a suitable pair of pliers from the guide mechanism -2- . See Fig. 245, Fig. 247.
Fig. 246: Unclipping shock absorber

2. Unclip shock absorber -3- from door trim panel -4- . See Fig. 246.
Microsoft
Fig. 247: Disengaging guide mechanism

3. Press together guide mechanism on the right and left -2- with a suitable pair of pliers -Arrow A- and
disengage from the door trim panel -4- -Arrow B- . See Fig. 247.
INSTALLING LID FOR ODDMENTS COMPARTMENT
Installing lid for oddments compartment
Microsoft
Fig. 248: Installation position of lid for oddments compartment

Microsoft
Fig. 249: Engaging guide mechanism

1. Insert guide mechanism on the right and left -2- in door trim panel -4- -Arrow A- and engage -Arrow B- .
See Fig. 249.
Microsoft
Fig. 250: Clip in shock absorber

2. Position shock absorber -3- in the door panel -4- and guide mechanism, and push in until it engages at the
groove. See Fig. 250.
Microsoft
Fig. 251: Engaging spring

3. Engage spring -1- with a suitable pair of pliers in the guide mechanism -2- . See Fig. 251.
SUBSEQUENT WORK
Subsequent work
1. Install door trim panel. --> 705919 Removing and installing door trim panel - chapter on "installing"
70 66 19 REMOVING AND INSTALLING ODDMENTS TRAY - AS OF MY 2006

PRELIMINARY WORK
Preliminary work
1. Remove trim panel for spring strut mount. --> 702319 Removing and installing trim panel for spring strut
2. Remove retaining strip for securing luggage. --> 703119 Removing rear wall trim panel - chapter on
"Removing"
REMOVING ODDMENTS TRAY

Microsoft
Removing oddments tray
Fig. 252: Installation position of oddments tray

Microsoft
Fig. 253: Removing oddments tray

2. Unclip oddments tray -2- in area of belt deflector -Arrow A- , remove in -direction of Arrow B- and then
disengage from the seat belt -3- . See Fig. 253.
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Fig. 254: Checking fastening nuts

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Fig. 255: Checking fastening nuts and clamps

4. Check fastening nuts -1- and clamps -2, 3- and replace if necessary. See Fig. 255.
INSTALLING ODDMENTS TRAY
Installing oddments tray
Microsoft
Fig. 256: Installation position of oddments tray

Microsoft
Fig. 257: Installing oddments tray

1. Thread through the seat belt -3- . See Fig. 257.
2. Insert oddments tray -2- in -direction of Arrow A- and clip in area of belt deflector -Arrow B- . See Fig.
257.
3. Screw down oddments tray -2- with the fastening screws -1- . --> Tightening torque: 1.5 (1.0 ftlb.) Nm See
Fig. 257.
SUBSEQUENT WORK
Subsequent work
Microsoft
1. Install retaining strip for securing luggage. --> 703119 Removing rear wall trim panel - chapter on
"Installing"
2. Install trim panel for spring strut mount. --> 702319 Removing and installing trim panel for spring strut
70 68 19 REMOVING AND INSTALLING C-PILLAR TRIM PANEL - AS OF MY

REMOVING C-PILLAR TRIM PANEL
Undoing seat belt and fitting
Fig. 258: Undoing seat belt and fitting

1. Press out cap -1- with a screwdriver. Unscrew fastening screw -2- . Remove seat belt with fitting -3- and
spacer sleeve -4- . See Fig. 258.
Removing seat belt rose
Microsoft
Fig. 259: Removing collar

1. Unclip rose -1- with a plastic wedge -Arrow A- . See Fig. 259.
2. Pull rose -1- out of seat belt -2- -Arrow B- . See Fig. 259.
Removing C-pillar trim panel
NOTE: Only for vehicles with luggage mesh.
1. Disengage luggage mesh at top and fold to the rear.
Microsoft
Fig. 260: Removing lid

2. Unclip cap -1- from C-pillar trim panel -2- . See Fig. 260.
Microsoft
Fig. 261: Removing C-pillar trim panel

4. Pull out C- pillar trim panel -2- slightly at the top -Arrow A- . See Fig. 261.
5. Unclip C- pillar trim panel -2- with a plastic wedge and remove in direction of arrow -B, C- . See Fig. 261.
Microsoft
Fig. 262: Pulling off connector for interior light

6. Pull off connector for interior light.
INSTALLING C-PILLAR TRIM
Installing C-pillar trim panel
Microsoft
Fig. 263: Pushing in connector for interior light

1. Push in connector for interior light -1- . See Fig. 263.
Microsoft
Fig. 264: Installing C-pillar trim

2. Insert C-pillar trim panel -2- in direction of arrow -A, B, C- and press in until the clamps engage. See Fig.
264.
3. Tighten fastening screw -1- . See Fig. 264.
Microsoft
Fig. 265: Installing cap

4. Clip cap -1- into C-pillar trim panel -2- . See Fig. 265.
NOTE: Only for vehicles with luggage mesh.
5. Fold luggage mesh forwards and engage at the top.
Installing rose for seat belt
Microsoft
Fig. 266: Installing collar

1. Pull seat belt -2- through the rose -1- -Arrow A- . See Fig. 266.
2. Press in the rose -1- until the locking tabs engage -Arrow B- . See Fig. 266.
Fastening seat belt with fitting
Microsoft
Fig. 267: Installing seat belt and fitting

NOTE: Ensure that belt strap can run properly!
1. Tighten fastening screw -2- , seat belt with fitting -3- and spacer sleeve -4- on the body. Tightening torque --
> Tightening torque: 50 (37 ftlb.) Nm +/-5 (3.5 ftlb.) Nm See Fig. 267.
2. Press in -1- cap. See Fig. 267.
70 70 19 REMOVING AND INSTALLING TRIM PANEL FOR MIRROR

TRIANGLE - AS OF MY 2005 (ALL MODELS)
REMOVING TRIM PANEL FOR MIRROR TRIANGLE
Microsoft


Microsoft
INSTALLING TRIM PANEL FOR MIRROR TRIANGLE

Microsoft

70 81 19 REMOVING AND INSTALLING TRIM FOR ROLL-OVER BAR - AS OF

REMOVING TRIM FOR ROLL-OVER BAR
Removing trim for roll-over bar
Microsoft
Fig. 272: Installation position of trim for roll-over bar

Fig. 273: Removing linings

1. Loosen linings -1 to 3- with plastic wedge and remove. See Fig. 273.
INSTALLING TRIM FOR ROLL-OVER BAR

Microsoft
Installing trim for roll-over bar
Fig. 274: Installation position of trim for roll-over bar

Microsoft
Fig. 275: Installing linings

1. Check plastic inserts -1- for damage, replacing if necessary. See Fig. 275.
2. Position linings -2 to 4- and press in. See Fig. 275.
70 83 19 REMOVING AND INSTALLING FRONT ROOF TRIM PANEL - AS OF

PRELIMINARY WORK
Preliminary work
Microsoft
1. Remove sun visor. Refer to 68 23 19 Removing and installing sun visor - as of MY 2005 (Boxster,
2. Remove front lock. Refer to 61 05 19 Removing and installing latch at front - as of MY 2005 (Boxster,
REMOVING FRONT ROOF TRIM PANEL
Removing front roof trim panel
Fig. 276: Installation position of front roof trim panel

Microsoft
Fig. 277: Removing convertible-top peg mount

1. Unscrew fastening screws -1- and remove convertible-top peg mount -2- downwards -arrow- . See Fig. 277.
Microsoft
Fig. 278: Removing front roof trim panel

2. Unclip front roof trim panel and remove by pulling downwards -arrows- . See Fig. 278.
INSTALLING FRONT ROOF TRIM PANEL
Installing front roof trim panel
Fig. 279: Installation position of front roof trim panel

Microsoft
Fig. 280: Installing front roof trim panel

1. Fit front roof trim panel to windscreen frame from below -arrows- and clip it into position. See Fig. 280.
Microsoft
Fig. 281: Installing convertible-top peg mount

2. Place convertible-top peg mount -2- on windscreen frame from below -arrow- , position it correctly and
screw down hand-tight using the fastening screws -1- . See Fig. 281.
3. To prevent rattling noises, the two convertible-top peg mounts (left and right) must be facing outwards with
respect to the centering pins fitted on the convertible top or hardtop when tightening the screws. The convertible
top must be closed or the hardtop must be fitted in order to check the adjustment.
4. Tighten fastening screws -1- . Tightening torque --> Final tightening: 10 (7.5 ftlb.) Nm See Fig. 281.
SUBSEQUENT WORK
Subsequent work
1. Install front lock. Refer to 61 05 19 Removing and installing latch at front - as of MY 2005 (Boxster,
2. Install sun visor. Refer to 68 23 19 Removing and installing sun visor - as of MY 2005 (Boxster, Boxster
70 84 19 REMOVING AND INSTALLING ROOF LINING - AS OF MY 2006

PRELIMINARY WORK
Preliminary work
1. Remove A-pillar trim. --> 705719 Removing and installing A-pillar trim - chapter on "Removing"
2. Remove C-pillar trim. --> 706819 Removing and installing C-pillar trim - chapter on "removing"
unit for garage door opener - as of MY 2005 (Cayman S, Cayman S RHD) .
REMOVING ROOF LINING
Removing headliner
Microsoft
Fig. 282: Installation position for headliner

Microsoft
Fig. 283: Removing mounting saddle and pivot bearing

1. Unclip cap on the mounting saddle -1- with a screwdriver and open -arrow A- . See Fig. 283.
2. Unscrew fastening screw -2- and remove mounting saddle -3- -arrow B- . See Fig. 283.
3. Carefully insert a screwdriver between headliner and pivot bearing and release cover -4- -arrow C- . See Fig.
283.
4. Unscrew fastening screw -5- and remove pivot bearing -6- -arrow D- . See Fig. 283.
Microsoft
Fig. 284: Loosening headliner

5. Unclip clamps -1- out of the cowl panel frame in the front area. See Fig. 284.
6. Unclip fixing clip -2- from the bodyshell in the rear area and loosen Velcro fasteners -3- . See Fig. 284.
Microsoft
Fig. 285: Removing the headliner

NOTE: Two persons are needed to remove and install the headliner!
7. Carefully take out headliner -1- toward the rear through the tailgate opening. See Fig. 285.
Microsoft
Fig. 286: Checking fastening elements

8. Check clamps -1- and fixing clip -2- of headliner -3- for deformation, replace if necessary. See Fig. 286.
9. Check Velcro fasteners -4- and replace if necessary. See Fig. 286.
INSTALLING ROOF LINING
Installing headliner
Microsoft
Fig. 287: Installation position for headliner

Fig. 288: Positioning the roof lining

NOTE: Two persons are needed to remove and install the headliner!
Microsoft
1. Guide headliner -1- into the vehicle through tailgate opening and position at roof frame. See Fig. 288.
Fig. 289: Fastening the headliner

2. Clip in fixing clip -2- in the bodyshell in the rear area and press in Velcro fasteners -3- . See Fig. 289.
NOTE: Pull wire harness for interior light and operator control unit for garage door
opener through the openings of the headliner.
3. Clip clamps -1- in the bodyshell in the front area. See Fig. 289.
Microsoft
Fig. 290: Installing mounting saddle and pivot bearing

4. Press in pivot bearing -6- until it clicks into place -arrow A- and tighten with fastening screw -5- .
Tightening torque --> Tightening torque: 5 (3.5 ftlb.) Nm +0.5 (0.5 ftlb.) Nm See Fig. 290.
5. Press in cover for pivot bearing -4- -arrow B- . See Fig. 290.
6. Position mounting saddle -3- at the top on the roof liner -arrow C- and secure using the fastening screw -2- .
Tightening torque --> Tightening torque: 2.5 (2 ftlb.) Nm +0.5 (0.5 ftlb.) Nm See Fig. 290.
7. Press in cap -1- on mounting saddle -arrow D- . See Fig. 290.
SUBSEQUENT WORK
Microsoft
Subsequent work
for garage door opener - as of MY 2005 (Cayman S, Cayman S RHD) .
3. Install C-pillar trim panel. --> 706819 Removing and installing C-pillar trim - chapter on "Installing"
Install A-pillar trim panel. --> 705719 Removing and installing A-pillar trim - chapter on "Installing"
70 87 19 REMOVING AND INSTALLING TRIM PANEL FOR REAR LID - AS

REMOVING TRIM PANEL FOR REAR LID
Removing luggage compartment light in rear lid
Fig. 291: Unclipping light

2. Use a plastic spatula or screwdriver to press out the light in the trim panel of the rear lid.
Microsoft
3. Pull out light, then release and remove connector -A- . See Fig. 291.
Removing lining for rear lid
Fig. 292: Removing cover for rear lock upper part

1. Unclip cover for rear lock upper part -1- and remove. See Fig. 292.
Microsoft
Fig. 293: Loosening trim panel

2. Unclip finger plate caps -1- . See Fig. 293.
Microsoft

4. Unclip lining for rear lid -1- . See Fig. 294.
INSTALLING TRIM PANEL FOR REAR LID
Installing lining for rear lid

Microsoft

NOTE: Remove wire harness for luggage compartment light through the opening of the
trim panel.
1. Position lining for rear lid -1- on the lid -2- and press in until the clamps -3- engage. See Fig. 295.
Microsoft

2. Tighten fastening screws -2- . --> Tightening torque: 3.4 (2.5 ftlb.) Nm See Fig. 296.
3. Press in finger plate caps -1- . See Fig. 296.
Microsoft
Fig. 297: Installing cover for rear lock upper part

4. Insert cover for rear lock upper part -1- and press in. See Fig. 297.
Installing luggage compartment light in rear lid
Microsoft
Fig. 298: Connecting plug connection for light

1. Push in plug until it is felt to engage.
2. Insert light into opening and clip it into the trim panel. Check that light is fitted securely.
70 91 19 REMOVING AND INSTALLING REAR LID HINGE TRIM - AS OF MY

REMOVING REAR LID HINGE TRIM
Removing rear lid hinge trim
Microsoft
Fig. 299: Installation position of rear lid hinge trim

1. Move rear lid to service position. Refer to 55 90 IN Rear lid in service position - as of MY 2006 (Cayman
S, Cayman S RHD) .
Fig. 300: Unclipping lid hinge trim

Microsoft
2. Unclip lid hinge trim -1- on the right and left in direction of arrow. See Fig. 300.
Fig. 301: Removing lid hinge trim

3. Release lid hinge trim -1- from the roof area and remove it in an upward direction. See Fig. 301.
Microsoft
Fig. 302: Checking clamps

4. Check clamps -1- and replace them if necessary. See Fig. 302.
5. Loosen and remove adhesive residue on the roof using silicone remover.
INSTALLING REAR LID HINGE TRIM
Installing rear lid hinge trim
NOTE:  The bonding surface must be free of dirt and grease. Clean it if necessary
using cleaning agent.
Microsoft

1. Before gluing in the lid hinge trim -1- , pull off protective film -2- on the adhesive tape without leaving any
residue. See Fig. 303.
Microsoft
Fig. 304: Installing lid hinge trim

2. Position lid hinge trim -1- and align wire harness for rear lid -2- with respect to the lid hinge trim. See Fig.
304.
Microsoft
Fig. 305: Securing lid hinge trim at the sides

3. Insert locking lugs on the lid hinge trim -1- at the right and left in -direction of arrow A- and press them in -
Arrow B- until the clamps engage. See Fig. 305.
Microsoft
Fig. 306: Pressing on lid hinge trim

4. Press lid hinge trim onto the body and press it on securely at the edges and at the right using a plastic wedge.
5. Wait for 15 minutes before pressing the rear lid into the lock.
70 92 19 REMOVING AND INSTALLING TRIM PANEL FOR REAR LID

(WINDOW FRAME) - AS OF MY 2006 (CAYMAN S, CAYMAN S RHD)
REMOVING TRIM PANEL FOR REAR LID (WINDOW FRAME)
Removing cover for center window frame
Microsoft
Fig. 307: Removing cover for center window frame

1. Unclip trim panel for center window frame -1- with a plastic wedge. See Fig. 307.
2. Check clamps -2, 3- , and replace if necessary. See Fig. 307.
Removing trim panel for side window frame
1. Remove trim panel for rear lid. --> 708719 Removing and installing trim panel for rear lid - section on
Microsoft
"Removing"
Fig. 308: Removing trim panel for side window frame

2. Unclip trim panel for side window frame -1- using a plastic wedge. See Fig. 308.
3. Check clamps -2, 3- and replace if necessary. See Fig. 308.
INSTALLING TRIM PANEL FOR REAR LID (WINDOW FRAME)
Installing trim panel for side window frame
Microsoft
Fig. 309: Installing trim panel for side window frame

1. Position trim panel for side window frame -1- on the lid and press in until the clamps -2- engage. See Fig.
309.
2. Install trim panel for rear lid. --> 708719 Removing and installing trim panel for rear lid - section on
"Installing"
Installing trim panel for center window frame
Microsoft
Fig. 310: Installing trim panel for center window frame

1. Position trim panel for center window frame -1- on the lid and press in until the clamps -2- engage. See Fig.
310.
70 94 19 REMOVING AND INSTALLING REAR LIGHT COVER - AS OF MY

REMOVING REAR LIGHT COVER
Removing rear light cover
Microsoft
Fig. 311: Installation location for rear light cover

Microsoft
Fig. 312: Removing rear light cover

2. Release rotary knob -1- in direction of arrow -A - . See Fig. 312.
3. Disengage rear light cover -2- from side trim panel -3- . See Fig. 312.
INSTALLING REAR LIGHT COVER
Installing rear light cover
Microsoft
Fig. 313: Installation location for rear light cover

Microsoft
Fig. 314: Installing rear light cover

1. Insert pegs in the side trim panel -3- and lock rear light cover -2- with the rotary knob -1- in direction of
arrow -A- . See Fig. 314.
2. Close rear lid.
70 75 19 REMOVING AND INSTALLING SIDE TRIM PANEL - AS OF MY 2006

PRELIMINARY WORK
Preliminary work
Microsoft
Remove oddments tray. --> 706619 Removing and installing oddments tray - chapter on "Removing"
REMOVING SIDE TRIM PANEL
Removing side trim panel
Fig. 315: Removing side trim panel

1. Unscrew fastening screws -1- , lift side trim panel -2- from lower side member and pull out. See Fig. 315.
Microsoft
Fig. 316: Checking fastening nuts

INSTALLING SIDE TRIM PANEL
Installing side trim panel
Microsoft
Fig. 317: Installing side trim panel

1. Insert side trim panel -1- with locking tab -2- and rubber sleeve -3- into the inner side member and then screw
into place with the fastening screws -4- . --> Starting torque: 1.5 (1.0 ftlb.) Nm +0.1 (0.1 ftlb.) Nm . See Fig.
317.
Microsoft
Fig. 318: Aligning rubber seal

2. Lift up the rubber seal for the door -1- using a plastic wedge -2- along the side trim panel -3- . See Fig. 318.
SUBSEQUENT WORK
Subsequent work
Install oddments tray. --> 706619 Removing and installing oddments tray - chapter on "Installing"
70 75 19 REMOVING AND INSTALLING SIDE TRIM PANEL - AS OF MY 2005

Microsoft
REMOVING SIDE TRIM PANEL
Removing side trim panel
1. Unscrew fastening screw 1 .
2. Unclip plastic clip 2 in the direction of arrow A .
3. Lift side trim panel up 3 and off.
Fig. 319: Removing side trim panel

INSTALLING SIDE TRIM PANEL
Installing side trim panel
Installation position for rear side trim panel ILLUSTRATION
1. Check support 4 and replace if necessary.
Microsoft
Fig. 320: Check support and replace if necessary.

2. Position side trim panel 3 and clip in plastic clip 2 .
3. Screw in fastening screws 1 .
Microsoft
Fig. 321: Installing side trim panel

Microsoft
ACCESSORIES & EQUIPMENT Passenger protection
Passenger protection
69 AW SAFETY REGULATIONS FOR AIRBAG AND BELT TENSIONER

UNITS - AS OF MY 2005 (ALL MODELS)
TOOLS

PIWIS Tester special tool 97180
TOOLS AND MATERIALS
Materials
Use Porsche work clothing. See Workshop Equipment Manual, Group 2.6.
General warnings for handling airbag and belt tensioner units
CAUTION: Danger of injury and material damage if airbag unit is not handled
correctly!
 Triggering of airbag unit!
--> The airbag units are pyrotechnical items in hazard class T 1!
--> Handling, transport and storage of these units must conform to hazardous goods regulation and explosives
legislation!
--> The listed statutory requirements refer to the Federal Republic of Germany. The relevant valid regulations
must be observed in all other countries. Enquire of the importer for the country concerned!
--> The commencement of work with pyrotechnical items must be reported 14 days in advance to the Trade
Supervisory Office (responsible authority)!
Microsoft
--> Airbag units must only be dispatched in transport packaging officially approved for that purpose!
--> Internally and otherwise, they must always be transported in the luggage compartment or cargo hold of a
vehicle using the above-mentioned transport packaging!
--> They must not be transported in the passenger compartment!
--> Airbag units must be stored in accordance with the second ordinance of the explosives legislation!
--> This ordinance stipulates that small quantities of materials and items may be stored at certain locations
without special storage approval!
--> Airbag units must be kept in a locked place!
--> When storing airbag units, ensure that the airbag opening faces upwards (risk of injury caused by inflation
of the airbag units in the event of accidental ignition)!
--> Airbag units must be stored in a dry place and must not be stored together with other hazardous goods
(varnishes, etc.)!
--> Loose airbag units or airbag units located in a removed steering wheel must never become the actual
(physical) property of the customer!
--> The possession of loose airbag units not installed in the vehicle is not permissible in the private sector!
--> Airbag units may become the property of the customer only when installed in the vehicle!
Warnings about assembly and straightening work
CAUTION: Danger of personal injury and material damage as a result of malfunction

of the airbag system!
 Malfunction of the airbag system
--> Never drive with an airbag triggering unit that has not been taught.
--> The airbag triggering unit must be taught using the PIWIS Tester 97180! Until the airbag triggering unit
has been taught, the warning light lights up continuously.
--> Inspection and assembly work must only be carried out by specialist staff!
--> Before working on the airbag system and also when working on neighboring parts where there is a risk
because live parts are close to the airbag system, always implement the following safety measures:
--> Remove ignition key.
Microsoft
--> Disconnect and cover the negative terminal of the battery.
--> After the battery is disconnected, assembly work or work on the vehicle with a hammer or similar tools must
not be started until after a waiting period of 1 minute! This is necessary in order to interrupt the power supply to
the airbag system and to ensure it is not triggered accidentally!
--> Airbag units must be fitted immediately after being removed from their storage location!
--> Airbag units must never be left lying around unattended!
--> If work is interrupted, airbag units must immediately be locked away again!
--> Airbag units must not come into contact with grease, oil, detergents, liquids, or similar substances!
--> Airbag units must not be exposed to temperatures above 90 °C!
--> Airbag units and control units which have fallen from a low height must no longer be installed!
--> Additional linings, stickers or similar must not be attached in the vicinity of the airbag units!
--> Changes must not be made to the wiring or the components of the airbag system!
--> The battery must always be disconnected before starting straightening and welding work with an electrical
welding unit!
--> Electrostatic charge: In general, suitable work clothing and footwear are to be worn. --> Tools and
materials under 69 AW Safety regulations for airbag and belt tensioner units - as of MY 2005 (All
Models).
--> Do not remove the short-circuit spring of the plug contacts.
--> Never connect airbag units to electrical power sources not in accordance with regulations (danger of
immediate ignition). Only use testers prescribed by the manufacturer. Airbag diagnosis 6901.
--> If you have to perform welding in the immediate vicinity of the airbag triggering unit, ensure it is removed
before starting work!
--> Airbag components must not be repaired!
--> Airbag components must always be replaced!
--> Cleanse your hands after touching ignited airbag units.
INFORMATION FOR AIRBAG AND BELT TENSIONER UNITS
Dangers for persons and the environment
Microsoft
NOTE: Dangers for persons and the environment
Injury caused by incorrect triggering of the installed unit.
Injury caused by spinning away, e. g. of the entire unit.
Burns caused by touching the hot surfaces of a triggered unit.
Damage to hearing due to the explosion when gas is released.
Irritation caused by breathing in fuel particles.
Irritation caused by skin and eye contact with fuel particles.
Airbag/belt tensioner components must not be opened nor repaired; always use only new parts.
Injury caused by incorrect triggering due to tampering with the short circuit bridges.
Protective measures and rules of behavior
NOTE: Protective measures and rules of behavior
Assembly work only by trained staff.
Carry out tests only with the PIWIS Tester 97180 diagnostic module; do not use test lamps, voltmeters or
ohmmeters.
Do not bring into contact with grease, solvents, cleaning agents, or liquids.
Do not expose to temperatures above 100 °C.
Keep the unfolding area of the airbag clear; e. g. do not hang test devices over the steering wheel. When
carrying, hold the airbag with the blow-out direction facing away from the body. Lay the airbag unit aside with
the airbag pointing upwards.
Electrostatic charge: In general, wear appropriate work clothing and footwear. --> Tools and materials under
69 AW Safety regulations for airbag and belt tensioner units - as of MY 2005 (All Models).
Do not remove the short-circuit spring of the plug contacts.
Never connect an airbag unit to electrical power sources not in accordance with regulations (danger of ignition).
Only use testers prescribed by the manufacturer. Airbag diagnosis 6901.
During installation/removal or work on the vehicle involving vibrations: switch off ignition, disconnect and
cover the negative terminal of the battery, wait 1 minute and only then disconnect the plug connection.
Microsoft
Transport: In transport packaging. Forbidden in passenger compartment!
Storage in the workshop: max. 10 kg (=100 driver's or 50 passenger's airbags); protect against theft!
The installation of the airbag/belt tensioner unit must be carried out immediately after removal from the
transport container.
If work is interrupted, the airbag/belt tensioner unit must be stored in the transport container again.
Leaving the airbag/belt tensioner unit unsupervised is not permitted.
behavior in cases of malfunction or danger
NOTE: behavior in cases of malfunction or danger
Protect from flames and heat.
In case of fire, inform the fire brigade on arrival about the units present.
Do not install mechanically damaged units or units that have fallen, even from a low height.
Always replace units that are mechanically damaged (bulges, cracks).
Because of the irritating combustion residues, only handle triggered airbags with protective gloves and goggles.
In the case of contact with combustion residues, wash the affected skin with soap and water.
In the case of eye contact, wash the eyes out with water.
General information
NOTE: Airbags - general
A period of 10 seconds is required to enable the triggering unit to identify all

faults in the system!
In order to guarantee that every possible fault source is checked during the
vehicle test, the ignition must be switched on for at least 10 seconds!
The fault memory must be cleared following a fault in the airbag system and
after it has been remedied!
The replacement of a component must be noted in the Guarantee and

Maintenance booklet!
Microsoft
To do this, attach the documentation number in a free panel intended for that
purpose!
The documentation number is attached to the replacement part as a tear-off

sticker!
Exchanged airbag units or airbag modules must be taken into possession by

the Porsche center or by a dealer authorised by Porsche and must not be
handed over to the customer (customer has no right to possess them). They
must be destroyed, disposed of or returned to the manufacturer in accordance
with the explosives ordinance and the hazardous materials ordinance!
When the steering wheel is exchanged, e. g. to install a steering wheel from the
Tequipment product range, the airbag unit of the replaced steering wheel must
be removed and destroyed, disposed of or returned to the manufacturer before
the steering wheel is handed over to the customer!
The airbag system is constantly monitored by a diagnosis unit in the triggering unit. Any fault is signalled by a
warning light. The warning light for the airbag system lights up in the event of a fault. The airbag warning light
lights for approx. 3 seconds after the ignition is switched on and goes out if no fault has been entered in the fault
memory. If it lights up again, this indicates a fault in the system. The fault can be read out with the PIWIS
Tester P 9718.
Component exchange after airbag/belt tensioner triggering
The following components must be removed and replaced after the airbag system is triggered:
Airbag unit, driver's side:
1. Contact unit.
2. Airbag unit, driver's side.
3. Triggering unit after the third time the airbag is triggered.
Airbag unit, passenger's side:
1. Airbag unit, passenger's side.
2. Triggering unit after the third time the airbag is triggered.
3. Instrument panel.
4. Check instrument panel bracket for deformation and replace if necessary.

Microsoft
Side-airbag unit, seat:
1. Side-airbag unit, seat.
6. Seat covering, deformed seat components.
7. Sensor for the side-airbag unit after the third time the side-airbag is triggered
Head airbag unit, door:
1. Head airbag unit.
9. Check door unit carrier for deformation and replace if necessary.
10. Sensor for the side-airbag unit after the third time the side-airbag is triggered.
Belt tensioner:
1. All belt tensioner units.
Because it is difficult to visually determine if one or more belt tensioners has been triggered, check the
following points:
- Using the PIWIS Tester P 9718, read out the fault memory.
- Check plug connection on the belt tensioner for damage.
- Pull out the belt strap as far as possible and check for wear.
- Perform a function test on the automatic belt device.
69 54 19 REMOVING AND INSTALLING THE CONTACT UNIT - AS OF MY

2005 (ALL MODELS)
TOOLS

PRELIMINARY WORK
Preliminary work for contact unit

Microsoft
Remove driver's airbag unit. --> 69 58 19 Removing and installing driver's airbag unit - as of MY 2005 (All
Models).
Remove steering wheel. Refer to 48 10 19 Removing and installing steering wheel - as of MY 2005 (All
Models) .
Remove steering column trim.
Remove and disassemble steering column switch. --> 94 50 19 REMOVING AND INSTALLING
STEERING-COLUMN SWITCH - AS OF MY 2005 (ALL MODELS) .
General warnings for contact unit
CAUTION: Danger of injury and material damage if airbag units are not handled
correctly!
 Incorrect triggering of airbag unit!
--> Always observe the safety regulations for handling airbag units! --> 69 AW Safety regulations for airbag
and belt tensioner units - as of MY 2005 (All Models).
WARNING: If the contact unit has been adjusted, proceed in accordance with the
following work instruction:
 Damage to the contact unit!
--> Then turn the rotor carefully to the right, approx. 3.5 to 3.75 revolutions, until the band printed on one side
is visible in the window.
REMOVING CONTACT UNIT FOR AIRBAG
Removing contact unit for airbag
Microsoft
Fig. 1: Marking the contact unit

NOTE: Ensure that arrow -A- of the rotor is positioned between the markings -B- of the
arrows -C- of the airbag contact unit and that the locking element -D- is
engaged. See Fig. 1.
Fig. 2: Airbag contact unit

1. Carefully lift up the three retaining tabs and remove airbag contact unit.
INSTALLING AIRBAG CONTACT UNIT
Installing contact unit for airbag
Microsoft

1. Position airbag contact unit and press onto the steering column switch until the three tabs engage.
2. Calibrate steering angle sensor. --> 695419 Removing and installing contact unit - calibrating
REWORKING
Work in wake of airbag contact unit
Install steering column switch. --> 94 50 19 REMOVING AND INSTALLING STEERING-COLUMN

SWITCH - AS OF MY 2005 (ALL MODELS) .
Install steering column trim.
Install steering wheel. Refer to 48 10 19 Removing and installing steering wheel - as of MY 2005 (All
Models) .
Install driver's airbag unit. --> 69 58 19 Removing and installing driver's airbag unit - as of MY 2005 (All
Models).
CALIBRATING STEERING-ANGLE SENSOR
Calibrating steering-angle sensor
NOTE:  The steering-angle sensor must be re-calibrated after replacing the airbag
contact unit.
 To correctly calibrate the angle sensor, the vehicle must be on the
measuring platform.
 The steering angle sensor must be calibrated using the menu with the
PIWIS Tester P 9718 under the specified test conditions:
 Running gear set according to Porsche specifications --> 44
ADJUSTMENT VALUES FOR SUSPENSION ALIGNMENT - AS OF MY 2005
(ALL MODELS) .
 Wheels in straight-ahead position and steering wheel horizontal.
Microsoft
 In the straight-ahead position, the steering wheel may depart from the
horizontal position (steering center position) by +/- 2.0° max.
1. Connect the PIWIS Tester P 9718 to the vehicle and start the System Tester. Switch on ignition and press
>> to continue.
2. Select vehicle type and press >> to continue.
3. Select control unit PSM and confirm with >>.
4. Select Actual values and confirm with >>.
5. Select Security code and confirm with >>.
6. Note theSecurity code and use << to go back to Calibration .
7. Select Calibration and confirm with >>.
8. Enter Security code and confirm with >>.
9. ConfirmSecurity code with F7.
10. Select Steering angle sensor and confirm with >>.
11. ReadSafety instructions using F7.
12. After successful calibration, the stored fault code is erased from the fault memory. The PSM indicator light
in the instrument cluster goes out.
13. Read out the fault memory and, if necessary, erase it and read it again.
69 72 REMOVING AND INSTALLING ROLL-OVER BAR - AS OF MY 2005

TECHNICAL VALUES
Adjustment values
Measuring dimensions for roll-over bar in vehicle
Microsoft
Fig. 4: Measuring dimensions for roll-over bar in vehicle

1. Dimension A from center of sash guide mount (round material as an aid) to top of inner side section.
Dimension B from center of round material to end of inner side section flange.
1.1. Shop-made tool: Round material with diameter of 10 mm, 160 mm long

value 1 2
Sash guide mount to upper edge of inner Dimension
92.5 mm +/-1 mm
side section A
Round material to end of inner side section Dimension
52.5 mm +/-1 mm
flange B
Fig. 5: Measuring dimensions for roll-over bar in vehicle

2. Dimension C from center of edge of housing for convertible-top pegs - inner attachment point - to center of
sash guide.

value 1 2
Sash guide to housing for convertible- Oblique
825 mm +/-1 mm
top pegs dimension C
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REMOVING ROLL-OVER BAR
Preliminary work
NOTE:  The roll-over bar can only be removed together with the cover.
1. Convertible top in service position.
1.1. Convertible top in service position: Open convertible top approx. 40 cm away from the windshield frame.
Pull velcro of the fixing strap off tension bow and secure on centring peg in front. Refer to 61 01 IN Diagram
of convertible top - as of MY 2005 (Boxster, Boxster RHD, Boxster S, Boxster S RHD) .
2. --> 691119 Removing and installing front three-point belt - removing [987120 987121].
3. Refer to 70 75 19 Removing and installing side trim panel - as of MY 2005 (Boxster, Boxster RHD,
Removing roll-over bar
Microsoft
Fig. 6: Installation location for roll-over bar

CAUTION: Operation of the convertible top in the service position!
 Material damage to convertible top frame and rear window!
--> When in the service position, the convertible top must not be electrically actuated to the "Close" position.
NOTE: The roll-over bar can only be removed together with the cover.
To make measuring easier when installing the roll-over bar, the number of
plates must be recorded.
Microsoft
1. Press both locking lugs A of the electric plug connection 1 and disconnect in direction of arrow B .
Fig. 7: Removal location for electric plug connection

Microsoft

Fig. 9: Unscrewing fastening nuts on roll-over bar at front

Microsoft
2. Unscrew fastening nuts at the front 1 .
Fig. 10: Unscrewing fastening nuts at the rear on the roll-over bar
3. Unscrew fastening nuts at the rear 1 .
Microsoft
Fig. 11: Detaching push rod

4. Detach push rod.
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5. Remove fastening screws from lever for convertible top gear.
5.1. Unscrew the fastening screw 1 out of the lever 2 and remove the cover 3 and lever 2 from the convertible
top gear 4 .
Microsoft
Fig. 13: Removing water drip pan

6. Removing water drip pan
6.1. Separate water drip pan 7 from rail 8 .
Microsoft
Fig. 14: Lifting roll-over bar up and off

7. Lift roll-over bar up and off.
INSTALLING ROLL-OVER BAR
Installing roll-over bar
Microsoft
Fig. 15: Inserting roll-over bar into vehicle

1. Insert roll-over bar into vehicle.
Microsoft
Fig. 16: Tightening fastening nuts at rear

2. Tighten fastening nuts at the rear 1 . --> Tightening torque: 23 (17 ftlb.) Nm +/-2 (1.5 ftlb.) Nm
Microsoft
Fig. 17: Tightening fastening nuts at front

3. Tighten fastening nuts at the front 1 . --> Tightening torque: 23 (17 ftlb.) Nm +/-2 (1.5 ftlb.) Nm
4. Connect electric plug connection 1 .
Microsoft
Fig. 18: Installation position for electric plug connection

Microsoft

Adjusting roll-over bar
CAUTION: Do not remove or re-install dowel sleeves or dowel pins
 If there is a malfunction in the convertible top, you will no longer be

able to open or close it!
--> The dowel sleeves and dowel pins must not be removed!
The roll-over bar is measured in the vehicle at the factory and fixed with dowel pins 6.5 and dowel sleeves 4 on
the left and right sides.
Microsoft
Fig. 20: Adjustment of roll-over bar

1. Adjustment procedure: Loosen collar nuts at the roll-over bar screw points front and rear.
2. Raise roll-over bar and insert or remove shim plates 2 and 3 according to the test and adjustment values.
When inserting, position shim plates 2 and 3 on screw bolt 7 .
3. Tighten collar nuts. --> Tightening torque: 17 ftlb. +/-1.5 ftlb.
Subsequent work
Microsoft
Fig. 21: Fitting water drip pan

1. Install water drip pan
1.1. Position water drip pan 7 under rail 8 .
Microsoft
Fig. 22: Fitting lever and cover

2. Install lever of convertible top mechanism
2.1. Position cover 3 and lever 2 on convertible top gear 4 and tighten with fastening screw 1 (micro-self-
locking). After loosening fastening screw 1 it must be replaced or secured with Loctite 243 at medium strength.
--> M12: 59 ftlb.
Microsoft
Fig. 23: Engaging push rod

3. Engage push rod.
4. Install three-point seat belt --> 691119 Removing and installing front three-point belt - removing [987120
987121].
5. Install side trim panel Refer to 70 75 19 Removing and installing side trim panel - as of MY 2005
69 13 01 CHECKING SEAT BELTS - AS OF MY 2005 (ALL MODELS)

Warning note for seat belts
WARNING: Damage to seat belt system
Microsoft
--> After any accident, the seat belt system must be checked systematically for proper function and damage. If
damage is found according to the test points, the entire seat belt system must be replaced.
WARNING: Road test on public roads
--> For safety reasons, this driving test must be carried out on a traffic-free road, so that there is absolutely no
danger to other road users.
CHECKING SEAT BELTS
Checking procedure for seat belt
NOTE:  After any accident, the seat belt system must be checked systematically
for proper function and damage. If damage is found according to the test
points, the entire seat belt system must be replaced.
NOTE:  In the case of damage which does not occur as the result of an accident, e.
g. wear, only the damaged part needs to be replaced.
NOTE:  The following requirements must be met when fitting the seat belt.
 If one of the requirements listed below is not met, the seat belt or the
buckle must be replaced.
Checking belt strap
- Pull out the belt strap on the automatic belt device fully.
- Check the belt strap for soiling; clean, if necessary, with mild soap suds. When drying, avoid direct sunshine.
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Fig. 24: Damage type 1

1. Damage type 1
1.1. If one of the damage types shown below -damage type 1, 2- is found on an vehicle involved in an accident,
the seat belt and belt buckle must be replaced. See Fig. 24.
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2. Damage type 2
2.1. If damage such as damage type -damage type 1, 2, 3- is found on a vehicle not involved in an accident, it is
sufficient to replace the damaged seat belt. See Fig. 25.
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3. Damage type 3
3.1. Burn marks from cigarettes, or similar.
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4. Damage type 4
4.1. The belt tensioner must always be replaced if it has been triggered. The seat belt is damaged by the
deflector -damage type 4- . See Fig. 27.
Checking automatic belt device (locking effect)
The automatic belt device has two locking functions
 The first locking function is triggered by pulling the seat belt out quickly (belt extension acceleration).
Test
- Pull the seat belt out of the automatic belt device with a strong pull.
If no locking effect occurs, the entire seat belt and belt buckle must be replaced.
In the case of faults in the extension or retraction of the seat belt, check whether the locking tab of the automatic
belt device is engaged correctly in the sheetmetal bracket on the body.
 The second locking function is triggered by a change in the sequence of vehicle movement (vehicle-
dependent locking function).
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Test
- Fasten the seat belt.
WARNING: Road test on public roads
--> For safety reasons, this driving test must be carried out on a traffic-free road, so that there is absolutely no
danger to other road users.
- Accelerate the vehicle to 20 km/h (12 mph) and then perform an emergency stop with the foot brake.
If the belt is not locked by the blocking mechanism during the braking phase, the entire seat belt and belt buckle
must be replaced.
Checking look and operation of seat-belt buckle
- Inspect the belt buckle for crack formation and flaking.
In the case of damage, the entire seat belt and belt buckle must be replaced.
Check belt buckle
- Push the buckle into the belt buckle until it engages audibly. Check whether the lock mechanism has engaged
by pulling strongly on the belt strap.
If the belt tongue fails to lock in the belt buckle even just once in at least 5 test procedures, the entire seat belt
and belt buckle must be replaced.
Checking belt buckle release
- Release the seat belt by pressing with a finger on the button on the belt buckle.
Carry out the test procedure at least 5 times. If the belt tongue fails to jump out even just once, the entire seat
belt and belt buckle must be replaced.
NOTE:  Lubricants must never be used to remedy noises or sluggishness of the

buttons on the belt buckles.
Checking sash guides
Plastic-coated covers show fine, parallel scores after the belt system has been subjected to stress (seat belt
buckled during accident). On the other hand, wear caused by frequent use is indicated by a stripe-free, smooth
surface.
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- Inspect the sash guides for distortion, flaking and crack formation.
In the case of scoring and/or damage, the entire seat belt and belt buckle must be replaced.
Checking mounting elements and mounting points
 Check the belt buckle strap for distortion.

 Check the function of the height adjuster.
 Check the mounting points (seat, B-pillar, C-pillar, vehicle floor) for distortion or thread damage.
If damage is found on the parts, the entire seat belt and belt buckle must be replaced.
Replace damaged or distorted mounting points.
69 AW DISPOSAL OF AIRBAG AND BELT TENSIONER UNITS - AS OF MY

2005 (ALL MODELS)
TOOLS

ignition device special tool P 9257
adapter cable special tool P 9257/3
GENERAL WARNING NOTES FOR AIRBAG AND BELT TENSIONER UNITS
Disposal of airbag and belt tensioner units
NOTE: Country-specific statutory regulations and legislation based on them which go

beyond these instructions must always be observed and take precedence over
these instructions!
 Airbag units are pyrotechnical items and can pose an environmental

hazard!
 For this reason, non-ignited airbag units or entire vehicles must not be
disposed of as normal scrap, refuse or in other final storage facilities!
 If the vehicle suffered fire damage which caused one or several airbags or
belt tensioners to be triggered, additional ignition with the adapter cable
must be carried out in order to ensure that only parts without
pyrotechnical contents are scrapped!
 In the case of airbag units which cannot be ignited or if the conditions for
safe ignition are insufficient, always return the airbag units to Porsche or
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the respective importer in their original packaging!
Safety procedures when igniting airbag units
CAUTION: Uncontrolled triggering of airbag units.
 Danger of injury and damage to property as a result of incorrect

handling of airbag units.
--> Before disposal, render the airbag units harmless by electrical ignition and while observing all precautionary
measures, thereby preventing them being used incorrectly!
--> Ignition and preparations may only be carried out by skilled staff, supervised by a second responsible
person!
--> Other normal accident prevention regulations must also be observed!
--> Ignite airbag units only in their securely installed, original condition in the vehicle!
--> Carry out ignition only in suitable, free areas!
--> Use only the ignition tool intended for that purpose!
--> All loose objects must first be removed from the expansion area of the airbag!
--> Each ignition circuit of all airbag units and belt tensioners must be ignited individually.
--> Persons possibly affected must be informed of the resulting noise beforehand!
--> Use ear protectors!
--> Maintain a safety distance by utilising the entire cable length of the ignition tool!
--> Do not connect the voltage source until all other preparations are complete!
--> Choose a place in front of the vehicle. This also applies to persons not involved!
--> Perform ignition with the doors closed and the side windows open!
--> Do not approach the vehicle until after a waiting period (approx. 3 minutes) if ignition fails!
--> Allow airbag units to cool down under observation following ignition!
--> Avoid skin contact with ignited airbag units!
CAUTION: Unintentional triggering when ignition tool is connected.

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--> Remove ignition key. Disconnect and insulate the ground line on the battery. --> 27 06 IN WORK
INSTRUCTIONS AFTER DISCONNECTING THE BATTERY - AS OF MY 2005 (ALL MODELS) .
--> After the battery is disconnected, always wait for 1 minute before disconnecting the airbag plugs.
TOOLS AND MATERIALS
Tools for airbag units and belt tensioners
Fig. 28: Ignition device 9257

The ignition device P 9257 is used for triggering the airbag units.
A - Ignition device 9257
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Fig. 29: Driver's airbag adapter cable 9257/4

The adapter cable P 9257/4 is used for the driver's airbag.
B - Marking A - adapter for 1st stage of driver's airbag unit
C - Marking B - adapter for 2nd stage of driver's airbag unit
E - Adapter for ignition device
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Fig. 30: Adapter cable of side airbag in the seat

Adapter cable of side airbag in the seat
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Fig. 31: Passenger's airbag adapter cable, left side

The adapter cable P 9257/3 -E- is used for the passenger's airbag, left side . See Fig. 31.
The adapter cable P 9257/5 is used for the passenger's airbag, right side .
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Fig. 32: Head airbag adapter cable

The adapter cable P 9257/3 -E- is used for the head airbag. See Fig. 32.
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Fig. 33: Adapter cable of side airbag in the seat

The adapter cable P 9257/6 is used for the side airbag in the seat.
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Fig. 34: Belt tensioner adapter cable

The adapter cable P 9257/3 -E- is used for the belt tensioner. See Fig. 34.
Designation Special tool Explanation

Ignition device 9257
Adapter cable 9257/4 For driver's airbag
Adapter cable 9257/3 Passenger's airbag, left side
Adapter cable 9257/5 Passenger's airbag, right side
Adapter cable 9257/3 Head airbag
Adapter cable 9257/6 Side airbag
Adapter cable 9257/3 Belt tensioner
CONNECTING IGNITION TOOL
Driver's side
NOTE: This is a two-stage airbag module which must be ignited separately.
 Remove trim panel for steering column.
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Fig. 35: Driver's side

1. Disconnect plug from the airbag at the steering column switch and first insert the plug with marking A (1st
stage) of adapter cable No. 9257/4.
2. Connect ignition device No. 9257 to the 2-pin plug E of adapter cable No. 9257/4.
3. Place the ignition device in front of the vehicle through the door gap.
4. After triggering, repeat the work step with the plug with the marking B (2nd stage).
Passenger's side
NOTE: Deformation of the instrument panel bracket must be expected after triggering
of the passenger's airbag unit. An installed airbag unit should be intentionally
triggered in installed state only if the vehicle is to be scrapped. If the instrument
panel bracket is deformed in the area of the airbag mount, the instrument panel
bracket will have to be replaced.
This is a two-stage airbag module which must be ignited separately.
 Remove glove compartment, Refer to 68 15 19 Removing and installing

glove compartment - as of MY 2005 (All Models) .
 Remove passenger's airbag unit. --> 69 59 19 Removing and installing
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passenger's airbag unit - as of MY 2005 (All Models).
1. If the instrument panel is to be re-used, remove the instrument panel. Refer to 70 18 19 Removing and
installing instrument panel - as of MY 2005 (All Models) .
Fig. 36: Connecting adapter cable

2. Connect the adapter cables 9257/3 (left) and 9257/5 (right) to the removed airbag unit. Re-install airbag unit
with the adapter cables.
3. Connect ignition device No. 9257 to the 2-pin plug E of adapter cable No. 9257/3.
4. Place the ignition device in front of the vehicle through the door gap.
5. After triggering, repeat the work step with adapter cable No. 9257/5.
Side airbag
NOTE: Before disconnecting the battery, move the seat to the uppermost position.
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Fig. 37: Side airbag

1. Unlock and separate the electrical plug for the seat.
2. Connect plug of adapter cable 9257/6 to the electrical plug for the seat.
3. Connect ignition device No. 9257 to the 2-pin plug of adapter cable No. 9257/6.
4. Place the ignition device in front of the vehicle through the door gap and trigger it.
Head airbag
Remove door trim panel. --> 70 59 19 REMOVING AND INSTALLING DOOR TRIM PANEL - AS OF
MY 2005 (ALL MODELS) .
1. Connect plug of adapter cable 9257/3 to the head airbag.
Belt tensioner
Remove the side panel lining at rear. Refer to 70 75 19 Removing and installing side trim panel - as of MY
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2006 (Cayman S, Cayman S RHD) . Refer to 70 75 19 Removing and installing side trim panel - as of MY
Fig. 38: Connecting plug of adapter cable to belt tensioner

1. Connect plug of adapter cable 9257/3 to the belt tensioner.
Triggering of airbag units
WARNING: Detonation of airbag units.
 Danger of injury from emerging objects, e. g. splinters.

 Hearing impairment by explosion noises.
 Danger of burns from hot airbag units.
 Danger of poisoning by emerging gases.
--> Observe a safety distance of at least 10 m.
--> Wear hearing protection.

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--> Each airbag unit, the respective ignition stages 1 and 2, and each belt tensioner must be triggered
individually.
--> Allow airbag units to cool down for the appropriate time.
--> Open the vehicle doors to allow the gases to escape.
Connect the ignition device to a separate battery and press the button.
Fig. 39: Triggering of airbag units

69 01 01 AIRBAG DIAGNOSIS - AS OF MY 2005 (ALL MODELS)

TOOLS

AIRBAG DIAGNOSIS
1. Function test on airbag system:
1.1. Connect and switch on the PIWIS tester P 9718.
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1.2. Switch on ignition.
1.3. Establish communication with the airbag control module.
1.4. Read out fault memory: No fault stored.
1.5. Select Drive link test menu.
1.6. Read out fault memory for all control units and erase if necessary.
1.7. Remove ignition key. Disconnect battery. Route or isolate the ground strap so that all contact with a ground
carrier (e. g. body) is avoided. --> 27 06 IN WORK INSTRUCTIONS AFTER DISCONNECTING THE
Fig. 40: Side airbag plug connection

CAUTION: Danger of injury and material damage if airbag units are not handled
correctly!
--> Always observe the safety regulations for handling airbag units --> 69 AW Safety regulations for airbag
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2. Simulating the fault:
NOTE:  To check the operation of the airbag system, a plug connection is

disconnected from an airbag unit. A fault code - Static fault - must then be
stored in the Porsche System Tester.
2.1. Simulate the fault using the side airbag, for example. Move seat all the way forward. Switch off ignition,
disconnect the battery and wait for 1 minute.
2.2. Unlock and disconnect electric plug for the seat.
2.3. Connect the battery and switch on ignition.
2.4. Read out fault memory. Static fault present.
3. Correcting the fault:
3.1. Switch off ignition, disconnect the battery and wait for 1 minute.
3.2. Insert connector in plug socket until connector is felt to engage.
4. Reading out and deleting faults:
NOTE:  Fault memory shows a sporadic fault.
4.1. Connect the battery, switch ignition on and read out the fault memory with the Porsche System Tester.
4.2. Erase fault memory.
Carry out work instruction after disconnecting the battery. --> 27 06 IN WORK INSTRUCTIONS AFTER
DISCONNECTING THE BATTERY - AS OF MY 2005 (ALL MODELS) .
69 11 19 REMOVING AND INSTALLING FRONT THREE-POINT BELT - AS OF

TOOLS

PRELIMINARY WORK
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Preliminary work
(All Models) .
2. Remove side trim panel. Refer to 70 75 19 Removing and installing side trim panel - as of MY 2006
Safety instructions for seat-belt tensioner unit
WARNING: Removing and installing seat-belt tensioner unit.

handling of seat-belt tensioner units!
--> Always observe the safety regulations for handling seat-belt tensioner units. --> 69 AW Safety regulations
for airbag and belt tensioner units - as of MY 2005 (All Models).
--> Disposal regulations for seat-belt tensioner units must be observed. --> 6900AW Disposal of airbag and
seat-belt tensioner units
--> If removed for an extended period, the seat-belt tensioner unit must be kept in a secure location!
--> Remove ignition key. Disconnect battery. Route or isolate ground strap so that all contact with a ground
carrier (e. g. body, seat frame) is avoided. Refer to 27 06 IN External power connection, jump lead starting -
--> After the battery is disconnected, always wait for 1 minute before disconnecting the seat-belt tensioner
plugs.
REMOVING FRONT THREE-POINT BELT
Removing deflector
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Fig. 41: Installation position for front three-point belt

Fig. 42: Removing deflector

1. Unscrew fastening screw -1- , and remove deflection fitting -2- together with the support -3- . See Fig. 42.
Removing seat-belt tensioner

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NOTE:  After the seat-belt tensioners have been triggered, they must be replaced.
The fault can be read out with the PIWIS Tester P 9718. Observe direction
of travel.
 If the seat-belt tensioner has been triggered, cut through the belt strap
before removing the seat-belt tensioner. This ensures that the defective
automatic belt device is not installed again.
 It is necessary to make sure that the negative terminal of the battery is
disconnected.
PIWIS Tester P 9718. Observe direction of travel.
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1. Release lock for electric connector -1- on seat-seat-belt tensioner -2- with a screwdriver in -direction of
2. Pull off connector -1- from seat-belt tensioner -2- -Arrow B- See Fig. 44.
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Fig. 45: Removing seat-belt tensioner

3. Unscrew fastening screw -1- and remove seat-belt tensioner -2- . See Fig. 45.
INSTALLING FRONT THREE-POINT BELT
Installing seat-belt tensioner
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WARNING: Loosen the safety-related threaded joint.
 Danger of injury if threaded joint is incorrect.
--> Always replace fastening screws.
--> It is not permissible to make alterations to the microencapsulated fastening screws (e. g. by using lubricant,
loosening the screws and screwing them down again).
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Fig. 47: Installing seat-belt tensioner

NOTE:  The seat-belt tensioner may only be installed with the ground terminal of
the vehicle battery disconnected.
 The vehicle battery may only be re-connected after the re-installation of
the belt has been completed.
1. Position seat-belt tensioner -2- . Observe direction of travel. See Fig. 47.
2. Tighten fastening screw -1- . Tightening torque --> Tightening torque: 50 (37 ftlb.) Nm +/-10 % See Fig.
47.
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3. Insert electrical plug -1- in the seat-belt tensioner -2- . See Fig. 48.
4. Push in lock with a tool such as a screwdriver -direction of arrow- until it engages. See Fig. 48.
5. By gently pulling on the belt, check the winding ability of the belt strap.
Installing deflector
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 Danger of injury if threaded joint is incorrect.
--> Always replace fastening screws.
--> It is not permissible to make alterations to the microencapsulated fastening screws (e. g. by using lubricant,
loosening the screws and screwing them down again).
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Fig. 50: Installing deflector

1. Insert deflection fitting -2- together with the support -3- on the inner side section and fasten with the
fastening screw -1- . Tightening torque --> Tightening torque : 46 (34 ftlb.) Nm +/-10 % See Fig. 50.
Subsequent work
1. Install side-panel lining. Refer to 70 75 19 Removing and installing side trim panel - as of MY 2006
(All Models) .
3. Using the PIWIS Tester P 9718, read out the fault memory.
69 24 19 REMOVING AND INSTALLING FRONT BELT LOCK - AS OF MY

2005 (ALL MODELS)
PRELIMINARY WORK
Preliminary work
Remove front seat. Refer to 72 01 19 Removing and installing front seat - as of MY 2005 (All LHD Models)
or 72 01 19 Removing and installing front seat - as of MY 2005 (All RHD Models) .
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REMOVING FRONT BELT LOCK
Removing control unit for memory seat adjustment with support

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Fig. 52: Removing control unit for memory seat adjustment with support
1. Unscrew the two fastening screws -1- and remove control unit for memory seat adjustment together with the
support -2- from the seat frame. See Fig. 52.
Fig. 53: Pulling off connectors on control unit for memory seat adjustment
2. Unlock and pull off the three connectors on the control unit for memory seat adjustment -arrows a- . See Fig.
53.
Removing front belt lock
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Fig. 54: Installation position of front belt lock

Fig. 55: Loosening support with compressor and air distributor valve
1. Unscrew the two fastening screws -1- on the support -2- . See Fig. 55.
2. Set support -2- with connected motor and air cushion control valve aside. See Fig. 55.
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Fig. 56: Loosening wire harness

3. Remove the three tie-wraps -1- and take the wire harness -2- out of the two line holders -3- . See Fig. 56.
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Fig. 57: Pulling off connector socket

4. Release connector socket -arrows a- and pull out of holder. See Fig. 57.
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Fig. 58: Disassembling connector socket

5. Remove tie-wraps -2- on connector socket -1- . See Fig. 58.
6. Release connector socket -1- ( -arrows a- ) and remove the three individual connectors -3- . See Fig. 58.
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Fig. 59: Removing front belt lock

7. Pull wire harness -1- out of the metal clip -2- ( -arrow A- ). See Fig. 59.
9. Pull off wire harness -1- and remove front belt lock -4- . See Fig. 59.
INSTALLING FRONT BELT LOCK
Installing front belt lock
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Fig. 60: Installing front belt lock

 Danger of injury if belt lock is not screwed on correctly.
--> Always replace fastening screws for belt lock after customer service and reworking.
--> It is not permissible to make alterations to the microencapsulated screws (e. g. use lubricant, loosen bolts,
and screw them down again).
1. Position belt lock -4- and secure using the fastening screw -3- . --> Tightening torque: 50 (37 ftlb.) Nm See
Fig. 60.
NOTE:  The electric lead must not be routed too tightly around the seat cushion.
2. Lay wire harness -1- and press into the metal clip -2- ( -arrow A- ). See Fig. 60.
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Fig. 61: Assembling connector socket

3. Press the three individual connectors -3- into the connector socket -1- until they engage firmly. See Fig. 61.
4. Secure new tie-wraps -2- on connector socket -1- . See Fig. 61.
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Fig. 62: Attaching connector socket

5. Attach connector socket to support until it clicks into place.
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Fig. 63: Securing wiring harness

6. Place wire harness -2- into the two line holders -3- and secure with three new tie-wraps -1- . See Fig. 63.
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Fig. 64: Securing support with compressor and air distributor valve
7. Position support -2- with connected motor and air cushion control valve and screw down with the two
fastening screws -1- . See Fig. 64.
Installing control unit for memory seat adjustment with support
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Fig. 65: Attaching connectors on control unit for memory seat adjustment
1. Attach the three connectors on the control unit for memory seat adjustment until they are felt to engage.
Fig. 66: Installing control unit for memory seat adjustment with support
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2. Position control unit for memory seat adjustment with support -2- on seat frame and secure with both
SUBSEQUENT WORK
Subsequent work
Install front seat. Refer to 72 01 19 Removing and installing front seat - as of MY 2005 (All LHD Models) or
72 01 19 Removing and installing front seat - as of MY 2005 (All RHD Models) .
69 51 19 REMOVING AND INSTALLING AIRBAG SENSOR - AS OF MY 2005

(ALL MODELS)
TOOLS

Removal tool, universal special tool NR.21
PRELIMINARY WORK
Preliminary work for front airbag sensor
1. Disconnect battery. --> 27 06 IN WORK INSTRUCTIONS AFTER DISCONNECTING THE

2. Remove front apron. Refer to 63 15 19 Removing and installing front spoiler - as of MY 2005 (All
Models) .
Preliminary work for center airbag sensor

2. Remove front seat --> 72 01 19 Removing and installing front seat - as of MY 2005 (All LHD Models) or
72 01 19 Removing and installing front seat - as of MY 2005 (All RHD Models) .
Microsoft
3. Remove the rear side-panel lining. Refer to 70 75 19 Removing and installing side trim panel - as of MY
4. Remove sill. Refer to 68 05 19 Removing and installing inner door sill trim - as of MY 2005 (All
Models) .
5. Undo screw fastening seat belt to the body. --> 691119 Removing and installing front three-point belt -
removing [987120 987121].
Safety instructions for airbag sensor
CAUTION: Incorrect triggering of airbag modules.
 Danger of injury and material damage if airbag sensors are not

handled correctly!
carrier (e. g. body, seat frame) is avoided.
--> Always wait one minute after disconnecting the battery before disconnecting the connector from the sensor.
--> The airbag sensor must not be removed with the plug plugged in!
--> The airbag sensors cannot be interchanged. Install the sensor listed in the Spare Parts Catalogue (PET).
--> Always replace fastening nuts and bolts of sensors after customer service and reworking.
--> Never make alterations to the micro-encapsulated nuts and bolts which have a negative effect on the bond
(e. g. using lubricant, loosening bolts and screwing them down again).
TOOLS AND MATERIALS
Tools
Removal tool, universal NR.21
REMOVING AIRBAG SENSOR
Removing sensor for front airbag
Microsoft
Fig. 67: Installation locations, illustrated on 997

A - Sensors for front airbag
B - Sensors for center airbag
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1. Release electric connector -1- -A- and remove from sensor. See Fig. 68.
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Fig. 69: Mounting for removal of sensor

2. Unscrew the two fastening nuts -2- and remove the sensor. See Fig. 69.
Removing sensor for center airbag
1. Disengage floor covering at the support and lay it in the vehicle interior.
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Fig. 70: Unlocking locating peg using the removal tool

2. Unlock locating peg -1- using the removal tool See Fig. 70.
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3. Unscrew fastening screws -2- and nuts -3- and carefully pull the support up and out of the retaining points.
See Fig. 71.
Incorrect triggering of airbag modules. --> 695119 Removing and installing airbag sensor - general
warnings
Microsoft
Fig. 72: Removing airbag sensor

4. Unscrew the two fastening nuts -2- . See Fig. 72.
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Fig. 73: Removing connector for airbag sensor

5. Unlock electrical connector -A- and remove sensor. See Fig. 73.
INSTALLING AIRBAG SENSOR
Installing sensor for front airbag
Fig. 74: Mounting for installation of sensor

1. Position sensor on retaining bracket and screw it down with the fastening nuts -2- . --> M6: 8 ftlb. +/-1 Nm
(ftlb.) See Fig. 74.
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Fig. 75: Installing the sensor plug connection

2. Push on the electrical connector -1- and lock. See Fig. 75.
Installing sensor for center airbag
Incorrect triggering of airbag modules. --> 695119 Removing and installing airbag sensor - general
warnings
Microsoft
Fig. 76: Mounting for installation of sensor

1. Position sensor on the body and screw it down with the fastening nuts -2- . --> M6: 8 (6) ftlb. +/-1 (0.5) ftlb.
See Fig. 76.
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Fig. 77: Installing the sensor plug connection

2. Push on the electrical connector until it clicks into place.
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Fig. 78: Engaging the support

3. Position the support and engage in lower side member.
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Fig. 79: Installing the support

4. Clip in locating peg -1- and check it is seated correctly. See Fig. 79.
5. Tighten the plastic fastening nuts -3- . See Fig. 79.
6. Screw in fastening screws -2- . --> Final tightening: 7.2 (5.5) Nm(ftlb.) See Fig. 79.
7. Lay the floor covering over the support and engage.
REWORKING
Work in wake of front airbag sensor
2. Connect the battery --> 27 06 IN WORK INSTRUCTIONS AFTER DISCONNECTING THE

3. Using the PIWIS Tester 97180, read out the fault memory and erase if required. If further faults exist,
proceed in accordance with airbag diagnosis fault code.
Work in wake of center airbag sensor
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1. Screw in screw fastening seat belt to the body. --> 691119 Removing and installing front three-point belt -
installing [987120 987121].
2. Insert sill. Refer to 68 05 19 Removing and installing inner door sill trim - as of MY 2005 (All Models) .
3. Install the rear side-panel lining. Refer to 70 75 19 Removing and installing side trim panel - as of MY
4. Installing front seat. Refer to 72 01 19 Removing and installing front seat - as of MY 2005 (All LHD
Models) or 72 01 19 Removing and installing front seat - as of MY 2005 (All RHD Models) .

6. Using the PIWIS Tester 97180, read out the fault memory and erase if required. If further faults exist,
proceed in accordance with airbag diagnosis fault code.
69 53 19 REMOVING AND INSTALLING TRIGGERING UNIT FOR AIRBAG -

TOOLS

PRELIMINARY WORK
Preliminary work for triggering unit
NOTE: If a new control unit has to be installed, read out as much of the data from the
old control unit as possible using the PIWIS Tester P 9718.

2. Remove left and right covers of console. Refer to 68 14 19 Removing and installing center console cover -
3. Remove center console cover. Refer to 68 19 19 Removing and installing cover for center console - as of
Microsoft
4. Remove center console. Refer to 68 17 19 Removing and installing center console - as of MY 2005 (All
Models) .
5. If installed, remove control unit for tilt sensor. Refer to 96 63 19 Removing and installing tilt sensor
General warning notes for airbag triggering unit
WARNING: Incorrect triggering of airbag modules.
 Danger of injury and material damage to as a result of incorrect

carrier (e. g. body, seat frame) is avoided. --> 27 06 IN WORK INSTRUCTIONS AFTER
--> Before disconnecting the airbag plug from the triggering unit, always wait for one minute after
disconnecting the battery.
--> The airbag triggering unit must not be removed with the connector still plugged in!
REMOVING TRIGGERING UNIT FOR AIRBAG
Overview, triggering unit for the airbag
Microsoft
Fig. 80: Overview, triggering unit for the airbag

Removing triggering unit for airbag
WARNING: Incorrect triggering of airbag modules.
 Danger of injury and material damage to as a result of incorrect

--> Before disconnecting the airbag plug from the triggering unit, always wait for one minute after
disconnecting the battery.
--> The airbag triggering unit must not be removed with the connector still plugged in!
Incorrect triggering of airbag modules.
Microsoft
Fig. 81: Triggering unit plug

1. From the passenger's side, release electric plug -a- and open the latching lever -arrow- . See Fig. 81.
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2. Unscrew the three fastening screws -1- . See Fig. 82.
3. Take off both ground straps -2- from the bolt for the triggering unit. See Fig. 82.
4. Remove triggering unit laterally.
INSTALLING THE TRIGGERING UNIT
Installing triggering unit
Microsoft
Fig. 83: Installing triggering unit

1. Position triggering unit, move both ground straps -2- on the left fastening bolts and screw down with the
three fastening nuts -1- . --> Tightening torque: 6 ftlb. . See Fig. 83.
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2. Connect electric plug and lock it until the lock engages.
3. If the triggering unit is new, lock the airbag triggering unit using the PIWIS Tester P 9718. --> 69 53 19
Removing and installing triggering unit for airbag - as of MY 2005 (All Models).
SUBSEQUENT WORK
Subsequent work for triggering unit
1. If installed, install control unit for tilt sensor. Refer to 96 63 19 Removing and installing tilt sensor control
unit - as of MY 2005 (All Models) .
2. Connect battery. --> 27 06 IN WORK INSTRUCTIONS AFTER DISCONNECTING THE BATTERY -

AS OF MY 2005 (ALL MODELS) .
3. Install center console. Refer to 68 17 19 Removing and installing center console - as of MY 2005 (All
Models) .
4. Install center console cover. Refer to 68 19 19 Removing and installing cover for center console - as of
5. Install left and right covers of console. Refer to 68 14 19 Removing and installing center console cover - as
Microsoft
PROGRAMMING TRIGGERING UNIT
Triggering unit - reading out and writing in data
Continue.
3. Move from vehicle type to the list of control units. Locking is only possible after an automatic control unit
search.
4. Select Posip with the cursor keys and press the >> key.
9. Switch on ignition. Switch to the Special functions menu and perform the vehicle handover using the F8
key.
10. In the Special functions menu, erase All fault memories >> , compare Vehicle identification number and
confirm.
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11. With the cursor keys on Posip - Replacing control unit , after replacement of the control unit, the read-out
data (see Section 6) are installed under the menu Write in data press >>.
13. Locking is only possible after an automatic control unit search.
Lock triggering unit:
14. Change to the menu Posip - lock and press >>.
15. Select the country-specific Equipment and press >>.
16. Start Lock with F8.
17. Observe message on Tester.
18. Quit menu, carry out a test drive, and read out fault memory.
CODING TRIGGERING UNIT
Coding triggering unit
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3. In the Special functions menu, erase All fault memories >> , compare Vehicle identification number and
confirm.
5. Using the >> , move from the vehicle type to the list of control units. Locking is only possible after an
automatic control unit search.
6. Select Posip with the cursor keys and press >>.
8. Select Thorax driver and code with F8.
Thorax driver
yes
no
9. Select Thorax driver and code with F8.
Thorax passenger
yes
no
10. Select Head airbag driver and code with F8.
Head airbag driver

yes
no
11. Select Head airbag passenger and code with F8.
Head airbag passenger

yes
no
12. Select Front airbag driver and code with F8.
Front airbag driver

yes
no
13. Select Front airbag passenger and code with F8.
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Front airbag passenger

yes
no
14. Select Seat-belt tensioner driver and code with F8.
Seat-belt tensioner driver

yes
no
15. Select Seat-belt tensioner passenger and code with F8.
Seat-belt tensioner passenger

yes
no
16. Select Front sensor driver and code with F8.
Front sensor driver

yes
no
17. Select Front sensor passenger and code with F8.
Front sensor passenger

yes
no
18. Select Side sensor driver and code with F8.
Side sensor driver

yes
no
19. Select Side sensor passenger and code with F8.
Side sensor passenger

yes
no
20. Select AWS and code with F8.
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AWS
yes
no
21. Select Seat-belt buckle driver and code with F8.
Seat belt buckle driver

yes
no
22. Select Seat-belt buckle passenger and code with F8.
Seat belt buckle passenger

yes
no
23. Select Left/Right-hand drive and code with F8.
Left/Right-hand drive
LHD
RHD
24. Select Key-operated switch and code with F8.
Key-operated switch
yes
no
Lock triggering unit:
25. Change to the menu Posip - lock and press >>.
26. Select the country-specific Equipment and press >>.
27. Start Lock with F8.
28. Observe message on Tester.
69 58 19 REMOVING AND INSTALLING DRIVER'S AIRBAG UNIT - AS OF MY

2005 (ALL MODELS)
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PRELIMINARY WORK FOR DRIVER'S AIRBAG UNIT
NOTE: Operate the steering wheel with the battery disconnected. Before disconnecting
the battery, observe the following points:
1. Insert ignition key into ignition lock, switch on ignition and then off again.
2. Leave ignition key inserted.

General warnings for driver's airbag unit
WARNING: Incorrect triggering of airbag module.

handling of airbag units!
--> The safety regulations --> 69 AW Safety regulations for airbag and belt tensioner units - as of MY 2005
(All Models) must be followed.
--> The airbag unit must always be stowed so that the airbag opening faces upwards!
--> If removed for an extended period, the airbag unit must be kept in a locked place!
CAUTION: Incorrect release of airbag unit.
 Danger of injury and material damage if airbag units are not installed
correctly!
--> Before installing the airbag unit, check whether the locking clip, the airbag unit mounting and/or the metal
stop on the steering wheel are deformed. If there is deformation, replace the damaged component (steering
wheel/airbag unit).
--> The airbag unit must only be installed with locking clips that are operational and are in the correct position.
--> The locking clip must not jam or grind.
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--> Do not expose face and other parts of the body to the airbag unit.
REMOVING DRIVER'S AIRBAG UNIT
Removing driver's airbag unit
Fig. 85: Overview of driver' airbag unit

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Fig. 86: Releasing driver's airbag unit

1. Turn steering wheel 90° and stick a T30 (Torx with handle) or medium-size screwdriver through the opening
of the steering wheel.

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Incorrect triggering of airbag module.
2. Use the screwdriver or T30 to compress the locking clip and pull the airbag unit from the steering wheel with
the fingers.
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Fig. 87: Locking clip

Locking clip compressed -A- See Fig. 87.
Locking clip relieved -B- See Fig. 87.
Fig. 88: Unlocking connector for airbag wiring harness

3. Unlock electrical connector -2- on steering wheel -A- and remove. See Fig. 88.
Removing airbag lead:
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Fig. 89: Removing airbag lead

4. Unlock electrical connectors -1, 2- with a screwdriver and unplug. See Fig. 89.
5. Unplug electrical connector -3- . See Fig. 89.
INSTALLING DRIVER'S AIRBAG UNIT
Installing driver's airbag unit
CAUTION: Incorrect release of airbag unit.
 Danger of injury and material damage if airbag units are not installed
correctly!
--> Before installing the airbag unit, check whether the locking clip, the airbag unit mounting and/or the metal
stop on the steering wheel are deformed. If there is deformation, replace the damaged component (steering
wheel/airbag unit).
--> The airbag unit must only be installed with locking clips that are operational and are in the correct position.
--> The locking clip must not jam or grind.
--> Do not expose face and other parts of the body to the airbag unit.
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Installing airbag lead:
Fig. 90: Installing airbag lead

1. Push in the electrical connector -3- until it clicks into place. See Fig. 90.
2. Press in the electrical connectors -1, 2- until they click into place, then clip the retainer into the electrical
connectors -1, 2- . See Fig. 90.
Incorrect triggering of airbag module. --> Removing and installing driver's airbag unit - General warning
notes.
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Fig. 91: Inserting connector for airbag wiring harness

3. Insert electrical connector for the airbag wiring harness -2- until it clicks into place. See Fig. 91.
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Fig. 92: Engaging the airbag unit

4. Engage the airbag unit into the steering wheel with both hands using intermittent pressure.
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Fig. 93: Checking the airbag unit is positioned firmly:

5. Each time the airbag unit is fitted, it is important to check that it is installed correctly by pulling the airbag
unit, tapping the steering wheel rim and performing a visual inspection (position of airbag unit on steering
wheel).
REWORKING
Work in wake of driver's airbag unit
1. Connect the battery. Carry out --> 27 06 IN WORK INSTRUCTIONS AFTER DISCONNECTING THE
Microsoft
69 59 19 REMOVING AND INSTALLING PASSENGER'S AIRBAG UNIT - AS

PRELIMINARY WORK
Preliminary work - airbag unit, passenger's side

2. Remove glove compartment Refer to 68 15 19 Removing and installing glove compartment - as of MY

2005 (All Models) .
Safety instructions, passenger's airbag unit

CAUTION: Loosen the safety-related screw connection!
 Danger of injury and material damage if the airbag module is screwed

on incorrectly!
--> Always replace fastening screws for the airbag unit after customer service and reworking.
--> It is not permissible to make alterations to the microencapsulated screws (e. g., use lubricant, loosen bolts,
REMOVING PASSENGER'S AIRBAG UNIT
Removing passenger's airbag unit
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Fig. 94: Installation location illustrated on 997

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Fig. 95: Bend up the reinforcing panel.

1. Bend up the curved metal straps -1- at the right and left of the reinforcing panel with a screwdriver. See Fig.
95.

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Fig. 96: Screws for airbag unit

2. Unscrew the four fastening screws -2- for the airbag unit and carefully lower the airbag unit out a few
centimeters. See Fig. 96.
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Fig. 97: Removing the reinforcing panel

3. Push the reinforcing panel -3- back so that it rests on the airbag unit and carefully lower the airbag unit out a
few centimeters. See Fig. 97.
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Fig. 98: Connection of electric plugs

4. Unclip the electrical leads -4- to the left and right of the airbag unit. See Fig. 98.
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Fig. 99: Unfastening the plugs for the airbag

5. Carefully prise out the locking unit -5- and -6- the electrical plugs to the left and right with a screwdriver -a-
and then pull the plugs out of the airbag unit. See Fig. 99.
6. Remove airbag unit and lay to one side in the appropriate manner.
INSTALLING PASSENGER'S AIRBAG UNIT
Installing passenger's airbag unit
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Fig. 100: Locking plug for airbag

1. Lift the airbag unit under the dashboard and push in the plug -5- and -6- and lock. See Fig. 100.
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Fig. 101: Routing the electric plug

2. Clip in the electrical wire -4- on the left and right in the airbag unit. See Fig. 101.
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Fig. 102: Engaging the reinforcement plate

3. Position the airbag module from below on the mounting bracket and engage the reinforcement plate -3- on
the airbag module. See Fig. 102.
CAUTION: Loosen the safety-related screw connection!
 Danger of injury and material damage if the airbag module is screwed

on incorrectly!
--> Always replace fastening screws for the airbag unit after customer service and reworking.
--> It is not permissible to make alterations to the microencapsulated screws (e. g., use lubricant, loosen bolts,
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Fig. 103: Fastening screws for airbag module

4. Screw down the airbag module and reinforcement plate using the four fastening screws -2- . --> Tightening
torque: 7 ftlb. See Fig. 103.
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Fig. 104: Reinforcement plate

5. Bend over both projecting tabs -1- . See Fig. 104.
REWORKING
Reworking for passenger's airbag unit
1. Install glove compartment. Refer to 68 15 19 Removing and installing glove compartment - as of MY

2005 (All Models) .
2. Connect the battery.--> 27 06 IN WORK INSTRUCTIONS AFTER DISCONNECTING THE

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69 63 19 REMOVING AND INSTALLING SIDE AIRBAG - AS OF MY 2005 (ALL

MODELS)
PRELIMINARY WORK
Preliminary work for side airbag
1. Disconnect seat from the power supply. Refer to 72 01 19 Removing and installing front seat - as of MY
2005 (All LHD Models) or 72 01 19 Removing and installing front seat - as of MY 2005 (All RHD
Models) . or Disconnecting battery --> 27 06 IN WORK INSTRUCTIONS AFTER DISCONNECTING
THE BATTERY - AS OF MY 2005 (ALL MODELS) .
2. Remove heating element for front seat backrest. Refer to 74 19 19 Removing and installing cover for front
backrest - as of MY 2005 (All Models) .
3. Partially detaching covering for front backrest, outboard side of seat. Refer to 74 19 19 Removing and
installing cover for front backrest - as of MY 2005 (All Models) .
General warnings for side airbag

REMOVING SIDE AIRBAG
Removing side airbag
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Fig. 105: Mounting of side airbag

1. Lift up the appropriate detached side bolster and undo the two fastening screws -1- from the airbag unit. See
Fig. 105.
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Fig. 106: Electrical lead for side airbag

2. Pull the side airbag out from the backrest frame.
3. Undo and remove the fastening nut -2- . See Fig. 106.
4. Unlock the electrical connector for the side airbag -3- and remove -A- . See Fig. 106.
INSTALLING SIDE AIRBAG
Installing side airbag
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Fig. 107: Electrical lead for side airbag

1. Push on the electrical connector for the side airbag -3- and lock. See Fig. 107.
2. Fit the ground lead -2- and tighten with fastening nut. --> Tightening torque: 7 ftlb. See Fig. 107.
3. Insert side airbag into backrest frame and counter.
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Fig. 108: Mounting of side airbag

4. Lift the appropriate loosened side bolster and tighten the two fastening screws -1- . --> Tightening torque: 7
ftlb. See Fig. 108.
REWORKING
Work in wake of side airbag
1. Fasten covering for front backrest. Refer to 74 19 19 Removing and installing cover for front backrest - as
2. Install heating element for front seat backrest. Refer to 74 19 19 Removing and installing cover for front
backrest - as of MY 2005 (All Models) .
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3. Connect the seat to the power supply. Refer to 72 01 19 Removing and installing front seat - as of MY
2005 (All LHD Models) or 72 01 19 Removing and installing front seat - as of MY 2005 (All RHD
Models) . or Connecting battery. --> 27 06 IN WORK INSTRUCTIONS AFTER DISCONNECTING THE
69 66 19 REMOVING AND INSTALLING THE HEAD AIRBAG UNIT - AS OF

PRELIMINARY WORK
Preliminary work

2. Remove door trim panel. --> 70 59 19 REMOVING AND INSTALLING DOOR TRIM PANEL - AS OF
Safety instructions for head airbag unit
WARNING: Removal and installation of airbag units
 Danger of injury and material damage if airbag units are not handled
correctly!
REMOVING HEAD AIRBAG UNIT
Removing head airbag unit
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Fig. 109: Overview of head airbag unit

correctly!
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Fig. 110: Releasing the plug connection for the head airbag
1. With a screwdriver, carefully release the locking element of the plug connection for the airbag unit and
remove the plug from the airbag module.
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Fig. 111: Head airbag fastening

2. Unscrew the three fastening nuts -1- and remove the ground lead -2- . See Fig. 111.
3. Remove the airbag unit
INSTALLING HEAD AIRBAG UNIT
Installing head airbag unit
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correctly!
Fig. 112: Head airbag fastening

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1. Position airbag unit on the door unit carrier.
2. Tighten the two outer fastening screws -1- . Tightening torque 7.5 ftlb. --> Tightening torque: 7.5 ftlb. See
Fig. 112.
3. Tighten fastening screw -1- and ground lead -2- . --> Tightening torque: 7.5 ftlb. See Fig. 112.
Fig. 113: Locking the plug connection for the head airbag
4. Connect the electrical plug to the airbag unit and lock.
REWORKING
Work in wake
1. Install door trim panel. --> 70 59 19 REMOVING AND INSTALLING DOOR TRIM PANEL - AS OF
2. Connect the battery and carry out "Work instructions after disconnecting the battery". --> 27 06 IN WORK
69 68 K2 CALIBRATING AWS CONTROL UNIT - AS OF MY 2005 (ALL

Microsoft
MODELS)
TOOLS

test weight special tool P 9742
CALIBRATING AWS CONTROL UNIT
Calibrating AWS control unit
NOTE: A system test can only be performed successfully if:
 There are no faults in the AWS and airbag control unit.
NOTE: Calibration applies to vehicles as of MY '06 with country equipment (USA,

Canada, Mexico).
WARNING: Incorrect information for AWS control module.
 Passenger's airbag is triggered differently.
--> If the passenger's seat was removed and re-installed, the AWS control module must be calibrated.
--> If the seat bracket was replaced, the AWS control module must be calibrated.
--> If the AWS control module was replaced, the AWS control module must be calibrated.
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1. Connect battery charger to the vehicle. Move passenger's seat longitudinally until flush with the seat rails and
to its lowest position.
on ignition. Press >> to continue.
4. Switch from the vehicle type to the list of control units >>.
5. Select AWS control unit and press the >> key.
6. Select the Calibration menu. Press >>.
7. The Tester displays several messages and instructions relating to the individual work steps until the message
Test step was completed successfully appears. Press >>.
8. Select the System test menu in the AWS control unit.
9. Follow the instructions on the Tester. Press >> and perform the test using the default sequence.
9.1. Seat empty - the passenger's seat must be empty. The Passenger Airbag Off indicator light in the center
console must not come on. To determine the status, press F7 or F8. Then press >>.
9.2. Child - place the special tool test weight P 9742 on the passenger's seat. The Passenger Airbag Off
indicator light in the center console must come on. To determine the status, press F7 or F8. Then press >>.
9.3. Adult - get an assistant, for example, to sit on the passenger's seat. The Passenger Airbag Off indicator light
in the center console must not come on. To determine the status, press F7 or F8. Then press >>.
9.4. Seat jammed - the passenger's seat must be empty. The seat must also be relieved of any pressure, e. g. by
lifting the seat up with your hand. The Passenger Airbag Off indicator light in the center console must come on.
In addition to the Airbag Off indicator light, a message is displayed in the instrument cluster: Check passenger
seat adjustment . To determine the status, press F7 or F8. Then press >>.
10. To check the system, select the Actual values menu under the AWS control unit. Then press >>.
10.1. Select the Weight group (0-4) and Gross weight calibrated options.
10.1.1. If there is no weight on the passenger's seat, compare values (see Calibrated Values) using the PIWIS
Tester. The Passenger Airbag Off indicator light in the center console must not come on.
10.1.2. Place the special tool test weight P 9742 on the passenger's seat. The Passenger Airbag Off indicator
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light in the center console must come on. Compare values (see table below) using the PIWIS Tester.
10.1.3. Get an assistant with a body weight of more than 55 kg, for example, to sit on the passenger's seat. The
Passenger Airbag Off indicator light in the center console must not come on. Compare values (see table below)
using the PIWIS Tester.
Calibrated Values
Weight Gross weight calibrated (seat in calibration
Test state
group (0-4) position)
No weight on the passenger's seat. 0 --> Control value: 0 kg +/-1 kg
Special tool test weight P 9742 on
1 --> Control value: 6.7 kg +/-1 kg
passenger's seat
Get a person weighing > 55 kg at least to --> Control value for person's weight: > 55
2, 3 or 4
sit on the passenger's seat. kg ; person's weight +/- 25 %
11. Read out and erase the fault memories in the Airbag and AWS control unit, perform a test drive and then
read out the fault memories again. If faults are found, determine the cause using the PIWIS Tester and correct
the faults.
69 68 19 REMOVING AND INSTALLING AWS CONTROL UNIT - AS OF MY

2005 (ALL MODELS)
TOOLS

test weight special tool P 9742
PRELIMINARY WORK
Preliminary work for AWS control unit
Disconnect battery. Refer to 27 06 IN External power connection, jump lead starting - as of MY 2005 (All
Models) .
Remove right front seat. Refer to 72 01 19 Removing and installing front seat - as of MY 2005 (All LHD
REMOVING AWS CONTROL UNIT
Removing AWS control unit
Microsoft

Fig. 115: Loosening seat central connector

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1. Turn seat central connector -A- at AWS holder to the left and remove from the holder. See Fig. 115.
Fig. 116: Fastening screws for AWS holder

2. Unscrew the three fastening screws -1- for the AWS holder on the seat bracket. See Fig. 116.
3. Release electric connector on AWS control unit -a- , unplug and tilt the AWS holder to the right side. See
Fig. 116.
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Fig. 117: Unscrewing fastening screws for AWS control unit.

4. Unscrew the three fastening screws -2- of the AWS control unit and remove the control unit. See Fig. 117.
INSTALLING AWS CONTROL UNIT
Installing AWS control unit
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Fig. 118: Screwing AWS control unit and holder together

1. Position AWS control unit on the holder and screw it down using the three fastening screws -2- . See Fig.
118.
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Fig. 119: Screwing AWS holder to seat bracket

2. Position AWS holder on the seat bracket and screw it down using the three fastening screws -1- . See Fig.
119.
3. Push electric connector onto AWS control unit until it is felt to engage.
4. Insert seat central connector into AWS holder and clamp by turning to the right.
SUBSEQUENT WORK
Subsequent work for AWS control unit
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Install right front seat. Refer to 72 01 19 Removing and installing front seat - as of MY 2005 (All LHD
Connect the battery and carry out work instructions after disconnecting the battery. Refer to --> 27 06 IN
WORK INSTRUCTIONS AFTER DISCONNECTING THE BATTERY - AS OF MY 2005 (ALL
MODELS) .
1. If the AWS control unit has been replaced, the new AWS control unit must be taught and calibrated under
AWS Control unit replacement . --> 696819 Removing and installing AWS control unit - section on
"Programming", --> 6968K2 Calibrating AWS control unit - section on "Calibrating"
PROGRAMMING AWS CONTROL UNIT
Reading and writing values for AWS control unit
1. Replace control unit. --> 696819 Removing and installing AWS control unit
2. Connect battery charger to the vehicle. Move passenger's seat longitudinally until flush with the seat rails and
to its lowest position.
on ignition. Press >> to continue.
5. Switch from the vehicle type to the list of control units >>.
6. Select AWS with the cursor keys and press the >> key.
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8. The Tester displays several messages and instructions relating to the individual work steps until the message
Control unit replacement was completed successfully appears. Press >>.
9. To check the system, select the Actual values menu under the AWS control unit. Then press >>.
9.1. Select the Weight group (0-4) and Gross weight calibrated options.
9.1.1. If there is no weight on the passenger's seat, compare values (see Calibrated Values) using the PIWIS
Tester. The Passenger Airbag Off indicator light in the center console must not come on.
9.1.2. Place the special tool test weight P 9742 on the passenger's seat. The Passenger Airbag Off indicator
light in the center console must come on. Compare values (see table below) using the PIWIS Tester.
9.1.3. Get an assistant with a body weight of more than 55 kg, for example, to sit on the passenger's seat. The
Passenger Airbag Off indicator light in the center console must not come on. Compare values (see table below)
using the PIWIS Tester.
Calibrated Values
Weight Gross weight calibrated (seat in calibration
Test state
group (0-4) position)
No weight on the passenger's seat. 0 --> Control value: 0 kg +/-1 kg
Special tool test weight P 9742 on
1 --> Control value: 6.7 kg +/-1 kg
passenger's seat
Get a person weighing > 55 kg at least to --> Control value for person's weight: > 55
2, 3 or 4
sit on the passenger's seat. kg ; person's weight +/- 25 %
10. Read out and erase the fault memories in the Airbag and AWS control unit, perform a test drive and then
read out the fault memories again. If faults are found, determine the cause using the PIWIS Tester and correct
the faults.
Microsoft
ACCESSORIES & EQUIPMENT Radio, telephone, on-board computer, navigation
Radio, telephone, on-board computer, navigation
91 10 19 REMOVING AND INSTALLING PCM DISPLAY AND CONTROL UNIT

TOOLS

PRELIMINARY WORK
Preliminary work for PCM display and operator control unit
Remove both covers on center console. Refer to 68 14 19 Removing and installing center console cover - as
REMOVING PCM DISPLAY AND CONTROL UNIT
Removing display for the PCM operator control unit
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Fig. 1: PCM screw locking lacquer

1. Loosen the side fastening screw a few turns.
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Fig. 2: Fastening the PCM

2. Insert a hexagon-socket wrench sideways into the screw connection of the PCM detent hooks.
3. Close the detents (2 each side) with an Allen key -A- and carefully pull out the PCM. See Fig. 2.
4. For reinstallation, open the detents with the hexagon-socket wrench -B- . See Fig. 2.
The number of plug connections will vary, depending on the I No. (CD changer, amplifier, etc.).
The variant without additional audio components (external Most control units) has a jumper (output to input)
connected to the optical waveguide plug.
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Fig. 3: PCM plug connections

5. Unlock antenna plug -D, E- and remove. See Fig. 3.
6. Unlock and disconnect the electrical plug connections in the order -A, B, C- . See Fig. 3.
INSTALLING PCM DISPLAY AND CONTROL UNIT
Installing display and PCM operator control unit
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1. Push on the electrical plug connections for the display and operator control unit in the sequence -C, B, A- and
the antenna amplifiers -D, E- until the plugs are felt to engage. See Fig. 4.
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Fig. 5: Locking tabs on the PCM

2. Check that the locking tabs on the PCM are out, open the lock with an Allen key if necessary.
NOTE: Before sliding the PCM/radio into the installation slot, make sure that the
electric lines are not trapped by the PCM/radio or damaged .
After installation of a new display and PCM/radio operator control unit, the
system must be activated with the PIWIS tester P 9718. --> 911019 Removing
and installing display and PCM operator control unit - programming
3. Push the navigation unit into the installation slot until the locks engage on the PCM housing.
Microsoft
Fig. 6: PCM screw locking lacquer

4. Screw in the locking screw for the PCM and tighten it.
SUBSEQUENT WORK
Subsequent work for PCM display and operator control unit
Install both covers on center console. Refer to 68 14 19 Removing and installing center console cover - as of
READING OUT PCM DISPLAY AND CONTROL UNIT
Reading from and writing to the PCM display and operator control unit
NOTE:  When installing a new PCM/CDR in a vehicle, the PCM/CDR code specified
in IPAS should be present. Normally, the code is stored in the instrument
cluster, and is read out from the PCM/CDR.
 You can get the codes from IPAS or from your importer by specifying the
 During coding, there should be a guaranteed power supply for the PIWIS
tester P 9718. It is essential to connect a battery charger with a current
rating of at least 40 A to the vehicle battery.
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 The PIWIS tester P 9718 instructions take precedence and in the event of a
discrepancy these are the instructions that must be followed. Deviations
may occur with later software versions.
 The procedure described here has been structured in general terms;
different text or additions may appear in the PIWIS tester P 9718.
4. Select PCM-MMI and press the >> .
5. In the menu PCM-MMI , select Control unit replacement and press the >> .
6. Select Read coding and press >> .
7. On the screen of the PIWIS tester appears the message Coding read-out complete >> .
8. Switch off ignition and replace the PCM. --> 911019 Removing and installing PCM display and operator
control unit
9. Switch on ignition << return to vehicle type , for the control units select Special functions and start the
vehicle handover with F8 .
10. Read out and erase all fault memories.
11. Using the >> change from vehicle type to control units .
12. Select PCM-MMI and press the >> .
13. In the menu PCM-MMI , select Control unit replacement and press the >> .
14. Under the menu Write coding , the data read out (see Section 7) is installed >> .
15. PIWIS tester displays Coding write-in complete >> .
16. In the menu PCM-MMI , select Required & Actual Configuration and press the >> .
17. Compare the Actual/Required listing. Use F8 to start Mapping . All installed audio components will now be
listed with a plus under Actual/Required.
18. Read out the fault memory again and erase as necessary.
19. PCM is now taught.

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PROGRAMMING PCM DISPLAY AND CONTROL UNIT
Programming the display and operator control unit
2. Switch on ignition << return to vehicle type , for the control units select Special functions and start the
vehicle handover with F8 .
3. Read out and erase all fault memories.
4. Switch from the vehicle type to the list of control units >> .
5. Select PCM and press the >> .
6. In the menu PCM, select PCM2 MMI and press the >> .
8. Select Write coding and write in the coding. (Even if no coding data was read out, the required data is loaded
for the control unit.)
9. Select Coding and press >> .
10. Select Equipment and press >> .
The following codings can be performed:
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11. If the PCM code is not displayed with an * , then select the PCM code , enter, and code with F8 .
12. Select Country coding and the relevant country, and code with F8 .
13. Select Vehicle type vehicle coding and code with F8 .
Vehicle type vehicle coding

911 (997)
Boxster (987)
14. Select Vehicle version vehicle coding and code with F8 .
Vehicle version vehicle coding

Coupe
Cabriolet
Targa
15. Select Air conditioner and code with F8 .
Air conditioner
Without air conditioner
With air conditioner
16. Select Units and code with F8 .
Units
RoW (°C, liter, km)
UK (°C, gal, mph)
USA (°F, gal, mph)
17. Select Right/left-hand drive vehicle coding and code with F8 .
Right/left-hand drive vehicle coding

Right-hand drive
Left-hand drive
18. Select Windscreen wiper/washer system and code with F8 .
Windscreen wiper/washer system

Not present
Present
19. Select Rain sensor and code with F8 .

Microsoft
Rain sensor
Not present
Present
20. Select Electronic air conditioner and code with F8 .
Electronic air conditioner

Not installed
Installed
21. Select Daytime driving lights and code with F8 .
Daytime driving light

Not installed
Installed
22. Select ASK amplifier and code with F8 .
ASK amplifier
Not installed
Installed
23. Select Adjustability of orientation light and code with F8 .
Adjustability of orientation light

Not installed
Installed
24. Select Multi-function steering wheel and code with F8 .
Multi-function steering wheel

Not installed
Installed
25. In the other submenus (e. g. Porsche Assistance, Additional and freely-selectable codes, e. g., Sport watch)
of Coding , further customer-specific settings can be selected and coded in the same way.
26. In the menu PCM MMI , change to MOST actual installed components list ; here a version installed in
the vehicle (e. g. CD changer) must be displayed
27. Change to MOST required installed components list ; here too the same version (e. g. CD changer) must
be displayed - if this is not the case, select the version and code with F8 .
Microsoft
28. Select Required & Actual configuration and press the >> .
29. Compare the Actual/Required listing. Use F8 to start Mapping . All installed audio components must now
be listed with a plus under Actual/Required. If this is not the case, the versions in the MOST actual installed
components list or MOST required installed components list must be coded manually.
30. Use << to quit the menu PCM MMI and change to the menu PCM GW .
In the menu PCM GW :
31. Select Coding and press the >> .
32. Select Vehicle equipment vehicle coding and code with F8 .

911 (997)
Boxster (987)

Coupe
Cabriolet
Targa
Air conditioner
Without air conditioner
With air conditioner
36. Select Right/left-hand drive vehicle coding and code with F8 .

Right-hand drive
Left-hand drive
37. Select Tuner parameters and code with F8 .
Tuner parameters
Europe
Microsoft
USA
South America
Australia
Asia
(South) Africa
Japan
38. Press << to quit the menu PCM .
39. Read out fault memory of all control units and erase if required.
40. PCM is now taught.
41. If the PCM/vehicle equipment does not have a DVD navigation unit, then adjust the time/date using the
SET button on the PCM and in the menu PCM system .
42. For vehicle equipment with DVD navigation unit, switch on the PCM in clear surroundings (to load GPS
almanac); as soon as four satellites are identified the almanac will reload. The time is updated again when there
is a plausible GPS reception (four satellites). The date and time are also adopted once the GPS almanac has
been loaded; it may be necessary to change over to summer time (daylight-saving time). This time is transferred
to the instrument cluster. If the time is then manually changed by means of the instrument cluster, this time is
adopted by the PCM and synchronized with GPS time.
43. For vehicle equipment with telephone, the telephone is enabled again when the telephone PIN code is
entered with the SIM telephone card inserted.
91 12 19 REMOVING AND INSTALLING NAVIGATION UNIT - AS OF MY 2005

(ALL MODELS)
TOOLS

removal tool special tool P 9570/1
PRELIMINARY WORK
Preliminary work for navigation unit
Microsoft
REMOVING NAVIGATION UNIT
Removing navigation unit
NOTE: If the navigation unit has to be replaced, the coding must be read out prior to
removal using the PIWIS tester P 9718.
Fig. 7: Installation position navigation unit

Remove ignition key.
Depending on the equipment I No., the navigation unit is located next to or on the CD - changer.
Microsoft
Fig. 8: Unlocking the navigation unit

1. Push the removal tool P 9570/1 -1- into the navigation unit and pull the navigation unit forward. See Fig. 8.
Microsoft
Fig. 9: Electrical plug

2. Unlock the electrical plug -1, 2, 3- on the navigation unit and pull out the navigation unit. See Fig. 9.
Removing the navigation unit with retaining bracket
NOTE: If the navigation unit has to be replaced, the coding must be read out prior to
removal using the PIWIS tester P 9718.
If the navigation unit is removed with the retaining bracket, then new clips must
be used before reinstallation.
Microsoft
Fig. 10: Removing the navigation unit with retaining bracket

1. Give the navigation unit with the retaining bracket a pull forward, and lever out the clips with a screwdriver if
necessary.
Microsoft

2. Unlock the electrical plug -1, 2, 3- on the navigation unit and remove the navigation unit with holder. See
Fig. 11.
INSTALLING NAVIGATION UNIT
Installing navigation unit
Microsoft

1. Insert the navigation unit into the retaining bracket and plug into the electrical plug connections -1, 2, 3- until
the plug is felt to click into place. See Fig. 12.
2. Slide the navigation unit further into the retaining bracket until the navigation unit is felt to click into place.
Installing the navigation unit with retaining bracket
NOTE: If the navigation unit is removed with the retaining bracket, then new clips must
be used before reinstallation.
1. Install new clips, push in the navigation unit in the retaining bracket until the navigation unit is felt to engage.
Microsoft

2. Push in electrical plug connections -1, 2, 3- until plugs are felt to engage. See Fig. 12.
Microsoft
Fig. 14: Installing the navigation unit with retaining bracket

3. Position the navigation unit with retaining bracket on the body and push into the four holders. Check proper
seating of holder by pulling up on the retaining bracket.
SUBSEQUENT WORK
Subsequent work for navigation unit
Microsoft
PROGRAMMING NAVIGATION UNIT
Reading out and writing values for navigation unit
1. Connect the Porsche System tester to the vehicle and start the System tester. Switch on ignition. >> Continue.
4. Select PCM 2.1 , Navigation with the cursor keys and press the >> key.
6. Select Read out codings (codings) with the cursor keys and press >> .
7. The message Codes successfully read out appears on the screen of the Porsche System tester. Press >> .
10. In the Special functions menu, erase All fault memories by pressing >> .
12. In the menu Write in codings >> the data read-out are installed.
13. System tester displays Coding write-in complete >> .
Microsoft
14. Quit menu, insert navigation CD, switch off ignition and lock the vehicle, then unlock, switch on ignition
and load navigation CD.
15. Perform navigation during the test drive and afterwards read out fault memory.
CODING NAVIGATION UNIT
Coding navigation unit
7. Select PCM 2.1 , Navigation with the cursor keys and press the >> .
9. In the menu Coding the PCM code has to be displayed using * .
Microsoft
10. Quit menu, insert navigation CD, switch off ignition and lock the vehicle, then unlock, switch on ignition
and load navigation CD.
11. Perform navigation during the test drive and afterwards read out fault memory.
91 13 19 REMOVING AND INSTALLING GPS ANTENNA - AS OF MY 2005

(ALL MODELS)
PRELIMINARY WORK
Preliminary work for GPS antenna
Refer to 50 87 19 Removing and installing cowl panel cover - as of MY 2005 (All Models) .
Depending on the I No., --> 914719 Removing and installing radio antenna - removing
REMOVING GPS ANTENNA
Removing GPS antenna

1. On the cover for the cowl panel, release the electrical plug connection -A- and remove. See Fig. 15.
Microsoft
Fig. 16: Fastening screw for GPS

2. Unscrew the fastening screw -1- and pull out the GPS antenna out of the cowl panel cover. See Fig. 16.
INSTALLING GPS ANTENNA
Installing GPS antenna
Microsoft
Fig. 17: Engaging the GPS antenna

1. Engage the GPS antenna on the cowl panel cover.
Microsoft
Fig. 18: Fastening screw for GPS

2. Screw down the GPS antenna with the fastening screw -1- . See Fig. 18.
Microsoft

3. When installing the cowl panel cover, push on the electrical plug until the plug can be felt to engage.
SUBSEQUENT WORK
Subsequent work for GPS antenna
Depending on the I No., --> 914719 Removing and installing radio antenna - installing
91 24 19 REMOVING AND INSTALLING CAR RADIO CD PLAYER - AS OF

TOOLS

Microsoft
PRELIMINARY WORK
Preliminary work for car radio
Remove both covers on center console. Refer to 68 14 19 Removing and installing center console cover - as
REMOVING THE CAR RADIO
Removing the car radio
Fig. 20: Screw locking device

1. Loosen the side fastening screws a few turns.
Microsoft
Fig. 21: Mounting of the radio

2. Insert an Allen key sideways into the screw connection of the radio latch hooks.
3. Close the latches (2 each side) with an Allen key -A- and carefully pull out the radio. See Fig. 21.
4. For reinstallation, open the latches with the Allen key -B- . See Fig. 21.
The number of plug connections will vary, depending on the I No. (CD changer, amplifier, etc.).
The variant without additional audio components (external Most control units) has a jumper (output to input)
connected to the optical waveguide plug.
Microsoft
Fig. 22: Radio plug connections

5. Unlock antenna plug -D, E- and remove. See Fig. 22.
6. Unlock and disconnect the electrical plug connections in the order -A, B, C- . See Fig. 22.
INSTALLING THE CAR RADIO
Installing the car radio
Microsoft
Fig. 23: Plug connections

1. Connect the electric plug connections in the sequence -C, B, A- and the antenna amplifiers -D, E- so that the
plugs are felt to engage. See Fig. 23.
Microsoft
Fig. 24: Locking tabs shown on the PCM

2. Check that the locking tabs on the radio are out, opening the locking mechanism with an Allen key if
necessary.
NOTE: Before sliding the PCM/radio into the installation slot, make sure that the
electric lines are not trapped by the PCM/radio or damaged .
After installation of a new display and PCM/radio operator control unit, the
system must be activated with the PIWIS tester P 9718. --> 911019 Removing
and installing display and PCM operator control unit - programming
3. Push the radio into the installation slot until the locking mechanisms engage on the radio housing.
Microsoft
Fig. 25: Screw locking device

4. Screw in the locking screw for the radio and tighten it.
SUBSEQUENT WORK
Subsequent work for car radio
Install both covers on center console. Refer to 68 14 19 Removing and installing center console cover - as of
READING OUT CAR RADIO
Reading out and transferring car radio codes
Microsoft
4. Select CDR24 with the cursor keys and press the >> .
5. In the menu CDR24 , select Control unit replacement and press the >> .
6. Select Read codes and press >> .
7. On the screen of the PIWIS tester appears the message Coding read-out complete >> .
8. Switch off ignition and replace radio. --> 912419 Removing and installing car radio "CD player" -
chapter on "Removing" --> 912419 Removing and installing car radio "CD player" - chapter on
"Installing"
9. Switch on ignition. After replacement of the radio, the data previously read out (see Item 7) is reloaded under
the menu Write in codes . >> .
10. PIWIS tester displays Coding write-in complete >> .
11. In the menu CDR24 , select Required & Actual installed components list and press >> .
12. Compare the Actual/Required listing.
13. Remove ignition key, close and lock vehicle, then unlock and switch on ignition
15. Car radio is now taught.
PROGRAMMING CAR RADIO
Programming the car radio
Microsoft
4. Select CDR24 with the cursor keys and press the >> .
The following codings can be performed:
6. Select PCM code , enter and code with F8 .
7. Select Traffic broadcast loudspeaker boost and code with F8 .
8. Select GAL (NLB) and code with F8 .

911 (997)
Boxster (987)

Coupe
Cabriolet
Targa
Microsoft
Air conditioning
Without air conditioning
With air conditioning
12. Select Tuner parameters and code with F8 .
Tuner parameters
Europe
USA
South America
Australia
Asia
(South) Africa
Japan
13. Select ASK amplifier and code with F8 .
ASK amplifier
Not installed
Installed
14. Select Loudness and code with F8 .
Loudness
off
on
15. Select Factory settings and code with F8 .
Factory settings
no
yes
16. In the menu CDR24 , change to MOST actual installed components list ; here a version (e. g. CD
changer) installed in the vehicle must be displayed
17. Change to MOST required installed components list ; here too the same version (e. g. CD changer) must
be displayed - if this is not the case, select the version and code with F8 .
18. Select Required & Actual configuration and press the >> .
Microsoft
19. Compare the Actual/Required listing. Use F8 to start Mapping . All installed audio components must now
be listed with a plus under Actual/Required. If this is not the case, the versions in the MOST actual installed
components list or MOST required installed components list must be coded manually.
21. Use << to quit the menu CDR24 .
22. Remove ignition key, close and lock vehicle, then unlock and switch on ignition
23. In the menu CDR24 select Control unit replacement and perform the functions Read codes and Write
codes .
25. Car radio is now taught.
91 28 55 REPLACING THE ANTENNA LEADS - AS OF MY 2005 (ALL

MODELS)
PRELIMINARY WORK
Preliminary work for PCM/radio antenna lead up to antenna control unit
1. Remove cover for center console on the left and right. Refer to 68 14 19 Removing and installing center
console cover - as of MY 2005 (All Models) .
2. Remove PCM display and operator control unit. --> 911019 Removing and installing PCM display and
operator control unit - section on "Removing"
Preliminary work for antenna lead for left antenna amplifier up to right antenna amplifier
1. Remove A-pillar trim panel on the left and right. Refer to 70 57 19 Removing and installing A-pillar trim -
as of MY 2006 (Cayman S, Cayman S RHD) . Refer to 70 57 19 Removing and installing A-pillar trim - as
2. Remove trim panel under dashboard on the left and right. Refer to 70 19 19 Removing and installing trim
3. Remove glove compartment. Refer to 68 15 19 Removing and installing glove compartment - as of MY

2005 (All Models) .
4. Remove right air guide. Refer to 85 34 19 Removing and installing air guide - as of MY 2005 (All
Models) .
Preliminary work for antenna lead for left antenna amplifier up to KESSY/PAS control unit
Microsoft
1. Remove A-pillar trim panel on the left. Refer to 70 57 19 Removing and installing A-pillar trim - as of
MY 2006 (Cayman S, Cayman S RHD) . Refer to 70 57 19 Removing and installing A-pillar trim - as of
2. Remove trim panel under dashboard on left. Refer to 70 19 19 Removing and installing trim under
dashboard - as of MY 2005 (All Models) .
3. Remove control unit for KESSY/PAS. Refer to 96 66 19 Removing and installing KESSY/PAS control
Preliminary work for antenna lead for right antenna amplifier up to rod antenna
1. Remove rear part of right front wheel housing liner. Refer to 50 56 19 Removing and installing front wheel
housing liner - as of MY 2005 (All Models) ..
3. Remove battery cover. Refer to 27 06 19 Removing and installing battery - as of MY 2005 (All Models) .
4. Remove cover on the left and right. Refer to 85 22 19 Removing and installing cover - as of MY 2005 (All
Models) .
5. Remove A-pillar trim panel on the right. Refer to 70 57 19 Removing and installing A-pillar trim - as of
MY 2006 (Cayman S, Cayman S RHD) . Refer to 70 57 19 Removing and installing A-pillar trim - as of

2005 (All Models) .
Models) .
Preliminary work for navigation unit antenna lead up to GPS antenna
1. Remove cowl panel cover. Refer to 50 87 19 Removing and installing cowl panel cover - as of MY 2005
(All Models) .
2. Remove navigation unit. --> 911219 Removing and installing navigation unit - section on "Removing"
3. Remove luggage compartment trim panels. Refer to 70 05 19 Removing and installing front luggage
compartment trim panel - as of MY 2005 (All Models) .
5. Detach relay carrier 1. Refer to 97 83 19 Removing and installing relay carrier 1 - as of MY 2005 (All
Microsoft
Models) .

2005 (All Models) .
Models) .
INSTALLING THE ANTENNA LEADS
Installing antenna leads
CAUTION: Risk of destruction when removing electric components with the ignition
on.
Fig. 26: Overview of antenna leads, shown on the 911

A - PCM/radio
B - Antenna control unit
C - Antenna amplifier, left
D - Antenna amplifier, right
E - KESSY/PAS control unit

Microsoft
F - Rod antenna
G - Navigation unit
H - GPS antenna

NOTE:  The number of plugs can vary, depending on the vehicle equipment.
1. Release and pull off connectors -D and E- on the damaged antenna lead on the affected components. The
illustration shows the connectors for the PCM display and operator control unit as an example. See Fig. 27.
2. Cut off the connectors on the damaged antenna lead, then insulate it and tie it to the main wire harness.
Microsoft
Fig. 28: Securing antenna lead to the main wire harness

3. Route the new antenna lead along the main wire harness, guide it through the existing cable ducts and tie it to
the main wire harness using tie-wraps.
Microsoft

4. Connect the connectors -D and E- for the new antenna lead to the affected components until the connectors
are felt to engage. The illustration shows the connectors for the PCM display and operator control unit as an
example. See Fig. 29.
SUBSEQUENT WORK
Subsequent work for PCM/radio antenna lead up to antenna control unit
1. Install PCM display and operator control unit. --> 911019 Removing and installing PCM display and
operator control unit - section on "Installing"
2. Install cover for center console on the left and right. Refer to 68 14 19 Removing and installing center
console cover - as of MY 2005 (All Models) .
Subsequent work for antenna lead for left antenna amplifier up to right antenna amplifier
1. Install right air guide. Refer to 85 34 19 Removing and installing air guide - as of MY 2005 (All Models) .

2005 (All Models) .
3. Install trim panel under dashboard on the left and right. Refer to 70 19 19 Removing and installing trim
Microsoft
4. Install A-pillar trim panel on the left and right. Refer to 70 57 19 Removing and installing A-pillar trim -
as of MY 2006 (Cayman S, Cayman S RHD) . Refer to 70 57 19 Removing and installing A-pillar trim - as
Subsequent work for antenna lead for left antenna amplifier up to KESSY/PAS control unit
1. Install control unit for KESSY/PAS. Refer to 96 66 19 Removing and installing KESSY/PAS control unit
2. Install trim panel under dashboard on the left. Refer to 70 19 19 Removing and installing trim under
3. Install A-pillar trim panel on the left. Refer to 70 57 19 Removing and installing A-pillar trim - as of MY
2006 (Cayman S, Cayman S RHD) . Refer to 70 57 19 Removing and installing A-pillar trim - as of MY
Subsequent work for antenna lead for right antenna amplifier up to rod antenna

2005 (All Models) .
3. Install A-pillar trim panel on the right. Refer to 70 57 19 Removing and installing A-pillar trim - as of MY
2006 (Cayman S, Cayman S RHD) . Refer to 70 57 19 Removing and installing A-pillar trim - as of MY
4. Install cover on the left and right. Refer to 85 22 19 Removing and installing cover - as of MY 2005 (All
Models) .
5. Install battery cover. Refer to 27 06 19 Removing and installing battery - as of MY 2005 (All Models) .
7. Install rear section of front right wheel housing liner. Refer to 50 56 19 Removing and installing front
wheel housing liner - as of MY 2005 (All Models) .
Subsequent work for navigation unit antenna lead up to GPS antenna

2005 (All Models) .
3. Attach relay carrier 1. Refer to 97 83 19 Removing and installing relay carrier 1 - as of MY 2005 (All
Models) .
Microsoft
5. Install trim panels for luggage compartment. Refer to 70 05 19 Removing and installing front luggage
6. Install navigation unit. --> 911219 Removing and installing navigation unit - section on "Installing"
7. Install cowl panel cover. Refer to 50 87 19 Removing and installing cowl panel cover - as of MY 2005 (All
Models) .
91 36 19 REMOVING AND INSTALLING SUBWOOFER - AS OF MY 2005

PRELIMINARY WORK
Preliminary work for subwoofer
Move convertible top to service position. Refer to 61 01 IN Diagram of convertible top - as of MY 2005
REMOVING SUBWOOFER
Removing subwoofer
Microsoft

1. Remove ignition key and switch off audio system.
Microsoft
Fig. 31: Opening the screw plugs

2. Open the screw plugs by turning in the -A- direction. See Fig. 31.
Microsoft
Fig. 32: Opening lid on the subwoofer

3. Open the subwoofer lid on the left side -A- . See Fig. 32.
Microsoft

4. The electric connector for the subwoofer is located under the lid. Release and unplug connector.
5. Pull subwoofer out to the rear.
INSTALLING SUBWOOFER
Installing subwoofer
1. Position the subwoofer from behind on the engine compartment lid.
Microsoft
Fig. 34: Inserting plug connection from subwoofer

2. Insert the plug connection from the subwoofer until the connector audibly engages.
3. Close subwoofer lid.
Microsoft
Fig. 35: Screwing down screw plugs for subwoofer

4. Screw down the subwoofer screw plugs on the left and right -A- . See Fig. 35.
SUBSEQUENT WORK
Touch up for subwoofer
Move convertible top from the service position and check operation. Refer to 61 01 IN Diagram of convertible
top - as of MY 2005 (Boxster, Boxster RHD, Boxster S, Boxster S RHD) .
91 36 19 REMOVING AND INSTALLING SUBWOOFER - AS OF MY 2006

REMOVING SUBWOOFER
Removing subwoofer
The subwoofer is located next to the center console under the glove box cover.
1. Switch ignition off, remove ignition key and switch off audio system.
Microsoft
Fig. 36: Removing subwoofer cover

2. Unclip cover.
Microsoft
Fig. 37: Unscrewing fastening screw for cover

3. Unscrew fastening screw -1- for subwoofer cover and remove cover. Disconnect electric plug connection for
socket. See Fig. 37.
Microsoft
Fig. 38: Unscrewing fastening screw and disengaging subwoofer

4. Unscrew fastening screw -2- for subwoofer and slide subwoofer to the rear. See Fig. 38.
Microsoft

5. Release connector and remove from subwoofer.
INSTALLING SUBWOOFER
Installing subwoofer
Microsoft
Fig. 40: Connecting connector on subwoofer

1. Push in electric plug for subwoofer until it is felt to engage.
Microsoft
Fig. 41: Engaging and screwing down subwoofer

2. Engage subwoofer at the four retaining clips, slide forwards and screw down with the fastening screw -2- .
See Fig. 41.
Microsoft
Fig. 42: Screwing down cover for subwoofer

3. Connect electric connector for socket in cover of subwoofer, position the cover and screw down with the
fastening screw -1- . See Fig. 42.
Microsoft
Fig. 43: Engaging cover for subwoofer.

4. Position and engage cover for subwoofer.
91 38 19 REMOVING AND INSTALLING ROD ANTENNA - AS OF MY 2005

(ALL MODELS)
PRELIMINARY WORK
Preliminary work
housing liner - as of MY 2005 (All Models) ..
REMOVING ROD ANTENNA
Removing rod antenna
Microsoft
Fig. 44: Installation location for rod antenna

1. Remove the ignition key and switch off the audio system.
2. Unscrew antenna rod on the antenna base cover.
Microsoft
Fig. 45: Antenna base cover

3. Unscrew fastening nut -B- and remove antenna base cover -A- . See Fig. 45.
4. Remove -arrow- seal. See Fig. 45.
Microsoft
Fig. 46: Antenna base connector

5. Take out antenna base downward and pull off both connectors -A and B- from the antenna base. See Fig. 46.
INSTALLING ROD ANTENNA
Installing rod antenna
Microsoft
Fig. 47: Antenna base connector

1. Push both connectors -A and B- onto the antenna base until they are felt to engage. See Fig. 47.
Microsoft
Fig. 48: Inserting the antenna base

2. Insert antenna base in the cut-out from below. The bar of the antenna base must be inserted in the guide nut -
A- while doing so. See Fig. 48.
Fig. 49: Inserting the seal on the antenna base cover

3. Insert seal with the locating pins -A- in the holes -B- on the antenna base cover. See Fig. 49.
NOTE: The seal (arrow) must make contact all the way around on the antenna base
cover.
Microsoft
Fig. 50: Antenna base cover

4. Position antenna base cover -A- and tighten the fastening nut -B- . --> Tightening torque: 3 (2 ftlb.) Nm See
Fig. 50.
5. Screw in antenna rod hand-tight in the antenna base cover.
REWORKING
Subsequent work
2. Install rear section of front right wheel housing liner. Refer to 50 56 19 Removing and installing front
wheel housing liner - as of MY 2005 (All Models) .
91 40 19 REMOVING AND INSTALLING FRONT LOUDSPEAKERS - AS OF

PRELIMINARY WORK
Preparation for front loudspeakers (dashboard)
Microsoft
Refer to 70 20 19 Removing and installing cover for dashboard (defroster trim) - as of MY 2005 (All
Models) .
REMOVING FRONT LOUDSPEAKERS (DASHBOARD)
Removing front loudspeakers (dashboard)
The two dashboard loudspeakers are clipped into the instrument panel.
Fig. 51: Unclipping loudspeaker

1. -A- Unclip the speaker with a plastic spatula. See Fig. 51.
2. -B- Unplug electrical plug connection. See Fig. 51.
Removing central speaker from dashboard.
Microsoft
Fig. 52: center speaker cover

1. Remove the cover for the center speaker with a plastic spatula and pull it out upwards.
Microsoft
Fig. 53: center speaker

2. Unscrew both fastening screws -1- for the center speaker. See Fig. 53.
3. Unplug electrical plug connection.
INSTALLING FRONT LOUDSPEAKERS (DASHBOARD)
Installing front loudspeakers (dashboard)
Microsoft
Fig. 54: Clipping in loudspeaker

1. -A- Plug in the electrical plug connection to the speaker. See Fig. 54.
2. -B- Clip the speaker into the dashboard and check that it is firmly in place. See Fig. 54.
Installing the center speaker into the instrument panel
Microsoft
Fig. 55: center speaker

1. Plug in the electrical plug connection to the speaker.
2. Position the speaker on the instrument panel and screw it down tight with fastening screws -1- . --> 4.2: 3.0
ftlb. +/-0.5 ftlb. See Fig. 55.
Microsoft
Fig. 56: Clipping in cover

3. Position cover for center speaker and clip into dashboard.
SUBSEQUENT WORK
Subsequent work for front speakers (dashboard)
Refer to 70 20 19 Removing and installing cover for dashboard (defroster trim) - as of MY 2005 (All
Models) .
91 41 19 REMOVING AND INSTALLING FRONT LOUDSPEAKERS - AS OF

PRELIMINARY WORK
Preliminary work - front door speakers
REMOVING FRONT LOUDSPEAKERS (DOOR)
Removing bass speaker
Microsoft
Fig. 57: Bass speaker

1. Release electrical connector -a- and unplug it. See Fig. 57.
2. Unscrew the four fastening nuts -1- and remove the speaker. See Fig. 57.
Removing mid-tone speaker
Microsoft
Fig. 58: Mid-tone speaker

1. Release electrical connector and unplug it.
2. Unscrew the two fastening nuts -2- and remove the speaker. See Fig. 58.
INSTALLING FRONT LOUDSPEAKERS (DOOR)
Installing bass speaker
Microsoft

1. Position the speaker on the door unit carrier and screw it down with the four fastening screws -1- . -->
M6x30: 2.0 ftlb. +/-0.5 ftlb. See Fig. 59.
2. Push in electrical connector for the speaker until it is felt to engage.
Installing mid-tone speaker
Microsoft
Fig. 60: Screwing down loudspeaker

1. Position the speaker on the door trim panel and screw it down with the two fastening screws -2- . --> 5x12:
1.5 ftlb. +0.5 ftlb. See Fig. 60.
2. Push in electrical connector for the speaker until it is felt to engage.
SUBSEQUENT WORK
Subsequent work - front door speakers
91 42 19 REMOVING AND INSTALLING REAR LOUDSPEAKER - AS OF MY

PRELIMINARY WORK
Preliminary work for rear loudspeaker
Remove spring strut trim panel, left and right. Refer to 70 23 19 Removing and installing trim panel for
spring strut mount - as of MY 2006 (Cayman S, Cayman S RHD) .
REMOVING REAR LOUDSPEAKER

Microsoft
Removing rear loudspeaker
Fig. 61: Installation position of rear loudspeaker


Microsoft
2. Remove loudspeaker from trim panel of spring strut.
INSTALLING REAR LOUDSPEAKER
Installing rear loudspeaker

1. Insert loudspeaker into the spring strut trim panel and screw tight with the two fastening screws -1- . See Fig.
63.
SUBSEQUENT WORK
Subsequent work for rear loudspeaker
Install spring strut trim panel, left and right. Refer to 70 23 19 Removing and installing trim panel for spring
strut mount - as of MY 2006 (Cayman S, Cayman S RHD) .
91 44 19 REMOVING AND INSTALLING LOUDSPEAKER AMPLIFIER - AS OF

TOOLS
Microsoft

REMOVING LOUDSPEAKER AMPLIFIER
Removing speaker amplifier
Microsoft

NOTE: If the amplifier is to be replaced, the coding must be read out using the PIWIS
tester P 9718 before removing the amplifier.
1. Remove panel for hazard warning triangle and tire air bottle.
Fig. 65: Metal clips for amplifier

2. Remove sheet metal clips -1- from amplifier. See Fig. 65.
Microsoft
Fig. 66: Amplifier bracket

3. Pull amplifier out of its two retaining brackets -2- . See Fig. 66.
Microsoft
Fig. 67: Electric connector

4. Release electric connector -3- and remove from amplifier. See Fig. 67.
INSTALLING LOUDSPEAKER AMPLIFIER
Installing loudspeaker amplifier
Microsoft
Fig. 68: Electrical connector

1. Push electric connector -3- onto the amplifier and lock it. See Fig. 68.
Microsoft
Fig. 69: Amplifier bracket

2. Push the amplifier into its two brackets -2- and allow it to rest on the guide rail. See Fig. 69.
Microsoft
Fig. 70: Metal clips for amplifier

3. Push amplifier into its brackets and clip on the metal clips -1- . See Fig. 70.
PROGRAMMING LOUDSPEAKER AMPLIFIER
Reading out and writing to the BOSE loudspeaker amplifier
Microsoft
Continue.
3. Using the >> key, move from Vehicle type to the list of Control units and perform the automatic control
unit search.
4. Select PCM2 with the cursor keys and press the >> key.
5. Select External BOSE amplifier with the cursor keys and press the >> key.
6. Select Coding using the cursor keys and press >> .
7. Select Read out coding (codings) with the cursor keys and press >> .
11. In the menu Write in coding >>, the data read out are installed.
12. In Coding select the version and follow the instructions of the Tester.
Coding the BOSE loudspeaker amplifier
The PCM 2 code from the IPAS is needed for coding the loudspeaker amplifier.
Microsoft
Continue.
3. Using the >> key, move from the vehicle type to the list of control modules. Perform the automatic control
module search.
4. Select the relevant control module with the cursor keys and press the >> key.
6. Select the version required for the vehicle in question, code it with F8 and follow the instructions on the
Tester.
911 (997)
Boxster (987)
Coupe
Vehicle version vehicle coding Cabriolet
Targa
Left-hand drive
Right-hand drive
Normal bass box
Bass box
Large bass box (50l)
PCM 2 code Enter PCM 2 code
8. PerformVehicle handover and follow the instructions of the tester.
91 47 19 REMOVING AND INSTALLING RADIO ANTENNA - AS OF MY 2005

(ALL MODELS)
PRELIMINARY WORK
Preliminary work - radio antenna
Removing and installing cowl panel cover - removing. Manufacturer does not provide specific instructions.
REMOVING RADIO ANTENNA
Removing radio antenna
Microsoft

Microsoft
Fig. 72: Antenna lead

1. Before removing cowl cover, unclip the retaining clamps for the antenna lead. Disconnect antenna lead and
undo the fastening screws -1- . See Fig. 72.
Microsoft
Fig. 73: Radio antenna installation

2. Turn around cowl cover and unscrew the two fastening screws -3- . See Fig. 73.
3. Unclip the radio antenna from the cowl in both places -2- . See Fig. 73.
INSTALLING RADIO ANTENNA
Installing radio antenna
Microsoft
Fig. 74: Radio antenna installation

1. Clip the antenna onto the cowl cover to the left and right -2- . See Fig. 74.
2. Screw down radio antenna with both fastening screws -3- . See Fig. 74.
Microsoft
Fig. 75: Antenna lead

3. Connect the antenna lead and clip on the fuse.
4. Position the antenna on its bracket and screw it down tight with fastening screws -1- . See Fig. 75.
SUBSEQUENT WORK
Subsequent work - radio antenna
Removing and installing cowl panel cover - removing. Manufacturer does not provide specific instructions.
91 57 19 REMOVING AND INSTALLING MICROPHONE FOR TELEPHONE -

Microsoft

PRELIMINARY WORK
Preliminary work - microphone
Removing and installing trim - removing --> STEERING. . Manufacturer does not provide specific
instructions.
REMOVING MICROPHONE FOR TELEPHONE
Removing microphone for telephone
Fig. 76: Removing steering column trim.

1. Unscrew the two fastening screws -1- for the steering column trim. See Fig. 76.
2. Disconnect the electrical plug and remove the upper part of the steering column trim.
Microsoft
Fig. 77: Microphone wiring

3. Unclip the microphone and the electrical connector from the steering column trim -A- . See Fig. 77.
INSTALLING MICROPHONE FOR TELEPHONE
Installing microphone for telephone
Microsoft
Fig. 78: Microphone wiring

1. Insert the wiring harness with the microphone into the steering column trim.
2. Position the microphone and connector and clip them into the trim.
3. Position the upper part of the steering column trim back over the steering column, plug in the connector and
screw the top part of the trim down tight with fastening screws.
SUBSEQUENT WORK
Subsequent work - microphone for telephone
Refer to 48 15 19 Removing and installing steering column center - as of MY 2005 (All Models) .
91 60 19 REMOVING AND INSTALLING CD CHANGER - AS OF MY 2005

(ALL MODELS)
PRELIMINARY WORK
Preliminary work - removing CD changer
Microsoft
Refer to 70 30 19 REMOVING AND INSTALLING FRONT LUGGAGE COMPARTMENT COVER -

REMOVING CD CHANGER
Removing CD changer

A - CD changer
Microsoft
Fig. 80: Retaining clips

1. Push both retaining clips -A- back. See Fig. 80.
Microsoft
Fig. 81: Removal

2. Jerk the CD changer with its retaining bracket forward.
Microsoft
Fig. 82: Electrical connectors

3. Release the electrical connectors and unplug them.
Microsoft

4. Unscrew the 6 fastening screws -6- and pull the CD changer out of its retaining bracket. See Fig. 83.
Removing the US version of the CD changer.
Microsoft

A - CD changer

1. Unscrew the 6 fastening screws -1- and pull the CD changer out of its retaining bracket. See Fig. 85.
Microsoft
Fig. 86: Electrical connectors

2. Release the electrical connectors -4, 5- and unplug them. See Fig. 86.
Microsoft
Fig. 87: Removing holder for CD changer

3. Undo the two fastening screws -2- . See Fig. 87.
4. Pull out holder for CD changer -1- toward the front from both fastening parts -4- and take off. See Fig. 87.
INSTALLING CD CHANGER
Installing CD changer
Microsoft
Fig. 88: CD changer adjusting screw position

NOTE: If a new CD changer is installed, the adjusting screw must be in position H .
Microsoft
Fig. 89: Retaining clips

1. Replace retaining clips for CD changer retaining frame.
Microsoft

2. Insert the CD changer into its retaining frame and screw down tight with the six fastening screws -6- . -->
Tightening torque: 2.5 (2 ftlb.) Nm See Fig. 90.
Microsoft
Fig. 91: Electric connectors

3. Insert electric connectors into the audio components until they are felt to engage.
Microsoft
Fig. 92: Installation

4. Position the support with the CD changer already attached on the body and move it backwards until the
support clicks into place.
5. Check whether the clips have engaged in the body by pulling the CD changer.
Installing the US version of the CD changer.
Microsoft
Fig. 93: CD changer adjusting screw position

NOTE: If a new CD changer is installed, the adjusting screw must be in position H .
Microsoft
Fig. 94: Installing holder for CD changer

1. Check both sheetmetal clips -3- and both fastening parts -4- , replace if necessary. See Fig. 94.
2. Press in holder for CD changer -1- with both fastening parts -4- to the body and tighten both fastening
screws. --> Tightening torque: 6.5 (5 ftlb.) Nm See Fig. 94.
Microsoft

3. Plug the electrical connectors -4, 5- into the CD changer until they are felt to engage. See Fig. 95.
Microsoft
Fig. 96: Fastening screw

4. Insert the CD changer into its retaining frame and screw down tight with six fastening screws -1- . -->
SUBSEQUENT WORK
Subsequent work - CD changer
Refer to 70 30 19 REMOVING AND INSTALLING FRONT LUGGAGE COMPARTMENT COVER -

91 61 19 REMOVING AND INSTALLING MULTI-FUNCTION REMOTE

CONTROL - AS OF MY 2005 (ALL MODELS)
PRELIMINARY WORK
Preliminary work for multi-function remote control
Remove driver's airbag unit. Refer to 69 58 19 Removing and installing driver's airbag unit - as of MY 2005
(All Models) .
REMOVING MULTI-FUNCTION REMOTE CONTROL
Microsoft
Removing multi-function remote control
Fig. 97: Installation position of steering wheel, shown on the 911

Fig. 98: Removing remote control from steering wheel

Microsoft
1. Unscrew the fastening screws -2- and washers -3- for the remote control and carefully lever the remote
control out using a screwdriver. See Fig. 98.
Fig. 99: Releasing plug connection on the remote control

2. Release the electric plug connection on the remote control -A- and disconnect it. See Fig. 99.
3. Remove remote control.
INSTALLING MULTI-FUNCTION REMOTE CONTROL
Installing multi-function remote control
Microsoft
Fig. 100: Connecting plug connection on the remote control

1. Insert electric connector into the remote control until it clicks into place.
Microsoft
Fig. 101: Installing remote control

2. Insert remote control into the steering wheel, position washers -3- and screw down with the fastening screw -
2- . See Fig. 101.
SUBSEQUENT WORK
Subsequent work for multi-function remote control
Install driver's airbag unit. Refer to 69 58 19 Removing and installing driver's airbag unit - as of MY 2005
(All Models) .
91 62 19 REMOVING AND INSTALLING CONTROL UNIT FOR STEERING

WHEEL ELECTRONICS - AS OF MY 2005 (ALL MODELS)
TOOLS

Microsoft
PRELIMINARY WORK
Preliminary work
1. Remove driver's airbag unit. Refer to 69 58 19 Removing and installing driver's airbag unit - as of MY
2005 (All Models) .
2. Remove steering wheel. Refer to 48 10 19 Removing and installing steering wheel - as of MY 2005 (All
Models) .
3. Remove steering column trim. --> STEERING. . Manufacturer does not provide specific instructions.
4. Remove steering column switch. Refer to 94 50 19 Removing and installing steering-column switch - as of
REMOVING CONTROL UNIT FOR STEERING WHEEL ELECTRONICS
Removing control unit for steering wheel electronics
NOTE: The control unit for steering wheel electronics is bolted to the steering-column
switch.
Before the ground strap of the battery is disconnected, the data in the control
unit for steering wheel electronics must be read out using the Porsche System
Tester.
Microsoft
Fig. 102: Position of markings

NOTE:  Ensure that the arrow -A- of the rotor is positioned between the markings -
B- of the arrows -C- of the airbag contact unit and that the latch -D- is
engaged. See Fig. 102.
Fig. 103: Removing contact unit

1. Remove contact unit.
1.1. Carefully lift up the three retaining tabs and remove airbag contact unit.

Microsoft
2. Unscrew fastening screws for steering wheel electronics control unit.
2.1. Unscrew the five fastening screws.
Fig. 105: Pushing out the line holder

3. Push out the line holder.
3.1. Push line holder down and out of the steering-column switch.
Microsoft
Fig. 106: Removing control unit for steering wheel electronics

4. Remove control unit for steering wheel electronics.
4.1. Turn steering column switch round and remove control unit for steering wheel electronics.
INSTALLING CONTROL UNIT FOR STEERING WHEEL ELECTRONICS
Installing control unit for steering wheel electronics
WARNING: Risk of damaging airbag contact unit.
 If the airbag contact unit has been adjusted, proceed in accordance

with the following work instruction:
--> Then turn the rotor carefully to the right, approx. 3.5 to 3.75 revolutions, until the band printed on one side
is visible in the window.
Microsoft
Fig. 107: Mounting control unit for steering wheel electronics

1. Install control unit for steering wheel electronics.
1.1. Position control unit for steering wheel electronics on the steering-column switch.
Microsoft
Fig. 108: Pushing on line holder

2. Push on line holder.
2.1. Push line holder onto steering-column switch.
Microsoft

3. Unscrew fastening screws for steering wheel electronics control unit
3.1. Turn the steering column switch round and screw in the five fastening screws.
Fig. 110: Engaging contact unit

4. Install contact unit.
4.1. Position airbag contact unit and press onto the steering column switch until the three tabs are felt to engage.
SUBSEQUENT WORK
Subsequent work
Microsoft
1. Install steering column switch. Refer to 94 50 19 Removing and installing steering-column switch - as of
2. Install steering column trim. --> STEERING. . Manufacturer does not provide specific instructions.
3. Install steering wheel. Refer to 48 10 19 Removing and installing steering wheel - as of MY 2005 (All
Models) .
4. Install driver's airbag unit. Refer to 69 58 19 Removing and installing driver's airbag unit - as of MY 2005
(All Models) .
5. Read data into the control unit for steering wheel electronics.
6. Calibrating steering angle sensor
READING DATA OUT OF AND WRITING DATA INTO THE CONTROL UNIT FOR STEERING
WHEEL ELECTRONICS.
Reading and printing values
NOTE:  If reading out the data is not possible, the new control unit for steering
wheel electronics must be coded. --> 916219 Removing and installing
control unit for steering wheel electronics - chapter on "Coding"
Continue.

Microsoft
4. Select steering wheel electronics with the cursor keys and press the >> key.
7. The message Codes successfully read out appears on the screen of the Porsche System Tester. Press >> .
8. Switch off ignition and replace control unit. --> 916219 Removing and installing control unit for steering
wheel electronics - section on "Removing"
12. In the menu Write in data >>, the data read-out is installed.
13. System tester displays Coding write-in complete >> .
CODING CONTROL UNIT FOR STEERING WHEEL ELECTRONICS
Coding control unit for steering wheel electronics
Microsoft
7. Select the control unit Steering wheel electronics and activate with the >> key.
8. Select Coding and activate with the >> key.
9. Select the respective equipment versions and code them.
Coding Setting
Tiptronic yes/no
Multi-function steering wheel yes/no
Cruise control yes/no
Headlight washing system yes/no
Push-to-talk yes/no
Rear wiper/washer system yes/no
10. Follow the instructions on the Tester.
11. Calibrate steering angle sensor . --> 916219 Remove and install control unit for steering wheel
electronics - section on "Calibration"
12. Carry out a test drive and read out fault memory.
CALIBRATING STEERING-ANGLE SENSOR
NOTE:  The steering-angle sensor must be recalibrated on the measuring platform

following repairs to or work on the chassis/steering or if the steering-angle
sensor/steering column switch/hydraulic unit is replaced.
 In order to be able to calibrate the steering angle sensor correctly, the
vehicle must be on the measuring platform, the wheel alignment values
correct and the steering in the straight-ahead position.
Microsoft
 The security code is displayed in the Porsche System Tester under menu
PSM , Actual values , Security code .
The steering angle sensor must be calibrated using the menu with PIWIS tester under the specified test
conditions:
2. Turn wheels or steering wheel to straight-ahead position. In the straight-ahead position, the steering wheel
must deviate by no more than ± 2.0° from the horizontal position (steering center position).
3. Before calibrating, first turn the steering wheel from the straight-ahead position approx. 20° to the left and
20° to the right (past straight-ahead position).
4. Turn wheels or steering wheel to straight-ahead position and calibrate the steering-angle sensor in the menu
PSM , Calibration . To calibrate, you must enter the security code in the actual values menuPSM , Actual
values .
5. Enter security code and confirm with F7 .
6. Turn steering-wheel to Tester default position.
7. Tester confirms Calibration successful .
91 68 19 REMOVING AND INSTALLING OUTSIDE TEMPERATURE SENSOR

REMOVING OUTSIDE TEMPERATURE SENSOR
Removing outside temperature sensor
Microsoft

Microsoft
Fig. 112: Outside temperature sensor

1. Pull the outside temperature sensor out of the holder and out through the opening in the floor.
2. Release and unplug electric connector -a- . See Fig. 112.
INSTALLING OUTSIDE TEMPERATURE SENSOR
Installing outside temperature sensor
Microsoft
Fig. 113: Outside temperature sensor

1. Push electrical connector onto outside temperature sensor until it is felt to engage.
2. Insert outside temperature sensor into its holder. Ensure that the temperature sensor is fitted securely.
91 74 19 REMOVING AND INSTALLING CONTROL MODULE FOR

PARKASSIST - AS OF MY 2005 (ALL MODELS)
TOOLS
Microsoft
PRELIMINARY WORK
Preliminary work - control module for ParkAssist
Refer to 72 01 19 Removing and installing front seat - as of MY 2005 (All LHD Models) . Refer to 72 01 19
Removing and installing front seat - as of MY 2005 (All RHD Models) .
REMOVING CONTROL MODULE FOR PARKASSIST
Removing control module for ParkAssist
NOTE: If the ParkAssist control unit has to be replaced, the values from the control
unit should first be read out using the PIWIS Tester P 9718. --> 917419
Removing and installing ParkAssist control unit - chapter on "Programming"

Microsoft
Fig. 115: Control unit holder.

1. Push control unit forwards in direction of travel from behind, unclip it, detach it and turn the holder 180°.
Microsoft
Fig. 116: Mounting point for control unit

2. Push together the retaining tabs for the control unit and pull the two catches back. Lift control unit up and
out.
Microsoft
Fig. 117: Connector


destroyed.
3. -A- Carefully lever the connector away from the control unit using two screwdrivers. See Fig. 117.
4. -B- Carefully lever the connector away from the control unit using one screwdriver. See Fig. 117.
Microsoft
INSTALLING CONTROL MODULE FOR PARKASSIST
Installing control module for ParkAssist
NOTE: If the ParkAssist control unit has to be replaced, the values from the control
unit should first be read out using the PIWIS Tester P 9718. --> 917419
Removing and installing ParkAssist control unit - chapter on "Programming"
Fig. 118: Connector

1. Press electrical connectors -A, B- into control unit until they are felt to engage. See Fig. 118.
Microsoft
Fig. 119: Positioning control unit on its holder

2. Position control unit on its holder, press it in and clip it into the holder.
Microsoft
Fig. 120: Control unit holder.

3. Turn the bracket by 180° into the direction of travel, attach it at the front and clip it into place at the rear.
SUBSEQUENT WORK
Subsequent work - control module for ParkAssist
91 75 19 REMOVING AND INSTALLING SENSOR FOR PARKASSIST - AS OF

Microsoft
PRELIMINARY WORK
Preliminary work - sensor for ParkAssist
Refer to 63 55 19 REMOVING AND INSTALLING REAR APRON - AS OF MY 2006 (CAYMAN S,

CAYMAN S RHD) .
REMOVING SENSOR FOR PARKASSIST
Removing sensor for ParkAssist
Fig. 121: Removing sensor

Microsoft
1. Pull apart retaining tabs -a- and remove sensor -1- . See Fig. 121.
2. Press catch -a- for connector -2- and pull connector off . See Fig. 121.
INSTALLING SENSOR FOR PARKASSIST
Installing sensor for ParkAssist
Fig. 122: Installing sensor

1. Slide the connector -2- onto the sensor -1- until it is felt to engage. See Fig. 122.
2. Insert sensor into mounting point of bumper until retaining tabs on sensor engage.
Microsoft
SUBSEQUENT WORK
Subsequent work - sensor for ParkAssist
Refer to 63 55 19 REMOVING AND INSTALLING REAR APRON - AS OF MY 2006 (CAYMAN S,

CAYMAN S RHD) .
91 77 19 REMOVING AND INSTALLING MULTI-FUNCTION CONTROL UNIT -

PRELIMINARY WORK
Preliminary work for multi-function remote control
Remove driver's airbag unit. Refer to 69 58 19 Removing and installing driver's airbag unit - as of MY 2005
(All Models) .
REMOVING MULTI-FUNCTION CONTROL UNIT
Removing multi-function control unit
NOTE: The control unit is removed and, if necessary, replaced without reading, writing
or coding the data with the PIWIS Tester. This procedure is not required at
present.
NOTE: When removing the locking plate, take note of how many washers are used on
each fastening screw.
During installation make sure that the washers are fitted in the same way as
they were before removal.
Microsoft
Fig. 123: Removing the locking plate

1. Unscrew the four fastening screws -1- from the locking plate in the steering wheel and remove along with the
locking plate. See Fig. 123.
Microsoft
Fig. 124: Removing multi-function control unit

2. Use a screwdriver to carefully lever the multi-function control unit out of the steering wheel.
Microsoft
Fig. 125: Releasing electric plug connection

3. Release electric plug connection -A- and disconnect it from the multi-function control unit. See Fig. 125.
INSTALLING MULTI-FUNCTION CONTROL UNIT
Installing multi-function control unit
NOTE: The control unit is removed and, if necessary, replaced without reading, writing
or coding the data with the PIWIS Tester. This procedure is not required at
present.
Microsoft
Fig. 126: Clipping multi-function control unit into steering wheel

1. Attach electric plug connection to multi-function control unit until the plug clicks into place.
2. Clip multi-function control unit into steering wheel. Check that it is secure.
NOTE: When removing the locking plate, take note of how many washers are used on
each fastening screw.
During installation make sure that the washers are fitted in the same way as
they were before removal.
Microsoft
Fig. 127: Screwing down locking plate

3. Position locking plate on steering wheel and screw down using the four fastening screws -1- and the washers.
--> Tightening torque: 4.5 ftlb. See Fig. 127.
SUBSEQUENT WORK
Subsequent work for multi-function control unit
Install driver's airbag unit. Refer to 69 58 19 Removing and installing driver's airbag unit - as of MY 2005
(All Models) .
91 84 19 REMOVING AND INSTALLING ANTENNA AMPLIFIER - AS OF MY

2005 (ALL MODELS)
PRELIMINARY WORK
Preliminary work - antenna amplifier
Refer to 70 57 19 Removing and installing A-pillar trim - as of MY 2006 (Cayman S, Cayman S RHD) .
Refer to 70 57 19 Removing and installing A-pillar trim - as of MY 2005 (Boxster, Boxster RHD, Boxster
S, Boxster S RHD) .
REMOVING ANTENNA AMPLIFIER

Microsoft
Removing antenna amplifier
NOTE: The antenna amplifier is installed together with the PCM.
The antenna amplifier is located on the A-pillars.
Remove the ignition key and switch off the audio system.
Fig. 128: Connector for antenna amplifier

1. Unplug the antenna plug for the windscreen -1, 2- . See Fig. 128.
2. Unplug the plug connections for the antenna control unit -3, 4- on the left-hand side and -3, 4, 5- on the right-
hand side. See Fig. 128.
3. Unscrew both fastening screws -6- . See Fig. 128.
INSTALLING ANTENNA AMPLIFIER
Installing antenna amplifier
Microsoft
Fig. 129: Connector for antenna amplifier

1. Position the antenna amplifier on the A-pillar and screw down the fastening screws -6- . See Fig. 129.
2. Plug in the connectors for the antenna control unit -3, 4- on the left-hand side and -3, 4, 5- on the right-hand
side. See Fig. 129.
3. Plug in the antenna connectors for the windscreen -1- and -2- . See Fig. 129.
SUBSEQUENT WORK
Subsequent work - antenna amplifier
Refer to 70 57 19 Removing and installing A-pillar trim - as of MY 2006 (Cayman S, Cayman S RHD) .
Refer to 70 57 19 Removing and installing A-pillar trim - as of MY 2005 (Boxster, Boxster RHD, Boxster
S, Boxster S RHD) .
91 86 19 REMOVING AND INSTALLING CONTROL UNIT FOR ANTENNA - AS

PRELIMINARY WORK
Preliminary work - antenna control unit
Microsoft
Remove right-hand panel of center console. --> 68 14 19 REMOVING AND INSTALLING CENTER
CONSOLE COVER - AS OF MY 2005 (ALL MODELS) .
REMOVING CONTROL UNIT FOR ANTENNA
Removing antenna control unit

Microsoft
Fig. 131: Velcro fastening on carpet

2. Undo the velcro strip on the carpet underneath the center console.
Microsoft
Fig. 132: Levering up control unit at both front and rear

3. Push a screwdriver under the control unit and lever it up at the front and rear.
Microsoft
Fig. 133: Releasing electric connectors

4. Release the electric connectors -A- and pull them off the antenna control unit. See Fig. 133.
INSTALLING CONTROL MODULE FOR ANTENNA
Installing antenna control unit
Microsoft

1. Press electrical connectors onto control module until they are felt to engage.
Microsoft
Fig. 135: Installing control module

2. Position control unit on body and secure it with retaining clips.
3. Draw the carpeting beneath the center console together and secure with the velcro fastener.
SUBSEQUENT WORK
Subsequent work - antenna control unit
Install right-hand panel of center console. --> 68 14 19 REMOVING AND INSTALLING CENTER
CONSOLE COVER - AS OF MY 2005 (ALL MODELS) .
91 88 19 REMOVING AND INSTALLING CONSOLE FOR TELEPHONE - AS

REMOVING CONSOLE FOR TELEPHONE
Removing console for telephone
Microsoft

Fig. 137: Unscrewing fastening screw -1-

1. Unscrew the two fastening screws -1- and remove the mounting plate -2- . See Fig. 137.
Microsoft
Fig. 138: Unclipping cap

2. Carefully unclip the cover -3- with a screwdriver. See Fig. 138.
3. Unscrew the fastening screw -4- and remove the carrier -5- . See Fig. 138.
Microsoft
Fig. 139: Unscrewing fastening screw and removing trim

4. Unscrew the fastening screw -6- and remove the trim -7- . See Fig. 139.
Microsoft
Fig. 140: Unscrewing fastening screw and removing telephone console

5. Unscrew the three fastening screws -8- and remove console for the telephone -9- . See Fig. 140.
INSTALLING CONSOLE FOR TELEPHONE
Installing console for telephone
Microsoft
Fig. 141: Positioning and securing telephone console

1. Position console for telephone -9- and screw down with the three fastening screws -8- . --> Tightening
torque: 1.5 ftlb. +/-0.2 ftlb. See Fig. 141.
Microsoft
Fig. 142: Positioning trim and securing with the fastening screw
2. Press trim -7- on the console and screw down with the fastening screw -6- . --> Tightening torque: 1.5 ftlb.
+/-0.2 ftlb. See Fig. 142.
Microsoft
Fig. 143: Positioning and securing carrier

3. Press carrier -5- on the console and screw down with the fastening screw -4- . --> Tightening torque: 1.5
ftlb. +/-0.2 ftlb. See Fig. 143.
4. Position the cover -4- and clip it into place. See Fig. 143.
Microsoft
Fig. 144: Securing mounting plate

5. Secure the mounting plate with the fastening screws -1- . --> Tightening torque: 1.5 ftlb. +/-0.2 ftlb. See
Fig. 144.
6. Place the handset in the bracket.
91 90 19 REMOVING AND INSTALLING CONTROL UNIT FOR TELEPHONE -

PRELIMINARY WORK
Preliminary work - telephone control unit
REMOVING CONTROL UNIT FOR TELEPHONE
Removing control unit for telephone
Microsoft

Fig. 146: Fastening screws for cover

1. Unscrew the two fastening screws -1- and rotate the cover and telephone control unit by 180°. See Fig. 146.
Microsoft
Fig. 147: Inserting the plug


destroyed.
2. Press latch on the electric plug -A- , open the locking lever -a- , and remove plug. See Fig. 147.
3. Press latch on the electric plug -B- for the optical waveguide and remove plug. See Fig. 147.
Microsoft
Fig. 148: Pulling the control unit from the cover

4. Undo both fastening screws -2- on the telephone control unit and pull the control unit from the cover. See
Fig. 148.
INSTALLING CONTROL UNIT FOR TELEPHONE
Installing control unit for telephone
WARNING: If the wiring at the telephone holder is not routed correctly, the wires can
catch at the seat.
 Danger of destroying/damaging wire harness for the telephone

control unit
--> The wire harness at the telephone holder must not be routed over the edge.
Microsoft
Fig. 149: Routing of wire harness

NOTE: The routing of the wire harness for the control unit must be checked before
installing the seat.
The wire harness must not be routed over the cover, but should be laid along side the cover -A- . See Fig. 149.
Microsoft
Fig. 150: Inserting the control unit in the cover.

1. Insert control unit into the cover and screw tight with the two fastening screws -2- . --> Tightening torque: 2
Microsoft

2. Push in electrical plug connections -C, B - until plugs are felt to engage. See Fig. 151.
3. Position plug -A- and close with the locking lever until the retainer clicks into place. See Fig. 151.
Microsoft
Fig. 152: Fastening screws for cover

4. Turn over the cover and telephone control unit, position it on the floor of the vehicle and screw down with
fastening screws -1- . --> Tightening torque: 5 (3.5 ftlb.) Nm See Fig. 152.
If a new telephone control unit has been installed, it must be programmed (coded) in the vehicle. --> 919019
Removing and installing telephone control unit - section on "coding"
SUBSEQUENT WORK
Subsequent work - telephone control unit
CODING CONTROL UNIT FOR TELEPHONE
Coding control unit for telephone
Microsoft
Continue.
3. Using the >> key, move from Vehicle type to the list of Control units and perform the automatic control
unit search.
4. Select PCM2 with the cursor keys and press the >> key.
5. Select Telephone with the cursor keys and press the >> key.
7. Select Read out coding (codings) with the cursor keys and press >> .
9. Switch on ignition. Select Control unit replacement Write in coding >> to install the data that was read
out.
10. Change to the Coding menu, select the following coding variants in sequence and code the vehicle
equipment by pressing F8 . Follow the instructions on the Tester.
10.1. Vehicle type vehicle coding
10.2. Vehicle version vehicle coding
10.3. Air conditioning
10.4. Right/left-hand drive vehicle coding
10.5. Engine version
11. Switch to Telephone function selection and then read out the fault memory and erase it.
Microsoft
91 91 19 REMOVING AND INSTALLING ADDITIONAL RECEIVER FOR

TELEPHONE - AS OF MY 2005 (ALL MODELS)
PRELIMINARY WORK
Preliminary work for additional receiver for telephone
--> 918819 Removing and installing console for telephone - chapter on "removing"
Refer to 68 14 19 Removing and installing center console cover - as of MY 2005 (All Models) .
REMOVING ADDITIONAL TELEPHONE RECEIVER
Removing additional receiver for telephone

Microsoft

2. Cut through the tie-wrap for the electric wire and disengage the wire at the retaining bracket.
3. Release electric plug from additional receiver -A- and unplug it. See Fig. 154.
INSTALLING ADDITIONAL TELEPHONE RECEIVER
Installing additional receiver for telephone
Microsoft
Fig. 155: Connecting plug connection

1. Insert electrical plug for additional receiver until it is felt to engage.
2. Engage electric wire at the retaining bracket and secure with a tie-wrap.
SUBSEQUENT WORK
Subsequent work for additional receiver for telephone
Refer to 68 14 19 Removing and installing center console cover - as of MY 2005 (All Models) .
--> 918819 Removing and installing console for telephone - chapter on "installing"
Microsoft
ACCESSORIES & EQUIPMENT Rear
Rear
53 06 55 REPLACING SIDE SECTION REINFORCEMENT - AS OF MY 2006

TOOLS

Equipment Manual

dimensions

--> 5000AW AW Safety instructions - Chapter entitled "General warning notes"
TOOLS AND MATERIALS
Materials and tools
Microsoft
Spotweld drill NR.129 Star gauges for body gap dimensions NR.127-1 Press-out tool 97290 Pneumatic
body saw No. PS1, see Gr. 3.5; Workshop Equipment Manual 00000 Angle grinder, see Gr. 3.5; see
Workshop Equipment Manual 00000 Oscillating body saw (special electrical cutter), see Gr. 3.5;
Workshop Equipment Manual 00000 Rotary brush, see Gr. 3.5; Workshop Equipment Manual 00000
Hole punch, see Gr. 3.5; Workshop Equipment Manual 00000 Elektron hot-air gun from Leister, see Gr.
3.5; Workshop Equipment Manual 00000 Inverter welding equipment ATL Inverterspot WE1194
00000 Straightening attachments for Boxster (986), see Gr. 3.5; Workshop Equipment Manual 00000
Betamate adhesive 2096 see Gr. 8, Parts Catalogue 00000 Primer for Betamate adhesive 2096 see Gr. 8
Parts Catalogue 00000 Processing nozzle for Betamate adhesive 2096 see Gr. 8 Parts Catalogue 00000
2K-AFS Vario acoustic foam, see Gr. 8 Parts Catalogue 00000
attachment set.
covers.
Microsoft
REMOVING SIDE SECTION REINFORCEMENT
Removing side section reinforcement
Fig. 1: Installation location for side section reinforcement

1. Remove outer hinge pillar. --> 513755 21 Replacing outer hinge pillar - chapter on "Removing"
2. Remove side panel. --> 535555 Replacing rear side section - chapter on "Removing"
Microsoft
Fig. 2: Loosening riveted joints

3. Loosening riveted joints
3.1. Cut through riveted joints in area -A- using a parting grinder and remove. See Fig. 2.

4.1. Mill off spotwelds in area -A- and -B- using a spotweld cutter. See Fig. 3.
Microsoft

NOTE: Removing expanded sealant
 The side section reinforcement is factory-sealed for roof reinforcement

with expanded sealant in area. -Y- . See Fig. 5.
 The expanded sealant will be destroyed when you change the side section
reinforcement and must be replaced.
Fig. 5: Expanded sealant

NOTE: Separating body parts
 In the case of bonded panel joints with a hardened bonded layer on the
outer panel, apply a generous amount of heat to heat up the outer panel in
the area of the spotwelds. Refer to 50 IN Processing structural body
 After removing the loosened body part, old adhesive must be removed and
any uneven spots sanded down. The flange area must then be pre-treated
for bonding. For the procedure see: Information on the use of structural
adhesive in vehicle manufacturing Refer to 50 IN Processing structural
body adhesive - as of MY 2005 (All Models) .
Microsoft
6. Separating bonded joints and removing expanded sealant
6.1. Heat up bonded joints in the area between the side section reinforcement and body using the Leister
Elektron hot-air gun; see Gr. 3.5, Workshop Equipment Manual 00000 and remove side section
reinforcement.
PREPARING CONNECTION AREAS OF THE BODY FOR INSTALLING SIDE SECTION

REINFORCEMENT
welding work!

Preparing connection areas of body for installing side section reinforcement
Microsoft

NOTE:  Keep bonding areas clean and free of grease and do not coat with zinc
powder paint.
Microsoft
Fig. 7: Preparing bonded flanges

3. Preparing bonded flanges
3.1. Sand and clean the bonded flanges in the marked areas -A- and -B- . See Fig. 7.
See: Working with adhesive Refer to 50 IN Processing structural body adhesive - as of MY 2005 (All
Models) .
Microsoft
Fig. 8: Priming bonded flanges

4. Priming bonded flanges
4.1. Prime bonded flanges on the body in the marked areas -A- and -B- . See Fig. 8.
See Working with primer Refer to 50 IN Processing structural body adhesive - as of MY 2005 (All Models) .
FITTING SIDE SECTION REINFORCEMENT AND PREPARING FOR INSTALLATION
Aligning side section reinforcement and preparing for installation
Microsoft

1. Drilling holes for plug welding using inert gas
1.1. Drill holes (Ø = 7 mm) in area -A- for plug welding using shielding gas. Always maintain original spacing.
See Fig. 9.
Fig. 10: Cleaning welding and riveting areas

2. Cleaning welding and riveting areas
2.1. Grind both sides of the connection flanges of the side section reinforcement in the marked areas -A, B, C,
Microsoft
D- until bare using a rotary brush. See Fig. 10.
powder paint.
3. Fitting the side section reinforcement to the body
3.1. Position and fit the side section reinforcement to the body.

5.1. Sand and clean the bonded flanges in the marked areas -A- and -B- . See Fig. 11.
Models) .
Microsoft

6.1. Prime bonded flanges in the marked areas -A- and -B- . See Fig. 12.
INSTALLING SIDE SECTION REINFORCEMENT

safety components!
Microsoft
protective mask.
beginning work.
Installing side section reinforcement
WARNING: Traffic safety warning for bonding structural components with structural
adhesive!
--> Join, fix and resistance spot-weld parts within the processing time. The jointing operation must take place
directly after application of the adhesive in order to guarantee high-quality and reliable bonding. Otherwise the
adhesive bead must be removed and pre-treatment of the surface and application of the adhesive must be
repeated.
--> To ensure that the substance is completely mixed, apply a 30 mm long adhesive bead of fresh adhesive to a
piece of cardboard before processing.
--> Process the adhesive within the processing time. The adhesive must be applied and the body part must be
jointed within this period. Any resistance welding to be carried out in the area of the bonding must be
performed within this period as well. --> Processing time: 60 min
--> Do not apply pressure to bonded parts until hardening is complete!
--> If the contents of the cartridge is not used up completely, the processing nozzle must be kept on the
cartridge until the adhesive hardens. If you intend to use the adhesive again later, a new processing nozzle must
be used.
Microsoft
Fig. 13: Applying adhesive

1. Applying adhesive
1.1. Apply adhesive to the inside of side section reinforcement in the area -A- and -B- in the form of a triangular
bead -dimension X = approx. 3 mm- . See: Working with body structural adhesive Refer to 50 IN Processing
structural body adhesive - as of MY 2005 (All Models) . See Fig. 13.
2. Fitting the side section reinforcement to the body
2.1. Fit the side section reinforcement to the body and fix in place with tensioning clamps.
Microsoft
Fig. 14: Securing the side section reinforcement

3. Securing the side section reinforcement
3.1. Secure the side section reinforcement in the area -A- and -B- with rivets -1- . See Fig. 14.
Microsoft
Fig. 15: Welding in the side section reinforcement

4. Welding in the side section reinforcement
4.1. Resistance spot-weld the side section reinforcement in area -A- and -B- . See Fig. 15.
Fig. 16: Welding in the side section reinforcement

5. Welding in the side section reinforcement
5.1. Plug-weld the side section reinforcement in area -A- using shielding gas. See Fig. 16.
Microsoft
Fig. 17: Filling out side section reinforcement with foam

6. Filling out side section reinforcement with foam
6.1. Fill out the side section reinforcement with foam through the bore in area -A- 2x, 1 sec. each. See Fig. 17.
See: Processing body acoustic foam 2K-AFS Vario. Refer to 50 IN Processing structural body adhesive - as
7. Install side panel. --> 535555 Replacing rear side section - chapter on "Installing"
8. Install outer hinge pillar. --> 513755 23 Replacing outer hinge pillar - chapter on "Installing"
SUBSEQUENT WORK
2005 (All Models) .
Microsoft
53 48 55 REPLACING REAR SIDE MEMBER (SECTION) - AS OF MY 2005

(ALL MODELS)
TOOLS

Equipment Manual

dimensions

TOOLS AND MATERIALS
Microsoft
Tools and materials
Hole punch, see Gr. 3.5; Workshop Equipment Manual 00000 Leister Elektron hot-air gun, see Gr. 3.5;
Workshop Equipment Manual 00000 Inverter welding equipment ATL Inverterspot WE1194 Additional
straightening attachments for 911 Carrera (997), see Gr. 3.5; Workshop Equipment Manual 00000
Test gauge 9748, see Porsche special tools, Workshop Equipment Manual 00000
attachment set.
REMOVING SIDE MEMBER
Possible separation points
Microsoft

1. Possible separation points
1.1. In the rear side member
1.2. The joint on the inner side member must be located in front of the tailored blank weld (laser weld) X , area
a or b at dimension Y = 30 mm .
Removing side member
Microsoft
Fig. 19: Replacement rear side member

A - Inner side member
B - Outer side member
WARNING: Possible separation points on inner side member
--> The possible cuts on the inner side member are located 30 mm in front of the tailored blank (laser weld),
starting from the rear of the vehicle.
Microsoft
Fig. 20: Determination of inner cut

1. Determine cut.
1.1. Mark cut on outer and inner side members.
1.2. The possible cuts on the inner side member are located Y = 30 mm in front of the tailored blank (laser
weld) X , starting from the rear of the vehicle.
1.3. The possible cuts on the outer side members are located V = 50 mm offset from the inner cut.
Microsoft
Fig. 21: Determination of outer cut

Fig. 22: Milling off luggage compartment floor

Microsoft
2. Mill off spotwelds on the luggage compartment floor and outer side member.
2.1. Using a spotweld cutter, mill off the spotwelds between the luggage compartment floor and the inner side
member in area A . Make sure that area A projects beyond point X on the cut.
Fig. 23: Cutting off inner side member

3. Cutting off inner side member
3.1. Using the body saw, cut off the inner side member in front of the tailored blank (laser weld) in area H ;
dimension Y = 30 mm .
Microsoft
Fig. 24: Milling off wheel housing

4. Mill off wheel housing
4.1. Mill off wheel housing in area E using a spotweld cutter. Use an angle drill.
Microsoft
Fig. 25: Cutting off outer side member

5. Cut off outer side member
5.1. Cut off the outer side member and inner side member in area V = 50 mm offset from the cut on the inside
using the body saw.
PREPARING CONNECTION AREA OF BODY FOR INSTALLING REAR SIDE MEMBER
welding work!

Preparing connection areas of the body for installing the side members
Microsoft
Fig. 26: Preparing connection areas of the body for installing the side members
1. Clean the body connection flanges of undersealing, adhesive residues and paint in the marked areas A, H, F,
I using a hot-air gun or rotary brush. Grind the connecting flanges until they are bright.
FITTING FRONT SIDE MEMBER AND PREPARING FOR INSTALLATION
Fitting front side members and preparing for installation
Microsoft
Fig. 27: Transferring the cut for the inner rear side members
1. Transfer the cut to the inner rear side members and make the cut with the body saw. Fasten the replacement
side members on the straightening set for the impact absorbers and fit in place.
Microsoft
Fig. 28: Transferring cut to the outer rear side members

2. Transfer the cut to the outer rear side members and make the cut with the body saw. Pay attention to the
offset, dimension V = 50 mm , on the outer side member with respect to the inner side member.
Microsoft
Fig. 29: Removing primer on welding areas of spare parts using a rotary brush
3. Remove the factory-applied primer on the welding areas of the replacement parts in areas A, B, C, D, E, F, H
using a rotary brush.
INSTALLING REAR SIDE MEMBER (SECTION)

safety components!
Microsoft
protective mask.
beginning work.
welding work!

Installing rear side member (section)
Microsoft
Fig. 30: Welding in inner side member

1. Weld in the inner side member.
1.1. Weld the inner side member with a continuous butt weld under shielding gas in area H . Spot-weld the
inner side member to the outer side member in area B .
Microsoft
Fig. 31: Welding in outer side member

2. Weld in outer side member.
2.1. Weld the outer side member with a continuous butt weld under shielding gas in area F . Spot-weld the outer
side member to the inner side member in area D .
Microsoft
Fig. 32: Plug-welding wheel housing under shielding gas

3. Weld the wheel housing under shielding gas
3.1. Plug-weld the wheel housing under shielding gas in area E .
Microsoft
Fig. 33: Plug-welding luggage compartment floor under shielding gas, spot-welding side members
4. Plug-weld luggage compartment floor under shielding gas and spot-weld side members
4.1. Plug-weld luggage compartment floor and outer side member A under shielding gas.
4.2. Spot-weld outer side member to the inner side member in area C .
1. Removing vehicle from alignment bench
4. Restore standard sealing with body sealant Refer to 50 IN Processing structural body adhesive - as of MY
2005 (All Models) .
5. Restore standard undersealing with underbody sealant Refer to 50 IN Processing structural body adhesive -
7. Install removed accessories in the repair area

Microsoft
8. Applying cavity preservation
53 16 55 REPLACING CLOSING CROSS MEMBER - AS OF MY 2005 (ALL

MODELS)
TOOLS

Equipment Manual

dimensions

TOOLS AND MATERIALS
Tools and materials
Microsoft
attachment set.
covers.
REMOVING CLOSING CROSS MEMBER
Removing closing cross member
Microsoft
Fig. 34: Installation location for closing cross member


Microsoft

2.1. Separate spotwelds in area -A- and -B- using a parting grinder. See Fig. 36.

3.1. Separate inert-gas welded seams in area -A- and -B- using a parting grinder. See Fig. 37.
Microsoft
Fig. 38: Making a rough cut

4. Making a rough cut
4.1. Make a rough cut in area -A- on the right and left in order to expose covered areas. See Fig. 38.

5.1. Mill off spotwelds at the right and left in area -A- and -B- using a spotweld cutter. See Fig. 39.
Microsoft

6.1. Mill off spotwelds on the right and left in area -A- using a spotweld cutter (2 plate thicknesses). See Fig.
40.
PREPARING CONNECTION AREAS OF THE BODY FOR INSTALLING THE CLOSING CROSS
MEMBER
welding work!

Preparing connection areas of body for installing the closing cross member
Microsoft
Fig. 41: Preparing connection areas of body for installing the closing cross member
PREPARING CLOSING CROSS MEMBER FOR INSTALLATION
Preparing closing cross member for installation
Microsoft

1.1. Grind both sides of the connection flanges of the closing cross member in the marked areas -A, B, C- until
INSTALLING CLOSING CROSS MEMBER

Microsoft

safety components!
protective mask.
beginning work.
Install closing cross member
CAUTION: Subsequent damage to the body following repair work!
 Rear body parts cannot be replaced without using the test gauge
9748
 The rear spoiler joint cannot be adjusted.
 The rear apron can only be fitted braced.
--> Use the test gauge 9748 for positioning when replacing and aligning rear body parts.
--> The Boxster and Cayman have functional dimensions; body parts are positioned interdependently with very
close tolerance values; parts cannot be positioned/centerd with respect to other parts.
1. Fitting closing cross member to the body
1.1. Insert the closing cross member, fit it on the side panels on the left and right.
Microsoft
Fig. 43: Installing test gauge 9748

1.2. Screw test gauge 9748, see Porsche special tool Workshop Equipment Manual 00000 securely to side
member (impact pipe/impact absorber) -A- . On the closing cross member, position the fastening screws for the
retaining strip with the positioning sleeves -B- and screw in positioning screws. See Fig. 43.
Microsoft
Fig. 44: Positioning square pin on light frame

1.3. Position the test gauge with the square pin -C- on the light frame. See Fig. 44.
To complete the fit, adjust the gap clearance between rear lid and side panel according to the adjustment values.
Refer to 50 IN Processing structural body adhesive - as of MY 2005 (All Models) .
1.4. Secure the closing cross member with tensioning clamps.
1.5. Tack-weld closing cross member.
1.6. Remove test gauge
Microsoft
Fig. 45: Welding in closing cross member

2. Welding in closing cross member
2.1. Resistance spot-weld the closing cross member in areas -A, B, C- . See Fig. 45.

3.1. Resistance spot-weld closing cross member in area -A- and -B- . See Fig. 46.
Microsoft

4.1. Resistance spot-weld closing cross member in area -A- . See Fig. 47.

5.1. Apply a full weld to the closing cross member in area -A- and -B- using shielding gas. See Fig. 48.
Microsoft
SUBSEQUENT WORK
2005 (All Models) .
53 24 55 REPLACING REAR TRUNK FLOOR PANEL - AS OF MY 2005 (ALL

MODELS)
TOOLS

PS 1, see Gr. 3.5;
Workshop Equipment
Manual

dimensions
Microsoft

TOOLS AND MATERIALS
Tools and materials
body saw No. PS 1, see Gr. 3.5; Workshop Equipment Manual 00000 Angle grinder, see Gr. 3.5; see
Workshop Equipment Manual 00000 Oscillating body saw (special electric cutter), see Gr. 3.5; Workshop
Equipment Manual 00000 Rotary brush, see Gr. 3.5; Workshop Equipment Manual 00000 Hole punch,
see Gr. 3.5; Workshop Equipment Manual 00000 Leister Elektron hot-air gun, see Gr. 3.5; Workshop
Equipment Manual 00000 Inverter welding equipment ATL Inverterspot WE1194 Additional
Microsoft
attachment set.
covers.
REMOVING REAR TRUNK FLOOR PANEL
Removing rear cross member
Fig. 49: Installation location for rear trunk floor panel

Microsoft

Removing rear trunk floor panel
1. Remove closing cross member. --> 531655 Replacing closing cross member- chapter on "Removing"

Microsoft
2.1. Mill off spotwelds from below in area -A- using a spotweld cutter. See Fig. 51.

3.1. Separate spotwelds at the left and right in area -A- using a parting grinder. See Fig. 52.
Microsoft

Microsoft

5.1. Mill off spotwelds from below in areas -A- and -B- using a spotweld cutter. See Fig. 54.
PREPARING CONNECTION AREAS OF THE BODY FOR INSTALLING THE REAR TRUNK
FLOOR PANEL
welding work!

Microsoft
Preparing connection areas of body for installing the rear trunk floor panel
Fig. 55: Preparing connection areas of body for installing the rear trunk floor panel
Fig. 56: Preparing connection areas of body for installing the rear trunk floor panel
Microsoft
PREPARING REAR TRUNK FLOOR PANEL FOR INSTALLATION
Preparing the rear trunk floor panel for installation
Fig. 57: Punching holes for plug welding using shielding gas
Microsoft
1. Punching holes for plug welding using shielding gas
1.1. Punch holes (Ø = 7 mm) in areas -A, B, C, D- for plug welding using shielding gas. Maintain spacing as on
the old part. See Fig. 57.

2.1. Grind both sides of the connection flanges of the rear trunk floor panel in the marked areas -A, B, C- until
Preparing the rear cross member for installation
Microsoft
1.1. Drill holes (Ø = 7 mm) in areas -A, B, C- for plug welding using shielding gas. Maintain spacing as on the
old part. See Fig. 59.
Microsoft

2.1. Grind both sides of the connecting flanges of the rear cross member in the marked areas -A- and -B- until
INSTALLING REAR TRUNK FLOOR PANEL

safety components!
Microsoft
protective mask.
beginning work.
Installing rear trunk floor panel
1. Aligning rear trunk floor panel to the body
1.1. Fit the rear trunk floor panel to the body and fix in place with tensioning clamps.
Fig. 61: Welding in rear trunk floor panel

2. Welding in rear trunk floor panel
2.1. Resistance spot-weld rear trunk floor panel in area -A- . See Fig. 61.
Microsoft

3.1. Resistance spot-weld rear trunk floor panel in areas -A- and -B- . See Fig. 62.
Microsoft

4.1. Plug weld the rear trunk floor panel on the left and right in the area -A- using shielding gas. See Fig. 63.
Microsoft

5.1. Plug-weld the rear trunk floor panel in the areas -A- and -B- using shielding gas. See Fig. 64.
6. Install closing cross member. --> 531655 Replacing closing cross member- chapter on "Installing"
Installing rear cross member

Microsoft
3. Fitting rear cross member to the body
3.1. Fit in the rear cross member on the body and fix in place with tensioning clamps.
Fig. 66: Welding in rear cross member

4. Welding in rear cross member
4.1. Resistance spot-weld rear cross member in area -A- . See Fig. 66.
4.2. Plug weld the rear cross member in area -B- using shielding gas. See Fig. 66.
Microsoft
Fig. 67: Welding in rear cross member

5. Welding in rear cross member
5.1. Plug-weld the rear cross member at the left and right in areas -A, B, C- using shielding gas. See Fig. 67.
SUBSEQUENT WORK
2005 (All Models) .
53 24 55 REPLACING REAR TRUNK FLOOR PANEL (SECTION) - AS OF MY

Microsoft
2005 (ALL MODELS)

TOOLS

PS 1, see Gr. 3.5;
Workshop Equipment
Manual

dimensions

TOOLS AND MATERIALS
Tools and materials
Microsoft
attachment set.
covers.
REMOVING REAR TRUNK FLOOR PANEL (SECTION)
Removing rear trunk floor panel (section)
Microsoft
Fig. 68: Installation location for rear trunk floor panel (section)
1. Remove closing cross member. --> 531655 Replacing closing cross member- chapter on "Removing"

2.1. Position rear trunk floor panel separation point -A- so that the rear trunk floor panel spare part overlaps by
approx. 40 mm. Mark the separation point. See Fig. 69.
Microsoft
Fig. 70: Cutting through rear trunk floor panel

3. Cutting through rear trunk floor panel
3.1. Cut through rear trunk floor panel in front of the laser weld (visible continuous weld in rear trunk floor
panel) on the marked connection point -A- with the oscillating body saw. See Fig. 70.

Microsoft

PREPARING CONNECTION AREAS OF THE BODY FOR INSTALLING THE REAR TRUNK
FLOOR PANEL (SECTION)
welding work!

Microsoft
Preparing connection areas of body for installing the rear trunk floor panel (section)
Fig. 73: Preparing connection areas of body for installing the rear trunk floor panel (section)
PREPARING REAR TRUNK FLOOR PANEL (SECTION) FOR INSTALLATION
Preparing the rear trunk floor panel (section) for installation
Microsoft
Fig. 74: Punching holes for plug welding using shielding gas
1. Punching holes for plug welding using shielding gas
1.1. Punch holes (Ø = 7 mm) in areas -A- and -B- for plug welding using shielding gas. Maintain spacing as on

2.1. Grind both sides of the connection flanges of the rear trunk floor panel in the marked areas -A, B, C- until
Microsoft
INSTALLING REAR TRUNK FLOOR PANEL (SECTION)

safety components!
protective mask.
beginning work.
Installing rear trunk floor panel (section)
 Rear body parts cannot be replaced without using the test gauge
Microsoft
9748
--> Use the test gauge 9748 for positioning when replacing and aligning rear body parts.
1.1. Insert the rear trunk floor panel spare part overlapping the side member and the protruding trunk floor
panel.
1.2. Insert the closing cross member and fit it on the side panels on the left and right.

2.1. Screw test gauge 9748, see Porsche special tool Workshop Equipment Manual 00000 securely to side
member (impact pipe/impact absorber) -A- . On the closing cross member, position the fastening screws for the
retaining strip with the positioning sleeves -B- and screw in positioning screws. See Fig. 76.
Microsoft
2.2. Align rear trunk floor panel to the body.

2.3. Position the test gauge with the square pin -C- on the light frame. See Fig. 77.
To complete the fit, adjust the gap clearance between rear lid and side panel according to the adjustment values.
Refer to 50 IN Processing structural body adhesive - as of MY 2005 (All Models) .
2.4. Fix rear trunk floor panel and closing cross member with tensioning clamps.
2.5. Tack-weld the rear trunk floor panel.
2.6. Remove test gauge and closing cross member.
Microsoft

3.1. Apply a full weld to the overlapping of the rear cross member to cross member in area -A- using shielding
gas (interrupted). See Fig. 78.

4.1. Resistance spot-weld overlapping of rear trunk floor panel to cross member in area -A- . See Fig. 79.
Microsoft

5.1. Plug-weld the rear trunk floor panel in the areas -A- and -B- using shielding gas. See Fig. 80.
Microsoft

6.1. Resistance spot-weld rear trunk floor panel in areas -A- and -B- . See Fig. 81.
7. Install closing cross member. --> 531655 Replacing closing cross member- chapter on "Installing"
SUBSEQUENT WORK
2005 (All Models) .
Microsoft
53 48 55 REPLACING REAR SIDE MEMBER - AS OF MY 2005 (ALL

MODELS)
TOOLS

PS 1, see Gr. 3.5;
Workshop Equipment
Manual

dimensions


Microsoft
TOOLS AND MATERIALS
Tools and materials
PRELIMINARY WORK
attachment set.
REMOVING REAR SIDE MEMBER
Removing retaining bracket for support tube
Microsoft
Fig. 82: Installation position of rear side member

1. Remove inner rear wheel housing. --> 536855 Replacing rear wheel housing - section on
"Removing" [987120 987121]--> 536855 21 Replacing rear wheel housing - section on "Removing" [987310
987311 987320 987321]
2. Remove rear luggage compartment floor panel. --> 532455 Replacing rear luggage compartment floor
panel - section on "Removing"
CAUTION: Cut on retaining bracket for support tube
--> The cut on the retaining bracket for the support tube can only be at the marked area A.
--> Position the cut between the openings (holes).
--> The cut must not obstruct the openings (holes).
Microsoft

3.1. Determine the position of the cut in area -A- between the openings (holes). Mark the cut. See Fig. 83.
Fig. 84: Cutting through retaining bracket for support tube

4. Cutting through retaining bracket for support tube
4.1. Cut through retaining bracket for support tube in area -A- . See Fig. 84.

Microsoft
Fig. 86: Separating welded joints

6. Separating welded joints
6.1. Separate spotwelds in area -A- using a parting grinder. See Fig. 86.
6.2. Separate inert-gas welded seams in area -B- using a parting grinder. See Fig. 86.
Removing center side member
CAUTION: Cut on center side member
--> The cut on the center side member can only be at the marked area A.
--> Position the cut between the openings (holes).
--> The cut must not obstruct the openings (holes).

1.1. Determine the position of the cut in area -A- between the openings (holes). Mark the cut. See Fig. 87.
Microsoft
Fig. 88: Cutting through center side member

2. Cutting through center side member
2.1. Cut through the center side member in area -A- . See Fig. 88.

Fig. 90: Milling off and separating spotwelds

Microsoft
4. Milling off and separating spotwelds
4.2. Separate spotwelds in area -C- using a parting grinder. See Fig. 90.

5.1. Separate inert-gas welded seam in area -A- using a parting grinder. See Fig. 91.
5.2. Separate spotwelds in area -B- using a parting grinder. See Fig. 91.
Removing rear side member

1.1. Determine the position of the cut in area -A- at dimension -X= approx. 200 mm- . Mark the cut. See Fig.
92.
Microsoft
Fig. 93: Cutting through rear side member

2. Cutting through outer rear side member
2.1. Cut through the outer rear side member in area -A- . See Fig. 93.


Microsoft

Fig. 97: Milling off spotweld

6. Milling off spotweld
6.1. Mill off spotweld in area -A- using a spotweld cutter. See Fig. 97.
Microsoft

7.2. Mill off spotweld in area -E- using a spotweld cutter (2 plate thicknesses). See Fig. 98.

Fig. 100: Milling off spotweld

Microsoft
9. Milling off spotweld
9.1. Mill off spotweld in area -A- using a spotweld cutter. See Fig. 100.

10.2. Separate spotwelds in area -B- using a parting grinder. See Fig. 101.
PREPARING CONNECTION AREAS OF THE BODY FOR INSTALLING THE REAR SIDE
MEMBER
welding work!

Preparing connection areas of the body for installing the rear side member
Microsoft


FITTING REAR SIDE MEMBER AND PREPARING FOR INSTALLATION
Adjusting rear side members and preparing for installation

Microsoft

1.1. Grind both sides of the connecting flanges of the inner rear side member in the marked areas -A, B, C, D,
E, F, G, H- until bare using a rotary brush. See Fig. 104.

2.1. Grind both sides of the connecting flanges of the inner rear side member in the marked areas -A, B, C, D-
Microsoft

4.1. Grind both sides of the connecting flanges of the outer rear side member in the marked areas -A- and -B-
INSTALLING REAR SIDE MEMBER
Microsoft

safety components!
protective mask.
beginning work.
Installing rear side member
1. Fitting inner rear side member to the body
1.1. Fit inner rear side member to the body and secure to the straightening set.
1.2. Fix inner rear side member in place with tensioning clamps.
Microsoft
Fig. 108: Welding in inner rear side member

2. Welding in inner rear side member
2.1. Resistance spot-weld the inner rear side member in areas -A- and -B- . See Fig. 108.

3.1. Plug-weld the inner rear side member in area -A- using inert gas. See Fig. 109.
3.2. Resistance spot-weld the inner rear side member in area -B- . See Fig. 109.

Microsoft
4.1. Resistance spot-weld the inner rear side member in areas -A, B, C, D, E- . See Fig. 110.

5.1. Resistance spot-weld the inner rear side member in areas -A, B, C- . See Fig. 111.

6.1. Resistance spot-weld the inner rear side member in area -A- . See Fig. 112.
Microsoft

7.1. Apply a full weld to the inner rear side member in area -A- using inert gas. See Fig. 113.
7.2. Resistance spot-weld the inner rear side member in area -B- . See Fig. 113.
8. Fitting outer rear side member to the body
8.1. Fit outer rear side member to the body and fix in place with tensioning clamps.
Fig. 114: Welding in outer rear side member

9. Welding in outer rear side member
9.1. Plug-weld the outer rear side member in area -A- using inert gas. See Fig. 114.
9.2. Resistance spot-weld the outer rear side member in areas -B, C, D- . See Fig. 114.
Fitting in reinforcement plate and preparing for installation
Microsoft

1.1. Grind both sides of the connecting flanges of the body in the marked areas -A- and -B- until bare using a
rotary brush. See Fig. 115.

2.1. Grind both sides of the connecting flanges of the reinforcement plate in the marked areas -A- and -B- until
Installing reinforcement plate
1. Fitting reinforcement plate to the body
1.1. Fit the reinforcement plate to the body and fix in place with tensioning clamps.
Microsoft

2. Welding in reinforcement plate
2.1. Resistance spot-weld the reinforcement plate in areas -A, B, C- . See Fig. 117.

3. Welding in reinforcement plate
3.1. Apply a full weld to the reinforcement plate in areas -A- and -B- using inert gas. See Fig. 118.
Fitting in center side member and preparing for installation

Microsoft
1.1. Grind both sides of the connecting flanges of the body in the marked areas -A, B, C, D- until bare using a
Fig. 120: Fitting center side member to the body

2. Fitting center side member to the body
2.1. Separate replacement part in area -A- to obtain a welding slit width s = 1 x sheet thickness. See Fig. 120.

3.1. Grind both sides of the connecting flanges of the center side member in the marked areas -A, B, C, D- until
Installing center side member

Microsoft
1. Fitting center side member to the body
1.1. Fit center side member to the body and fix in place with tensioning clamps.
Fig. 122: Welding in center side member

2. Welding in center side member
2.1. Resistance spot-weld the center side member in areas -A, B, C, D, E, F- . See Fig. 122.

3.1. Resistance spot-weld the center side member in area -A- . See Fig. 123.
Microsoft

4.1. Apply a full weld to the center side member in areas -A- and -B- using inert gas. See Fig. 124.
Fitting in retaining bracket for support tube and preparing for installation

1.1. Grind both sides of the connecting flanges of the body in the marked areas -A- and -B- until bare using a
Microsoft
Fig. 126: Fitting retaining bracket for support tube to the body
2. Fitting retaining bracket for support tube to the body
2.1. Separate replacement part in area -A- to obtain a welding slit width s = 1 x sheet thickness. See Fig. 126.

3.1. Grind both sides of the connecting flanges of the retaining bracket for the support tube in the marked areas -
A- and -B- until bare using a rotary brush. See Fig. 127.
Installing retaining bracket for support tube
1. Fitting retaining bracket for support tube to the body
1.1. Fit the retaining bracket to the body and fix in place with tensioning clamps.
Microsoft
Fig. 128: Welding in retaining bracket for support tube

2. Welding in retaining bracket for support tube
2.1. Resistance spot-weld retaining bracket for support tube in area -A- . See Fig. 128.
Fig. 129: Welding in retaining bracket for support tube

3. Welding in retaining bracket for support tube
3.1. Apply a full weld to the retaining bracket for the support tube in areas -A- and -C- using inert gas. See Fig.
129.
3.2. Resistance spot-weld retaining bracket for support tube in area -B- . See Fig. 129.
4. Install rear luggage compartment floor panel. --> 532455 Removing and installing rear luggage
compartment floor panel - section on "Installing"
5. Install inner rear wheel housing. --> 536855 Replacing rear wheel housing - section on
"Installing" [987120 987121]--> 536855 23 Replacing rear wheel housing - section on "Installing" [987310
987311 987320 987321]
SUBSEQUENT WORK

Microsoft
2005 (All Models) .
53 55 55 REPLACING SIDE SECTION - AS OF MY 2006 (CAYMAN S,

CAYMAN S RHD)
TOOLS

Equipment Manual

dimensions

Microsoft
TOOLS AND MATERIALS
Tools and materials
Betamate adhesive 2096, see Gr. 8, Parts Catalogue 00000 Primer for Betamate adhesive 2096, see Gr. 8,
Parts Catalogue 00000 Processing nozzle for Betamate adhesive 2096, see Gr. 8, Parts Catalogue 00000
Microsoft
attachment set.
covers.
attachment set.
REMOVING SIDE SECTION
Removing side section

Microsoft
Fig. 130: Installation position for side section

NOTE:  Separation points on the side section can only be at the marked areas A
and B .

Microsoft
1.1. Determine separation point on C-pillar -A- to the dimension -X = 18 mm- , then mark the cut. See Fig. 131.
1.2. Position cut on lower side member -B- so that the replacement body part overlaps the lower side member
by approx. 60 mm, then mark the cut. See Fig. 131.
Fig. 132: Cutting the lower side member

2. Cutting through the lower side member
2.1. Cut through the side section at the marked separation point in the lower side member -A- using the
oscillating body saw. See Fig. 132.
CAUTION: Separating side section
 Risk of damage to roof reinforcement and/or internal body parts.
--> Only separate parts using the oscillating body saw.
--> In the event of damage: Repair affected area by applying inert-gas welds.
Microsoft
Fig. 133: Cutting the C-pillar

3. Cutting the C-pillar
3.1. Cut through the side section at the marked separation point in the C-pillar -A- using the oscillating body
saw. Do not damage internal components when doing this. See Fig. 133.

Microsoft


Microsoft


Microsoft

9.1. Mill off spotwelds in areas -A, B, D- using a spotweld cutter. See Fig. 139.
9.2. Mill off spotwelds in areas -E- and -C- using a spotweld cutter (2 plate thicknesses). See Fig. 139.
Fig. 140: Cutting and milling off spotwelds

10. Separating and milling off spotwelds
Microsoft
10.2. Mill off spotwelds in area -C- using a spotweld cutter. See Fig. 140.
Fig. 141: Cutting and milling off spotwelds

11.2. Separate spotwelds in areas -B- using a parting grinder. See Fig. 141.

Microsoft

Fig. 144: Bending up side section

Microsoft
14. Bending up the side section
14.1. Bend side section up in area -A- until the internal spotwelds are accessible. See Fig. 144.

15. Milling off internal spotwelds
NOTE: Removing expanded sealant
 The outer side section is factory-sealed to the inner side section with
expanded sealant in area -Y- . See Fig. 146.
 The expanded sealant will be destroyed when you change the side section
and must be replaced.
Microsoft
Fig. 146: Expanded sealant

Microsoft
Fig. 147: Loosening bonded joints

16. Separating bonded joints and removing expanded sealant
16.1. Heat up bonded joints in the areas -A, B, C- between the side section and body using the Leister Elektron
hot-air gun; see Gr. 3.5, Workshop Equipment Manual 00000 and remove side section. See Fig. 147.
PREPARING CONNECTION AREAS OF THE BODY FOR INSTALLING THE SIDE SECTION
welding work!

Preparing connection areas of the body for installing the side section
Microsoft
Fig. 148: Preparing connection areas of the body for installing the side section
Fig. 149: Preparing connection areas of the body for installing the side section
Microsoft

4.1. Prepare bonded flanges in the marked area -A- . See Fig. 150.
Models) ..

Microsoft
5.1. Prime bonded flanges on the body in the marked area -A- . See Fig. 151.
FITTING SIDE SECTION AND PREPARING FOR INSTALLATION
Fitting side section and preparing for installation
 The side section and rear closing panel cannot be replaced without
using the test gauge 9748
--> Use the test gauge 9748 for positioning when replacing and aligning the side section and rear closing panel.
Microsoft

1. Screw test gauge 9748 securely to side member (impact pipe/impact absorber mount) -A- . On the closing
plate, position the fastening screws for the retaining strip with the positioning sleeves -B- and screw in
positioning screws. See Fig. 152.
1.1. Fitting rear side section to the body
Microsoft

1.2. Position the side section on the light frame with the square pin -A- at the test gauge 9748 . See Fig. 153.
To do the alignment, install the doors and rear lid and set the gap dimensions between rear door, rear lid and
side section according to the respective adjustment values. Refer to 50 IN Processing structural body
1.3. Securing side section with tensioning clamps
Microsoft
Fig. 154: Fitting the side section to the body

Fig. 155: Fitting in side section joint and make the cuts
2. Aligning side section joints and making the cuts
2.1. Use the oscillating body saw to cut the two sheetmetal panels in the area -A- of the overlap between the
side section and lower side member. Do not damage internal components when doing this. Use test gauge
9748 . See Fig. 155.
Microsoft
Fig. 156: Drilling hole for plug welding using inert gas
3. Drilling hole for plug welding using inert gas
3.1. With the side section fitted, drill a hole (diameter = 7 mm) in area -A- for plug welding using inert gas (2
panel strengths). Always maintain original spacing. See Fig. 156.
Microsoft
4.1. Drill holes (diameter = 7 mm) in area -A- for plug welding using inert gas (2 panel strengths). Maintain
spacing as on roof frame between the bores. See Fig. 157.
Microsoft
Fig. 158: Cleaning welding and sealing areas

5. Cleaning welding and sealing areas
5.1. Grind both sides of the connection flanges of the side section in the marked areas -A, B, C, D, E- until bare
Microsoft

7.1. Prepare bonded flanges in the marked areas -A- . See Fig. 159.
See: Working with body structural adhesive Refer to 50 IN Processing structural body adhesive - as of MY
2005 (All Models) ..


Microsoft
8.1. Prime bonded flanges on the body in the marked areas -A- . See Fig. 160.
INSTALLING SIDE SECTION

safety components!
protective mask.
beginning work.
Installing side section
WARNING: Risk of damage if the processing time is not observed!
 The quality of the joint will be affected if the adhesive processing

time is not observed.
Microsoft
--> The new part must be welded within 30 minutes in the area of the adhesive, otherwise the adhesion of the
adhesive will be affected.

1. Installing seal
1.1. Apply a triangular bead of body sealant measuring -dimension X = approx. 12 mm- high all around the
seal. Position seal on inside of side section and press on firmly. See Fig. 161.
Check dimension -Y= 20 mm- with respect to roof reinforcement. See Fig. 161.
Fig. 162: Applying adhesive to the inside of the side section

Microsoft
2. Apply adhesive on the inside of the side section
2.1. Apply a triangular bead of Betamate 2096 adhesive measuring -dimension X = approx. 8 mm- in height
to the joint between the light housing and the inside of the side section. The light frame must lie flush with the
inside of the side section. See Fig. 162.
Fig. 163: Applying adhesive to the side section

3. Applying adhesive to the side section
3.1. Apply a triangular bead of adhesive (Teromix-6700) measuring -dimension X = approx. 8 mm- to the
inside of the side section, along the wheel arch up as far as the start of the door sill. See Fig. 163.
Microsoft
Fig. 164: Fitting the side section to the body

4. Fitting the side section to the body
4.1. Secure the side section with tensioning clamps. Use test gauge 9748 .
4.2. Tack-weld the side section.
Fig. 165: Welding in the side section

5. Welding in the side section
Microsoft
5.1. Resistance spot-weld the side section in area -A- . See Fig. 165.


Microsoft
WARNING: Welding in body components
--> Once the spare parts have been fixed in place, repair spotwelds must be placed on the old spotwelds because
there is no current flow possible in areas with a hardened adhesive layer. Welding procedures other than
resistance spot-welding are not permitted since the thermal effect would destroy the bonded joint over a wide
area. Refer to 50 IN Processing structural body adhesive - as of MY 2005 (All Models) .

Microsoft


10.1. Resistance spot-weld the side section in area -A, B, C, D, E- . See Fig. 170.
Microsoft

11.1. Resistance spot-weld the side section in areas -A- and -B- . See Fig. 171.

12.1. Resistance spot-weld the side section in areas -A- and -C- . See Fig. 172.
Microsoft
12.2. Plug-weld the side section in area -B- using inert gas. See Fig. 172.


Microsoft
14.1. Plug-weld the side section in area -A- using inert gas. See Fig. 174.

15.1. Apply a full weld to the side section in area -A- using inert gas. See Fig. 175.

Microsoft
16.1. Apply a full weld to the side section in area -A- using inert gas. See Fig. 176.
SUBSEQUENT WORK
WARNING: There will not be a proper adhesive bond if the prescribed curing time of
the adhesive is not observed.
 Danger of material damage if specified curing time of adhesive is not

observed.
--> When there are repairs in the area of the structure bond, the vehicle may not be used until the curing time
has elapsed.
--> For details of curing time, see Refer to 50 IN Processing structural body adhesive - as of MY 2005 (All
Models) .
2005 (All Models) .
7. Installing removed accessories in the repair area
53 55 55 REPLACING SIDE SECTION - AS OF MY 2005 (BOXSTER,

TOOLS

Equipment Manual
Microsoft

dimensions

TOOLS AND MATERIALS
Tools and materials
Microsoft
attachment set.
covers.

Microsoft
attachment set.
REMOVING SIDE SECTION
Removing side section
Microsoft
Fig. 177: Side section installation position

1 - Side section
Y - Seal
Microsoft
Fig. 178: Determining cut

1. Determining cut
1.1. Position the cut L on the lower side member so that the replacement body part overlaps the lower side
member by approx. 60 mm. Mark the cut.
Microsoft
Fig. 179: Cutting the lower side member

2. Cutting through the lower side member
2.1. Cut through the side section at the marked connection point L .
Microsoft

3.1. Mill off spotwelds in area A using a spotweld cutter.
Microsoft

4.1. Mill off spotwelds in areas B, C, D, P with a spotweld cutter.
4.2. Cut through the shielding gas weld in area E using the parting grinder.
Microsoft

5. Cutting the spotwelds
5.1. Mill off spotwelds in areas F, G, H, I using a spotweld cutter.
Microsoft
Fig. 183: Mill off and cut through spotwelds

6. Mill off and cut through spotwelds
6.1. Mill off spot welds in area K using a spotweld cutter.
6.2. Cut through the side section at the connection point J with the parting grinder.
Microsoft
Fig. 184: Removing expanded sealant

7. Remove expanded sealant
7.1. The outer side section is factory sealed to the inner side section with expanded sealant Y . The expanded
sealant will be destroyed when replacing the side section and must be replaced.
PREPARING CONNECTION AREAS OF THE BODY FOR INSTALLING THE SIDE SECTION
welding work!

Preparing connection areas of the body for installation of the side section
Microsoft
Fig. 185: Preparing connection areas of the body for installation of the side section
1. Clean the body connection flanges of undersealing, adhesive residue and paint in the marked areas using a
hot-air gun or rotary brush. Grind the connection flanges until bare.
FITTING SIDE SECTION AND PREPARING FOR INSTALLATION
Fitting side section and preparing for installation
 The side section and rear closing panel cannot be replaced without
using the test gauge 9748
Microsoft

--> Use the test gauge 9748 for positioning when replacing and aligning the side section and rear closing panel.

1. Screw test gauge securely to side member (impact pipe/impact absorber mount) A . On the closing panel,
position the fastening screws for the retaining strip with the positioning sleeves B and screw in positioning
screws.
1.1. Fitting rear side section to the body
Microsoft
Fig. 187: Positioning square pin on light housing

1.2. Position side section on the light housing with the square pin C at the test gauge 9748.
To do the alignment, install the doors and rear lid and set the gap dimensions between rear door, rear lid and
side section according to the respective adjustment values. Refer to 50 IN Processing structural body
1.3. Securing rear side section with tensioning clamps
Microsoft
Fig. 188: Fitting rear side section to the body

Fig. 189: Fitting in side section joints and making the cuts
Microsoft
2. Fitting in side section joints and making the cuts
2.1. Use a body saw to cut the two sheetmetal plates in the area of the overlap between the side section and
body. Do not damage internal components when doing this. Use test gauge 9748.
Fig. 190: Cleaning welding and sealing areas

3. Cleaning welding and sealing areas
3.1. Grind both sides of the connecting flanges of the side sections in the marked areas A, B, C, D, F, G, H, I, J
with a rotary brush until they are bare.
INSTALLING SIDE SECTION
Installing side section
WARNING: Welding in body components
--> Once the spare parts have been fixed in place, repair spotwelds must be placed on the old spotwelds because
Microsoft
there is no current flow possible in areas with a hardened adhesive layer. Welding procedures other than
resistance spot-welding are not permitted since the thermal effect would destroy the bonded joint over a wide
area. Refer to 50 IN Processing structural body adhesive - as of MY 2005 (All Models) .

1. Installing seal
1.1. Apply a triangular bead of body sealant Y measuring dimension "X" = approx. 12 mm high all around the
seal. Position seal on the inside of the side section and press firmly.
Check dimension for viewing window for inner side section --> Length: X = 28 mm
Microsoft
Fig. 192: Applying adhesive to the side section

2. Applying adhesive to the side section
2.1. Apply a triangular bead of adhesive - dimension "X" = approx. 8 mm - to the inside of the side section,
along the wheel arch and up to the start of the sill.

2.2.
Microsoft
Fig. 193: Applying adhesive to the inside of the side section

3. Applying adhesive to the inside of the side section

3.1. Apply a triangular bead of adhesive (Teromix-6700) - dimension "X" = approx. 10 mm high - to the inside
of the side section.
Microsoft
Fig. 194: Fitting rear side section to the body

4.1. Secure the rear side section with tensioning clamps. Use test gauge 9748.
4.2. Tack-weld the side section at the rear.

4.3. Spot-weld area A of the side section.
Microsoft

Microsoft


5.1. Spot weld areas H, F, G, I of the side section.

6.1. Spot weld areas B, C, D of the side section.
6.2. Weld area E of the side section using inert gas.
Microsoft
6.3. Plug-weld area P of the side section using inert gas.
Fig. 198: Brazing side section

7.1. Spot-weld area K of the side section.
7.2. Braze weld area J of the side section
Fig. 199: Welding side section using inert gas

Microsoft
8.1. Weld area L of the side section using inert gas.
SUBSEQUENT WORK
WARNING: There will not be a proper adhesive bond if the prescribed curing time of
the adhesive is not observed.
 Danger of material damage if specified curing time of adhesive is not

observed.
--> When there are repairs in the area of the structure bond, the vehicle may not be used until the curing time
has elapsed.
--> For details of curing time, see Refer to 50 IN Processing structural body adhesive - as of MY 2005 (All
Models) .
2005 (All Models) .
7. Installing removed accessories in the repair area
53 61 55 REPLACING INNER SIDE SECTION - AS OF MY 2006 (CAYMAN S,

CAYMAN S RHD)
TOOLS

Microsoft

Equipment Manual

dimensions

TOOLS AND MATERIALS
Materials and tools
Hole punch, see Gr. 3.5; Workshop Equipment Manual 00000 Elektron hot-air gun from Leister, see Gr.
3.5; Workshop Equipment Manual 00000 Inverter welding equipment ATL Inverterspot WE1194
00000 Straightening attachments for Boxster (986), see Gr. 3.5; Workshop Equipment Manual 00000
Betamate Kleber 2096 see Gr. 8, Parts Catalogue 00000 Primer for Betamate adhesive 2096 see Gr. 8
Parts Catalogue 00000 Processing nozzle for Betamate adhesive 2096 see Gr. 8 Parts Catalogue 00000
Microsoft
attachment set.
REMOVING INNER SIDE SECTION
Removing rear inner side section
Microsoft
Fig. 200: Installation position of inner side section

1. Remove outer rear wheel housing. --> 536855 Replacing rear wheel housing - section on "Removing"

Microsoft

Removing front inner side section
1. Remove center side member. --> 514855 21 Replacing center side member - section on "Removing"

Microsoft

3.1. Mill off spotwelds in area -A- from the inside using a spotweld cutter. See Fig. 204.

Microsoft

Fig. 207: Separating and milling off spotwelds

Microsoft
6.2. Mill off spotwelds in area -B- using a spotweld cutter. See Fig. 207.

7.1. Separate spotwelds in area -A- from below using a parting grinder. See Fig. 208.

Microsoft
8.1. Separate spotwelds in area -A- from below using a parting grinder. See Fig. 209.

9.1. Separate inert-gas welded seams through the cut-out in area -A- using a parting grinder. See Fig. 210.
Fig. 211: Loosening rivet connections

Microsoft
10. Loosening rivet connections
10.1. Separate rivet connections in area -A- using a parting grinder and remove them. See Fig. 211.
11. Loosening bonded joint
11.1. Heat up bonded joint in the areas between the side reinforcement and front inner side section using the
Leister Elektron hot-air gun; see Gr. 3.5, Workshop Equipment Manual 00000.

12. Separating inert-gas welded seam
Microsoft

13.1. Separate inert-gas welded seams in area -A- using a parting grinder. See Fig. 213.
PREPARING CONNECTION AREAS OF THE BODY FOR INSTALLING THE INNER SIDE
SECTION
welding work!

Preparing connection areas of the body for installing the front inner side section
Microsoft


Microsoft

D, E, F, G- using a hot-air gun or rotary brush. Grind the connecting flanges until bare. See Fig. 216.
powder paint.
Microsoft

5.1. Sand down bonded flanges in the marked area -A- from below and clean them off. See Fig. 217.
Models) ..

6.1. Prime bonded flanges in the marked area -A- from below. See Fig. 218.
Preparing connection areas of the body for installing the rear inner side section
Microsoft

PREPARING INNER SIDE SECTION FOR INSTALLATION
Preparing front inner side section for installation
Microsoft

2.1. Grind both sides of the connecting flanges of the bracket for the inner side section in the marked areas -A,
Microsoft
B, C- until bare using a rotary brush. See Fig. 221.
3.1. Drill holes (Ø = 7 mm) in areas -A, B, C- for plug welding using inert gas. Maintain spacing between the
bores as on the old part. See Fig. 222.
Microsoft

4.1. Grind both sides of the connecting flanges of the front inner side section in the marked areas -A, B, C, D,
E, F, G, H- until bare using a rotary brush. See Fig. 223.
powder paint.
Microsoft

6.1. Sand down bonded flanges in the marked area -A- and clean them off. See Fig. 224.
Models) ..


Microsoft
7.1. Prime bonded flanges in the marked area -A- . See Fig. 225.
Preparing rear inner side section for installation
Microsoft

2.1. Grind both sides of the connecting flanges of the rear inner side section in the marked areas -A- and -B-
INSTALLING INNER SIDE SECTION

safety components!
protective mask.
beginning work.
Microsoft
Installing front inner side section
WARNING: Traffic safety warning for bonding structural components with structural
adhesive!
--> Join, fix and resistance spot-weld parts within the processing time. The jointing operation must take place
directly after application of the adhesive in order to guarantee high-quality and reliable bonding. Otherwise the
adhesive bead must be removed and pre-treatment of the surface and application of the adhesive must be
repeated.
--> To ensure that the substance is completely mixed, apply a 30 mm long adhesive bead of fresh adhesive to a
piece of cardboard before processing.
--> Process the adhesive within the processing time. The adhesive must be applied and the body part must be
jointed within this period. Any resistance welding to be carried out in the area of the bonding must be
performed within this period as well. --> Processing time: 60 min
--> Do not apply pressure to bonded parts until hardening is complete!
--> If the contents of the cartridge is not used up completely, the processing nozzle must be kept on the
cartridge until the adhesive hardens. If you intend to use the adhesive again later, a new processing nozzle must
be used.
1. Fitting bracket for side section and front inner side section to the body
1.1. Fit bracket for side section and front inner side section to the body, check them and fix in place with
tensioning clamps.
Microsoft
Fig. 228: Marking the bonding area

1.2. Mark front inner side section in the bonding area -A- with a scriber. See Fig. 228.
1.3. Remove front inner side section.
Fig. 229: Welding in bracket for side section

2. Welding in bracket for side section
2.1. Apply a full weld to the side section bracket in area -A- using inert gas. See Fig. 229.
Microsoft
Fig. 230: Welding in bracket for side section

3. Welding in bracket for side section
3.1. Apply a full weld to the side section bracket in area -A- using inert gas. See Fig. 230.
Fig. 231: Applying adhesive

4. Applying adhesive
4.1. Using the bonding gun, apply structural adhesive to the front inner side section in the marked area -A- in
the form of a triangular bead measuring -dimension X = approx. 3 mm- . See: Working with body structural
adhesive Refer to 50 IN Processing structural body adhesive - as of MY 2005 (All Models) . See Fig. 231.
5. Fitting the front inner side section to the body
5.1. Fit the front inner side section to the body and fix in place with tensioning clamps.
Microsoft
Fig. 232: Securing front inner side section

6. Securing front inner side section
6.1. Secure front inner side section in areas -A- and -B- with rivets -1- . See Fig. 232.
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Fig. 233: Welding in front inner side section

7. Welding in front inner side section
7.1. Resistance spot-weld the front inner side section in area -A- . See Fig. 233.

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9.1. Resistance spot-weld the front inner side section in areas -A, B, C- . See Fig. 235.

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11.1. Plug-weld the front inner side section in area -A- using inert gas. See Fig. 237.
11.2. Resistance spot-weld the front inner side section in areas -B- and -C- . See Fig. 237.

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14.1. Plug-weld the front inner side section in areas -A- and -B - using inert gas. See Fig. 240.

15.1. Apply a full weld to the front inner side section in area -A- using inert gas. See Fig. 241.
16. Install center side member. --> 514855 23 Replacing center side member - section on "Installing"
Installing rear inner side section
1. Fitting rear inner side section to the body
1.1. Fit the rear inner side section to the body and fix in place with tensioning clamps.
Microsoft
Fig. 242: Welding in rear inner side section

2. Welding in rear inner side section
2.1. Plug-weld the rear inner side section in areas -A- and -B- using inert gas. See Fig. 242.
2.2. Resistance spot-weld the rear inner side section in area -C- . See Fig. 242.
Fig. 243: Welding in rear inner side section

3. Welding in rear inner side section
Microsoft
3.1. Resistance spot-weld the rear inner side section in area -A- . See Fig. 243.
4. Install outer rear wheel housing. --> 536855 Replacing rear wheel housing - section on "Installing"
SUBSEQUENT WORK
2005 (All Models) .
53 62 55 REPLACING FRAME FOR LIGHT (SECTION) - AS OF MY 2006

TOOLS

PS 1, see Gr. 3.5;
Workshop Equipment
Manual

dimensions
Microsoft

TOOLS AND MATERIALS
Tools and materials
PRELIMINARY WORK FOR BODY REPAIRS
Microsoft
attachment set.
covers.
REMOVING FRAME FOR LIGHT (SECTION)
Removing light frame (section)
Fig. 244: Installation location of light frame

Microsoft
Fig. 245: Cutting through light frame

1. Cutting through light frame
1.1. Cut through the light frame of connection point -A- using the body saw. See Fig. 245.
1.2. Cut through the light frame of connection point -B- using the body saw. See Fig. 245.

Microsoft
2.1. Separate spotwelds in areas -A- and -C- using a parting grinder. See Fig. 246.

3.1. Mill off spotwelds in areas -A- and -C- using a spotweld cutter. See Fig. 247.
3.2. Mill off spotwelds in areas -B- and -D- using a spotweld cutter (2 plate thicknesses). See Fig. 247.
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5.1. Mill off spotwelds in areas -A- and -C- using a spotweld cutter. See Fig. 249.
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5.2. Mill off spotwelds in area -B- using a spotweld cutter (2 plate thicknesses). See Fig. 249.
PREPARING CONNECTION AREAS OF THE BODY FOR INSTALLING FRAME FOR LIGHT
(SECTION)
welding work!

Preparing connection areas of body for installing light frame (section)
Fig. 250: Preparing connection areas of body for installing light frame
Microsoft
FITTING FRAME FOR LIGHT (SECTION) AND PREPARING FOR INSTALLATION
Fitting in light frame (section) and preparing for installation
1. Fitting light frame to the body
1.1. Cut the light frame so that there is approx. 40 mm overlap at the joint.
1.2. To complete the fit, install the rear light and set the gap clearance between the rear light and side panel
according to the adjustment values. Refer to 50 IN Processing structural body adhesive - as of MY 2005 (All
Models) .
1.3. Fix the light frame with tensioning clamps and remove rear light.
Fig. 251: Cutting through light frame connection points

2. Cutting through light frame connection points
2.1. Use a body saw to cut the two sheetmetal plates in the area -A- and -B- of the overlap between the light
frame and body. See Fig. 251.
Microsoft
3.1. Drill holes (Ø = 7 mm) in areas -A- and -B- for plug welding using shielding gas. Maintain spacing as on

4.1. Grind both sides of the connection flanges on the light frame in the marked areas -A, B, C- until bare using
Microsoft
a rotary brush. See Fig. 253.
INSTALLING FRAME FOR LIGHT (SECTION)

safety components!
protective mask.
beginning work.
Installing light frame (section)
Microsoft
1. Fitting light frame to the body
1.1. Fit the light frame to the body and fix in place with tensioning clamps.
1.2. To complete the fit, install the rear light and set the gap clearance between the rear light and side panel
according to the adjustment values. Refer to 50 IN Processing structural body adhesive - as of MY 2005 (All
Models) .
2. Welding in light frame
2.1. Tack-weld the light frame and remove rear light.
Fig. 254: Welding in light frame

3.1. Resistance spot-weld the light frame in area -A, B, C, D- . See Fig. 254.
Microsoft

4.1. Plug-weld the light frame in the areas -A, B, C- under shielding gas. See Fig. 255.

5.1. Plug-weld the light frame in the areas -A- and -B- under shielding gas. See Fig. 256.
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6.1. Apply a full weld the light frame in the areas -A- and -B- using shielding gas. See Fig. 257.
SUBSEQUENT WORK
2005 (All Models) .
53 68 55 REPLACING REAR WHEEL HOUSING - AS OF MY 2006 (CAYMAN

Microsoft
S, CAYMAN S RHD)
TOOLS

PS 1, see Gr. 3.5;
Workshop Equipment
Manual

dimensions

TOOLS AND MATERIALS
Tools and materials
Microsoft
PRELIMINARY WORK
attachment set.
REMOVING REAR WHEEL HOUSING
Removing outer rear wheel housing
Microsoft
Fig. 258: Installation position of rear wheel housing

1. Remove side panel. --> 535555 Replacing side panel - section on "Removing"

Microsoft

Removing inner rear wheel housing
Fig. 261: Installation position of inner rear wheel housing

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1. Remove lower B-pillar reinforcement. Refer to 51 42 55 Replacing B-pillar reinforcement - as of MY 2006




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6.1. Separate inert-gas welded seams in area -A- using a parting grinder. See Fig. 266.
PREPARING CONNECTION AREAS OF THE BODY FOR INSTALLING THE REAR WHEEL
HOUSING
welding work!

Preparing connection areas of the body for installing the outer rear wheel housing
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Preparing connection areas of the body for installing the inner rear wheel housing

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FITTING IN REAR WHEEL HOUSING AND PREPARING FOR INSTALLATION
Fitting outer rear wheel housing and preparing for installation

1.1. Grind both sides of the connecting flanges of the outer rear wheel housing in the marked area -A- until bare
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Fitting inner rear wheel housing and preparing for installation
1.1. Drill holes (Ø = 7 mm) in areas -A, B, C, D, E- for plug welding using inert gas. Maintain spacing between
Microsoft
Microsoft

3.1. Grind both sides of the connecting flanges of the inner rear wheel housing in the marked areas -A, B, C, D,
E- until bare using a rotary brush. See Fig. 272.
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4.1. Grind both sides of the connecting flanges of the inner rear wheel housing in the marked areas -A- and -B-
INSTALLING REAR SIDE MEMBER

safety components!
Microsoft
protective mask.
beginning work.
Installing inner rear wheel housing
1. Fitting inner rear wheel housing to the body
1.1. Fit inner rear wheel housing to the body and secure to the straightening set.
1.2. Fix the inner rear wheel housing in place with tensioning clamps.
Fig. 274: Welding in inner rear wheel housing

2. Welding in inner rear wheel housing
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2.1. Resistance spot-weld inner rear wheel housing in area -A- . See Fig. 274.

3.1. Plug-weld the inner rear wheel housing in areas -A, B, C- using inert gas. See Fig. 275.

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4.1. Plug-weld the inner rear wheel housing in areas -A- and -B- using inert gas. See Fig. 276.

5.1. Plug-weld the inner rear wheel housing in areas -A- and -B- using inert gas. See Fig. 277.

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6.1. Apply a full weld to the inner rear wheel housing in area -A- using inert gas. See Fig. 278.
7. Install lower B-pillar reinforcement. Refer to 51 42 55 Replacing B-pillar reinforcement - as of MY 2006

Installing outer rear wheel housing
1. Fitting outer rear wheel housing to the body
1.1. Fit outer rear wheel housing to the body and fix in place with tensioning clamps.
Fig. 279: Welding in outer rear wheel housing

2. Welding in outer rear wheel housing
2.1. Resistance spot-weld outer rear wheel housing in area -A- . See Fig. 279.
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Fig. 280: Welding in outer rear wheel housing

3. Welding in outer rear wheel housing
3.1. Resistance spot-weld outer rear wheel housing in area -A- . See Fig. 280.
4. Install side panel. --> 535555 Replacing side panel - section on "Installing"
SUBSEQUENT WORK
2005 (All Models) .

Microsoft
53 69 19 REMOVING AND INSTALLING REAR WHEEL HOUSING LINER - AS

PRELIMINARY WORK
Preliminary work
Remove rear wheel. Refer to 44 05 19 Removing and installing wheel - as of MY 2005 (All Models) .
REMOVING REAR WHEEL HOUSING LINER
Removing heat protection cover
Fig. 281: Installation position of rear wheel housing liner

Microsoft
Fig. 282: Removing heat protection cover

1. Unscrew fastening nuts -2- and fastening screw -1- . See Fig. 282.
2. Take off heat protection cover -3- . See Fig. 282.
Removing rear wheel housing liner
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Fig. 284: Removing rear wheel housing liner

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1. Unscrew fastening screws -1- and fastening nuts -2- . See Fig. 284.
2. Remove wheel housing liner -3- . See Fig. 284.
INSTALLING REAR WHEEL HOUSING LINER
Installing rear wheel housing liner

Microsoft
Fig. 286: Installing rear wheel housing liner

1. Insert wheel housing liner -3- . See Fig. 286.
See Fig. 286.
3. Screw on fastening nuts -2- and tighten to the specified tightening torque --> Final tightening: 1 ftlb. . See
Fig. 286.
Installing heat protection cover
Microsoft

Fig. 288: Installing heat protection cover

1. Insert heat protection cover -3- . See Fig. 288.
2. Screw on fastening screw -1- and tighten to tightening torque --> Tightening torque: 1.5 ftlb. . See Fig. 288.
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3. Screw on fastening nuts -2- and tighten to the specified tightening torque --> Tightening torque: 1 ftlb. . See
Fig. 288.
SUBSEQUENT WORK
Subsequent work
Install rear wheel. Refer to 44 05 19 Removing and installing wheel - as of MY 2005 (All Models) .
Microsoft
ACCESSORIES & EQUIPMENT Seats, frames
Seats, frames
72 01 19 REMOVING AND INSTALLING FRONT SEAT - AS OF MY 2005 (ALL

RHD MODELS)
REMOVING FRONT SEAT
Removing seat rail cover
Fig. 1: Installation position of front seat

NOTE: Caution! Locking lugs can break.
Microsoft
Fig. 2: Removing seat rail cover

1. Insert a screwdriver -1- under the lugs and press upwards slightly -Arrow A- . See Fig. 2.
2. Pull seat rail covers -2- on right and left seat rails off in forward direction. See Fig. 2.
Undoing seat screws at front
Microsoft

Fig. 4: Undoing seat screws at front

1. Move seat -1- to its rear limit position and undo the front fastening screws -2- from the right and left seat rails
-3- . See Fig. 4.
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Undoing seat screws at rear

Fig. 6: Undoing seat screws at rear

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1. Move seat to its front limit position and undo the fastening screws -1- from the right and left seat rails -2- .
See Fig. 6.
Releasing electrical line

(All Models) .
Microsoft
Fig. 8: Releasing electrical line

2. Tilt seat backwards.
3. Unclip wiring harness -1- . See Fig. 8.
Disconnecting central plug
Microsoft

Fig. 10: Disconnecting central plug

1. Release plug connector locking device -1- on the side -Arrow A- and separate the plug connection -2- -
Microsoft
Disconnecting electrical plug connection (power seat)

NOTE: Only for vehicles with electrically adjustable seat
Microsoft
Fig. 12: Disconnecting seat memory plug connection

1. Release electrical plug connection -1- by activating the locking tab -arrow A- and remove from seat memory
control unit -arrow B- . See Fig. 12.
2. Remove front seat.
INSTALLING FRONT SEAT
Fastening electric line

catch at the seat.

control unit
Microsoft

Microsoft
Fig. 15: Fastening electric line

NOTE: Before installing and securing the front seat, make sure the electric lines are
not pinched or damaged.
1. Place front seat in vehicle and tilt backwards.
2. Check tie-wrap -1- ; replace tie-wrap -1- if necessary. See Fig. 15.
3. Clip wire harness -2- into place. See Fig. 15.
Connecting electrical plug connection (power seat)
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Fig. 17: Locking plug connection for seat memory

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1. Push in electrical plug connection -1- -arrow A- until the locking tab audibly engages -arrow B- . See Fig.
17.
Locking central plug

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Fig. 19: Locking central plug

1. Join the plug connection -1- -Arrow A- , press in plug connector locking device -2- on the side -Arrow B- .
See Fig. 19.
Tightening seat screws at rear
Microsoft

 Danger of injury if front seat is not screwed down correctly.
--> Always replace fastening screws for the front seat after customer service and reworking.
--> It is not permissible to make alterations to the micro-encapsulated screws (e. g., use lubricant, loosen bolts,
Microsoft
Fig. 21: Tightening seat screws at rear

1. Tip seat forwards and position seat rails on the seat baseframe.
2. Screw left and right fastening screws -1- into seat bracket -2- and tighten to specified tightening torque -->
Final tightening: 50 (37 ftlb.) Nm . See Fig. 21.
Tightening seat screws at the front
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(All Models) .
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Fig. 23: Tightening seat screws at the front

2. Move seat -1- to rear end position and screw down front fastening screws -2- to specified tightening torque --
> Final tightening: 50 (37 ftlb.) Nm . See Fig. 23.
Fit seat rail cover
Microsoft

Fig. 25: Fitting seat rail cover

1. Push seat rail cover -1- into front end of the left and right seat rails -Arrow A- until the locking tab audibly
engages -Arrow B- . See Fig. 25.
Microsoft
72 01 19 REMOVING AND INSTALLING FRONT SEAT - AS OF MY 2005 (ALL

LHD MODELS)
REMOVING FRONT SEAT
Removing seat rail cover

NOTE: Caution! Locking lugs can break.
Microsoft
Fig. 27: Removing seat rail cover

1. Insert a screwdriver -1- under the lugs and press upwards slightly -Arrow A- . See Fig. 27.
2. Pull seat rail covers -2- on right and left seat rails off in forward direction. See Fig. 27.
Undoing seat screws at front
Microsoft

Fig. 29: Undoing seat screws at front

1. Move seat -1- to its rear limit position and undo the front fastening screws -2- from the right and left seat rails
-3- . See Fig. 29.
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Undoing seat screws at rear

Fig. 31: Undoing seat screws at rear

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1. Move seat to its front limit position and undo the fastening screws -1- from the right and left seat rails -2- .
See Fig. 31.
Releasing electrical line

(All Models) .
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Fig. 33: Releasing electrical line

2. Tilt seat backwards.
3. Unclip wiring harness -1- . See Fig. 33.
Disconnecting central plug
Microsoft

Fig. 35: Disconnecting central plug

1. Release plug connector locking device -1- on the side -Arrow A- and separate the plug connection -2- -
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Disconnecting electrical plug connection (power seat)

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Fig. 37: Disconnecting seat memory plug connection

1. Release electrical plug connection -1- by activating the locking tab -arrow A- and remove from seat memory
control unit -arrow B- . See Fig. 37.
2. Remove front seat.
Disconnecting the electrical plug connection of the AWS control module

NOTE:  Passenger's seat only.
Microsoft
Fig. 39: Disconnecting the plug connection of the AWS control module
1. Release electric connector -1- by pressing the lug -arrow a- and pull off from control module. See Fig. 39.
INSTALLING FRONT SEAT
Fastening electric line
Microsoft

catch at the seat.

control unit
Microsoft

Microsoft

NOTE: Before installing and securing the front seat, make sure the electric lines are
not pinched or damaged.
1. Place front seat in vehicle and tilt backwards.
2. Check tie-wrap -1- ; replace tie-wrap -1- if necessary. See Fig. 42.
3. Clip wire harness -2- into place. See Fig. 42.
Locking the electrical plug connection of the AWS control module
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Microsoft
Fig. 44: Locking the plug connection of the AWS control module
1. Push electric connector -1- onto AWS control module until it is felt to engage. See Fig. 44.
Connecting electrical plug connection (power seat)

Microsoft
Fig. 46: Locking plug connection for seat memory

1. Push in electrical plug connection -1- -arrow A- until the locking tab audibly engages -arrow B- . See Fig.
46.
Locking central plug
Microsoft

Fig. 48: Locking central plug

1. Join the plug connection -1- -Arrow A- , press in plug connector locking device -2- on the side -Arrow B- .
See Fig. 48.
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Tightening seat screws at rear

Microsoft
Fig. 50: Tightening seat screws at rear

1. Tip seat forwards and position seat rails on the seat baseframe.
2. Screw left and right fastening screws -1- into seat bracket -2- and tighten to specified tightening torque -->
Final tightening: 50 (37 ftlb.) Nm . See Fig. 50.
Tightening seat screws at the front
Microsoft

(All Models) .
Microsoft
Fig. 52: Tightening seat screws at the front

2. Move seat -1- to rear end position and screw down front fastening screws -2- to specified tightening torque --
> Final tightening: 50 (37 ftlb.) Nm . See Fig. 52.
Fit seat rail cover
Microsoft

Fig. 54: Fitting seat rail cover

1. Push seat rail cover -1- into front end of the left and right seat rails -Arrow A- until the locking tab audibly
engages -Arrow B- . See Fig. 54.
Microsoft
SUBSEQUENT WORK
Subsequent work
WARNING: Incorrect information for AWS control module.
 Passenger's airbag is triggered differently.
--> If the passenger's seat was removed and re-installed, the AWS control module must be calibrated.
--> If the seat bracket was replaced, the AWS control module must be calibrated.
--> If the AWS control module was replaced, the AWS control module must be calibrated.
1. Calibrate the AWS control module. Refer to 69 68 K2 Calibrating AWS control unit - as of MY 2005 (All
Models) .
72 06 19 REMOVING AND INSTALLING AIR CUSHION SWITCH - AS OF MY

2005 (ALL MODELS)
PRELIMINARY WORK
Preliminary work
Remove control module trim panel (electric). --> 721619 Removing and installing control module trim panel
REMOVING AIR CUSHION SWITCH
Microsoft

Microsoft
57.
Removing switch for air cushion
Microsoft
Fig. 58: Installation position of switch for air cushion

Fig. 59: Removing switch for air cushion

1. Remove the two tie-wraps -2- on wire harness of switch for air cushion -1- . See Fig. 59.
2. Pull plug connection -3- out of holder -4- ( -arrow B- ). See Fig. 59.
3. Release plug connection -3- ( -arrow a- ) and disconnect it -arrows C- . See Fig. 59.
INSTALLING AIR CUSHION SWITCH
Installing switch for air cushion
Microsoft
Fig. 60: Installing switch for air cushion

1. Push plug connection -3- together -arrows A- until it engages securely. See Fig. 60.
2. Push plug connection -3- into holder -4- ( -arrow B- ). See Fig. 60.
3. Lay wire harness of switch for air cushion -1- and secure with two new tie-wraps -2- . See Fig. 60.
Microsoft
Microsoft
SUBSEQUENT WORK
Subsequent work
Install control module trim panel (electric). --> 721619 Removing and installing control module trim panel -
72 09 55 REPLACING SEAT FRAME - AS OF MY 2005 (ALL RHD MODELS)

PRELIMINARY WORK
Preliminary work
1. Remove padding for front seat. Refer to 74 10 19 Removing and installing padding for front seat - as of
2. Remove belt lock. Refer to 69 24 19 Removing and installing front belt lock - as of MY 2005 (All
Models) .
NOTE: Only for vehicles with adaptive sports seats.
3. Remove air cushion motor. --> 723919 Removing and installing air cushion motor - section on
"Removing"
4. Remove air cushion control valve. --> 723819 Removing and installing air cushion control valve - section
on "Removing"
5. Remove switch for air cushion. --> 720619 Removing and installing air cushion switch - section on
"Removing"
6. Remove wire harness for electrically adjustable seats. Refer to 97 57 19 Removing and installing wire
harness for electrically adjustable seat - as of MY 2005 (All Models) .
NOTE:
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 Passenger's seat only.
7. Remove AWS control unit. Refer to 69 68 19 Removing and installing AWS control unit - as of MY 2005
(All Models) .
8. Remove air cushion for seat. --> 721419 Removing and installing air cushion for seat - section on
"Removing"
DISASSEMBLING SEAT FRAME
Removing frame for seat surface
Microsoft
Fig. 63: Removing frame for seat surface

1. Press out retaining pins -1- at the left and right with a screwdriver. See Fig. 63.
2. Unscrew fastening screws -2- , pull frame for seat surface -3- downwards -arrow A- and remove outwards -
arrow B- from the seat frame -4- . See Fig. 63.
Removing backrest frame
Fig. 64: Removing backrest frame

NOTE: Two persons are needed to remove and install the backrest frame.
1. Secure backrest frame -2- in upright position. See Fig. 64.
2. Unscrew fastening screws -1- on left and right and remove backrest frame -2- up out of the seat frame. See
Fig. 64.
ASSEMBLING SEAT FRAME
Installing backrest frame
Microsoft
Fig. 65: Installing backrest frame

1. Fit backrest frame -2- into the seat frame, position it correctly and secure with the fastening screws -1- .
Tightening torque --> Tightening torque: 34 (25 ftlb.) Nm +/-4 (3 ftlb.) Nm . See Fig. 65.
Installing frame for seat surface
Microsoft
Fig. 66: Installing frame for seat surface

1. Position frame for seat surface -3- on the seat frame -4- ( -arrow A- ), press it upwards -arrow B- and screw
down the fastening screws -2- . See Fig. 66.
2. Press in new retaining pins -1- at the left and right. See Fig. 66.
SUBSEQUENT WORK
Subsequent work
Microsoft
1. Install air cushion for seat. --> 721419 Removing and installing air cushion for seat - section on
"Installing"
2. Install wire harness for electrically adjustable seats. Refer to 97 57 19 Removing and installing wire
3. Install AWS control unit. Refer to 69 68 K2 Calibrating AWS control unit - as of MY 2005 (All Models) .
4. Install switch for air cushion. --> 720619 Removing and installing air cushion switch - section on
"Installing"
5. Install air cushion control valve. --> 723819 Removing and installing air cushion control valve - section
on "Installing"
6. Install air cushion motor. --> 723819 Removing and installing air cushion motor - section on "Installing"
7. Install belt lock. Refer to 69 24 19 Removing and installing front belt lock - as of MY 2005 (All Models) .
8. Install padding for front seat. Refer to 74 10 19 Removing and installing padding for front seat - as of MY
2005 (All Models) .
72 09 55 REPLACING SEAT FRAME - AS OF MY 2005 (ALL LHD MODELS)

PRELIMINARY WORK
Preliminary work
2. Remove belt lock. Refer to 69 24 19 Removing and installing front belt lock - as of MY 2005 (All
Models) .

Microsoft
3. Remove air cushion motor. --> 723919 Removing and installing air cushion motor - section on
"Removing"
4. Remove air cushion control valve. --> 723819 Removing and installing air cushion control valve - section
on "Removing"
5. Remove switch for air cushion. --> 720619 Removing and installing air cushion switch - section on
"Removing"
6. Remove wire harness for electrically adjustable seats. Refer to 97 57 19 Removing and installing wire
7. Remove AWS control unit. Refer to 69 68 19 Removing and installing AWS control unit - as of MY 2005
(All Models) .
8. Remove air cushion for seat. --> 721419 Removing and installing air cushion for seat - section on
"Removing"
DISASSEMBLING SEAT FRAME
Removing cover for AWS sensor on left and right
Microsoft
Fig. 67: Removing cover for AWS sensor

1. Unscrew fastening screws -1- and remove cover for AWS sensor -2- in direction of arrow. See Fig. 67.
Removing frame for seat surface
Microsoft
Fig. 68: Removing frame for seat surface

1. Press out retaining pins -1- at the left and right with a screwdriver. See Fig. 68.
2. Unscrew fastening screws -2- , pull frame for seat surface -3- downwards -arrow A- and remove outwards -
arrow B- from the seat frame -4- . See Fig. 68.
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Fig. 69.
ASSEMBLING SEAT FRAME
Microsoft

Installing frame for seat surface
Microsoft
Fig. 71: Installing frame for seat surface

1. Position frame for seat surface -3- on the seat frame -4- ( -arrow A- ), press it upwards -arrow B- and screw
down the fastening screws -2- . See Fig. 71.
2. Press in new retaining pins -1- at the left and right. See Fig. 71.
Installing cover for AWS sensor on left and right
Microsoft
Fig. 72: Installing cover for AWS sensor

1. Fit cover for AWS sensor -2- in direction of arrow and tighten hand-tight using the fastening screws -1- . See
Fig. 72.
SUBSEQUENT WORK
Subsequent work
1. Install air cushion for seat. --> 721419 Removing and installing air cushion for seat - section on
"Installing"
Microsoft
2. Install wire harness for electrically adjustable seats. Refer to 97 57 19 Removing and installing wire
3. Install AWS control unit. Refer to 69 68 K2 Calibrating AWS control unit - as of MY 2005 (All Models) .
4. Install switch for air cushion. --> 720619 Removing and installing air cushion switch - section on
"Installing"
5. Install air cushion control valve. --> 723819 Removing and installing air cushion control valve - section
on "Installing"
6. Install air cushion motor. --> 723819 Removing and installing air cushion motor - section on "Installing"
7. Install belt lock. Refer to 69 24 19 Removing and installing front belt lock - as of MY 2005 (All Models) .
2005 (All Models) .
72 14 19 REMOVING AND INSTALLING AIR CUSHION FOR SEAT - AS OF

PRELIMINARY WORK
Preliminary work
REMOVING AIR CUSHION FOR BACKREST
Removing air cushion for seat
Microsoft
Fig. 73: Installation position of air cushion for seat

Microsoft
Fig. 75: Pulling hose off the air cushion control valve
3. Pull the white hose -1- off the air cushion control valve. See Fig. 75.
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Fig. 76: Unscrewing fastening screws on the air cushion support plate
4. Fold the air cushion for the seat -1- aside -Arrow A- and unscrew the two fastening screws -2- on the air
cushion support plate -3- . See Fig. 76.
5. Take air cushion support plate -3- off -Arrow B- . See Fig. 76.
Fig. 77: Removing air cushion for seat

6. Push the pins -2- of the two expanding clips -1- back ( -Arrow A- ) and remove the expanding clips -1- -
Arrows B- . See Fig. 77.
7. Remove air cushion for seat ( -3- ). See Fig. 77.
INSTALLING AIR CUSHION FOR BACKREST
Installing air cushion for seat
Microsoft
Fig. 78: Installing air cushion for seat

1. Position air cushion for seat -3- on the air cushion support plate -Arrow A- . See Fig. 78.
NOTE: The air cushion for the seat is fastened only with the rear air cushion on the air
cushion support plate.
2. Secure the air cushion for the seat -3- . Use the two expanding clips -1- to fasten -Arrows B- it. To do this,
the pins -2- must be forced into the expanding clips -1- by pressing Fig. 78 -Arrow C- . See Fig. 78.
Microsoft
Fig. 79: Tightening the fastening screws on the air cushion support plate
3. The air cushion support plate -3- must be fitted into the seat frame -4- by inserting -Arrow A- the guides into
the seat frame. See Fig. 79.
4. Fasten the air cushion support plate -3- with the two fastening screws -2- . See Fig. 79.
5. The air cushion for the seat -1- must be folded over -Arrow B- and aligned with the air cushion support plate
-3- . See Fig. 79.
Microsoft
Fig. 80: Pushing hose onto the air cushion control valve
6. Push the white hose -1- onto the air cushion control valve. See Fig. 80.
Microsoft
SUBSEQUENT WORK
Subsequent work
2005 (All Models) .
72 16 19 REMOVING AND INSTALLING CONTROL MODULE TRIM PANEL -

REMOVING CONTROL MODULE TRIM PANEL
Preliminary work
1. Remove front seat. --> 720119 Removing and installing front seat - chapter on "Removing" [987120
987310 987320] --> 720119 Removing and installing front seat - chapter on "Removing" [987121 987311
987321]
Removing control part trim panel
Microsoft
Fig. 82: Installation location for control part trim panel

Microsoft
Fig. 83: Unscrewing front fastening screw

1. Unscrew front fastening screws 1 from the control part trim panel2 .
Microsoft
Fig. 84: Unscrewing the rear fastening screw

2. Unscrew rear fastening screws 1 from the control part trim panel2 .
Microsoft
Fig. 85: Pulling out control part trim panel

3. Pull out control part trim panel 2 from the cushion in direction of arrow.
Microsoft

4. Disconnect electric plug connection 3 and 4 , unscrew fastening screws 5 from the tip switch 6 and take off
the tip switch from the control part trim panel 2 .
Removing control part trim panel (with mechanical lever)
Microsoft
Fig. 87: Pressing out trim panel

1. Press out trim panel 7 using a plastic spatula.
Microsoft
Fig. 88: Unscrewing fastening screw

2. Unscrew fastening screw 8 from the lever 9 and remove lever.
3. Removing control part trim panel, work step 1, 2, 3
Microsoft

4. Disconnect electric plug connection 10 by pressing together the lugs arrow .
Installing control part trim panel
Microsoft
Fig. 90: Connect electrical plug connection

1. Position tip switch 6 on the control part trim panel 2 and screw down with the fastening screws 5 . Plug in
electrical plug connection 3 and 4 .
Microsoft
Fig. 91: Positioning control part trim panel

2. Insert control part trim panel 2 into the cushion in direction of arrow.
Microsoft
Fig. 92: Screwing down rear control part trim panel

3. Screw down rear control part trim panel 2 with the fastening screws 1 . --> Tightening torque: 2 ftlb.
Microsoft
Fig. 93: Screwing down front control part trim panel

4. Screw down front control part trim panel 2 with the fastening screws 1 . --> Tightening torque: 2 ftlb.
Installing control part trim panel (mechanical)
Microsoft

1. Connect electrical plug connection 10 .
2. Procedure: Installing control part trim panel, work step 2, 3, 4
Microsoft
Fig. 95: Screwing down lever

3. Position lever 9 on seat, screw down fastening screw 8 . --> Tightening torque: 4.5 ftlb.
Microsoft
Fig. 96: Pressing in trim panel

4. Press in trim panel.
Subsequent work
1. Install front seat. --> 720119 Removing and installing front seat - chapter on "Installing" [987120
987310 987320] --> 720119 Removing and installing front seat - chapter on "Installing" [987121 987311
987321]
72 17 19 REMOVING AND INSTALLING AIR CUSHION FOR BACKREST - AS

TOOLS

test cable special tool P 9745
test cable special tool P 9745/1
Microsoft
PRELIMINARY WORK
Preliminary work
1. Remove padding for front backrest. Refer to 74 17 19 Removing and installing padding for front backrest
NOTE: Only necessary if you are removing the hose for the air cushion control valve!
2. Remove cover for left backrest. --> 722619 Removing and installing cover for backrest - section on
"Removing"
REMOVING AIR CUSHION FOR BACKREST
Removing air cushion for backrest
Fig. 97: Installation position of air cushion for backrest

Microsoft
Fig. 98: Pulling off hoses on air cushion for backrest

1. Remove the two tie-wraps -1- . See Fig. 98.
2. Pull off the two hoses for the air cushion for backrest -2- at the branch piece -3- . See Fig. 98.
Microsoft
Fig. 99: Removing air cushion for backrest

3. Push out the pins -2- on the two expanding clips -1- ( -arrow A- ) and remove the expanding clips -1- . See
Fig. 99.
4. Remove air cushion for backrest -3- ( -arrow C- ). See Fig. 99.
Microsoft
Fig. 100: Pulling out hose

5. Pull air cushion for backrest -1- together with the hose out of the backrest frame. See Fig. 100.
Removing hose for air cushion control valve
Microsoft
Fig. 101: Removing hose

1. Remove tie-wraps -2- and push hose -1- for air cushion control valve through in a downward direction -
arrow A- . See Fig. 101.
2. Unclip the hose -1- at the holder -3- ( -arrow B- ). See Fig. 101.
Microsoft
Fig. 102: Pulling hose off the air cushion control valve
3. Pull hose -1- off the air cushion control valve. See Fig. 102.
INSTALLING AIR CUSHION FOR BACKREST
Installing hose for air cushion control valve
Microsoft
Fig. 103: Pushing hose onto the air cushion control valve
1. Push hose -1- onto the air cushion control valve. See Fig. 103.
Microsoft
Fig. 104: Fitting hose

2. Lay the hose -1- and clip it into the holder -3- ( -arrow A- ). See Fig. 104.
3. Pull the hose -1- through in an upward direction -arrow B- and secure with a new tie-wrap -2- . See Fig. 104.
Installing air cushion for backrest
Microsoft
Fig. 105: Routing the hose

1. Slide hose for the air cushion for backrest -1- into the backrest frame. See Fig. 105.
Microsoft
Fig. 106: Installing air cushion for backrest

2. Position air cushion for backrest -3- ( -arrow A- ). See Fig. 106.
3. Secure the air cushion for backrest -3- with the two expanding clips -1- ( -arrows B- ). To do this, press the
pins -2- into the expanding clips -1- ( Fig. 106 -arrow C- ). See Fig. 106.
Fig. 107: Connecting hoses on air cushion for backrest

4. Slide the two hoses for the air cushion for backrest -2- onto the branch piece -3- and secure with two new tie-
wraps -1- . See Fig. 107.
Checking seat following removal
1. Connect the removed seat to the vehicle's wiring harness via test cable P 9745 and test cable P 9745/1.
2. Connect electric plug to control module trim panel. --> 721619 Removing and installing control module
trim panel - section on "Installing"
(All Models) .
Microsoft
5. Carry out a function check on the seat components.
6. Switch off ignition after function test and disconnect battery.
7. Disconnect test cable P 9745 and test cable P 9745/1.
SUBSEQUENT WORK
Subsequent work
1. Install cover for left backrest. --> 722619 Removing and installing cover for backrest - section on
"Installing"
2. Install padding for front backrest. Refer to 74 17 19 Removing and installing padding for front backrest -
72 19 55 REPLACING BACKREST FRAME - AS OF MY 2005 (ALL MODELS)

PRELIMINARY WORK
Preliminary work
1. Remove cushion carrier for front backrest. --> 722419 Removing and installing cushion carrier for front
backrest - section on "Removing"
NOTE: Only for vehicles with lumbar support.
2. Remove control valve for lumbar support adjustment. --> 723319 Removing and installing control valve
for lumbar support adjustment - section on "Removing"
3. Remove lumbar support. --> 723419 Removing and installing lumbar support - section on "Removing"
4. Remove motor for lumbar support. --> 723619 Removing and installing motor for lumbar support -
5. Remove air cushion for backrest. --> 721719 Removing and installing air cushion for backrest - section
on "Removing"
DISASSEMBLING BACKREST FRAME

Microsoft
Removing foam part
Fig. 108: Taking off foam part

1. Remove foam part -1- at the headrest. See Fig. 108.
Removing supports for backrest side parts
Microsoft
Fig. 109: Removing support for right backrest side part

1. Unscrew fastening screws -1- and remove support for right backrest side part -2- . See Fig. 109.
Microsoft
Fig. 110: Removing support for left backrest side part

2. Unscrew fastening screws -1- and remove support for left backrest side part -2- . See Fig. 110.
Removing inner spring on backrest frame
Microsoft
Fig. 111: Removing inner spring on backrest frame

1. Disengage tension springs -1- at left and right on inner spring -2- ( -arrows A- ). See Fig. 111.
2. Unclip inner spring -2- on backrest frame at the drive shaft -arrow B- and remove inner spring. See Fig. 111.
3. Disengage tension springs -1- on the backrest frame. See Fig. 111.
Disconnecting wire harnesses on backrest frame
Microsoft
Fig. 112: Pulling out wire harness for backrest


Make sure not to trap or damage the wire harness when pulling it through.
1. Pull wire harness for backrest -1- down out of the backrest frame -2- . See Fig. 112.
Microsoft

2. Turn plug connection -1- approx. 90° anti-clockwise -arrow A- and pull it off the backrest frame -arrow B- .
See Fig. 113.
3. Release plug connection -arrows C- and disconnect it -arrows D- . See Fig. 113.
NOTE: Make sure not to trap or damage the wire harness when pulling it through.
4. Press locking tabs on fixing clip -2- together and unclip it -arrow E- . Pull wire harness for backrest -3-
down and out -arrow F- . See Fig. 113.
5. Press locking tabs on fixing clip -2- together and unclip wire harness for side airbag -4- from the backrest
Microsoft
frame -arrow G- . See Fig. 113.
Removing frame for side airbag
Fig. 114: Removing frame for side airbag

1. Unscrew fastening screws -1- and unclip frame for side airbag -2- from the backrest frame -3- . See Fig. 114.
Disassembling backrest frame
Microsoft
Fig. 115: Removing fastening nuts

1. Remove fastening nuts -1- from the backrest frame -2- , check them and replace if necessary. See Fig. 115.
Microsoft
Fig. 116: Removing fixing clips

2. Unclip fixing clips -1- from the backrest frame -2- , check them and replace if necessary. See Fig. 116.
Microsoft

Fig. 117.
ASSEMBLING BACKREST FRAME
Microsoft

Assembling backrest frame
Microsoft

1. Press in fixing clips -1- on the backrest frame -2- . See Fig. 119.
Microsoft
Fig. 120: Screwing on fastening nuts

2. Screw fastening nuts -1- onto the backrest frame -2- . See Fig. 120.
Installing frame for side airbag
Microsoft
Fig. 121: Installing frame for side airbag

1. Clip frame for side airbag -2- to backrest frame -3- and secure with the fastening screws -1- . See Fig. 121.
Securing wire harnesses on backrest frame
Microsoft
Fig. 122: Pulling through wire harness for backrest


Make sure not to trap or damage the wire harness when pulling it through.
1. Pull wire harness for backrest -1- up into the backrest frame -2- . See Fig. 122.
Microsoft
Fig. 123: Securing wire harness for backrest

2. Press fixing clip -2- on wire harness for side airbag onto the backrest frame -arrow A- . See Fig. 123.
NOTE: Make sure not to trap or damage the wire harness when pulling it through.
3. Pull wire harness for backrest -3- through -arrow B- and press in fixing clip -2- ( -arrow C- ). See Fig. 123.
4. Push plug connection -1- together -arrows D- until it engages securely. See Fig. 123.
5. Insert plug connection -1- into the backrest frame -arrow E- and turn it clockwise by approx. 90° -arrow F- .
See Fig. 123.
Microsoft
Installing inner spring on backrest frame
Fig. 124: Engaging inner spring on backrest frame

1. Engage tension springs -1- in the backrest frame. See Fig. 124.
2. Clip in inner spring -2- on lower part of backrest frame at the drive shaft -arrow A- . See Fig. 124.
3. Engage tension springs -1- in the inner spring -2- on the backrest frame -arrow B- . See Fig. 124.
Installing supports for backrest side parts
Microsoft
Fig. 125: Installing support for left backrest side part

NOTE: Observe hose routing!
In vehicles with lumbar support, make sure the hoses are routed correctly in the
area of the backrest side support.
1. Insert support for left backrest side part -2- and secure with the fastening screws -1- . See Fig. 125.
Microsoft
Fig. 126: Routing wire harness for side airbag

2. Route wire harness for side airbag -1- as shown behind the backrest side part support -2- . See Fig. 126.
Microsoft
Fig. 127: Installing support for right backrest side part

3. Insert support for right backrest side part -2- and secure with the fastening screws -1- . See Fig. 127.
Fitting foam part
Microsoft
Fig. 128: Fitting foam part

1. Fit foam part -1- to the headrest. See Fig. 128.
SUBSEQUENT WORK
Subsequent work
1. Install air cushion for backrest. --> 721719 Removing and installing air cushion for backrest - section on
"Installing"
2. Install motor for lumbar support. --> 723619 Removing and installing motor for lumbar support - section
on "Installing"
3. Install lumbar support. --> 723419 Removing and installing lumbar support - section on "Installing"
Microsoft
4. Install control valve for lumbar support adjustment. --> 723319 Removing and installing control valve for
lumbar adjustment - section on "Installing"
5. Install cushion carrier for front backrest. --> 722419 Removing and installing cushion carrier for front
backrest - section on "Installing"
72 24 19 REMOVING AND INSTALLING CUSHION CARRIER FOR FRONT

BACKREST - AS OF MY 2005 (ALL MODELS)
PRELIMINARY WORK
Preliminary work
Remove padding for backrest. Refer to 74 17 19 Removing and installing padding for front backrest - as of
Preliminary work
1. Remove padding for front backrest. Refer to 74 17 19 Removing and installing padding for front backrest
2. Remove side airbag. Refer to 69 63 19 Removing and installing side airbag - as of MY 2005 (All
Models) .
3. Remove control button for backrest release. --> 723119 Removing and installing control button for
backrest adjustment - section on "Removing"
REMOVING CUSHION CARRIER FOR FRONT BACKREST
Removing cushion carrier for front backrest
Microsoft
Fig. 129: Loosening cushion carrier

1. Undo fastening screws -1, 2- . See Fig. 129.
Microsoft
Fig. 130: Loosening cushion carrier at the sides

2. Pull out frame for side airbag -2- slightly and unclip locking tabs from cushion carrier -1- using a
Microsoft
Fig. 131: Removing cushion carrier

3. Release upper locking tabs in direction of arrow -Inset A- . See Fig. 131.
4. Press lower locking tabs together and unclip cushion carrier -1- ( -Inset B- ). See Fig. 131.
5. Press cushion carrier -1- outward slightly in area of backrest release and remove it. See Fig. 131.
Removing cushion carrier for front backrest
Microsoft
Fig. 132: Installation position of cushion carrier

Microsoft
Fig. 133: Removing foam part of headrest

1. Remove foam part of headrest -1- . See Fig. 133.
Microsoft
Fig. 134: Removing collar

2. Insert a plastic wedge between the cushion carrier -1- and the collar -2- and unclip collar. See Fig. 134.
Fig. 135: Loosening cushion carrier

Microsoft
Fig. 136: Removing cushion carrier

4. Release upper locking tabs in direction of arrow -Inset A- . See Fig. 136.
5. Press lower locking tabs together and unclip cushion carrier -1- ( -Inset B- ). See Fig. 136.
6. Press cushion carrier -1- outward slightly close to the backrest release and remove it. See Fig. 136.
INSTALLING CUSHION CARRIER FOR FRONT BACKREST
Installing cushion carrier for front backrest
Microsoft
Fig. 137: Installing cushion carrier

1. Press cushion carrier -1- outward slightly in area of backrest release and position it on the backrest frame -2-
until the locking tabs engage at the top -Inset A- and bottom -Inset B- . See Fig. 137.
Microsoft
Fig. 138: Fastening cushion carrier at the sides

2. Press cushion carrier -1- at the sides into the frame for the side airbag -2- until the locking tabs engage. See
Fig. 138.
Microsoft
Fig. 139: Securing cushion carrier

3. Tighten fastening screws -1, 2- . See Fig. 139.
Installing cushion carrier for front backrest
Microsoft
Fig. 140: Installation position of cushion carrier

Microsoft
Fig. 141: Installing cushion carrier

1. Press cushion carrier -1- outward slightly close to the backrest release and position it on the backrest frame -
2- until the locking tabs engage at the top -Inset A- and bottom -Inset B- . See Fig. 141.
Microsoft
Fig. 142: Securing cushion carrier

2. Tighten fastening screws -1- . See Fig. 142.
Microsoft
Fig. 143: Installing collar

3. Position collar -2- on the cushion carrier -1- and press in until it clicks into place. See Fig. 143.
Microsoft
Fig. 144: Fitting foam part of headrest

4. Fit foam part of headrest -1- . See Fig. 144.
SUBSEQUENT WORK
Subsequent work
Install padding for backrest. Refer to 74 17 19 Removing and installing padding for front backrest - as of
Subsequent work
1. Install control button for backrest release. --> 723119 Removing and installing control button for backrest
adjustment - section on "Installing"
2. Install side airbag. Refer to 69 63 19 Removing and installing side airbag - as of MY 2005 (All Models) .
3. Install padding for front backrest. Refer to 74 17 19 Removing and installing padding for front backrest -
72 25 19 REMOVING AND INSTALLING BOWDEN CABLE FOR BACKREST

RELEASE - AS OF MY 2005 (ALL MODELS)
PRELIMINARY WORK
Preliminary work
REMOVING BOWDEN CABLE FOR BACKREST RELEASE
Removing bowden cable for backrest release
1. Release backrest and tilt forwards.
Microsoft
Fig. 145: Disengaging bowden cable upwards

2. Swivel pin -2- of bowden cable -1- up by 90° -arrow A- and disengage it -arrow B- . See Fig. 145.
3. Press locking tab on fixing clip -3- outwards slightly and press fixing clip -3- down and out with a plastic
hammer -arrow C- . See Fig. 145.
Microsoft
Fig. 146: Disengaging bowden cable downwards

4. Swivel eye -2- of bowden cable -1- by 90° -arrow A- and pull it out of the locking lever. See Fig. 146.
5. Unclip fixing clip -3- from the backrest frame -1- ( -arrow B- ). See Fig. 146.
6. Pull bowden cable -1- up out of the backrest frame -arrows C- . See Fig. 146.
Removing backrest frame release
Microsoft
Fig. 147: Removing backrest frame release

1. Disengage tension spring -1- . See Fig. 147.
2. Press retaining pins -2- out with a screwdriver and remove backrest frame release -3- . See Fig. 147.
3. Press out rubber stop -4- . See Fig. 147.
INSTALLING BOWDEN CABLE FOR BACKREST RELEASE
Installing backrest frame release
Microsoft
Fig. 148: Installing backrest frame release

1. Press in rubber stop -4- . See Fig. 148.
2. Position backrest frame release -3- and secure with new retaining pins -2- . See Fig. 148.
3. Engage tension spring -1- . See Fig. 148.
Installing bowden cable for backrest release
Microsoft
Fig. 149: Installing bowden cable

1. Insert bowden cable -1- downwards into the backrest frame from above -Arrows A- . See Fig. 149.
2. Insert eye -2- of bowden cable -1- into the locking lever and swivel by 90° -Arrow B- . See Fig. 149.
3. Press fixing clip -3- with bowden cable into the backrest frame -Arrow C- . See Fig. 149.
Microsoft
Fig. 150: Engaging bowden cable at the top

4. Position fixing clip -3- on backrest frame and tap it upwards into place with a plastic hammer -Arrow A- .
See Fig. 150.
5. Engage pin -2- of bowden cable -1- ( -Arrow B- ) and swivel downwards by 90° -Arrow C- . See Fig. 150.
SUBSEQUENT WORK
Subsequent work
Microsoft
72 26 19 REMOVING AND INSTALLING COVER FOR BACKREST - AS OF

REMOVING COVER FOR BACKREST
Preliminary work
1. Remove front seat. --> 720119 Removing and installing front seat - chapter on "Removing" [987120
987310 987320] --> 720119 Removing and installing front seat - chapter on "Removing" [987121 987311
987321]
2. Remove control module trim panel. --> 721619 Removing and installing control module trim panel -
chapter on "Removing"
Removing cover for outer backrest
Fig. 151: Installation position of backrest cover

Microsoft
Fig. 152: Unscrewing fastening screw laterally

1. Unscrew fastening screw -1- laterally out of the cover -2- . See Fig. 152.
Microsoft
Fig. 153: Unscrewing lower fastening screw

2. Unscrew lower fastening screw -1- out of the cover -2- . See Fig. 153.
Microsoft
Fig. 154: Remove cover

3. Unclip cover -1- at the front -inset A- and remove by pulling backwards in direction of arrow -inset B- . See
Fig. 154.
Installing cover for outer backrest

1. Insert cover -1- at the back in direction of arrow -inset A- and press into position at the front -inset B- . See
Fig. 155.
Microsoft
Fig. 156: Screwing down lower fastening screw

2. Screw down the cover -2- from below with the fastening screw -1- . --> Tightening torque: 2.7 (1.8 ftlb.)
Nm . See Fig. 156.
Microsoft
Fig. 157: Tightening the fastening screw laterally

3. Screw down the cover -2- laterally with the fastening screw -1- . --> Tightening torque: 2.7 (1.8 ftlb.) Nm .
See Fig. 157.
Subsequent work
1. Install control module trim panel. --> 721619 Removing and installing control module trim panel -
chapter on "Installing"
2. Install front seat. --> 720119 Removing and installing front seat - chapter on "Installing" [987120
987310 987320] --> 720119 Removing and installing front seat - chapter on "Installing" [987121 987311
987321]
72 28 19 REMOVING AND INSTALLING HEIGHT ADJUSTMENT LEVER - AS

REMOVING HEIGHT ADJUSTMENT LEVER
Removing height adjustment lever
Microsoft

Microsoft
Fig. 159: Pressing out trim panel

1. Press out trim panel -7- using a plastic spatula. See Fig. 159.
Microsoft

2. Unscrew fastening screw -8- from the lever -9- and remove lever. See Fig. 160.
INSTALLING HEIGHT ADJUSTMENT LEVER
Installing height adjustment lever
Microsoft

Microsoft
Fig. 162: Screwing down lever

1. Position lever -9- on the seat and screw down fastening screw -8- . Tightening torque --> Tightening torque:
5.9 (4.5 ftlb.) Nm . See Fig. 162.
Microsoft
Fig. 163: Pressing in trim panel

2. Press in trim panel -7- . See Fig. 163.
72 31 19 REMOVING AND INSTALLING CONTROL BUTTON FOR

BACKREST ADJUSTMENT - AS OF MY 2005 (ALL MODELS)
REMOVING CONTROL BUTTON FOR BACKREST RELEASE
Removing control button for backrest release
Microsoft
Fig. 164: Removing control button

1. Press the control button -1- up and maintain in this position. See Fig. 164.
NOTE:  The cloth protects the collar from damage when pushing out the control
button.
 Note that the control button will be damaged during removal. It must not
be reused.
2. Insert a screwdriver -2- underneath the control button and press the control button -1- out. See Fig. 164.
INSTALLING CONTROL BUTTON FOR BACKREST RELEASE
Installing control button for backrest release
Microsoft
Fig. 165: Installing control button

1. Press in control button -1- until it clicks into place. See Fig. 165.
72 33 19 REMOVING AND INSTALLING CONTROL VALVE FOR LUMBAR

SUPPORT ADJUSTMENT - AS OF MY 2005 (ALL MODELS)
TOOLS

PRELIMINARY WORK
Preliminary work
Microsoft
REMOVING CONTROL VALVE FOR LUMBAR SUPPORT ADJUSTMENT
Taking off foam part
Fig. 166: Installation position of control valve for lumbar support adjustment
Microsoft

Removing control valve for lumbar support adjustment
Microsoft
Fig. 168: Removing control valve for lumbar support adjustment

1. Release connector -1- on control valve for lumbar support adjustment -3- ( -arrow a- ) and pull it off -arrow
B- . See Fig. 168.
2. Pull off the three hoses -2- on the control valve for lumbar support adjustment -3- ( -arrows C- ). See Fig.
168.
3. Unscrew fastening screw -4- and pull control valve for lumbar support adjustment -3- (with the clip -5- ) off
the backrest frame -arrow D- . See Fig. 168.
INSTALLING CONTROL VALVE FOR LUMBAR SUPPORT ADJUSTMENT
Installing control valve for lumbar support adjustment

Microsoft
Fig. 169: Installing control valve for lumbar support adjustment

1. Push control valve for lumbar support adjustment -3- (with the clip -5- ) onto the backrest frame -arrow A-
and screw down with the fastening screw -4- . --> Tightening torque: 4 (3 ftlb.) Nm . See Fig. 169.
NOTE: Observe the installation position of the hoses!
Push on the blue hose onto the connection marked B and push on the red hose
onto the connection marked R .
2. Push on the three hoses -2- onto the control valve for lumbar support adjustment -3- ( -arrows B- ). See Fig.
169.
Microsoft
3. Push connector -1- onto the control valve for lumbar support adjustment -3- ( -arrow C- ) until it engages
securely. See Fig. 169.
(All Models) .
Fitting foam part

Microsoft
Make sure that the hoses are not pinched. Insert hoses exactly into the cut-outs
on the foam part.
1. Fit foam part -1- at the headrest. See Fig. 170.
SUBSEQUENT WORK
Reworking
72 34 19 REMOVING AND INSTALLING LUMBAR SUPPORT - AS OF MY

2005 (ALL MODELS)
TOOLS

PRELIMINARY WORK
Preliminary work
REMOVING LUMBAR SUPPORT
Microsoft

Removing lumbar support

Microsoft
Fig. 173: Installation position of lumbar support

Fig. 174: Pulling off hoses on the lumbar support control valve
1. Pull off the red and blue hose -1- on the lumbar support control valve -2- . See Fig. 174.
Microsoft
Fig. 175: Pulling hoses out of the backrest frame

2. Pull the red and blue hose -1- out of the backrest frame -2- . See Fig. 175.
NOTE: Only for seats with a memory function
Microsoft
Fig. 176: Pulling connectors off the lumbar support sensors

3. Pull connectors off the lumbar support sensors.
3.1. Swivel lumbar support -1- upward -arrow A- . See Fig. 176.
3.2. Pull the two sensors -2- forward behind the backrest panel -arrows B- . See Fig. 176.
3.3. Release both connectors -3- at the sensors -2- ( -arrow a- ) and unplug them -arrow C- . See Fig. 176.
Microsoft
Fig. 177: Removing lumbar support

4. Remove the two tie-wraps -2- on the lumbar support -1- . See Fig. 177.
5. Remove lumbar support -1- together with the red and blue hose -3- . See Fig. 177.
INSTALLING LUMBAR SUPPORT
Installing lumbar support
Microsoft
Fig. 178: Installing lumbar support

1. Install the lumbar support -1- together with the red and blue hose -3- . See Fig. 178.
2. Secure the lumbar support -1- to the grille using two new tie-wraps -2- . See Fig. 178.
NOTE: Only for seats with a memory function
Microsoft
Fig. 179: Attaching connectors to the lumbar support sensors

3. Attach connectors to the lumbar support sensors.
NOTE: Observe installation position of connectors!
Push red-lilac-brown connector onto the sensor at the top air cushion.
Push red-white-brown connector onto the sensor at the bottom air cushion.
3.1. Connect the two connectors -3- to the sensors -2- ( -arrow A- ) until they engage securely. See Fig. 179.
3.2. Push the two sensors -2- behind the backrest panel -arrows B- and fold down the lumbar support -1- ( -
arrow C- ). See Fig. 179.
Microsoft
Fig. 180: Laying hoses on the backrest frame

4. Lay the red hose and the blue hose -1- on the backrest frame -2- . See Fig. 180.
Microsoft
Fig. 181: Sliding hoses onto the lumbar support control valve
5. Slide the red and blue hose -1- onto the lumbar support control valve -2- . See Fig. 181.
6. Check the function of the lumbar support using the test cable.
(All Models) .
Microsoft
Fitting foam part

on the foam part.
SUBSEQUENT WORK
Reworking
72 36 19 REMOVING AND INSTALLING MOTOR FOR LUMBAR SUPPORT -

Microsoft
TOOLS

PRELIMINARY WORK
Preliminary work
2. Remove left air cushion for backrest. --> 721719 Removing and installing air cushion for backrest -
REMOVING MOTOR FOR LUMBAR SUPPORT
Removing support for left backrest side part
Microsoft
Fig. 183: Installation position of motor for lumbar support

Microsoft

1. Unscrew the four fastening screws -1- and remove support for backrest side part -2- . See Fig. 184.
Microsoft

Removing motor for lumbar support

Microsoft
Fig. 187: Pulling hose off the control valve for lumbar support
1. Pull the white hose -1- off the control valve for lumbar support -2- . See Fig. 187.
Microsoft
Fig. 188: Pulling hose out of the backrest frame

2. Pull the white hose -1- out of the backrest frame -2- . See Fig. 188, Fig. 187.
Microsoft
Fig. 189: Removing motor for lumbar support

3. Release plug connection -1- ( -arrow a- ) and disconnect it -arrows B- . See Fig. 189.
4. Take motor for lumbar support -2- out of the backrest frame ( -arrow C- ) and pull the hose -3- along with
the motor out of the backrest frame -arrow D- . See Fig. 189.
INSTALLING MOTOR FOR LUMBAR SUPPORT
Installing motor for lumbar support
Microsoft
Fig. 190: Installing motor for lumbar support

1. Push hose -3- into the backrest frame -arrow A- and insert motor for lumbar support -2- into the backrest
frame -arrow B- . See Fig. 190.
2. Push plug connection -1- together -arrows C- until it engages securely. See Fig. 190.
Microsoft
Fig. 191: Laying hose on backrest frame

3. Lay the white hose -1- on the backrest frame -2- . See Fig. 191, Fig. 192.
Microsoft
Fig. 192: Pushing hose onto the control valve for lumbar support
4. Push the white hose -1- onto the control valve for lumbar support -2- . See Fig. 192.
(All Models) .
Fitting foam part
Microsoft

on the foam part.
Installing support for left backrest side part
Microsoft

1. Insert support for backrest side part -2- and secure with the four fastening screws -1- . See Fig. 194.
Microsoft
Fig. 195: Routing wire harness for airbag

2. Route wire harness for airbag -1- as shown behind the backrest side part support -2- . See Fig. 195.
SUBSEQUENT WORK
Subsequent work
1. Install right air cushion for backrest. --> 721719 Removing and installing air cushion for backrest -
72 38 19 REMOVING AND INSTALLING AIR CUSHION CONTROL VALVE -

PRELIMINARY WORK
Preliminary work
Remove front seat. --> 720119 Removing and installing front seat - section on "Removing" [987120 987310
987320] --> 720119 Removing and installing front seat - section on "Removing" [987121 987311 987321]
Microsoft
REMOVING AIR CUSHION CONTROL VALVE
Removing air cushion control valve
Fig. 196: Installation position for air cushion control valve

Microsoft
Fig. 198: Pulling off connector and hoses on air cushion control valve
3. Release connector -1- on air cushion control valve -arrow a- and pull it off. See Fig. 198.
4. Pull off the three hoses -2- from the air cushion control valve. See Fig. 198.
Microsoft
Fig. 199: Removing air cushion control valve

5. Unscrew fastening screw -1- and remove air cushion control valve -2- . See Fig. 199.
INSTALLING AIR CUSHION CONTROL VALVE
Installing air cushion control valve
Microsoft
Fig. 200: Installing air cushion control valve

1. Position air cushion control valve -2- and tighten with the fastening screw -1- . See Fig. 200.
Microsoft
Fig. 201: Pushing on connector and hoses onto air cushion control valve
2. Push on the three hoses -2- onto the air cushion control valve. See Fig. 201.
3. Push on connector -1- onto air cushion control valve until this engages audibly. See Fig. 201.
SUBSEQUENT WORK
Subsequent work
Install front seat. --> 720119 Removing and installing front seat - section on "Installing" [987120 987310
987320] --> 720119 Removing and installing front seat - section on "Installing" [987121 987311 987321]
Microsoft
72 39 19 REMOVING AND INSTALLING AIR CUSHION MOTOR - AS OF MY

2005 (ALL MODELS)
PRELIMINARY WORK
Preliminary work
REMOVING AIR CUSHION MOTOR
Removing air cushion motor
Fig. 203: Installation position for air cushion motor

Microsoft
Microsoft
Fig. 205: Removing air cushion motor

3. Remove the two tie-wraps -1- on the air cushion motor -2- . See Fig. 205.
4. Release plug connection -3- -arrow a- and disconnect -arrows B- . See Fig. 205.
5. Pull off the white hose -4- from the air cushion control valve -arrow C- and remove the air cushion motor -2-
. See Fig. 205.
INSTALLING AIR CUSHION MOTOR
Installing air cushion motor
Microsoft
Fig. 206: Installing air cushion motor

1. Position air cushion motor -2- and push on the white hose -4- onto the air cushion control valve -arrow A- .
See Fig. 206.
2. Push the plug connection -3- together -arrows B- until it is felt to engage. See Fig. 206.
Ensure that no hoses are disconnected by the tie-wraps.
3. Secure air cushion motor -2- onto support using two new tie-wraps -1- . See Fig. 206.
Microsoft
SUBSEQUENT WORK
Subsequent work
72 86 19 REMOVING AND INSTALLING SWITCH FOR SEAT ADJUSTMENT -

PRELIMINARY WORK
Preliminary work
Remove control module trim panel (electric). --> 721619 Removing and installing control module trim panel
REMOVING SWITCH FOR SEAT ADJUSTMENT
Microsoft
Removing switch for seat adjustment
Fig. 208: Installation position of seat adjustment switch

Fig. 209: Unclipping control buttons

Microsoft
1. Carefully unclip the two control buttons -1- using a plastic wedge. See Fig. 209.
Fig. 210: Removing switch for seat adjustment

2. Unscrew the three fastening screws -1- and remove seat adjustment switch -2- . See Fig. 210.
INSTALLING SWITCH FOR SEAT ADJUSTMENT
Installing switch for seat adjustment
Microsoft
Fig. 211: Installing switch for seat adjustment

1. Position switch for seat adjustment -2- and screw down using the three fastening screws -1- . See Fig. 211.
Fig. 212: Clipping in control buttons

Microsoft
2. Position the two control buttons -1- precisely and carefully press down onto the seat adjustment switch until
they are felt to engage. See Fig. 212.
Fig. 213: Removing assembly clip

NOTE: The assembly clip must be removed in order to install a new seat adjustment
switch.
3. Use a small screwdriver to lever the assembly clip -1- out of the seat adjustment switch -2- . See Fig. 213.
SUBSEQUENT WORK
Subsequent work
Install control module trim panel (electric). --> 721619 Removing and installing control module trim panel -
72 87 19 REMOVING AND INSTALLING MOTOR FOR SEAT ADJUSTMENT -

PRELIMINARY WORK
Microsoft
Preliminary work
REMOVING MOTOR FOR SEAT ADJUSTMENT
Removing motor for seat adjustment
Fig. 214: Installation position of motor for seat adjustment

Microsoft
Fig. 215: Unclipping sleeve of shaft of seat adjustment motor

1. Unclip sleeve of long drive shaft -2- of seat adjustment motor -1- at the support. See Fig. 215.
Microsoft
Fig. 216: Pressing motor for seat adjustment out of support

2. Press motor for seat adjustment -1- out of the support -2- at the boot -arrow A- . See Fig. 216.
3. Pull motor for seat adjustment -1- off the short drive shaft -arrow B- . See Fig. 216.
4. Pull motor for seat adjustment -1- forward under the support -2- ( -arrow C- ) and pull off connector -3- ( -
arrow D- ). See Fig. 216.
Microsoft
Fig. 217: Pulling motor for seat adjustment off the drive shaft
5. Pull motor for seat adjustment -1- and sleeve off the long drive shaft -2- ( -arrow A- ). See Fig. 217.
6. Pull the long drive shaft -2- out of the gear mount -arrow B- and check for damage. See Fig. 217.
Microsoft
Fig. 218: Removing drive shaft

7. Pull the short drive shaft -1- out of the gear mount -2- and check for damage. See Fig. 218.
INSTALLING MOTOR FOR SEAT ADJUSTMENT
Installing motor for seat adjustment
Microsoft
Fig. 219: Installing drive shaft

1. Insert the short drive shaft -1- into the gear mount -2- by twisting slightly. See Fig. 219.
Microsoft
Fig. 220: Pushing motor for seat adjustment onto the drive shaft
2. Insert the long drive shaft -2- into the gear mount -arrow A- by twisting slightly. See Fig. 220.
NOTE: When installing the motor for seat adjustment, make sure the two seat rails are
in the same position.
3. Push motor for seat adjustment -1- and sleeve onto the long drive shaft -2- by twisting slightly -arrow A- .
See Fig. 220.
Fig. 221: Pressing motor for seat adjustment into support

Microsoft
4. Attach the connector -3- to the motor for seat adjustment -1- ( -arrow A- ) until it engages firmly. See Fig.
221.
5. Push motor for seat adjustment -1- under the support -2- ( -arrow B- ). See Fig. 221.
NOTE: When installing the motor for seat adjustment, make sure the two seat rails are
in the same position.
6. Push motor for seat adjustment -1- onto the short drive shaft by twisting slightly -arrow C- . See Fig. 221.
7. Press motor for seat adjustment -1- into the support -2- at the boot -arrow D- . See Fig. 221.
Fig. 222: Clipping in sleeve of shaft of seat adjustment motor

Microsoft
8. Clip in sleeve of long drive shaft -2- of seat adjustment motor -1- on the support. See Fig. 222.
SUBSEQUENT WORK
Subsequent work
72 88 19 REMOVING AND INSTALLING MOTOR FOR FRONT VERTICAL

ADJUSTMENT - AS OF MY 2005 (ALL MODELS)
PRELIMINARY WORK
Preliminary work
REMOVING MOTOR FOR FRONT VERTICAL ADJUSTMENT

Microsoft
Microsoft
225.
Removing motor for front vertical adjustment
Fig. 226: Installation position of motor for front vertical adjustment

Microsoft
Fig. 227: Removing motor for front vertical adjustment

1. Pull connector -1- off the motor for front vertical adjustment -3- . See Fig. 227.
2. Unscrew the two fastening screws -2- and remove motor for front vertical adjustment -3- . See Fig. 227.
Microsoft

3. Pull drive shaft -1- out of the gear mount -2- and check for damage. See Fig. 228.
INSTALLING MOTOR FOR FRONT VERTICAL ADJUSTMENT
Installing motor for front vertical adjustment
Microsoft

1. Insert the drive shaft -1- into the gear mount -2- by twisting slightly. See Fig. 229.
Microsoft
Fig. 230: Installing motor for front vertical adjustment

2. Push motor for front vertical adjustment -3- onto the drive shaft by twisting slightly and secure with the two
fastening screws -2- . --> Tightening torque: 7 (5 ftlb.) Nm . See Fig. 230.
3. Attach connector -1- to motor for front vertical adjustment -3- until it engages firmly. See Fig. 230.
Microsoft
SUBSEQUENT WORK
Subsequent work
72 89 19 REMOVING AND INSTALLING MOTOR FOR BACKREST

TOOLS

Microsoft
PRELIMINARY WORK
Preliminary work
2. Remove right air cushion for backrest. --> 721719 Removing and installing air cushion for backrest -
REMOVING MOTOR FOR BACKREST ADJUSTMENT
Removing backrest side support
Fig. 233: Installation position of motor for backrest adjustment

1. Unscrew the four fastening screws -1- and remove backrest side support -2- . See Fig. 233.
Removing motor for backrest adjustment

Microsoft
Fig. 234: Disconnecting plug connection on motor for backrest adjustment

1. Unclip inner spring for backrest frame -1- at the drive shaft -2- ( -arrows B- ) and swivel it upwards ( -arrow
C- ). See Fig. 234.
2. Turn plug connection -3- approx. 90° anti-clockwise -arrow D- and remove it from the backrest frame -
arrow E- . See Fig. 234.
3. Release plug connection -3- ( -arrows a- ) and disconnect it -arrows F- . See Fig. 234.
Microsoft
Fig. 235: Removing motor for backrest adjustment

4. Unscrew the two fastening screws -1- and remove motor for backrest adjustment -2- . See Fig. 235.
Microsoft

INSTALLING MOTOR FOR BACKREST ADJUSTMENT
Installing motor for backrest adjustment

Microsoft
Fig. 238: Installing motor for backrest adjustment

2. Push motor for backrest adjustment -2- onto the drive shaft by twisting slightly and secure with the two
Microsoft
Fig. 239: Connecting plug connection on motor for backrest adjustment

3. Push plug connection -3- together -arrows A- until it engages securely. See Fig. 239.
4. Insert plug connection -3- into the backrest frame -arrow B- and turn approx. 90° clockwise -arrow C- . See
Fig. 239.
5. Swivel inner spring for backrest frame -1- downwards -arrow D- and clip in at the drive shaft -2- ( -arrows
E- ). See Fig. 239.
Microsoft
(All Models) .
Installing backrest side support
Microsoft
Fig. 240: Installing backrest side support

1. Fit backrest side support -2- and screw down with the four fastening screws -1- . See Fig. 240.
SUBSEQUENT WORK
Subsequent work
Microsoft
1. Install right air cushion for backrest. --> 721719 Removing and installing air cushion for backrest -
72 92 19 REMOVING AND INSTALLING MOTOR FOR REAR VERTICAL

PRELIMINARY WORK
Preliminary work
REMOVING MOTOR FOR REAR VERTICAL ADJUSTMENT
Removing motor for rear vertical adjustment
Fig. 241: Installation position of motor for rear vertical adjustment

Microsoft
Fig. 242: Removing motor for rear vertical adjustment

1. Pull connector -1- off the motor for rear vertical adjustment -3- . See Fig. 242.
2. Unscrew the two fastening screws -2- and remove motor for rear vertical adjustment -3- . See Fig. 242.
Microsoft

INSTALLING MOTOR FOR REAR VERTICAL ADJUSTMENT
Installing motor for rear vertical adjustment
Microsoft

Microsoft
Fig. 245: Installing motor for rear vertical adjustment

2. Push motor for rear vertical adjustment -3- onto the drive shaft by twisting slightly and secure with the two
fastening screws -2- . --> Tightening torque: 7 (5 ftlb.) Nm . See Fig. 245.
3. Attach connector -1- to motor for rear vertical adjustment -3- until it engages firmly. See Fig. 245.
SUBSEQUENT WORK
Subsequent work
72 93 19 REMOVING AND INSTALLING CONTROL UNIT FOR MEMORY

SEAT ADJUSTMENT - AS OF MY 2005 (ALL MODELS)
TOOLS

PRELIMINARY WORK
Preliminary work for control unit for memory seat adjustment
Remove seat. --> 720119 Removing and installing front seat - section on "Removing" [987120 987310
REMOVING CONTROL UNIT FOR MEMORY SEAT ADJUSTMENT
Removing control unit for memory seat adjustment
Microsoft
NOTE: If the control unit must be replaced, first read out the values using the PIWIS
Tester P 9718.

Microsoft

Fig. 248: Disconnecting electric connectors on the control unit

2. Release electric connectors -A- on the control unit and disconnect them. See Fig. 248.
INSTALLING CONTROL UNIT FOR MEMORY SEAT ADJUSTMENT
Installing control unit for memory seat adjustment
Microsoft
Fig. 249: Inserting electric connectors into control unit

1. Insert electric connectors into control unit until they are felt to engage.
Microsoft
Fig. 250: Screwing control unit to seat

2. Position control unit on the holder and screw it down using the two fastening screws -1- . See Fig. 250.
SUBSEQUENT WORK
Subsequent work for control unit for memory seat adjustment
Install seat. --> 720119 Removing and installing front seat - section on "Installing" [987120 987310
PROGRAMMING CONTROL UNIT
Microsoft
Continue.
3. Move from vehicle type to the list of control units and press >>.
4. Select the relevant control unit using the cursor keys and press >>.
9. Switch on ignition. Select the vehicle type, choose the Special functions menu, start Vehicle handover and
follow the instructions on the Tester.
11. Using the >> key, move from the vehicle type to the list of control units. Perform the automatic control unit
search.
12. After replacing the control unit, the data that was previously read out (see Item 6) is reloaded under the
Write in data menu. Press >>.
13. The System Tester displays the message Coding write-in complete . Press >>.
14. Go to the Coding menu by pressing >>, compare the coding with the vehicle equipment and code it if
necessary.
15. Check the operation of the memory switch, read out the fault memory and erase it if necessary.
Programming control unit

Microsoft
Continue.
NOTE: If the control unit values cannot be read out, proceed according to the
instructions given here.
2. Select the vehicle type, choose the Special functions menu, start Vehicle handover and follow the
instructions on the Tester.
module search.
5. Use the cursor keys to select the Memory seat adjustment control unit and press >>.
6. Select Coding using the cursor keys and press >>.
7. Select the coding required for the vehicle and follow the instructions on the Tester.
8. Check the operation of the memory switch, read out the fault memory and erase it if necessary.
72 94 19 REMOVING AND INSTALLING SWITCH FOR MEMORY SEAT

REMOVING SWITCH FOR MEMORY SEAT ADJUSTMENT
Removing switch for memory seat adjustment
Microsoft
Fig. 251: Installation position of switch for memory seat adjustment

Fig. 252: Removing switch for memory seat adjustment

1. Release switch for memory seat adjustment -1- at the four locking tabs -arrows a- . Swivel switch for
memory seat adjustment -1- out of the door trim panel at the clip -2- in -direction of arrow- . See Fig. 252.
Microsoft
Fig. 253: Pulling off connector on switch for memory seat adjustment
2. Release connector -2- and remove it -arrow a- . Remove switch for memory seat adjustment -1- . See Fig.
253.
INSTALLING SWITCH FOR MEMORY SEAT ADJUSTMENT
Installing switch for memory seat adjustment
Microsoft
Fig. 254: Attaching connector on switch for memory seat adjustment

1. Place switch for memory seat adjustment -1- into position and attach connector -2- until it engages correctly.
See Fig. 254.
Microsoft
Fig. 255: Installing switch for memory seat adjustment

2. Guide switch for memory seat adjustment -1- with the clip -2- into position behind the door trim panel and
press down until the locking tabs -arrows- engage correctly. See Fig. 255.
Microsoft
ACCESSORIES & EQUIPMENT Windshield wiper and washer system
Windshield wiper and washer system
92 12 19 REMOVING AND INSTALLING RAIN SENSOR - AS OF MY 2005

(ALL MODELS)
REMOVING RAIN SENSOR
Removing rain sensor
NOTE:  An adhesive pad must be used when reinstalling the rain sensor.
 When fitting the adhesive pad, make sure there is no air trapped between
the windscreen and the adhesive pad or between the adhesive pad and the
rain sensor.
 When installing the adhesive pad, the temperature of the windscreen, rain
sensor and adhesive pad must be approx 20°C. Carefully heat the
windscreen with a hot-air gun for example.
 Do not touch the adhesive surface of the sensor with your fingers.
 If the sensor is new, remove the protection cap before sticking the sensor
on to the windscreen.
 When sticking on a new sensor, make sure that no air pockets are caught
between the gel and the windscreen. Air pockets could impair the function
of the sensor.
 Sensor, orientation lights, wires and wiring ducts are spare parts.
Limited functionality of the rain sensor if the following points are not observed: --> Please observe note
"An adhesive pad must be used when reinstalling the rain sensor".
Microsoft
Fig. 1: Removing roof console, shown for the 911 Carrera

1. Unclip the two covers on the roof console and unscrew both fastening screws -1- . See Fig. 1.
Microsoft
Fig. 2: Wire routing

2. Disengage holder -2- for the line -arrow- and pull line forward behind the roof liner. See Fig. 2.

3. Release and pull electrical plug apart -3- . See Fig. 3.
Microsoft
Fig. 4: Removing cover of rain sensor

4. Carefully unclip the cover -1- from the rain sensor from above using a narrow screwdriver. See Fig. 4.
Microsoft
Fig. 5: Removing orientation lights

5. Remove orientation lights -2- . See Fig. 5.
Microsoft

6. Carefully pull the plug connection -3- out of the holder and pull it apart. See Fig. 6.
Fig. 7: Pushing mirror down from mirror holder

7. Fold mirror downwards -4- and push down from the front windscreen bracket. See Fig. 7.
Microsoft
Fig. 8: Unclipping rain sensor holder

8. Carefully unclip holder from rain sensor at the top, bottom left and right.
Microsoft
Fig. 9: Removing rain sensor from windscreen

9. Slowly remove rain sensor -6- from the windscreen. See Fig. 9.
Microsoft
Fig. 10: Pulling off adhesive buffer

10. If the rain sensor is to be reinstalled, then slowly pull the adhesive buffer -7- off the rain sensor. See Fig. 10.
INSTALLING RAIN SENSOR
Installing rain sensor
NOTE:  An adhesive pad must be used when reinstalling the rain sensor.
 When fitting the adhesive pad, make sure there is no air trapped between
the windscreen and the adhesive pad or between the adhesive pad and the
rain sensor.
 When installing the adhesive pad, the temperature of the windscreen, rain
sensor and adhesive pad must be approx 20°C. Carefully heat the
windscreen with a hot-air gun for example.
 Do not touch the adhesive surface of the sensor with your fingers.
 If the sensor is new, remove the protection cap before sticking the sensor
on to the windscreen.
 When sticking on a new sensor, make sure that no air pockets are caught
between the gel and the windscreen. Air pockets could impair the function
of the sensor.
 Sensor, orientation lights, wires and wiring ducts are spare parts.
Limited functionality of the rain sensor if the following points are not observed: --> Please observe note
"An adhesive pad must be used when reinstalling the rain sensor".
NOTE:  If the removed rain sensor is to be reinstalled, the surfaces must be free of
adhesive residues. Do not use harsh cleaning agents. Stick the adhesive
pad onto the rain sensor at a temperature of approx. 20°C.
Microsoft
Fig. 11: Sticking on rain sensor

1. Press the rain sensor -6- onto the windscreen. See Fig. 11.
Microsoft
Fig. 12: Clipping in holder

2. Push and press holder -5- onto the rain sensor until it engages. See Fig. 12.
Microsoft
Fig. 13: Pushing on rear-view mirror

3. Push rear-view mirror -4- onto the mirror holder from below. See Fig. 13.
Microsoft

4. Join the plug connection -3- and insert it into the mirror base. See Fig. 14.
Microsoft
Fig. 15: Inserting orientation lights

5. Insert orientation light into the cover.
Fig. 16: Attaching mirror base cover

6. Join both covers -1- , ensuring that the orientation light is positioned correctly.
Microsoft

7. Push the electrical plug connection together -1- until the plug is felt to engage. See Fig. 17.
Microsoft
Fig. 18: Wire routing

8. Engage holder -2- for the electric line and push line in behind the roof liner. See Fig. 18.
Fig. 19: Tightening fastening screw, shown on the roof console for the 911 Carrera
9. Tighten fastening screws -1- and clip in both covers. See Fig. 19.
92 15 19 REMOVING AND INSTALLING WIPER MOTOR - AS OF MY 2005

(ALL MODELS)
PRELIMINARY WORK FOR WIPER MOTOR
Preliminary work on wiper motor
Disconnect the battery and cover terminal or battery. --> 27 06 IN WORK INSTRUCTIONS AFTER
Left plenum chamber cover. Refer to 85 22 19 Removing and installing cover - as of MY 2005 (All Models) .
REMOVING WIPER MOTOR
Removing wiper motor
Microsoft
Fig. 20: Removing wiper link drive

1. Unscrew the fastening nut -1- for the wiper link drive and remove the drive. See Fig. 20.
2. Unscrew the three fastening screws -2- for the wiper motor and the fastening screw -3- for the wiper link. See
Fig. 20.
Microsoft
Fig. 21: Removing wiper motor in a downward direction

3. Carefully raise the wiper link and remove the wiper motor downwards.
4. Unlock the electric connector a and pull it out of the wiper motor.
INSTALLING WIPER MOTOR
Installing wiper motor
Microsoft
Fig. 22: Positioning wiper motor from below

1. Carefully raise the wiper link and position the wiper motor from below.
2. Push electrical connector onto wiper motor until it is felt to engage.
Microsoft
Fig. 23: Screwing down wiper motor to wiper link

3. Secure the wiper motor with the three fastening screws -2- to the wiper link. --> Tightening torque: 6 ftlb.
See Fig. 23.
4. Screw down the fastening screw -3- for the wiper link. --> Tightening torque: 7.5 ftlb. See Fig. 23.
5. Connect battery, ignition on, and actuate wiper motor.
Microsoft
Fig. 24: Installation position for wiper motor drive

6. Allow wiper motor to run in parking position. Place the link on the drive on the wiper motor. Place fastening
nuts -1- . The installation position of the link is identified by a 0 marking (parking position) on the console. See
Fig. 23.
7. If the position -0- matches, then screw down the fastening nut -1- . --> Tightening torque: 13 ftlb. See Fig.
24, Fig. 23.
8. Connect the battery.
9. Switch on the wiper motor and check the wiper position.
SUBSEQUENT WORK FOR WIPER MOTOR
Touching up wiper motor
Left plenum chamber cover Refer to 85 22 19 Removing and installing cover - as of MY 2005 (All Models) .
Carry out work instruction after disconnecting the battery. --> 27 06 IN WORK INSTRUCTIONS AFTER
92 19 19 REMOVING AND INSTALLING WIPER LINK - AS OF MY 2005 (ALL

MODELS)
Microsoft
PRELIMINARY WORK
Preliminary work for wiper link
Remove wiper arms. --> 924119 Removing and installing wiper arm for rear window wiper system -
chapter on "Removing" [987120 987121].
Removing cowl panel cover. Refer to 50 87 19 Removing and installing cowl panel cover - as of MY 2005
(All Models) .
REMOVING WIPER LINK
Removing wiper link
Microsoft
Fig. 25: Dome strut fastening screws

1. Unscrew the fastening screws for the dome strut -1, 2- and remove the strut. See Fig. 25.

2. Unscrew the three fastening screws -3- for the wiper link, release and unplug the electrical plug for the wiper
motor. See Fig. 26.
3. Remove wiper link, if the wiper motor should be removed from the wiper link, then proceed according to
Removing and installing wiper motor --> 921519 Removing and installing wiper motor - chapter on
"Removing".
Microsoft
INSTALLING WIPER LINK
Installing wiper link
1. If necessary, fit the wiper motor to the wiper link. --> 921519 Removing and installing wiper motor -
chapter on "Installing"
Fig. 27: Tightening order

2. Position wiper link in radiator tank and screw down the fastening screws -3A, 3B, 3,C- in turn. -->
Microsoft
Fig. 28: Installing dome strut

3. Lowre vehicle onto the wheels, position dome strut and screw down with the fastening screws -1, 2- . -->
Tightening torque: 7 ftlb. --> Tightening torque: 17 ftlb. See Fig. 28.
SUBSEQUENT WORK
Reworking wiper link
Left plenum chamber cover Refer to 85 22 19 Removing and installing cover - as of MY 2005 (All Models) .
Microsoft
--> 922519 Removing and installing wiper arm - chapter on "installing"
Connect battery. --> 27 06 IN WORK INSTRUCTIONS AFTER DISCONNECTING THE BATTERY -

92 25 15 ADJUSTING WIPER ARM ATTACK ANGLE - AS OF MY 2005 (ALL

MODELS)
TOOLS

Adjustment device special tool P 9737
PRELIMINARY WORK
Preliminary work for adjusting wiper arm attack angle
NOTE: The wiper arm attack angle will need to be checked and adjusted if the
customer complains of: rubbing or hesitation of wiper, noises when wiping or
uneven wiping area.
It is important that the wiper blades are inspected for wear and the windscreen
is free of contamination.
1. Check condition of windscreen and clean off any contamination.
2. Remove wiper blade. --> 922719 Removing and installing wiper blade - chapter on "Removing"
3. Inspect condition of wiper blade and replace if necessary.
ADJUSTING WIPER ARM
Adjusting wiper arm attack angle
Special tools: Adjustment device P 9737
Microsoft
Fig. 29: Tools overview

A - Angle measuring device
B - Adapter
C - Angle adjusting tool - holder
D - Angle adjusting tool - arm bracket
NOTE: Wiper system must be in the parking position. Before starting work, allow the
wiper system to run 2 - 3 times with water spray.
WARNING: Unexpected switching on of wiper system while working on the wiper

arms.
 Danger of trapping from wiper arms.
Microsoft
Fig. 30: Screw adapter onto wiper arm

1. Fit adapter -B- for the sports car flush on the wiper and tighten with the knurled screw. See Fig. 29.
Microsoft
Fig. 31: Screwing angle measuring device to adapter

2. Mount the angle measuring device -A- on the adapter and tighten with the knurled screw. See Fig. 29.
3. Read off wiper arm attack angle using the angle measuring device and compare with the nominal values.
Wiper position Nominal angle Tolerance

Parking position on driver's side + 5° +/- 2°
Parking position on passenger's side + 3° +/- 2°
4. If the nominal values are not achieved, the wiper arm must be adjusted using the two adjusting tools.
Microsoft
Fig. 32: Adjusting wiper arm angle to nominal value

5. Mount both adjusting tools on the wiper arm and adjust the angle to the nominal value by turning the front
adjusting tool.
SUBSEQUENT WORK
Subsequent work for adjusting wiper arm attack angle
1. Install wiper blade. --> 922719 Removing and installing wiper blade - chapter on "Installing"
2. Check wiper function of wiper system.
92 25 19 REMOVING AND INSTALLING WIPER ARM - AS OF MY 2005 (ALL

MODELS)
REMOVING WIPER ARM
Removing wiper arm
WARNING: Danger of trapping and injury due to uncontrolled activation of wiper

arms when fitting.
Microsoft
Fig. 33: Removing caps and fastening nuts

1. Remove caps -1- and unscrew the fastening nuts -2- . See Fig. 33.
2. Push wiper arm down at the joint and pull off the wiper link.
INSTALLING WIPER ARM
Installing wiper arm

arms when fitting.
Microsoft
Fig. 34: Screw tight wiper arm

1. Position wiper arm on wiper link, align, and screw tight using the fastening nuts -2- . --> Tightening torque:
16 ftlb. +/-1.6 ftlb. , See Fig. 34.
2. Attach and press down cap -1- until it is heard to engage. See Fig. 34.
3. Start wiper, observe wiping area and wiper rest, re-adjust wiper arms again if necessary.
92 27 19 REMOVING AND INSTALLING WIPER BLADE - AS OF MY 2005

(ALL MODELS)
REMOVING WIPER BLADE
Removing wiper blade

arms when fitting.
Microsoft
Fig. 35: Releasing wiper arm

1. Raise wiper arm, release holder -A- and remove wiper blade by sliding it downwards and to the side. See Fig.
35.
INSTALLING WIPER BLADE
Installing wiper blade

arms when fitting.
Microsoft
Fig. 36: Sliding in wiper arm

1. Slide wiper blade in from the side and engage in the wiper arm.
2. Lower wiper arm and check wiper function.
92 34 19 REMOVING AND INSTALLING WIPER MOTOR FOR REAR

WINDOW WASHER - AS OF MY 2006 (CAYMAN S, CAYMAN S RHD)
PRELIMINARY WORK
Microsoft
Preliminary work for wiper motor for rear window wiper system
Remove lining for rear lid. Refer to 70 87 19 Removing and installing trim panel for rear lid - as of MY
Remove wiper arm for rear window wiper system. --> 924119 Removing and installing wiper arm for rear
window wiper system - chapter on "Removing"
REMOVING WIPER MOTOR FOR REAR WINDOW WASHER
Removing wiper motor for rear window washer

Microsoft
Fig. 38: Removing wiper motor

1. Unscrew the fastening screw -1- and fastening nuts -2- . See Fig. 38, Fig. 39.
Microsoft

2. Take out wiper motor and release and unplug the electric connector -A- . See Fig. 39.
3. Take out the wiper motor.
INSTALLING WIPER MOTOR FOR REAR WINDOW WASHER
Installing wiper motor for rear window washer
NOTE: If you are installing a new wiper motor or re-installing a previously installed
wiper motor, check the rubber grommet for damage - to prevent water leakage -
and replace it if necessary.
Microsoft
Fig. 40: Centering the wiper motor

1. Position the wiper motor on the rear lid, while making sure that the drive for the wiper arm is positioned
centrally in the sleeve.
2. Plug in the electric connector on the wiper motor until it clicks into place.
Microsoft
Fig. 41: Positioning and screwing down wiper motor

3. Screw down the wiper motor using the fastening screw -1- and fastening nuts -2- . --> Tightening torque: 8
(6 ftlb.) Nm --> Tightening torque: 8 (6 ftlb.) Nm . See Fig. 41.
4. Switch on ignition. Then actuate the wiper motor at least once and allow to run until it stops.
SUBSEQUENT WORK
Reworking for wiper motor for rear window wiper system
Install trim panel for rear lid. Refer to 70 87 19 Removing and installing trim panel for rear lid - as of MY
Install wiper arm for rear window wiper system. --> 924119 Removing and installing wiper arm for rear
window wiper system - chapter on "Installing"
INSTALLING GROMMET FOR WIPER DRIVE MECHANISM
Installing grommet for wiper drive mechanism
If the grommet for the wiper drive mechanism is damaged, this grommet must be replaced.
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Fig. 42: Installation marking on grommet

The grommet is marked with an arrow, which must be pointing upwards following installation.
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Fig. 43: Inserting the grommet

Rub the grommet with soap suds and insert it into the rear lid, making sure that the sealing edge is sitting
properly on the rear lid.
92 41 19 REMOVING AND INSTALLING WIPER ARM FOR REAR WINDOW

WASHER - AS OF MY 2006 (CAYMAN S, CAYMAN S RHD)
REMOVING WIPER ARM FOR REAR WINDOW WASHER
Removing wiper arm for rear window washer
Microsoft

Fig. 45: Removing wiper arm

1. Pull cover -1- up and off. See Fig. 45.
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2. Unscrew the fastening nut -2- . See Fig. 45.
3. Press wiper arm -3- down at joint and pull down from the wiper motor drive. See Fig. 45.
INSTALLING WIPER ARM FOR REAR WINDOW WASHER
Installing wiper arm for rear window washer
Fig. 46: Fitting wiper arm

1. Position wiper arm -3- on the wiper motor drive and tighten the fastening nut -2- by hand. See Fig. 46.
Microsoft
Fig. 47: Aligning wiper arm

2. Align wiper arm with the mark on the windscreen.
3. Screw on fastening nut -2- and push on the cover -1- . The cap must engage audibly. --> Tightening torque:
19 (14 ftlb.) Nm See Fig. 46.
4. Actuate wiper motor of the rear window washer system, allow it to come to rest and check the position of the
wiper arm once more.
92 43 19 REMOVING AND INSTALLING WIPER BLADE FOR REAR WINDOW

WASHER - AS OF MY 2006 (CAYMAN S, CAYMAN S RHD)
REMOVING WIPER BLADE FOR REAR WINDOW WASHER SYSTEM
Removing wiper blade for rear window washer system

arms when fitting.
Microsoft
Fig. 48: Releasing wiper blade

1. Raise wiper arm and release and disengage wiper blade -A- . See Fig. 48.
INSTALLING WIPER BLADE FOR REAR WINDOW WASHER SYSTEM
Installing wiper blade for rear window washer system

arms when fitting.
Microsoft
Fig. 49: Engaging wiper blade

1. Insert the wiper blade in the wiper arm until it engages.
92 56 19 REMOVING AND INSTALLING PUMP FOR WINDSCREEN WASHER

SYSTEM - AS OF MY 2005 (ALL MODELS)
TOOLS

removal tool, universal special tool NR.21
PRELIMINARY WORK
Preliminary work
Remove tank for windscreen washer system. --> 92 60 19 Removing and installing reservoir for windscreen
washer system - as of MY 2005 (All Models).
REMOVING PUMP FOR WINDSCREEN WASHER SYSTEM

Microsoft
Removing pump for windscreen washer system
Fig. 50: Overview of pump for windscreen washer system
Microsoft
Fig. 51: Removing pump for windscreen washer system

1. Pull the water line off the pump for the windscreen washer system -arrow A- . See Fig. 51.
2. Pull the pump for the windscreen washer system upwards out of the tank -arrow B- . See Fig. 51.
Microsoft
Fig. 52: Levering out the rubber seal

3. Use the removal tool, universal NR.21 to lever the rubber seal out of the tank -arrow A- and remove it -
INSTALLING PUMP FOR WINDSCREEN WASHER SYSTEM
Installing pump for windscreen washer system
Microsoft
Fig. 53: Fitting rubber seal

1. Apply a suitable rubber lubricant (tire mounting paste) to the sealing surface -arrows A- and press the rubber
seal into the tank -arrow B- until it is felt to engage. See Fig. 53.
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Fig. 54: Installing pump for windscreen washer system

2. Apply a suitable rubber lubricant (tire mounting paste) to the sealing surface -arrows A- and press the pump
for the windscreen washer system into the rubber seal -arrow B- until the pump is felt to engage. See Fig. 54.
3. Connect the water pipe to the connections at the pump for the windscreen washer system -arrow C- . See
Fig. 54.
SUBSEQUENT WORK
Subsequent work
Install tank for windscreen washer system. --> 92 60 19 Removing and installing reservoir for windscreen
Microsoft
92 60 19 REMOVING AND INSTALLING RESERVOIR FOR WINDSCREEN

WASHER SYSTEM - AS OF MY 2005 (ALL MODELS)
PRELIMINARY WORK
Preliminary work - tank for windscreen washer system
Remove front left wheel. Refer to 44 05 19 Removing and installing wheel - as of MY 2005 (All Models) .
Remove front left wheel housing liner. Refer to 50 56 19 Removing and installing front wheel housing liner -
Remove cover of plenum chamber on left. Refer to 85 22 19 Removing and installing cover - as of MY 2005
(All Models) .
Drain windscreen washer water with the pump for windscreen or headlights. If this does not function, the filled
tank be removed.
REMOVING RESERVOIR FOR WINDSCREEN WASHER SYSTEM
Removing tank for windscreen washer system
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Fig. 55: Installation position, shown for the 911 Carrera

A - 2.5 l tank
B - 6.5 l tank (M288)
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Fig. 56: Removing tank

1. Lift lever on water filler neck and pull out the filler neck.
2. Release water connection for the windscreen washer spray nozzles and pull apart.
3. Release water connection for the headlight washer spray nozzles and pull apart.
4. Unscrew fastening screw -2- and pull the tank from the mounting point on the A-pillar. See Fig. 56.
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Fig. 57: Removing tank from the A-pillar and disconnecting the electrical plug connections
5. Release the electrical plugs -a- and pull them off. See Fig. 57.
INSTALLING RESERVOIR FOR WINDSCREEN WASHER SYSTEM
Installing tank for windscreen washer system
Microsoft
Fig. 58: Connecting the plugs and engaging the tank at the A-pillar
1. Retain the tank in the wheel housing and push in electrical plug connections until plugs are felt to engage.
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Fig. 59: Installing tank:

2. Engage the windscreen washer tank in the A-pillar and secure with the fastening screw -2- . --> Tightening
3. Engage the electrical leads in the windscreen washer tank.
4. Connect water connection for the windscreen washer spray nozzles.
5. Connect water connection for the headlight washer spray nozzles.
6. Route and engage the water lines to the tank.
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SUBSEQUENT WORK
Subsequent work - tank for windscreen washer system
Install front left wheel housing liner. Refer to 50 56 19 Removing and installing front wheel housing liner -
Install front left wheel. Refer to 44 05 19 Removing and installing wheel - as of MY 2005 (All Models) .
Install cover of plenum chamber on left. Refer to 85 22 19 Removing and installing cover - as of MY 2005
(All Models) .
92 67 19 REMOVING AND INSTALLING SENDER FOR WASHER FLUID-

LEVEL INDICATOR - AS OF MY 2005 (ALL MODELS)
TOOLS

universal disassembly tool special tool NR.21
PRELIMINARY WORK
Preliminary work
REMOVING SENDER FOR WASHER FLUID-LEVEL INDICATOR
Removing sender for washer fluid-level indicator
Microsoft
Fig. 60: Overview of sender for washer fluid-level indicator
Fig. 61: Removing sender for washer fluid-level indicator

1. Remove sender using the universal disassembly tool NR.21 to lever it out of the rubber seal -arrow A- and
remove it -arrow B- . See Fig. 61.
Microsoft

2. Remove rubber seal.
INSTALLING SENDER FOR WASHER FLUID-LEVEL INDICATOR
Installing sensor for fluid level display
Microsoft

seal into the tank -arrow B- until it is felt to engage. See Fig. 63.
Microsoft
Fig. 64: Installing sensor for fluid level display

2. Apply a suitable rubber lubricant (tire mounting paste) to the sealing surface -arrows A- and press the sensor
for fluid level display into the rubber seal -arrow B- until the sensor is felt to engage. See Fig. 64.
SUBSEQUENT WORK
Subsequent work
Install reservoir for windscreen washer. --> 92 60 19 Removing and installing reservoir for windscreen
92 72 19 REMOVING AND INSTALLING SPRAY NOZZLE FOR HEADLIGHT

WASHER SYSTEM - AS OF MY 2005 (ALL MODELS)
PRELIMINARY WORK
Preliminary work for spray nozzle of headlight washer system
Remove front apron. --> 63 10 19 REMOVING AND INSTALLING FRONT BUMPER - AS OF MY 2005
(ALL MODELS) .
Remove fog lights. --> 94 71 19 REMOVING AND INSTALLING AUXILIARY HEADLIGHT - AS OF

Microsoft
REMOVING SPRAY NOZZLE FOR HEADLIGHT WASHER SYSTEM
Removing spray nozzle for headlight washer system
Fig. 65: Installation position for the 911 Carrera

Microsoft
Fig. 66: Pressing retaining lugs of spray nozzles together

1. Press both retaining lugs of spray nozzle together and remove it from front apron.
Microsoft
Fig. 67: Pressing quick-connecting lock and removing water connection

2. Release quick-connecting lock of water connection -a- and pull away from the spray nozzle. See Fig. 67.
INSTALLING SPRAY NOZZLE FOR HEADLIGHT WASHER SYSTEM
Installing spray nozzle for headlight washer system
Microsoft
Fig. 68: Inserting spray nozzle in front apron

1. Insert spray nozzle in front apron until it engages.
Microsoft
Fig. 69: Inserting spray nozzle in front apron and connecting hose line
2. Push water hose onto the spray nozzle until it is felt to engage.
SUBSEQUENT WORK
Subsequent work for spray nozzle of headlight washer system
1. Install fog lights. --> 94 71 19 REMOVING AND INSTALLING AUXILIARY HEADLIGHT - AS OF

2. Install front apron. --> 63 10 19 REMOVING AND INSTALLING FRONT BUMPER - AS OF MY 2005
(ALL MODELS) .
3. Bleed the spray nozzles. The system is bled by activating the spray nozzles for the headlight washer multiple
times. Depending on whether it is a left or right spray nozzle, or whether the water reservoir for the headlight
washer was completely emptied or not, the bleeding process can require frequent activations of the spray
nozzle.
REMOVING AND INSTALLING SPRAY NOZZLE HEAD
Removing spray nozzle head
Microsoft
Fig. 70: Pulling out spray nozzle

1. Insert an angled scriber, for example, into the opening on the nozzle head and pull the spray nozzle up and
out.
2. Hold the nozzle head at the top and disengage the catch on the spray nozzle with a small screwdriver -A- .
The nozzle head is released from the spray nozzle and the spray nozzle moves back into place. See Fig. 70.
Installing spray nozzle head
Microsoft
Fig. 71: Pressing nozzle head into place

1. Insert the nozzle head into the opening on the spray nozzle and slide it in as far as it will go. The nozzle head
clicks into place in the spray nozzle.
2. Check function of spray nozzle and spray range.
92 77 19 REMOVING AND INSTALLING HOSE FOR HEADLIGHT WASHER -

PRELIMINARY WORK
Preliminary work for removing hose for headlight washer system (front apron)
Remove front apron. --> 63 10 19 REMOVING AND INSTALLING FRONT BUMPER - AS OF MY 2005
(ALL MODELS) .
Preliminary work for removing hose for headlight washer system (at tank)
REMOVING HOSE FOR HEADLIGHT WASHER
Microsoft
Removing hose for headlight washer (front apron)
Fig. 72: Overview of hose for headlight washer system

Fig. 73: Pulling off hose for headlight washer

Microsoft
1. Release hose for headlight washer system -Arrow a- and pull it off the spray nozzle. See Fig. 73.
Fig. 74: Removing hose for headlight washer

2. Pull hose for headlight washer from retaining clips on both sides -Arrow A- . See Fig. 74.
3. Remove hose for headlight washer from clips on the apron -Arrows B- . See Fig. 74.
Removing hose for headlight washer (at reservoir)
Microsoft
Fig. 75: Overview of hose for headlight washer system

Fig. 76: Removing hose for headlight washer from clips at the reservoir
1. Remove hose for headlight washer from clips at the reservoir.
Microsoft
Fig. 77: Pulling hose for headlight washer off the pump
2. Pull hose for headlight washer off the pump.
INSTALLING HOSE FOR HEADLIGHT WASHER
Installing hose for headlight washer (front apron)
Microsoft
Fig. 78: Installing hose for headlight washer

1. Insert hose for headlight washer into clips on the front apron -A- . See Fig. 78.
2. Press hose for headlight washer into retaining clips on both sides -Arrow A- . See Fig. 78.
Microsoft
Fig. 79: Pushing on hose for headlight washer

3. Push hose for headlight washer onto the spray nozzle until it is felt to engage.
Installing hose for headlight washer system (at tank)
Microsoft
Fig. 80: Pushing hose for headlight washer system onto the pump
1. Push hose for headlight washer system onto the pump.
Microsoft
Fig. 81: Inserting hose for headlight washer system into the clips at the tank
2. Insert hose for headlight washer system into the clips at the tank.
SUBSEQUENT WORK
Subsequent work for installing hose for headlight washer system (front apron)
Install front apron. --> 63 10 19 REMOVING AND INSTALLING FRONT BUMPER - AS OF MY 2005
(ALL MODELS) .
Subsequent work for installing hose for headlight washer system (at tank)
Install tank for windscreen washer system. --> 92 60 19 Removing and installing reservoir for windscreen
92 78 19 REMOVING AND INSTALLING PUMP FOR HEADLIGHT WASHING

TOOLS

universal disassembly tool special tool NR.21
Microsoft
PRELIMINARY WORK
Preliminary work
REMOVING PUMP FOR HEADLIGHT WASHING SYSTEM
Removing pump for headlight washer
Fig. 82: Overview of pump for headlight washer
Microsoft
Fig. 83: Removing pump for headlight washer

1. Pull off water line from pump for washer -arrow A- . See Fig. 83.
2. Pull the pump for headlight washer upwards out of the tank -arrow B- . See Fig. 83.
Microsoft

3. Remove rubber seal using the universal disassembly tool NR.21 to lever it out of the tank -arrows A- and
remove it -arrow B- . See Fig. 84.
INSTALLING PUMP FOR HEADLIGHT CLEANING SYSTEM
Installing pump for headlight washer system
Microsoft

seal into tank -arrow B- until it is felt to engage. See Fig. 85.
Microsoft
Fig. 86: Installing pump for windscreen washer system

2. Apply a suitable rubber lubricant (tire mounting paste) to the sealing surface -arrows A- and press the pump
for the windscreen washer system into the rubber seal -arrow B- until it is felt to engage. See Fig. 86.
3. Connect the water pipe to the connections at the pump for the windscreen washer system -arrow C- . See
Fig. 86.
SUBSEQUENT WORK
Subsequent work
Install reservoir for windscreen washer. --> 92 60 19 Removing and installing reservoir for windscreen
Microsoft
2007 Porsche Boxster
ACCESSORIES & EQUIPMENT Wiring
Wiring
97 IN MEASUREMENT OF CLOSED-CIRCUIT CURRENT - AS OF MY 2005

(ALL MODELS)
TOOLS

Multimeter commercially 155
available tool
TOOLS AND MATERIALS
Tools
Fig. 1:
Closed-circuit current should be measured using an analogue ammeter or a digital multimeter with a long
integration time (to filter out voltage peaks).
Item Special tool designation Explanation

--> "Gr. 2,5; Workshop Equipment
-1- Multimeter 155
Manual "
MEASUREMENT OF CLOSED-CIRCUIT CURRENT
Preliminary work on vehicle
NOTE: Before measuring the closed-circuit current, determine the vehicle equipment (I
numbers) and establish the expected closed-circuit current with the aid of the
attached table.
1. Open the front luggage compartment.
Microsoft
2. Using a suitable tool, e. g. upper part of lock with a suitable handle, close lower part of luggage compartment
lock while keeping the luggage compartment lid open.
3. Remove ignition key, close doors and rear lid, do not lock vehicle.
4. Set the measuring instrument to the highest possible current-measuring range.
5. With two alligator clips, connect the measuring instrument to the battery ground and to the unoccupied
second body ground which is always available for RHD or LHD.
6. Remove ground strap from the body and secure against contact with the body. The entire vehicle current now
flows through the ammeter.
Testing
Select a measuring range which ensures that the pointer of the instrument is in the upper third of the scale, as far
as possible. Switch over measuring range without interruption. Read off the measuring values after the waiting
period specified in the table.
Do not switch on any electrical loads when measuring.
NOTE:  If the value of the closed-circuit current is higher than the value
determined in the table, the cause must be established systematically.
 Recommended troubleshooting procedure: With the measuring device
connected, remove the fuses of terminal 30 and the relays successively.
Observe the display values of the measuring instrument when removing in
order to recognize a reduction in current.
 After troubleshooting, screw the ground strap back onto the body in the
proper manner.
 The measured values could vary by approx. 20%.
 The values listed in the table depend on the condition of the battery, the
room temperature and the engine temperature.
Reading off the measuring range:
Read off the measuring range only after at least 60 minutes have passed since locking the vehicle.
From to mA
Approx. 60 min until battery is empty up to approx.
System reaches closed-

Closed-circuit circuit current after X
Control unit Equipment current in mA sec
Generator Standard 0.3 instantaneous
Microsoft
DME Standard 0.31 66

Instrument cluster Standard 1.75 958
Driver ID/PAS Standard 0.8 223
Passenger compartment
I No. 1.93 60
sensor
Tilt sensor I No. 1.15 instantaneous
Door control unit, right Standard 0.1 221
Door control unit, left Standard 0.1 221
Tiptronic* I No. 0.4
On-board control unit Standard 0.41 226
PSM Standard 0.1 61
Front end control unit Standard 0.52 226
CD changer I No. 0.25 80
Bose amplifier I No. 0.47 226
Navi DVD I No. 3.18 117
ASK sound package I No. 0.1
PCM I No. 0.59 308
Telephone I No. 0.15 104
Seat memory, both I No. 0.15 221
Air-conditioning control unit Standard 0.1 3506
Ignition lock Standard 0.1 instantaneous
Gateway control unit Standard 0.1 308
Rear control unit Standard 1.27 222
Steering column module Standard 0.71 221
Fan control unit Standard 0.1 instantaneous
PASM I No. 0.1 62
RDK (Tire pressure
I No. 0.12 221
monitoring system)
Sport Chrono I No. 0.1 308
Alarm siren I No. 0.2
Total current calculated 15.66

Total current max. 20 after 60 minutes
97 09 19 REMOVING AND INSTALLING MAIN WIRE HARNESS - AS OF MY

TOOLS

Disassembly tool, universal special tool NR.21
Microsoft
PRELIMINARY WORK
Preliminary work
1. Remove battery. Refer to 27 06 19 Removing and installing battery - as of MY 2005 (All Models) .
2. Remove plenum panel cover. Refer to 85 22 19 Removing and installing cover - as of MY 2005 (All
Models) .
3. Remove CD changer. Refer to 91 60 19 Removing and installing CD changer - as of MY 2005 (All

Models) .
4. Remove navigation unit with retaining bracket Refer to 91 12 19 Removing and installing navigation unit -
5. Remove loudspeaker amplifier. Refer to 91 44 19 Removing and installing loudspeaker amplifier - as of

6. Remove front luggage compartment linings. Refer to 70 05 19 Removing and installing front luggage
7. Remove front-end control unit. Refer to 94 49 19 Removing and installing front control unit - as of MY
2005 (All Models) .
8. Remove front wheel housing liner on left and right. Refer to 50 56 19 Removing and installing front wheel
housing liner - as of MY 2005 (All Models) .
9. Remove front cover. Refer to 51 92 19 Removing and installing cover for front underbody - as of MY
2005 (All Models) .
10. Remove tank for windscreen washer system. Refer to 92 60 19 Removing and installing reservoir for
12. Remove relay carrier. --> 979019 Removing and installing relay carrier - section on "Removing"
13. Remove rear wheel housing liner. Refer to 53 69 19 Removing and installing rear wheel housing liner -
Microsoft
14. Remove convertible top and water drip pan. Refer to 61 01 19 Removing and installing convertible top -
15. Remove rear side trim panel at left and right. Refer to 70 75 19 Removing and installing side trim panel -
16. Remove auxiliary brake light. Refer to 94 70 19 Removing and installing auxiliary brake light - as of
17. Remove dashboard. Refer to 70 18 19 Removing and installing instrument panel - as of MY 2005 (All
Models) .
18. Remove heating/fresh-air unit. Refer to 85 15 19 Removing and installing heating/fresh air unit - as of
19. Remove front seat at left and right. Refer to 72 01 19 Removing and installing front seat - as of MY 2005
(All LHD Models) . Refer to 72 01 19 Removing and installing front seat - as of MY 2005 (All RHD
Models) .
20. Remove left and right scuff plate. Refer to 68 05 19 Removing and installing inner door sill trim - as of
21. Loosen fuse box. --> 978409 Loosening and securing fuse box - section on "Loosening"
22. Remove B+ line from power distributor to engine connection point. --> 974519 Installing and removing
wire harness for starter battery - section on "Removing"
23. Remove relay carrier 1. --> 978319 Removing and installing relay carrier 1 - section on "Removing"
24. Remove vehicle electrical system control unit. --> 971019 Removing and installing vehicle electrical
system control unit - section on "Removing"
26. Remove front roof lining. --> 70 84 19 REMOVING AND INSTALLING ROOF LINING - AS OF MY
2006 (CAYMAN S, CAYMAN S RHD) .
REMOVING MAIN WIRE HARNESS
Removing main wire harness
CAUTION: Damage caused by improper handling of main wire harness.
--> The main wire harness contains all airbag lines, antenna lines and optical waveguides.
Microsoft
--> The main wire harness must therefore not be cut for major repair work and must be replaced complete.
--> If individual wires are damaged, these must be "shut down" (disconnect wires, remove plug-in contacts from
plug connections, etc.) and replaced by installing new wires. Lay the new wires along the main wire harness and
tie them to it.
NOTE: Depending on the equipment I No., the installation positions of the audio
components in the front luggage compartment differ.
Fig. 2: Overview of connectors for front main wire harness, shown on the 911
1 - Plug connection between main wire harness and front-end wire harness right
2 - Fuse box for fan
3 - Connector for front-end control unit
4-6 - Connector for navigation unit
7-8 - Connector for CD changer
9 - Connector for loudspeaker amplifier
10 - Connector for luggage compartment light
11 - Ground point
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12 - Plug connection between main wire harness and front-end wire harness left
13 - Connector for hydraulic unit
14 - Connector for brake fluid sender
15 - Connector for Tire pressure monitoring system control unit
16 - Grommet
17-18 - Plug connection for ABS wire harness, front left and right
19-20 - Connector for Tire pressure monitoring system antenna, left and right
21 - Connector for filler flap switching element
22 - Connector for tank filler neck
23 - Connector for rod antenna
24 - Connector for GPS antenna
25 - Connector for radio antenna
26 - Connector for vertical sensor
27 - Connector for pressure switch
28 - Connector for alarm siren
29 - B+ line to power distributor
30-31 - Plug connection for PASM, front left and right
32-33 - Connector for windscreen washer system spray nozzle, left and right
34 - Connector for headlight beam adjustment angle sensor
35 - Connector for fluid level indicator sender
36 - Connector for windscreen washer system pump
37 - Connector for headlight washer pump
38 - Connector for wiper motor
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39 - Connector for alarm horn
40 - Connector for fuel level sensor
41 - Grommet
Fig. 3: Disconnecting plug connection between front-end wire harness and main wire harness, right
1. Disconnect plug connection between main wire harness and front-end wire harness, right -1- . See Fig. 2.
1.1. Release plug connection between front-end wire harness and main wire harness, right -Arrow a- and
disconnect -Arrow B- . See Fig. 3.
1.2. Turn socket 90° clockwise and remove.
Microsoft
Fig. 4: Pulling off connector on fuse box for fan

2. Pull off connector on fuse box for fan -2- . See Fig. 2.
2.1. Unclip fuse box for fan -Arrow A- and lift up and off -Arrow B- . See Fig. 4.
2.2. Release lid -arrows- and open -Arrow C- . See Fig. 4.
2.3. Pull off connector on fuse box for fan -Arrow D- . See Fig. 4.
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Fig. 5: Loosening ground point

3. Loosen ground point left -11- . See Fig. 2.
3.1. Screw off fastening nut and remove ground straps.
4. Release plug connection between main wire harness and front-end wire harness, left -12- and disconnect.
Unclip connector socket. See Fig. 2.
5. Release connector on hydraulic unit -13- and pull it off. Refer to 45 30 19 Removing and installing
hydraulic unit - as of MY 2005 (All Models) . See Fig. 2.
6. Release connector on brake fluid sender -14- and pull it off. See Fig. 2.
7. Release connector for Tire pressure monitoring system control unit -15- and pull it off. Refer to 44 34 19
Removing and installing Tire pressure monitoring system control module - as of MY 2005 (All Models) .
See Fig. 2.
Microsoft
Fig. 6: Unclipping wire harness

8. Unclip wire harness for front end control unit -arrow- . See Fig. 6.
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Fig. 7: Unclipping wire harness to loudspeaker amplifier

9. Unclip wire harness to loudspeaker amplifier -Arrows A- and remove adhesive tape -Arrow B- . See Fig. 7.
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Fig. 8: Unclipping wire harness to CD changer/navigation unit

10. Unclip wire harness to CD changer/navigation unit -arrows- . See Fig. 8.
11. Remove grommets -16- left and right. See Fig. 2.
12. Pull through main wire harness in direction of plenum panel.
13. Disconnect and release ABS wire harness front left and right -17 and 18- . --> 976555 Replacing ABS wire
harness - chapter on "Removing"See Fig. 2.
13.1. Release and disconnect plug connection for wheel sensor at left and right.
13.2. Unscrew fastening screw of connector socket.
13.3. Release rear wire harness.
14. Release and pull off connectors on front antenna for Tire pressure monitoring system -19 and 20- at left and
right. Refer to 44 38 19 Removing and installing Tire pressure monitoring system antenna - as of MY 2005
(All Models) . See Fig. 2.
15. Release and pull off connector of switching element for filler flap -21- . Refer to 55 38 19 Removing and
installing switching element for filler flap - as of MY 2005 (All Models) . See Fig. 2.
16. Pull off connector from tank filler neck -22- . See Fig. 2.
Microsoft
NOTE: Only in the Cabriolet.
17. Release connector on rod antenna -23- and pull it off. See Fig. 2.

18. Unclip wire harness on end plate under windscreen at the three retaining clips -arrow- . See Fig. 9.
19. Release connector on GPS antenna -24- and pull it off. Refer to 91 13 19 Removing and installing GPS
antenna - as of MY 2005 (All Models) . See Fig. 2.
20. Release connector on radio antenna -25- and pull it off. Refer to 91 47 19 Removing and installing radio
21. Release connector for vertical sensor -26- and pull it off. See Fig. 2.
22. Release connector for pressure switch -27- and pull it off. Refer to 87 83 19 Removing and installing
pressure switch - as of MY 2005 (All Models) . See Fig. 2.
NOTE: Only for vehicles with I number 536
23. Release connector for alarm siren -28- and pull it off. Refer to 96 65 19 Removing and installing the
alarm siren - as of MY 2005 (All Models) . See Fig. 2.
Microsoft
24. Release and pull off B+ line -29- from power distributor. --> 978919 Removing and installing power
distributor - chapter on "Removing"See Fig. 2.
Fig. 10: Disconnecting PASM plug connection

25. Release plug connections for PASM, front left and right -30 and 31- -Arrow a- and disconnect. See Fig. 2,
Fig. 10.
26. Release and pull off connectors for windscreen washer system spray nozzle, left and right -32 and 33- . See
Fig. 2.
NOTE: Only for vehicles with HBA.
27. Release and pull off connector on front angle sensor for headlight beam adjustment -34- . Refer to 94 78 19
Removing and installing front angle sensor for headlight levelling system - as of MY 2005 (All Models) .
See Fig. 2.
28. Release and pull off connector on wiper motor -38- . Refer to 92 15 19 Removing and installing wiper
motor - as of MY 2005 (All Models) . See Fig. 2.
29. Release and pull off connector on alarm horn -39- . Refer to 96 65 19 Removing and installing the alarm
siren - as of MY 2005 (All Models) . See Fig. 2.
Microsoft
Fig. 11: Removing and installing battery retaining bracket

30. Undo the four fastening nuts on the battery retaining bracket and remove the battery retaining bracket.
Microsoft
Fig. 12: Pulling off tank connector

31. Release connector on fuel level sender -40- -Arrow A- and pull it off -Arrow B- . See Fig. 2, Fig. 12.

32. Unclip wire harness on end plate under windscreen at the two retaining clips -arrow- . See Fig. 13.
33. Remove grommets -41- in center, and on left and right. See Fig. 2.
34. Pull through main wire harness in direction of interior.
Exposing main wire harness in passenger compartment
Microsoft

1. Loosen seat belt mount at left and right.
1.1. Press off cap -1- with a screwdriver and unscrew the fastening screw -2- . Remove seat belt with fitting -3-
and spacer sleeve -4- . See Fig. 14.
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3. Remove left and right support.
3.1. Unlock locating peg -1- of the support using the commercially available removal tool Disassembly tool,
universal NR.21. See Fig. 15.
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3.2. Unscrew fastening screws -2- and nuts -3- and carefully pull the support up and out of the retaining points.
See Fig. 16.
Removing main wire harness in passenger compartment
Microsoft
Fig. 17: Overview of main wire harness for dashboard

1-3 - Connector for steering column switch
4 - Connector for main light switch
5 - Connector for ignition lock
6 - Connector for diagnostic box
7 - Connector for floor light left
8 - Connector for instrument cluster
9-10 - Connector for passenger's airbag, stage 1 and stage 2
11 - Connector for floor light right
12 - Plug connection for glove compartment
13 - Connector for stopwatch
14 - Connector for sun sensor
15 - Connector for center speaker
16-17 - Connector for loudspeaker, left and right
18 - Connector for switch console

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19-20 - Connector for climate control
21-26 - Connector for PCM
27 - Connector for central locking
28 - Connector for hazard warning light switch
29-30 - Plug connection for illumination of center nozzle
31-32 - Plug connection for illumination of left and right nozzle
Microsoft
Fig. 18: Overview of connectors for main wire harness in passenger compartment
33-34 - Plug connection between main wire harness and wire harness for rear end
35-36 - Plug connection between main wire harness and wire harness for engine
37 - Connector for rear vertical sensor
38-39 - DME control module connector
40 - Rear luggage compartment ground point
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41 - Rear luggage compartment light connector
42 - Angle sensor connector for HBA, rear
43 - Rubber sleeve
44 - Connector for auxiliary brake light
45-46 - Plug connection for PASM, left and right
47 - Motor connector for convertible-top compartment lid drive mechanism
50-51 - Plug connection for ABS wire harness, rear left and right
52 - Rubber sleeve
53 - Rear window heating plug connection
54 - Convertible top mechanism connector
55 - Subwoofer connector
56-57 - Connector for seat-belt tensioner, front left and right
58-59 - Connector for airbag sensor, center left and right
60-61 - Connector for ParkAssist control unit
62-64 - Connector for rear end convenience systems control unit
65 - Ground point under driver's seat
66-69 - Connector for telephone control unit
70 - Ground point under passenger's seat
71-72 - Connector for front seat, left and right
73 - Connector for driver's seat with memory
74 - Connector for door sill button module
75-76 - Plug connection between main wire harness and wire harness for door, left and right
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77 - Fuse box
78 - Relay carrier
79-80 - Connector for vehicle electrical system control unit
81 - Connector for gateway control unit
82-83 - Connector for KESSY/PAS control unit
84 - Connector for stop light switch
85 - Connector for pedal sensor
86 - Plug connection between main wire harness and wire harness for center console
87 - Plug connection for telephone handset
88 - Airbag control unit connector
89 - Connector for parking-brake lever contact switch
90 - Tiptronic position switch
91 - Ground point under unit carrier
92 - Connector for tilt sensor control unit
93 - Power distributor
94-95 - Plug connection between main wire harness and wire harness for heater/air-conditioning unit
96-97 - Connector for garage door opener control unit
98 - Connector for interior light
99 - Latching hook microswitch connector
100 - Plug connection for rain sensor
101-102 - Plug connection for make-up mirror, left and right
103-107 - Connector for antenna unit, left and right
Microsoft
Fig. 19: Disconnect plug connections for main wire harness to rear wire harness.
1. Disconnect plug connections for main wire harness to rear wire harness -33 and 34- . See Fig. 18.
1.1. Release plug connections for main wire harness to rear wire harness -35 and 36- and -arrows A-
disconnect. See Fig. 18, Fig. 19.
Microsoft
Fig. 20: Disconnecting plug connections for main wire harness to engine wire harness
2. Disconnect plug connections for main wire harness to engine wire harness.
2.1. Release plug connections for main wire harness to engine wire harness -arrows A- and disconnect -arrows
B- . See Fig. 19.
2.2. Release sockets for main wire harness -arrows C- and push down from relay carrier -arrows D- . See Fig.
19.
3. Release connector for rear vertical sensor -37- and pull it off. See Fig. 18.
4. Release and pull off connector on DME control module -38 and 39- . Refer to 24 70 19 Removing and
Microsoft
installing DME control module - as of MY 2005 (Boxster, Boxster RHD, Boxster S, Boxster S RHD) . See
Fig. 18.

5. Loosen ground point in luggage compartment -40- . See Fig. 18.
5.1. Screw off fastening nut and remove ground strap.
6. Release and pull off connector on rear angle sensor for headlight beam adjustment -42- . Refer to 94 79 19
Removing and installing rear angle sensor for headlight levelling system - as of MY 2005 (All Models) .
See Fig. 18.
Microsoft
Fig. 22: Unclipping main wire harness in rear luggage compartment

8. Unclip main wire harness in rear luggage compartment.
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Fig. 23: Disconnecting PASM plug connections at left and right

9. Disconnect PASM plug connections -45 and 46- at left and right. See Fig. 18.
9.1. Remove PASM plug connections on the left and right from both holders -arrow B- , release -arrow a- and
disconnect them -arrows C- . See Fig. 23.
9.2. Open both holders -arrow D- and take off from actuating cable. See Fig. 23.
9.3. Remove wire harness to engine for convertible-top compartment lid drive from the holder -arrow B- . See
Fig. 23.
10. Release connector on engine for convertible-top compartment lid drive -47- and pull off. Refer to 61 70 19
Removing and installing motor for drive mechanism - as of MY 2005 (Boxster, Boxster RHD, Boxster S,
Boxster S RHD) . See Fig. 18.
11. Release and pull off connector on rear antenna for Tire pressure monitoring system -48 and 49- at left and
12. Disconnect and expose ABS wire harness rear on left and right -50 and 51- . --> 976555 Replacing ABS
wire harness - chapter on "Removing"See Fig. 18.
Microsoft
Fig. 24: Unclipping the main wire harness in the area of the rear left spring strut
13. Unclip the main wire harness in the area of the rear left spring strut.
14. Release rear window heating plug connection -53- and disconnect. Refer to 61 02 19 Removing and
installing hardtop - as of MY 2005 (Boxster, Boxster RHD, Boxster S, Boxster S RHD) . See Fig. 18.
15. Release connector on convertible top mechanism -54- and pull off. Refer to 61 72 19 Removing and
installing convertible top gear - as of MY 2005 (Boxster, Boxster RHD, Boxster S, Boxster S RHD) . See
Fig. 18.
16. Pull off connector on front seat-belt tensioner -56 and 57- at left and right. Refer to 69 11 19 REMOVING
AND INSTALLING FRONT THREE-POINT BELT - AS OF MY 2006 (CAYMAN S, CAYMAN S
RHD) . See Fig. 18.
Microsoft
Fig. 25: Unclipping main wire harness to the left side wall
17. Unclip main wire harness to the left side wall.
17.1. Unclip main wire harness to the left side wall -arrow A- . See Fig. 25.
17.2. Unclip cable duct to the left side wall -arrow B- . See Fig. 25.
Microsoft
Fig. 26: Loosening cable duct to the left side wall

18. Loosen cable duct to the left side wall.
18.1. Unclip main wire harness to the bottom of the B-pillar -arrow A- . See Fig. 26.
18.2. Take out cable duct upwards out of the rear wall plate -arrow B- . See Fig. 26.
19. Release and pull off connector for airbag sensor, center left and right -58 and 59- . Refer to 69 51 19
Removing and installing airbag sensor - as of MY 2005 (All Models) . See Fig. 18.
20. Release and pull off connector for ParkAssist control unit -60 and 61- . Refer to 91 74 19 Removing and
installing control module for ParkAssist - as of MY 2005 (All Models) . See Fig. 18.
Microsoft
21. Release and pull off connector for rear end convenience systems control unit -62 to 64- . Refer to 57 89 19
Removing and installing control unit for rear convenience systems - as of MY 2005 (All Models) . See Fig.
18.

22. Loosen ground point under the driver's seat -65- . See Fig. 18.
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Fig. 28: Unclipping ground point under driver's seat

23. Unclip ground point under driver's seat.
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Fig. 29: Unclipping wire harness for telephone control unit

24. Release and remove connectors for telephone control unit -66 to 69- . Refer to 91 90 19 Removing and
installing control unit for telephone - as of MY 2005 (All Models) . See Fig. 18.
24.1. Unclip wire harness for telephone control unit.

25. Loosen ground point under the passenger's seat -70- . See Fig. 18.
Microsoft
Fig. 31: Unclipping wire harness at door sill

26. Unclip wire harness at door sill.
27. Disconnect the plug connection between main wire harness and wire harness for door, left and right -75 and
76- . --> 973219 Removing and installing wire harness for door - chapter on "Disconnecting". See Fig. 18.
28. Release and pull off connector for gateway control unit -81- . Refer to 90 35 19 Removing and installing
gateway control unit - as of MY 2005 (All Models) . See Fig. 18.
29. Release and pull off connectors for KESSY/PAS control unit -82 and 83- . Refer to 96 66 19 Removing
and installing KESSY/PAS control unit - as of MY 2005 (All Models) . See Fig. 18.
30. Release and pull off connector for stop light switch -84- . Refer to 94 36 19 Removing and installing
brake light switch - as of MY 2005 (All Models) . See Fig. 18.
31. Release and pull off connector for pedal sensor -85- . See Fig. 18.
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32. Loosen ground point under the unit carrier -91- . See Fig. 18.
33. Release and pull off connector for tilt sensor control unit -92- . Refer to 96 63 19 Removing and installing
tilt sensor control unit - as of MY 2005 (All Models) . See Fig. 18.
Microsoft

34. Disconnect plug connections between main wire harness and wire harness for heater/air-conditioning unit -
94 and 95- . See Fig. 18.
34.1. Release lower plug connection on heater/air-conditioning unit -arrows a- and unplug. See Fig. 33.
Microsoft
Fig. 34: Releasing plug connection

34.2. Release upper plug connection on heater/air-conditioning unit -arrows a- and unplug. See Fig. 34.
Microsoft
Fig. 35: Cutting tie-wraps

34.3. Cut tie-wraps (main wire harness to heater/air-conditioning unit wire harness) with side cutters. Remove
main wire harness.
35. Release and disconnect plug connection for rain sensor -100- . Refer to 92 12 19 Removing and installing
rain sensor - as of MY 2005 (All Models) . See Fig. 18.
Microsoft
Fig. 36: Disconnecting plug connection of make-up mirror

36. Disconnect plug connection of make-up mirror, left and right -101 and 102- . See Fig. 18.
36.1. Unclip plug connection from console -arrow B- . See Fig. 36.
36.2. Release plug connection -arrow a- and disconnect it -arrows C- . See Fig. 36.
Microsoft
Fig. 37: Unclipping cable duct at front of roof frame

37. Unclip cable duct at front of roof frame.
Microsoft
Fig. 38: Unclipping main wire harness at front of roof frame

38. Unclip main wire harness at front of roof frame.
Fig. 39: Removing main wire harness from A-pillar

39. Remove main wire harness from A-pillar -area A- . See Fig. 39.
40. Pull off connector for antenna amplifier, left and right -103 to 107- . Refer to 91 84 19 Removing and
installing antenna amplifier - as of MY 2005 (All Models) . See Fig. 18.
Microsoft
Fig. 40: Loosening ground points on dashboard bracket

41. Loosen ground points on dashboard bracket.
41.1. Unscrew fastening nuts and remove ground straps.
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Fig. 41: Unclipping length compensation

42. Unclip length compensation at the steering column.
42.1. Remove expansion rivet and length compensation.
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Fig. 42: Unclipping cable guide

43. Unclip cable guide on dashboard bracket.
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Fig. 43: Loosening holder for relay carrier

44. Loosen holder for relay carrier.
44.1. Unscrew the two fastening screws and remove the relay carrier holder from the dashboard bracket.
Fig. 44: Loosening main wire harness at left dashboard bracket

45. Loosen main wire harness at left dashboard bracket.
45.1. Screw off fastening nut and remove fastening screw.
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45.2. Unclip main wire harness on cable guide.
Fig. 45: Loosening main wire harness at right dashboard bracket

46. Loosen main wire harness at right dashboard bracket.
46.1. Unclip main wire harness on both cable guides.
Microsoft
Fig. 46: Loosening main wire harness at center dashboard bracket

47. Loosen main wire harness at center dashboard bracket.
47.1. Undo the four tie-wraps and remove main wire harness.
INSTALLING MAIN WIRE HARNESS
Installing main wire harness in passenger compartment
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41 - Rear luggage compartment light connector
43 - Rubber sleeve
44 - Connector for auxiliary brake light
47 - Motor connector for convertible-top compartment lid drive mechanism
52 - Rubber sleeve
53 - Rear window heating plug connection
54 - Convertible top mechanism connector
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77 - Fuse box
78 - Relay carrier
93 - Power distributor
96-97 - Connector for garage door opener control unit
99 - Latching hook microswitch connector
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Fig. 49: Fastening main wire harness at center dashboard bracket

1. Fasten main wire harness at center dashboard bracket.
1.1. Lay main wire harness and fasten with four new tie-wraps .
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Fig. 50: Fastening main wire harness at right dashboard bracket

2. Fasten main wire harness at right dashboard bracket.
2.1. Clip in main wire harness on both cable guides.
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Fig. 51: Fastening main wire harness at left dashboard bracket

3. Fasten main wire harness at left dashboard bracket.
3.1. Clip in main wire harness on cable guide.
3.2. Insert fastening screw and tighten fastening nut. --> Tightening torque: 3.5 (2.5 ftlb.) Nm
Microsoft
Fig. 52: Fastening holder for relay carrier

4. Fasten holder for relay carrier.
4.1. Position holder for relay carrier and tighten with the two fastening screws to the dashboard bracket. -->
Tightening torque: 3.5 (2.5 ftlb.) Nm
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Fig. 53: Clipping in cable guide

5. Clip in cable guide on dashboard bracket.
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Fig. 54: Clipping in length compensation

6. Clip in length compensation at the steering column.
6.1. Position length compensation at the steering column and fasten with the expansion rivet.
Fig. 55: Fastening ground points on dashboard bracket

7. Fasten ground points on dashboard bracket.
7.1. Fit ground straps and tighten with fastening nuts. --> Tightening torque: 9 (6.5 ftlb.) Nm
Microsoft
8. Push on connector for antenna amplifier, left and right -103 to 107- . Refer to 91 84 19 Removing and
Fig. 56: Affixing main wire harness to A-pillar

9. Remove protective film of adhesive strip on main wire harness -area A- and affix main wire harness to A-
pillar. See Fig. 56.
Microsoft
Fig. 57: Clipping in main wire harness at front of roof frame

10. Clip in main wire harness at front of roof frame.
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Fig. 58: Clipping in cable duct at front of roof frame

11. Clip in cable duct at front of roof frame.
Fig. 59: Connecting plug connection of make-up mirror

12. Connect plug connection of make-up mirror, left and right -101 and 102- . See Fig. 48.
12.1. Push together plug connection -arrows A- until it is felt to engage. See Fig. 59.
12.2. Clip plug connection into console -arrow B- . See Fig. 59.
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13. Push together plug connection -100- until it is felt to engage. Refer to 92 12 19 Removing and installing

14. Connect plug connections between main wire harness and wire harness for heater/air-conditioning unit -94
and 95- . See Fig. 48.
14.1. Lay main wire harness to heater/air-conditioning unit wire harness and fix with a tie-wrap.
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Fig. 61: Connecting upper electrical plug connection

14.2. Push in upper electric plug connection at heater/air-conditioning unit until it is felt to engage.
Microsoft
Fig. 62: Connecting lower electrical plug connection

14.3. Push in lower electric plug connection at heater/air-conditioning unit until it is felt to engage.
15. Push on connector for tilt sensor control unit -92- until it is felt to engage. Refer to 96 63 19 Removing and
installing tilt sensor control unit - as of MY 2005 (All Models) . See Fig. 48.
Microsoft
Fig. 63: Securing ground point

16. Fasten ground point under the unit carrier -91- . See Fig. 48.
16.1. Connect ground straps and screw down fastening nut. --> Tightening torque: 9 (6.5 ftlb.) Nm
17. Push on connector for pedal sensor -85- until it is felt to engage. See Fig. 48.
18. Push on connector for stop light switch -84- until it is felt to engage. Refer to 94 36 19 Removing and
installing brake light switch - as of MY 2005 (All Models) . See Fig. 48.
19. Push on connectors of KESSY/PAS control unit -82 and 83- until they are felt to engage. Refer to 96 66 19
Removing and installing KESSY/PAS control unit - as of MY 2005 (All Models) . See Fig. 48.
20. Push on connector of Gateway control unit -81- until it is felt to engage. Refer to 90 35 19 Removing and
installing gateway control unit - as of MY 2005 (All Models) . See Fig. 48.
21. Push the plug connection together between main wire harness and wire harness for door, left and right -75
and 76- . --> 973219 Removing and installing wire harness for door - chapter on "Locking"See Fig. 48.
Microsoft
Fig. 64: Clipping in wire harness at door sill

22. Clip in wire harness at door sill.
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23. Fasten ground point under the passenger seat -70- . See Fig. 48.
Fig. 66: Clipping in wire harness for telephone control unit

24. Push on connectors for telephone control unit -66 to 69- until they are felt to engage. Refer to 91 90 19
Removing and installing control unit for telephone - as of MY 2005 (All Models) . See Fig. 48.
24.1. Clip in wire harness for telephone control unit.
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Fig. 67: Clipping in wire harness under driver's seat

25. Clip in wire harness under driver's seat.
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26. Fasten ground point under the driver's seat -65- . See Fig. 48.
27. Push on connectors for rear end convenience systems control unit -62 to 64- until they are felt to engage.
Refer to 57 89 19 Removing and installing control unit for rear convenience systems - as of MY 2005 (All
Models) . See Fig. 48.
28. Push on connectors for ParkAssist control unit -60 and 61- until they are felt to engage. Refer to 91 74 19
Removing and installing control module for ParkAssist - as of MY 2005 (All Models) . See Fig. 48.
29. Push on connectors for airbag sensor, center left and right -58 and 59- until it is felt to engage. Refer to 69
51 19 Removing and installing airbag sensor - as of MY 2005 (All Models) . See Fig. 48.
Microsoft
Fig. 69: Fastening cable duct to the left side wall

30. Fasten cable duct to the left side wall.
30.1. Insert cable duct downward in the rear wall plate -arrow A- See Fig. 69.
30.2. Clip in cable duct to the bottom of the B-pillar -arrow B- . See Fig. 69.
Microsoft
Fig. 70: Clipping in main wire harness to the left side wall
31. Clip in main wire harness to the left side wall.
31.1. Clip in cable duct to the left side wall.
31.2. Clip in main wire harness to the left side wall.
32. Plug in connector on front seat-belt tensioner -56 and 57- at left and right. --> 69 11 19 REMOVING AND
INSTALLING FRONT THREE-POINT BELT - AS OF MY 2006 (CAYMAN S, CAYMAN S RHD) . See
Fig. 48.
33. Push on connector for convertible top mechanism -54- until it is felt to engage. Refer to 61 72 19 Removing
and installing convertible top gear - as of MY 2005 (Boxster, Boxster RHD, Boxster S, Boxster S RHD) .
See Fig. 48.
34. Push the plug connection for the rear window heating -53- together until it is felt to engage. Refer to 61 02
19 Removing and installing hardtop - as of MY 2005 (Boxster, Boxster RHD, Boxster S, Boxster S RHD) .
See Fig. 48.
Microsoft
Fig. 71: Clipping in the main wire harness in the area of the rear left spring strut
35. Clip in the main wire harness in the area of the rear left spring strut.
36. Lay and connect ABS wire harness, front left and right -50 and 51- . --> 976555 Replacing ABS wire
harness - chapter on "Installing"See Fig. 48.
36.1. Laying ABS wire harness
36.2. Tighten fastening screw of connector socket. --> Tightening torque: 10 (7.5 ftlb.) Nm
36.3. Lock the plug connection securely.
37. Push on connectors of front antenna for Tire Pressure Monitoring -48 and 49- at left and right until they are
felt to engage. Refer to 44 38 19 Removing and installing Tire pressure monitoring system antenna - as of
MY 2005 (All Models) . See Fig. 48.
38. Push connector onto motor for convertible-top compartment lid drive -47- , until it is felt to engage. Refer to
61 70 19 Removing and installing motor for drive mechanism - as of MY 2005 (Boxster, Boxster RHD,
Boxster S, Boxster S RHD) . See Fig. 48.
Microsoft
Fig. 72: Connecting PASM plug connections at left and right

39. Connect PASM plug connections -45 and 46- at left and right. See Fig. 48.
39.1. Press wire harness to motor for convertible-top compartment lid drive into the holder -arrow C- . See Fig.
72.
39.2. Position both holders on the actuating cable and close -arrow A- . See Fig. 72.
39.3. Push plug connections for PASM together on left and right -arrows B- , until these are felt to engage and
press in both holders -arrow C- . See Fig. 72.
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Fig. 73: Clipping in main wire harness in rear luggage compartment

40. Clip in main wire harness in rear luggage compartment.
42. Push connector onto rear angle sensor for headlight beam adjustment -42- until it is felt to engage. Refer to
94 79 19 Removing and installing rear angle sensor for headlight levelling system - as of MY 2005 (All
Microsoft

43. Fasten ground point in rear luggage compartment -40- . See Fig. 48.
43.1. Fit ground strap and secure with fastening nut. --> Tightening torque: 9 (6.5 ftlb.) Nm
44. Push on connector of DME control module -38 and 39- until it is felt to engage. Refer to 24 70 19
Removing and installing DME control module - as of MY 2005 (Boxster, Boxster RHD, Boxster S,
Boxster S RHD) . See Fig. 48.
45. Push on connector of rear vertical sensor -37- until it is felt to engage. See Fig. 48.
Microsoft
Fig. 75: Pushing main wire harness plug connections for motor wire harness
46. Push main wire harness plug connections for motor wire harness -35 and 36- . See Fig. 48.
46.1. Push sockets for main wire harness onto relay carrier -arrows A- , until these are felt to engage. See Fig.
75.
46.2. Push plug connections for main wire harness to motor wire harness together -arrows B- , until these are
felt to engage. See Fig. 75.
Microsoft
Fig. 76: Pushing main wire harness plug connections together for rear wire harness
47. Push together plug connections for main wire harness to rear wire harness -33 and 34- and lock them, until
these are felt to engage. See Fig. 48.
Completing the vehicle
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1. Install left and right support.
1.1. Position the support and engage in lower side member.
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Fig. 78: Securing the support

1.2. Press in the locating peg -1- of the support and check it is seated correctly. See Fig. 78.
1.3. Tighten the fastening nut -3- and fastening screws -2- . --> Tightening torque: 7.2 (5.5 ftlb.) Nm See Fig.
78.
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3. Fasten seat belt mount at left and right.
3.1. Tighten fastening screw -2- , seat belt with fitting -3- and spacer sleeve -4- on inner lower side member. -->
Tightening torque: 50 (37 ftlb.) Nm See Fig. 79.
3.2. Press in -1- cap. See Fig. 79.
Installing front main wire harness
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11 - Ground point
16 - Grommet
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41 - Grommet
1. Push through main wire harness in direction of plenum panel.
2. Fit grommets -41- center, left and right. See Fig. 80.
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Fig. 81: Clipping in wire harness

3. Clip in wire harness on end plate under windscreen at the two retaining clips -arrow- . See Fig. 81.
Microsoft
Fig. 82: Pushing on tank connector

4. Push on connector for fuel level sender -40- -Arrow A- and lock -Arrow B- . See Fig. 80, Fig. 82.

5. Position battery retaining bracket and secure with the four fastening nuts. --> Tightening torque: 10 (7.5
ftlb.) Nm
6. Push on connector for alarm horn -39- until it is felt to engage. Refer to 96 65 19 Removing and installing
the alarm siren - as of MY 2005 (All Models) . See Fig. 80.
7. Push on connector for wiper motor -38- until it is felt to engage. Refer to 92 15 19 Removing and installing
wiper motor - as of MY 2005 (All Models) . See Fig. 80.
8. Push connector onto front angle sensor for headlight beam adjustment -34- until it is felt to engage. Refer to
94 78 19 Removing and installing front angle sensor for headlight levelling system - as of MY 2005 (All
9. Push on connectors for windscreen washer system spray nozzle, left and right -32 and 33- until they are felt
to engage. See Fig. 80.
Microsoft
Fig. 84: Connecting PASM plug connection

10. Connect plug connections for PASM, front left and right -30 and 31- until they are felt to engage. See Fig.
80.
11. Push B+ line -29- onto mounting point at the power distributor as far as the stop. Check B+ line sits firmly. -
-> 978919 Removing and installing power distributor - chapter on "Installing"See Fig. 80.
12. Push on connector for alarm siren -28- until it is felt to engage. Refer to 96 65 19 Removing and installing
13. Push on connector for pressure switch -27- until it is felt to engage. Refer to 87 83 19 Removing and
installing pressure switch - as of MY 2005 (All Models) . See Fig. 80.
14. Push on connector of vertical sensor -26- until it is felt to engage. See Fig. 80.
15. Push on connector for radio antenna -25- until it felt to engage. Refer to 91 47 19 Removing and installing
radio antenna - as of MY 2005 (All Models) . See Fig. 80.
16. Push on connector for GPS antenna -24- until it is felt to engage. Refer to 91 47 19 Removing and
installing radio antenna - as of MY 2005 (All Models) . See Fig. 80.
Microsoft

17. Clip in wire harness for end plate under windscreen at the three retaining clips -arrow- . See Fig. 85.
18. Push in connector for rod antenna -23- until it is felt to engage. See Fig. 80.
19. Push on connector for tank filler neck -22- . See Fig. 80.
20. Push on connector for filler flap switching element -21- until it is felt to engage. Refer to 55 38 19
Removing and installing switching element for filler flap - as of MY 2005 (All Models) . See Fig. 80.
21. Push on connectors of front antenna for Tire pressure monitoring system -19 and 20- at left and right until
they are felt to engage. Refer to 44 38 19 Removing and installing Tire pressure monitoring system antenna
- as of MY 2005 (All Models) . See Fig. 80.
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23. Push through main wire harness in direction of luggage compartment.
24. Fit grommets -16- left and right. See Fig. 80.
Fig. 86: Clipping in wire harness to CD changer/navigation unit.

25. Clip in wire harness to CD changer/navigation unit -arrows- . See Fig. 86.
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Fig. 87: Clipping in wire harness to loudspeaker amplifier

26. Clip in wire harness to loudspeaker amplifier -Arrows A- and fix with new adhesive tape -Arrow B- . See
Fig. 87.
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27. Clip in wire harness for front end control unit -arrow- . See Fig. 88.
28. Push on connector for Tire pressure monitoring system control unit -15- until it is felt to engage. Refer to 44
34 19 Removing and installing Tire pressure monitoring system control module - as of MY 2005 (All
29. Push on connector for brake fluid sender -14- until it is felt to engage. See Fig. 80.
30. Push on connector for hydraulic unit -13- and lock it. Refer to 45 30 19 Removing and installing
31. Push together plug connection between main wire harness and front-end wire harness, left -12- until it
engages securely. Clip in connector socket. See Fig. 80.
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32. Secure ground point left -11- . See Fig. 80.
32.1. Connect ground straps and tighten fastening nut. --> Tightening torque: 9 (6.5 ftlb.) Nm
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Fig. 90: Pushing connector onto fuse box for fan

33. Push connector onto fuse box for fan -2- . See Fig. 80.
33.1. Push connector onto fuse box for fan -Arrow A- . See Fig. 90.
33.2. Close lid -Arrow B- until it is felt to engage. See Fig. 90.
33.3. Position bottom of fuse box for fan on the clip -Arrow C- and clip in -Arrow D- . See Fig. 90.
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Fig. 91: Pushing together plug connection between front end wire harness and main wire harness, right
34. Push together plug connection between main wire harness and front end wire harness, right -1- . See Fig. 80.
34.1. Insert connector socket in the holder and turn anti-clockwise 90°.
34.2. Push together plug connection between front-end wire harness and main wire-harness right -Arrow A-
and lock -Arrow B- . See Fig. 91.
SUBSEQUENT WORK
Subsequent work
1. Install front roof lining. --> 70 84 19 REMOVING AND INSTALLING ROOF LINING - AS OF MY
2006 (CAYMAN S, CAYMAN S RHD) .
3. Install vehicle electrical system control unit. --> 971019 Removing and installing vehicle electrical system
control unit - section on "Installing"
4. Install relay carrier 1. --> 978319 Removing and installing relay carrier 1 - section on "Installing"
5. Install B+ line from power distributor to engine connection point. --> 974519 Removing and installing wire
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harness for starter battery - section on "Installing"
6. Secure fuse box. --> 978409 Loosening and securing fuse box - section on "Securing"
7. Install left and right scuff plate. Refer to 68 05 19 Removing and installing inner door sill trim - as of MY
2005 (All Models) .
8. Install front seat at left and right. Refer to 72 01 19 Removing and installing front seat - as of MY 2005
Models) .
9. Install heating/fresh-air unit. Refer to 85 15 19 Removing and installing heating/fresh air unit - as of MY
2005 (All Models) .
10. Install dashboard. Refer to 70 18 19 Removing and installing instrument panel - as of MY 2005 (All
Models) .
11. Install auxiliary brake light. Refer to 94 70 19 Removing and installing auxiliary brake light - as of MY
12. Install rear side trim panel at left and right. Refer to 70 75 19 Removing and installing side trim panel - as
13. Install convertible top and water drip pan. Refer to 61 01 19 Removing and installing convertible top - as
14. Install rear wheel housing liner. Refer to 53 69 19 Removing and installing rear wheel housing liner - as
15. Install relay carrier. --> 979019 Removing and installing relay carrier - section on "Installing"
17. Install tank for windscreen washer system. Refer to 92 60 19 Removing and installing reservoir for
18. Install front cover. Refer to 51 92 19 Removing and installing cover for front underbody - as of MY
2005 (All Models) .
19. Install front wheel housing liner on left and right. Refer to 50 56 19 Removing and installing front wheel
20. Installing front-end control unit Refer to 94 49 19 Removing and installing front control unit - as of MY
2005 (All Models) .
21. Install trim panels for front luggage compartment. Refer to 70 05 19 Removing and installing front
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luggage compartment trim panel - as of MY 2005 (All Models) .
22. Install loudspeaker amplifier. Refer to 91 44 19 Removing and installing loudspeaker amplifier - as of
23. Install navigation unit with retaining frame. Refer to 91 12 19 Removing and installing navigation unit -
24. Install CD changer. Refer to 91 60 19 Removing and installing CD changer - as of MY 2005 (All
Models) .
25. Install plenum panel cover. Refer to 85 22 19 Removing and installing cover - as of MY 2005 (All
Models) .
26. Install battery. Refer to 27 06 19 Removing and installing battery - as of MY 2005 (All Models) .
97 09 19 REMOVING AND INSTALLING MAIN WIRE HARNESS - AS OF MY

TOOLS

Disassembly tool, universal special tool NR.21
PRELIMINARY WORK
Preliminary work
Models) .
3. Remove CD changer. Refer to 91 60 19 Removing and installing CD changer - as of MY 2005 (All

Models) .
4. Remove navigation unit with retaining bracket. Refer to 91 12 19 Removing and installing navigation unit
5. Remove loudspeaker amplifier. Refer to 91 44 19 Removing and installing loudspeaker amplifier - as of

Microsoft
6. Remove trim panels for front luggage compartment. Refer to 70 05 19 Removing and installing front
2005 (All Models) .
8. Remove front wheel housing liner on left and right. Refer to 50 56 19 Removing and installing front wheel
9. Remove front cover. Refer to 51 92 19 Removing and installing cover for front underbody - as of MY
2005 (All Models) .
10. Remove tank for windscreen washer system. Refer to 92 60 19 Removing and installing reservoir for
11. Remove rear luggage-compartment lining. Refer to 70 06 19 Removing and installing rear luggage
12. Remove relay carrier. --> 979019 Removing and installing relay carrier - section on "Removing"
13. Remove rear wheel housing liner. Refer to 53 69 19 Removing and installing rear wheel housing liner -
14. Remove left and right side trim panels. Refer to 70 75 19 Removing and installing side trim panel - as of
Models) .
16. Remove heating/fresh-air unit. Refer to 85 15 19 Removing and installing heating/fresh air unit - as of
17. Remove front seat at left and right. Refer to 72 01 19 Removing and installing front seat - as of MY 2005
Models) .
18. Remove left and right scuff plate. Refer to 68 05 19 Removing and installing inner door sill trim - as of
19. Loosen fuse box. --> 978409 Loosening and securing fuse box - section on "Loosening"
20. Remove B+ line from power distributor to engine connection point. --> 974519 Removing and installing
wire harness for starter battery - section on "Removing"
21. Remove relay carrier 1. --> 978319 Removing and installing relay carrier 1 - section on "Removing"
22. Remove vehicle electrical system control unit. --> 971019 Removing and installing vehicle electrical
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system control unit - section on "Removing"
unit for garage door opener - as of MY 2005 (Cayman S, Cayman S RHD) .
24. Remove front roof lining. Refer to 70 84 19 Removing and installing roof lining - as of MY 2006
REMOVING MAIN WIRE HARNESS
Removing main wire harness
CAUTION: Damage caused by improper handling of main wire harness.
--> The main wire harness contains all airbag lines, antenna lines and optical waveguides.
--> The main wire harness must therefore not be cut for major repair work and must be replaced complete.
--> If individual wires are damaged, these must be "shut down" (disconnect wires, remove plug-in contacts from
plug connections, etc.) and replaced by installing new wires. Lay the new wires along the main wire harness and
tie them to it.
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11 - Ground point
16 - Grommet
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41 - Grommet
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1. Disconnect plug connection between main wire harness and front-end wire harness, right -1- . See Fig. 92.
1.1. Release plug connection between front-end wire harness and main wire harness, right -Arrow a- and
disconnect -Arrow B- . See Fig. 93.
1.2. Turn socket 90° clockwise and remove.

2.1. Unclip fuse box for fan -Arrow A- and lift up and off -Arrow B- . See Fig. 94.
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2.2. Release lid -arrows- and open -Arrow C- . See Fig. 94.
2.3. Pull off connector on fuse box for fan -Arrow D- . See Fig. 94.

3. Loosen ground point left -11- . See Fig. 92.
4. Release plug connection between main wire harness and front-end wire harness, left -12- and disconnect.
Unclip connector socket. See Fig. 92.
5. Release connector on hydraulic unit -13- and pull it off. Refer to 45 30 19 Removing and installing
6. Release connector on brake fluid sender -14- and pull it off. See Fig. 92.
7. Release connector for Tire pressure monitoring system control unit -15- and pull it off. Refer to 44 34 19
Removing and installing Tire pressure monitoring system control module - as of MY 2005 (All Models) .
See Fig. 92.
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8. Unclip wire harness for front end control unit -arrow- . See Fig. 96.
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Fig. 97: Unclipping wire harness to loudspeaker amplifier

9. Unclip wire harness to loudspeaker amplifier -Arrows A- and remove adhesive tape -Arrow B- . See Fig. 97.
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Fig. 98: Unclipping wire harness to CD changer/navigation unit

10. Unclip wire harness to CD changer/navigation unit -arrows- . See Fig. 98.
11. Remove grommets -16- left and right. See Fig. 92.
12. Pull through main wire harness in direction of plenum panel.
13. Disconnect and release ABS wire harness front left and right -17 and 18- . --> 976555 Replacing ABS wire
harness - chapter on "Removing". See Fig. 92.
14. Release and pull off connectors on front antenna for Tire pressure monitoring system -19 and 20- at left and
15. Release and pull off connector of switching element for filler flap -21- . Refer to 55 38 19 Removing and
installing switching element for filler flap - as of MY 2005 (All Models) . See Fig. 92.
16. Pull off connector from tank filler neck -22- . See Fig. 92.
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17. Release connector on rod antenna -23- and pull it off. See Fig. 92.

18. Unclip wire harness on end plate under windscreen at the three retaining clips -arrow- . See Fig. 99.
19. Release connector on GPS antenna -24- and pull it off. Refer to 91 13 19 Removing and installing GPS
20. Release connector on radio antenna -25- and pull it off. Refer to 91 47 19 Removing and installing radio
21. Release connector for vertical sensor -26- and pull it off. See Fig. 92.
22. Release connector for pressure switch -27- and pull it off. Refer to 87 83 19 Removing and installing
pressure switch - as of MY 2005 (All Models) . See Fig. 92.
23. Release connector for alarm siren -28- and pull it off. Refer to 96 65 19 Removing and installing the
alarm siren - as of MY 2005 (All Models) . See Fig. 92.
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24. Release and pull off B+ line -29- from power distributor. --> 978919 Removing and installing power
distributor - chapter on "Removing"See Fig. 92.

25. Release plug connections for PASM, front left and right -30 and 31- -Arrow a- and disconnect. See Fig. 92,
Fig. 100.
26. Release and pull off connectors for windscreen washer system spray nozzle, left and right -32 and 33- . See
Fig. 92.
27. Release and pull off connector on front angle sensor for headlight beam adjustment -34- . Refer to 94 78 19
Removing and installing front angle sensor for headlight levelling system - as of MY 2005 (All Models) .
See Fig. 92.
28. Release and pull off connector on wiper motor -38- . Refer to 92 15 19 Removing and installing wiper
motor - as of MY 2005 (All Models) . See Fig. 92.
29. Release and pull off connector on alarm horn -39- . Refer to 96 65 19 Removing and installing the alarm
siren - as of MY 2005 (All Models) . See Fig. 92.
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30. Undo the four fastening nuts on the battery retaining bracket and remove the battery retaining bracket.
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Fig. 102: Pulling off tank connector

31. Release connector on fuel level sender -40- -Arrow A- and pull it off -Arrow B- . See Fig. 92, Fig. 102.

32. Unclip wire harness on end plate under windscreen at the two retaining clips -arrow- . See Fig. 103.
33. Remove grommets -41- in center, and on left and right. See Fig. 92.
34. Pull through main wire harness in direction of interior.
Exposing main wire harness in passenger compartment
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1. Loosen seat belt mount at left and right.
1.1. Press off cap -1- with a screwdriver and unscrew the fastening screw -2- . Remove seat belt with fitting -3-
and spacer sleeve -4- . See Fig. 104.
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3. Remove left and right support.
3.1. Unlock locating peg -1- of the support using the commercially available removal tool Disassembly tool,
universal NR.21. See Fig. 105.
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3.2. Unscrew fastening screws -2- and nuts -3- and carefully pull the support up and out of the retaining points.
See Fig. 106.
Removing main wire harness in passenger compartment
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42 - Rubber sleeve
45-46 - Connector for rear interior light, left and right
47-48 - Plug connection between main wire harness and wire harness for rear lid
51-52 - Connector for TPM antenna, left and right
55 - Rubber sleeve
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77 - Fuse box
78 - Relay carriers
94 - Current distributor
97 - Connector for garage door opener control unit
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Fig. 109: Disconnect plug connections for main wire harness to rear wire harness.
1. Disconnect plug connections for main wire harness to rear wire harness -33 and 34- . See Fig. 108.
1.1. Release plug connections for main wire harness to rear wire harness -arrows A- and disconnect. See Fig.
109.
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Fig. 110: Disconnecting plug connections for main wire harness to engine wire harness
2. Disconnect plug connections for main wire harness to engine wire harness -35 and 36- . See Fig. 108.
2.1. Release plug connections for main wire harness to engine wire harness -arrows A- and disconnect -arrows
B- . See Fig. 109.
2.2. Release sockets for main wire harness -arrows C- and push down from relay carrier -arrows D- . See Fig.
109.
3. Release connector for rear vertical sensor -37- and pull it off. See Fig. 108.
4. Release and pull off connector on DME control module -38 and 39- . Refer to 24 70 19 Removing and
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installing DME control module - as of MY 2006 (Cayman S, Cayman S RHD) . See Fig. 108.

5. Loosen ground point in luggage compartment -40- . See Fig. 108.
6. Release and pull off connector on rear angle sensor for headlight beam adjustment -41- . Refer to 94 79 19
Removing and installing rear angle sensor for headlight levelling system - as of MY 2005 (All Models) .
See Fig. 108.
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Fig. 112: Disconnecting main wire harness plug connections for rear lid wire harness
8. Disconnect main wire harness plug connections for rear lid wire harness -47 and 48- . See Fig. 108.
8.1. Release main wire harness plug connections for rear lid wire harness -arrows A- and -arrows B-
disconnect. See Fig. 112.
8.2. Release connector sockets for main wire harness -arrows C- and push down from retaining clip -arrows
D- . See Fig. 112.
8.3. Unclip tie-wrap -arrow E- . See Fig. 112.
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9. Disconnect PASM plug connections -49 and 50- at left and right. See Fig. 108.
9.1. Release and disconnect plug connection for wheel sensor at left and right -arrow a- . See Fig. 113.
10. Release and pull off connector on rear antenna for Tire pressure monitoring system -51 and 52- at left and
11. Disconnect and expose ABS wire harness rear on left and right -53 and 54- . --> 976555 Replacing ABS
wire harness - chapter on "Removing"See Fig. 108.
Microsoft
Fig. 114: Unclipping the main wire harness in the area of the rear left spring strut
12. Unclip the main wire harness in the area of the rear left spring strut.
13. Pull off connector on front seat-belt tensioner -56 and 57- at left and right. --> 69 11 19 REMOVING AND
Fig. 108.
Microsoft
Fig. 115: Unclipping main wire harness to the left side wall
14. Unclip main wire harness to the left side wall.
14.1. Unclip main wire harness to the left side wall -arrow A- . See Fig. 115.
14.2. Unclip cable duct to the left side wall -arrow B- . See Fig. 115.
Microsoft
Fig. 116: Loosening cable duct to the left side wall

15. Loosen cable duct to the left side wall.
15.1. Unclip main wire harness to the bottom of the B-pillar -arrow A- . See Fig. 116.
15.2. Take out cable duct upwards out of the rear wall plate -arrow B- . See Fig. 116.
16. Release and pull off connector for airbag sensor, center left and right -58 and 59- . Refer to 69 51 19
17. Release and pull off connector for ParkAssist control unit -60 and 61- . Refer to 91 74 19 Removing and
installing control module for ParkAssist - as of MY 2005 (All Models) . See Fig. 108.
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18. Release and pull off connector for rear end convenience systems control unit -62 to 64- . Refer to 57 89 19
Removing and installing control unit for rear convenience systems - as of MY 2005 (All Models) . See Fig.
108.

19. Loosen ground point under the driver's seat -65- . See Fig. 108.
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Fig. 118: Unclipping ground point under driver's seat

20. Unclip ground point under driver's seat.
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Fig. 119: Unclipping wire harness for telephone control unit

21. Release and remove connectors for telephone control unit -66 to 69- . Refer to 91 90 19 Removing and
installing control unit for telephone - as of MY 2005 (All Models) . See Fig. 108.
21.1. Unclip wire harness for telephone control unit.

22. Loosen ground point under the passenger's seat -70- . See Fig. 108.
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Fig. 121: Unclipping wire harness at door sill

23. Unclip wire harness at door sill.
24. Disconnect the plug connection between main wire harness and wire harness for door, left and right -75 and
76- . --> 973219 Removing and installing wire harness for door - chapter on "Disconnecting"See Fig. 108.
25. Release and pull off connector for gateway control unit -81- . Refer to 90 35 19 Removing and installing
gateway control unit - as of MY 2005 (All Models) . See Fig. 108.
26. Release and pull off connectors for KESSY/PAS control unit -82 and 83- . Refer to 96 66 19 Removing
and installing KESSY/PAS control unit - as of MY 2005 (All Models) . See Fig. 108.
27. Release and pull off connector for stop light switch -84- . Refer to 94 36 19 Removing and installing
brake light switch - as of MY 2005 (All Models) . See Fig. 108.
28. Release and pull off connector for pedal sensor -85- . See Fig. 108.
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29. Loosen ground point under the unit carrier -92- . See Fig. 108.
30. Release and pull off connector for tilt sensor control unit -93- . Refer to 96 63 19 Removing and installing
tilt sensor control unit - as of MY 2005 (All Models) . See Fig. 108.
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31. Disconnect plug connections between main wire harness and wire harness for heater/air-conditioning unit -
95 and 96- . See Fig. 108.
31.1. Release lower plug connection on heater/air-conditioning unit -arrows a- and unplug. See Fig. 123.
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Fig. 124: Releasing plug connection

31.2. Release upper plug connection on heater/air-conditioning unit -arrows a- and unplug. See Fig. 124.
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31.3. Cut tie-wraps (main wire harness to heater/air-conditioning unit wire harness) with side cutters. Remove
main wire harness.
32. Release and disconnect plug connection for rain sensor -99- . Refer to 92 12 19 Removing and installing
Microsoft
Fig. 126: Disconnecting plug connection of make-up mirror

33. Disconnect plug connection of make-up mirror, left and right -100 and 101- . See Fig. 108.
33.1. Unclip plug connection from console -arrow B- . See Fig. 126.
33.2. Release plug connection -arrow a- and disconnect it -arrows C- . See Fig. 126.
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Fig. 127: Unclipping cable duct at front of roof frame

34. Unclip cable duct at front of roof frame.
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Fig. 128: Unclipping main wire harness at front of roof frame

35. Unclip main wire harness at front of roof frame.
Fig. 129: Removing main wire harness from A-pillar

36. Remove main wire harness from A-pillar -area A- . See Fig. 129.
37. Pull off connector for antenna amplifier, left and right -102 to 106- . Refer to 91 84 19 Removing and
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Fig. 130: Loosening ground points on dashboard bracket

38. Loosen ground points on dashboard bracket.
38.1. Unscrew fastening nuts and remove ground straps.
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Fig. 131: Unclipping length compensation

39. Unclip length compensation at the steering column.
39.1. Remove expansion rivet and length compensation.
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Fig. 132: Unclipping cable guide

40. Unclip cable guide on dashboard bracket.
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Fig. 133: Loosening holder for relay carrier

41. Loosen holder for relay carrier.
41.1. Unscrew the two fastening screws and remove the relay carrier holder from the dashboard bracket.
Fig. 134: Loosening main wire harness at left dashboard bracket

42. Loosen main wire harness at left dashboard bracket.
42.1. Screw off fastening nut and remove fastening screw.
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42.2. Unclip main wire harness on cable guide.
Fig. 135: Loosening main wire harness at right dashboard bracket

43. Loosen main wire harness at right dashboard bracket.
43.1. Unclip main wire harness on both cable guides.
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Fig. 136: Loosening main wire harness at center dashboard bracket

44. Loosen main wire harness at center dashboard bracket.
44.1. Undo the four tie-wraps and remove main wire harness.
INSTALLING MAIN WIRE HARNESS
Installing main wire harness in passenger compartment
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42 - Rubber sleeve
45-46 - Connector for rear interior light, left and right
47-48 - Plug connection between main wire harness and wire harness for rear lid
51-52 - Connector for TPM antenna, left and right
55 - Rubber sleeve
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77 - Fuse box
78 - Relay carriers
94 - Current distributor
97 - Connector for garage door opener control unit
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Fig. 139: Fastening main wire harness at center dashboard bracket

1. Fasten main wire harness at center dashboard bracket.
1.1. Lay main wire harness and fasten with four new tie-wraps .
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Fig. 140: Fastening main wire harness at right dashboard bracket

2. Fasten main wire harness at right dashboard bracket.
2.1. Clip in main wire harness on both cable guides.
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Fig. 141: Fastening main wire harness at left dashboard bracket

3. Fasten main wire harness at left dashboard bracket.
3.1. Clip in main wire harness on cable guide.
3.2. Insert fastening screw and tighten fastening nut. --> Tightening torque: 3.5 (2.5 ftlb.) Nm
Microsoft
Fig. 142: Fastening holder for relay carrier

4. Fasten holder for relay carrier.
4.1. Position holder for relay carrier and tighten with the two fastening screws to the dashboard bracket. -->
Tightening torque: 3.5 (2.5 ftlb.) Nm
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Fig. 143: Clipping in cable guide

5. Clip in cable guide on dashboard bracket.
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Fig. 144: Clipping in length compensation

6. Clip in length compensation at the steering column.
6.1. Position length compensation at the steering column and fasten with the expansion rivet.
Fig. 145: Fastening ground points on dashboard bracket

7. Fasten ground points on dashboard bracket.
7.1. Fit ground straps and tighten with fastening nuts. --> Tightening torque: 9 (6.5 ftlb.) Nm
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8. Push on connector for antenna amplifier, left and right -102 to 106- . Refer to 91 84 19 Removing and
Fig. 146: Affixing main wire harness to A-pillar

9. Remove protective film of adhesive strip on main wire harness -area A- and affix main wire harness to A-
pillar. See Fig. 146.
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Fig. 147: Clipping in main wire harness at front of roof frame

10. Clip in main wire harness at front of roof frame.
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Fig. 148: Clipping in cable duct at front of roof frame

11. Clip in cable duct at front of roof frame.
Fig. 149: Connecting plug connection of make-up mirror

12. Connect plug connection of make-up mirror, left and right -100 and 101- . See Fig. 138.
12.1. Push together plug connection -arrows A- until it is felt to engage. See Fig. 149.
12.2. Clip plug connection into console -arrow B- . See Fig. 149.
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13. Push together plug connection -99- until it is felt to engage. Refer to 92 12 19 Removing and installing

14. Connect plug connections between main wire harness and wire harness for heater/air-conditioning unit -95
and 96- . See Fig. 138.
14.1. Lay main wire harness to heater/air-conditioning unit wire harness and fix with a tie-wrap.
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14.2. Push in upper electric plug connection at heater/air-conditioning unit until it is felt to engage.
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14.3. Push in lower electric plug connection at heater/air-conditioning unit until it is felt to engage.
15. Push on connector for tilt sensor control unit -93- until it is felt to engage. Refer to 96 63 19 Removing and
installing tilt sensor control unit - as of MY 2005 (All Models) . See Fig. 138.
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16. Fasten ground point under the unit carrier -92- . See Fig. 138.
17. Push on connector for pedal sensor -85- until it is felt to engage. See Fig. 138.
18. Push on connector for stop light switch -84- until it is felt to engage. Refer to 94 36 19 Removing and
installing brake light switch - as of MY 2005 (All Models) . See Fig. 138.
19. Push on connectors of KESSY/PAS control unit -82 and 83- until they are felt to engage. Refer to 96 66 19
Removing and installing KESSY/PAS control unit - as of MY 2005 (All Models) . See Fig. 138.
20. Push on connector of Gateway control unit -81- until it is felt to engage. Refer to 90 35 19 Removing and
installing gateway control unit - as of MY 2005 (All Models) . See Fig. 138.
21. Push the plug connection together between main wire harness and wire harness for door, left and right -75
and 76- . --> 973219 Removing and installing wire harness for door - chapter on "Locking"See Fig. 138.
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Fig. 154: Clipping in wire harness at door sill

22. Clip in wire harness at door sill.
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23. Fasten ground point under the passenger seat -70- . See Fig. 138.
Fig. 156: Clipping in wire harness for telephone control unit

24. Push on connectors for telephone control unit -66 to 69- until they are felt to engage. Refer to 91 90 19
Removing and installing control unit for telephone - as of MY 2005 (All Models) . See Fig. 138.
24.1. Clip in wire harness for telephone control unit.
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Fig. 157: Clipping in wire harness under driver's seat

25. Clip in wire harness under driver's seat.
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26. Fasten ground point under the driver's seat -65- . See Fig. 138.
27. Push on connectors for rear end convenience systems control unit -62 to 64- until they are felt to engage.
Refer to 57 89 19 Removing and installing control unit for rear convenience systems - as of MY 2005 (All
28. Push on connectors for ParkAssist control unit -60 and 61- until they are felt to engage. Refer to 91 74 19
Removing and installing control module for ParkAssist - as of MY 2005 (All Models) . See Fig. 138.
29. Push on connectors for airbag sensor, center left and right -58 and 59- until it is felt to engage. Refer to 69
51 19 Removing and installing airbag sensor - as of MY 2005 (All Models) . See Fig. 138.
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Fig. 159: Fastening cable duct to the left side wall

30. Fasten cable duct to the left side wall.
30.1. Insert cable duct downward in the rear wall plate -arrow A- See Fig. 159.
30.2. Clip in cable duct to the bottom of the B-pillar -arrow B- . See Fig. 159.
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Fig. 160: Clipping in main wire harness to the left side wall
31. Clip in main wire harness to the left side wall.
31.1. Clip in cable duct to the left side wall.
31.2. Clip in main wire harness to the left side wall.
32. Plug in connector on front seat-belt tensioner -56 and 57- at left and right. --> 69 11 19 REMOVING AND
Fig. 138.
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Fig. 161: Clipping in the main wire harness in the area of the rear left spring strut
33. Clip in the main wire harness in the area of the rear left spring strut.
35. Push on connectors of front antenna for Tire Pressure Monitoring -51 and 52- at left and right until they are
felt to engage. Refer to 44 38 19 Removing and installing Tire pressure monitoring system antenna - as of
Microsoft

36. Connect PASM plug connections -49 and 50- at left and right. See Fig. 138.
36.1. Connect plug connections for PASM, front left and right until they are felt to engage.
Microsoft
Fig. 163: Pushing together main wire harness plug connections for rear lid wire harness
37. Push main wire harness plug connections for rear lid wire harness -47 and 48- . See Fig. 138.
37.1. Release connector sockets for main wire harness and push down from retaining clip.
37.2. Release and disconnect main wire harness plug connections for rear lid wire harness.
37.3. Unclip tie-wrap .
39. Push connector onto rear angle sensor for headlight beam adjustment -41- until it is felt to engage. Refer to
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94 79 19 Removing and installing rear angle sensor for headlight levelling system - as of MY 2005 (All

40. Fasten ground point in rear luggage compartment -40- . See Fig. 138.
41. Push on connector of DME control module -38 and 39- until it is felt to engage. Refer to 24 70 19
Removing and installing DME control module - as of MY 2006 (Cayman S, Cayman S RHD) . See Fig.
138.
42. Push on connector of rear vertical sensor -37- until it is felt to engage. See Fig. 138.
Microsoft
Fig. 165: Pushing main wire harness plug connections for motor wire harness
43. Push main wire harness plug connections for motor wire harness -35 and 36- . See Fig. 138.
43.1. Push sockets for main wire harness onto relay carrier -arrows A- , until these are felt to engage. See Fig.
165.
43.2. Push plug connections for main wire harness to motor wire harness together -arrows B- , until these are
felt to engage. See Fig. 165.
Microsoft
Fig. 166: Pushing main wire harness plug connections together for rear wire harness
44. Push together plug connections for main wire harness to rear wire harness -33 and 34- and lock them, until
these are felt to engage. See Fig. 138.
Completing the vehicle
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1. Install left and right support.
1.1. Position the support and engage in lower side member.
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Fig. 168: Securing the support

1.2. Press in the locating peg -1- of the support and check it is seated correctly. See Fig. 168.
1.3. Tighten the fastening nut -3- and fastening screws -2- . --> Tightening torque: 7.2 (5.5 ftlb.) Nm See Fig.
168.
Microsoft

3. Fasten seat belt mount at left and right.
3.1. Tighten fastening screw -2- , seat belt with fitting -3- and spacer sleeve -4- on inner lower side member. -->
Tightening torque: 50 (37 ftlb.) Nm See Fig. 169.
3.2. Press in -1- cap. See Fig. 169.
Installing front main wire harness
Microsoft
11 - Ground point
16 - Grommet
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41 - Grommet
1. Push through main wire harness in direction of plenum panel.
2. Fit grommets -41- center, left and right. See Fig. 170.
Microsoft

3. Clip in wire harness on end plate under windscreen at the two retaining clips -arrow- . See Fig. 171.
Microsoft
Fig. 172: Pushing on tank connector

4. Push on connector for fuel level sender -40- -Arrow A- and lock -Arrow B- . See Fig. 170, Fig. 172.

5. Position battery retaining bracket and secure with the four fastening nuts. --> Tightening torque: 10 (7.5
ftlb.) Nm
6. Push on connector for alarm horn -39- until it is felt to engage. Refer to 96 65 19 Removing and installing
7. Push on connector for wiper motor -38- until it is felt to engage. Refer to 92 15 19 Removing and installing
wiper motor - as of MY 2005 (All Models) . See Fig. 170.
8. Push connector onto front angle sensor for headlight beam adjustment -34- until it is felt to engage. Refer to
94 78 19 Removing and installing front angle sensor for headlight levelling system - as of MY 2005 (All
9. Push on connectors for windscreen washer system spray nozzle, left and right -32 and 33- until they are felt
to engage. See Fig. 170.
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10. Connect plug connections for PASM, front left and right -30 and 31- until they are felt to engage. See Fig.
170.
11. Push B+ line -29- onto mounting point at the power distributor as far as the stop. Check B+ line sits firmly. -
-> 978919 Removing and installing power distributor - chapter on "Installing"See Fig. 170.
12. Push on connector for alarm siren -28- until it is felt to engage. Refer to 96 65 19 Removing and installing
13. Push on connector for pressure switch -27- until it is felt to engage. Refer to 87 83 19 Removing and
installing pressure switch - as of MY 2005 (All Models) . See Fig. 170.
14. Push on connector of vertical sensor -26- until it is felt to engage. See Fig. 170.
15. Push on connector for radio antenna -25- until it felt to engage. Refer to 91 47 19 Removing and installing
radio antenna - as of MY 2005 (All Models) . See Fig. 170.
16. Push on connector for GPS antenna -24- until it is felt to engage. Refer to 91 47 19 Removing and
installing radio antenna - as of MY 2005 (All Models) . See Fig. 170.
Microsoft

17. Clip in wire harness for end plate under windscreen at the three retaining clips -arrow- . See Fig. 175.
18. Push in connector for rod antenna -23- until it is felt to engage. See Fig. 170.
19. Push on connector for tank filler neck -22- . See Fig. 170.
20. Push on connector for filler flap switching element -21- until it is felt to engage. Refer to 55 38 19
Removing and installing switching element for filler flap - as of MY 2005 (All Models) . See Fig. 170.
21. Push on connectors of front antenna for Tire pressure monitoring system -19 and 20- at left and right until
they are felt to engage. Refer to 44 38 19 Removing and installing Tire pressure monitoring system antenna
Microsoft
23. Push through main wire harness in direction of luggage compartment.
24. Fit grommets -16- left and right. See Fig. 170.
Fig. 176: Clipping in wire harness to CD changer/navigation unit.

25. Clip in wire harness to CD changer/navigation unit -arrows- . See Fig. 176.
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Fig. 177: Clipping in wire harness to loudspeaker amplifier

26. Clip in wire harness to loudspeaker amplifier -Arrows A- and fix with new adhesive tape -Arrow B- . See
Fig. 177.
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27. Clip in wire harness for front end control unit -arrow- . See Fig. 178.
28. Push on connector for Tire pressure monitoring system control unit -15- until it is felt to engage. Refer to 44
34 19 Removing and installing Tire pressure monitoring system control module - as of MY 2005 (All
29. Push on connector for brake fluid sender -14- until it is felt to engage. See Fig. 170.
30. Push on connector for hydraulic unit -13- and lock it. Refer to 45 30 19 Removing and installing
31. Push together plug connection between main wire harness and front-end wire harness, left -12- until it
engages securely. Clip in connector socket. See Fig. 170.
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32. Secure ground point left -11- . See Fig. 170.
32.1. Connect ground straps and tighten fastening nut. --> Tightening torque: 9 (6.5 ftlb.) Nm
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33.3. Position bottom of fuse box for fan on the clip -Arrow C- and clip in -Arrow D- . See Fig. 180.
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34. Push together plug connection between main wire harness and front end wire harness, right -1- . See Fig.
170.
34.1. Insert connector socket in the holder and turn anti-clockwise 90°.
34.2. Push together plug connection between front-end wire harness and main wire-harness right -Arrow A-
and lock -Arrow B- . See Fig. 181.
SUBSEQUENT WORK
Subsequent work
1. Install front roof lining. Refer to 70 84 19 Removing and installing roof lining - as of MY 2006 (Cayman
S, Cayman S RHD) .
for garage door opener - as of MY 2005 (Cayman S, Cayman S RHD) .
3. Install vehicle electrical system control unit. --> 971019 Removing and installing vehicle electrical system
control unit - section on "Installing"
4. Install relay carrier 1. --> 978319 Removing and installing relay carrier 1 - section on "Installing"
Microsoft
5. Install B+ line from power distributor to engine connection point. --> 974519 Removing and installing wire
harness for starter battery - section on "Installing"
6. Secure fuse box. --> 978409 Loosening and securing fuse box - section on "Securing"
7. Install left and right scuff plate. Refer to 68 05 19 Removing and installing inner door sill trim - as of MY
2005 (All Models) .
8. Install front seat at left and right. Refer to 72 01 19 Removing and installing front seat - as of MY 2005
Models) .
9. Install heating/fresh-air unit. Refer to 85 15 19 Removing and installing heating/fresh air unit - as of MY
2005 (All Models) .
Models) .
11. Install left and right side trim panels. Refer to 70 75 19 Removing and installing side trim panel - as of
12. Install rear wheel housing liner. Refer to 53 69 19 Removing and installing rear wheel housing liner - as
13. Install relay carrier. --> 979019 Removing and installing relay carrier - section on "Installing"
14. Install rear luggage-compartment lining. Refer to 70 06 19 Removing and installing rear luggage
15. Install tank for windscreen washer system. Refer to 92 60 19 Removing and installing reservoir for
16. Install front cover. Refer to 51 92 19 Removing and installing cover for front underbody - as of MY
2005 (All Models) .
17. Install front wheel housing liner on left and right. Refer to 50 56 19 Removing and installing front wheel
2005 (All Models) .
19. Install trim panels for front luggage compartment. Refer to 70 05 19 Removing and installing front
20. Install loudspeaker amplifier. Refer to 91 44 19 Removing and installing loudspeaker amplifier - as of
Microsoft
21. Install navigation unit with retaining frame. Refer to 91 12 19 Removing and installing navigation unit -
22. Install CD changer. Refer to 91 60 19 Removing and installing CD changer - as of MY 2005 (All
Models) .
Models) .
24. Install battery. Refer to 27 06 19 Removing and installing battery - as of MY 2005 (All Models) .
97 10 19 REMOVING AND INSTALLING VEHICLE ELECTRICAL SYSTEM

CONTROL UNIT - AS OF MY 2005 (ALL MODELS)
PRELIMINARY WORK
Preliminary work - vehicle electrical system control unit
Detach relay carrier 1. --> 978319 Removing and installing relay carrier 1 - "removing"
REMOVING VEHICLE ELECTRICAL SYSTEM CONTROL UNIT
Removing vehicle electrical system control unit
Microsoft


destroyed.
Microsoft
Fig. 183: Bracket for vehicle electrical system control unit

1. Pull apart the locking tabs -A- for the vehicle electrical system control unit, pull the control unit forward and
down with connectors still attached, then pull it out of its holder at the rear. See Fig. 183.
Microsoft
Fig. 184: Release connector A and disconnect.

2. Release both connectors -A- and unplug them. See Fig. 184.
INSTALLING VEHICLE ELECTRICAL SYSTEM CONTROL UNIT
Installing vehicle electrical system control unit
Microsoft

1. Press electrical plugs into control unit and lock them -arrow- so they are felt to engage. See Fig. 185.
Microsoft
Fig. 186: Push the electrical system wiring into its retaining bracket so that it engages.
2. Push vehicle electrical system control unit upwards into the holder. It must engage properly. Make sure the
electrical leads are not pinched.
SUBSEQUENT WORK FOR VEHICLE ELECTRICAL SYSTEM CONTROL UNIT
Subsequent work - vehicle electrical system control unit
Attach relay carrier 1. --> 978319 Removing and installing relay carrier 1 - "installing"
CODING VEHICLE ELECTRICAL SYSTEM CONTROL UNIT
Programming the vehicle electrical system control unit:

Microsoft
Continue.
3. Switch from vehicle type to list of control units >> .
4. Select the relevant control unit with the cursor keys and press the >> key.
5. Select Control Unit Replacement with the cursor keys and press the >> key.
6. Select Read Out Values (Code) with the cursor keys and press the >> key.
7. The message "Reading code" will appear on the screen of the Porsche System Tester. Press the >> key.
9. Switch on ignition. After replacement of the control unit, the vehicle data that has been read out is transferred
to the new unit using the "Write data" menu option (see Section 6). Press the >> key.
11. Read out fault memory again and erase.
Coding (programming) the control module
Microsoft
Continue.
module search.
4. Select the relevant control module with the cursor keys and press the >> key.
6. Select Write in data and write in the relevant data. (Even if no data was read out, the required data is loaded
for the control unit.)
7. Select Coding with the cursor keys and press the >> key.
8. Select the version required for the vehicle in question and follow the instructions on the Tester.
10. PerformVehicle handover and follow the instructions of the Tester.
97 15 19 REMOVING AND INSTALLING FRONT WIRING HARNESS - AS OF

PRELIMINARY WORK
Preliminary work for front wiring harness

Microsoft
Models) .
REMOVING FRONT WIRING HARNESS
Removing front wiring harness
Fig. 187: Releasing electric connector on auxiliary headlight, shown here on 911 headlight
1. Release electric connector on auxiliary headlight -A- See Fig. 187.
Microsoft
Fig. 188: Laying the wiring harness

2. Disengage electric lines from auxiliary headlight and front apron.
3. Remove wiring harness.
INSTALLING FRONT WIRING HARNESS
Installing front wiring harness
Microsoft
Fig. 189: Laying the wiring harness

1. Position and engage wiring harness in front apron.
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Fig. 190: Engaging lines on auxiliary headlight, shown here on 911 headlight
2. Connect plug connection to auxiliary headlight and engage the lines on the auxiliary headlight.
SUBSEQUENT WORK
Subsequent work for front wiring harness
Installing front apron. Refer to 63 15 19 Removing and installing front spoiler - as of MY 2005 (All
Models) .
97 16 19 REMOVING AND INSTALLING WIRE HARNESS FOR FRONT-END -

PRELIMINARY WORK
Preliminary work

2. Remove luggage compartment linings Refer to 70 30 19 Removing and installing front luggage
compartment cover - as of MY 2005 (All Models) . Refer to 70 30 19 Removing and installing rear luggage
compartment cover - as of MY 2006 (Cayman S, Cayman S RHD) .
Microsoft
2005 (All Models) .
4. Remove left and right headlight. Refer to 94 15 19 Removing and installing main headlight - as of MY
2005 (All Models) .
5. Remove front apron. Refer to 63 15 19 Removing and installing front spoiler - as of MY 2005 (All
Models) .
REMOVING WIRE HARNESS FOR FRONT-END
Removing wire harness for front-end
Fig. 191: Installation position for wire harness at front end of car, shown on 911
Microsoft
Fig. 192: Overview of connectors for front-end wire harness

1 - Plug connection for front-end wire harness to main wire harness, right
4 - Ground point, left and right
5 - Connector for headlight, left and right
6 - Plug connection between front-end wire harness and front apron wire harness
7 - Plug connection for coolant fan
8 - Connector for control unit for coolant control
10 - Cable guide for sensor line for airbag, front left and right
11 - Connector for sensor line for airbag, front left and right
12 - Connector for emergency release, front
13 - Connector for outside temperature sensor
14 - Connector for horn, high-pitch

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15 - Connector for horn, low-pitch
16 - Connector for servo motor for front lid release
17 - Connector for control unit for garage door opener/HomeLink
18 - Plug connection for microswitch for roof lock, front
19 - Connector for servo motor for lid, front
20 - Plug connection between front-end wire harness and main wire harness, left
21 - Grommet
22 - Tie-wrap
23 - Line holder
24 - Line holder
1. Disconnect plug connection between front-end wire harness and main wire harness, right -1- . See Fig. 192.
1.1. Release plug connection between front-end wire harness and main wire harness, right -arrow a- and
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disconnect -arrow B- . See Fig. 193.

2.1. Unclip fuse box for fan -arrow A- and lift up and off -arrow B- . See Fig. 194.
2.2. Release lid -arrows- and open -arrow C- . See Fig. 194.
2.3. Pull off connector on fuse box for fan -arrow D- . See Fig. 194.
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3. Loosen ground point -4- at left and right. See Fig. 192.
Microsoft
Fig. 196: Pulling off connector on headlight

4. Pull off connector on headlight -5- at left and right. See Fig. 192.
4.1. Pull securing clip down and out -arrow A- . See Fig. 196.
4.2. Pull off connector on headlight at left and right -arrow B- . See Fig. 196.
Microsoft
Fig. 197: Removing plug on control unit for coolant control

5. Pull off connector and plug connection on control unit for coolant control -7 to 9- . See Fig. 192.
5.1. Release and remove plug connection to coolant fan -7- . See Fig. 197.
5.2. Release and remove connector on control unit for coolant control -8 and 9- . See Fig. 197.
6. Unclip cable guide for sensor line for front airbag -10- . See Fig. 192.
7. Release connectors on both sensors for front airbag -11- and pull them off. Refer to 69 51 19 Removing and
installing airbag sensor - as of MY 2005 (All Models) . See Fig. 192.
8. Unclip front-end wire harness on right side at tie-wraps -22- . See Fig. 192.
9. Unclip front-end wire harness on left side at holders -23- . See Fig. 192.
NOTE: Only for USA/Canada version vehicles
10. Release connector on front emergency release -12- and pull it off. Refer to 55 62 19 Removing and
installing front emergency release - as of MY 2005 (Cayman S) . See Fig. 192.
11. Release connector for outside temperature sensor -13- and pull it off. Refer to 91 68 19 Removing and
installing outside temperature sensor - as of MY 2005 (All Models) . See Fig. 192.
Microsoft
12. Release connectors on both horns -14 and 15- and pull them off. Refer to 90 50 19 Removing and
installing horn - as of MY 2005 (All Models) . See Fig. 192.
13. Release and pull off connector on servo motor for front lid release -16- . Refer to 55 13 19 Removing and
installing servo motor for hood release - as of MY 2005 (All Models) . See Fig. 192.
14. Release and pull off connector on control unit for garage door opener/HomeLink -17- . Refer to 96 79 19
Removing and installing garage door opener control unit - as of MY 2005 (All Models) . See Fig. 192.
15. Unclip front-end wire harness on right side at tie-wraps -22- . See Fig. 192.
16. Release and disconnect plug connection on microswitch for front lid lock lower part -18- . Refer to 55 17 19
Removing and installing front lower part of lid lock - as of MY 2005 (All Models) . See Fig. 192.
Fig. 198: Pull off connector on servo motor for front lid
17. Release connector on servo motor for front lid -19- and -arrows a- pull it off. See Fig. 192, Fig. 198.
18. Release plug connection for front-end wire harness to main wire harness, left -20- and disconnect. See Fig.
192.
19. Pull off holders -24- . See Fig. 192.
20. Remove the three grommets -21- and pull the wire harness through the openings in the body. See Fig. 192.
Microsoft
21. Remove wire harness for front-end.
INSTALLING WIRE HARNESS FOR FRONT-END
Installing wire harness for front-end
NOTE: The wire harness for front end spare parts scope means the scope for fully-
equipped vehicles. Depending on the vehicle equipment, connectors not
required are tied to the wire harness for front end using tie-wraps.
When doing this, ensure the lines are routed correctly so that no line becomes
trapped or damaged.
Fig. 199: Overview of connectors for front-end wire harness

1 - Plug connection for front-end wire harness to main wire harness right
4 - Ground point, left and right
5 - Connector for headlight, left and right
6 - Plug connection between front-end wire harness and front apron wire harness
Microsoft
7 - Plug connection for coolant fan
10 - Cable guide for sensor line for airbag, front left and right
11 - Connector for sensor line for airbag, front left and right
12 - Connector for emergency release, front
13 - Connector for outside temperature sensor
14 - Connector for horn, high-pitch
15 - Connector for horn, low-pitch
16 - Connector for servo motor for front lid release
17 - Connector for control unit for garage door opener/HomeLink
18 - Plug connection for microswitch for roof lock, front
19 - Connector for servo motor for lid, front
20 - Plug connection for front-end wire harness to main wire harness, left
21 - Grommet
22 - Tie-wrap
23 - Line holder
24 - Line holder
1. Lay wire harness for front-end.
2. Push the wire harness for the front-end through the openings in the body and fit the three grommets -21- . See
Fig. 199.
3. Fasten wire harness for the front-end with the holders -24- to the body. See Fig. 199.
4. Push together plug connection for front-end wire harness to main wire harness, left -20- until it engages
securely. See Fig. 199.
Microsoft
Fig. 200: Pushing connector onto servo motor for front lid
5. Push connector onto servo motor for front lid -19- . See Fig. 199.
5.1. Push connector onto servo motor for front lid until it is felt to engage.
6. Push together plug connection on microswitch for front lid lock lower part -18- until it is felt to engage. Refer
to 55 17 19 Removing and installing front lower part of lid lock - as of MY 2005 (All Models) . See Fig.
199.
7. Clip in front-end wire harness on right side at tie-wraps -22- . See Fig. 199.
8. Push connector onto control unit for garage door opener/HomeLink -17- until it is felt to engage. Refer to 96
79 19 Removing and installing garage door opener control unit - as of MY 2005 (All Models) . See Fig.
199.
9. Push connector onto servo motor for front lid release -16- until it is felt to engage. Refer to 55 13 19
Removing and installing servo motor for hood release - as of MY 2005 (All Models) . See Fig. 199.
10. Push connectors onto the two horns -14 and 15- until they click into place. Refer to 90 50 19 Removing
and installing horn - as of MY 2005 (All Models) . See Fig. 199.
11. Push connector onto outside temperature sensor -13- until it is felt to engage. Refer to 91 68 19 Removing
and installing outside temperature sensor - as of MY 2005 (All Models) . See Fig. 199.
Microsoft
NOTE: Only for USA/Canada version vehicles
12. Push connector onto front emergency release -12- until it is felt to engage. Refer to 55 62 19 Removing and
installing front emergency release - as of MY 2005 (Cayman S) . See Fig. 199.
13. Clip in front-end wire harness on left side at holder -23- . See Fig. 199.
14. Clip in front-end wire harness on right side at tie-wraps -22- . See Fig. 199.
15. Push connectors onto both sensors for front airbag -11- until they are felt to engage. Refer to 69 51 19
16. Clip in cable guide for sensor line for front airbag -10- . See Fig. 199.
Fig. 201: Pushing connectors onto control unit for coolant control.
17. Push connector and plug connection onto control unit for coolant control -7 to 9- . See Fig. 199.
17.1. Push the two connectors onto the control unit for coolant control -8 and 9- until they are felt to engage.
See Fig. 201.
17.2. Push on plug connection to coolant fan -7- until it is felt to engage. See Fig. 201.
Microsoft
Fig. 202: Pushing connector onto headlight

18. Push connector onto headlight -5- at left and right. See Fig. 199.
18.1. Push connector onto headlight at left and right -Arrow A- . See Fig. 202.
18.2. Push on securing clip from below until it is felt to engage -Arrow B- . See Fig. 202.
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19. Fasten ground point -4- at left and right. See Fig. 199.
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20.3. Position fuse box below on the clip -Arrow C- and clip in -Arrow D- . See Fig. 204.
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21. Push together plug connection between front end wire harness and main wire harness, right -1- . See Fig.
199.
21.1. Push together plug connection between front end wire harness and main wire harness, right -Arrow A-
and lock -Arrow B- until it is felt to engage. See Fig. 205.
SUBSEQUENT WORK
Subsequent work
2. Install headlight at left and right. Refer to 94 15 19 Removing and installing main headlight - as of MY
2005 (All Models) .
2005 (All Models) .
4. Install linings for luggage compartment. Refer to 70 30 19 Removing and installing front luggage
compartment cover - as of MY 2005 (All Models) . Refer to 70 30 19 Removing and installing rear luggage
compartment cover - as of MY 2006 (Cayman S, Cayman S RHD) .
5. Carry out work instructions after disconnecting the battery. --> 27 06 IN WORK INSTRUCTIONS
Microsoft
AFTER DISCONNECTING THE BATTERY - AS OF MY 2005 (ALL MODELS) .
97 20 19 REMOVING AND INSTALLING WIRING HARNESS FOR CENTER

CONSOLE - AS OF MY 2005 (ALL MODELS)
PRELIMINARY WORK
Preliminary work for interior monitoring sensor
Models) .
REMOVING WIRING HARNESS FOR CENTER CONSOLE
Removing wiring harness for center console

1. Release electric connectors for the equipment versions (e. g. cigarette lighter, interior sensor etc. -A- and
unplug. See Fig. 206.
Microsoft
Fig. 207: Disengaging wiring harness

2. Disengage retaining clips with wiring harness on center console and remove the harness.
INSTALLING WIRING HARNESS FOR CENTER CONSOLE
Installing wiring harness for center console
NOTE: The wire harness for center console spare parts scope means the scope for
fully-equipped vehicles. Depending on the vehicle equipment, connectors not
required are tied to the wire harness for center console using tie-wraps.
trapped or damaged.
Microsoft
Fig. 208: Laying wiring harness

1. Lay wiring harness with retaining clips in center console and push on retaining clips at the points provided.
2. Push electric connectors onto equipment versions until they are felt to engage.
SUBSEQUENT WORK
Subsequent work for interior monitoring sensor
Models) .
97 25 19 REMOVING AND INSTALLING REAR WIRE HARNESS - AS OF MY

2005 (ALL MODELS)
PRELIMINARY WORK
Preliminary work
(All Models) .
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compartment trim panel - as of MY 2005 (Boxster, Boxster RHD, Boxster S, Boxster S RHD) . Refer to 70
06 19 Removing and installing rear luggage compartment trim (carpet lining) - as of MY 2006 (Cayman
S, Cayman S RHD) .
3. Remove relay carrier. --> 979019 Removing and installing relay carrier - section on
"Removing" [987310 987311 987320 987321] --> 979019 Removing and installing relay carrier - section
on "Removing" [987120 987121]
4. Remove rear lid-release motor. Refer to 55 84 19 Removing and installing rear lid release motor - as of
5. Remove rear spoiler. Refer to 63 55 19 Removing and installing rear spoiler - as of MY 2005 (Boxster S,
Boxster S RHD) . Refer to 63 55 19 Disassembling and assembling rear apron - as of MY 2006 (Cayman S,
Cayman S RHD) . Refer to 63 55 19 Removing and installing rear spoiler - as of MY 2005 (Boxster,
Boxster RHD) .
REMOVING REAR WIRE HARNESS
Removing rear wire harness
Fig. 209: Overview of plugs for rear wire harness

1 - Plug connection for rear wire harness to engine wire harness
2 - Plug connection for rear wire harness to main wire harness on the left
3 - Plug connection for rear wire harness to main wire harness on the right
Microsoft
4 - Connector for rear light, left and right
5 - Ground point
6 - Plug connection for spoiler drive engine
7 - Plug connection for rear lid lock
8 - Connector for rear lid-release motor
9 - Plug connection for rear apron wire harness
10 - Connector on sender for coolant-level indicator
11 - Line holder
12 - Rubber sleeve
13 - Retaining clip
14 - Line holder
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Fig. 210: Disconnecting plug connection for rear wire harness to engine wire harness
1. Disconnect plug connection for rear wire harness to engine wire harness -1- . See Fig. 209.
1.1. Release and disconnect plug connection for rear wire harness to engine wire harness -arrows A- -arrow B-
. See Fig. 210.
1.2. Release connector socket for rear wire harness -arrows C- and push down from relay carrier -arrow D- .
See Fig. 210.
Microsoft
Fig. 211: Disconnecting plug connections for rear wire harness to main wire harness
2. Disconnect plug connections for rear wire harness to main wire harness -2 and 3- . See Fig. 209.
2.1. Release -arrows A- and disconnect -arrows B- plug connections for rear wire harness to main wire
harness. See Fig. 211.
2.2. Release connector sockets for rear wire harness -arrows C- and push down from relay carrier -arrows D- .
See Fig. 211.
3. Release and pull off connector for rear light at left and right. Refer to 94 31 19 Removing and installing tail
Microsoft

4. Loosen ground point -5- . See Fig. 209.
5. Release and pull off plug connection for spoiler drive engine. Refer to 66 72 19 Removing and installing
spoiler drive - as of MY 2005 (Boxster, Boxster RHD, Boxster S, Boxster S RHD) . Refer to 66 72 19
Removing and installing spoiler drive - as of MY 2005 (Cayman S, Cayman S RHD) .
6. Release and pull off plug connection for rear lid lock. Refer to 55 86 19 Removing and installing lower
part of lid lock at rear - as of MY 2005 (Cayman S, Cayman S RHD) . Refer to 55 86 19 Removing and
installing lower part of lid lock at rear - as of MY 2005 (Boxster, Boxster RHD, Boxster S, Boxster S
RHD) .
NOTE: Only in the Boxster.
Microsoft
Fig. 213: Pulling off connector on sender for coolant-level indicator

7. Pull off connector on sender for coolant-level indicator -10- . See Fig. 209.
7.1. Release connector on sender for coolant-level indicator -arrow A- and pull it off -arrow B- . See Fig. 213.
7.2. Unclip rear wire harness from both holders -11- . See Fig. 209.
8. Remove rear wiring harness.
8.1. Remove rubber sleeve -12- . See Fig. 209.
8.2. Unclip rear wire harness at the left and right at both retaining clips -13- from the rear vent. See Fig. 209.
8.3. Remove rear wire harness from the four holders -14- at the end plate. See Fig. 209.
8.4. Remove rear wiring harness.
INSTALLING REAR WIRE HARNESS
Installing rear wire harness
Microsoft
Fig. 214: Overview of plugs for rear wire harness

1 - Plug connection for rear wire harness to engine wire harness
2 - Plug connection for rear wire harness to main wire harness on the left
3 - Plug connection for rear wire harness to main wire harness on the right
4 - Connector for rear light, left and right
5 - Ground point
6 - Plug connection for spoiler drive engine
7 - Plug connection for rear lid lock
8 - Connector for rear lid-release motor
9 - Plug connection for rear apron wire harness
10 - Connector on sender for coolant-level indicator
11 - Line holder
12 - Rubber sleeve
13 - Retaining clip
14 - Line holder
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1. Install rear wire harness.
1.1. Lay out rear wiring harness.
1.2. Insert rear wire harness in the four holders -14- at the end plate. See Fig. 214.
1.3. Clip rear wire harness at the left and right at both retaining clips -13- into the rear vent. See Fig. 214.
1.4. Fit rubber sleeve -12- . See Fig. 214.
NOTE: Only in the Boxster.
Fig. 215: Pushing on connector on sender for coolant-level indicator

2. Pushing on connector on sender for coolant-level indicator -10- . See Fig. 214.
2.1. Push on connector on sender for coolant-level indicator -arrow- until it is felt to engage. See Fig. 215.
2.2. Clip in rear wire harness at both holders -11- . See Fig. 214.
3. Push the plug connection for the rear lid lock together until it is felt to engage. Refer to 55 86 19 Removing
and installing lower part of lid lock at rear - as of MY 2005 (Cayman S, Cayman S RHD) . Refer to 55 86
19 Removing and installing lower part of lid lock at rear - as of MY 2005 (Boxster, Boxster RHD, Boxster
S, Boxster S RHD) .
Microsoft
4. Press plug connection for spoiler drive engine together until it is felt to engage. Refer to 66 72 19 Removing
and installing spoiler drive - as of MY 2005 (Boxster, Boxster RHD, Boxster S, Boxster S RHD) . Refer to
66 72 19 Removing and installing spoiler drive - as of MY 2005 (Cayman S, Cayman S RHD) .

5. Secure ground point -5- . See Fig. 214.
6. Push on connector for rear light at the left and right until it is felt to engage. Refer to 94 31 19 Removing and
installing tail light - as of MY 2005 (All Models) .
Microsoft
Fig. 217: Pushing together plug connections for rear wire harness to main wire harness
7. Push together plug connections for rear wire harness to main wire harness -2 and 3- . See Fig. 214.
7.1. Push connector sockets for rear wire harness onto relay carrier -arrows A- until they are felt to engage. See
Fig. 217.
7.2. Push together plug connections for rear wire harness to main wire harness -arrows B- and lock until they
are felt to engage. See Fig. 217.
Microsoft
Fig. 218: Pushing together plug connection for rear wire harness to engine wire harness
8. Push together plug connection for rear wire harness to engine wire harness -1- . See Fig. 214.
8.1. Push connector socket for rear wire harness onto relay carrier -arrow A- until it is felt to engage. See Fig.
218.
8.2. Push together plug connection for rear wire harness to engine wire harness -arrow B- until it is felt to
engage. See Fig. 218.
SUBSEQUENT WORK
Subsequent work
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1. Install rear spoiler. Refer to 63 55 19 Removing and installing rear spoiler - as of MY 2005 (Boxster S,
Boxster RHD) .
2. Install rear lid-release motor. Refer to 55 84 19 Removing and installing rear lid release motor - as of MY
2005 (All Models) .
3. Install relay carrier. --> 979019 Removing and installing relay carrier - section on "Installing" [987310
987311 987320 987321] --> 979019 Removing and installing relay carrier - section on "Installing" [987120
987121]
S, Cayman S RHD) .
5. Carry out work instruction after disconnecting the battery. Refer to 27 06 IN External power connection,
jump lead starting - as of MY 2005 (All Models) .
97 32 19 REMOVING AND INSTALLING WIRE HARNESS FOR DOOR - AS OF

PRELIMINARY WORK
Preliminary work for door wiring harness

Models) .
3. Remove power window motor. Refer to 64 54 19 Removing and installing power window motor - as of
4. Remove head airbag. Refer to 69 66 19 Removing and installing the head airbag unit - as of MY 2005
(All Models) .
Preliminary work for wiring harness for door trim panel

Models) .
Microsoft
REMOVING WIRING HARNESS FOR DOOR
Removing lateral footwell trim on driver's side
Fig. 219: Overview of wire harness for door

NOTE: Work is only necessary for removing or installing the wire harness for the
driver's door.
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Fig. 220: Removing lateral footwell trim on driver's side

1. Remove fuse carrier cover -1- -arrow A- . See Fig. 220.
2. Unscrew the three fastening screws -2- and take off the footwell trim panel -3- -arrow B- . See Fig. 220.
Removing lateral footwell trim on passenger's side
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NOTE: Work is only necessary for removing or installing the wire harness for the
passenger's door.
Fig. 222: Removing lateral footwell trim on passenger's side

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1. Partly loosen carpet -1- at the bottom in the area of the A-pillar -arrow A- . See Fig. 222.
2. Unscrew both plastic nuts -2- and take off the footwell trim panel -3- -arrow B- . See Fig. 222.
Disconnect wire harness for door (driver's side) at the A-pillar

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Fig. 224: Unclipping plug connection

1. Unclip wire harness plug connection for door -1- at the fuse carrier -2- . See Fig. 224.
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2. Release locking mechanism -5- on the wire harness plug connection for door -6- -arrow B- and disconnect -
arrow C- . See Fig. 225.
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3. Remove rubber sleeve -7- and pull out together with the wire harness for door -8- from the A-pillar. See Fig.
226.
Disconnect wire harness for door (passenger's side) at the A-pillar
Microsoft

Fig. 228: Disengaging wire harness plug connection for door to the body
1. Disengage wire harness plug connection for door to the body.
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Fig. 229: Disconnecting wire harness plug connection for door

2. Release locking mechanism on the wire harness plug connection for door -arrow A- and disconnect wire
harness plug connection for door -arrow B- . See Fig. 229.
Microsoft

3. Remove rubber sleeve and pull out together with the wire harness for door from the A-pillar.
Removing wiring harness for door
Microsoft

(All Models) .

2. Release connector on woofer -arrows a- and pull off. See Fig. 232.
Microsoft
Fig. 233: Removing wiring harness for door

3. Unclip wire harness for door to the five retaining clips -arrows A- . Remove both rubber sleeves -arrow B-
and take off wire harness for door. See Fig. 233.
Removing wiring harness for door trim panel
Microsoft
Fig. 234: Overview of wiring harness for door trim panel

1 - Mirror adjustment switch connector
2 - Overview of switch connector for power windows
3 - Midrange loudspeaker connector
4 - Switch connector for memory seat adjustment
5 - Wire harness plug connection for door trim panel to door wire harness
6 - Door control module connector
7 - Door warning light connector
1. Release connector to switch for power windows -2- and remove. Refer to 64 58 19 Removing and installing
switch for power windows - as of MY 2005 (All Models) . See Fig. 234.
2. Release connector on midrange loudspeaker -3- and pull off. Refer to 91 41 19 Removing and installing
front loudspeakers - as of MY 2005 (All Models) . See Fig. 234.
3. Release connector on switch for memory seat adjustment -4- and remove. Refer to 72 94 19 Removing and
installing switch for memory seat adjustment - as of MY 2005 (All Models) . See Fig. 234.
4. Pull off plug on door warning light -7- . Refer to 96 16 19 Removing and installing door warning light - as
of MY 2005 (All Models) . See Fig. 234.
Microsoft
Fig. 235: Removing wiring harness for door trim panel

5. Unclip connector of wire harness plug connection for door trim panel to door wire harness to the door trim
panel -arrow A- . See Fig. 235.
6. Remove wire harness in -direction of arrow- from the clips of door trim panel. See Fig. 235.
INSTALLING WIRING HARNESS FOR DOOR
Installing wiring harness for door
NOTE: The wire harness for door spare parts scope means the scope for fully-
equipped vehicles. Depending on the vehicle equipment, connectors not
required are tied to the wire harness for door using tie-wraps.
trapped or damaged.
Microsoft

Fig. 237: Installing wiring harness for door

1. Route wire harness for door. Fit both rubber sleeves -Arrows A- and clip in the wire harness for door with
five retaining clips -Arrows B- . See Fig. 237.
Microsoft

2. Connect connector on woofer until connector is felt to engage.
Models) .
Locking wire harness for door (driver's side) at the A-pillar
Microsoft

Fig. 240: Installing rubber sleeve

1. Push wire harness for door -8- through the A-pillar and mount rubber sleeve -8- . See Fig. 240.
Microsoft
Fig. 241: Connecting plug connection

2. Push together wire harness plug connection for door -6- -arrow A- and lock -arrow B- See Fig. 241.
Microsoft
Fig. 242: Clipping in the plug connection

3. Unclip wire harness plug connection for door -1- at the fuse carrier -2- . See Fig. 242.
Locking wire harness for door (passenger's side) at the A-pillar
Microsoft


1. Push wire harness for door through the A-pillar and mount rubber sleeve.
Microsoft
Fig. 245: Connecting wire harness plug connection for door

2. Push together wire harness plug connection for door -arrow A- and lock -arrow B- . See Fig. 245.
Microsoft
Fig. 246: Engaging wire harness plug connection for door to the body
3. Engage wire harness plug connection for door to the body.
Installing lateral footwell trim on driver's side

Microsoft
Fig. 248: Installing lateral footwell trim on driver's side

1. Insert footwell trim panel -3- -arrow A- and screw down with the three fastening screws -2- . --> Tightening
2. Insert the fuse carrier cover -1- with both clips -4- into the lateral footwell trim panel -2- and clip in -arrow
B- . See Fig. 248.
Installing lateral footwell trim on passenger's side
Microsoft

Fig. 250: Installing lateral footwell trim on passenger's side

1. Position footwell trim panel -3- -arrow A- and screw down with both plastic nuts -2- . See Fig. 250.
2. Fasten carpet -1- at the bottom in the area of the A-pillar -arrow B- Double-sided adhesive tape or suitable
Microsoft
adhesive . See Fig. 250.
Installing wiring harness for door trim panel
NOTE: The wire harness for door trim panel spare parts scope means the scope for
fully-equipped vehicles. Depending on the vehicle equipment, connectors not
required are tied to the wire harness for door trim panel using tie-wraps.
trapped or damaged.
Fig. 251: Overview of wiring harness for door trim panel

1 - Mirror adjustment switch connector
2 - Overview of switch connector for power windows
3 - Midrange loudspeaker connector
4 - Switch connector for memory seat adjustment
5 - Wire harness plug connection for door trim panel to door wire harness
6 - Door control module connector
7 - Door warning light connector
Microsoft
Fig. 252: Installing wiring harness for door trim panel

1. Insert wire harness in -direction of arrow- in the clips of the door trim panel. See Fig. 252.
2. Clip connector of wire harness plug connection for door trim panel to door wire harness in the door trim
panel -arrow A- . See Fig. 252.
3. Push connector on to door warning light -7- . Refer to 96 16 19 Removing and installing door warning
light - as of MY 2005 (All Models) . See Fig. 251.
4. Attach connector to switch for memory seat adjustment -4- until it engages firmly. Refer to 72 94 19
Removing and installing switch for memory seat adjustment - as of MY 2005 (All Models) . See Fig. 251.
5. Push connector on midrange loudspeaker -3- until it is felt to engage. Refer to 91 41 19 Removing and
installing front loudspeakers - as of MY 2005 (All Models) . See Fig. 251.
6. Push on connector to switch for power windows -2- until it is felt to engage. Refer to 64 58 19 Removing
and installing switch for power windows - as of MY 2005 (All Models) . See Fig. 251.
SUBSEQUENT WORK
Subsequent work for door wiring harness
1. Install head airbag. Refer to 69 66 19 Removing and installing the head airbag unit - as of MY 2005 (All
Models) .
Microsoft
2. Install power window motor. Refer to 64 54 19 Removing and installing power window motor - as of MY
2005 (All Models) .
Models) .
Subsequent work for wiring harness for door trim panel
Models) .
97 37 55 REPLACING WIRE HARNESS FOR PASM - AS OF MY 2005

TOOLS

repair kit for harnesses special tool NR.155-1
PRELIMINARY WORK
Preliminary work for wire harness for front PASM
(All Models) .
Models) .
Preliminary work for wire harness for rear PASM
(All Models) .
REMOVING WIRE HARNESS FOR PASM
Removing wire harness for front PASM
Microsoft
Fig. 253: Installation position of wire harness for front PASM, shown on the 911
Fig. 254: Exposing wire harness for front PASM

1. Unlock PASM plug connection -Arrow a- and disconnect it. See Fig. 254.
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NOTE: When cutting the PASM wire harness, make sure there is enough length of
cable left to join to the new lines.
2. Cut wire harness for PASM at -b- and remove it. See Fig. 254.
3. Cut through the fabric tape at -c- and expose the remaining PASM wires. See Fig. 254.
Removing wire harness for rear PASM
Fig. 255: Installation position of wire harness for rear PASM

Microsoft
Fig. 256: Exposing wire harness for rear PASM

INSTALLING WIRE HARNESS FOR PASM
Installing wire harness for front PASM
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Fig. 257: Routing and connecting wire harness for rear PASM
1. Press the PASM plug connection together until it clicks into place.
NOTE: Select a place for the joint where there is enough space to join all the lines
present.
Do not cut the lines too short in case they have to be laid in a different position
if there is insufficient space in the area of the joint.
The electric lines are located in the plenum panel and are thus exposed to the
highest demands.
The greatest care must be used in the individual work steps for stripping
insulation from, crimping, and shrinking/insulating the electric lines.
The procedure for stripping insulation from, crimping, and shrinking/insulating

the electric lines must be complied with and observed. The procedures are
described in detail in the repair kit for harnesses NR.155-1.
Crimping samples are to be prepared before beginning work.
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2. Crimp the lines at -a- . See Fig. 257.
2.1. Cut off lines in different lengths (due to the shrink-fit connections).
2.2. Slide shrink-fit hoses onto the lines.
2.3. Strip 10 mm of insulation off the lines.
2.4. Crimp the lines using crimping sleeves and the manual crimping pliers from the repair kit for wire
harnesses NR.155-1.
2.5. Slide the shrink-fit hoses over the crimp connections and carefully shrink them using the hot-air blower
with special nozzle (recommended accessories for the repair kit for wire harnesses) so that they are watertight.
2.6. Wrap commercially available PVC tape all around the area of the connection points.
3. Secure the repaired area -a- to the main wire harness with tie-wraps. See Fig. 257.
Installing wire harness for rear PASM
present.

described in detail in the repair kit for wire harnesses NR.155-1.
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present.
highest demands.

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harnesses NR.155-1.
SUBSEQUENT WORK
Subsequent work for wire harness for front PASM
Models) .
2. Carry out work instructions after disconnecting the battery. Refer to 27 06 IN External power connection,
Subsequent work for wire harness for rear PASM
97 37 55 REPLACING WIRE HARNESS FOR PASM - AS OF MY 2005

TOOLS

PRELIMINARY WORK
Microsoft
Preliminary work for wire harness for front PASM
(All Models) .
Models) .
Preliminary work for wire harness for rear PASM
(All Models) .
2. Move convertible top to service position. Refer to 61 01 IN Diagram of convertible top - as of MY 2005
REMOVING WIRE HARNESS FOR PASM
Removing wire harness for front PASM
Fig. 259: Installation position of wire harness for front PASM, shown on the 911
Microsoft
Fig. 260: Exposing wire harness for front PASM

Removing wire harness for rear PASM
Microsoft
Fig. 261: Installation position of wire harness for rear PASM

Fig. 262: Exposing wire harness for rear PASM

1. Remove PASM plug connection from the holder -Arrow B- , unlock it -Arrow a- and then disconnect it -
Arrow C- . See Fig. 262.
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2. Open cable holder -Arrow D- and remove it from the actuating cable and main wire harness. See Fig. 262.
3. Remove wire harness from the holder -Arrow B- . See Fig. 262.
4. Cut wire harness for PASM at -e- and remove it. See Fig. 262.
5. Cut through the fabric tape at -f- and expose the remaining PASM wires. See Fig. 262.
INSTALLING WIRE HARNESS FOR PASM
Installing wire harness for front PASM
present.
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highest demands.

harnesses NR.155-1.
Installing wire harness for rear PASM
Microsoft
1. Press the PASM plug connection together -Arrows B- until it clicks into place. See Fig. 264.
present.

described in detail in the repair kit for wire harnesses NR.155-1.
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harnesses NR.155-1.
4. Secure a new cable holder on the main wire harness, position it at the actuating cable and close it -Arrow C-
. See Fig. 264.
5. Press main wire harness and plug connection into the cable holder -Arrow D- . See Fig. 264.
SUBSEQUENT WORK
Subsequent work for wire harness for front PASM
Models) .
Subsequent work for wire harness for rear PASM
1. Move convertible top from service position. Refer to 61 01 IN Diagram of convertible top - as of MY 2005
97 45 19 REMOVING AND INSTALLING WIRE HARNESS FOR BATTERY

WIRING - AS OF MY 2005 (ALL MODELS)
TOOLS

PRELIMINARY WORK
Microsoft
Preliminary work for ground strap and B+ line of battery
1. Disconnect battery . Refer to 27 06 IN External power connection, jump lead starting - as of MY 2005
(All Models) .
Preliminary work for B+ line from power distributor to engine connection point
1. Disconnect battery . Refer to 27 06 IN External power connection, jump lead starting - as of MY 2005
(All Models) .
2. Remove current distributor. --> 978919 Removing and installing power distributor - chapter on
"Removing"
3. Unscrew triggering unit. Refer to 69 53 19 Removing and installing triggering unit for airbag - as of MY
2005 (All Models) .
4. Remove shift console. Refer to 34 08 19 Removing and installing gearshift bracket - as of MY 2005 (All
Models) .
5. Remove selector frame. Refer to 37 08 19 Removing and installing selector support - as of MY 2005 (All
Models) .
6. Remove parking-brake lever. Refer to 46 61 19 Removing and installing parking-brake lever - as of MY

2005 (All Models) .
7. Remove rear wall cover. Refer to 55 59 19 Removing and installing rear wall cover - as of MY 2005 (All
Models) .
8. Remove engine-compartment lid. Refer to 55 78 19 Removing and installing engine compartment lid - as
of MY 2005 (Boxster, Boxster RHD, Boxster S, Boxster S RHD) . Refer to 55 78 19 Removing and
installing engine compartment lid - as of MY 2005 (Cayman S, Cayman S RHD) .
Preliminary work for B+ line from starter to engine connection point
(All Models) .
2. Remove throttle housing. Refer to 24 42 19 Removing and installing throttle body - as of MY 2005 (All
Models) .
3. Remove generator. Refer to 27 22 19 Removing and installing three-phase generator - as of MY 2006

(Cayman S, Cayman S RHD) . Refer to 27 22 19 Removing and installing three-phase generator - as of
Microsoft
Preliminary work for engine ground strap
1. Lift the vehicle. --> 40 LIFTING THE VEHICLE - AS OF MY 2005 (ALL MODELS) .
REMOVING WIRE HARNESS FOR BATTERY WIRING
Removing ground strap and B+ line of battery
Fig. 265: Installation position of wire harness for battery wiring, shown on Boxster
1 - Ground strap for battery
2 - B+ line for battery
Microsoft
Fig. 266: Ground strap from battery to body

1. Remove ground strap for battery -1- . See Fig. 265.
1.1. Unscrew fastening nut of battery ground strap to body and remove ground strap for battery.
Microsoft
Fig. 267: Cutting through the positive cable

2. Remove B+ line for battery -2- . See Fig. 265.
2.1. Cut through the positive cable of main wire harness -3- at the place indicated -arrows- . See Fig. 267.
2.2. Remove binding band from main wire harness until the sheathing of the positive cable -3- can be removed -
2.3. Unscrew B+ line from battery. Refer to 27 06 19 Removing and installing battery - as of MY 2005 (All
Models) .
2.4. Release and pull off B+ line from power distributor --> 978919 Removing and installing power
distributor - chapter on "Removing"
2.5. Remove B+ line of battery.
Removing B+ line from power distributor to engine connection point
Microsoft
3 - B+ line from power distributor to engine connection point
4 - Connection point of B+ box on engine
Microsoft
Fig. 269: Fastening B+ line to heater/air-conditioning unit

1. Unclip B+ line -3- on heater/air-conditioning unit. See Fig. 268.
1.1. Unclip B+ line at tie-wrap from heater/air-conditioning unit.
1.2. Disconnect B+ line from main wire harness. To do this, remove the tie-wrap and the binding band.
Microsoft
Fig. 270: Fastening of B+ line at unit carrier.

2. Unclip B+ line -3- at unit carrier. See Fig. 268.
2.1. Unclip B+ line at retaining clip -arrow- from unit carrier. See Fig. 270.
2.2. Pull B+ line out through unit carrier.
Microsoft
Fig. 271: Fastening B+ line at center tunnel

3. Loosen B+ lead -3- at center tunnel. See Fig. 268.
3.1. Pull B+ line out of the two holders -arrows- . See Fig. 271.
3.2. Push B+ line under the carpet away from the direction of travel.
Microsoft
Fig. 272: Unscrewing B+ line at box for B+ line

4. Unscrew B+ line -3- at box for B+ line -4- . See Fig. 268.
4.1. Open box for B+ line at engine -Arrow A- , unscrew fastening nut -Arrow B- and remove the B+ line. See
Fig. 272.
5. Remove B+ line -3- . See Fig. 268.
Removing B+ line from starter to engine connection point
Microsoft
5 - B+ line from starter to engine connection point
1. Unscrew fastening nut of starter lead for terminal 30 and remove starter lead. Refer to 27 60 19 Removing
and installing starter - as of MY 2005 (All Models) .
Microsoft
Fig. 274: Unscrewing B+ line at box for B+ line

2. Unscrew B+ line -5- at box for B+ line -4- . See Fig. 273.
2.1. Open box for B+ line at engine -Arrow A- , unscrew fastening nut -Arrow B- and remove the B+ line. See
Fig. 274.
3. Remove B+ line -5- . See Fig. 273.
Removing engine ground strap
Microsoft
6 - Engine ground strap
Fig. 276: Fastening engine ground strap

1. Remove engine ground strap -6- . See Fig. 275.

Microsoft
1.1. Unscrew fastening screw on engine and fastening nut on body, and remove ground strap.
INSTALLING WIRE HARNESS FOR BATTERY WIRING
Installing ground strap and B+ line of battery
1 - Ground strap for battery
2 - B+ line for battery
Microsoft
Fig. 278: Ground strap from battery to body

1. Install ground strap for battery -1- . See Fig. 277.
1.1. Screw down battery ground strap on the body with the fastening nut. --> Tightening torque: 5 (3.5 ftlb.)
Nm
2. Install B+ line for battery -2- . See Fig. 277.
2.1. Push the B+ line of the battery onto the mounting point at the power distributor as far as the stop. Check
that the B+ line sits firmly. --> 978919 Removing and installing power distributor - chapter on "Installing"
2.2. Tighten B+ line to battery. --> Tightening torque: 5 (3.5 ftlb.) Nm Refer to 27 06 19 Removing and
installing battery - as of MY 2005 (All Models) .
NOTE: The electric lines are located in the plenum panel and are thus exposed to the
highest demands.

Microsoft
Fig. 279: Trimming the positive cable

3. Crimp the positive cable.
3.1. Trim the new positive cable -4- to the -dimension X = approx. 20 cm- and strip the insulation. See Fig.
279.
Microsoft
Fig. 280: Crimping the positive cable

3.2. Strip insulation off original positive cable of main wire harness -3- and push on the shrink-fit hose -5- . See
Fig. 280.
3.3. Crimp crimping sleeve -6- using the hand crimping pliers from the repair kit for harnesses NR.155-1 to
the positive cable -3- . See Fig. 280.
3.4. Crimp crimping sleeve -6- using the hand crimping pliers from the repair kit for harnesses NR.155-1 to
the new positive cable -4- . Check the crimp connection carefully. See Fig. 280.
3.5. Slide the shrink-fit hose over the crimp connection and carefully shrink it using the hot-air blower with
special nozzle (recommended accessories for the repair kit for harnesses) so that it is watertight.
3.6. Tie positive cable to the main wire harness with adhesive tape.
Installing B+ line from power distributor to engine connection point
Microsoft
3 - B+ line from power distributor to engine connection point
1. Lay B+ line -3- . See Fig. 281.
Microsoft
Fig. 282: Screwing down B+ line at box for B+ line

2. Screw down B+ line -3- at box for B+ line -4- . See Fig. 281.
2.1. Insert B+ line into the box -Arrow A- and tighten with the fastening nut. --> Tightening torque: 23 (17
2.2. Close box for B+ line on engine -Arrow B- . See Fig. 282.
Fig. 283: Fastening of B+ line at center tunnel

3. Fasten B+ line -3- at center tunnel. See Fig. 281.
3.1. Push B+ line under the carpet in the direction of travel.
3.2. Insert B+ line into the two holders -arrows- . See Fig. 283.
Microsoft
Fig. 284: Fastening B+ line to unit carrier

4. Clip in B+ line -3- at unit carrier. See Fig. 281.
4.1. Push B+ line through the unit carrier and across the footwell air vent.
4.2. Clip in B+ line with retaining clip -arrow- at unit carrier. See Fig. 284.
Microsoft
Fig. 285: Fastening B+ line at heater/air-conditioning unit

5. Clip in B+ line -3- at heater/air-conditioning unit. See Fig. 281.
5.1. Secure B+ line to main wire harness with two new tie-wraps.
5.2. Clip in B+ line at heater/air-conditioning unit with the tie-wraps.
Installing B+ line from starter to engine connection point
Microsoft
5 - B+ line from starter to engine connection point
1. Lay B+ line -5- . See Fig. 286.
Microsoft
Fig. 287: Screwing down B+ line at box for B+ line

2. Screw down B+ line -5- at box for B+ line -4- . See Fig. 286.
2.1. Insert B+ line into the box -Arrow A- and tighten with the fastening nut. --> Tightening torque: 23 (17
2.2. Close box for B+ line on engine -Arrow B- . See Fig. 287.
3. Position starter lead for terminal 30 and secure with fastening nut. --> Tightening torque: 18 (13 ftlb.) Nm
Refer to 27 60 19 Removing and installing starter - as of MY 2005 (All Models) .
Fitting ground strap to engine
6 - Engine ground strap
Microsoft
Fig. 289: Fastening engine ground strap

1. Fit engine ground strap -6- . See Fig. 288.
1.1. Position ground strap and screw down with the fastening screw and fastening nut. --> Tightening torque:
23 (17 ftlb.) Nm --> Tightening torque: 23 (17 ftlb.) Nm
SUBSEQUENT WORK
Subsequent work for ground strap and B+ line of battery
Subsequent work for B+ line from power distributor to engine connection point
1. Install engine-compartment lid. Refer to 55 78 19 Removing and installing engine compartment lid - as of
MY 2005 (Boxster, Boxster RHD, Boxster S, Boxster S RHD) . Refer to 55 78 19 Removing and installing
engine compartment lid - as of MY 2005 (Cayman S, Cayman S RHD) .
2. Install rear wall cover. Refer to 55 59 19 Removing and installing rear wall cover - as of MY 2005 (All
Models) .
3. Install parking-brake lever. Refer to 46 61 19 Removing and installing parking-brake lever - as of MY

2005 (All Models) .
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4. Install selector support. Refer to 37 08 19 Removing and installing selector support - as of MY 2005 (All
Models) .
5. Installing gearshift bracket console. Refer to 34 08 19 Removing and installing gearshift bracket - as of
6. Fasten triggering unit. Refer to 69 53 19 Removing and installing triggering unit for airbag - as of MY
2005 (All Models) .
7. Install power distributor. --> 978919 Removing and installing power distributor - chapter on "Installing"
Subsequent work for B+ line from starter to engine connection point
1. Install generator. Refer to 27 22 19 Removing and installing three-phase generator - as of MY 2006

2. Install throttle housing. Refer to 24 42 19 Removing and installing throttle body - as of MY 2005 (All
Models) .
Subsequent work for engine ground strap
1. Lower vehicle.
97 52 19 REMOVING AND INSTALLING WIRE HARNESS FOR ENGINE - AS

PRELIMINARY WORK
Preliminary work
1. Remove rear wheels. Refer to 44 05 19 Removing and installing wheel - as of MY 2005 (All Models) .
(All Models) .
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3. Remove rear cover. Refer to 51 94 19 Removing and installing cover for rear underbody - as of MY 2005
(All Models) .
4. Remove generator. Refer to 27 22 19 Removing and installing three-phase generator - as of MY 2006

5. Remove intake-air distributor. Refer to 24 46 20 REMOVING AND INSTALLING INTAKE-AIR

DISTRIBUTOR - AS OF MY 2005 (ALL MODELS) .
S, Cayman S RHD) .
REMOVING WIRE HARNESS FOR ENGINE
Removing wire harness for engine
Fig. 290: Installation position of engine wire harness

Microsoft
Fig. 291: Overview of plugs for engine wire harness

1-3 - Ignition coil plug, cylinder 1 - 3
7-9 - Fuel injector plug, cylinder 1 - 3
13 - Camshaft sensor plug, cylinder row 1 - 3
15 - Knock sensor connector, cylinder row 1 - 3
17 - Solenoid hydraulic-valve plug (camshaft timing), cylinder row 1 - 3
19 - Connector for solenoid hydraulic valve (valve lift control), cylinder row 1 - 3 (only for engine
M9720/M9721)
20 - Connector for solenoid hydraulic valve (valve lift control), cylinder row 4 -6 (only for engine
M9720/M9721)
21 - Ground strap
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22 - Ground strap
23 - Speed sensor
24 - Connector for electric fan
25 - Secondary air blower plug
26 - Generator plug
27 - Tank vent connector
28 - Throttle valve connector
29 - Connector for oil temperature sensor
30 - Starter lead for terminal 30
32 - Pressure sensor plug
33 - Connector for engine-temperature sensor
34 - A/C compressor connector
35 - Connector for coolant temperature sensor
36-37 - Plug connections for oxygen sensor ahead of catalytic converter
38-39 - Plug connections for oxygen sensor behind catalytic converter
40 - Connector for intake-manifold flap
41 - Connector for intake-manifold switchover
42 - Connector for air flow sensor
43 - Connector for coolant change-over valve
44a - Connector for reversing light switch (only for 5-speed manual transmission)
44b - Connector for reversing light switch (only for 6-speed manual transmission)
45 - Connector for engine coolant level indicator (only for engine M9720/M9721)
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43 - Connector for Tiptronic position switch
47 - Connector for Tiptronic transmission control
48 - Plug connection for engine wire harness to rear wire harness
49-50 - Plug connections for engine wire harness to main wire harness left and right
51 - Ground strap
55 - Tiptronic control module connector
56 - Grommet
57 - Tie-wrap
1. Release connectors on the six ignition coils -1 to 6- and pull them off. Refer to 28 70 20 Removing and
fitting spark plugs - as of MY 2005 (All Models) . See Fig. 291.
2. Release connectors on the six fuel injectors -7 to 12- and pull them off. --> 24 40 20 REMOVING AND
INSTALLING FUEL INJECTOR - AS OF MY 2005 (ALL MODELS) . See Fig. 291.
3. Release connectors on both knock sensors -15 and 16- and pull them off. --> 28 72 20 REMOVING AND
INSTALLING KNOCK SENSOR - AS OF MY 2005 (BOXSTER, BOXSTER RHD, BOXSTER S,
BOXSTER S RHD) . See Fig. 291.
4. Release connectors on both solenoid hydraulic valves (camshaft timing) -17 and 18- and pull them off. Refer
to 15 37 19 Removing and installing solenoid hydraulic valve (camshaft timing) - as of MY 2005 (Boxster,
Boxster RHD, Boxster S, Boxster S RHD) . See Fig. 291.
5. Release connectors on both solenoid hydraulic valves (valve lift control) -19 and 20- and pull them off. See
Fig. 291.
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Fig. 292: Unscrewing ground straps on engine

6. Unscrew ground straps -22- . See Fig. 291.
6.1. Unscrew fastening screw and remove ground straps -22- . See Fig. 292.
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Fig. 293: Disconnecting plug connection on speed sensor

7. Disconnect plug connection on speed sensor -23- and unscrew ground straps -21- . See Fig. 291.
7.1. Pull plug connection -23- out of holder. See Fig. 293.
7.2. Release plug connection -23- and disconnect it -Arrows a- . See Fig. 293.
7.3. Unscrew fastening screw and remove ground straps -21- . See Fig. 293.
8. Release connector on electric fan -24- and pull it off. --> 19 70 19 REMOVING AND INSTALLING
RADIATOR - AS OF MY 2005 (ALL MODELS) . See Fig. 291.
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9. Release connector on secondary air blower -25- and pull it off. Refer to 26 65 19 Removing and installing
secondary air pump - as of MY 2005 (Boxster, Boxster RHD, Boxster S, Boxster S RHD) . See Fig. 291.
10. Release securing clip and pull off connector on tank vent -27- . See Fig. 291.
11. Release connector on oil temperature sensor -29- and pull it off. See Fig. 291.
12. Unscrew fastening nut of starter leads at terminal 30 and terminal 50 -30 and 31- and remove. Refer to 27
60 19 Removing and installing starter - as of MY 2005 (All Models) . See Fig. 291.
13. Pull off connector on pressure sensor -32- . See Fig. 291.
14. Release connector on engine temperature sensor -33- and pull it off. See Fig. 291.
Fig. 294: Removing connector on coolant temperature sensor

15. Pull off connector on coolant temperature sensor -35- . See Fig. 291.
15.1. Open holder -Arrow B- and remove line. See Fig. 294.
15.2. Release connector on coolant temperature sensor -35- -Arrow a- and pull it off. See Fig. 294.
16. Disconnect plug connections for oxygen sensor ahead of catalytic converter -36 and 37- . --> 24 69 20
REMOVING AND INSTALLING OXYGEN SENSOR IN FRONT OF CATALYTIC CONVERTER -
AS OF MY 2005 (ALL MODELS) . See Fig. 291.
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17. Disconnect plug connections for oxygen sensor behind catalytic converter -38 and 39- . --> 24 73 20
REMOVING AND INSTALLING OXYGEN SENSOR BEHIND CATALYTIC CONVERTER - AS OF
MY 2005 (ALL MODELS) . See Fig. 291.
18. Release securing clip and pull off connector on intake-manifold change-over switch -41- . See Fig. 291.
19. Release connector on air flow sensor -42- and pull it off. Refer to 24 45 19 Removing and installing air
flow sensor - as of MY 2005 (All Models) . See Fig. 291.
20. Release securing clip and pull off connector on coolant change-over valve -43- . See Fig. 291.
21. Release and pull off connector on reversing light switch -44- . Refer to 94 72 19 Removing and installing
switch for reversing light - as of MY 2005 (Boxster, Boxster RHD) . Refer to 94 72 19 Removing and
installing switch for reversing light - as of MY 2005 (Boxster S, Boxster S RHD, Cayman S, Cayman S
RHD) . See Fig. 291.
22. Release connector on coolant level indicator -45- and remove it. See Fig. 291.
23. Release and pull off connector on Tiptronic position switch -46- and Tiptronic control module -47- . Refer
to 37 35 19 Removing and installing automatic transmission - as of MY 2005 (Cayman S, Cayman S
RHD) . Refer to 37 35 19 Removing and installing automatic transmission - as of MY 2005 (Boxster S,
Boxster S RHD) . Refer to 37 35 19 Removing and installing automatic transmission - as of MY 2005
(Boxster, Boxster RHD) . See Fig. 291.
24. Release and disconnect plug connection for engine wire harness to rear wire harness -48- . --> 972519
Removing and installing rear wire harness - chapter on "Removing"See Fig. 291.
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Fig. 295: Disconnecting plug connection for engine wire harness to rear wire harness
25. Disconnect plug connections for engine wire harness to main wire harness rear left and right -49 and 50- .
See Fig. 291.
25.1. Release plug connections for engine wire harness to main wire harness rear left and right -Arrows A- and
disconnect -Arrows B- . See Fig. 295.
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26. Unscrew ground strap -51- . See Fig. 291.
27. Release and pull off connector on DME control module -52 to 54- . Refer to 24 70 19 Removing and
installing DME control module - as of MY 2005 (Boxster, Boxster RHD, Boxster S, Boxster S RHD) .
Refer to 24 70 19 Removing and installing DME control module - as of MY 2006 (Cayman S, Cayman S
28. Release and pull off connector on Tiptronic control module -55- . Refer to 37 30 19 Removing and
installing the Tiptronic control module - as of MY 2005 (Boxster, Boxster RHD, Boxster S, Boxster S
RHD) . Refer to 37 30 19 Removing and installing the Tiptronic control module (also referred to generally
as control unit below) - as of MY 2006 (Cayman S, Cayman S RHD) . See Fig. 291.
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Fig. 297: Unclipping wire harness to Tiptronic control module and DME control module
NOTE: Only on the Cayman.
29. Unclip wire harness to Tiptronic control module and DME control module at the two holders in the area of
the service flap.
30. Remove grommet -56- and pull through the engine wire harness in direction of engine compartment. See
Fig. 291.
31. Unclip engine wire harness at the tie-wraps -57- . See Fig. 291.
31.1. Unclip tie-wrap on the secondary pump.
31.2. Unclip tie-wrap at the branch (throttle valve, secondary pump, coolant change-over valve).
31.3. Unclip tie-wrap at cable duct in area of grommet.
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Fig. 298: Removing cable duct on the left and right

32. Remove cable duct on the left and right.
32.1. Unscrew fastening screw of cable duct on the left and right -Arrow A- . See Fig. 298.
32.2. Unclip cable duct on the left and right -Arrow B- . See Fig. 298.
32.3. Remove cable duct on the left and right -Arrow C- . See Fig. 298.
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Fig. 299: Removing cable duct

33. Remove center cable duct.
33.1. Unscrew fastening screws, unclip cable duct -arrow- and remove it. See Fig. 299.
34. Remove wire harness for engine.
INSTALLING WIRE HARNESS FOR ENGINE
Installing wire harness for engine
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Fig. 300: Overview of plugs for engine wire harness

M9720/M9721)
M9720/M9721)
21 - Ground strap
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22 - Ground strap
23 - Speed sensor
24 - Connector for electric fan
25 - Secondary air blower plug
26 - Generator plug
27 - Tank vent connector
28 - Throttle valve connector
29 - Connector for oil temperature sensor
32 - Pressure sensor plug
33 - Connector for engine-temperature sensor
34 - A/C compressor connector
35 - Connector for coolant temperature sensor
36-37 - Plug connections for oxygen sensor ahead of catalytic converter
38-39 - Plug connections for oxygen sensor behind catalytic converter
40 - Connector for intake-manifold flap
41 - Connector for intake-manifold switchover
42 - Connector for air flow sensor
43 - Connector for coolant change-over valve
44a - Connector for reversing light switch (only for 5-speed manual transmission)
44b - Connector for reversing light switch (only for 6-speed manual transmission)
45 - Connector for engine coolant level indicator (only for engine M9720/M9721)
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43 - Connector for Tiptronic position switch
47 - Connector for Tiptronic transmission control
48 - Plug connection for engine wire harness to rear wire harness
49-50 - Plug connections for engine wire harness to main wire harness left and right
51 - Ground strap
55 - Tiptronic control module connector
56 - Grommet
57 - Tie-wrap
1. Lay out wire harness for engine.
Fig. 301: Installing cable duct

2. Install center cable duct.
2.1. Clip in cable duct -arrow- and secure with the fastening screws. --> Tightening torque: 10 (7.5 ftlb.) Nm
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See Fig. 301.
Fig. 302: Installing cable duct at left and right

3. Install cable duct at left and right.
3.1. Position cable duct left and right -Arrow A- and clip in -Arrow B- . See Fig. 302.
3.2. Secure cable duct left and right with fastening screw -Arrow C- . --> Tightening torque: 10 (7.5 ftlb.) Nm
See Fig. 302.
4. Clip in engine wire harness at the tie-wraps -57- . See Fig. 300.
4.1. Clip in tie-wrap at cable duct in area of grommet.
4.2. Clip in tie-wrap at the branch (throttle valve, secondary pump, coolant change-over valve).
4.3. Clip in tie-wrap on the secondary pump.
5. Push through engine wire harness in direction of luggage compartment and fit grommet -56- . See Fig. 300.
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Fig. 303: Clipping in wire harness to Tiptronic control module and DME control module
NOTE: Only on the Cayman.
6. Clip in wire harness to Tiptronic control module and DME control module at the two holders in the area of
the service flap.
7. Push on connector of Tiptronic control module -55- until it is felt to engage. Refer to 37 30 19 Removing
and installing the Tiptronic control module - as of MY 2005 (Boxster, Boxster RHD, Boxster S, Boxster S
RHD) . Refer to 37 30 19 Removing and installing the Tiptronic control module (also referred to generally
as control unit below) - as of MY 2006 (Cayman S, Cayman S RHD) . See Fig. 300.
8. Push on connector of DME control module -52 to 54- until it is felt to engage. Refer to 24 70 19 Removing
and installing DME control module - as of MY 2005 (Boxster, Boxster RHD, Boxster S, Boxster S RHD) .
Refer to 24 70 19 Removing and installing DME control module - as of MY 2006 (Cayman S, Cayman S
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9. Screw down ground strap -51- . See Fig. 300.
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Fig. 305: Connecting plug connection for engine wire harness to rear wire harness
10. Connect plug connections for engine wire harness to main wire harness left and right -49 and 50- . See Fig.
300.
10.1. Connect plug connections for engine wire harness to main wire harness left and right until they are felt to
engage.
11. Connect plug connection for engine wire harness to rear wire harness -48- until it is felt to engage. -->
972519 Removing and installing rear wire harness - chapter on "Installing"See Fig. 300.
12. Push on connector of Tiptronic position switch -46- and Tiptronic control module -47- until they are felt to
engage. Refer to 37 35 19 Removing and installing automatic transmission - as of MY 2005 (Cayman S,
Cayman S RHD) . Refer to 37 35 19 Removing and installing automatic transmission - as of MY 2005
(Boxster S, Boxster S RHD) . Refer to 37 35 19 Removing and installing automatic transmission - as of
MY 2005 (Boxster, Boxster RHD) . See Fig. 300.
13. Push on connector of coolant level indicator -45- until it is felt to engage. See Fig. 300.
14. Push on connector for reversing light switch -44- until it is felt to engage. Refer to 94 72 19 Removing and
installing switch for reversing light - as of MY 2005 (Boxster, Boxster RHD) . Refer to 94 72 19 Removing
and installing switch for reversing light - as of MY 2005 (Boxster S, Boxster S RHD, Cayman S, Cayman
S RHD) . See Fig. 300.
15. Push on connector of intake-manifold change-over switch -43- until the securing clip is felt to engage. See
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Fig. 300.
16. Push on connector of air flow sensor -42- until it is felt to engage. Refer to 24 45 19 Removing and
installing air flow sensor - as of MY 2005 (All Models) . See Fig. 300.
17. Push on connector of intake-manifold change-over switch -41- until the securing clip is felt to engage. See
Fig. 300.
18. Connect plug connections for oxygen sensor behind catalytic converter -38 and 39- . --> 24 73 20
REMOVING AND INSTALLING OXYGEN SENSOR BEHIND CATALYTIC CONVERTER - AS OF
MY 2005 (ALL MODELS) . See Fig. 300.
19. Connect plug connections for oxygen sensor ahead of catalytic converter -36 and 37- . --> 24 69 20
REMOVING AND INSTALLING OXYGEN SENSOR IN FRONT OF CATALYTIC CONVERTER -
AS OF MY 2005 (ALL MODELS) . See Fig. 300.
Fig. 306: Pushing on connector of coolant temperature sensor.

20. Push on connector of coolant temperature sensor -35- . See Fig. 300.
20.1. Push on connector of coolant temperature sensor -35- -Arrow A- until it is felt to engage. See Fig. 306.
20.2. Insert line into holder and close holder -Arrow B- . See Fig. 306.
21. Push on connector of engine temperature sensor -33- until it is felt to engage. See Fig. 300.
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22. Push on connector of pressure sensor -32- . See Fig. 300.
23. Position starter lead for terminal 30 and terminal 50 -30 and 31- and secure with fastening nut. -->
Tightening torque: 18 (13 ftlb.) Nm --> Tightening torque: 6.5 (5.0 ftlb.) Nm Refer to 27 60 19 Removing
and installing starter - as of MY 2005 (All Models) . See Fig. 300.
24. Push on connector of oil temperature sensor -29- until it is felt to engage. See Fig. 300.
25. Push on connector of tank vent -27- until the securing clip is felt to engage. See Fig. 300.
26. Push on connector of secondary air blower -25- until it is felt to engage. Refer to 26 65 19 Removing and
installing secondary air pump - as of MY 2005 (Boxster, Boxster RHD, Boxster S, Boxster S RHD) . See
Fig. 300.
27. Push on connector of electric fan -24- until it is felt to engage. --> 19 70 19 REMOVING AND
INSTALLING RADIATOR - AS OF MY 2005 (ALL MODELS) . See Fig. 300.
Microsoft
Fig. 307: Connecting plug connection on speed sensor

28. Screw down ground straps -21- and connect plug connection of speed sensor -23- . See Fig. 300.
28.1. Position ground straps -21- and screw down with the fastening screw. --> Tightening torque: 10 (7.5
28.2. Push plug connection -23- together until it is felt to engage. See Fig. 307.
28.3. Push plug connection -23- into holder. See Fig. 307.
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Fig. 308: Screwing down ground straps on engine

29. Screw down ground straps -22- . See Fig. 300.
29.1. Position ground straps -22- and screw down with the fastening screw. --> Tightening torque: 10 (7.5
30. Push on connectors of the two solenoid hydraulic valves (valve lift control) -19 to 20- until they are felt to
31. Push on connectors of the two solenoid hydraulic valves (camshaft timing) -17 to 18- until they are felt to
engage. Refer to 15 37 19 Removing and installing solenoid hydraulic valve (camshaft timing) - as of MY
2005 (Boxster, Boxster RHD, Boxster S, Boxster S RHD) . See Fig. 300.
32. Push on connectors of the two knock sensors -15 to 16- until they are felt to engage. --> 28 72 20
REMOVING AND INSTALLING KNOCK SENSOR - AS OF MY 2005 (BOXSTER, BOXSTER RHD,
BOXSTER S, BOXSTER S RHD) . See Fig. 300.
33. Push on connectors of the six fuel injectors -7 to 12- until they are felt to engage. --> 24 40 20
REMOVING AND INSTALLING FUEL INJECTOR - AS OF MY 2005 (ALL MODELS) . See Fig. 300.
34. Push on connectors of the six ignition coils -1 to 6- until they are felt to engage. Refer to 28 70 20
Removing and fitting spark plugs - as of MY 2005 (All Models) . See Fig. 300.
SUBSEQUENT WORK
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Subsequent work
S, Cayman S RHD) .
2. Install intake-air distributor. Refer to 24 46 20 REMOVING AND INSTALLING INTAKE-AIR

DISTRIBUTOR - AS OF MY 2005 (ALL MODELS) .
3. Install the generator. Refer to 27 22 19 Removing and installing three-phase generator - as of MY 2006
4. Install rear cover. Refer to 51 94 19 Removing and installing cover for rear underbody - as of MY 2005
(All Models) .
5. Mount rear wheels. Refer to 44 05 19 Removing and installing wheel - as of MY 2005 (All Models) .
97 53 19 REMOVING AND INSTALLING WIRE HARNESS FOR SEAT

HEATER - AS OF MY 2005 (ALL MODELS)
INFORMATION
Spare parts information
NOTE: The seat-heating wire harness is only available as a spare part together with the
heating element. The heating element is stuck to the padding and can only be
replaced together with the padding. Depending on the I number, the padding
spare part is only supplied with the heating element and seat-heating wire
harness attached.
Replace padding for front seat. Refer to 74 10 19 Removing and installing padding for front seat - as of MY
2005 (All Models) .
97 55 19 REMOVING AND INSTALLING WIRING HARNESS FOR

CONVERTIBLE TOP - AS OF MY 2005 (BOXSTER, BOXSTER RHD,
REMOVING WIRING HARNESS FOR CONVERTIBLE TOP
Disconnecting electric plug connection at rear window
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CAUTION: Material damage when disconnecting the electric plug connection at the
rear window.
become loosened
--> Disconnect the plug connection carefully.
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1. Carefully disconnect plug connection -2- on left and right from the connector -1- at the rear window. See Fig.
310.
Loosening roof liner connection to tension bow
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1. Press out plastic expansion rivets -1- at the roof liner connection -2- on the right and left of the tension bow -
3- . See Fig. 311.
Removing clamping strip of cloth from convertible top frame
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Fig. 312: Removing clamping strip from convertible top frame

1. Remove clamping strip -1- of cloth -2- over the entire length of the convertible top frame -3- . See Fig. 312.
Disconnecting electric plug connection of wiring harness for convertible top
Fig. 313: Installation position of wiring harness for convertible top

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1. Fully open the convertible top
Fig. 314: Disconnecting electric plug connection of wiring harness for convertible top
3. Pull off connector -1- -Arrow A- , unclip retaining clip -2- -Arrow B- and pull out wiring harness from the
body -Arrow C- . See Fig. 314.
Removing wiring harness for convertible top
NOTE: The wiring harness for the convertible top is sewn into the cloth and can only
be replaced together with this.
NOTE: Move convertible top to service position, but do not engage retaining strap on
centering pin.
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Fig. 315: Disengaging restraining strap of cloth.

NOTE: The hook 3 must not be removed from the pin as this is tensioned by the rubber
strap.
4. Disengage cloth -1- with the two retaining straps -2- on the hook -3- -Arrow A- and remove -Arrow B- . See
Fig. 315.
INSTALLING WIRING HARNESS FOR CONVERTIBLE TOP
Installing wiring harness for convertible top
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Fig. 316: Engaging restraining strap of cloth.

1. Insert cloth -1- -Arrow A- , align and engage with the two retaining straps -2- on the hook -3- -Arrow B- .
See Fig. 316.
3. End convertible top service position. Refer to 61 01 IN Diagram of convertible top - as of MY 2005
Connecting electric plug connection of wiring harness for convertible top
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Fig. 317: Locking electric plug connection of wiring harness for convertible top
1. Push wiring harness through the body -Arrow A- and fasten with the retaining clip -2- . Push on the
connector -1- -Arrow C- . See Fig. 317.
2. Switch on ignition and close convertible top.
Fitting clamping strip of cloth on convertible top frame
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Fig. 318: Fitting clamping strip on convertible top frame

1. Fit clamping strip -1- of cloth -2- over the entire length of the convertible top frame -3- . See Fig. 318.
Fastening roof liner connection to tension bow
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Fig. 319: Fastening roof liner connection

1. Press plastic expansion rivets -1- at the roof liner connection -2- through the fastening holes of the cloth into
the tension bow -3- on the left and right. See Fig. 319.
Connecting electric plug connection at rear window
Microsoft

CAUTION: Material damage when connecting the electric plug connection at the rear
window.
become loosened
--> Connect the plug connection carefully.
Microsoft

1. Carefully connect plug connection -2- on left and right to the connector -1- at the rear window. See Fig. 321.
97 56 19 REMOVING AND INSTALLING WIRE HARNESS FOR BACKREST

(FRONT SEAT) - AS OF MY 2005 (ALL MODELS)
PRELIMINARY WORK
Preliminary work
1. Remove cushion carrier for front backrest. Refer to 72 24 19 Removing and installing cushion carrier for
front backrest - as of MY 2005 (All Models) .
2. Remove cover for backrest. Refer to 72 26 19 Removing and installing cover for backrest - as of MY 2005
(All Models) .
3. Remove air cushion for backrest. Refer to 72 17 19 Removing and installing air cushion for backrest - as
REMOVING WIRE HARNESS FOR BACKREST (FRONT SEAT)
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Removing support for left backrest side part
Fig. 322: Installation position of motor for lumbar support

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1. Unscrew the four fastening screws -1- and remove support for backrest side part -2- . See Fig. 323.
Removing backrest side support
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Fig. 324: Installation position of motor for backrest adjustment

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Fig. 325: Removing backrest side support

1. Unscrew the four fastening screws -1- and remove backrest side support -2- . See Fig. 325.
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Removing wire harness for backrest (front seat)

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NOTE: The description covers a wire harness for maximum equipment. Some plug
connections will not be present if the vehicle has less equipment.
Fig. 328: Installation position of wire harness for backrest (front seat)
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Fig. 329: Overview of plugs for wire harness for backrest

Overview of plugs for wire harness for backrest
A - Wire harness for backrest (front seat)
B - Wire harness for airbag
1 - Connector for control valve for lumbar support adjustment (only for lumbar support)
2 - Connector for sensor for lower air cushion on lumbar support (only for lumbar support with memory)
3 - Connector for sensor for upper air cushion on lumbar support (only for lumbar support with memory)
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4 - Connector for motor for backrest adjustment
5 - Plug connection for motor for lumbar support adjustment (only for lumbar support)
6 - Plug connection for air cushion switch (only for sports seats)
7 - Connector for control unit for memory seat adjustment (only for seats with memory)
8 - Plug connection for air cushion motor (only for sports seats)
9 - Connector for air cushion control valve (only for sports seats)
10 - Connector for airbag
11 - Connector for central plug
12 - Tie-wraps
1. Release and pull off connector -1- on control valve for lumbar support adjustment. Refer to 72 33 19
Removing and installing control valve for lumbar support adjustment - as of MY 2005 (All Models) . See
Fig. 329.
2. Release and pull off connectors -2 and 3- on sensors for lumbar support. Refer to 72 34 19 Removing and
installing lumbar support - as of MY 2005 (All Models) . See Fig. 329.
3. Release and pull off connector -4- on motor for backrest adjustment. Refer to 72 89 19 Removing and
installing motor for backrest adjustment - as of MY 2005 (All Models) . See Fig. 329.
4. Release and disconnect plug connection -5- on motor for lumbar support adjustment. Refer to 72 36 19
Removing and installing motor for lumbar support - as of MY 2005 (All Models) . See Fig. 329.
5. Release and disconnect plug connection -6- on air cushion switch. Refer to 72 86 19 Removing and
installing switch for seat adjustment - as of MY 2005 (All Models) . See Fig. 329.
6. Release and pull off connector -7- on control unit for memory seat adjustment. Refer to 72 93 19 Removing
and installing control unit for memory seat adjustment - as of MY 2005 (All Models) . See Fig. 329.
7. Release and disconnect plug connection -8- on air cushion motor. Refer to 72 39 19 Removing and
installing air cushion motor - as of MY 2005 (All Models) . See Fig. 329.
8. Release and disconnect connector -9- on control valve for air cushion. Refer to 72 38 19 Removing and
installing air cushion control valve - as of MY 2005 (All Models) . See Fig. 329.
9. Remove tie-wrap -12- and remove wire harness for backrest -A- . See Fig. 329.
NOTE: For standard vehicle equipment, the wire harness for airbags is incorporated
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into the wire harness for the backrest.
10. Remove connector -11- on central plug. Refer to 69 24 19 Removing and installing front belt lock - as of
11. Remove tie-wrap -12- and remove wire harness for airbag -B- . See Fig. 329.
INSTALLING WIRE HARNESS FOR BACKREST (FRONT SEAT)
Installing wire harness for backrest (front seat)
Fig. 330: Overview of plugs for wire harness for backrest

Microsoft
Overview of plugs for wire harness for backrest
A - Wire harness for backrest (front seat)
B - Wire harness for airbag
1 - Connector for control valve for lumbar support adjustment (only for lumbar support)
2 - Connector for sensor for lower air cushion on lumbar support (only for lumbar support with memory)
3 - Connector for sensor for upper air cushion on lumbar support (only for lumbar support with memory)
4 - Connector for motor for backrest adjustment
5 - Plug connection for motor for lumbar support adjustment (only for lumbar support)
6 - Plug connection for air cushion switch (only for sports seats)
7 - Connector for control unit for memory seat adjustment (only for seats with memory)
8 - Plug connection for air cushion motor (only for sports seats)
9 - Connector for control valve for air cushion (only for sports seats)
10 - Connector for airbag
11 - Connector for central plug
12 - Tie-wraps
1. Route wire harness for airbag -B- and secure with new tie-wraps -12- . See Fig. 329.
2. Fit connector -11- on central plug. Refer to 69 24 19 Removing and installing front belt lock - as of MY
2005 (All Models) . See Fig. 329.
3. Route wire harness for backrest -A- and secure with new tie-wraps -12- . See Fig. 329.
4. Push connector -9- onto air cushion control valve until it engages firmly. Refer to 72 38 19 Removing and
installing air cushion control valve - as of MY 2005 (All Models) . See Fig. 329.
5. Push plug connection -8- onto motor for air cushion until it engages firmly. Refer to 72 39 19 Removing and
installing air cushion motor - as of MY 2005 (All Models) . See Fig. 329.
6. Attach connector -7- to control unit for memory seat adjustment until it engages firmly. Refer to 72 93 19
Removing and installing control unit for memory seat adjustment - as of MY 2005 (All Models) . See Fig.
329.
Microsoft
7. Push plug connection -6- onto air cushion switch until it engages firmly. Refer to 72 86 19 Removing and
installing switch for seat adjustment - as of MY 2005 (All Models) . See Fig. 329.
8. Connect plug connection -5- on motor for lumbar support adjustment until it engages firmly. Refer to 72 36
19 Removing and installing motor for lumbar support - as of MY 2005 (All Models) . See Fig. 329.
9. Attach connector -4- to motor for backrest adjustment until it engages firmly. Refer to 72 89 19 Removing
and installing motor for backrest adjustment - as of MY 2005 (All Models) . See Fig. 329.
10. Push connectors -2 and 3- onto sensors for lumbar support until they click into place. Refer to 72 34 19
Removing and installing lumbar support - as of MY 2005 (All Models) . See Fig. 329.
11. Push connector -1- onto control valve for lumbar support adjustment until it engages firmly. Refer to 72 33
19 Removing and installing control valve for lumbar support adjustment - as of MY 2005 (All Models) .
See Fig. 329.
Fitting foam part

on the foam part.
Microsoft
Installing backrest side support
Fig. 332: Installing backrest side support

1. Fit backrest side support -2- and screw down with the four fastening screws -1- . See Fig. 332.
Microsoft
Installing support for left backrest side part

1. Insert support for backrest side part -2- and secure with the four fastening screws -1- . See Fig. 333.
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Fig. 334: Routing wire harness for airbag

2. Route wire harness for airbag -1- as shown behind the backrest side part support -2- . See Fig. 334.
SUBSEQUENT WORK
Subsequent work
1. Install air cushion for backrest. Refer to 72 17 19 Removing and installing air cushion for backrest - as of
2. Install cover for left backrest. Refer to 72 26 19 Removing and installing cover for backrest - as of MY
2005 (All Models) .
3. Install cushion carrier for front backrest. Refer to 72 24 19 Removing and installing cushion carrier for
front backrest - as of MY 2005 (All Models) .
97 57 19 REMOVING AND INSTALLING WIRE HARNESS FOR

ELECTRICALLY ADJUSTABLE SEAT - AS OF MY 2005 (ALL MODELS)
PRELIMINARY WORK
Preliminary work
Microsoft
Remove front seat. Refer to 72 01 19 Removing and installing front seat - as of MY 2005 (All LHD
Models) . Refer to 72 01 19 Removing and installing front seat - as of MY 2005 (All RHD Models) .
REMOVING WIRE HARNESS FOR ELECTRICALLY ADJUSTABLE SEAT
Removing wire harness for electrically adjustable seat
NOTE: This description covers the two-piece wire harness for an electrically adjustable
seat with memory. Some plug connections will not be present on a single-piece
wire harness without memory.
Fig. 335: Installation position of wire harness for electrically adjustable seat
Microsoft
Fig. 336: Connector overview for wire harness for electrically adjustable seat
Connector overview for wire harness for electrically adjustable seat
A - Wire harness for control unit for memory seat adjustment - seat adjustment motors
B - Wire harness for seat adjustment switch - control unit for memory seat adjustment
1 - Connector (grey) for control unit for memory seat adjustment (with memory only)
2 - Connector for seat adjustment motor
3 - Connector for motor for rear vertical adjustment

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4 - Connector for motor for front vertical adjustment
5 - Connector (black) for control unit for memory seat adjustment (with memory only)
6 - Connector for seat adjustment switch
7 - Tie-wraps
2. Release and pull off connector -2- on motor for seat adjustment. Refer to 72 87 19 Removing and installing
motor for seat adjustment - as of MY 2005 (All Models) . See Fig. 336.
3. Release and pull off connector -3- on motor for rear vertical adjustment. Refer to 72 92 19 Removing and
installing motor for rear vertical adjustment - as of MY 2005 (All Models) . See Fig. 336.
4. Release and pull off connector -4- on motor for front vertical adjustment. Refer to 72 88 19 Removing and
installing motor for front vertical adjustment - as of MY 2005 (All Models) . See Fig. 336.
5. Remove wire harness -A- . See Fig. 336.
7. Release and pull off connector on seat adjustment switch -6- . Refer to 72 16 19 Removing and installing
control module trim panel - as of MY 2005 (All Models) . See Fig. 336.
8. Remove tie-wraps -7- and pull out wire harness -B- . See Fig. 336.
INSTALLING WIRE HARNESS FOR ELECTRICALLY ADJUSTABLE SEAT
Installing wire harness for electrically adjustable seat
NOTE: Observe connector assignment!
Connect blue connector to the motor for fore-and-aft adjustment.
Connect white connector to the motor for front vertical adjustment.
Connect yellow connector to the motor for rear vertical adjustment.
Microsoft
Fig. 337: Connector overview for wire harness for electrically adjustable seat
Connector overview for wire harness for electrically adjustable seat
A - Wire harness for control unit for memory seat adjustment - seat adjustment motors
B - Wire harness for seat adjustment switch - control unit for memory seat adjustment
1 - Connector (grey) for control unit for memory seat adjustment (with memory only)
2 - Connector for seat adjustment motor
3 - Connector for motor for rear vertical adjustment

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4 - Connector for motor for front vertical adjustment
5 - Connector (black) for control unit for memory seat adjustment (with memory only)
6 - Plug connections for seat adjustment switch
7 - Tie-wraps
1. Route wire harness -B- and secure with new tie-wraps -7- . See Fig. 336, Fig. 337.
2. Push on connector -6- on seat adjustment switch until it engages firmly. Refer to 72 16 19 Removing and
installing control module trim panel - as of MY 2005 (All Models) . See Fig. 336.
336.
4. Route the wire harness -A- . See Fig. 336.
5. Attach connector -4- (white ) to motor for front vertical adjustment until it engages firmly. Refer to 72 88 19
Removing and installing motor for front vertical adjustment - as of MY 2005 (All Models) . See Fig. 336.
6. Attach connector -3- (yellow ) to motor for rear vertical adjustment until it engages firmly. Refer to 72 92 19
Removing and installing motor for rear vertical adjustment - as of MY 2005 (All Models) . See Fig. 336.
7. Attach connector -2- (blue ) to motor for seat adjustment until it engages firmly. Refer to 72 87 19 Removing
and installing motor for seat adjustment - as of MY 2005 (All Models) . See Fig. 336.
337.
SUBSEQUENT WORK
Subsequent work
Install front seat. Refer to 72 01 19 Removing and installing front seat - as of MY 2005 (All LHD Models) .
Refer to 72 01 19 Removing and installing front seat - as of MY 2005 (All RHD Models) .
97 65 55 REPLACING WIRE HARNESS FOR ANTI-LOCK BRAKE SYSTEM

(ABS) - AS OF MY 2005 (CAYMAN S, CAYMAN S RHD)
TOOLS

Microsoft
PRELIMINARY WORK
Preliminary work on front ABS wire harness
(All Models) .
2. Remove front wheel housing liner (rear section). Refer to 50 56 19 Removing and installing front wheel
Models) .
Preliminary work on rear ABS wire harness
(All Models) .
2. Remove rear wheel housing liner. Refer to 53 69 19 Removing and installing rear wheel housing liner - as
REMOVING WIRE HARNESS FOR ANTI-LOCK BRAKE SYSTEM (ABS)
Removing front ABS wire harness
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Fig. 338: Installation position for front ABS wire harness

Fig. 339: Disconnecting plug connection for front wheel sensor

1. Release the cable retainer -arrow A- and pull off the two connectors -arrow B- . See Fig. 339.
2. Unscrew the fastening screw and remove the connector socket -arrow C- . See Fig. 339.
Microsoft
Fig. 340: Removing the ABS wire harness from the brackets
3. Remove the ABS wire harness from the brackets -arrows A- . See Fig. 340.
4. Open the clips -arrows B- and remove the ABS wire harness -arrow C- . See Fig. 340.
5. Remove the fabric tape -D- . See Fig. 340.
NOTE: When cutting the ABS wire harness, make sure that there is enough line length
left to join to the new lines.
6. Cut off the ABS wire harness around -E- and remove it. See Fig. 340.
Microsoft
Fig. 341: Exposing ABS wire harness

7. Cut through the fabric tape in the plenum panel, in the area around -a- , and expose the remaining ABS lines.
See Fig. 341.
Removing rear ABS wire harness
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Fig. 342: Installation position for rear ABS wire harness

Fig. 343: Disconnecting plug connection for rear wheel sensor

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4. Open clip -arrow B- and remove ABS wire harness. See Fig. 344.
NOTE: When cutting the ABS wire harness make sure there is enough line length left in
the interior to join to the new lines.
5. Cut off the ABS wire harness around -d- and press downward with the rubber sleeve -arrow C- . See Fig.
344.
6. Cut through the fabric tape at -e- and expose remaining ABS lines. See Fig. 344.
Microsoft
Fig. 345: Cutting off rubber sleeve

7. Cut through the rubber sleeve at the side of the HBA line -a- and remove the HBA line -arrow B- . See Fig.
345.
INSTALLING WIRE HARNESS FOR ANTI-LOCK BRAKE SYSTEM (ABS)
Installing front ABS wire harness
Microsoft
Fig. 346: Connecting plug connection for front wheel sensor

1. Place socket in installation position -arrow A- and screw on the fastening screw. --> Tightening torque: 10
2. Plug in the two connectors -arrow B- . See Fig. 346.
3. Fold back the cable retainer -arrow C- until it engages correctly at the connectors. See Fig. 346.
Microsoft
Fig. 347: Pressing ABS wire harness into supports

4. Press the ABS wire harness into the supports by pressing on the rubber sleeves -arrows A- . See Fig. 347.
5. Secure line for headlight levelling system to the ABS wire harness using fabric tape -B- . See Fig. 347.
6. Place ABS wire harness in installation position -arrows C- and close clip -arrows D- . See Fig. 347.
Microsoft
Fig. 348: Routing and connecting ABS wire harness

7. Push through ABS wire harness to plenum panel -arrow- . See Fig. 348.
present.
highest demands.
Microsoft

8. Crimp lines in area around -b- . See Fig. 348.
8.4. Crimp lines using crimping sleeves and the hand crimping pliers from the repair kit for harnesses
NR.155-1.
with special nozzle (recommended accessories for the repair kit for harnesses) so that they are watertight.
9. Secure the repaired area to the neighboring wire harnesses using tie-wraps -c- . See Fig. 348.
Installing rear ABS wire harness
Microsoft
Fig. 349: Connecting plug connection for rear wheel sensor

Microsoft

4. Press the ABS wire harness into the supports on the spring strut by pressing on the rubber sleeves -arrows A-
. See Fig. 350.
5. Insert ABS wire harness into clip and close clip -arrow B- . See Fig. 350.
6. Push the ABS wire harness inward -arrow C- . See Fig. 350.
Microsoft
Fig. 351: Sticking rubber sleeve together

7. Cut through the rubber sleeve -a- and insert the HBA line -arrow B- . Stick the rubber sleeve together at the
cut edge -a- using a commercially available PUR adhesive and seal. See Fig. 351.
8. Fit rubber sleeve -arrow C- . See Fig. 351.
present.

Microsoft
Fig. 352: Crimping lines

9. Crimp lines in area around -a- . See Fig. 352.
NR.155-1.
10. Secure the repaired area -a- to the neighboring wire harnesses using fabric tape. See Fig. 352.
SUBSEQUENT WORK
Microsoft
Subsequent work on front ABS wire harness
Models) .
2. Install front wheel housing liner (rear section). Refer to 50 56 19 Removing and installing front wheel
Subsequent work on rear ABS wire harness
2. Install rear wheel housing liner. Refer to 53 69 19 Removing and installing rear wheel housing liner - as of
97 65 55 REPLACING WIRE HARNESS FOR ANTI-LOCK BRAKE SYSTEM

(ABS) - AS OF MY 2005 (BOXSTER, BOXSTER RHD, BOXSTER S,
BOXSTER S RHD)
TOOLS

PRELIMINARY WORK
Preliminary work on front ABS wire harness
(All Models) .
2. Remove front wheel housing liner (rear section). Refer to 50 56 19 Removing and installing front wheel
Models) .
Preliminary work on rear ABS wire harness
Microsoft
(All Models) .
2. Remove rear wheel housing liner. Refer to 53 69 19 Removing and installing rear wheel housing liner - as
3. Remove convertible top and water drip pan. Refer to 61 01 19 Removing and installing convertible top - as
REMOVING WIRE HARNESS FOR ANTI-LOCK BRAKE SYSTEM (ABS)
Removing front ABS wire harness
Fig. 353: Installation position for front ABS wire harness

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Fig. 354: Disconnecting plug connection for front wheel sensor

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4. Open the clips -arrows B- and remove the ABS wire harness -arrow C- . See Fig. 355.
5. Remove the fabric tape -D- . See Fig. 355.
NOTE: When cutting the ABS wire harness, make sure that there is enough line length
left to join to the new lines.
6. Cut off the ABS wire harness around -E- and remove it. See Fig. 355.
Microsoft
Fig. 356: Exposing ABS wire harness

7. Cut through the fabric tape in the plenum panel, in the area around -a- , and expose the remaining ABS lines.
See Fig. 356.
Removing rear ABS wire harness
Microsoft
Fig. 357: Installation position for rear ABS wire harness

Fig. 358: Disconnecting plug connection for rear wheel sensor

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4. Open clip -arrow B- and remove ABS wire harness. See Fig. 359.
NOTE: When cutting the ABS wire harness make sure there is enough line length left in
the interior to join to the new lines.
5. Cut off the ABS wire harness around -d- and press downward with the rubber sleeve -arrow C- . See Fig.
359.
6. Cut through the fabric tape at -e- and expose remaining ABS lines. See Fig. 359.
Microsoft
Fig. 360: Cutting off rubber sleeve

7. Cut through the rubber sleeve at the side of the HBA line -a- and remove the HBA line -arrow B- . See Fig.
360.
INSTALLING WIRE HARNESS FOR ANTI-LOCK BRAKE SYSTEM (ABS)
Installing front ABS wire harness
Microsoft
Fig. 361: Connecting plug connection for front wheel sensor

Microsoft

4. Press the ABS wire harness into the supports by pressing on the rubber sleeves -arrows A- . See Fig. 362.
5. Secure line for headlight levelling system to the ABS wire harness using fabric tape -B- . See Fig. 362.
6. Place ABS wire harness in installation position -arrows C- and close clip -arrows D- . See Fig. 362.
Microsoft
Fig. 363: Routing and connecting ABS wire harness

7. Push through ABS wire harness to plenum panel -arrow- . See Fig. 363.
present.
highest demands.
Microsoft

8. Crimp lines in area around -b- . See Fig. 363.
NR.155-1.
9. Secure the repaired area to the neighboring wire harnesses using tie-wraps -c- . See Fig. 363.
Installing rear ABS wire harness
Microsoft
Fig. 364: Connecting plug connection for rear wheel sensor

Microsoft

4. Press the ABS wire harness into the supports on the spring strut by pressing on the rubber sleeves -arrows A-
. See Fig. 365.
5. Insert ABS wire harness into clip and close clip -arrow B- . See Fig. 365.
6. Push the ABS wire harness inward -arrow C- . See Fig. 365.
Microsoft
Fig. 366: Sticking rubber sleeve together

7. Cut through the rubber sleeve -a- and insert the HBA line -arrow B- . Stick the rubber sleeve together at the
cut edge -a- using a commercially available PUR adhesive and seal. See Fig. 366.
8. Fit rubber sleeve -arrow C- . See Fig. 366.
present.

Microsoft
Fig. 367: Crimping lines

9. Crimp lines in area around -a- . See Fig. 367.
NR.155-1.
10. Secure the repaired area -a- to the neighboring wire harnesses using fabric tape. See Fig. 367.
SUBSEQUENT WORK
Microsoft
Subsequent work on front ABS wire harness
Models) .
2. Install front wheel housing liner (rear section). Refer to 50 56 19 Removing and installing front wheel
Subsequent work on rear ABS wire harness
1. Install convertible top and water drip pan. Refer to 61 01 19 Removing and installing convertible top - as
2. Install rear wheel housing liner. Refer to 53 69 19 Removing and installing rear wheel housing liner - as of
97 66 23 INSTALLING WIRE HARNESS FOR AIRBAG - AS OF MY 2005 (ALL

MODELS)
TOOLS

press-out and unlocking commercially NR.155
tools for flat and round available tool
plug connections of all
sizes
PRELIMINARY WORK
Preliminary work for wire harness for passenger's airbag unit

2. Remove cover of console at the left and right. Refer to 68 14 19 Removing and installing center console
cover - as of MY 2005 (All Models) .
Microsoft
Models) .

2005 (All Models) .
Preliminary work for wire harness for left seat-belt tensioner

Models) .
7. Remove front side section trim. Refer to 70 24 19 Removing and installing front side section trim - as of
8. Remove front seat. Refer to 72 01 19 REMOVING AND INSTALLING FRONT SEAT - AS OF MY

2005 (ALL RHD MODELS) or 72 01 19 REMOVING AND INSTALLING FRONT SEAT - AS OF MY
2005 (ALL LHD MODELS) .
9. Remove the rear side-panel lining. Refer to 70 75 19 Removing and installing side trim panel - as of MY
10. Remove sill. Refer to 68 05 19 Removing and installing inner door sill trim - as of MY 2005 (All
Models) .
11. Remove sill support. Refer to 69 51 19 Removing and installing airbag sensor - as of MY 2005 (All
Models) .
Preliminary work for wire harness for left head airbag (triggering unit to A-pillar connection point)
Microsoft

Models) .
Preliminary work for wire harness for right head airbag (triggering unit to A-pillar connection point)

Models) .

2005 (All Models) .
Preliminary work for head airbag wire harness (head airbag to A-pillar connection point)
Microsoft
Models) .
TOOLS AND MATERIALS
Tools
Fig. 368: Wire puller

Commercially available tool for pulling electric wires through.
INSTALLING WIRE HARNESS FOR AIRBAG
Installing components for airbag from triggering unit to passenger's airbag unit or seat-belt tensioner
WARNING: Danger of injury and material damage if airbag units are not handled
correctly.
--> Always observe the safety regulations for handling airbag units. Refer to 69 AW SAFETY
REGULATIONS FOR AIRBAG AND BELT TENSIONER UNITS - AS OF MY 2005 (ALL MODELS) .
--> Remove ignition key. Disconnect battery. Route or isolate the ground strap so that all contact with a ground
Microsoft
Fig. 369: Connector overview for airbag wire harness, shown on the 911
1-2 - Connectors for stage 1 and stage 2 of passenger's airbag unit
7-8 - Connector for seat-belt tensioner, left and right
9 - Rubber sleeve
10 - Connector for airbag triggering unit
1. Release connector on triggering unit for airbag -10- and fold open the locking lever. Refer to 69 53 19
Removing and installing triggering unit for airbag - as of MY 2005 (All Models) . See Fig. 369.
2. Remove connector from the relevant component.
2.1. Connectors for stage 1 and stage 2 of passenger's airbag unit -1 and 2- See Fig. 369.
Release and remove connectors for stage 1 and stage 2 of passenger's airbag unit Refer to 69 59 19 Removing
and installing passenger's airbag unit - as of MY 2005 (All Models) .
2.2. Connector for seat-belt tensioner, left -7- and right -8- See Fig. 369.
Microsoft
Release and remove connector on seat-belt tensioner. --> 69 11 19 REMOVING AND INSTALLING
FRONT THREE-POINT BELT - AS OF MY 2006 (CAYMAN S, CAYMAN S RHD) .
Remove rubber sleeves -9- . See Fig. 369.
2.3. Cut off the connector of the damaged wire harness, isolate it and secure it to the main wire harness with tie-
wraps.
Fig. 370: Levering out seal from connector housing

3. Using a small screwdriver, lever the seal out of the connector housing.
Microsoft
Fig. 371: Removing tie-wrap at connector housing

4. Cut and remove tie-wrap for fixing the wire harness to the connector housing.
Microsoft
Fig. 372: Removing connector housing from connector

5. Release connector housing with a small screwdriver, lift upwards and remove from connector.
Fig. 373: Removing connector guide from connector

6. Lift connector guide and remove from connector.
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Fig. 374: Pressing out the contacts

NOTE: Allocation of lines - see wiring diagram.
7. Release contact of the damaged line using the press-out tool 1575-1P of the press-out and unlocking tools
for flat and round plug connections of all sizes NR.155 -Arrow a- and pull out of the contact strip. See Fig.
374.
8. Push connector of the new wire harness on the relevant component until it is felt to engage.
8.1. Connectors for stage 1 and stage 2 of passenger's airbag unit -1 and 2- See Fig. 369.
Push on connectors for stage 1 and stage 2 of passenger's airbag unit until they are felt to engage. Refer to 69 59
19 Removing and installing passenger's airbag unit - as of MY 2005 (All Models) .
8.2. Connector for seat-belt tensioner, left -7- and right -8- See Fig. 369.
Push on connector for the seat-belt tensioner until it is felt to engage. --> 69 11 19 REMOVING AND
INSTALLING FRONT THREE-POINT BELT - AS OF MY 2006 (CAYMAN S, CAYMAN S RHD) .
Fit rubber sleeve -9- . See Fig. 369.
Microsoft
Fig. 375: Securing wire harness to the main wire harness

9. Route the new wire harness along the main wire harness, guide it through existing cable ducts and tie it to the
main wire harness using tie-wraps.
Microsoft
Fig. 376: Pressing in the contacts

10. Plug new line into the contact strip until the contact is felt to engage.
Microsoft
Fig. 377: Pushing connector guide onto the connector

11. Push connector guide onto the connector until it is felt to engage.
Microsoft
Fig. 378: Pushing connector housing onto the connector

12. Push connector housing onto the connector
12.1. Before fitting the connector housing, check for signs of damage, and replace if necessary. Airbag warning
light activated: seal in plug connection of triggering unit defective . Manufacturer does not provide specific
instructions.
12.2. Push connector housing onto the connector until it is felt to engage.
Fig. 379: Fitting tie-wrap at connector housing

13. Fasten wire harness with a new tie-wrap -arrow- to the connector housing. See Fig. 379.
Microsoft
Fig. 380: Inserting seal of connector housing

14. Insert seal into the connector.
14.1. Before inserting the seal, check for signs of damage, and replace if necessary. Airbag warning light
activated: seal in plug connection of triggering unit defective . Manufacturer does not provide specific
instructions.
14.2. Insert seal into the connector and press down as far as it will go. Check seal is seated properly.
15. Push on connector of triggering unit for airbag -10- until it is felt to engage, and lock it. Refer to 69 53 19
Removing and installing triggering unit for airbag - as of MY 2005 (All Models) . See Fig. 369.
Installing wire harness for airbag from the A-pillar connection point to the head airbag
WARNING: Danger of injury and material damage if airbag units are not handled
correctly.
--> Always observe the safety regulations for handling airbag units. Refer to 69 AW SAFETY
REGULATIONS FOR AIRBAG AND BELT TENSIONER UNITS - AS OF MY 2005 (ALL MODELS) .
--> Remove ignition key. Disconnect battery. Route or isolate the ground strap so that all contact with a ground
Microsoft
Fig. 381: Connector overview for airbag wire harness, shown on the 911
3-4 - Plug connections between main wire harness and wire harness for left and right doors
5-6 - Connector for head airbag, left and right
1. Release and disconnect plug connection for main wire harness to door wire harness -3 and 4- . --> 973219
Removing and installing wire harness for door - section on "Removing"See Fig. 381.
2. Release and pull off connector on head airbag on the left -5- and right -6- . Refer to 69 66 19 Removing and
installing the head airbag unit - as of MY 2005 (All Models) . See Fig. 381.
3. Cut off the head airbag connector on the damaged wire harness, insulate it and secure it to the door wire
harness with tie-wraps.
Microsoft

4. Remove rubber sleeve -A- and carefully pull it and the door wire harness out of the A-pillar. See Fig. 382.
Fig. 383: Removing foil hose

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5. Push rubber sleeve back slightly -Arrow- , remove adhesive tape and pull off foil hose -A- . See Fig. 383.
Fig. 384: Removing cap from connector housing.

6. Cut and remove tie-wraps for fixing the wire harness to the connector housing.
7. Release cap on both sides -Arrow a- and remove from the connector housing. See Fig. 384.
Microsoft
Fig. 385: Removing connector from connector housing

8. Release locking mechanism on connector housing with a small screwdriver -Arrow A- and remove it -
9. Pull connector out of the connector housing -Arrow C- . See Fig. 385.
Microsoft
Fig. 386: Pushing down connector guide from the contact strip
10. Release connector guide on both sides -Arrow a- and slide down from the contact strip. See Fig. 386.
Microsoft
Fig. 387: Pressing out contacts from the contact strip

11. Release contacts of the damaged lines using the press-out tool 1575-1P of the press-out and unlocking
tools for flat and round plug connections of every size NR.155 ( -Arrow a- ) and pull out of the contact strip.
See Fig. 387.
12. Cut off the contacts of the damaged lines, insulate them and secure them to the main wire harness with tie-
wraps.
Fig. 388: Sliding wire puller through the sleeve

13. Insert wire puller -1- with the flexible end on the right side -Arrow- into the rubber sleeve -2- . Coat the
wire puller -1- with soapy water and slide it through the rubber sleeve -2- ( Fig. 388 -Arrow A- ). --> 976623
Installing wire harness for airbag - section on "Tools and materials"See Fig. 388.
Microsoft
Fig. 389: Securing new lines on the wire puller

Microsoft
Fig. 390: Wire harness spare part

NOTE: Two different wire harnesses are available as spare parts, depending on the
model year. Up to model year 05, the wire harness -A- comes with insulation as
standard. From model year 2006 onwards, the wire harness -B- no longer has
this insulation. See Fig. 390.
NOTE: Observe wrapping direction of adhesive tape! To keep the resistance as low as
possible when pulling the new wire harness through, always start wrapping the
tape around at the new wire harness and end at the wire puller.
14. Push new lines -2- through the eye in the back of the wire puller -1- ( -Arrow A- ), fold them over and
secure with adhesive tape -3- ( -Arrow B- ). See Fig. 389.
Microsoft
Fig. 391: Pulling new wire harness through the rubber sleeve
15. Coat the new wire harness -2- with soapy water and use the wire puller -1- to pull it through the rubber
sleeve -3- ( -Arrow A- ). Push carefully on the new wire harness at the same time to make it easier to pull the
lines through. See Fig. 391.
Microsoft
Fig. 392: Releasing new line on wire puller

16. Remove adhesive tape -3- ( -Arrow A- ) and carefully pull the lines -2- out of the eye on the wire puller -1-
( -Arrow B- ). Make sure that the insulation on the new lines is not damaged. See Fig. 392.
Microsoft
Fig. 393: Securing line for head airbag at door sub-frame

17. Route new wire harness along the door wire harness and secure at the standard attachment points on the
door sub-frame.
18. Push on connector of new wire harness for head airbag at the left -5- and right -6- until it is felt to engage.
Refer to 69 66 19 Removing and installing the head airbag unit - as of MY 2005 (All Models) . See Fig.
381.
Microsoft
Fig. 394: Pressing in contacts on the contact strip

19. Push new lines into the contact strip until the contacts are felt to engage.
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Fig. 395: Pushing connector guide onto the contact strip

20. Push connector guide onto the contact strip until it is felt to engage.
Microsoft
Fig. 396: Inserting connector into the connector housing

21. Slide connector into the connector housing -Arrow A- . See Fig. 396.
22. Insert locking mechanism into the connector housing and press in -Arrow B- until it is felt to engage. See
Fig. 396.
Microsoft
Fig. 397: Pressing cap onto the connector housing

23. Press cap onto the connector housing until it is felt to engage.
24. Secure wire harness to the connector housing with a new tie-wrap -Arrow- . See Fig. 397.
Microsoft
Fig. 398: Attaching foil hose

25. Push the rubber sleeve back slightly -Arrow- , then pull the foil hose (500 mm in length) over the door wire
harness up to the rubber sleeve and secure in this position with insulating tape. See Fig. 398.
Pull foil hose tight and wrap it tightly over its entire length from the rubber sleeve up to the connector -A- of the
door wire harness with insulating tape. See Fig. 398.
Microsoft

NOTE: Route the door wire harness carefully through the A-pillar in the vehicle interior,
so that the foil hose and the door wire harness are not damaged!
26. Push wire harness for door through the A-pillar and fit rubber sleeve -A- . Check rubber sleeve for correct
installation position. See Fig. 399.
SUBSEQUENT WORK
Subsequent work for wire harness for passenger's airbag unit

2005 (All Models) .
2. If required, install control unit for tilt sensor. Refer to 96 63 19 Removing and installing tilt sensor control
3. Connect the battery. --> 27 06 IN WORK INSTRUCTIONS AFTER DISCONNECTING THE

Models) .
Microsoft
6. Install cover of console at the left and right. Refer to 68 14 19 Removing and installing center console
Subsequent work for wire harness for left head airbag (triggering unit to A-pillar connection point)
1. Install front side section trim. Refer to 70 24 19 Removing and installing front side section trim - as of

Models) .
Subsequent work for wire harness for right head airbag (triggering unit to A-pillar connection point)

2005 (All Models) .

Models) .
Microsoft
Subsequent work for head airbag wire harness (head airbag to A-pillar connection point)
Models) .
97 67 19 REMOVING AND INSTALLING WIRE HARNESS IN REAR LID - AS

PRELIMINARY WORK
Preliminary work for wire harness in rear lid
Remove trim panel for rear lid. Refer to 70 87 19 Removing and installing trim panel for rear lid - as of MY
Remove trim panel for tailgate or trim panel for rear lid. Refer to 70 92 19 Removing and installing trim
panel for rear lid (window frame) - as of MY 2006 (Cayman S, Cayman S RHD) .
Remove lid hinge cover. Refer to 70 91 19 Removing and installing rear lid hinge trim - as of MY 2006
Remove C-pillar trim panel, left side. Refer to 70 68 19 Removing and installing C-pillar trim panel - as of
Loosen headliner in rear area. Refer to 70 84 19 Removing and installing roof lining - as of MY 2006
REMOVING WIRE HARNESS IN REAR LID
Removing wire harness in rear lid
Microsoft

A - Plug connection for auxiliary stop light
B - Plug connection for rear window washer wiper motor
C - Plug connection for rear window heater, left
D - Plug connection for rear window heater, right
E - Plug connection for luggage compartment light
F - Plug connections to main wire harness in area of C-pillar, left
2. Disconnect electric plug connection -A-E - . See Fig. 400.
Microsoft
Fig. 401: Releasing plug connections

3. In area of left C-pillar, release both electric plug connections -F- - wire harness for rear lid to main wire
harness - -A- and disconnect. See Fig. 400, Fig. 401.
Microsoft
Fig. 402: Removing wire harness on roof

4. Unclip wire harness on roof and pull to the rear out of the "inner roof" area.
Microsoft
Fig. 403: Removing wire harness from lid

5. Unclip wire harness on rear lid -A, B- , press out the rubber covers for the rear lid wire harness, pull the wire
harness out through the lid -C- and remove. See Fig. 403.
INSTALLING WIRE HARNESS IN REAR LID
Installing wire harness in rear lid
Microsoft

A - Plug connection for auxiliary stop light
B - Plug connection for rear window washer wiper motor
C - Plug connection for rear window heater, left
D - Plug connection for rear window heater, right
E - Plug connection for luggage compartment light
F - Plug connections to main wire harness
Microsoft
Fig. 405: Routing wire harness in rear lid

1. Route plug connections from the passenger compartment wire harness in the rear lid and press in the two
rubber sleeves in the rear lid.
Microsoft
Fig. 406: Positioning wire harness on rear lid and clipping in

2. Position wire harness on rear lid and clip in.
Microsoft
Fig. 407: Routing harness in roof

3. Route wire harness through the roof opening, press on the rubber sleeve, route the wire harness in the roof
and fix with two clips.
Microsoft
Fig. 408: Routing harness in C-pillar

4. Route the harness along the C-pillar and connect to the passenger compartment harness -F- . See Fig. 408.
Microsoft
Fig. 409: Overview of plug connections

5. Insert electric connectors -A - E- . See Fig. 404.
6. Electrical loads: Check operation of auxiliary stop light, rear window heating, interior light, wiper motor.
SUBSEQUENT WORK
Subsequent work for wire harness in rear lid
Install headliner in rear area. Refer to 70 84 19 Removing and installing roof lining - as of MY 2006
Install C-pillar trim panel, left side. Refer to 70 68 19 Removing and installing C-pillar trim panel - as of
Microsoft
Install lid hinge cover. Refer to 70 91 19 Removing and installing rear lid hinge trim - as of MY 2006
Remove trim panel for tailgate or trim panel for rear lid. Refer to 70 92 19 Removing and installing trim
panel for rear lid (window frame) - as of MY 2006 (Cayman S, Cayman S RHD) .
Remove rear lid trim panel. Refer to 70 87 19 Removing and installing trim panel for rear lid - as of MY
97 70 19 REMOVING AND INSTALLING WIRING HARNESS FOR NUMBER

PLATE LIGHT - AS OF MY 2005 (ALL MODELS)
PRELIMINARY WORK
Preliminary work
Remove rear spoiler. --> 63 55 19 REMOVING AND INSTALLING REAR APRON - AS OF MY 2006
(CAYMAN S, CAYMAN S RHD) .
REMOVING WIRING HARNESS FOR NUMBER PLATE LIGHT
Removing wiring harness for number plate light
Fig. 410: Overview of wiring harness for number plate light

Microsoft
Fig. 411: Removing wiring harness for number plate light from the four holders
1. Remove wiring harness for number plate light from the four holders.
Microsoft
Fig. 412: Pulling off connector for number plate light

2. Release connectors of both number plate lights -Arrow a- and pull them off. See Fig. 412.
Fig. 413: Pulling connector off a sensor for ParkAssist

3. Release connectors of the four sensors for ParkAssist -Arrow a- and pull them off. See Fig. 413.
INSTALLING WIRING HARNESS FOR NUMBER PLATE LIGHT
Installing wiring harness for number plate light
Microsoft
Fig. 414: Pushing connector onto a sensor for ParkAssist

1. Push connectors onto the four sensors for ParkAssist until they are felt to engage.
Microsoft
Fig. 415: Pushing on connector for number plate light

2. Push connectors onto both number plate lights until they are felt to engage.
Fig. 416: Inserting wiring harness for number plate light into the four holders
3. Insert wiring harness for number plate light into the four holders.
SUBSEQUENT WORK
Subsequent work
Install rear apron. --> 63 55 19 REMOVING AND INSTALLING REAR APRON - AS OF MY 2006
(CAYMAN S, CAYMAN S RHD) .
97 72 23 INSTALLING OPTICAL WAVEGUIDE - AS OF MY 2005 (ALL

MODELS)
TOOLS

press-out and unlocking special tool NR.155
tools for tab and round plug
Microsoft
connectors of all sizes
PRELIMINARY WORK
Preliminary work
NOTE: Release the main wire harness only until the damaged optical waveguide has
been released and the new optical waveguide can be attached to the main wire
harness.
Expose main wire harness. --> 970919 Removing and installing main wire harness - chapter on
"Removing" [987120 987121] --> 970919 Removing and installing main wire harness - chapter on
"Removing" [987310 987311 987320 987321]
OPTICAL WAVEGUIDE VARIANTS
Optical waveguide variants
Fig. 417: MOST control units, variant A - B - C, shown on the 911

MOST control units, variant A - B - C

Microsoft
A - Radio/PCM
B - Connection point interior/luggage compartment
C - Loudspeaker amplifier
Fig. 418: MOST control units, variant A - B - D, shown on the 911

MOST control units, variant A - B - D
A - Radio/PCM
D - CD changer
Microsoft
Fig. 419: MOST control units, variant A - B - C - D, shown on the 911

MOST control units, variant A - B - C - D
A - Radio/PCM
D - CD changer
Microsoft
Fig. 420: MOST control units, variant A - B - E, shown on the 911

MOST control units, variant A - B - E
A - Radio/PCM
E - Navigation unit
Fig. 421: MOST control units, variant A - B - C - E, shown on the 911

MOST control units, variant A - B - C - E
A - Radio/PCM
E - Navigation unit
Microsoft
Fig. 422: MOST control units, variant A - B - D - E, shown on the 911

MOST control units, variant A - B - D - E
A - Radio/PCM
D - CD changer
E - Navigation unit
Microsoft
Fig. 423: MOST control units, variant A - B C - D - E, shown on the 911

MOST control units, variant A - B - C - D - E
A - Radio/PCM
D - CD changer
E - Navigation unit
Fig. 424: MOST control units, variant A - B - C - F, shown on the 911

MOST control units, variant A - B - C - F
A - Radio/PCM
F - Telephone control module
Microsoft
Fig. 425: MOST control units, variant A - B - D - F, shown on the 911

MOST control units, variant A - B - D - F
A - Radio/PCM
D - CD changer
Microsoft
Fig. 426: MOST control units, variant A - B - E - F, shown on the 911

MOST control units, variant A - B - E - F
A - Radio/PCM
E - Navigation unit
INSTALLING OPTICAL WAVEGUIDE
Disconnecting optical waveguide
NOTE: Observe the general information on optical waveguides. --> 97 72 IN Optical

waveguide (LWL) - MOST bus - as of MY 2005 (All Models).
Risk of destruction when removing electric components with the ignition on.
1.
Microsoft
Fig. 427: Disconnecting connector for optical waveguide

2. Release the connectors of the damaged optical waveguides on the affected components -Arrow a- and
disconnect them. The illustration shows the connector on the CD changer as an example. See Fig. 427.
3. Cut off the connector of the damaged optical waveguide, isolate it and tie it to the main wire harness.
Removing and installing optical contacts on connector side
Fig. 428: Unlocking secondary locking of the optical contacts (connector side)
1. Open the secondary locking mechanism using the press-out and unlocking tools for tab and round plug
connectors of all sizes NR.155. Insert the tool in the opening provided and lift the locking mechanism. The
locking mechanism engages in the upper position.
Fig. 429: Unlocking primary locking of the optical contacts (connector side)
2. Position the press-out and unlocking tools for tab and round plug connectors of all sizes NR.155 on the
primary locking mechanism and lift the locking mechanism.
A - Optical contact, grey
B - Optical contact, black
3. Carefully pull on the optical waveguide -A and B- in -direction of arrow- . If it is not possible to pull out
the optical waveguide, check again if the secondary locking mechanism is completely released and if the
primary locking mechanism is raised sufficiently. See Fig. 429.
Microsoft
Perform visual inspection of locking mechanisms, connector housings and contacts for possible damage, and
exchange the damaged parts, if necessary.
Installing optical contacts on connector side
Remove the dust boot right before plugging.
Check the proper condition of the contacts.
Fig. 430: Locking primary locking of the optical contacts (connector side)
1. Insert the optical contact -A and B- in the connector until it engages audibly. See Fig. 430.
Fig. 431: Locking secondary locking of the optical contacts (connector side)
2. Lock the secondary locking and check the optical contacts for tightness.
Removing and installing optical contacts on socket side
Microsoft
Fig. 432: Unlocking spring cap of the optical contacts (on the socket side)
1. Release the spring cap on both sides using the press-out and unlocking tools for tab and round plug
connectors of all sizes NR.155 and remove it.
2. Remove optical waveguide module from connector.
Fig. 433: Unlocking contact locking of the optical contacts (on the socket side)
3. Position the press-out and unlocking tools for flat-type and round plug connectors of all sizes NR.155
for releasing the contact locking mechanism of the optical waveguide module and lift up the locking
mechanism.
the optical waveguide, check again if the locking mechanism is completely released. See Fig. 433.
Installing optical contacts on socket side
Check the proper condition of the contact.
Microsoft
At a force of 10 N (7.5 lb.) the springs installed in the connection point will be compressed. This leads to an
increase in attenuation, which could lead to system impairment and system failure. Therefore a maximum force
of 10 N (7.5 lb.) may be used to pull on optical waveguides at connection points.
Fig. 434: Locking contact locking of the optical contacts (on the socket side)
1. Insert optical contact -B- into the optical waveguide module until it is felt to engage, and check the optical
contact is seated securely. See Fig. 434.
2. Insert optical waveguide module into the connection point on the socket side.
Fig. 435: Locking spring cap of the optical contacts (on the socket side)
Microsoft
3. Slide the spring cap on the connection point until it can be felt to engage -arrow- . See Fig. 435.
Installing optical waveguide
NOTE: Observe the general information on optical waveguides. --> 97 72 IN Optical

waveguide (LWL) - MOST bus - as of MY 2005 (All Models).
1. Cut off the optical contacts of the damaged optical waveguide, isolate it and tie it to the main wire harness.
Fig. 436: Tying optical waveguide to main wire harness

NOTE: The range of spare parts available for optical waveguides depends on the
vehicle equipment. Depending on the vehicle equipment, there is a specific set
containing the individual optical waveguides.
Select the required optical waveguide and remove it from the set.
2. Route the new optical waveguide along the main wire harness, guide it through the existing cable ducts and
tie it to the main wire harness using tie-wraps.
Microsoft
Fig. 437: Connecting connector for optical waveguide

3. Connect the connectors for the new optical waveguide to the affected parts until the connectors are felt to
engage. The illustration shows the connector on the CD changer as an example.
5. Check operation of audio components.
SUBSEQUENT WORK
Subsequent work
Install components for releasing main wire harness. --> 970919 Removing and installing main wire harness -
chapter on "Installing" [987120 987121] --> 970919 Removing and installing main wire harness - chapter
on "Installing" [987310 987311 987320 987321]
97 72 IN OPTICAL WAVEGUIDE (LWL) - MOST BUS - AS OF MY 2005 (ALL

MODELS)
TOOLS

press-out and unlocking special tool NR.155
Microsoft
tools for tab and round plug

connectors of all sizes
OPTICAL WAVEGUIDE (LWL) - MOST BUS
Requirements when working with LWL
The plug connections must not be plugged or separated with tools.
The LWL and the plug connections must not come into contact with fluids such as water, creeping compound,
preservative, anti-freeze protection, cleaning agent. They will impair the MOST system function or cause
complete system failure. Even plug connectors with plugged-in protective caps must not come into contact with
the fluids listed.
If the optical contacts, plug connections, or sockets are not plugged in, or if there are no protective caps
installed on the plug, contact with dust and other solid materials (lubricants) must also be avoided.
The optical contacts, plug connectors, or sockets must not be cleaned.
Storage, Packing, Transport
The LWL must not be stored outside.
The LWL must be protected from direct sunlight during storage.
The LWL must be protected from high humidity during storage. Recommended storage conditions:
Temperature - between -20 °C and +40 °C, humidity - between 40% and 60%.
The LWL must be stored in a box made of cardboard, or in a plastic bag.
Force must not be applied to the stored LWL which could deform or damage it.
The LWL must be stored with the dust boot attached.
While storing, the bending radius must not be smaller than 300 mm.
LWL with damaged surfaces must be replaced.
Installing the LWL in the vehicle
The following limit values listed must not be exceeded when installing a LWL in the vehicle.
Maximum permissible tensile load: 60 N (45 ftlb.)
Microsoft
Minimum bending radius after and during installation in the vehicle: 25 mm
Maximum number of torsions: 10 torsions per m
The following points must be observed when fitting the LWL and fitting wiring harnesses containing
LWL:
Damaged LWL must not be installed.
Before installing the LWL or wiring harness with LWL in the vehicle, it must be checked if the dust boots have
been attached properly. If this is not the case, the LWL set must not be installed.
After and during the installation of LWL in the vehicle, the bending radius must not be smaller than 25 mm.
During installation of the optical waveguide into the vehicle, the optical guide must not be pulled to set the
length of the wiring harness (max. tensile load 60 N) and the optical guide must not be twisted or coiled up.
After installing the LWL in the vehicle, the twisted LWL must be straightened out.
External forces on the LWL are to be avoided when installing the LWL in the vehicle.
Repair
The defective LWL must be replaced. The LWL will not be repaired.
When exchanging the LWL, the optical contacts from the plug connection must be removed.
Push-on connector - dust boots
Dust boot for optical contacts:
If a LWL is stored, transported, or installed in a vehicle, then the dust boot must only be removed right before
the LWL is used in the connector.
When testing the LWL, the dust boot must be put back on.
The dust boots can be removed without the use of a locking mechanism.
Do not touch the exposed contact surfaces while or after removing the dust boot, as otherwise the optical
contacts could become damaged or dirty.
Dust boot for connector (wiring harness side):
If a pre-assembled wiring harness is installed, there is a dust boot on the connector for the LWL.
Microsoft
Fig. 438: Dust boot for connector (wiring harness side)

The dust boots can be removed by activating the locking mechanism -arrow- . See Fig. 438.
When testing the LWL, the dust boot must be put back on.
Do not touch the exposed contact surfaces while or after removing the dust boot, as otherwise the optical
contacts could become damaged or dirty.
Control unit plug connector (wiring harness side)
The LWL is delivered with affixed plastic contacts. These contacts are latched in the connector housing in the
case of repairs. Grey and black contacts with identical mechanical dimensions are used.
Grey contacts are used in the wiring harness >> control unit junction (optical input).
Black contacts are used in the control unit >> wiring harness junction.
Push-on connector - connection points
Fig. 439: Structure of a LWL joint

Structure of a LWL joint:
1 - Optical contact, black
2 - Optical contact, grey
3 - Joint connector side

Microsoft
4 - Joint socket side
5 - Socket side LWL module
6 - Optical contact, grey
7 - Optical contact, black
8 - Springs
9 - Spring cap
Optical fiber (LWL) - module
In all MOST control units, at least one sending diode and one receiver diode are installed. The sending diode of
a MOST device is connected to a receiver diode of a 2nd MOST device. This results in a ring where the light
signal is reinforced in each control unit (in each control unit, the light signal is transformed into an electrical
signal).
The graphic clarifies the cabling of the individual MOST control units which vary according to their equipment.
Optical waveguide variants
Fig. 440: MOST control units, variant A - B - C, shown on the 911

MOST control units, variant A - B - C

Microsoft
A - Radio/PCM
Fig. 441: MOST control units, variant A - B - D, shown on the 911

MOST control units, variant A - B - D
A - Radio/PCM
D - CD changer
Microsoft
Fig. 442: MOST control units, variant A - B - C - D, shown on the 911

MOST control units, variant A - B - C - D
A - Radio/PCM
D - CD changer
Microsoft
Fig. 443: MOST control units, variant A - B - E, shown on the 911

MOST control units, variant A - B - E
A - Radio/PCM
E - Navigation unit
Fig. 444: MOST control units, variant A - B - C - E, shown on the 911

MOST control units, variant A - B - C - E
A - Radio/PCM
E - Navigation unit
Microsoft
Fig. 445: MOST control units, variant A - B - D - E, shown on the 911

MOST control units, variant A - B - D - E
A - Radio/PCM
D - CD changer
E - Navigation unit
Microsoft
Fig. 446: MOST control units, variant A - B C - D - E, shown on the 911

MOST control units, variant A - B - C - D - E
A - Radio/PCM
D - CD changer
E - Navigation unit
Fig. 447: MOST control units, variant A - B - C - F, shown on the 911

MOST control units, variant A - B - C - F
A - Radio/PCM
Microsoft
Fig. 448: MOST control units, variant A - B - D - F, shown on the 911

MOST control units, variant A - B - D - F
A - Radio/PCM
D - CD changer
Microsoft
Fig. 449: MOST control units, variant A - B - E - F, shown on the 911

MOST control units, variant A - B - E - F
A - Radio/PCM
E - Navigation unit
Removing and installing optical contacts on connector side
Fig. 450: Unlocking secondary locking of the optical contacts (connector side)
1. Open the secondary locking mechanism using the press-out and unlocking tools for tab and round plug
connectors of all sizes NR.155. Insert the tool in the opening provided and lift the locking mechanism. The
locking mechanism engages in the upper position.
Fig. 451: Unlocking primary locking of the optical contacts (connector side)
2. Position the press-out and unlocking tools for tab and round plug connectors of all sizes NR.155 on the
primary locking mechanism and lift the locking mechanism.

Microsoft
the optical waveguide, check again if the secondary locking mechanism is completely released and if the
primary locking mechanism is raised sufficiently. See Fig. 451.
Installing optical contacts on connector side
Check the proper condition of the contacts.
Fig. 452: Locking primary locking of the optical contacts (connector side)
1. Insert the optical contact -A and B- in the connector until it engages audibly. See Fig. 452.
Fig. 453: Locking secondary locking of the optical contacts (connector side)
2. Lock the secondary locking and check the optical contacts for tightness.
Removing and installing optical contacts on socket side
Microsoft
Fig. 454: Unlocking spring cap of the optical contacts (on the socket side)
1. Release the spring cap on both sides using the press-out and unlocking tools for tab and round plug
connectors of all sizes NR.155 and remove it.
2. Remove optical waveguide module from connector.
Fig. 455: Unlocking contact locking of the optical contacts (on the socket side)
3. Position the press-out and unlocking tools for flat-type and round plug connectors of all sizes NR.155
for releasing the contact locking mechanism of the optical waveguide module and lift up the locking
mechanism.
the optical waveguide, check again if the locking mechanism is completely released. See Fig. 455.
Installing optical contacts on socket side
Check the proper condition of the contact.
Microsoft
At a force of 10 N (7.5 lb.) the springs installed in the connection point will be compressed. This leads to an
increase in attenuation, which could lead to system impairment and system failure. Therefore a maximum force
of 10 N (7.5 lb.) may be used to pull on optical waveguides at connection points.
Fig. 456: Locking contact locking of the optical contacts (on the socket side)
1. Insert optical contact -B- into the optical waveguide module until it is felt to engage, and check the optical
contact is seated securely. See Fig. 456.
2. Insert optical waveguide module into the connection point on the socket side.
Fig. 457: Locking spring cap of the optical contacts (on the socket side)
Microsoft
3. Slide the spring cap on the connection point until it can be felt to engage -arrow- . See Fig. 457.
97 83 19 REMOVING AND INSTALLING RELAY CARRIER 1 - AS OF MY 2005

(ALL MODELS)
PRELIMINARY WORK
Preliminary work for relay carrier 1
Remove front side section trim. Refer to 70 24 19 Removing and installing front side section trim - as of MY
2005 (All Models) .
Remove trim panel under dashboard on driver's side. Refer to 70 19 19 Removing and installing trim under
REMOVING RELAY CARRIER 1
Removing relay carrier 1 from the retaining frame

A - Relay carrier 1
Microsoft
Fig. 459: Removing relay carrier

1. -A- Pull apart both retaining lugs on relay carrier support and press the relay carrier upward. See Fig. 459.
2. -B- Press relay carrier upward approx. 45° on the right side. See Fig. 459.
Microsoft
Fig. 460: Pulling relay carrier out of the retaining frame

3. -C- Pull out the support lugs of the relay carrier from the support and -D- pull out the relay carrier downward.
See Fig. 460.
INSTALLING RELAY CARRIER 1
Installing relay carrier 1 in the retaining frame
Microsoft
Fig. 461: Pushing and engaging the relay carrier into its retaining frame
1. Slide in the relay carrier from below at approx. 45° slant into the support.
2. Secure the support lugs from the relay carrier into the support and engage the relay carrier in the support.
SUBSEQUENT WORK
Subsequent work on relay carrier 1
Install trim under dashboard on driver's side. Refer to 70 19 19 Removing and installing trim under
Microsoft
Install front side section trim. Refer to 70 24 19 Removing and installing front side section trim - as of MY
2005 (All Models) .
97 84 09 UNDOING AND SECURING FUSE BOX - AS OF MY 2005 (ALL

MODELS)
PRELIMINARY WORK
Preliminary work for fusebox
Remove front left side section trim. Refer to 70 24 19 Removing and installing front side section trim - as of
UNDOING FUSE BOX
Undoing fusebox

C - Fusebox
Microsoft

1. Releasing and unplugging electric plug connection
Microsoft
Fig. 464: Unscrewing fastening nuts

2. Unscrew the fastening nuts -1- , pull the fusebox forward and disengage it from the support. See Fig. 464.
SECURING FUSE BOX
Securing fusebox
Microsoft
Fig. 465: Tightening the fastening nut

1. Engage the fusebox on the support and secure with the fastening nut -1- . Ensure that the electrical lines are
not trapped or installed live. --> Tightening torque: 9.7 (7 ftlb.) Nm See Fig. 465.
Microsoft
Fig. 466: Connecting electrical connectors

2. Insert the electrical connectors until they perceptibly engage.
SUBSEQUENT WORK
Subsequent work on fusebox
Install front left side section trim. Refer to 70 24 19 Removing and installing front side section trim - as of
97 89 19 REMOVING AND INSTALLING POWER DISTRIBUTOR - AS OF MY

2005 (ALL MODELS)
Microsoft
PRELIMINARY WORK
Preliminary work for power distributor
Disconnect and cover the ground terminal on the battery. --> 27 06 IN WORK INSTRUCTIONS AFTER
REMOVING POWER DISTRIBUTOR
Removing power distributor

Microsoft
Fig. 468: Releasing locking mechanism of the B+ line

2. Release the locking mechanism of the B+ line -A- and pull off the B+ connection from the power distributor -
B- . See Fig. 468.
3. Unscrew the two fastening nuts -2- . See Fig. 468.
Microsoft

4. Unscrew both plastic screws -1- for the cover in the passenger's footwell and remove the cover downwards.
See Fig. 469.
Microsoft
Fig. 470: Disengage the power distributor and pull it down and out.
5. Pull the power distributor away from the firewall and lower it down into the passenger's footwell.
NOTE: If a new power distributor needs to be installed or a fuse element replaced, then
a new cover for the fuse elements (blue) and a new seal label (red) must be
fitted. The spare parts are summarized in the PET as a package.
6. Disengage the lock and fold the cover open. Pull off the original seal label -arrow- . See Fig. 470.
Microsoft
Fig. 471: Unclipping cover with a screwdriver

7. Unclip the cover for the fuse elements with a screwdriver.
Microsoft
Fig. 472: Unscrewing fastening nuts and removing fuse element

8. Mark the connection leads to the relevant fuse element.
9. Unscrew the fastening nuts -1- , remove the washer -2- and take out the fuse element -3- . See Fig. 472.
10. Unscrew fastening nut for the B+ line and remove the power distributor.
INSTALLING POWER DISTRIBUTOR
Installing the current distributor
Microsoft
Fig. 473: Tightening a fuse element

1. Position the fuse elements -3- in the power distributor in accordance with the wiring diagram and position the
marked connection leads in turn, fit the washer -2- and tighten with the fastening nuts -1- . --> Tightening
torque: 6 ftlb. --> Tightening torque: 11 ftlb. See Fig. 473.
2. Position the B+ line on the power distributor and tighten with the fastening screws. --> Tightening torque:
11 ftlb.
NOTE: If a new power distributor needs to be installed or a fuse element replaced, then
a new cover for the fuse elements (blue) and a new seal label (red) must be
fitted. The spare parts are summarized in the PET as a package.
Microsoft

3. Insert the blue cover in power distributor and clip in place.
Microsoft
Fig. 475: Closing the power distributor and pushing upwards

4. Close the power distributor until the lid is felt to engage and seal with the red seal label.
5. Check the plastic seal on the power distributor for damage; replace it if in doubt.
6. Slide the power distributor upwards between the heater/air-conditioning unit and the bulkhead, and engage in
the bulkhead.
Microsoft
Fig. 476: Screwing down the power distributor

7. Screw down power distributor with the two fastening screws -2- . --> Tightening torque: 11 ftlb. See Fig.
476.
8. Push the B+ of the battery onto the mounting point as far as the stop. Check that the B+ line sits firmly.
SUBSEQUENT WORK
Subsequent work for power distributor
Connect the battery and carry out "Work instructions after disconnecting the battery". --> 27 06 IN WORK
Microsoft
97 90 19 REMOVING AND INSTALLING RELAY CARRIER - AS OF MY 2005

REMOVING RELAY CARRIER
Removing relay carrier
Fig. 477: Opening fastening clips

1. Open luggage-compartment lid, turn the two fixing clips at the side by 90° and fold down the luggage
compartment cover.
Microsoft
Fig. 478: Pulling relay carrier forward

2. Pull relay carrier forward on the two supports.
Microsoft
Fig. 479: Removing relay carrier from retaining frame.

3. Release retaining frame on left and right sides respectively and lift the relay carrier up and out.
INSTALLING RELAY CARRIER
Installing relay carrier
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Fig. 480: Clipping into retaining frames

1. Clip relay carrier into the left and right retaining frames.
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Fig. 481: Installing relay carrier

2. Engage the two retaining frames together with relay carrier and push back.
3. Position the luggage compartment cover and clip in place with the fixing clips.
97 90 19 REMOVING AND INSTALLING RELAY CARRIER - AS OF MY 2006

PRELIMINARY WORK
Preliminary work for relay carrier
Remove trim panel of rear luggage compartment at the left. Refer to 70 06 19 Removing and installing rear
luggage compartment trim (carpet lining) - as of MY 2006 (Cayman S, Cayman S RHD) .
REMOVING RELAY CARRIER
Removing relay carrier
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Fig. 482: Installation position of relay carrier

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Fig. 483: Removing relay carrier from retaining frame.

1. Release relay carrier at retaining frame on both left and right side and remove the relay carrier from the
bracket.
INSTALLING RELAY CARRIER
Installing relay carrier
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Fig. 484: Clipping into retaining frame

1. Clip relay carrier into the retaining frame at the left and right.
SUBSEQUENT WORK
Subsequent work for relay carrier
Install trim panel of rear luggage compartment at the left. Refer to 70 06 19 Removing and installing rear
97 92 55 REPLACING FUSE ELEMENT - AS OF MY 2005 (ALL MODELS)

PRELIMINARY WORK
Preliminary work for fuse element
Remove and open power distributor. --> 978919 Removing and installing power distributor - section on
"Removing"
REPLACING FUSE ELEMENT
Replacing fuse element
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NOTE: If a fuse element needs to be replaced, you must also fit a new cover for the
fuse elements (blue) and a new seal label (red). The spare parts are grouped
together as one package in the PET.
Fig. 485: Unclipping cover with a screwdriver

1. Unclip the cover for the fuse elements with a screwdriver.
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Fig. 486: Unscrewing fastening nuts and removing fuse element

2. Unscrew the fastening nuts on the faulty fuse element -1- , remove the washer -2- and take out the fuse
element -3- . See Fig. 486.
NOTE: If a fuse element needs to be replaced, you must also fit a new cover for the
fuse elements (blue) and a new seal label (red). The spare parts are grouped
together as one package in the PET.
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Fig. 487: Tightening a fuse element

3. Place the fuse element -3- into position, fit the washer -2- and secure with the fastening nuts -1- . -->
Tightening torque: M6>> 8 (6 ftlb.) Nm --> Tightening torque: M8 >> 15 (11 ftlb.) Nm See Fig. 487.
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4. Insert the blue cover in power distributor and clip in place.
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Fig. 489: Closing the power distributor and pushing upwards

5. Close the power distributor until the lid is felt to engage and seal with the red seal label.
SUBSEQUENT WORK
Subsequent work for fuse element
Install power distributor. --> 978919 Removing and installing power distributor - section on "Installing"
97 97 IN CONNECTOR - GENERAL INFORMATION - AS OF MY 2005 (ALL

MODELS)
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TOOLS

Repair kit for harnesses commercially NR.155-1
available tool
CONNECTOR - GENERAL INFORMATION
NOTE: For repairing wire harnesses, the wire harnesses listed in step 1 are only
offered as complete units, without exchanging individual connectors.
For repairing or replacing connectors on wire harnesses which do not have to

be completely replaced, the correct procedure is listed under Step 2 and 3.
1. Wire harnesses which are replaced only as a complete unit.
1.1. Wire harness for door and wire harness for door trim panel --> 973219 Removing and installing wiring
harness for door
1.2. Wire harness for center console --> 972019 Removing and installing wire harness for center console
1.3. Wire harness for number plate light --> 977019 Removing and installing wire harness for number plate
light
1.4. Wire harness for glove compartment Refer to 96 07 19 Removing and installing contact switch for glove
compartment light - as of MY 2005 (All Models) .
1.5. Wire harness for engine --> 975219 Removing and installing wire harness for engine
1.6. Wire harness for battery wiring --> 974519 Removing and installing wire harness for starter battery
1.7. Antenna leads Refer to 91 28 55 Replacing the antenna leads - as of MY 2005 (All Models) .
NOTE: Only in the coupe.
1.8. Wire harness for rear spoiler --> 976719 Removing and installing wire harness for rear spoiler [987120
987121].
2. Connectors contained in the Repair kit for harnesses NR.155-1 and can be replaced individually.
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WARNING: Danger of material damage by using plug-in contacts made of different

materials.
 Using plug-in contacts made of different materials can lead to

oxidation of the plug-in contacts.
--> Only use the plug-in contacts listed in the wiring diagram for the corresponding plug connection. Make sure
that gold contacts are always plugged together with gold contacts, for example.
--> The wiring diagrams can be displayed with the PIWIS tester P 9718.
For repairing wire harnesses individual connectors are offered in a Repair kit for harnesses NR.155-1. In this
Repair kit for harnesses NR.155-1, connectors are contained primarily that are installed in crash and external
areas.
The Repair kit for harnesses NR.155-1 contains detailed descriptions about removing and installing individual
plug-in contacts.
3. Connectors not contained in the Repair kit for harnesses NR.155-1.
Connectors not contained in the Repair kit for harnesses NR.155-1 can be ordered from the CARTOOL
company.
The order must contain the following specifications.
NOTE: Ordering connectors refers to the model Boxster as of model year 97 and
Cayman as of model year 06 .
3.1. Version 1 for identifying the required connector:
3.1.1. Legible specifications of the manufacturer on the connector, e. g., complete item number, number of pins,
housing color, and whether pin or socket housing.
3.1.2. If the data mentioned in Version 1 is not legible, is incomplete, or not present, Version 2 is also possible
for ordering.
3.2.1. Vehicle type
3.2.2. Model year
3.2.3. PORSCHE part number from the parts catalogue
3.2.4. Which wire harness (e. g. main wire harness, wire harness for engine, etc.)
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3.2.5. Specifications from the wiring diagram
a) Page number
b) Field
c) Component (for components with multiple connectors e. g. instrument cluster, please specify connector 1, 2,
3 etc.)
d) Connection point (e. g. X11, X12 etc.)
3.3.1. Call up corresponding wiring diagram in PIWIS tester P 9718.
3.3.2. Click on one of the plug-in contacts of the required connector with the mouse.
NOTE: The specifications displayed are subject to a constant updating process. For
this reason, it can happen that specifications are incomplete or not available. If
this is the case, use one of the other versions for ordering connectors if
possible.
3.3.3. Note all displayed specifications for this connector and specify when ordering the connector.
3.4. If the data listed under Version 1 to Version 3 is included and complete, the CARTOOL company can
identify the correct connector.
3.5. Ordering address:
CARTOOL company, GmbH
Strauenlettenstr. 15
85053 Ingolstadt
Tel. (0841) 96 500-70 (in Germany)
Tel. (0841) 96 500-80 (outside of Germany)
Fax (0841) 96 500-90
PROCEDURE FOR RELEASING CONNECTORS THAT ARE DIFFICULT TO MOVE
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Fig. 490: Pulling connector off lid-release motor from rear

1. Pull connector off lid-release motor.
1.1. Release connector on motor for lid-release with suitable auxiliary materials (e. g.. angled piece of wire with
diameter of approx. 1mm) -a- -arrow A- and pull off -arrow B- . See Fig. 490.
Engage wire at the release. Pulling on the wire in direction of arrow releases the connector and can be pulled
off.
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Fig. 491: Releasing connector for seat-belt tensioner

2. Pull off connector on seat belt tensioner.
2.1. Release connector -2- on seat-belt tensioner with a screw driver in -direction of arrow- . See Fig. 491.
2.2. Pull off connector on seat belt tensioner.
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Fig. 492: Pulling off connector on headlight

3. Pull off connector on headlight.
3.1. Pull securing clip completely down and out -arrow A- . See Fig. 492.
3.2. Pull off connector on headlight -arrow B- . See Fig. 492.
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Fig. 493: Pulling connector off sensor for fuel level

4. Pull connector off sensor for fuel level.
4.1. Release connector completely on fuel level sensor -arrow A- and pull it off -arrow B- . See Fig. 493.
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BRAKES Anti-Lock Brake System (ABS)
BRAKES
Anti-Lock Brake System (ABS)
45 01 01 PSM/ABS CHECK USING THE PIWIS TESTER - AS OF MY 2005

(ALL MODELS)
TOOLS

TEST OVERVIEW
Test overview
NOTE:  PSM is installed as standard.

 PSM comprises the functions ABS (anti-lock braking system), ABD
(automatic brake differential), ASR (anti-slip regulation), EDTC (engine
drag torque control), EBD (electronic brake-force distribution) and vehicle
dynamic control.
The ABS/PSM test includes:
 Reading out fault memory.

 Static test.
 Swap testing hydraulics in the Checks/Tests menu. The swap test is menu-driven. Once you start the test,
follow the instructions on the PIWIS Tester.
 Checking function and correct allocation of speed sensor in the Actual values menu. Turn all four wheels
individually during the test. The speed assigned to the wheel in question must be displayed when you turn
the wheel. The non-tested wheel must be held (by a second person) when the test is performed on the
driven axle.
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Fig. 1: Hydraulic unit

Procedure: If work has been done on the hydraulic unit -D- , the speed sensors and the wire harness or if the
hydraulic unit -D- is replaced, an ABS/PSM test (system check) must be performed using the PIWIS Tester!
This is the case, for example, after accident repairs! This prevents any confusion of electrical or hydraulic lines
and ensures faultless operation of the system! See Fig. 1.
If certain brake lines are replaced, e. g. at the intermediate piece in the front left wheel housing -E- , a swap test
must also be performed (in the Checks/Tests menu)! Unintentional bending of the brake lines could lead to
incorrect hydraulic allocation despite the markings (FL = front left, FR = front right, RL = rear left, RR = rear
right)! See Fig. 1.
If a fault is displayed during operation (when no assembly work was carried out beforehand), diagnosis and
fault finding are also carried out using the PIWIS Tester! To do this, select the PSM system and read out the
fault memory there! The fault can then be located using the appropriate menus (Drive links, Actual values,
Checks/Tests)!
PSM check using the PIWIS Tester
1. PIWIS Tester P 9718 must be connected to the vehicle, then start it. Switch on ignition and press >> to
continue.
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Fig. 2: Diagnostic socket

The PIWIS Tester 9718 is connected to the vehicle via a diagnostic socket. The diagnosis socket is located
inside the vehicle in the vicinity of the driver's A-pillar below the instrument panel.
2. Select the vehicle type and call up the PSM system.
3. Carry out ABS/PSM test (see Test overview).
45 30 19 REMOVING AND INSTALLING HYDRAULIC UNIT - AS OF MY 2005

(ALL MODELS)
INFORMATION
Information
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Fig. 3: Luggage compartment cover

The brake components (brake booster, brake master cylinder, hydraulic unit) are installed under the luggage
compartment cover -2- . See Fig. 3.
Fig. 4: Brake components

Remove hydraulic unit -D- together with the support and the four brake lines, which are fitted on the
intermediate piece -E- . See Fig. 4.
A - Brake fluid reservoir
B - Brake master cylinder
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C - Brake booster
D - Hydraulic unit
E - Intermediate piece
PRELIMINARY WORK
Preliminary work
1. Remove cover over hydraulic unit (front luggage compartment cover) Refer to 70 30 19 Removing and
installing front luggage compartment cover - as of MY 2005 (All Models) . Refer to 70 30 19 Removing
and installing rear luggage compartment cover - as of MY 2006 (Cayman S, Cayman S RHD) .

There are two types of luggage compartment covers -1- (drawings below). See Fig. 5.
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REMOVING HYDRAULIC UNIT
Removing hydraulic unit

1. Remove hydraulic unit -D- . See Fig. 7.
1.1. Hold down brake pedal with pedal holder so that the brake fluid (in the reservoir) does not drain
completely.
1.2. Loosen the brake lines -1- on the brake master cylinder. See Fig. 7.
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1.3. Loosen the brake lines -2- from the hydraulic unit -D- on the intermediate piece -E- . See Fig. 7.
1.4. Close the brake lines and connections with suitable plugs.
1.5. Release control unit connector on the hydraulic unit and pull it off. Cover the plug connection and
connector (to shield them from brake fluid or water).
1.6. Loosen support on hydraulic unit -Arrows- (3-point mount). See Fig. 7.
1.7. Remove support/hydraulic unit assembly.
INSTALLING HYDRAULIC UNIT
Installing hydraulic unit
NOTE: First connect the electric plug connections on the hydraulic unit. This will
protect the plug connections from brake fluid or water.
After bleeding, check the assignment of the brake lines to the correct brake
callipers. Carry out a swap test using the PIWIS Tester.

1. Install hydraulic unit -D- . Observe tightening torques Refer to 47 Tightening torques for brake hydraulics
1.1. Insert hydraulic unit with support and tighten fastening nuts -Arrows- (3-point mount). See Fig. 8.
1.2. Connect control unit connector to hydraulic unit and lock it.
1.3. Fit the brake lines -1- in the correct position on the brake master cylinder. HZ 1 = Brake master cylinder
push-rod circuit (close to fastening flange). HZ 2 = Intermediate piston circuit. See Fig. 8.
1.4. Fit brake lines -2- in correct position. Observe marking on the hydraulic unit -D- and intermediate piece -E-
. RL = rear left/RR = rear right/FR = front right/FL = front left. See Fig. 8.
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NOTE: First bleed the brake system in the normal way - with the bleeding device at the
reservoir and approx. 2.0 bar pressure (primary circuit).
Then, use the PIWIS Tester to bleed the brakes as well (secondary circuit). Only
necessary if the hydraulic unit was replaced and if brake pedal travel is
excessive after bleeding in the normal way (primary circuit). The process is
menu-driven. Always observe the specified sequence rear left, front left, front
right, rear right.
To bleed the secondary circuit, the bleeding device remains connected to the
brake fluid reservoir. Bleeding pressure is approx. 2.0 bar.
Throughout the entire bleeding process, the brake pedal must be operated
cyclically (keep depressed for 2 to 3 seconds, then release slowly). After
operating the pedal for the last time, hold the brake pedal down and close the
bleeder valve.
2. Bleed the brake system and adjust the brake-fluid level. Refer to 47 01 07 Bleeding the brake system - as of
3. When replacing the hydraulic unit, code the control unit (manual transmission/Tiptronic).
4. Carry out the following tests:
 Check the system for leaks.

 Read out and erase the fault memory of the ABS/PSM control unit using the PIWIS Tester. Carry out a
static test as well.
 Check electric and hydraulic lines for incorrect assignment using the PIWIS Tester. This test checks that
the brake lines/solenoid valves are assigned to the corresponding brake callipers.
 Then start the engine. The ABS/PSM-related lights in the instrument cluster must go out when the engine
is running.
 Carry out a function check on the brakes. Then take a short test drive and perform at least one ABS
control operation, taking the road conditions into consideration. Read out the ABS/PSM fault memory
again. There must not be any stored faults.
SUBSEQUENT WORK
Subsequent work
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Install cover over hydraulic unit (luggage compartment cover) -1- , Refer to 70 30 19 Removing and installing
front luggage compartment cover - as of MY 2005 (All Models) . Refer to 70 30 19 Removing and
installing rear luggage compartment cover - as of MY 2006 (Cayman S, Cayman S RHD) . See Fig. 9.
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45 59 19 REMOVING AND INSTALLING ROTATION-RATE SENSOR FOR

PSM - AS OF MY 2005 (ALL MODELS)
INFORMATION
Information
The lateral-acceleration sensor is integrated in the rotation-rate sensor.
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Fig. 11: Rotation-rate sensor

REMOVING ROTATION-RATE SENSOR
Removing
1. Move the left seat back and adjust the steering wheel upwards.
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Fig. 12: Cover in left footwell

2. Remove left cover on the center console.
Unscrew screw -2- and take off cover -1- . See Fig. 12.

3. Remove rotation-rate sensor.
Unscrew screws -1- (the screws -1- can only be accessed using a 1/4-inch tool). Pull off plug connection and
take out rotation-rate sensor. See Fig. 13.
INSTALLING ROTATION-RATE SENSOR
Installing
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1. Install in reverse order.
Subsequent work
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Fig. 15: Diagnostic tester

1. After installing the rotation-rate sensor, read out the PSM fault memory with the PIWIS Tester (diagnostic
tester) and erase it. Carry out a static test. Then start the engine. The PSM-related lights in the instrument cluster
must go out when the engine is running. Read out the PSM fault memory again. There must not be any stored
faults.
45 60 INITIALIZING AND CALIBRATING STEERING-ANGLE SENSOR - AS

CAUTION: Increased risk of accident whenever power supply is interrupted. PSM

does not function.
--> The steering-angle sensor must be initialized (taught) whenever the battery is disconnected.
NOTE:  The steering-angle sensor is integrated into the steering column switch
and records the movements of the steering wheel (steering wheel angle)
using light switches. The data is transmitted to the PSM control unit via
the CAN bus.
 During initialization, the steering-angle sensor learns its current position
(straight-ahead position).
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 The steering-angle sensor must always be initialized if terminal 30 was

interrupted (for example, battery replacement, undervoltage, steering
column switch disconnected, relevant fuse removed)!
 Calibration must be performed when working on or carrying out
subsequent work on the chassis. This is described in detail in the next
chapter --> 456000 Initializing and calibrating steering-angle sensor -
section on "Calibrating".
 The calibration results in zero point balancing (exactly straight ahead).
 The steering angle sensor is calibrated when first fitted and when any
work has been carried out on steering and chassis. Examples of this
would be opening the steering wiring and alterations to toe and camber.
 Calibration includes initialization.
CHECKING STEERING-ANGLE SENSOR
Initialize steering-angle sensor
1. Turn wheels to straight-ahead position.
2. Start engine.
3. From the straight-ahead position, turn steering wheel approx. 20° to the left and 20° to the right (past straight-
ahead position).
4. Drive the vehicle straight ahead for at least three seconds at a speed above 6 km/h (3.7 mph).
After successful initialization, the stored fault code is erased from the fault memory. The PSM indicator light in
the instrument cluster goes out.
After initialization has been completed, the battery must not be disconnected, the relevant fuse must not be
removed and there must not be undervoltage. Otherwise, initialization will have to be carried out again.
ADJUSTING STEERING-ANGLE SENSOR
NOTE:  The steering-angle sensor must be recalibrated on the measuring platform

following repairs to or work on the chassis/steering or if the steering-angle
sensor/steering column switch/hydraulic unit is replaced.
 In order to be able to calibrate the steering angle sensor correctly, the
vehicle must be on the measuring platform, the wheel alignment values
correct and the steering in the straight-ahead position.
 The security code is displayed in the PIWIS tester under Menu >> PSM >>
Actual values.
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The steering angle sensor must be calibrated using the menu with PIWIS tester under the specified test
conditions:
2. Turn wheels or steering wheel to straight-ahead position. In the straight-ahead position, the steering wheel
must deviate by no more than ± 2.0° from the horizontal position (steering center position).
3. Before calibrating, first turn the steering wheel from the straight-ahead position approx. 20° to the left and
20° to the right (past straight-ahead position).
4. Turn wheels or steering wheel to straight-ahead position and calibrate the steering-angle sensor. To calibrate,
you must enter the security code in the actual values menu.
45 60 19 REMOVING AND INSTALLING STEERING-ANGLE SENSOR FOR

PSM - AS OF MY 2005 (ALL MODELS)
INFORMATION
Information
The steering-angle sensor is integrated into the steering-column switch. The steering angle is recorded in the
airbag contact unit (spring).
Only replace the steering-angle sensor together with the airbag contact unit (spring) and electronic unit.
Fig. 16: Steering-angle sensor

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Fig. 17: Diagram of steering-column switch

A - Direction indicator switch
B - On-board computer switch
C - Wiper switch
D - Cruise control switch
E - Airbag contact unit (spring)/steering-angle sensor
F - Electronic unit
PRELIMINARY WORK
Preliminary work
1. Remove airbag unit --> 69 58 19 REMOVING AND INSTALLING DRIVER'S AIRBAG UNIT - AS OF
2. Remove steering wheel --> 48 10 19 REMOVING AND INSTALLING STEERING WHEEL - AS OF

Removing
CAUTION: Malfunction
 Fault in airbag contact unit (spring)!

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--> Airbag contact unit (spring) must not be twisted.
1. Remove steering-column panels.
Fig. 18: Steering-column panels

1.1. Remove lower steering-column panel -3- . See Fig. 18.
Unscrew screws -1- and unclip cable clamp -2- . See Fig. 18.
Move steering-wheel adjustment lever to a vertical position and remove lower steering-column panel -3- . See
Fig. 18.
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Fig. 19: Steering-column switch

1.2. Remove upper steering-column panel -4- . See Fig. 18.
Unclip upper steering-column panel -4- , see -Arrows- , and disconnect electric plug connection. See Fig. 18,
Fig. 19.
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Fig. 20: Steering-column switch, bottom

2. Remove steering-column switch.
Unscrew screw -1- , unclip cable guide -2- , pull out electric plug connections and remove steering-column
switch. See Fig. 20.
3. Remove airbag contact unit (spring) from steering-column switch.
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Fig. 21: Airbag contact unit marking

NOTE: Ensure that arrow -A- on the rotor is positioned between the markings -B- of the
arrows -C- on the airbag contact unit and that the locking element -D- is
engaged.
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Unclip airbag contact unit (spring) -Arrows- and carefully remove it. See Fig. 22.
REPLACING STEERING-ANGLE SENSOR FOR PSM
Replacing
The steering-angle sensor can only be replaced together with the airbag contact unit -E- and electronic
unit -F-. See Fig. 23.
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Fig. 23: Diagram of steering-column switch

A - Direction indicator switch
B - On-board computer switch
C - Wiper switch
D - Cruise control switch
E - Airbag contact unit (spring)/steering-angle sensor
F - Electronic unit
1. Replace the steering-angle sensor.
Replace the airbag contact unit (spring)/steering-angle sensor -E- and electronic unit -F- . See Fig. 23.
INSTALLING STEERING-ANGLE SENSOR FOR PSM
Installing
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Fig. 24: Steering-angle sensor

2. Install steering-column switch.
Location Explanation Type Basic value Tolerance Tolerance

1 2
Steering-column switch to Tightening +5 (3.5 ftlb.)
holder torque Nm
SUBSEQUENT WORK
Subsequent work
1. Install steering wheel --> 48 10 19 REMOVING AND INSTALLING STEERING WHEEL - AS OF MY

2005 (ALL MODELS) .
2. Install airbag unit --> 69 58 19 REMOVING AND INSTALLING DRIVER'S AIRBAG UNIT - AS OF
3. Initialize and calibrate steering-angle sensor --> 456000 Initializing and calibrating steering-angle sensor.
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BRAKES Brakes - Hydraulics, regulator, booster
BRAKES
Brakes - Hydraulics, regulator, booster
47 TIGHTENING TORQUES FOR BRAKE HYDRAULICS - AS OF MY 2005

(ALL MODELS)
TECHNICAL VALUES
Brake pressure line

value 1 2
Screw connection for securing brake pressure Tightening
15 ftlb.
line to brake master cylinder M12 x 1 torque
12 ftlb.
line to hydraulic unit M12 x 1 torque
Screw connection for securing brake pressure Tightening 9 - 10.5
line to hydraulic unit M10 x 1 torque ftlb.
Screw connection for securing brake pressure
Tightening 9 - 10.5
line to distributor, brake hose and brake
torque ftlb.
calliper M10 x 1
Screw connection for securing brake pressure Center Tightening 9 - 10.5
line to intermediate piece M10 x 1 underbody torque ftlb.
Screw connection for securing brake pressure Center Tightening
15 ftlb.
line to intermediate piece M12 x 1 underbody torque
Master brake cylinder / brake booster

value 1 2
tightening
Brake booster to body screw connection M8 17 ftlb
torque
Brake unit support to body screw connection tightening
17 ftlb
M8 torque
Brake master cylinder to brake booster screw tightening
36 ftlb
connection M14 torque
Brake pressure line to brake master cylinder tightening
15 ftlb
screw connection M12 x 1 torque
Hydraulic unit

value 1 2
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Screw connection for securing bracket for Tightening

3 ftlb.
hydraulic unit to body M6 torque
Screw connection for securing hydraulic unit Tightening
4 ftlb.
to bracket M6 torque
Screw connection for securing brake pressure Tightening 9 - 10.5
line to hydraulic unit M10 x 1 torque ftlb.
12 ftlb.
line to hydraulic unit M12 x 1 torque
Brake calliper

value 1 2
Screw connection for securing Replace screws on front
Tightening
brake calliper to wheel carrier and rear axle whenever 63 ftlb.
torque
M12 x 1.5 removed.
Screw connection for securing
Tightening 9 - 10.5
brake pressure line to brake
torque ftlb.
calliper M10 x 1
Tightening
connecting line to brake calliper 9 ftlb.
torque
M10 x 1
Tightening 6-9
bleeder screw to brake calliper
torque ftlb.
M10 x 1
47 01 07 BLEEDING THE BRAKE SYSTEM - AS OF MY 2005 (ALL MODELS)

NOTES
NOTE:  Observe brake-fluid quality! Use only new DOT 4 brake fluid!
 The Super DOT 4 brake fluid must be changed every two years!
 This brake fluid is available under the following part numbers: Container
quantity 1 liter = 000.043.203.66 Container quantity 30 liters =
000.043.203.67
BLEEDING BRAKE SYSTEM
Procedure for bleeding
1st. Step: Bleed brakes in the normal way (in combination with bleeding device at the brake fluid reservoir and
2.0 bar pressure) (primary circuit).
2nd. Step: In addition, use the Piwis Tester to bleed the brakes (secondary circuit). Only necessary if the
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hydraulic unit has been replaced and, after bleeding in the normal way (primary circuit), the brake pedal travel
is excessive.
1. Step: Bleeding (primary circuit)
NOTE:  Always bleed both bleeder valves on brake caliper!

 Bleed the outer bleeder valve first!
NOTE:  If the pedal travel is too long or the pedal feels too soft when applied, carry
out bleeding again. Operate (pump) the brake pedal at the same time. A
second person is required for this.
 Also carry out this procedure if the brake hydraulic system was largely
empty.
Fig. 1: Cover over brake fluid reservoir

1. Disengage and remove cover over brake fluid reservoir -B- . See Fig. 1.
2. Open expansion tank.
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Fig. 2: Bleeding brakes

3. Connect a bleeding device to the brake fluid reservoir. Switch on the bleeding device. Bleeding pressure is
approx. 2.0 bar.
4. Continue the bleeding procedure at the brake calipers. Do so in the following sequence: rear right/rear
left/front right/front left. Bleed the outer bleeder valve first.
5. Use a transparent hose and a collecting bottle to check the escaping brake fluid is clean and free of air
bubbles and to determine the amount of brake fluid used.
6. Open each bleeder valve until clear, bubble-free brake fluid emerges.
7. Tighten the bleeder valves to the stipulated tightening torque and remove the bleeder hoses.
8. Generate vacuum in brake booster by starting engine. Check brake-pedal travel and pedal feel.
Check the brake system for residual air by the amount of brake pedal travel. Repeat the bleeding procedure if
necessary. Operate (pump) the brake pedal at the same time as described below. This will remove the remaining
air bubbles from the primary circuit.
 Open the rear right bleeder valves, then fully rapidly depress the brake pedal hard several times. Hold the
brake pedal for 2 to 3 seconds after each depression, then release slowly. Continue bleeding until the
brake fluid emerging into the collection bottle is free of bubbles and foam.
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 Repeat this procedure in the sequence rear left/front right/front left.
9. If necessary, continue bleeding the secondary circuit (using the Piwis Tester). Only necessary if the hydraulic
unit has been replaced and, after bleeding in the normal way (primary circuit), the brake pedal travel is
excessive.
Fig. 3: Brake fluid level

10. Remove bleeding device from brake fluid reservoir and screw cap on. The brake fluid level in the brake
fluid reservoir must be between the MIN and MAX markings once the vehicle has been filled and bled. Adjust
the brake fluid level if necessary.
2nd Step: Bleeding (secondary circuit)
Bleeding of the secondary circuit is only necessary if the hydraulic unit has been replaced and, after bleeding in
the normal way (primary circuit), the brake pedal travel is excessive.
First bleed brakes as usual (primary circuit). Only then can you carry out bleeding of the secondary circuit with
the Piwis Tester. The process is menu-driven. You must observe the specified sequence rear left, front left, front
right, rear right.
To bleed the secondary circuit, the bleeding device remains connected to the brake fluid reservoir. Bleeding
pressure is approx. 2.0 bar.
Throughout the entire bleeding process, the brake pedal must be operated cyclically (hold depressed for 2 to 3
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seconds, then release slowly). After operating pedal for the last time, hold the brake pedal down and close
bleeder valve.
47 08 01 CHECK BRAKE FLUID LEVEL - AS OF MY 2005 (ALL MODELS)

CHECK BRAKE FLUID LEVEL
Checking brake fluid level
NOTE:  Observe brake fluid quality. Use only new DOT 4 brake fluid.
 This brake fluid is available under the following part numbers: Container
quantity: 1 liter = 000.043.203.66. 30 liters = 000.043.203.67.
The brake fluid level in the reservoir must be between the MIN and MAX markings.

- Disengage and remove cover over brake fluid reservoir -B- . Check brake fluid level. See Fig. 4.
-A- - Viewing window for brake fluid level (MIN marking only) See Fig. 4.
-B- - Cover See Fig. 4.
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47 08 55 REPLACING BRAKE FLUID - AS OF MY 2005 (ALL MODELS)

REPLACING BRAKE FLUID
Changing brake fluid

1. Disengage and remove cover over brake fluid reservoir -B- . See Fig. 5.
2. Fill reservoir up to the edge with new brake fluid.
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Fig. 6: Brakes: changing/bleeding brake fluid

3. Connect a bleeding device to the brake fluid reservoir. Switch on the bleeding device. Bleeding pressure -->
Changing/bleeding brake fluid: approx. 2.0 bar .
4. Continue changing the brake fluid at the brake callipers. Do so in the following sequence: rear right/rear
left/front right/front left.
Use a transparent hose and a collecting bottle to check the escaping brake fluid accurately for cleanliness, lack
of air bubbles and to determine the brake fluid used.
5. Open every bleeder valve until clear, bubble-free brake fluid emerges and until the corresponding change
quantity per brake calliper is reached. Per brake calliper --> Changing brake fluid (per wheel): approx. 250
cm3 .
Drain brake fluid on every brake calliper at both bleeder valves.
6. Tighten the bleeder valves to the stipulated tightening torque and remove the bleeder hoses.
7. Also drain off some brake fluid at the bleeder valve of the clutch slave cylinder.
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Fig. 7: Brake fluid level

8. Remove bleeding device from brake fluid reservoir and screw cap on. The brake fluid level in the brake fluid
reservoir must be between the MIN and MAX markings once the vehicle has been filled and bled. Adjust the
brake fluid level if necessary.
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9. Place cover over brake fluid reservoir -B- . See Fig. 8.
47 76 19 REMOVING AND INSTALLING VACUUM PUMP - AS OF MY 2005

(ALL MODELS)
INFORMATION
Information
A vacuum pump is used to provide the vacuum for the brake booster. This vacuum pump, together with the oil
suction pump on the left cylinder head, is designed as a tandem pump -1- . It is driven by the exhaust camshaft
on the left cylinder bank. See Fig. 9.
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Fig. 9: Overview of vacuum pump

1 - Tandem pump
2 - Screws
3 - Sealing ring
Preliminary work
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Fig. 10: Removing cover for rear underbody

1. Remove rear underbody cover.
Replace fastening nuts -2- following removal. See Fig. 10.
Refer to 51 94 19 Removing and installing cover for rear underbody - as of MY 2005 (All Models) .
REMOVING VACUUM PUMP
Removing
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Fig. 11: Tandem pump

1. Remove the tandem pump.
Release the vacuum line -2- and pull it off. See Fig. 11.
Screw out screws, see -Arrows- , and remove the tandem pump. See Fig. 11.
NOTE: When you loosen the fastening screws, engine oil will run out of the sucking jet
pump. Place a suitable container underneath to collect the emerging engine oil.
The engine-oil level must be checked and topped up afterwards (following
installation).
INSTALLING VACUUM PUMP
Installing
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Fig. 12: Overview of vacuum pump

1 - Tandem pump
2 - Screws
3 - Sealing ring
1. Clean contact surfaces.
Clean contact surfaces on the tandem pump -1- and left cylinder head. See Fig. 12.
2. Replace sealing ring.
Grease sealing ring -3- before fitting it. See Fig. 12.
Only use grease that has been approved for use on the sealing ring -3- . Details of approved products can
be found in the Parts Catalogue. See Fig. 12.
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3. Install the tandem pump.
Align and insert driver for the tandem pump -1- . See Fig. 13.
Tighten screws, see -Arrows- . See Fig. 13.
Connect the vacuum line -2- . See Fig. 13.

Screws for tandem pump Tightening torque +9 (6.5 ftlb.) Nm
SUBSEQUENT WORK
Subsequent work
1. Start the engine to allow it to warm up and carry out leak test.
2. Check engine-oil level and top up engine oil if necessary. Refer to 17 01 01 Checking engine oil level - as of
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Fig. 14: Cover for rear underbody

3. Install rear underbody cover Refer to 51 94 19 Removing and installing cover for rear underbody - as of
MY 2005 (All Models) ..
Replace fastening nuts -2- . See Fig. 14.
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BRAKES Brakes - Brake mechanics
BRAKES
Brakes - Brake mechanics
46 TIGHTENING TORQUES FOR MECHANICAL BRAKE - AS OF MY 2005

(ALL MODELS)
TECHNICAL VALUES
Tightening torques for mechanical brake

value 1 2
Replace brake
calliper to front
tightening 63
and rear axle bolts on front and rear axle after each removal.
torque ftlb
screw connection
M12 x 1.5
Brake disc to
wheel hub screw tightening 7.5
connection (front torque ftlb
and rear axle) M6
Brake cover plate
to front and rear tightening 7.5
axle screw torque ftlb
connection M6
speed sensor to
front and rear axle tightening 7.5
screw connection torque ftlb
M6
Brake unit to
body screw
tightening 17
connection
torque ftlb
(aluminum
interim. part) M8
Brake unit
support to body tightening 17
M8
Parking brake
console to body tightening 17
M8
Bracket for 3 ftlb

hydraulic unit to tightening
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body screw torque

connection M6
Hydraulic unit to
tightening
holder screw 4 ftlb
torque
connection M6
Thinly grease thread, shank and under head
(between screw head bearing surface and
Wheel to wheel spherical cap ring) of the wheel bolts with
tightening 96
hub screw Optimoly TA (aluminum paste). Do not grease
torque ftlb
connection bearing surface of the spherical cap facing
wheel. If heavily contaminated, clean bolts
first with a lint-free cloth.
Tightening torques for brake pedal/pedal bearing axle

value 1 2
Brake pedal to brake pushrod (threaded Tightening
7.5 ftlb.
bolt M8x1) torque
Brake pushrod to brake booster (collar Tightening
7.5 ftlb.
nut M6) torque
Brake pushrod to adjusting piece (lock Tightening
22 ftlb.
nut) M12 x 1.5 torque
Tightening 6 to 7.5
Pedal bearing axle in pedal block
torque ftlb.
Locknut pedal bearing axle to pedal block Tightening
7.5 ftlb.
right M8 torque
Locknut pedal bearing axle to pedal block Tightening
34 ftlb.
left M14 torque
46 36 02 CHECKING THICKNESS OF THE FRONT BRAKE PADS - AS OF MY

2005 (ALL MODELS)
PRELIMINARY WORK
Remove wheels Refer to 44 05 19 Removing and installing wheel - as of MY 2005 (All Models) .
CHECKING BRAKE PADS
WARNING: Risk of accidents if brake pads and/or brake discs are not replaced in
time.
 Danger of injury and damage to vehicle if braking effect is impaired.
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CAUTION: Increased risk of damage to brake discs when mounting/removing wheels.
 The brake discs can be damaged.
--> Use assembly aid (assembly pins) in order to exclude any possibility of heavy contact of the wheel with the
brake disc.
no later than when the pad thickness is 2.5 mm -arrows- . See Fig. 1.
 Warning contacts must be replaced if the core of the wire is worn.
need to replace it.
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Visually inspect the brake pads for wear.
SUBSEQUENT WORK
Fit wheels Refer to 44 05 19 Removing and installing wheel - as of MY 2005 (All Models) .
46 38 02 CHECKING THE THICKNESS OF THE REAR DISC BRAKE PADS -

PRELIMINARY WORK
Microsoft
Remove wheels Refer to 44 05 19 Removing and installing wheel - as of MY 2005 (All Models) .
CHECKING BRAKE PADS
WARNING: Risk of accidents if brake pads and/or brake discs are not replaced in
time.
 Danger of injury and damage to vehicle if braking effect is impaired.
CAUTION: Increased risk of damage to brake discs when mounting/removing wheels.
 The brake discs can be damaged.
--> Use assembly aid (assembly pins) in order to exclude any possibility of heavy contact of the wheel with the
brake disc.
no later than when the pad thickness is 2.5 mm -arrows- . See Fig. 2.
 Warning contacts must be replaced if the core of the wire is worn.
need to replace it.
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Visually inspect the brake pads for wear.
SUBSEQUENT WORK
Fit wheels Refer to 44 05 19 Removing and installing wheel - as of MY 2005 (All Models) .
46 BRAKE DISC MEASUREMENT SHEET - AS OF MY 2005 (ALL MODELS)

INFORMATION
Brake disc measurement sheet
Microsoft
To document the measured result, a copy or print of the data card illustrated can be used. The data cards cannot
be ordered.
1. Make a copy or print of the data card shown.
NOTE:  Actual values that are identical in all versions are already entered!
 In the course of further development these values may change. If
necessary, carry out a check and insert the new values accordingly.
2. Before measurement (Test 1 through Test 3), enter the general data, vehicle type and the missing nominal
values (new brake disc thickness / brake disc wear limit) into the data card.
3. Carry out measurements (actual status) and enter the values in the alignment card.
4. If brake discs are to be replaced, carry out Test 2 with the new discs again and enter the latest values in a new
data card.
Measuring prerequisites
- Note the labor operation numbers.
- Measuring brake discs: 80 time units per axle.
Brake disc measurement

Customer: Rep. Order No.:
Street: Vehicle Ident No.:
Place: Reg. number:
Telephone: Date of first registration:
Vehicle type: Odometer reading [km/miles]
Checker Date/Signature
Nominal values
Test 1 = brake disc thickness
- Brake disc thickness, new [mm]: Front: Rear:
- Wear limit [mm]: Front: Rear:
Test 2 = lateral runout
- Brake disc installed [mm] max.: 0.06
- Wheel hub max.:
- Brake disc removed [mm] max.: 0.03
Test 3 = Thickness tolerance of brake disc
Thickness tolerance of brake disc [mm] max.:
Measured values
front left front right rear left rear right
(actual values) [mm]
Test 1 = Brake disc thickness (measured at 3 points, each offset by 120°)
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Measurement point
A
Measurement point
B
Measurement point
C
Test 2 = lateral runout
- Brake disc
installed
- Wheel hub
- Brake disc
removed (difference
wheel hub/brake
disc installed)
Test 3 = Thickness tolerance of brake disc
Thickness tolerance
46 05 19 REMOVING AND INSTALLING BRAKE PEDAL - AS OF MY 2005

(ALL MODELS)
INFORMATION
Information
The brake pedal can only be removed when the clutch pedal has been removed.
The description (removing and installing brake pedal) also covers the procedure for removing and installing the
clutch pedal.
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Fig. 3: Overview of brake pedal

1 - Brake light switch
2 - Pedal axle
4 - Threaded bushing
5 - Bolt
6 - Brake pushrod
7 - Brake pedal
PRELIMINARY WORK
Preliminary work
1. Remove center console cover (driver's side). Refer to 68 14 19 Removing and installing center console
2. Remove trim panel (lower part of dashboard). Refer to 70 19 19 Removing and installing trim under
3. Remove Kessy control unit. Refer to 96 66 19 Removing and installing KESSY/PAS control unit - as of
REMOVING CLUTCH PEDAL
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Removing clutch pedal
1. Remove lid and side trim panel on fuse box.
Installation position: In driver's footwell at the left.
Fig. 4: Clutch pedal switch

2. Carefully pull off the connector from the clutch pedal switch (and interlock switch if necessary), see -
Arrows- . See Fig. 4.
3. Remove device support.
The device support is installed at the left next to the clutch pedal together with the vehicle electrical system
control unit and relay carrier.
3.1. Remove relay carrier.
3.2. Remove vehicle electrical system control unit.
3.3. Remove device support.
4. Secure clutch power spring.
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CAUTION: Increased risk of accidents when removing/installing the clutch boost

spring.
 Possible risk of damage and injury (e. g. crushing).
--> The boost spring must be secured with a cotter pin when working near the clutch pedal (except for work on
the clutch pedal switch and interlock switch).
Secure clutch power spring using a cotter pin, for example. Press the clutch pedal lightly, then unclip and
remove the clutch power spring.
Fig. 5: Clutch master cylinder

5. Remove clutch master cylinder -Arrows- and pin (master cylinder valve pushrod) - do not open the clutch
system. See Fig. 5.
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Fig. 6: Bracket for clutch power spring

6. Remove bracket for clutch power spring.
NOTE: When removing the bracket for the clutch power spring, carefully guide the
master cylinder valve pushrod past at the clutch pedal.
(Also remove clutch pedal switch and interlock switch, if necessary) --> Bracket for clutch power spring , See
Fig. 6. Carefully move bracket for clutch power spring approximately 2-4 mm to the left -A- . Carefully turn
bracket for clutch power spring clockwise by approximately 10-15 degrees on the pedal bearing axle -B- .
Remove bracket for clutch power spring to the left. See Fig. 6.
REMOVING BRAKE PEDAL
Removing brake pedal
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1. Remove brake light switch.
Release brake light switch -1- by turning it 90° and pull it out of the installation opening. See Fig. 7.
Fig. 8: Brake pedal

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2. Disconnect brake pushrod from brake pedal.
Remove bolt and threaded bushing, see -Inset- . See Fig. 8.
Fig. 9: Pedal axle

3. Remove pedal axle.
Screw out and remove lock nut -1b- and nut -1a- as well as pedal axle -2- . See Fig. 9.
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Fig. 10: Brake pedal

4. Pull out brake pedal.
Turn the brake pedal and brake pushrod as required, see -Inset- . See Fig. 10.
INSTALLING BRAKE PEDAL
Installing brake pedal

1 - Brake light switch
2 - Pedal axle
4 - Threaded bushing
5 - Bolt
6 - Brake pushrod
7 - Brake pedal
8 - Bearing sleeves
1. Grease the bracket for the brake pedal.
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Grease bracket in area of pedal bearing axle -Arrows- with Renocal (Glissando VW 745). Part No.
000.043.206.21 (10g tube). See Fig. 11.
2. Insert brake pedal.
Turn the brake pedal -7- and brake pushrod -6- as required. See Fig. 7.
Fig. 12: Brake pedal

3. Fit brake pushrod on brake pedal.
Tighten bolt, see -Inset- . See Fig. 12.
--> Tightening torque: +10 (7.5 ftlb.) Nm
4. Install pedal axle.
Tighten pedal axle -2- . See Fig. 12.
--> Tightening torque: +10 (7.5 ftlb.) Nm -2 (1.5 ftlb.) Nm
INSTALLING CLUTCH PEDAL
Installing clutch pedal
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Fig. 13: Advanced grease specification

NOTE: Grease bracket in area of pedal bearing axle -Arrows- with Renocal (Glissando
VW 745). Part No. 000.043.206.21 (10g tube). See Fig. 13.
Important: By contrast with previous models, do not grease the pedal bearing axle in the area of the clutch pedal
-A- (due to plastic-coated bearing sleeves). See Fig. 13.
Also grease the following contact surfaces with Renocal (Glissando VW 745) (Part No. 000.043.206.21): The
clutch pedal switch (interlock switch) system -Arrow- . In addition, the contact surface between the clutch
pedal (inside of prongs) -Arrow- and the guiding rods of the clutch power spring -Arrow- . See Fig. 13.
Observe correct tightening torques.
Use new lock for bolts.
When installing the bracket for clutch power spring, insert the valve pushrod for the master cylinder carefully
into the specified position in the clutch pedal.
Fig. 14: Clutch master cylinder (push rod)

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If creaking noises (over approx. 2/3 of the lift area) are heard after installing the clutch pedal, these may be
coming from the connection between the ball head piston rod and piston seat of the clutch master cylinder -
Arrow- . In this case, spray a minimal amount of multipurpose oil on the connection point using a metering
tube -Arrow- . Important: The lubricant must only be applied to this connection point so make sure not to use
too much. This connection point cannot be taken apart without damaging it irreparably. See Fig. 14.
1. Insert bracket for clutch power spring with clutch pedal.
Fig. 15: Support for clutch pedal switch

2. Install support for clutch pedal switch.
Position support for clutch pedal switch (and interlock switch, if necessary) in the correct position. Observe the
auxiliary bar! -Arrow- The auxiliary bar must be fitted in the correct position in the groove. See Fig. 15.
3. Install clutch power spring.
Observe the installation position of the bolt for the clutch power spring (hexagon). After installation, remove the
clutch power spring cotter pin.
4. Fit the clutch master cylinder.
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NOTE: Insert pin. Screw in the fastening screws slightly so that the master cylinder can
still be moved. Have the clutch pedal not actuated at the limit stop. Press the
clutch master cylinder in the direction of travel and tighten (make sure the
return bore in the clutch master cylinder is not blocked!).
Fig. 16: Adjustment for clutch pedal switch (interlock switch)

5. Check adjustment for clutch pedal switch (and interlock switch, if necessary).
NOTE: If the clutch pedal switch adjustment (interlock switch) has been changed, the
adjustment must be checked or adjusted. The switch must switch when the
clutch pedal is actuated approx. 1-2 mm before the limit stop of the clutch
master cylinder.
--> Adjustment for clutch pedal switch (interlock switch) Plug in connector. See Fig. 16.
6. Install device support.
The device support is installed at the left next to the clutch pedal together with the vehicle electrical system
control unit and relay carrier.
6.1. Install device support.
6.2. Install vehicle electrical system control unit.

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6.3. Install relay carrier.
7. Install side trim panel, fuse box and lid.
In driver's footwell at the left.
SUBSEQUENT WORK
Subsequent work
1. Install Kessy control unit Refer to 96 66 19 Removing and installing KESSY/PAS control unit - as of MY
2005 (All Models) .
2. Install trim panel (lower part of dashboard). Refer to 70 19 19 Removing and installing trim under
3. Install covers for center console Refer to 68 14 19 Removing and installing center console cover - as of
46 36 19 REMOVING AND INSTALLING THE FRONT DISC BRAKE PADS -

Danger of accidents
WARNING: Risk of accidents if brake pads with the wrong brake pad quality are
installed.
 This can result in longer braking distances and more wear.
--> Use only the type-specific brake pads specified in the Porsche Spare Parts Catalogue.
CAUTION: Increased risk of accidents if old parts are fitted on brake calliper.
 This can cause malfunctions.
--> Fit new expanding spring, new retainer pin and new retainer on the brake calliper.
REMOVAL
Removing front disc brake pads
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Fig. 17: Removing retainer pin

1. Remove the safety bracket and extract the retainer pin inwards.
2. Pull out the warning contact wire on the brake calliper and remove the warning contacts from the brake pad
plates.
3. Remove brake pads using the brake pad puller. Always observe the following important points:
Press the brake pads back as far as possible using the piston resetting fixture.
Pull out brake pads together with the vibration dampers. If this is not possible (depending on the amount of
wear on the brake pads), use a spatula to detach the vibration dampers from the brake pad backing plate before
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removing the pads.
INSTALLING
Installing front brake pads
NOTE: The brake pad backing plates (rear side) must not be greased.
Replace vibration dampers each time the pads are changed.
The vibration dampers have an adhesive protective film. The protective film
must be removed before installation.
Replace warning contacts if the core of the wire is worn.
The warning contact can still be used if there are only scrape marks on the
plastic part of the warning contact.
Remove some brake fluid from the brake fluid reservoir by suction if necessary.
1. Before installation of the brake pads, check the wear of the brake discs. For details of the minimum thickness
of the brake discs, see Technical data/Brake wear limit.
2. If necessary, reset the brake pistons using the piston resetting fixture.
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Fig. 18: Vibration damper

3. Fit new vibration dampers in the pistons. Remove protective film from the vibration dampers before
installation.
4. Insert the brake pads.
5. Fit new expanding spring, new retainer pin and new retainer. These parts are available as a repair set and
must be replaced each time the pads are changed.
6. Insert the warning contact wire and the warning contacts.
7. Press the brake pedal several times to position the brake pads on the brake discs.
8. Check and, if necessary, correct the brake fluid level.
Bedding in the brake pads
New brake pads require a bedding-in period of approx. 200 km. Only then do they achieve their best friction
and wear coefficient. During this period, the brakes should be subjected to full stress when travelling at high
speed only in emergencies.
46 38 19 REMOVING AND INSTALLING THE REAR DISC BRAKE PADS - AS

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REMOVING REAR DISC BRAKE PADS
Removing rear disc brake pads
Fig. 19: Removing retainer pin

1. Remove the safety bracket and extract the retainer pin inwards -arrows- . See Fig. 19.
2. Pull out the warning contact wire on the brake calliper and remove the warning contacts from the brake pad
plates.
Contrary to the illustration, there are no vibration balancers on the brake pads.
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3. Remove brake pads using the brake pad puller. Always observe the following important points:
Press the brake pads back as far as possible using the piston resetting fixture.
Pull out the brake pads together with the brake-piston damping plates (if present/Boxster S only). If this is not
possible (depending on the amount of wear on the brake pads), use a spatula to detach the vibration dampers
from the brake pad backing plate.
INSTALLING REAR DISC BRAKE PADS
Installing rear disc brake pads
WARNING: Risk of accidents if brake pads with the wrong brake pad quality are
installed.
 This can result in longer braking distances and more wear.
--> Use only the type-specific brake pads specified in the Porsche Spare Parts Catalogue.
CAUTION: Increased risk of accidents if old parts are fitted on brake calliper.
 This can cause malfunctions.
--> Fit new expanding spring, new retainer pin and new retainer on the brake calliper.
NOTE: The brake pad backing plates (rear side) must not be greased.
Replace the brake-piston damping plates (if present/Boxster S only) each time
that you change the brake pads.
The vibration dampers have an adhesive protective film. The protective film
must be removed before installation.
Replace warning contacts if the core of the wire is worn.
The warning contact can still be used if there are only scrape marks on the
plastic part of the warning contact.
Remove some brake fluid from the brake fluid reservoir by suction if necessary.
1. Before installation of the brake pads, check the wear of the brake discs. For details of the minimum thickness
of the brake discs, see Technical data/Brake wear limit .
2. If necessary, reset the brake pistons using the piston resetting fixture.
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Fig. 20: Vibration damper

3. Insert new brake-piston damping plates (if present/Boxster S only) into the pistons. Since the brake-piston
damping plate are covered by a protective film, the protective film must be removed before installation. -->
Vibration damper , See Fig. 20.
4. Insert the brake pads.
5. Fit new expanding spring, new retainer pin and new retainer. These parts are available as a repair set and
must be replaced each time the pads are changed.
6. Insert the warning contact wire and the warning contacts.
7. Press the brake pedal several times to position the brake pads on the brake discs.
8. Check and, if necessary, correct the brake fluid level.
Bedding in the brake pads
New brake pads require a bedding-in period of approx. 200 km. Only then do they achieve their best friction
and wear coefficient. During this period, the brakes should be subjected to full stress when travelling at high
speed only in emergencies.
46 61 19 REMOVING AND INSTALLING PARKING-BRAKE LEVER - AS OF

Microsoft

PRELIMINARY WORK FOR REMOVING PARKING-BRAKE LEVER
Fig. 21: center console

- Remove center console Refer to 68 17 19 Removing and installing center console - as of MY 2005 (All
Models) .
REMOVING PARKING-BRAKE LEVER
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Fig. 22: Parking-brake lever

The parking-brake lever -1- is supplied as a spare part, complete with bracket, cover -2- and switch -3- (for
warning light indicating that the parking brake is on). See Fig. 22.
Fig. 23: Mounting point for parking-brake lever

1. Disengage parking-brake cable -5- at the parking-brake lever. This releases the parking-brake lever -1- . See
Fig. 23.
Pull off plug on switch -3- . See Fig. 23.
2. Remove parking-brake lever and mounting saddle assembly -1- after first removing the fastening nuts -4- .
See Fig. 23.
INSTALLING PARKING-BRAKE LEVER
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Fig. 24: Mounting point for parking-brake lever

1. Install parking-brake lever -1- . Use new fastening nuts -4- and tighten them to 23 Nm (17 ftlb.). See Fig. 24.
2. Engage brake cable -5- . Connect plug to switch -3- . See Fig. 24.
3. Remove lock pin on mounting saddle if necessary (only fitted on new parking-brake levers/used to prevent
automatic readjustment of the parking-brake cable).
4. Tighten and loosen the parking-brake lever a number of times (due to automatic readjustment of the parking-
brake cable). Then check the free play of the parking-brake lever. If there is too much free play, adjust the
parking-brake shoes.
Check the free play of the parking-brake lever (permissible value) and adjustment specification of the parking
brake shoes, see --> 468316 Adjusting the parking-brake shoes.
SUBSEQUENT WORK AFTER INSTALLING PARKING-BRAKE LEVER
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Fig. 25: Installing center console

1. Install center console ( -1- ) Refer to 68 17 19 Removing and installing center console - as of MY 2005
2. Fit rear wheels if necessary (if the parking-brake shoes were adjusted) Refer to 44 05 19 Removing and
installing wheel - as of MY 2005 (All Models) .
46 83 16 ADJUSTING THE PARKING-BRAKE SHOES - AS OF MY 2005 (ALL

MODELS)
ADJUSTING THE PARKING-BRAKE SHOES
This includes: Checking the free play of the handbrake lever and adjusting the parking-brake shoes. The
parking-brake cable cannot be adjusted (automatic cable adjustment).
Checking free play of parking-brake lever
The parking-brake shoes must be adjusted if the parking-brake lever can be pulled up by more than 5 teeth or
more than 10 teeth through application of medium force without producing a braking effect. 10 teeth applies to
parking-brake levers with a modified/refined tooth system (introduction in standard production in February
2006).
Information
Microsoft
The first version of the parking-brake levers has a total of 12 teeth (index/last two digits of part number are less
than 50). The modified version (refined tooth system as of February 2006) has 20 teeth.
Adjusting the parking-brake shoes
1. Remove the rear wheels.
2. Undo the parking-brake lever and push back the disc brake pads of the rear axle until the brake disc can rotate
freely.
3. The adjustment fixture can be twisted through the bores in the wheel mounting.
Fig. 26: Adjusting the parking brake

4. Turn the brake disc in such a way that the adjustment fixture becomes visible. Using a -screwdriver- inserted
through the bore, move the adjustment device until the wheel can no longer be turned. To be specific, this
means: put transmission in neutral. Further torque of the brake disc between 50 Nm and 150 Nm (37 ftlb. and
111 ftlb.) (test with torque click wrench on the drive shaft lock nut clockwise). Next, turn the adjustment fixture
back again through 4 notches (release approx. 3 notches until the wheel can be turned freely, then release
another 1 notch). Repeat the procedure on the other wheel. See Fig. 26.
5. Pull up the parking-brake lever (check free play). If 2 to 4 teeth or 4 to 8 teeth are engaged, it must be
possible to turn both wheels by hand with considerable difficulty. 4 to 8 teeth applies to parking-brake levers
with a modified/refined tooth system (introduction in standard production in February 2006).
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6. Release the parking-brake lever and check whether both wheels can be turned freely.
46 83 20 REMOVING AND INSTALLING BRAKE SHOES - AS OF MY 2005

(ALL MODELS)
INFORMATION
Information
Installation: Ensure that the hooks (curved ends of the spring) of the compression springs -6- are engaged
correctly on the wheel carrier! See Fig. 27.
The ends of the springs must be pointing upwards on wheel carriers with index 04 or 05 (last 2 digits of the part
number).
In the case of modified wheel carriers with index 06 or higher (used in production from 21 October 2005
onwards), the ends of the springs must point towards the center of the wheel (left spring pointing right/right
spring pointing left).
The wheel carriers are differentiated based on the part number, which can be seen close to the (raised) steering
arm.
Adjustment: The brake shoes can be adjusted using the adjustment device -2- . No further adjustment is
required because the parking-brake cables cannot be adjusted manually (self-adjusting system). See Fig. 27.
Fig. 27: Overview of brake shoes

PRELIMINARY WORK
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Preliminary work
1. Remove rear wheel Refer to 44 05 19 Removing and installing wheel - as of MY 2005 (All Models) .
2. Remove rear brake calliper from the wheel carrier and suspend it in the wheel arch (do not open brake
hydraulics).
REMOVING BRAKE SHOES
Removing
Fig. 28: Removing/fitting parking-brake cable

1. Disengage the brake cable at the parking-brake lever.
2. Loosen adjustment device for parking-brake shoes.
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Fig. 29: Loosening and adjusting adjustment device

Using a -screwdriver- , turn the adjustment device towards "Release". See Fig. 29.
3. Remove rear brake disc.
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Fig. 30: Removing and installing brake disc

Remove the countersunk screws -1- and take off the brake disc. If a securely seated brake disc cannot be
removed by gentle tapping with a plastic hammer, evenly screw bolts into the two M8 threads of the brake disc,
thereby pressing off the brake disc. See Fig. 30.
4. Remove parking-brake shoes.
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Fig. 31: Brake shoes

This includes: removing compression springs -6- , adjustment device -2- , return springs -4, 5- and parking-
brake shoes -1- . See Fig. 31.
INSTALLING BRAKE SHOES
Installing
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Fig. 32: Brake shoes

1. Install parking-brake shoes -1- , return springs -4, 5- , adjustment device -2- and compression springs -6- and
check that they are seated correctly. See Fig. 32.
NOTE: Ensure that the hooks (curved ends of the spring) of the compression springs
are engaged correctly on the wheel carrier.
The ends of the springs must be pointing upwards on wheel carriers with index
04 or 05 (last 2 digits of the part number).
In the case of modified wheel carriers with index 06 or higher (used in

production from 21 October 2005 onwards), the ends of the springs must point
towards the center of the wheel (left spring pointing right/right spring pointing
left).
The wheel carriers are differentiated based on the part number, which can be
seen close to the (raised) steering arm.
2. Clean the levelling and centering surfaces on the brake disc and wheel hub.
Then apply a very thin coat of Optimoly TA to the centering surface on the wheel hub.
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3. Install brake discs. See Fig. 30.
NOTE: The grey cast-iron brake discs at the rear right and rear left are identical. They
are available with different external diameters and in different thicknesses
(depending on the vehicle variant).
Rear PCCB brake discs are not identical. Observe marking for "right" and "left"
side during assembly!

4. Engage the brake cable at the parking-brake lever.
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Fig. 34: Loosening and adjusting adjustment device

5. Adjust the parking-brake shoes --> 468316 Adjusting parking-brake shoes.
SUBSEQUENT WORK
Subsequent work
1. Fit the brake calliper. Tighten new fastening screws to 85 Nm (63 ftlb.).
2. Fit rear wheel Refer to 44 05 19 Removing and installing wheel - as of MY 2005 (All Models) .
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CABIN AIR FILTER Particle Filter - Boxster (987 Series)
CABIN AIR FILTER
Particle Filter - Boxster (987 Series)
REMOVAL & INSTALLATION
NOTE: Manufacturer's terminology for this filter is particle filter.
CABIN AIR FILTER
NOTE: The particle filter is installed on the passenger side of the vehicle, in front of the
heating and A/C system.
Removal & Installation (2005-2006)
1. Open front storage compartment. Remove battery cover. Remove cover on right for plenum chamber.
2. In conjunction with telephone preparation, loosen the antenna at the two top fastening screws and
unscrew the two bottom fastening screws. Remove antenna part.
3. Open the lock -1- on the filter housing. See Fig. 1.
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Fig. 1: Opening Lock On Particle Filter Cover

4. Remove the particle filter upwards and to the side -2- out of the housing guide. See Fig. 2.
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Fig. 2: Removing Particle Filter Out Of Housing Guide

5. Insert a new particle filter into the housing guide -2-. See Fig. 3.
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Fig. 3: Installing Particle Filter Into Housing Guide

6. Close the lock -1- on the filter housing. See Fig. 4. For vehicles with telephone preparation, insert
antenna part at the top. Secure the antenna with the four fastening screws.
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Fig. 4: Closing Lock On Particle Filter Guide

7. Install cover on right for plenum chamber. Install battery cover.
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ELECTRICAL Starter, power supply, cruise control
ELECTRICAL
Starter, power supply, cruise control
27 TW TECHNICAL DATA, ENGINE ELECTRONICS - AS OF MY 2005 (ALL

MODELS)
TECHNICAL VALUES
Engine electronics
Designation 987 987 S Cayman S

Radio interference suppression ECE-R 10/02 and 95/54/EC
Rated voltage 12 volts
Manual transmission:
Battery voltage 60 Ah/280 A Tiptronic: 70 Ah/340 A
Tiptronic: 70 Ah/340 A
Three-phase generator 2.1 kW
Starter 1.2 kW 1.7 kW
Tiptronic: 1.7 kW
27 06 01 CHECKING THE BATTERY - AS OF MY 2005 (ALL MODELS)

General warning notes for the battery
CAUTION: Emerging battery acid.
 Danger of injury and risk of damage to materials coming into contact

with battery acid.
--> Wear suitable protective clothing and goggles!
--> Do not tip battery; acid can emerge from the vent openings!
--> Only illuminate the inside of the battery with a torch. Danger of explosion!
--> Do not handle a naked flame or lit cigarette near the battery!
--> Do not tilt battery when removing it. Risk of caustic burns as a result of emerging acid!
--> Protect the vehicle exterior and interior against battery acid. Cover areas if necessary.
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--> Rinse acid splashes in the eyes immediately with clean water for a few minutes. Consult a doctor
immediately.
--> Neutralize acid splashes on the skin, clothing or objects immediately with soap suds and rinse again with
plenty of water.
--> If acid has been drunk unintentionally, consult a doctor immediately.
CAUTION: Ignition of the battery during charging.
 Danger of injury and risk of damage to materials coming into contact

with battery acid when the battery is being charged.
--> The battery plugs must always be screwed in correctly when charging and during voltage measurement and
load measurement.
--> Rooms in which batteries are being charged should not be entered with a naked flame or when smoking.
Gases form through the charging process in the batteries which are highly flammable.
NOTE: To prevent contact corrosion, only approved bolts, nuts, washers, etc. should
be used. These elements have a special surface coating and must be stored
separately.
The battery is one of the most important electrical components in the vehicle.
Fault-free functioning of the battery contributes greatly to customer
satisfaction. To guarantee long and efficient operation, the battery must be
checked and maintained according to the description in this chapter.
Besides the starting function, the battery also has the tasks of buffer and
supplier of electrical energy for the entire vehicle electrical system.
Warning notes and safety regulations for lead-acid batteries
-1- Fire, sparks, naked flames and smoking are forbidden: See Fig. 1.
 Avoid sparking when using cables and electrical devices.

 Avoid short circuits.
 In batteries with central venting, there is an increased concentration of
oxyhydrogen gas at the hose opening. The venting hose should not be
bent or blocked by dirt.
 In batteries with central venting, there is an increased concentration of
oxyhydrogen gas at the hose opening.
 Battery acid is highly caustic, therefore wear protective gloves.
 Do not tip battery; acid can emerge from the vent openings.
 A highly explosive detonating gas mixture is formed when charging
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batteries.
 Hand in old batteries at a collection point.
Fig. 1: Battery with warnings and safety regulations

-2- Wear eye protection. See Fig. 1.
Lead-acid -3- , Keep children away from acid and batteries. See Fig. 1.
-4- Danger of caustic burns: See Fig. 1.
First aid: Rinse acid splashes in the eyes immediately with clean water for a few minutes. Consult a doctor
immediately. Neutralize acid splashes on the skin, clothing or objects immediately with soap suds and rinse
again with plenty of water. If acid has been drunk unintentionally, consult a doctor immediately.
-5- Observe information on the battery, in the Technical Manual and in the Driver's Manual. See Fig. 1.
-6- Danger of explosion: See Fig. 1.
-7- Disposal: See Fig. 1.
-8- Never dispose of old batteries in the domestic rubbish. See Fig. 1.
Battery handling requirements
Low-maintenance battery
- Battery terminals do not need to be greased.
- The battery terminal clamps should only be attached manually, without excessive force, to prevent damage to
the battery housing.
- The tightening torque for the battery terminals is 5 Nm (3.5 ftlb.).
- If the battery is reconnected, proceed according to 27 06 IN Work instructions after disconnecting the
battery - as of MY 2005 (All Models).
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- To ensure that the battery does not leak, it is essential to ensure that the original plugs supplied with the
battery are screwed into the battery openings.
- In the event of loss or damage, only original plugs of the same design should be used.
- The plugs must be fitted with an O-ring seal.
Battery central venting
NOTE:  State of the art batteries are fitted with central venting -A- . See Fig. 2.
 The gas generated during charging emerges centrally through an opening
on the upper cover side. The backfire protection is integrated at the same
position, which prevents the ignition of the combustible gas present in the
battery.
 In batteries with hose/pipe -A- for the central venting, ensure that the hose
is not pinched. Only then can the battery be freely vented. See Fig. 2.
Fig. 2: Central venting

Visual inspection of battery
Before measurements such as open-circuit voltage, gravity of electrolyte or the battery load test are carried out,
a visual inspection of the battery must be performed.
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Through this check, it can be determined:
 Whether the housing of the battery is damaged. Acid can leak out due to damage of the housing.
 Whether the battery terminals (battery line connections) are damaged. Contact of the line connections
cannot be guaranteed if the battery terminals are damaged. This can cause a line fire and malfunctions in
the electrical system.
Checking acid level of low-maintenance battery
NOTE:  Use a commercially available battery filling bottle.

 The correct acid level of the battery is an important factor for long and
efficient operation of the battery.
 When the acid level is too low, a capacity loss (performance loss) of the
battery occurs, which is caused by the cell plates drying out. If the cell
plates are not surrounded by electrolyte (battery acid), this will lead to
corrosion of the lead plates, the plate bridges and the cell connectors. The
result of the corrosion is that battery functioning cannot be guaranteed.
The battery will become unserviceable.
 If the acid level is too high, damage can occur by the battery acid
(sulphuric acid/water mixture) leaking out of the battery.
Fig. 3: Removing battery cover

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2. Remove battery cover.
Emerging battery acid. Observe --> 270601 Checking battery - General warning notes.
3. Unscrew battery plugs.
4. Shine a torch into the battery. The acid level of the battery must be at the protruding lug.
- If the acid level is too low, refill with distilled water using the battery filling bottle.
5. Screw in battery plugs again and ensure that they are seated correctly.
6. Remount battery cover.
Checking gravity of electrolyte
NOTE:  Only for low-maintenance batteries.
NOTE:  Use commercially available battery acid tester.

 The acid density test provides information about the state of the battery in
conjunction with the battery load test.
 The temperature of the battery acid must be at least 10°C.
The gravity of electrolyte must be checked as follows in all battery cells (low-maintenance battery) :
Emerging battery acid. Observe --> 270601 Checking battery - General warning notes.
2. Unscrew all battery plugs (plugs of the battery cells).
3. Dip the acid siphon or the pipette into the battery cell and take up the battery acid.
4. Read off the gravity of electrolyte in kg/dm3 on the scale of the battery acid tester and compare with the
following table.
Battery charge state in normal climatic zones Spec. gravity in kg/dm3

discharged 1.12
half charged 1.20
well charged 1.28
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Battery charge state in tropical climatic zones (hot countries) Spec. gravity in kg/dm3
discharged 1.08
half charged 1.16
well charged 1.23
The gravity of electrolyte must be at least 1.24 kg/dm3 in normal climatic zones.
- If the gravity of electrolyte is too low, charge battery.
- After charging the battery, repeat the electrolyte gravity test.
The measured values for the gravity of electrolyte of the individual battery cells should not deviate by more
than 0.03 kg/dm3 from each other.
Examples of non-permissible specific gravity of electrolyte deviations:

Battery cell: 1 2 3 4 5 6
Gravity of electrolyte per cell in kg/dm3
Example 1: 1.24 1.25 1.25 1.10 1.24 1.25
Example 2: 1.26 1.26 1.25 1.14 1.18 1.24
Example 1: The gravity of electrolyte in cell 4 is too low.
Example 2: The gravity of electrolyte in cells 4 and 5 is too low. The specific gravity of electrolyte deviations
between the battery cells is greater than 0.03 kg/dm3 .
- If the nominal values are not achieved, replace battery.
- If the nominal values are achieved, screw in the original plugs again.
Open-circuit voltage measurement
NOTE:  Use a hand-held multimeter to measure the battery voltage.
NOTE:  After charging and waiting for at least 2 hours, during which time the
battery should neither be loaded nor charged:
2. Disconnect ground strap on the battery.
3. Measure the battery voltage with a hand-held multimeter.
- The battery open-circuit voltage should not fall below 12.5V.

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- If the hand-held multimeter shows 12.5V or more, the battery voltage is OK.
- If the hand-held multimeter shows a battery voltage below 12.5V: Charge battery.
Battery load test
NOTE:  The acid density test provides information about the state of the battery in
conjunction with the battery load test.
 A battery test device is required for the load test.
 The battery need not be removed or disconnected.
 The battery must be charged before the load test is performed.
Carrying out battery load test:
2. Observe the information in the operating instructions of the battery test device.
3. Connect the clamps of the test lines to the battery terminals as described in the operating instructions of the
test device.
- As the load current varies, the current must be set depending on the battery capacity (operating instructions of
test device).
4. Perform the battery load test in accordance with the operating instructions.
- The result of the battery load test is a voltage value that must be compared with the specified minimum
voltage (limit value).
Table:
Battery capacity: 80 Ah
Cold test current 380A
Load current 300A
Minimum voltage (limit value) 9.5V
5. If the minimum voltage is not attained, replace battery.
Remarks on battery load test:
The battery voltage sinks during this test due to the severe load on the battery.
If the battery is in order, the voltage value only decreases to the minimum voltage.
If the battery is faulty, the battery voltage will sink very quickly below the specified minimum voltage.
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After the test has taken place, the low voltage value remains over a long period of time; the voltage increases
again slowly.
Charging battery
NOTE:  A battery charging device is required.

 Observe charging device operating instructions.
 The battery must have a minimum temperature of 10°C.
 If possible, do not fast charge batteries as this can damage them.
 If exhaustively discharged batteries are charged quickly, they will not take
up a charge current or they will be identified too early as full due to the so-
called "surface charge".
1. Switch off battery charging device.
3. First disconnect the ground strap of the battery, then the positive battery line.
4. Connect positive line of the battery charging device to the positive terminal of the battery.
5. Connect negative line of the battery charging device to the negative terminal of the battery.
6. Set the charge current on the battery charging device according to the battery capacity.
7. Switch on battery charging device.
Procedure for charging totally discharged batteries:
Batteries which are not in operation for a long period of time discharge.
A battery is totally discharged if the open-circuit voltage has sunk below 11.6 V.
In totally discharged batteries, the battery acid (sulphuric acid and water mixture) consists of virtually only
water, as the sulphuric acid proportion is considerably reduced.
Totally discharged batteries sulphatize, i. e. the entire plate surfaces of the batteries harden.
If totally discharged batteries are immediately recharged after an exhaustive discharge, the self-cultivation
recedes again.
If these batteries are not recharged, the plates continue to harden and charge take-up ability is limited. A
reduction in the battery performance is the result.
Totally discharged batteries must be charged with a low charge current as follows:
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- Set charge current at maximum 10% of battery capacity, i. e. with a 80 AH battery the charge current is
maximum 8 A.
8. Charge battery.
27 06 IN ELECTRICAL EMERGENCY RELEASE, FRONT LID - AS OF MY

2005 (ALL MODELS)
ELECTRICAL EMERGENCY RELEASE, FRONT LID
NOTE:  In the event of a flat battery, the release motors of both lids can be
supplied with power through the power feed via a battery jump lead.
 An emergency power contact, colored red for identification, is located on
the fuse box in the driver's footwell.
 This emergency power contact, to which the positive jump lead is
connected, can be pulled out of the fuse box by Prix. 3 cm.
 The power supply is switched to the release motors by a change-over
relay (mini-relay), located behind the fuse box.
 If the vehicle is locked (alarm protected), the alarm will sound if the jumper
lead is connected.
 Turn off alarm system by locking and then unlocking the door lock.
1. Unlock the vehicle at the door lock with the key.
2. Remove lid on fuse box and pull emergency power contact out of the fuse box.
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Fig. 4: Connecting the positive terminal

3. Connect the red jumper lead (positive) to this contact.
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Fig. 5: Connecting the negative terminal

4. Connect second (negative) jump lead to vehicle ground (e. g. to the lock striker on the B-pillar).
5. Connect jumper leads to an appropriate power source (e. g. separate vehicle battery).
6. Actuate the lid switch on the sill cover and open the lid.
7. Disconnect jumper leads and push the emergency power contact back in.
8. Clip cover back onto the fuse box.
27 06 IN WORK INSTRUCTIONS AFTER DISCONNECTING THE BATTERY -

DISCONNECTING AND CONNECTING THE BATTERY
Disconnecting and connecting the battery
WARNING: Risk of explosion, injury, short circuit and damage to the generator and
electronic control units!
--> Protective goggles must be worn at all times when working on the battery.
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--> Do not disconnect battery with engine running.
--> Disconnect and reconnect battery with extreme caution. Risk of short circuit and explosion.
--> Do not tilt battery when removing it. Risk of acid burns as a result of emerging acid.
--> Do not rub the battery with a dry cloth. Risk of explosion as a result of static charge.
--> All loads must be switched off beforehand!
--> Never start engine without securely connected battery!
--> Do not use a boost charger to start the engine!
--> Whenever possible, use jump leads with overvoltage protection!
--> Always disconnect and cover both battery terminals before carrying out welding work on the vehicle!
--> For vehicles with auxiliary battery, also disconnect and cover both terminals of this battery before carrying
out welding work!
--> Always pull off or push on the wiring harness plugs of control units or other electronic components when
the ignition is switched off.
The battery is located at the front in the radiator tank.
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Fig. 6: Battery cover

1. Open the turn-lock caps -A- of the battery cover and take off the plastic lid. See Fig. 6.
Fig. 7: Disconnecting battery

2. Disconnect the negative cable from the battery.
3. Route or isolate negative cable so that all contact with a ground carrier (e. g. body) is avoided.
Screwing ground strap onto battery:
4. Connect the negative cable. --> M6: 5 (3.5 ftlb.) Nm
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5. Position the battery cover and secure by means of the two turn-lock caps -A- . See Fig. 8.
Effect of disconnection or total discharge of battery on electrical systems in the vehicle and the precautions to be taken
NOTE: Control unit memories
Values and faults stored in the control units can be deleted if the battery is
disconnected or completely discharged.
 If possible, all fault memories should be checked and, if necessary, printed

out before the battery is disconnected.
NOTE: Supply voltage fault entry
The entry "supply voltage" may be stored in various control units if the battery
has been completely discharged.
 Delete the "supply voltage" entry from the control units in question.
NOTE: Ready status
In some countries (presently the U. S. A. and Canada), after disconnecting the

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battery, it is necessary to reach the Ready status by a test drive and/or by using
the Porsche System Tester DME control module menu). If in doubt about this,
contact the relevant importer.
2470 DME control module
With all DME systems, the engine must run for several minutes before the
engine control module can relearn the idle speed and mixture adaptation
values!
After disconnection of the power supply, the idle speed might change or
fluctuate briefly until the throttle valve adjusting unit has been readapted.
The mixture adaptation is also lost.
After the battery is connected:
With the DME, it is necessary to carry out a learning and adaptation routine as
described below:
 Switch ignition on for 30 seconds without starting the engine.

 Do not actuate accelerator pedal.
This completes the adaptation of the throttle valve adjusting unit.
NOTE: Tire pressure monitoring system
When the battery is disconnected and connected, the Tire pressure is first
displayed as "- - - ".
 Once the battery has been disconnected and work is complete, the vehicle
must be driven for a short distance.
The actual pressures will then be displayed again.
NOTE: Steering angle sensor
The steering angle sensor must be reinitializes when the battery is

disconnected and connected. refer to 45 60 INITIALIZING AND CALIBRATING
STEERING-ANGLE SENSOR - AS OF MY 2005 (ALL MODELS) .
 Turn wheels to straight-ahead position.
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 Switch ignition off and then on again twice.

 Start engine.
 From the straight-ahead position, turn steering wheel approx. 20° to the
right, past the straight-ahead position.
 Drive the vehicle straight ahead for at least one second at a speed above 4
km/h (2.5 mph).
The steering angle sensor segment is recognized again in this process.
Once the sensor has been successfully initialized, the fault code that is stored in the fault memory is
documented using the fault deletion counter. The fault memory erases itself automatically.
The PSM indicator light in the instrument cluster goes out.
NOTE: 6452 Power windows
The end positions of the power windows are deleted from the control unit when
the battery is disconnected and connected.
Perform the following procedure for all power windows:
 Actuate rocker switch and fully close window once.

 Actuate rocker switch once more to close.
 Actuate rocker switch and fully open window once.
 Actuate rocker switch once more to open.
The upper end position of the window is stored.
The lower end position of the window is stored.
NOTE: 9025 Instrument cluster
Clock
The time is deleted when the power supply is disconnected.
 Press clock control button approx. 1 second on instrument cluster. Hour

display flashes.
 Press clock control button in the corresponding direction. Hours can be
adjusted.
 Press the clock control button again, the minute display flashes and can
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be adjusted by turning the clock control button.

 The trip counter is set to 0 when the power supply is disconnected.
Trip odometer
NOTE: Airbag control module
If the battery is disconnected for less than 100 seconds when the ignition is
switched on, a CAN time fault, which makes diagnosis of the airbag control unit
impossible, may be stored in the airbag control unit.
 The fault is erased by removing the ignition key.
NOTE: On-board computer
Disconnection of the vehicle battery deletes the memories for average speed
and average consumption. As a result, the displayed range on remaining fuel
can be markedly different or even 0. The outside temperature display loses its
memory effect. In other words, the indicated outside temperature can be too
high due to the heat radiated when the vehicle is hot.
PCM
When the power supply is disconnected, the built-in GPS receiver loses the so-
called almanac containing the satellite orbital paths.
 Switch on PCM when there is a free panoramic view (load GPS almanac);
the almanac is reloaded as soon as four satellites have been identified.
 The date and time are also adopted once the GPS almanac has been
loaded; it may be necessary to change over to summer time (daylight-
saving time). This time is transferred to the instrument cluster. If the time
is then manually changed by means of the instrument cluster, this time is
adopted by the PCM and synchronized with GPS time.
 The telephone is enabled again when the telephone PIN code is entered
with the SIM telephone card inserted.
The date and time are deleted when the battery is disconnected. The summer-/wintertime recognition feature is
maintained. The time is lost and is updated again when there is a plausible GPS reception (four satellites).
If the telephone car had been inserted and the telephone was ready for operation, the telephone is subsequently
disabled (only if "Use last PIN" is deactivated).
Test drive after disconnecting battery
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NOTE: Depending on the vehicle equipment fitted, all these work steps are carried out
during the test drive.
The fault memories of all vehicle control units should be read out again after the
test drive!
Effects of overvoltage on electrical and electronic systems during welding work and the precautions to be taken
CAUTION: Risk of damage to generator and electronic control units.
--> Disconnect and cover both battery terminals before carrying out welding work on the vehicle! --> 270619
Removing and reinstalling battery - chapter on "Removing".
--> Risk of triggering of airbag modules! Before starting welding work, the airbag triggering unit must be
disconnected from the vehicle electrical system by pulling off the connector. Refer to 69 53 19 Removing and
installing triggering unit for airbag - as of MY 2005 (All Models) .
--> During electric arc welding (e. g. gas shielded arc welding), high currents and voltages flow; these are
greater than the vehicle voltage and can lead to the damage or destruction of electric and electronic components.
To keep the risk of damage as low as possible, the ground strap must be clamped as near as possible to the
welding area.
--> On completion, first install the airbag triggering unit Refer to 69 53 19 Removing and installing triggering
unit for airbag - as of MY 2005 (All Models) ., then connect the battery --> 270619 Removing and
reinstalling battery - chapter on "Installing" --> 270619 Removing and reinstalling battery - chapter on
"Removing and reinstalling".
27 06 IN EXTERNAL POWER CONNECTION, JUMP LEAD STARTING - AS

PRELIMINARY WORK
Preliminary work for external power connection, jump lead starting
Jump lead starting:
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Fig. 9: Battery cover turn-lock fasteners

1. Open the turn-lock fasteners -A- of the battery cover and remove cover. See Fig. 9.
External power connection:
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Fig. 10: Cover for the fuse carrier

1. Unclipping the cover for the fuse carrier.
Warning notes for external power connection, jump lead starting
WARNING: Improper handling of jump leads.
 Risk of explosion as a result of electrolytic gas.

 Danger of injury from short circuit.
 Risk of damage to the vehicle's electrical system, e. g. control
modules.
 Risk of causticisation.
--> Keep ignition sources away from the battery, e. g. naked flames, lit cigarettes or sparking from wire contact.
--> A frozen battery must always be thawed before connecting just leads.
--> Use only standard jump leads with a sufficiently wide cross section and fully insulated terminal clamps.
Observe the cable manufacturer's specifications.
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--> Route the jump leads so that they cannot become entangled in moving parts in the engine compartment.
--> No contact is allowed between the vehicles, otherwise electricity could flow as soon as the positive terminal
is connected.
INFORMATION
External power connection
NOTE:  If the battery is flat, jump leads can be used together with the battery of
another vehicle to start the car or to supply external power to the vehicle.
Both batteries must be 12 V batteries.
The capacity (Ah) of the battery supplying the power must not be significantly lower than that of the flat
battery.
The flat battery must be properly connected to the vehicle electrical system.
Fig. 11: Pulling out power connection at fuse carrier

1. Pull out the power connection -A- on the fuse carrier. See Fig. 11.
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Fig. 12: Connecting battery

2. First connect the positive cable to the battery, then to the power connection -A- on the fuse carrier.
3. First connect the negative cable to the negative terminal of the battery supplying the power, then to the
ground point -B- .
4. Now the servomotors for the front and rear covers can be operated.
Jump lead starting
Both batteries must be 12 V batteries.
The capacity (Ah) of the battery supplying the power must not be significantly lower than that of the flat
battery.
The flat battery must be properly connected to the vehicle electrical system.
1. First connect the positive cable to the positive terminal of the recipient battery, then to the positive terminal
of the donor battery.
2. First connect the negative cable to the negative terminal of the donor battery, then to a suitable ground point
on the recipient car.
A suitable ground point can be e. g. one specially for jump starts, a solid metal component or the engine block.
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The ground point should be as far away from the battery as possible.
If a suitable ground point is only present in the donor vehicle, then first connect the negative cable to the
negative terminal of the recipient battery and then to the ground point of the donor vehicle.
If neither vehicle has a ground point, first connect the negative cable to the negative terminal of the donor
battery, then carefully to the negative terminal of the recipient battery.
3. Have the engine of the vehicle supplying the power run at a higher speed.
4. Start engine. Do not spend longer than 15 seconds trying to start the vehicle with the jump leads - after 15
seconds have elapsed, wait for at least one minute.
Before disconnecting the jump leads, switch on high electrical loads in the recipient vehicle, e. g. rear window
heater and interior blower, in order to reduce any voltage peaks on disconnection. The light must not be turned
on.
5. Disconnect the two jump leads in reverse sequence when the engine is running.
SUBSEQUENT WORK
Rework on external power connection, jump lead starting
Jump lead starting:
Fig. 13: Battery cover turn-lock fasteners

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1. Put on the battery cover and secure by means of the two turn-lock fasteners -A- . See Fig. 13.
External power connection:
1. Clip in the cover for the fuse carrier.
27 06 01 BATTERY TRICKLE CHARGE - AS OF MY 2005 (ALL MODELS)

PRELIMINARY WORK
1. Remove battery cover. --> 270601 Checking battery - removing.
2. Connect rapid-start battery charger to the vehicle battery.
3. Follow the instructions for the rapid-start battery charger under: "Battery charging condition/operating
status".
--> 270601 Checking the battery
TOOLS AND MATERIALS
Check battery voltage using a rapid-start battery charger.
See Workshop Equipment Manual, Gr. 2.5
CHECKING BATTERY CHARGING CONDITION WITH BATTERY TESTER
1. Check the battery charging condition according to the operating instructions for the relevant rapid-start
battery charger.
Evaluating the test results and further procedures:
Open-circuit Battery charging

Evaluation and procedure
voltage in volts condition in %
12.7 - 12.5 100 - 80 Battery charging condition OK
Battery charging condition reduced, recharge battery and observe an
12.5 - 12.2 80 - 50 inactive period for two hours after charging. --> 270601 Checking
battery
Battery flat; recharge battery and observe an inactive period for two
12.2 - 11.6 50 - 10
hours after charging. --> 270601 Checking battery
Battery totally discharged; replace battery. --> 270619 Removing
below 11.6 below 10
and installing battery
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REWORKING
1. Install battery cover. --> 270601 Checking battery - removing.
27 06 19 REMOVING AND INSTALLING BATTERY - AS OF MY 2005 (ALL

MODELS)
REMOVING BATTERY
Removing battery
The battery is located at the front in the radiator tank.
Observe the warning notes and safety regulations for lead-acid batteries. Refer to General warning notes for
instructions for handling batteries.

1. Open the turn-lock caps -A- of the battery cover and take off the plastic lid. See Fig. 14.
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Fig. 15: Disconnecting battery

electronic control units.
 Risk of acid burns as a result of emerging acid.
--> Switch off all loads and remove ignition key.
2. First disconnect the negative then the positive leads from the battery.
3. Pull the vent hose -C- away from the battery. See Fig. 15.
4. Unscrew the fastening screw for the battery mount -B- and remove the battery mount. See Fig. 15.
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5. Risk of contact with corrosive fluid Remove battery from battery case by the folding handles, if at all
possible without tilting it.
INSTALLING BATTERY
Installing battery
Make sure that the vent hose is in good condition. If the hose is deformed or damaged, replace it.
1. Risk of contact with corrosive fluid! Position the battery in the battery case below the stops, if at all possible
without tilting it.
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Fig. 16: Battery mount

2. Position the battery mount and tighten with the fastening screw -B- . --> M8: 23 (17 ftlb.) Nm See Fig. 16.
3. Insert the vent hose for the battery.
4. Risk of short circuit! First connect the positive cable then the negative cable. --> M6: 5 (3.5 ftlb.) Nm
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5. Position the battery cover and secure using the two twist locks -A- . --> 271219 Removing and installing
battery cover - section on "Reworking"See Fig. 17.
SUBSEQUENT WORK
Subsequent work - battery
Work instructions after disconnecting the battery --> 27 06 IN Work instructions after disconnecting the
battery - as of MY 2005 (All Models).
27 12 19 REMOVING AND INSTALLING BATTERY COVER - AS OF MY 2005

(ALL MODELS)
REMOVING BATTERY COVER
Removing battery cover
1. Open luggage compartment.
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Fig. 18: Opening turn-lock fasteners

2. Twist turn-lock fasteners of cover 90° to the right, lift up with cover and disengage from cowl panel cover.
3. Place battery cover on a level surface.
INSTALLING BATTERY COVER
Installing battery cover
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Fig. 19: Engaging battery cover

1. Engage battery cover with external hooks in left and right mounting points of cowl panel cover.
2. Insert battery cover as far as it will go by pivoting it inward and applying simultaneous pressure in
direction of windscreen.
3. Align turn-lock fasteners fore-and-aft and engage by pressing down lightly.
4. Locate locking hooks at the connecting flanges with the plenum panel side covers by pressing down lightly.
5. Check gap dimension of battery cover; if necessary, rework the cowl panel covers or adjust the covers of
battery, cowl panel, plenum panel so that they mate. --> 271219 Removing and installing battery cover -
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chapter on "Reworking"
SUBSEQUENT WORK
Reworking if cowl panel cover deformed
Possible causes for difficulty in fitting battery cover:
Fig. 20: Deformation of cowl panel cover

- A deformed connecting flange on the cowl panel cover or a cowl panel cover installed twisted.
1. Loosen all threaded joints of cowl panel cover.
2. Loosen antenna holder fastening screws.
3. Mask off the Velcro connection for plenum panel cover on left and right using commercially available
adhesive tape.
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Fig. 21: Greasing the hook of the battery cover

NOTE: Lightly grease the hook of the battery cover with the following grease, Part No.
000.043.204.68.
4. Fit the battery cover as follows:
4.1. Engage battery cover with external hooks in left and right mounting points of cowl panel cover.
4.2. Insert battery cover as far as it will go by screwing in and applying simultaneous pressure in direction of
windscreen.
4.3. Do not engage turn-lock fasteners.

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4.4. Release tension from the entire set of covers (covers: plenum panel, battery, cowl panel) by sideways
shifting. Make sure there is no warping in the area where the plenum panel adjoins the luggage
compartment seal.
4.5. Align turn-lock fasteners fore-and-aft and engage by pressing down lightly.
5. If the battery cover still protrudes at the sides then it is deformed and must be replaced.
6. If the gaps look correct, screw down the cowl panel cover at its three fastening points in the area of the
windscreen to the specified tightening torque. --> Tightening torque: 4.0 (3.0 ftlb.) Nm --> Tightening
torque: 2.0 (1.5 ftlb.) Nm
7. Remove battery cover and tighten the two fastening screws of the cowl panel cover (to rear of battery) to the
specified tightening torque. --> Tightening torque: 2.0 (1.5 ftlb.) Nm
8. Tighten fastening screws for telephone antenna holder.
9. Fit cowl panel cover and battery cover as described.
27 22 19 REMOVING AND INSTALLING THREE-PHASE GENERATOR - AS

PRELIMINARY WORK
Preliminary work
1. Disconnect battery. 27 06 IN Work instructions after disconnecting the battery - as of MY 2005 (All
Models)
2. Remove drive belt. Refer to 13 78 19 Removing and installing drive belt - as of MY 2005 (All Models) .
REMOVING THE THREE-PHASE GENERATOR
Removing three-phase generator
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Fig. 22: Installation position of generator

Fig. 23: Unscrewing fastening screws of three-phase generator

2. Unscrew fastening screw -3- three turns. The threaded bush in the linkage lever of the generator -1- must be
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reset in order to establish the required play to extend the generator. This can be done by tapping lightly on the
fastening screw using an aluminum mandrel -2- . See Fig. 23.
3. Remove generator -1- upwards out of the slotted support. Unscrew fastening screw -3- and remove, together
with the deflection roller -4- . See Fig. 23.
Fig. 24: Extending generator

4. Turn generator -1- clockwise -arrow A- until the holding arm projects beyond the lug. See Fig. 24.
5. Tilt generator -1- carefully outwards and to the front -arrow B- until the electrical connections are accessible.
See Fig. 24.
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Fig. 25: Disconnecting electrical connections on the generator

6. Release connector -2- and remove it -arrow a- . See Fig. 25.
7. Unscrew fastening nut -3- for the B+ lead -4- and remove the B+ lead -4- . Remove generator -1- . See Fig.
25.
INSTALLING THE THREE-PHASE GENERATOR
Installing three-phase generator
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Fig. 26: Connecting electrical connections on the generator

1. Insert generator -1- , connect B+ lead -4- and tighten with fastening nut -3- . --> Tightening torque: 15 (11
2. Connect plug -2- until it clicks into place. See Fig. 26.
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Fig. 27: Running in generator

3. Run in generator -1- carefully to the rear -arrow A- . See Fig. 27.
4. Turn generator -1- in an anticlockwise direction -arrow B- until the holding arm fits into its installation
position behind the lug. See Fig. 27.
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Fig. 28: Tightening the fastening screws of the three phase generator
5. Insert and position fastening screw -3- and deflection roller -4- in generator -1- . See Fig. 28.
6. Insert generator -1- and fastening screw -3- from above into the slotted support and tighten fastening screw -
3- . --> Tightening torque: 46 (34 ftlb.) Nm . See Fig. 28.
7. Tighten fastening screw -2- . --> Tightening torque: 46 (34 ftlb.) Nm . See Fig. 28.
SUBSEQUENT WORK
Subsequent work
1. Install drive belt. Refer to 13 78 19 Removing and installing drive belt - as of MY 2005 (All Models) .
2. Connect the battery and carry out "Work instructions after disconnecting the battery". 27 06 IN Work
instructions after disconnecting the battery - as of MY 2005 (All Models)
27 22 19 REMOVING AND INSTALLING THREE-PHASE GENERATOR - AS

PRELIMINARY WORK
Preliminary work
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1. Disconnect battery.27 06 IN Work instructions after disconnecting the battery - as of MY 2005 (All
Models)
REMOVING THE THREE-PHASE GENERATOR
Removing three-phase generator
Fig. 29: Installation position of generator

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Fig. 30: Unscrewing fastening screws of three-phase generator

2. Unscrew fastening screw -3- by three turns. The threaded bush in the linkage lever of the generator -1- must
be reset in order to establish the required play to extend the generator. This can be done by tapping lightly on
the fastening screw using an aluminum mandrel -2- . See Fig. 30.
3. Remove generator -1- upwards out of the slotted support. Unscrew fastening screw -3- and remove, together
with the deflection roller -4- . See Fig. 30.
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Fig. 31: Extending generator

4. Turn generator -1- clockwise -Arrow A- until the holding arm projects beyond the retaining lug. See Fig. 31.
5. Tilt generator -1- carefully outwards and to the front -Arrow B- until the electric connections are accessible.
See Fig. 31.
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Fig. 32: Disconnecting electric connections on the generator

6. Release connector -2- and remove it -Arrow a- . See Fig. 32.
7. Unscrew fastening nut -3- for the B+ lead -4- and remove the B+ lead -4- . Remove generator -1- . See Fig.
32.
INSTALLING THE THREE-PHASE GENERATOR
Installing three-phase generator
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Fig. 33: Connecting electrical connections on the generator

1. Insert generator -1- , connect B+ lead -4- and tighten with fastening nut -3- . --> Tightening torque: 15 (11
2. Connect plug -2- until it clicks into place. See Fig. 33.
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Fig. 34: Running in generator

3. Run in generator -1- carefully to the rear -arrow A- . See Fig. 34.
4. Turn generator -1- in an anticlockwise direction -arrow B- until the holding arm fits into its installation
position behind the lug. See Fig. 34.
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Fig. 35: Tightening the fastening screws of the three phase generator
5. Insert and position fastening screw -3- and deflection roller -4- in generator -1- . See Fig. 35.
6. Insert generator -1- and fastening screw -3- from above into the slotted support and tighten fastening screw -
3- . --> Tightening torque: 46 (34 ftlb.) Nm See Fig. 35.
7. Tighten fastening screw -2- . --> Tightening torque: 46 (34 ftlb.) Nm See Fig. 35.
SUBSEQUENT WORK
Subsequent work
1. Install drive belt. Refer to 13 78 19 Removing and installing drive belt - as of MY 2005 (All Models) .
2. Connect the battery and carry out "Work instructions after disconnecting the battery". 27 06 IN Work
27 60 19 REMOVING AND INSTALLING STARTER - AS OF MY 2005 (ALL

MODELS)
PRELIMINARY WORK
Preliminary work - starter
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Remove the engine-compartment lid. Refer to 55 78 19 Removing and installing engine compartment lid - as
Disconnect battery. 27 06 IN Work instructions after disconnecting the battery - as of MY 2005 (All
Models)
Remove rear wall cover. Refer to 55 59 19 Removing and installing rear wall cover - as of MY 2005 (All
Models) .
Remove center intake-air distributor with throttle valve. Refer to 24 46 20 Removing and installing intake-air
distributor - as of MY 2005 (All Models) .
REMOVING THE STARTER
Removing starter
WARNING: If the battery has not been disconnected, battery voltage will be present at
the leads during removal and installation.
 Risk of injury from burns and electric shock.

 Damage to electrical leads, control units and components due to
accidental contact of leads with ground.
--> Disconnect both battery terminals and cover the + terminal.
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Fig. 36: Removing starter

1. Unscrew fastening nuts for electric line, terminal 30 (M8) and terminal 50 (M6), on solenoid switch, remove
the electric lines -1, 2- and place them to one side. See Fig. 36.
2. Undo top fastening screw -3- . See Fig. 36.
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Fig. 37: Undoing the lower fastening screw

3. Unscrew lower fastening screw -4- through the rear wall cover opening using a ratchet spanner and an extra
long extension. See Fig. 36.
4. Lift starter out of the bracket.
INSTALLING THE STARTER
Installing starter
WARNING: If the battery has not been disconnected, battery voltage will be present at
the leads during removal and installation.
 Risk of injury from burns and electric shock.

 Damage to electrical leads, control units and components due to
accidental contact of leads with ground.
--> Disconnect both battery terminals and cover the + terminal.
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Fig. 38: Installing starter

1. Insert starter into the bracket from above and install with the upper fastening screw -3- . --> Tightening
2. Screw down the lower fastening screw -4- through the tailgate. --> Tightening torque: 33 ftlb. See Fig. 38.
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Fig. 39: Screwing down lower fastening screw

3. Position electrical leads on the starter and tighten with fastening nuts -1, 2- . --> Tightening torque: 13 ftlb.
--> Tightening torque: 5 ftlb. See Fig. 38.
SUBSEQUENT WORK
Subsequent work - starter
Install center intake-air distributor with throttle valve. Refer to 24 46 20 Removing and installing intake-air
distributor - as of MY 2005 (All Models) .
Install rear wall cover. Refer to 55 59 19 Removing and installing rear wall cover - as of MY 2005 (All
Models) .
Connect the battery and carry out "Work instructions after disconnecting the battery". 27 06 IN Work
Install the engine-compartment lid. Refer to 55 78 19 Removing and installing engine compartment lid - as
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ENGINE Cooling
ENGINE
Cooling
19 01 TW TECHNICAL DATA, COOLING SYSTEM - AS OF MY 2005

TECHNICAL VALUES
Engine cooling
Designation 987 987 S

Water cooled in front end of car, radiators ahead of front
Cooling type/installation location
wheels
Manual transmission: 2 Radiators
No. of radiators
Tiptronic: Three coolers
Fans 2 Electric fans, infinitely controllable
22 l manual transmission 22.3 l
Coolant filling capacity (depending on vehicle)
Tiptronic: 22.4 l Tiptronic: 23.3 l
19 01 01 CHECKING COOLING SYSTEM - AS OF MY 2005 (CAYMAN S,

CAYMAN S RHD)
TOOLS

Vacuum cleaner nozzle, special tool NR.160
long crevice tool for
cleaning cooling air inlet
shafts
CHECKING COOLING SYSTEM
Coolant - check antifreeze and fluid level
WARNING: Danger of scalding from hot pressurized coolant.
--> Only work on the coolant system when the engine is "cool".
NOTE:  The coolant filled in at the factory is intended for lifetime cooling and,
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ENGINE Cooling
thus, need not be changed.
NOTE:  On Cayman vehicles, the coolant reservoir is located in the engine

compartment.
 Testing and inspection work are performed via an opening in the service
tray (right).
 Filling and bleeding procedures are performed on the coolant reservoir.
Fig. 1: Boxster cap

1. Open cap on coolant expansion tank.
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ENGINE Cooling
Fig. 2: Service tray in Cayman

Cayman service tray
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ENGINE Cooling
Fig. 3: Example showing use of antifreeze tester

CAUTION: Mixing coolant.
 Corrosion of components and flocculation of coolant
--> Do not mix Porsche coolant with other coolants.
--> When replacing or topping up coolant, use only original Porsche coolant (see Porsche Parts Catalogue).
2. Check antifreeze content with a commercially available antifreeze tester. If this is below - 35°C, correct the
anti-freeze content by raising the proportion of pure coolant accordingly. ;
Fig. 4: Tightening cap

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ENGINE Cooling
3. Screw on cap and tighten it. Do not tilt lid.
Cleaning the cooling air guides
Fig. 5: Cooling air openings (example from Tiptronic with middle radiator)
CAUTION: Soiling and damage to radiator surface (vanes).
 Engine overheating due to lack of cooling performance.
--> Clean radiator surface regularly.
--> Do not use a high-pressure steam cleaner to clean it.
1. Check cooling air guides and radiator for foreign bodies such as leaves. If necessary, carefully clean the
cooling air guides and radiator surfaces at the front using a vacuum cleaner with a single nozzle, see Vacuum
cleaner nozzle, long crevice tool for cleaning cooling air inlet shafts NR.160. If a high-pressure steam
cleaner is used, the steam jets can cause additional particles of dirt to attach to the radiator surface and the
cooling vanes can be bent. The engine becomes overheated due to lack of cooling performance.
19 01 01 CHECKING COOLING SYSTEM - AS OF MY 2005 (BOXSTER,

TOOLS
Microsoft
ENGINE Cooling

Vacuum cleaner nozzle, special tool NR.160
long crevice tool for
cleaning cooling air inlet
shafts
CHECKING COOLING SYSTEM
Coolant - check antifreeze and fluid level
NOTE:  The coolant filled in at the factory is intended for lifetime cooling and,
thus, need not be changed.

compartment.
tray (right).
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ENGINE Cooling
Fig. 6: Boxster cap

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ENGINE Cooling
Fig. 7: Service tray in Cayman

Cayman service tray
Fig. 8: Example showing use of antifreeze tester

CAUTION: Mixing coolant.
 Corrosion of components and flocculation of coolant
--> Do not mix Porsche coolant with other coolants.
--> When replacing or topping up coolant, use only original Porsche coolant (see Porsche Parts Catalogue).
2. Check antifreeze content with a commercially available antifreeze tester. If this is below - 35°C, correct the
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ENGINE Cooling
anti-freeze content by raising the proportion of pure coolant accordingly. ;

Checking the cooling system for leaks
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ENGINE Cooling
Fig. 10: Opening the cap

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ENGINE Cooling
Fig. 11: Connection for coolant system tester

2. Check the cooling system for leaks. To do this, apply a test pressure of approx. 1 bar using the cooling
system test device and check hose connections for leakage.

Cleaning the cooling air guides
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ENGINE Cooling
Fig. 13: Cooling air openings (example from Tiptronic with middle radiator)
CAUTION: Soiling and damage to radiator surface (vanes).
 Engine overheating due to lack of cooling performance.
--> Clean radiator surface regularly.
--> Do not use a high-pressure steam cleaner to clean it.
1. Check cooling air guides and radiator for foreign bodies such as leaves. If necessary, carefully clean the
cooling air guides and radiator surfaces at the front using a vacuum cleaner with a single nozzle, see Vacuum
cleaner nozzle, long crevice tool for cleaning cooling air inlet shafts NR.160. If a high-pressure steam
cleaner is used, the steam jets can cause additional particles of dirt to attach to the radiator surface and the
cooling vanes can be bent. The engine becomes overheated due to lack of cooling performance.
19 24 19 REMOVING AND INSTALLING AIR GUIDE - AS OF MY 2005

PRELIMINARY WORK
Preliminary work for removing air guide

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ENGINE Cooling
REMOVING AIR GUIDE
Removing air guide for middle radiator
Fig. 14: Air guide

1. Pull off the air guide for the middle radiator. To do this, pull the right and left rubber tabs for the air guide off
the radiator -1- . Pull the top three rubber tabs up -2- and release them. Loosen the air guide around the radiator
and remove it. See Fig. 14.
Removing air guide for side radiator
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ENGINE Cooling
Fig. 15: Air guide for side radiator

1. Remove the air guide at the left side. To do this, remove the three fastening screws -1- and pull the air guide
sideways out of the plastic tabs -2- . See Fig. 15.
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ENGINE Cooling
Fig. 16: Temperature sensor

2. Remove the air guide on the right side in the same way as on the left. The temperature sensor must also be
pulled out of the air guide from behind -arrow- . See Fig. 16.
The relevant radiator must be removed in order to remove the rear air guide. --> 197019 Removing and
installing radiator - section on "Removing"
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ENGINE Cooling
Fig. 17: Bracket for side radiator

3. Remove the sheetmetal clips and washers under the radiator bracket -arrows- . To do this, release the
sheetmetal clips using a suitable screwdriver and push them sideways out of the plastic pegs of the radiator. Pull
the radiator from the bracket up out of the guide. See Fig. 17.
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ENGINE Cooling
Fig. 18: Air guide behind side radiator

4. Disengage the rear air guide from the cooling fan. To do this, disconnect the cable plug -1- and press the
plastic lock together -2- . Then, lift the air guide out of the tabs -3- . See Fig. 18.
INSTALLING AIR GUIDE
Installing air guide for middle radiator
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ENGINE Cooling
Fig. 19: Air guide

1. Fit air guide for middle radiator. Move air guide on radiator to installation position. To do this, press on the
right and left rubber tabs for the air guide on the radiator -1- . Push in the top three rubber tabs -2- . Press the
edge of the air guide around the radiator. Check that it is fitted correctly. See Fig. 19.
Installing air guide for side radiator
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ENGINE Cooling
Fig. 20: Air duct behind side radiator

1. Fit rear air guide on cooling fan. To do this, push air guide into the tabs -3- and press air guide into the lock -
2- . Fit cable connector -1- . See Fig. 20.
2. Install side radiator --> 197019 Removing and installing radiator - chapter on "installing".
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ENGINE Cooling
Fig. 21: Air guide for side radiator

3. Fit air guide. To do this, push radiator sideways into the plastic tabs -2- and screw in 3 fastening screws -1- .
See Fig. 21.
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ENGINE Cooling
Fig. 22: Temperature sensor

4. Fit the air guide on the right side in the same way as on the left side. In addition, push the temperature sensor
into the air guide from behind -arrow- . See Fig. 21.
SUBSEQUENT WORK
Subsequent work for installing air guide
19 29 19 REMOVING AND INSTALLING CONTROL UNIT FOR COOLING AIR

CONTROL - AS OF MY 2005 (ALL MODELS)
TOOLS

socket wrench insert special tool P 300
PRELIMINARY WORK FOR REMOVING CONTROL UNIT FOR COOLING AIR CONTROL
Preliminary work for removing control unit for cooling air control
1. Disconnect ground lead of battery --> 27 06 IN WORK INSTRUCTIONS AFTER DISCONNECTING

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ENGINE Cooling
WARNING: Incorrect raising of the vehicle
 Damage to person or property caused by the car falling down
--> Raise the vehicle at the prescribed jacking points.
2. Raise the vehicle at the prescribed jacking points. --> 40 LIFTING THE VEHICLE - AS OF MY 2005
(ALL MODELS) .
3. Remove front right wheel. Use special tool socket wrench insert P 300 to avoid damage to the rim.
4. Remove right front wheel housing liner. Refer to 50 56 19 Removing and installing front wheel housing
liner - as of MY 2005 (All Models) .
REMOVING CONTROL UNIT FOR COOLING AIR CONTROL
Removing control unit for cooling air control
1. Unclip vent line -1- from the bracket and set aside. See Fig. 23.
Fig. 23: Retaining screw for control unit

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ENGINE Cooling
2. Unscrew the Torx screw (M6 x 16) -2- . See Fig. 23.
3. Pull out control unit for cooling air control to the rear.
Fig. 24: Cable plug for control unit

4. Release and disconnect cable plug -arrows- . See Fig. 24.
5. Unscrew two M6 hexagon nuts on the support and take off the control unit.
INSTALLING CONTROL UNIT FOR COOLING AIR CONTROL
Installing control unit for cooling air control
1. Position control unit in support and tighten with two M6 hexagon nuts. --> Tightening torque: 10 (7.5 ftlb.)
Nm
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ENGINE Cooling
Fig. 25: Cable plug for control unit

2. Push on cable plug -arrows- . See Fig. 25.
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ENGINE Cooling
Fig. 26: Retaining lug for control unit

3. Insert control unit into the retaining lug -arrow- . See Fig. 26.
4. Clip vent line -1- into the bracket. See Fig. 27.
Fig. 27: Retaining screw for control unit

5. Screw in the Torx screw (M6 x 16) -2- . --> Tightening torque: 10 (7.5 ftlb.) Nm . See Fig. 27.
SUBSEQUENT WORK FOR INSTALLING CONTROL UNIT FOR COOLING AIR CONTROL
Subsequent work for installing control unit for cooling air control
1. Install right front wheel housing liner Refer to 50 56 19 Removing and installing front wheel housing liner
2. Install front right wheel. Use special tool socket wrench insert P 300 to avoid damage to the rim.

4. Read out fault memory and correct any faults that are present. Erase fault memory Refer to 03 35 00 On-
board diagnosis (OBD) - as of MY 2005 (All Models) .
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ENGINE Cooling
19 38 17 DRAINING AND FILLING IN COOLANT - AS OF MY 2005 (ALL

MODELS)
TOOLS

Radiator filling device special tool P 9696
PRELIMINARY WORK
Preliminary work
1. Removing rear underside panel Refer to 51 94 19 Removing and installing cover for rear underbody - as
Cayman only:
Fig. 28: Removing engine compartment lid

2. Remove engine cover Refer to 55 78 19 Removing and installing engine compartment lid - as of MY 2005
(Boxster, Boxster RHD, Boxster S, Boxster S RHD) . Refer to 55 78 19 Removing and installing engine
compartment lid - as of MY 2005 (Cayman S, Cayman S RHD) .
DRAINING COOLANT
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ENGINE Cooling
Draining coolant
Fig. 29: Open cap (view of Boxster)


compartment.
tray (right).
1. Open cap on expansion tank.
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ENGINE Cooling
Fig. 30: "Henn coupling" in coolant hoses

NOTE:  Check Henn coupling O-rings and replace if necessary.

 Clean push-in connector and coolant hoses before assembly.
NOTE: In order to facilitate assembly of coolant pipes and hoses smear with Kluber
Syntheso Glep or alternatively Kluberplus S06-100 assembly gel (available from
the Porsche Parts catalogue)
2. Remove inlet and outlet hoses from radiators Do this by pulling off the spring clips for the two Henn
couplings -2- and pulling the hoses away from the coolant pipes -3- . Collect coolant in a clean container. After
draining the coolant, insert the clamps in the correct position in the couplings and connect the hoses. The
connection should audibly snap into place. Check correct positioning once again by pulling on the hoses. See
Fig. 30.
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ENGINE Cooling
Fig. 31: Water pump coolant hoses, thermostat, heater

NOTE: In order to facilitate assembly of coolant pipes and hoses smear with Kluber
Syntheso Glep or alternatively Kluberplus S06-100 assembly gel (available from
the Porsche Parts catalogue)
3. Pull off spring band clamp -1- on supply hose to water pump -2- . Open spring band clamp -3- on thermostat
hose and pull off hose -4- . Collect draining coolant in a clean container. Refit coolant hoses. See Fig. 31.
4. Remove heating hoses on underside of car -5- . Secure the pipes with hose clips and then open the spring
band clamps. Remove both hoses and slowly open hose clamps. Allow coolant to drain into a clean container.
Clean hoses, stick them back and attach the clips. Check that the hoses are firmly in place. See Fig. 31.
FILLING WITH COOLANT
Filling coolant (includes bleeding)

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ENGINE Cooling
NOTE: The process of filling and bleeding the cooling system continues to be
performed using the special tool Radiator filling device P 9696.
 On Cayman vehicles, the coolant reservoir is located in the engine

compartment.
tray (right).
1. Fit the vehicle protective covers.
2. Protect the luggage compartment against soiling with a cover.
Fig. 32: Connecting K22 adapter (view of Boxster)

3. Screw cap adapter for coolant expansion tank (K22) onto the tank and attach flexible extension (Fz100) to the
cap.
Microsoft
ENGINE Cooling
Fig. 33: Connecting K22 adapter (Cayman)

4. Connect vacuum pressure gauge of bleeder tool to the flexible extension. When doing so, ensure that both
shutoff valves are closed (positioned at 90° to flow direction).
Microsoft
ENGINE Cooling
Fig. 34: Venturi nozzle on vacuum pressure gauge

5. Connect the Venturi nozzle to the vacuum pressure gauge.
NOTE:  The quantity of coolant available should exceed the amount required to fill
the system by about two liters in order to prevent air being sucked in.
 An antifreeze content of -35 °C corresponds to a mixture of 50:50
(antifreeze: water).
6. Place a canister with a sufficient amount of coolant and with an antifreeze content for -35 °C behind the
vehicle near to the expansion tank
Microsoft
ENGINE Cooling
Fig. 35: Special canister filling tool

NOTE:  The bleeding process is completed more quickly if the canister is

positioned at roughly the same height as the coolant expansion tank.
7. Push the filler hose of the vacuum pressure gauge -5- onto the canister connection. Draw off the return line -
6- of the Venturi nozzle into a second container. See Fig. 35.
Microsoft
ENGINE Cooling
Fig. 36: Compressed air supply on Venturi nozzle

NOTE:  A hissing sound after connecting the compressed air supply is usual.
8. Connect compressed air supply to Venturi nozzle
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ENGINE Cooling
Fig. 37: Shutoff valves open

9. Open both shutoff valves on the vacuum pressure gauge until the transparent filler hose has completely filled
with coolant.
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ENGINE Cooling
Fig. 38: Left-hand shutoff valve closed

10. Close left shutoff valve on the vacuum pressure gauge -arrow- and allow a vacuum to build up in the
coolant circuit. See Fig. 38.
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ENGINE Cooling
Fig. 39: Vacuum established (pointer in green region)

NOTE:  If a vacuum does not build up, there is a leaking valve in the coolant
circuit.
 Deformation of the rubber hoses of the cooling system is normal.
 When the pressure gauge pointer is in the green area of the display scale,
a sufficient vacuum has been built up.
 After both shutoff valves on the vacuum pressure gauge have been closed
and the compressed air supply has been disconnected, the vacuum must
not drop. If the vacuum drops within approx. 30 seconds, there is a leak in
the coolant circuit.
11. When there is enough vacuum in the cooling system --> Vacuum established (pointer in green region) ,
close right shutoff valve and subsequently unplug the compressed air supply. See Fig. 39.
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ENGINE Cooling
Fig. 40: Left-hand shutoff valve open - right-hand valve (arrow) closed
12. Open left-hand shutoff valve to the vacuum pressure gauge (right-hand valve closed -arrow- ). The cooling
system is then filled. See Fig. 40.
13. When the cooling system no longer contains a vacuum (vacuum pressure gauge shows zero), i. e. no more
coolant is being sucked out of the canister, open right-hand shutoff valve.
14. Now remove the complete filling device filling device P 9696 (including cap K 22).
Microsoft
ENGINE Cooling
Fig. 41: Tighten cap (view of Boxster)

15. If necessary, fill the coolant expansion tank with coolant up to the maximum marking and screw on the cap
of the expansion tank (do not tilt).
REWORKING
Subsequent work
1. Check coolant line connections and hoses for leaks.
2. Completely install rear underside panel. Refer to 51 94 19 Removing and installing cover for rear
underbody - as of MY 2005 (All Models) .
Cayman:
Microsoft
ENGINE Cooling
Fig. 42: Installing engine compartment lid

3. Install engine cover Refer to 55 78 19 Removing and installing engine compartment lid - as of MY 2005
(Boxster, Boxster RHD, Boxster S, Boxster S RHD) . Refer to 55 78 19 Removing and installing engine
compartment lid - as of MY 2005 (Cayman S, Cayman S RHD) .
4. Perform a test drive with the vehicle. Following the test drive and when the engine is still at operating
temperature, accelerate briefly to greater than 6,000 rpm a number of times at idle speed in order to fully
ventilate the system.
5. Check the fluid level with the aid of the marks on the expansion tank. If necessary, correct the coolant level
after the engine has cooled.
19 50 19 REMOVING AND INSTALLING COOLANT PUMP - AS OF MY 2005

PRELIMINARY WORK FOR REMOVING COOLANT PUMP
Preliminary work for removing coolant pump
1. Place protective covers on the vehicle to avoid damaging the body.
2. Remove drive belt Refer to 13 78 19 Removing and installing drive belt - as of MY 2005 (All Models) .
Microsoft
ENGINE Cooling
3. Remove rear underbody cover Refer to 51 94 19 Removing and installing cover for rear underbody - as of
4. Drain coolant --> 193817 Draining and filling coolant - chapter on "Draining"
REMOVING COOLANT PUMP
Removing coolant pump
Microsoft
ENGINE Cooling
Fig. 43: View of coolant hoses

1. Open spring band clamps -1, 4- then loosen and pull off coolant hoses -2, 3- . See Fig. 43.
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ENGINE Cooling
Fig. 44: Threaded joint for coolant pump

2. Unscrew seven Torx screws, two M6 x 30 and five M6 x 25 -arrows- . See Fig. 44.
3. Remove coolant pump.
INSTALLING COOLANT PUMP
Installing coolant pump
1. Carefully remove remains of gasket from sealing faces; do not use sharp-edged tools.
Fig. 45: Seal for coolant pump

2. Fit new seal on the coolant pump.
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ENGINE Cooling
Fig. 46: Threaded joint for coolant pump

3. Fit coolant pump to crankcase and secure with seven Torx screws, two M6 x 30 and five M6 x 25. Tighten
screws --> Tightening torque: 7.5 ftlb. .
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ENGINE Cooling
Fig. 47: View of coolant hoses

4. Coat inside of coolant hoses with Kluber Plus (obtainable from Porsche Parts Catalogue) , push onto the
connection pieces and position spring band clamps -1, 4- . See Fig. 47.
SUBSEQUENT WORK FOR INSTALLING COOLANT PUMP
Subsequent work for installing coolant pump
1. Install drive belt Refer to 13 78 19 Removing and installing drive belt - as of MY 2005 (All Models) .
2. Fill coolant and bleed cooling system --> 193817 Draining and filling coolant - chapter on "Filling".
4. Remove protective covers.
19 58 19 REMOVING AND INSTALLING COOLANT REGULATOR

(THERMOSTAT) - AS OF MY 2005 (ALL MODELS)
TOOLS

Microsoft
ENGINE Cooling
assembly aid special tool P 9627
PRELIMINARY WORK FOR REMOVING COOLANT REGULATOR (THERMOSTAT)
Preliminary work for removing coolant regulator (thermostat)
3. Drain coolant --> 193817 Draining and filling in coolant - section on "Draining"
REMOVING COOLANT REGULATOR (THERMOSTAT)
Removing coolant regulator (thermostat)
1. Loosen spring band clamp -1- , then loosen and pull off hose -2- . See Fig. 48.
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ENGINE Cooling
Fig. 48: View of thermostat housing

2. Remove thermostat housing by unscrewing the four Torx screws (M6 x 20) -Arrows- . See Fig. 48.
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ENGINE Cooling
Fig. 49: Thermostat

3. Position special tool assembly aid P 9627 and remove thermostat -1- by simultaneously pressing and
twisting. See Fig. 49.
INSTALLING COOLANT REGULATOR (THERMOSTAT)
Installing coolant regulator (thermostat)
1. Carefully remove remains of gasket from sealing faces. Do not use sharp-edged tools.
2. Fit thermostat using assembly aid P 9627.
3. Fit thermostat housing with a new gasket by screwing in the four Torx screws (M6 x 20) -arrows- and
tightening evenly. --> Tightening torque: 7.5 ftlb. . See Fig. 50.
Fig. 50: View of thermostat housing

4. Coat inside of coolant hose -2- with Kluber Plus (obtainable from Porsche Parts Catalogue) and push
onto housing connection piece. Position spring band clamp -1- . See Fig. 50.
SUBSEQUENT WORK FOR INSTALLING COOLANT REGULATOR (THERMOSTAT)
Subsequent work for installing coolant regulator (thermostat)

Microsoft
ENGINE Cooling
19 70 19 REMOVING AND INSTALLING RADIATOR - AS OF MY 2005 (ALL

MODELS)
PRELIMINARY WORK
Preliminary work for removing radiator
Refer to 50 56 19 REMOVING AND INSTALLING FRONT WHEEL HOUSING LINER - AS OF MY

2005 (ALL MODELS) .
--> 193817 Draining and topping up with coolant - chapter on "draining".
1. Remove air guides in front of radiator --> 192419 Removing and installing air guide - chapter on
"removing" [987310 987311 987320 987321].
NOTE: The air-conditioning condenser remains in the vehicle. The air-conditioning

system is not opened.
2. Detach air-conditioning condenser from side radiator and allow it to hang freely. To do this, remove
hexagon-head sheetmetal screw between air-conditioning condenser and side radiator and pull air-conditioning
condenser out of side brackets.
REMOVING RADIATOR
Removing radiator
Microsoft
ENGINE Cooling

Fig. 52: Vent line

1. Remove the vent line at the top of the side radiator. To do this, press the lock and pull the line off the support
-1- . Pull the vent line out of the holder -2- . See Fig. 52.
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ENGINE Cooling
Fig. 53: Cable plug

2. Remove cable plug from fan motor -arrow- . To do this, press cable plug together (relieve plug), open the
release and disconnect the cable plug. See Fig. 53.
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ENGINE Cooling
Fig. 54: Attachment for hose holder

3. Remove M6 x 16 fastening screw (outer Torx) on hose holder -arrow- . See Fig. 54.
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ENGINE Cooling
Fig. 55: Radiator connections

NOTE: Despite the fact that the coolant has been drained, residual amounts of coolant
can still emerge at the joints during removal. Have sufficient collecting
containers and cloths to hand.
4. Disconnect the two coolant hoses from the supports for the side radiator -arrows- . To do this, loosen the
spring-band clamps from the front and push them on to the supports. See Fig. 55.
Microsoft
ENGINE Cooling
Fig. 56: Draining coolant

5. Open up the coolant hoses at the supports using a screwdriver and allow the coolant hoses to drain -arrow- .
Pull coolant hoses off the supports. See Fig. 56.
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ENGINE Cooling
Fig. 57: Lower fastening screw

6. Remove M8 x 25 fastening screw on bracket from below at the body -arrow- . See Fig. 57.
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ENGINE Cooling
Fig. 58: Fastening nuts

7. Undo two M8 fastening nuts on the bracket in the wheel housing at the side wall -arrows- . Carefully remove
side radiator complete with bracket to the side. Collect remaining coolant from the hoses and side radiator. Air-
conditioning condenser remains in installation position. See Fig. 58.

8. When the side radiator is removed, remove the sheetmetal clips and washers for the bracket -arrows- .
Carefully pull the side radiator upwards out of the bracket. See Fig. 59.
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ENGINE Cooling
Fig. 60: Cooling fan

9. Remove two hexagon-head sheetmetal screws at the side -1- and lift cooling fan housing with rear air guide
out of the tabs on the side radiator -2- . See Fig. 60.
INSTALLING RADIATOR
Installing radiator
NOTE: The air-conditioning condenser remains in the vehicle. The air-conditioning

system is not opened.
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ENGINE Cooling

Fig. 62: Cooling fan

1. Fit cooling fan housing with rear air guide on side radiator. To do this, push side tabs of cooling fan housing
into the brackets for the side radiator -2- , move housing into installation position and fit with two fastening
screws -1- . See Fig. 62.
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ENGINE Cooling

2. Push radiator module into the radiator bracket. Make sure that the radiator is positioned correctly in the side
guide and in the lower bores. Fit washers and sheetmetal clips on the lower fastening pins of the radiator in such
a way that the sheetmetal clips engage correctly into the pins -arrows- . See Fig. 63.
Microsoft
ENGINE Cooling
Fig. 64: Securing hose holder

3. Move side radiator with bracket into installation position. Make sure that the hose holder for the coolant
hoses is inserted correctly into the side bracket. Push side radiator with bracket on to the studs on the side
member and insert fastening screw M6 x 16 (outer Torx) for the hose holder -arrow- . See Fig. 64.
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ENGINE Cooling
Fig. 65: Fastening nuts

4. Position the M8 fastening nuts on the body studs -arrows- . See Fig. 65.
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ENGINE Cooling
Fig. 66: Lower fastening screw

5. Fit fastening screws to the body from below --> Tightening torque: 23 (17) Nm (ftlb.) -arrow- . See Fig.
66.
6. Tighten the fastening nuts on the body studs --> Tightening torque: 23 (17) Nm (ftlb.) . Tighten fastening
screw M6 x 16 (outer Torx) for hose holder --> Tightening torque: 10 (7.5) Nm (ftlb.) .
Fig. 67: Radiator connections

7. Push spring band clamps on to radiator flanges and fit radiator hoses to the flanges. Move engaged spring
band clamps into installation position and loosen using a water-pump pliers (use a screwdriver as well, if
necessary) and then fasten again -arrows- . See Fig. 67.
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ENGINE Cooling
Fig. 68: Vent line

8. Fit radiator vent line to the flange -1- and clip vent line into the plastic holder -2- . See Fig. 68.
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ENGINE Cooling
Fig. 69: Cable plug

9. Connect cable plug for fan motor -arrow- . See Fig. 69.
SUBSEQUENT WORK
Subsequent work for installing radiator
1. Fit air guide in front of radiator --> 192419 Removing and installing air guide - chapter on
"installing" [987310 987311 987320 987321].
Refer to 50 56 19 Removing and installing front wheel housing liner - as of MY 2005 (All Models) .
--> 193817 Draining and topping up with coolant - chapter on "topping up"
19 78 19 REMOVING AND INSTALLING COOLANT TEMPERATURE SENSOR

RHD)
PRELIMINARY WORK FOR REMOVING COOLANT TEMPERATURE SENSOR
Preliminary work for removing coolant temperature sensor
3. Drain coolant --> 193817 Draining and filling coolant - chapter on "Draining"
REMOVING COOLANT TEMPERATURE SENSOR
Removing coolant temperature sensor
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ENGINE Cooling
1. Release and disconnect cable plug -1- . See Fig. 70.
Fig. 70: View of coolant temperature sensor

2. Remove safety clip -2- . See Fig. 70.
3. Pull coolant temperature sensor from coolant guide housing
INSTALLING COOLANT TEMPERATURE SENSOR
Installing coolant temperature sensor
Microsoft
ENGINE Cooling
Fig. 71: O-ring for coolant temperature sensor

1. Replace O-Ring -arrow- with a new one and lightly smear with Kluber Plus (available from Porsche Parts
Catalogue) . See Fig. 71.
2. Insert coolant temperature sensor into coolant guide housing. Ensure correct seating of the O-ring.
3. Push on safety clip -2- . See Fig. 72.
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ENGINE Cooling
Fig. 72: View of coolant temperature sensor

4. Push on cable plug -1- . See Fig. 72.
SUBSEQUENT WORK FOR INSTALLING COOLANT TEMPERATURE SENSOR
Subsequent work for installing coolant temperature sensor
Microsoft
ENGINE Crankcase, suspension
ENGINE
Crankcase, suspension
10 01 TW TECHNICAL DATA, ENGINE - AS OF MY 2005 (ALL MODELS)

TECHNICAL VALUES
Engine M96/25, M96/26 and M97/21
Engine data 987 987 S Cayman S

Engine type M96/25 M96/26 M97/21
No. of cylinders 6
Cubic capacity 2,687 cm3 3,179 cm3 3,386 cm3
Bore 85.5 mm 93 mm 96 mm
Stroke 78 mm 78 mm 78 mm
Compression ratio 11.0 : 1 (±0.3) 11.0 : 1 (±0.3) 11,1 : 1 (±0,3)
Max. engine power (EU) 176 KW (240 HP) 206 KW (280 HP) 217 kW (295 HP)
6,400 rpm (5,500
At engine speed 6,200 rpm 6250 rpm
Belgium)
Max. torque (EU) 200 ftlb. 237 ftlb. 340 Nm (252 ftlb.)
4,700 - 6,000 rpm
At engine speed 4,700 - 6,000 rpm 4400 - 6000 rpm
(4,600 - 5,300 Belgium)
Max. output per liter 65.2 KW/l (88.9 HP/l) 64.4 KW/l (87.5 HP/l) 64.1 KW/l (87.1 HP/l)
rpm limitation due to E-gas, ignition engagement, cylinder cut-out injection
At engine speed 7,200 rpm 7,200 rpm 7,300 rpm
Idle speed 680 ± 40 rpm
Manual transmission*: Manual transmission*: Manual transmission*:
Engine weight according to 190.5 kg 196.3 kg 197.3 kg
DIN 70020 A Automatic transmission: Automatic transmission: Automatic transmission:
182.8 kg 187.8 kg 189.2 kg
* including double-mass flywheel
Engine design

Type 6-cylinder aluminum opposed-cylinder engine, water-cooled
Vertically split light alloy cylinder housing with separate aluminum
Crankcase
crankshaft bearing housing with GGG inserts
Crankshaft Forged, supported by 7 bearings
Ø 63, sub-groove, three-
Crankshaft bearings Three-component plain bearings
component plain bearings
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Connecting rods Forged Crack connecting rod

Con-rod bearings Three-component plain bearings
Pistons Light alloy cast Pressed light alloy
Cylinders Lokasil oil running surface
Cylinder head Three-part light alloy head
Valve guide Bearing material pressed in
Two input and output valves per cylinder suspended in parallel v-
Valve arrangement
format
Diameter of inlet valve 33.3 mm 37.1 mm 40.2 mm
Diameter of exhaust valve 28.1 mm 32.5 mm 34.5 mm
Large 11 mm
Valve lift of inlet 9.85 mm 10.5 mm
Small 3.6 mm
Valve lift of outlet 9.85 mm 10 mm 11 mm
Valve gear Via flat-base tappets Switchable flat-base tappets
Camshaft Chilled cast iron, hollow-cast
Porsche VarioCam Plus
Porsche VarioCam with axial camshaft with axial camshaft
Camshaft adjustment
adjustment adjustment and valve lift
control
From the crankshaft via a 3/8" tooth-type chain to the intermediate
Camshaft drive shaft, and from there to the inlet and exhaust camshafts via one 3/8"
duplex roller-type chain each.
Valve clearance Hydraulic valve clearance compensation
Large lift
21° before TDC/19° 26° before TDC/14°
Timing: intake opens, early/late 29° before TDC/11° after
after TDC after TDC
TDC
Large lift
9° after BDC/49° 20° after BDC/60°
Timing: intake closes, early/late 20° after BDC/60° after
after BDC after BDC
BDC
Timing: intake opens, small lift, 1° before TDC/39° after
- -
early/late TDC
Timing: intake closes, small lift, 59° before BDC/ 19° before
- -
early/late BDC
Timing: Outlet opens 39° before BDC 39° before BDC 50° before BDC
Timing: Outlet closes 8° before TDC 6° before TDC 4.5° after top dead center
Engine control

Engine control module Bosch ME 7.8 - 40
Ignition DME, individual spark coils, knock control
Firing order 1-6-2-4-3-5
Spark plugs Bosch FRG 5 KQEO
Microsoft
Electrode gap 1.6 ± 0.05 mm

Electronic throttle Electronic throttle actuator control via DME
USA-LEV trim On Board Diagnose II (OBDII), LEV 2, Tier 2
Euro 4 Euro-On Board Diagnosis (EOBD)
Euro 2 Customer service - OBD I
10 01 19 REMOVING AND INSTALLING ENGINE - AS OF MY 2005

TOOLS

mounting peg special tool P 9163/2
retainer plate special tool P 9592
support plate special tool P 9592/1
PRELIMINARY WORK
Preliminary work
--> Raise the vehicle at the prescribed jacking points --> 40 LIFTING THE VEHICLE - AS OF MY 2005
(ALL MODELS) .
NOTE:  Take care to maintain access to the screws for the diagonal struts in the
vicinity of the rear jacking points.
(ALL MODELS) .
2. Place protective covers on the vehicle to avoid damaging the body and passenger compartment.
3. Read out fault memory and print log. Refer to 03 35 00 On-board diagnosis (OBD) - as of MY 2005 (All
Models) .
Microsoft
5. Remove linings (carpet for rear wall cover and engine cover).
Fig. 1: Engine compartment lid

6. Remove engine compartment lid. Refer to 55 78 19 Removing and installing engine compartment lid - as
Microsoft
Fig. 2: Cover with grommet

Models) .
8. Disconnect ground lead of battery. Refer to 27 06 IN External power connection, jump lead starting - as
9. Remove throttle body with distributor pipe (do not disassemble!). Refer to 24 42 19 Removing and
installing throttle body - as of MY 2005 (All Models) .
10. Unclip shift or selector cables on the engine.
11. Remove both rear wheels. Use the specified special tool socket wrench insert P 300 to avoid damaging the
wheel rims. Refer to 44 05 19 Removing and installing wheel - as of MY 2005 (All Models) .
REMOVING ENGINE
Removing engine
WARNING: Danger of injury from hot engine parts.
 Risk of burns, damage to skin, injury to the eyes.
Microsoft
--> Do not work on the engine while it is hot.
NOTE:  If the vehicle is placed on its wheels or moved in the workshop, the rear
axle carrier must be refitted under all circumstances to maintain the
structural strength.
Fig. 3: Tensioning pulley for drive belt

1. Slacken the drive belt. To do this, turn the tensioning roller clockwise using a ring wrench (a/f 24), remove
the drive belt, check for damage and wear and replace if necessary.
WARNING: Danger of injury and damage to material through Pentosin
 Irritation and damage to skin

 Damage to hoses and wiring
--> Wear protective gloves and goggles
--> If the eyes or skin come into contact with the fluid, wash immediately with water!
--> Collect escaping Pentosin
--> Use caps to protect the wiring against soiling and damage!
Microsoft
--> Immediately clean hoses and wiring thoroughly
2. Remove Pentosin by suction out of the power-steering pump reservoir and dispose of according to the
country-specific regulations for hazardous substances.
Fig. 4: Servo-tank
3. Release bayonet lock -arrow- on the power-steering reservoir and remove power-steering reservoir. Collect
dripping Pentosin with a cloth. See Fig. 4.
4. Loosen B+ box -1- . To do this, unscrew two M6 fastening screws. See Fig. 4.
Microsoft
Fig. 5: Connector on scavenging-air fan

5. Release and pull off connector -1- on scavenging-air fan -2- . See Fig. 5.
Microsoft
Fig. 6: Vent line

WARNING: Coolant is hazardous to health
 Irritation of skin
--> In case of contact with the skin or eyes, wash immediately with plenty of water!
7. Boxster: Disconnect vent line at the rapid-action coupling.
Microsoft
Fig. 7: MAF line

8. Unclip mass air flow sensor (MAF) line -arrow- from the air-cleaner box. See Fig. 7.
Microsoft
Fig. 8: Levering off clip

9. Remove rear luggage-compartment lining. To do this, remove the luggage compartment seal and lever off the
rear fastening clips.
10. Pull connectors off the luggage compartment light.
11. Mark the position of the connectors at the engine control module so that it will be easier to arrange them
during installation.
12. Release and remove connectors at the engine control module. Refer to 24 70 19 Removing and installing
DME control module - as of MY 2005 (Boxster, Boxster RHD, Boxster S, Boxster S RHD) .
Fig. 9: Engine control module

13. Unscrew nut (M6) -1- and remove ground leads. See Fig. 9.
14. Tiptronic: release combination connector on transmission control module and pull off.
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Fig. 10: Connectors for engine wire harness

15. Release and pull off connectors -1- and -2- above the left wheel arch. See Fig. 10.
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16. Press the rubber sleeve -1- on the luggage compartment rear wall inwards and guide the engine wire harness
-2- towards the engine compartment, if the engine is to be lowered later. See Fig. 11.
17. Remove rear underbody cover. Refer to 51 94 19 Removing and installing cover for rear underbody - as
18. Remove center underbody cover. Refer to 51 93 19 Removing and installing cover for center underbody
19. Release plastic support for the coolant hoses -1- on the underbody. See Fig. 12.
Fig. 12: Coolant hoses

 Irration of skin
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20. Disconnect coolant hoses -3- at the rapid-action couplings. To do this, release the safety clips -2- with a
screwdriver and pull off coolant hoses. Collect coolant in a suitable container. Seal open lines with suitable
plugs. Clip in safety clips again at their original positions. See Fig. 12.
Fig. 13: Coolant hoses for engine and heating

21. Loosen spring band clamps -1, 3, 5- and pull off coolant hoses -2, 4, 6- . See Fig. 71.
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Fig. 14: Tiptronic coolant hoses

22. Tiptronic: Disconnect coolant hoses from oil-water heat exchanger (transmission), loosen spring band
clamps and pull off hoses.
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Fig. 15: Diagonal braces

23. Unscrew collar nuts (M10) -D- , unscrew screw (M10 x 45) -C- and remove diagonal braces -B- . See Fig.
15.
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Fig. 16: Support plate

24. Unscrew collar nuts (M8) and screws (M8 x 40). Remove support plate -A- . See Fig. 16.
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Fig. 17: V-brace

25. Unscrew screws (M10 x 70) -arrows- and remove V-brace. See Fig. 17.
Fig. 18: Anti-roll-bar bearing shells

26. Unscrew screws (M8 x 40) -arrows- for anti-roll-bar bearing shells. See Fig. 18.
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Fig. 19: Connecting link for anti-roll bar

27. Unscrew nuts (M10) on suspension/anti-roll bar and disengage suspension/anti-roll bar. Counter threaded
bolts with an internal Torx socket.
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Fig. 20: Restraining cable

28. Unscrew nuts (M8) on restraining-cable holder. (The cable must be countered with a suitable wrench and
must not be twisted!)
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Fig. 21: Oxygen sensor connector

29. Unclip electric plug connections -1- for the oxygen sensors on the left and right transverse bar from the
brackets. Unclip the lead -2- from the bracket. Release and disconnect plug connections. See Fig. 21.
30. Headlight beam adjustment: Pull off cable plug on sensor.
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Fig. 22: Cross member

31. Unscrew cross-member screws (M10 x 45) -arrows- and remove cross member. Pay attention to the bracket
for the headlight beam adjustment (if present). See Fig. 22.
32. Remove rear silencer. Refer to 26 33 19 Removing and installing rear silencer - as of MY 2005 (Boxster,
Microsoft
Fig. 23: Ground strap to engine

33. Unscrew nut (M8) -1- and remove ground strap -2- (right side of vehicle). See Fig. 23.
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Fig. 24: Drive shaft

NOTE: Protect drive shafts against mechanical damage (e. g. with a rubber hose which
has been cut open).
34. Disconnect drive shafts at transmission side. To do this, unscrew the six hexagon socket head bolts (M10 x
50) joining each drive shaft and transmission flange. To prevent the brake disc turning, a second person in the
vehicle must operate the brakes.
Fig. 25: Vacuum line on vacuum pump

35. Release vacuum line -2- on vacuum pump for brake booster and pull off. Then pull off the small vacuum
line -1- . See Fig. 25.
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Fig. 26: Connector for left oxygen sensor

36. Unclip electric plug connections for oxygen sensors -1- at the left and right rear wall from the brackets.
Unclip lines -2- from the brackets. See Fig. 26.
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Fig. 27: Connector for right oxygen sensor

Disassembly of shift and selector cables:
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Fig. 28: Shift and selector cables, 6-speed

37. Lever out the shift and selector cables from the ball pins and disengage from the supports.

Shift connection for 5-speed manual transmission
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Fig. 30: Tiptronic selector cable

Shift connection for Tiptronic
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38. Tiptronic: Release and disconnect multi-function connector.
Fig. 32: Plug

39. Tiptronic: Release and disconnect cable plug.
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Fig. 33: Servo-line coupling

40. Unclip safety clips -arrow- at the servo-line couplings. See Fig. 33.

NOTE:  If the holder on the servo line's plug-in coupling needs to be replaced, the
special tool
assembly aid P 9622 is already contained in the parts set.
Microsoft
41. Disconnect hydraulic lines for power-steering at the underbody. Unclip lines from the brackets. Collect
Pentosin in a suitable container.
Fig. 34: Removing pressure pipe holder

special tool
42. Tilt holder on one side -C, arrow- and simultaneously pull to disengage. Detach nipple from the pipe and
remove the old O-ring. Close off line. See Fig. 34.
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Fig. 35: Servo line plug-in coupling

43. Fit holder rosette -C- in threaded part -A- and, if necessary, fix using assembly aid P 9622. Screw threaded
part with new O-ring into the screw coupling -B- and tighten. Counter the coupling when tightening. -->
Tightening torque: 30 (22 ftlb.) Nm --> Tightening torque: 40 (30 ftlb.) Nm . See Fig. 35.
44. Seal open lines with suitable plugs.
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Fig. 36: Fuel lines

WARNING: Fuel can escape when fuel line is disconnected.
 Risk of fatal injury!

 Damage to skin
--> Do not work on fuel system if engine is hot!
--> Do not smoke, avoid fire and naked flames!
--> Wear fuel-resistant protective gloves and goggles.
--> Attach warning sign to vehicle in a clearly visible position.
45. Disconnect fuel lines -1- and -2- at underbody. Collect emerging fuel in a suitable container. Seal open lines
with suitable plugs. See Fig. 36.
WARNING: Danger of injury and damage from brake fluid!
 Poisonous if swallowed!
 Avoid contact with paint surfaces
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--> Store brake fluid in suitable, labelled containers only
--> In the event of contact with paint surfaces, wash off immediately with water, do not wipe off
46. Disconnect hydraulic line for clutch control. Collect emerging brake fluid in a suitable container. Seal open
lines with suitable plugs. The rapid-action coupling is handled in the same way as the servo line. --> Tightening
torque: 30 (22 ftlb.) Nm
47. Attach special tool retainer plate P 9592 to engine.
Fig. 37: Position of mounting peg for lifting table

48. Screw special tool support plate P 9592/1 to retainer plate in position -9592- using four M8x20 hexagon
bolts. See Fig. 37.
48.1. Screw special tool mounting peg P 9163/2 to the support plate in the marked position -Boxster- using
four M8x25 hexagon bolts. See Fig. 37.
49. To support the transmission, use special tool support plate P 9592/2. Depending on transmission type, use
the associated spacers.
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Fig. 38: Engine retainer complete

Retainer plate 9592 complete fitted to engine/transmission
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Fig. 39: Mounting plate on Master Gear

50. Prepare lifting table for the removal. Fasten mounting plate (Order No. 102 543) for sports cars using four
screws and nuts -2- to the Master Gear unit lifting table. See Fig. 39.
Master Gear: Workshop Equipment Manual Gr. 3.0.13 Unit lifting table (+ sports car mounting
accessory)
Fig. 40: Left transmission support

51. Unscrew three M10 screws -arrows- on the left transmission support and remove these. See Fig. 40.
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Fig. 41: Right transmission support

52. Loosen the three M10 screws -arrows- on the right transmission support. See Fig. 41.
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Fig. 42: Transmission bracket

NOTE: Do not loosen transmission support at the central nut as this will damage the
hydraulic mount.
Do not loosen transmission support at the central nut as this will damage the
hydraulic mount.
53. Unscrew the two fastening nuts (M8) -arrows- . Remove left transmission bracket -A- . Remove the right
transmission bracket by lowering the unit. See Fig. 42.
A - Transmission support
B - Hydraulic mount
C - Central nut (never loosen)
Fig. 43: Transmission mount

54. Position lifting table under vehicle and support engine by raising the mounting plate on the mounting peg P
9163/2. Unscrew collar nuts (M10) -arrows- on the engine carrier. See Fig. 43.
55. Gently lower the engine/transmission unit with the lifting table.
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Fig. 44: Rear screw for air-conditioning compressor

56. Unscrew rear Torx screw for air-conditioning compressor (M8 x 120) -1- . To do this, press the line for the
charcoal canister load carefully to the side. See Fig. 44.
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Fig. 45: Front screws for air-conditioning compressor

57. Unscrew front Torx screws for air-conditioning compressor (M8 x 90) -1- and -2- . See Fig. 45.
58. Disconnect plug connection for air-conditioning compressor supply line to the intake distributor.
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Fig. 46: Refrigerant hoses

59. Unclip refrigerant hoses -1- and -2- between body and intake-air distributor. See Fig. 46.
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Fig. 47: Air-conditioning compressor

NOTE: The air-conditioning lines on the compressor do not have to be disconnected in

order to remove engine/transmission unit.
 After removal, place the air-conditioning compressor on a suitable

protective support (e. g. foam, neoprene, etc.).
60. Guide refrigerant compressor through the rear wall opening and place on a suitable surface on the center
tunnel.
CAUTION: Material damage when lowering engine
--> Enlist assistance of second and, if necessary, third person
61. Lower engine/transmission unit and guide the engine wire harness into the engine compartment.
INSTALLING ENGINE
Installing engine
NOTE:  The engine/transmission unit is installed in reverse order to removal. The

following work steps are specifically repeated here in order to avoid
damage.
CAUTION: Risk of damage when inserting the engine/transmission unit into the
vehicle
 Material damage!
1. Raise engine/transmission unit into the engine compartment and guide the engine wire harness through the
assembly opening.
2. Pre-position right transmission bracket and guide when inserting the engine/transmission unit.
3. Guide air-conditioning compressor through the rear wall opening and place in installation position.
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4. Clip in refrigerant hoses -1- and -2- between body and intake-air distributor. See Fig. 48.
5. Insert connector for air-conditioning compressor supply line and clip connector housing into the holder
provided on the intake distributor.
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6. Screw in front Torx screws for air-conditioning compressor (M8 x 90) -1- and -2- . See Fig. 45.
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7. Screw in rear Torx screw for air-conditioning compressor (M8 x 120) -1- and tighten all three screws for air-
conditioning compressor. --> Tightening torque: 23 (17 ftlb.) Nm . See Fig. 44.
8. Move engine/transmission unit into the final installation position.
Fig. 51: Engine mount

9. Screw in collar nuts (M10) -arrows- on the engine carrier and tighten. --> Tightening torque: 65 (48 ftlb.)
Nm . See Fig. 51.
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10. Insert left transmission bracket -A- . Screw in and tighten the two collar nuts (M8) -arrows- . -->
Tightening torque: 33 (24 ftlb.) Nm . See Fig. 52.
B - Hydraulic mount
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11. Position screws -arrows- on the left transmission support and tighten. --> Tightening torque: 65 (48 ftlb.)
Nm . See Fig. 53.
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12. Position screws -arrows- on the right transmission support and tighten. --> Tightening torque: 65 (48
ftlb.) Nm . See Fig. 54.
13. Lower elevating platform and move out of work area. Remove special tool retainer plate P 9592 from
engine.
14. Insert hydraulic line for clutch control into the rapid-action coupling and clip in safety clip.
15. Join fuel lines at the underbody.
16. Join hydraulic lines for power-steering at the underbody.
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17. Clip in safety clips -arrows- at the servo-line couplings. See Fig. 55.
Fit shift and selector cables:
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18. Engage shift and selector cable in support and press onto ball pins.
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Shift connection for Tiptronic transmission
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Fig. 59: Locking plug

19. Tiptronic: Push on multi-function connector and lock it.
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Fig. 60: Tiptronic connector

20. Tiptronic: Push on cable plug.

21. Insert connectors for oxygen sensors -1- and clip into the brackets. Clip wires -2- into the brackets. See Fig.
61.
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22. Connect small vacuum line with connecting piece of vacuum pump and connect to pump connection piece.
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23. Fit drive shafts at transmission side. To do this, screw in and tighten the six hexagon socket head bolts (M10
x 50) joining each drive shaft and transmission flange. --> Tightening torque: 81 (60 ftlb.) Nm .
Fig. 64: Engine ground strap

24. Position ground strap -2- and screw down collar nut (M8) -1- . --> Tightening torque: 23 (17 ftlb.) Nm See
Fig. 64.
25. Install rear silencer. Refer to 26 33 19 Removing and installing rear silencer - as of MY 2005 (Boxster,
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26. Position cross member and screw in and tighten cross-member screws (M10 x 45) -arrows- . -->
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Fig. 66: Connectors for monitor sensor

27. Insert connectors -1- for monitor sensors and clip into the brackets. Clip wire -2- into the bracket. See Fig.
66.
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28. Guide the restraining cable holders through the bores and tighten nuts (M8). (The cable must be countered
with a suitable wrench and must not be twisted!) --> Tightening torque: 23 (17 ftlb.) Nm
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Fig. 68: Connecting link to anti-roll bar

29. Engage suspension/stabilizer and tighten nuts (M10) to the specified tightening torque stage 1. The threaded
pin must be countered with an internal Torx socket. --> Tightening torque stage 1: 50 (37 ftlb.) Nm . Loosen
nuts by 90° and tighten to the specified tightening torque stage 2 (counter). --> Tightening torque stage 2: 65
(48 ftlb.) Nm
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Fig. 69: Anti-roll bar bearing shells

30. Screw in and tighten screws (M8 x 40) -arrows- of the anti-roll bar bearing shells. --> Tightening torque:
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Fig. 70: V-brace

31. Position V-brace and tighten screws (M10 x 70) -arrows- . --> Tightening torque: 65 (48 ftlb.) Nm . See
Fig. 70.
32. Position support plate then screw in and tighten collar nuts (M10) and screws (M10). --> Tightening
torque: 65 (48 ftlb.) Nm ; --> Tightening torque: 65 (48 ftlb.) Nm
33. Position diagonal braces and screw in collar nuts (M10) and screws (M10 x 45). --> Tightening torque: 65
(48 ftlb.) Nm ; --> Tightening torque: 65 (48 ftlb.) Nm .
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34. Push on coolant hoses -2, 4, 6- . Position spring band clamps -1, 3, 5- . See Fig. 71.
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35. Insert coolant hoses -3- into the rapid-action couplings and ensure secure seating. Clip in plastic holders -1-
. Ensure that safety clips -2- are fitted correctly. See Fig. 72.

36. Tiptronic: Push on hoses and secure spring band clamps.
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37. Pull in rubber sleeve -1- . Ensure that rubber sleeve is fitted correctly. See Fig. 74.
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38. Insert connectors for engine wire harness -1- and -2- above the left wheel arch. See Fig. 75.
39. Position ground lead and tighten nut (M6) -1- . --> Tightening torque: 10 (7.5 ftlb.) Nm See Fig. 76.

40. Plug in connectors at the engine control module. Refer to 24 70 19 Removing and installing DME control
module - as of MY 2005 (Boxster, Boxster RHD, Boxster S, Boxster S RHD) .
41. Tiptronic: connect combination connector to transmission control module and lock.
42. Insert connectors for luggage compartment light.
43. Fit rear luggage-compartment lining and clip in fastening clips. Fit luggage-compartment lid seal and ensure
a correct fit. Refer to 70 06 19 Removing and installing rear luggage-compartment trim panel - as of MY
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Fig. 77: MAF line

44. Clip mass air flow sensor (MAF) line -arrow- into the air-cleaner box. See Fig. 77.
45. Insert cooling system vent line into the rapid-action coupling.
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46. Push in connector -1- for scavenging -air fan -2- . See Fig. 78.
47. Fit B+ box -1- . --> Tightening torque: 10 (7.5 ftlb.) Nm . See Fig. 4.
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Fig. 79: Servo-tank

48. Position power-steering reservoir. Lock bayonet lock -arrow- on power-steering reservoir. See Fig. 4.
49. Replace the quantity of Pentosin removed during removal with new Pentosin and pour this into the power-
steering reservoir.
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Fig. 80: Belt tensioner for drive belt

50. Turn the tensioning roller clockwise using a ring wrench (a/f 24), position the drive belt and then tension it.
SUBSEQUENT WORK
Subsequent work for installing engine
1. Fit both rear wheels. Use the specified special tool socket wrench insert P 300 to avoid damaging the wheel
rims. Refer to 44 05 19 Removing and installing wheel - as of MY 2005 (All Models) .
2. Install throttle body with distributor pipe. Refer to 24 42 19 Removing and installing throttle body - as of
3. Connect ground lead of battery. Refer to 27 06 IN External power connection, jump lead starting - as of
4. Bleed the clutch hydraulic system. Refer to 30 01 07 Bleeding the clutch system - as of MY 2005 (All
Models) .
5. Fill and bleed cooling system. Refer to 19 38 17 Draining and filling in coolant - as of MY 2005 (All
Models) .
6. Check Pentosin level in power-steering reservoir. Refer to 48 02 01 Checking the fluid level for the power-
assisted steering - as of MY 2005 (All Models) .
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7. Start engine. Turn the steering wheel from stop to stop while the engine is running in order to bleed the
steering system.
8. Check all fluid levels and seal tightness after the engine test run.
9. Install middle underbody cover. Refer to 51 93 19 Removing and installing cover for center underbody -
10. Install rear underbody cover. Refer to 51 94 19 Removing and installing cover for rear underbody - as of
11. Align the vehicle. Refer to 44 95 03 Suspension alignment, complete - as of MY 2005 (All Models) .

Models) .
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Fig. 82: Boxster engine compartment lid

13. Install engine compartment lid. Refer to 55 78 19 Removing and installing engine compartment lid - as
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Fig. 83: Cayman engine compartment lid

14. Boxster: Close convertible top.
15. Install linings (carpet for rear wall cover and engine cover).
16. Read out fault memory and correct any faults that are present. Erase fault memory. Refer to 03 35 00 On-
17. Perform a test drive.
10 01 19 REMOVING AND INSTALLING ENGINE - AS OF MY 2005 (CAYMAN

S, CAYMAN S RHD)
TOOLS

mounting peg special tool P 9163/2
retainer plate special tool P 9592
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PRELIMINARY WORK
Preliminary work
--> Raise the vehicle at the prescribed jacking points --> 40 LIFTING THE VEHICLE - AS OF MY 2005
(ALL MODELS) .
NOTE:  Take care to maintain access to the screws for the diagonal struts in the
vicinity of the rear jacking points.
(ALL MODELS) .
3. Read out fault memory and print log. Refer to 03 35 00 On-board diagnosis (OBD) - as of MY 2005 (All
Models) .
4. Remove the trim panel for engine compartment lid. Refer to 70 08 19 Removing and installing trim panel
for convertible top rest/engine compartment lid - as of MY 2005 (Cayman S, Cayman S RHD) .
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of MY 2005 (Cayman S, Cayman S RHD) .

Models) .
7. Disconnect ground lead of battery --> 27 06 IN WORK INSTRUCTIONS AFTER DISCONNECTING

8. Remove throttle body with distributor pipe (do not disassemble!). Refer to 24 42 19 Removing and
installing throttle body - as of MY 2005 (All Models) .
9. Unclip shift or selector cables on the engine.
10. Remove both rear wheels. Use the specified special tool socket wrench insert P 300 to avoid damaging the
wheel rims. Refer to 44 05 19 Removing and installing wheel - as of MY 2005 (All Models) .
REMOVING ENGINE
Removing engine
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WARNING: Danger of injury from hot engine parts.
 Risk of burns, damage to skin, injury to the eyes.
--> Do not work on the engine while it is hot.
NOTE:  If the vehicle is placed on its wheels or moved in the workshop, the rear
axle carrier must be refitted under all circumstances to maintain the
structural strength.

1. Slacken the drive belt. To do this, turn the tensioning roller clockwise using a ring wrench (a/f 24), remove
the drive belt, check for damage and wear and replace if necessary.

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2. Remove Pentosin by suction out of the power-steering pump reservoir and dispose of according to the
country-specific regulations for hazardous substances.
Fig. 87: Servo-tank

3. Release bayonet lock -arrow- on the power-steering reservoir and remove power-steering reservoir. Collect
dripping Pentosin with a cloth. See Fig. 87.
4. Loosen B+ box -1- . To do this, unscrew two M6 fastening screws. See Fig. 87.
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5. Release and pull off connector -1- on scavenging-air fan -2- . See Fig. 88.
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Fig. 89: Vent line

7. Boxster: Disconnect vent line at the rapid-action coupling.
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Fig. 90: MAF line

8. Unclip mass air flow sensor (MAF) line -arrow- from the air-cleaner box. See Fig. 90.
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Fig. 91: Levering off clip

9. Remove rear luggage-compartment lining. To do this, remove the luggage compartment seal and lever off the
rear fastening clips.
10. Pull connectors off the luggage compartment light.
11. Mark the position of the connectors at the engine control module so that it will be easier to arrange them
during installation.
12. Release and remove connectors at the engine control module. Refer to 24 70 19 Removing and installing
DME control module - as of MY 2006 (Cayman S, Cayman S RHD) .

13. Unscrew nut (M6) -1- and remove ground leads. See Fig. 92.
14. Tiptronic: release combination connector on transmission control module and pull off.
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15. Release and pull off connectors -1- and -2- above the left wheel arch. See Fig. 93.
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16. Press the rubber sleeve -1- on the luggage compartment rear wall inwards and guide the engine wire harness
-2- towards the engine compartment, if the engine is to be lowered later. See Fig. 94.
18. Remove center underbody cover. Refer to 51 93 19 Removing and installing cover for center underbody
19. Release plastic support for the coolant hoses -1- on the underbody. See Fig. 95.

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20. Disconnect coolant hoses -3- at the rapid-action couplings. To do this, release the safety clips -2- with a
screwdriver and pull off coolant hoses. Collect coolant in a suitable container. Seal open lines with suitable
plugs. Clip in safety clips again at their original positions. See Fig. 95.

21. Loosen spring band clamps -1, 3, 5- and pull off coolant hoses -2, 4, 6- . See Fig. 154.
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22. Tiptronic: Disconnect coolant hoses from oil-water heat exchanger (transmission), loosen spring band
clamps and pull off hoses.
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Fig. 98: Diagonal braces

23. Unscrew collar nuts (M10) -D- , unscrew screw (M10 x 45) -C- and remove diagonal braces -B- . See Fig.
98.
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24. Unscrew collar nuts (M8) and screws (M8 x 40). Remove support plate -A- . See Fig. 99.
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Fig. 100: V-brace

25. Unscrew screws (M10 x 70) -arrows- and remove V-brace. See Fig. 100.
Fig. 101: Anti-roll-bar bearing shells

26. Unscrew screws (M8 x 40) -arrows- for anti-roll-bar bearing shells. See Fig. 101.
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Fig. 102: Connecting link for anti-roll bar

27. Unscrew nuts (M10) on suspension/anti-roll bar and disengage suspension/anti-roll bar. Counter threaded
bolts with an internal Torx socket.
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28. Unscrew nuts (M8) on restraining-cable holder. (The cable must be countered with a suitable wrench and
must not be twisted!)
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Fig. 104: Oxygen sensor connector

29. Unclip electric plug connections -1- for the oxygen sensors on the left and right transverse bar from the
brackets. Unclip the lead -2- from the bracket. Release and disconnect plug connections. See Fig. 104.
30. Headlight beam adjustment: Pull off cable plug on sensor.
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31. Unscrew cross-member screws (M10 x 45) -arrows- and remove cross member. Pay attention to the bracket
for the headlight beam adjustment (if present). See Fig. 105.
32. Remove rear silencer. Refer to 26 33 19 Removing and installing rear silencer - as of MY 2005 (Cayman
S, Cayman S RHD) .
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Fig. 106: Ground strap to engine

33. Unscrew nut (M8) -1- and remove ground strap -2- (right side of vehicle). See Fig. 106.
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has been cut open).
34. Disconnect drive shafts at transmission side. To do this, unscrew the six hexagon socket head bolts (M10 x
50) joining each drive shaft and transmission flange. To prevent the brake disc turning, a second person in the
vehicle must operate the brakes.
Fig. 108: Vacuum line on vacuum pump

35. Release vacuum line -2- on vacuum pump for brake booster and pull off. Then pull off the small vacuum
line -1- . See Fig. 108.
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36. Unclip electric plug connections for oxygen sensors -1- at the left and right rear wall from the brackets.
Unclip lines -2- from the brackets. See Fig. 109.
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Disassembly of shift and selector cables:
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37. Lever out the shift and selector cables from the ball pins and disengage from the supports.

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Shift connection for Tiptronic
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38. Tiptronic: Release and disconnect multi-function connector.
Fig. 115: Plug

39. Tiptronic: Release and disconnect cable plug.
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40. Unclip safety clips -arrow- at the servo-line couplings. See Fig. 116.

special tool
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41. Disconnect hydraulic lines for power-steering at the underbody. Unclip lines from the brackets. Collect
Pentosin in a suitable container.
Fig. 117: Removing pressure pipe holder

special tool
Assembly aid P 9622 is already contained in the parts set.
42. Tilt holder on one side -C, arrow- and simultaneously pull to disengage. Detach nipple from the pipe and
remove the old O-ring. Close off line. See Fig. 117.
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Fig. 118: Servo line plug-in coupling

43. Fit holder rosette -C- in threaded part -A- and, if necessary, fix using assembly aid P 9622. Screw threaded
part with new O-ring into the screw coupling -B- and tighten. Counter the coupling when tightening. -->
Tightening torque: 30 (22 ftlb.) Nm --> Tightening torque: 40 (30 ftlb.) Nm . See Fig. 118.
44. Seal open lines with suitable plugs.
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Fig. 119: Fuel lines


 Damage to skin
45. Disconnect fuel lines -1- and -2- at underbody. Collect emerging fuel in a suitable container. Seal open lines
WARNING: Danger of injury and damage from brake fluid!
 Poisonous if swallowed!
 Avoid contact with paint surfaces
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--> Store brake fluid in suitable, labelled containers only
--> In the event of contact with paint surfaces, wash off immediately with water, do not wipe off
46. Disconnect hydraulic line for clutch control. Collect emerging brake fluid in a suitable container. Seal open
lines with suitable plugs. The rapid-action coupling is handled in the same way as the servo line. --> Tightening
torque: 30 (22 ftlb.) Nm
47. Attach special tool retainer plate P 9592 to engine.
Fig. 120: Position of mounting peg for lifting table

48. Screw special tool support plate P 9592/1 to retainer plate in position -9592- using four M8x20 hexagon
bolts. See Fig. 120.
48.1. Screw special tool mounting peg P 9163/2 to the support plate in the marked position -Boxster- using
four M8x25 hexagon bolts. See Fig. 120.
49. To support the transmission, use special tool support plate P 9592/2. Depending on transmission type, use
the associated spacers.
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Fig. 121: Engine retainer complete

Retainer plate 9592 complete fitted to engine/transmission
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Fig. 122: Mounting plate on Master Gear

50. Prepare lifting table for the removal. Fasten mounting plate (Order No. 102 543) for sports cars using four
screws and nuts -2- to the Master Gear unit lifting table. See Fig. 122.
Master Gear: Workshop Equipment Manual Gr. 3.0.13 Unit lifting table (+ sports car mounting
accessory)

51. Unscrew three M10 screws -arrows- on the left transmission support and remove these. See Fig. 123.
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52. Loosen the three M10 screws -arrows- on the right transmission support. See Fig. 124.
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NOTE: Do not loosen transmission support at the central nut as this will damage the
hydraulic mount.
Do not loosen transmission support at the central nut as this will damage the
hydraulic mount.
53. Unscrew the two fastening nuts (M8) -arrows- . Remove left transmission bracket -A- . Remove the right
transmission bracket by lowering the unit. See Fig. 125.
B - Hydraulic mount
Fig. 126: Transmission mount

54. Position lifting table under vehicle and support engine by raising the mounting plate on the mounting peg P
9163/2. Unscrew collar nuts (M10) -arrows- on the engine carrier. See Fig. 126.
55. Gently lower the engine/transmission unit with the lifting table.
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56. Unscrew rear Torx screw for air-conditioning compressor (M8 x 120) -1- . To do this, press the line for the
charcoal canister load carefully to the side. See Fig. 127.
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58. Disconnect plug connection for air-conditioning compressor supply line to the intake distributor.
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NOTE: The air-conditioning lines on the compressor do not have to be disconnected in

order to remove engine/transmission unit.
 After removal, place the air-conditioning compressor on a suitable

tunnel.
CAUTION: Material damage when lowering engine
61. Lower engine/transmission unit and guide the engine wire harness into the engine compartment.
INSTALLING ENGINE
Installing engine
NOTE:  The engine/transmission unit is installed in reverse order to removal. The

following work steps are specifically repeated here in order to avoid
damage.
CAUTION: Risk of damage when inserting the engine/transmission unit into the
vehicle
 Material damage!
1. Raise engine/transmission unit into the engine compartment and guide the engine wire harness through the
assembly opening.
2. Pre-position right transmission bracket and guide when inserting the engine/transmission unit.
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5. Insert connector for air-conditioning compressor supply line and clip connector housing into the holder
provided on the intake distributor.
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8. Move engine/transmission unit into the final installation position.
Fig. 134: Engine mount

9. Screw in collar nuts (M10) -arrows- on the engine carrier and tighten. --> Tightening torque: 65 (48 ftlb.)
Nm . See Fig. 134.
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10. Insert left transmission bracket -A- . Screw in and tighten the two collar nuts (M8) -arrows- . -->
B - Hydraulic mount
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11. Position screws -arrows- on the left transmission support and tighten. --> Tightening torque: 65 (48 ftlb.)
Nm . See Fig. 136.
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12. Position screws -arrows- on the right transmission support and tighten. --> Tightening torque: 65 (48
13. Lower elevating platform and move out of work area. Remove special tool retainer plate P 9592 from
engine.
14. Insert hydraulic line for clutch control into the rapid-action coupling and clip in safety clip.
15. Join fuel lines at the underbody.
16. Join hydraulic lines for power-steering at the underbody.
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17. Clip in safety clips -arrows- at the servo-line couplings. See Fig. 138.
Fit shift and selector cables:
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18. Engage shift and selector cable in support and press onto ball pins.
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Shift connection for Tiptronic transmission
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Fig. 142: Locking plug

19. Tiptronic: Push on multi-function connector and lock it.
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Fig. 143: Tiptronic connector

20. Tiptronic: Push on cable plug.

21. Insert connectors for oxygen sensors -1- and clip into the brackets. Clip wires -2- into the brackets. See Fig.
144.
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22. Connect small vacuum line with connecting piece of vacuum pump and connect to pump connection piece.
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23. Fit drive shafts at transmission side. To do this, screw in and tighten the six hexagon socket head bolts (M10
x 50) joining each drive shaft and transmission flange. --> Tightening torque: 81 (60 ftlb.) Nm .

24. Position ground strap -2- and screw down collar nut (M8) -1- . --> Tightening torque: 23 (17 ftlb.) Nm See
Fig. 147.
25. Install rear silencer. Refer to 26 33 19 Removing and installing rear silencer - as of MY 2005 (Cayman
S, Cayman S RHD) .
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26. Position cross member and screw in and tighten cross-member screws (M10 x 45) -arrows- . -->
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27. Insert connectors -1- for monitor sensors and clip into the brackets. Clip wire -2- into the bracket. See Fig.
149.
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28. Guide the restraining cable holders through the bores and tighten nuts (M8). (The cable must be countered
with a suitable wrench and must not be twisted!) --> Tightening torque: 23 (17 ftlb.) Nm
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Fig. 151: Connecting link to anti-roll bar

29. Engage suspension/stabilizer and tighten nuts (M10) to the specified tightening torque stage 1. The threaded
pin must be countered with an internal Torx socket. --> Tightening torque stage 1: 50 (37 ftlb.) Nm . Loosen
nuts by 90° and tighten to the specified tightening torque stage 2 (counter). --> Tightening torque stage 2: 65
(48 ftlb.) Nm
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Fig. 152: Anti-roll bar bearing shells

30. Screw in and tighten screws (M8 x 40) -arrows- of the anti-roll bar bearing shells. --> Tightening torque:
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Fig. 153: V-brace

31. Position V-brace and tighten screws (M10 x 70) -arrows- . --> Tightening torque: 65 (48 ftlb.) Nm . See
Fig. 153.
32. Position support plate then screw in and tighten collar nuts (M10) and screws (M10). --> Tightening
torque: 65 (48 ftlb.) Nm ; --> Tightening torque: 65 (48 ftlb.) Nm
33. Position diagonal braces and screw in collar nuts (M10) and screws (M10 x 45). --> Tightening torque: 65
(48 ftlb.) Nm ; --> Tightening torque: 65 (48 ftlb.) Nm .
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34. Push on coolant hoses -2, 4, 6- . Position spring band clamps -1, 3, 5- . See Fig. 154.
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35. Insert coolant hoses -3- into the rapid-action couplings and ensure secure seating. Clip in plastic holders -1-
. Ensure that safety clips -2- are fitted correctly. See Fig. 155.

36. Tiptronic: Push on hoses and secure spring band clamps.
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37. Pull in rubber sleeve -1- . Ensure that rubber sleeve is fitted correctly. See Fig. 157.
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38. Insert connectors for engine wire harness -1- and -2- above the left wheel arch. See Fig. 158.
39. Position ground lead and tighten nut (M6) -1- . --> Tightening torque: 10 (7.5 ftlb.) Nm See Fig. 159.

40. Plug in connectors at the engine control module. Refer to 24 70 19 Removing and installing DME control
module - as of MY 2006 (Cayman S, Cayman S RHD) .
41. Tiptronic: connect combination connector to transmission control module and lock.
42. Insert connectors for luggage compartment light.
43. Fit rear luggage-compartment lining and clip in fastening clips. Fit luggage-compartment lid seal and ensure
a correct fit. Refer to 70 06 19 Removing and installing rear luggage compartment trim (carpet lining) - as
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Fig. 160: MAF line

44. Clip mass air flow sensor (MAF) line -arrow- into the air-cleaner box. See Fig. 160.
45. Insert cooling system vent line into the rapid-action coupling.
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46. Push in connector -1- for scavenging -air fan -2- . See Fig. 161.
47. Fit B+ box -1- . --> Tightening torque: 10 (7.5 ftlb.) Nm . See Fig. 87.
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Fig. 162: Servo-tank

steering reservoir.
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SUBSEQUENT WORK
Subsequent work for installing engine
1. Fit both rear wheels. Use the specified special tool socket wrench insert P 300 to avoid damaging the wheel
2. Install throttle body with distributor pipe. Refer to 24 42 19 Removing and installing throttle body - as of
3. Connect ground lead of battery. Refer to 27 06 IN External power connection, jump lead starting - as of
4. Bleed the clutch hydraulic system. Refer to 30 01 07 Bleeding the clutch system - as of MY 2005 (All
Models) .
5. Fill and bleed cooling system. Refer to 19 38 17 Draining and filling in coolant - as of MY 2005 (All
Models) .
6. Check Pentosin level in power-steering reservoir. Refer to 48 02 01 Checking the fluid level for the power-
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steering system.
8. Check all fluid levels and seal tightness after the engine test run.
9. Install middle underbody cover. Refer to 51 93 19 Removing and installing cover for center underbody -
11. Align the vehicle. Refer to 44 95 03 Suspension alignment, complete - as of MY 2005 (All Models) .

Models) .
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Fig. 165: Boxster engine compartment lid

13. Install engine compartment lid. Refer to 55 78 19 Removing and installing engine compartment lid - as
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Fig. 166: Cayman engine compartment lid

14. Boxster: Close convertible top.
15. Install linings (carpet for rear wall cover and engine cover).
17. Perform a test drive.
10 01 37 DISASSEMBLING AND ASSEMBLING ENGINE - AS OF MY 2005

(ALL MODELS)
TOOLS

cover for dust protection special tool NR.165
when fitting the engine
release key special tool P 9204
Engine support special tool P 9589
mounting elements special tool P 9590
retaining device special tool P 9593
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PRELIMINARY WORK FOR DISASSEMBLING ENGINE
Preliminary work for disassembling engine
1. Remove engine --> 100119 Removing and installing engine [987310 987311 987320 987321] --> 100119
Removing and installing engine [987120 987121].
2. Remove transmission. Refer to 34 35 27 Removing and refitting transmission - as of MY 2005 (Boxster,

Boxster RHD) . Refer to 34 35 27 Removing and refitting transmission - as of MY 2005 (Boxster S,
Boxster S RHD, Cayman S, Cayman S RHD) .
3. Remove exhaust manifold. Refer to 26 10 19 Removing and installing exhaust manifold (with primary
catalytic converter) - as of MY 2005 (All Models) .
Tiptronic transmission:
4. Remove drive plate for converter. Refer to 13 63 19 Removing and installing drive plate for converter - as
5. Remove clutch. Refer to 30 50 19 Removing and installing clutch - as of MY 2005 (All Models) .
6. Remove flywheel. Refer to 13 60 19 Removing and installing flywheel - as of MY 2005 (All Models) .
COMPONENT OVERVIEW - ENGINE
Component overview - engine
NOTE: The overview graphics are shown schematically and may be different to how
the components actually look.
Intake system, belt drive
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Fig. 167: Overview of intake system, belt drive

 1 - Intake distributor
 2 - Belt drive
 3 - Belt guide and belt tensioner
Engine lubrication, engine cooling
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Fig. 168: Overview of cooling, lubrication

 4 - Oil pump, heat exchanger, water pump, coolant guide housing

 5 - Oil pan, oil separator
Cylinder head, crankcase
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Fig. 169: Overview of cylinder head, crankcase

 6 - Cylinder-head cover, camshafts, flat-base tappet housing, cylinder head

 7 - Cylinder head, flat-base tappets
 8 - Crankcase halves
Crank drive, pistons
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Fig. 170: Overview of crank drive, pistons

 9 - Pistons, connecting rods

 10 - Bearing housing with intermediate shaft
 11 - Bearing housing halves with crankshaft
DISASSEMBLING ENGINE DOWN TO CRANKCASE
Disassembling engine down to crankcase
CAUTION: Risk of damage due to particles of dirt.
 Oil bores/oil ducts can become blocked up.
--> When working on the engine, absolute cleanliness is essential.
--> Lay removed engine parts on a clean base and cover them without fail.
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--> Use the cover for dust protection when fitting the engine NR.165 on the engine assembly support.
WARNING: Pentosin is hazardous to health
--> If the eyes or skin come into contact with the fluid, wash immediately with water.
--> Collect emerging Pentosin. Clean hoses which come into contact with Pentosin thoroughly.
--> Use caps to protect the wiring against soiling and damage.
WARNING: Danger due to oil draining out and spraying when the engine is hot!
 Danger of scalding and injury
--> Allow the engine to cool
--> Wear specified protective gear.
NOTE:  The central screws of the camshaft adjustment elements must be undone
before removing the cylinder head cover.
NOTE:  The bearing housing remains screwed to the retaining device when the
bearing housing and intermediate shaft are disassembled.
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Fig. 171: Engine support

1. Engine support P 9589 must be secured to the crankcase using special tool mounting elements P 9590.
Refit engine with support on the engine assembly support.
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Fig. 172: Oil drain plug

2. Drain engine oil. Unscrew the oil drain plug (hexagon socket a/f 8). Refer to 17 01 55 Engine oil and oil
filter change - as of MY 2005 (All Models) .
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Fig. 173: Pulley on power-steering pump

3. Remove pulley -2- of power-steering pump; to do this, counter the pulley -2- as shown using a screwdriver,
then remove three Torx screws (M8 x 12) -1- . See Fig. 173.
4. Disconnect cable plug -2- of solenoid valves -3- . See Fig. 174.
5. Disconnect cable plug -4- of engine-temperature sensor -5- . See Fig. 174.
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Fig. 174: Engine compartment temperature sensor

6. Disconnect cable plug -1- of all fuel injector valves. See Fig. 174.
Fig. 175: Carbon canister valve

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7. Disconnect cable plug -Arrow- for carbon canister solenoid valve. See Fig. 175.
Fig. 176: Servo line supports

8. Loosen support for servo lines -2- by unclipping the oxygen sensor line from the support -3- and unscrewing
two Torx screws (M6 x 12) -1- . See Fig. 176.
9. Unscrew six fastening screws (M6 x 35) for each intake-air distributor.
10. Completely remove the intake bridge. Replace gaskets during installation.
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Fig. 177: Cover for pulley

11. Remove drive belt cover by unscrewing three Torx screws (M6 x 12) -Arrows- . See Fig. 177.
12. Disconnect cable plug -1- on generator. See Fig. 178.
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Fig. 178: Generator connections

13. Unscrew collar nut (M8) -2- and remove ground B+ line -3- . See Fig. 178.
Fig. 179: Generator

14. Remove generator -3- by unscrewing the Torx screws (M10 x 35) -1- and (M10 x 145) -2- . The deflection
roller is removed together with the generator (-3- ). Refer to 27 22 19 Removing and installing three-phase
generator - as of MY 2006 (Cayman S, Cayman S RHD) . Refer to 27 22 19 Removing and installing
three-phase generator - as of MY 2005 (Boxster, Boxster RHD, Boxster S, Boxster S RHD) . See Fig. 179.
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Fig. 180: Oil filler neck

15. Remove oil filler neck -2- by unscrewing two Torx screws (M6 x 11) -1- . Replace O-ring and screws
during installation. See Fig. 180.
16. Unscrew union nut of servo pressure line (a/f 16) -1- . See Fig. 181.
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Fig. 181: Fastening screws for power-steering pump

17. Remove power-steering pump with the lines by unscrewing three Torx screws (M8 x 30) -3- and the Torx
screw (M8 x 12) -2- . See Fig. 181.
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Fig. 182: Power-steering pump support

18. Remove power-steering pump support -2- by unscrewing four Torx screws (M8 x 35) -1- . The power-
steering pump support -2- is also fixed with roll pins; if necessary use a rubber hammer for the removal. See
Fig. 182.
Fig. 183: Positive crankcase ventilation line

19. Remove the positive crankcase ventilation line -1- by releasing and disconnecting the rapid-action couplings
-Arrows- . Replace O-rings during installation. See Fig. 183.
20. Unscrew collar nut (M8) -1- and remove terminal 30 line -2- . See Fig. 184.
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Fig. 184: Electric leads on starter

21. Unscrew collar nut (M6) -3- and remove terminal 50 line -4- . See Fig. 184.
Fig. 185: Ground lead

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22. Remove engine wire harness; to do this, remove all remaining cable plugs, unscrew Torx screws (M6 x12) -
1- of the ground straps -2- and unscrew two Torx screws (M6 x 12) and (M8 x 20) for each of the plastic cable
wire harness guides. See Fig. 185.
Fig. 186: Support

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Fig. 187: Heat exchanger

23. Remove oil-water heat exchanger -1- by unscrewing four Torx screws (M6 x 16) -2- . Replace all O-rings
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Fig. 188: Oil mist separator

24. Remove oil mist separator -3- by unscrewing two Torx screws (M6 x 20) -1- and loosening the spring band
clamp -2- . Pull oil mist separator -3- from the cylinder head and pull off the hose. Replace O-ring during
installation. See Fig. 188.
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Fig. 189: Secondary air pump with bracket

25. Unscrew three Torx screws (M6 x 20) -1- on the bracket for the secondary air pump. See Fig. 189.
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Fig. 190: Secondary air line

26. Unscrew two Torx screws (M6 x 20) -1- on the flange of the secondary air pump -2- . Remove secondary air
pump. Replace both metal seals during installation. See Fig. 190.
Fig. 191: Starter

27. Remove starter -2- by unscrewing two Torx screws (M10 x 35) -1- . Refer to 27 60 19 Removing and
installing starter - as of MY 2005 (All Models) . See Fig. 191.
28. Remove knock sensors -2- by unscrewing one Torx screw (M8 x 35) on each -1- . Mark the position of the
electric connection for re-installation. See Fig. 192.
29. Unscrew oil level sensor with a ring wrench (a/f 19) -3- . Replace copper sealing ring during installation.
See Fig. 192.
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Fig. 192: View of knock sensors

30. Remove spacer sleeve -4- . See Fig. 192.
Fig. 193: Oil pressure sender

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31. Unscrew oil pressure sender with a ring wrench (a/f 24) -1- . Replace aluminum sealing ring during
Fig. 194: Connection piece for positive crankcase ventilation

32. Remove connection piece for positive crankcase ventilation -2- by unscrewing two Torx screws (M6 x 11) -
1- . Replace O-ring during installation. See Fig. 194.
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Fig. 195: Hall sender

33. Remove both hall senders -2- by unscrewing one Torx screw (M6 x 11) on each -1- . Replace O-rings
34. Remove deflection roller by unscrewing the Torx screw (M8 x 60). Check deflection roller for damage,
wear and smooth operation.
35. Remove engine ground strap on cylinder 1-3 by unscrewing the Torx screw (M8 x 30).
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Fig. 196: Screw on pulley

36. Remove crankshaft belt pulley by countering the belt pulley with special tool retaining device P 9593 and
screwing out central screw (M16 x 60).
37. Remove engine mounting by unscrewing the three hexagon-head bolts (M10 x 120) and the hexagon-head
bolt (M10 x 80). Only loosen the left upper hexagon-head bolt (M10 x 120); the hexagon-head bolt can be
unscrewed after the engine mounting has been removed.
38. Tiptronic only: Remove clip for belt routing by unscrewing two Torx screws (M6 x 12).
39. Remove coolant guide housing by unscrewing five external Torx screws (M6 x 35) and three internal Torx
screws (M6 x 20). Replace O-rings during installation.
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Fig. 197: Ignition coil

40. Remove ignition coils -1- by unscrewing two Torx screws (M6 x 25) -2- . See Fig. 197.
Fig. 198: Crankshaft pulse sender

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41. Remove crankshaft pulse sender -1- by unscrewing the Torx screw (M6 x 15) -2- . See Fig. 198.
Fig. 199: Coolant lines

42. Remove coolant lines -1- and -2- by unscrewing two Torx screws (M6 x 16) -3- . See Fig. 199.
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Fig. 200: Coolant pump

43. Remove coolant pump by unscrewing six hexagon-head bolts (M6 x 25, M6 x 30) -Arrows- . Replace metal
seal during installation. See Fig. 200.
44. Remove thermostat housing. Unscrew four Torx screws (M6 x 20) and remove housing complete with
thermostat. Replace seal during installation.
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45. Remove tandem pump by unscrewing four Torx screws (micro-self-locking, M6 x 30) -Arrows- . During
installation, note the position of the pump drive with respect to the groove on the camshaft sprocket. Both parts
must be in line in installation position. Otherwise the pump drive must be rotated. Replace O-ring and screws
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Fig. 202: Pump drive

46. Remove solenoid hydraulic valve for camshaft adjustment. Refer to 15 37 19 Removing and installing
solenoid hydraulic valve (camshaft timing) - as of MY 2005 (Boxster, Boxster RHD, Boxster S, Boxster S
RHD) .
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Fig. 203: Coolant adapter

47. Remove coolant adapter by unscrewing six Torx screws (M6 x 20) -Arrows- . Replace metal seal during
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Fig. 204: Brackets for oxygen sensors 1 - 3

48. Remove brackets for oxygen sensor cables by unscrewing five Torx screws (M6 x 12) -Arrows- . See Fig.
204.
Fig. 205: Brackets for oxygen sensors 4 - 6

49. Remove all remaining plastic accessories (clips, supports etc.).
50. Remove transport eyebolt -1- by unscrewing two Torx screws (M6 x 16) -2- . See Fig. 206.
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Fig. 206: Assembly eye

51. Remove supports -3- by unscrewing one Torx screw (M6 x 12) -4- . See Fig. 206.
52. Remove spark plugs. Refer to 28 70 20 Removing and fitting spark plugs - as of MY 2005 (All Models) .
53. Remove cylinder head cover 1 - 3. Refer to 15 82 20 Removing and installing cylinder head cover -
engine removed - as of MY 2005 (Cayman S, Cayman S RHD) . Refer to 15 82 20 Removing and installing
cylinder head cover - engine removed - as of MY 2005 (Boxster, Boxster RHD, Boxster S, Boxster S
RHD) .
54. Remove camshaft 1 - 3. Refer to 15 05 20 Removing and installing camshaft - as of MY 2005 (Boxster S,
Boxster S RHD) . Refer to 15 05 20 Removing and installing camshaft - as of MY 2005 (Boxster, Boxster
RHD) .
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Fig. 207: Example of laying aside flat-base tappets

CAUTION: Interchanged or dirty flat-base tappets.
 Damage to engine components
--> The components have been run in the fitting bores in the housing, therefore do not interchange them.
--> Pay attention to cleanliness.
55. Remove flat-base tappet 1 - 3. Refer to 15 70 19 Removing and installing cylinder head - as of MY 2005
56. Remove cylinder head 1-3. Loosen and unscrew 12 Torx screws M10 x 230 from outside to inside on each
cylinder head. Lift cylinder head and seal from crankcase. Refer to 15 70 19 Removing and installing cylinder
head - as of MY 2005 (Boxster, Boxster RHD, Boxster S, Boxster S RHD) .
57. Remove cylinder head cover 4 - 6. Refer to 15 82 20 Removing and installing cylinder head cover -
engine removed - as of MY 2005 (Cayman S, Cayman S RHD) . Refer to 15 82 20 Removing and installing
RHD) .
58. Remove camshaft 4 - 6. Refer to 15 05 20 Removing and installing camshaft - as of MY 2005 (Boxster S,
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RHD) .
59. Remove flat-base tappet 4 - 6. Refer to 15 70 19 Removing and installing cylinder head - as of MY 2005
60. Remove cylinder head 4 - 6. Loosen and unscrew 12 Torx screws (M10 x 230) from outside to inside on
each cylinder head. Lift cylinder head and seal from crankcase. Refer to 15 70 19 Removing and installing
cylinder head - as of MY 2005 (Boxster, Boxster RHD, Boxster S, Boxster S RHD) .
Fig. 208: Oil pump with housing

61. Remove oil pump with housing -1- by unscrewing two hexagon-head bolts (M6 x 80) -2- , two Torx screws
(M6 x 20) -3- and (M10 x 100) -4- . Remove housing and ensure that the flange projection of the oil pump drive
is not tilted. Replace the two O-rings during installation. See Fig. 208.
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Fig. 209: View of installation position of pistons

62. Remove all carbon deposits and other residues on all six pistons with a brass brush, which will make the
engraved markings -Arrow- visible. In addition, number and mark the pistons in installation position before
removal. See Fig. 209.
63. Unscrew aluminum screw plug (M27) for the assembly bore (piston pin).
64. Remove lower M6 guide and tensioning rail screws (hexagon socket a/f 5), remove the guide and tensioning
rails from the chain spaces.
65. Remove oil filter with special tool release key P 9204.
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Fig. 210: Lifting the oil pan cover

66. Unscrew 13 Torx screws M6 x 20 on the oil pan cover. Tap cover gently on the sides using a plastic
hammer, then carefully lift it at the leverage bar --> Lifting the oil pan cover using a plastic-coated mounting
lever and remove the oil pan. See Fig. 210.
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Fig. 211: Components in the oil pan

67. Remove air/oil separator (swirl pots) and oil suction pipe. To remove each separator, unscrew two M6 x 20
Torx screws and pull out the separator. Unscrew two M6 x 20 Torx screws on the oil suction pipe and remove
the oil suction pipe. Replace O-rings during installation.
68. Remove bearing cover for intermediate shaft. Refer to 15 21 19 Removing and installing bearing cover
for intermediate shaft - M96/26 - as of MY 2005 (Boxster S, Boxster S RHD) . Refer to 15 21 19 Removing
and installing bearing cover for intermediate shaft - M96/25 - as of MY 2005 (Boxster, Boxster RHD) .
ASSEMBLING ENGINE
Assembling engine
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NOTE:  All O-rings and seals (shaft seals) and micro-encapsulated screws or lock
nuts must be replaced.
NOTE:  Replace all O-rings and grease shaft seals lightly with Optimol MP3 or
Kluber Syntheso Glep.
NOTE:  The O-rings for the spark-plug recesses must be replaced.
NOTE:  Re-insert flat-base tappets in the fitted bores in which they were
positioned before the disassembly. The flat-base tappets have been run in
the fitting bores in the housing and therefore may not be switched.
The engine is assembled in reverse order to the disassembly. Components that are not replaced must be
cleaned.
Markings on crankcase:
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Fig. 212: Engine number, example of 3.8 ltr. engine

Engine number
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Fig. 213: Cylinder arrangement

Cylinder arrangement
1. Fit bearing cover for intermediate shaft. Refer to 15 21 19 Removing and installing bearing cover for
intermediate shaft - M96/26 - as of MY 2005 (Boxster S, Boxster S RHD) . Refer to 15 21 19 Removing
and installing bearing cover for intermediate shaft - M96/25 - as of MY 2005 (Boxster, Boxster RHD) .
2. Fit air/oil separator (swirl pots) and oil suction tube.

1 2
Air/oil separator and oil suction tube Tightening 10 (7.5 ftlb.)
M6 x 20
to crankcase torque Nm
3. Install oil pan. Apply a bead of sealant, Loctite 5900 , to the cleaned and greased oil pan and secure with 13
Torx screws from the inside out. --> Tightening torque: 10 (7.5 ftlb.) Nm
4. Install new oil filter using special tool oil filter spanner P 9204.

Oil filter Tightening torque 25 (19 ftlb.) Nm
5. Fit lower guide and tensioning rail screws.

1 2
Fastening screw for tensioning rail Tightening 10 (7.5 ftlb.)
M6
and guide rail torque Nm
6. Screw in aluminum screw plug (M27) for the assembly bore (piston pin).
7. Fit oil pump with housing.

1 2
Fastening screw for oil pump housing Tightening 10 (7.5 ftlb.)
M6
to engine block torque Nm
Fastening screw for oil pump housing Tightening 65 (48 ftlb.)
M10
NOTE:  Cylinder-head gaskets are identical parts, lay them down with the TOP
identification facing upwards.
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8. Fit cylinder head 4-6. Refer to 15 70 19 Removing and installing cylinder head - as of MY 2005 (Boxster,
9. Install flat-base tappets 4-6. Refer to 15 70 19 Removing and installing cylinder head - as of MY 2005
10. Install camshaft 4-6. Refer to 15 05 20 Removing and installing camshaft - as of MY 2005 (Boxster S,
RHD) .
11. Fit tandem pump.

1 2
Screw for tandem pump to M6 x 30, micro-self- Tightening 10 (7.5 ftlb.)
engine block locking torque Nm
12. Install cylinder head cover 4-6. Refer to 15 82 20 Removing and installing cylinder head cover - engine
removed - as of MY 2005 (Cayman S, Cayman S RHD) . Refer to 15 82 20 Removing and installing
RHD) .
13. Fit cylinder head 1-3. Refer to 15 70 19 Removing and installing cylinder head - as of MY 2005
14. Install flat-base tappets 1-3. Refer to 15 70 19 Removing and installing cylinder head - as of MY 2005
15. Install camshaft 1-3. Refer to 15 05 20 Removing and installing camshaft - as of MY 2005 (Boxster S,
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RHD) .
16. Install cylinder head cover 1-3. Refer to 15 82 20 Removing and installing cylinder head cover - engine
removed - as of MY 2005 (Cayman S, Cayman S RHD) . Refer to 15 82 20 Removing and installing
RHD) .
17. Install spark plugs. Refer to 28 70 20 Removing and fitting spark plugs - as of MY 2005 (All Models) .

Spark plugs Using new spark plugs Tightening torque 30 (22 ftlb.) Nm
Spark plugs Re-using old spark plugs Tightening torque 25 (19 ftlb.) Nm
18. Fit support for servo lines.

1 2
Screw for servo lines support to Tightening 10 (7.5 ftlb.)
M6 x 12
engine block torque Nm
19. Fit transport eyebolt.

1 2
Screw for transport eyebolt to engine Tightening 10 (7.5 ftlb)
M6 x 16
block torque Nm
20. Fit all plastic components that have been removed (clips, support, etc.).
21. Fit brackets for oxygen sensor cable.

1 2
Brackets for oxygen sensor cable to Tightening 10 (7.5 ftlb.)
M6 x 12
cylinder head cover torque Nm
22. Fit coolant adapter.

1 2
Screw for coolant adapter to engine Tightening 10 (7.5 ftlb.)
M6 x 20
block torque Nm
23. Fit solenoid hydraulic valves for camshaft adjustment. Refer to 15 37 19 Removing and installing solenoid
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hydraulic valve (camshaft timing) - as of MY 2005 (Boxster, Boxster RHD, Boxster S, Boxster S RHD) .
24. Install thermostat housing.

1 2
Screw for thermostat housing to Tightening 10 (7.5 ftlb.)
M6 x 20
25. Fit coolant pump.

1 2
Screw for coolant pump to M6 x 25, M6 x Tightening 10 (7.5 ftlb.)
engine block 30 torque Nm
26. Fit coolant lines.

1 2
Screw for coolant lines to engine Tightening 10 (7.5 ftlb.)
M6 x 16
block torque Nm
27. Fit crankshaft pulse sender.

1 2
Screw for crankshaft pulse sender to Tightening 10 (7.5 ftlb.)
M6 x 15
28. Fit ignition coils.

1 2
Screw for ignition coil to engine Tightening 10 (7.5 ftlb.)
M6 x 25
block torque Nm
29. Fit coolant guide housing.

1 2
Screw for coolant guide housing to M6 x 35, M6 x Tightening 10 (7.5 ftlb.)
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30. Tiptronic only: Fit clip for guide belt.

1 2
Screw for clip for guide belt to Tightening 10 (7.5 ftlb.)
M6 x 12
31. Fit engine mounting.

1 2
Screw for engine mounting to M10 x 120, M10 x Tightening 65 (48 ftlb.)
32. Fit crankshaft belt pulley retaining device P 9593.

1 2
Screw for pulley to M16 x 60, 1st Tightening 50 (37 ftlb.)
crankshaft stage torque Nm
Screw for pulley to M16 x 60, 2nd
Torque angle 90 °
crankshaft stage
33. Fit engine ground lead on cylinder 1-3.

1 2
Screw for engine ground lead to Tightening 23 (17 ftlb.)
M8 x 30
34. Fit deflection roller.

1 2
Screw for deflection roller to engine Tightening 23 (17 ftlb.)
M8 x 60
block torque Nm
35. Fit both hall senders.

1 2
Screw for hall sender to cylinder Tightening 10 (7.5 ftlb.)
M6 x 11
head torque Nm
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36. Fit flange for positive crankcase ventilation.

value 1 2
Screw for flange for positive
M6 x 11, micro- Tightening 10 (7.5
crankcase ventilation to cylinder
self-locking torque ftlb.) Nm
head
37. Install oil pressure sender.
Location Explanation Type Basic value Tolerance 1 Tolerance

2
Oil pressure sender to valve Tightening 30 (22 ftlb.) +/-5 (3.5 ftlb.)
cover torque Nm Nm
38. Coat spacer sleeve with acid-free grease at the base and insert it.
39. Install oil-level sensor.

Oil-level sensor to crankcase Tightening torque 20 (15 ftlb.) Nm
40. Fit knock sensors.
Location Explanation Type Basic value Tolerance 1 Tolerance

2
Screw for knock sensor to Tightening 20 (15 ftlb.) +/-2 (1.5 ftlb.)
M8 x 35
engine block torque Nm Nm
41. Fit starter.

Screw for starter to crankcase M10 x 35 Tightening torque 45 (33 ftlb.) Nm
42. Fit secondary air pump.

1 2
Screw for secondary air line/secondary air Tightening 10 (7.5
M6 x 20
pump to engine block torque ftlb.) Nm
43. Fit oil mist collector. Fix hose with spring band clamp.

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1 2
Screw for oil mist collector to M6 x 20, micro-self- Tightening 10 (7.5 ftlb.)
44. Fit oil/water heat exchanger.

1 2
Screw for oil/water heat exchanger to Tightening 10 (7.5 ftlb.)
M6 x 16
45. Fit engine wire harness.

1 2
Tightening 10 (7.5 ftlb.)
Screw for ground lead to engine block M6 x 12
torque Nm
Screw for plastic wiring harness guide Tightening 10 (7.5 ftlb.)
M6 x 12
Screw for plastic wiring harness guide Tightening 23 (17 ftlb.)
M8 x 20
46. Fit terminal 50 starter line.

1 2
Line collar nut, terminal 50 to Tightening 10 (7.5 ftlb.)
M6
starter torque Nm
47. Fit terminal 30 starter line.

1 2
Line collar nut, terminal 50 to Tightening 15 (11 ftlb.)
starter torque Nm
48. Fit positive crankcase ventilation line.
49. Fit power-steering pump support.

1 2
Screw for power-steering-pump support Tightening 23 (17 ftlb.)
M8 x 35
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50. Fit power-steering pump.

1 2
Screw for power-steering pump to power- Tightening 23 (17 ftlb.)
steering pump support torque Nm
51. Tighten union nut for servo pressure line.

Union nut for servo pressure line Tightening torque 24 (18 ftlb.) Nm
52. Fit oil filler neck.

1 2
Screw for oil filler neck to M6 x 11, micro-self- Tightening 10 (7.5 ftlb.)
53. Fit generator and deflection roller. Refer to 27 22 19 Removing and installing three-phase generator - as
of MY 2006 (Cayman S, Cayman S RHD) . Refer to 27 22 19 Removing and installing three-phase
generator - as of MY 2005 (Boxster, Boxster RHD, Boxster S, Boxster S RHD) .

1 2
Screw for generator to M10 x 35, M10 x Tightening 45 (33 ftlb.)
support 145 torque Nm
54. Fit B+ wire on generator.

1 2
Collar nut for B+ wire to Tightening 15 (11 ftlb.)
M8
generator torque Nm
55. Connect cable plug to generator.
56. Fit cover for drive belt.

1 2
Screw for drive belt cover to M6 x 12, micro-self- Tightening 10 (7.5 ftlb.)
crankcase locking torque Nm
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57. Fit intake-air distributor.

1 2
Screw for intake-air distributor to Tightening 10 (7.5 ftlb.)
M6 x 35
cylinder head torque Nm
58. Fit support for servo lines. Clip oxygen sensor line into support.

1 2
Screw for support to M6 x 12, micro-self- Tightening 10 (7.5 ftlb.)
59. Connect cable plug for carbon canister solenoid valve.
60. Connect cable plug for all fuel injectors.
61. Push on cable plug for engine compartment temperature sensor.
62. Connect cable plug for the solenoid valves.
63. Fit pulley for power-steering pump.

1 2
Screw for pulley to power-steering Tightening 23 (17 ftlb.)
M8 x 12
pump torque Nm
ASSEMBLING ENGINE, TOUCHING UP
Assembling engine, touching up
1. Install flywheel. Refer to 13 60 19 Removing and installing flywheel - as of MY 2005 (All Models) .
2. Fit clutch. Refer to 30 50 19 Removing and installing clutch - as of MY 2005 (All Models) .
Tiptronic transmission:
3. Install drive plate for converter. Refer to 13 63 19 Removing and installing drive plate for converter - as
4. Remove exhaust manifold. Refer to 26 10 19 Removing and installing exhaust manifold (with primary
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catalytic converter) - as of MY 2005 (All Models) .
5. Fit transmission. Refer to 34 35 27 Removing and refitting transmission - as of MY 2005 (Boxster,

6. Install engine --> 100119 Removing and installing engine [987310 987311 987320 987321] --> 100119
Removing and installing engine [987120 987121].
7. Fill in engine oil. Unscrew oil drain plug (hexagon socket a/f 8). Refer to 17 01 55 Engine oil and oil filter
change - as of MY 2005 (All Models) .

Oil drain plug M18 x 1.5 Tightening torque 37 ftlb.
10 52 19 REMOVING AND INSTALLING CRANKCASE VENT LINE - AS OF

PRELIMINARY WORK FOR REMOVING CRANKCASE VENT LINE
Preliminary work for removing crankcase vent line
2. Remove intake-air distributor 1-3. Refer to 24 46 20 Removing and installing intake-air distributor - as of
REMOVING CRANKCASE VENT LINE
Removing crankcase vent line
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Fig. 214: View of holding clamp

1. Remove holding clamp by unscrewing the Torx screw (M6 x 12) -arrow- . See Fig. 214.
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Fig. 215: Rapid-action coupling on vent line

2. Release and disconnect rapid-action couplings on both cylinder heads -arrow- . See Fig. 215.
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Fig. 216: View of rapid-action coupling (cylinders 1 - 3)

3. Unclip all line clips.
4. Guide line out of the engine compartment.
INSTALLING CRANKCASE VENT LINE
Installing crankcase vent line
1. Replace the two O-rings on the rapid-action couplings. Apply a thin coat of Optimol MP3 grease to the O-
rings.
2. Position line in the engine compartment.
Fig. 217: Rapid-action coupling on vent line

3. Attach rapid-action couplings to the cylinder heads -arrow- . See Fig. 217.
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Fig. 218: View of rapid-action coupling (cylinders 1 - 3)

Fig. 219: View of holding clamp

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4. Fit and tighten Torx screw (M6 x 12) to secure holding clamp on vent line -arrow- . --> Tightening torque:
7.5 ftlb. See Fig. 219.
5. Clip in all line clips.
SUBSEQUENT WORK FOR INSTALLING CRANKCASE VENT LINE
Subsequent work for installing crankcase vent line
1. Install intake-air distributor 1-3. Refer to 24 46 20 Removing and installing intake-air distributor - as of
2. Remove protective covers on vehicle.
10 55 19 REMOVING AND INSTALLING OIL SEPARATOR - AS OF MY 2005

PRELIMINARY WORK FOR REMOVING OIL SEPARATOR
Preliminary work for removing oil separator
REMOVING OIL SEPARATOR
Removing oil separator
1. Disconnect oil filler pipe at the rapid-action coupling.
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Fig. 220: Distributor pipe

2. Remove crankcase vent line at distributor pipe and oil separator. To do this, release and pull off rapid-action
couplings -arrows- . See Fig. 220.
3. Release and pull off rapid-action coupling on crankcase vent line -1- . See Fig. 221.
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Fig. 221: View of oil separator

4. Unscrew two Torx screws (M6 x 20) -2- . See Fig. 221.
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Fig. 222: Spring band clamp on breather hose

5. Release spring band clamp -arrow- and loosen hose carefully to turning it using a water pump pliers if
6. Pull oil separator up and out. Cover openings with a cloth in order to catch any drops of oil.
INSTALLING OIL SEPARATOR
Installing oil separator
NOTE:  All O-rings, seals and micro-encapsulated screws or lock nuts must
always be replaced.
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Fig. 223: Oil separator removed

1. Replace O-ring on oil separator -arrow- . See Fig. 223.
Fig. 224: Spring band clamp on breather hose
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2. Position oil separator, push hose onto connection piece and fit spring band clamp -arrow- . See Fig. 224.
3. Fit and tighten two new Torx screws (M6 x 20) -2- . --> Tightening torque: 7.5 ftlb. . See Fig. 225.
Fig. 225: View of oil separator

4. Fit rapid-action coupling on crankcase vent line -1- . See Fig. 225.
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5. Fit crankcase vent line at distributor pipe and oil separator. To do this, fit rapid-action couplings -arrows- .
See Fig. 226.
6. Insert oil filler pipe into the rapid-action coupling and secure with a plastic ring. Ensure that it is locked
correctly.
SUBSEQUENT WORK FOR INSTALLING OIL SEPARATOR
Subsequent work for installing oil separator
1. Install engine compartment lid. Refer to 55 78 19 Removing and installing engine compartment lid - as of
2. Remove protective covers on vehicle.
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ENGINE Crankshaft, pistons
ENGINE
Crankshaft, pistons
13 10 20 REMOVING AND INSTALLING PISTONS - AS OF MY 2005 (ALL

MODELS)
TOOLS

universal piston ring commercially NR.55
restraining strap, 75 - 125 available tool
mm
piston ring pliers Gr. 1 commercially NR.58

available tool
assembly tool special tool P 9500

assembly aid special tool P 9500/3
fixing pin special tool P 9595/1
spacer ring special tool P 9597/1
assembly tool special tool P 9602/1
centring aid special tool P 9602/2
assembly aid special tool P 9603/1
centring mandrel special tool P 9608
spacer sleeves special tool P 9613
centring mandrel special tool P 9645
insertion device special tool P 9699
measuring mandrel special tool P 9699/1
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REMOVING PISTONS, PRELIMINARY WORK
Removing pistons, preliminary work
1. Remove engine. Refer to 10 01 19 Removing and installing engine - as of MY 2005 (Boxster, Boxster
RHD, Boxster S, Boxster S RHD) . Refer to 10 01 19 Removing and installing engine - as of MY 2005
(Cayman S, Cayman S RHD) ..

Boxster S RHD, Cayman S, Cayman S RHD) ..
3. Disassemble engine to crankcase. Refer to 10 01 37 Disassembling and assembling engine - as of MY 2005

(All Models) ..
REMOVING PISTONS
Removing pistons
NOTE:  Fix the gear carrier for removing the pistons with two auxiliary screws to
crankcase half 1-3.
NOTE:  Mark pistons in installation position before removal. Combustion residues

(carbon desposits) can be removed with a brass brush.
 Hard to remove residues can be removed in the ultrasound bath following
disassembly.
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Fig. 1: Additional screws for gear carrier, side 1-3

1. Unscrew inner Torx screws with O-ring (M9 x 94 inside and M9 x 84 outside) for gear carrier -Arrows- on
crankcase half 1-3. See Fig. 1.
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Fig. 2: Additional screw for gear carrier, side 4-6

2. Unscrew inner Torx screw with O-ring M9 x 140 for gear carrier -Arrow- on crankcase half 4-6. See Fig. 2.
3. Turn crankcase at assembly support until crankcase half 4-6 stands vertically upwards.
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Fig. 3: Coated screws for cross bolt connection

4. Unscrew four coated M6 x 35 Torx screws -1- on crankcase half 4-6 on flywheel side. Replace screws during
assembly. See Fig. 3.
5. Unscrew 20 remaining M6 x 35 Torx screws in the crankcase cross bolt connection.
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Fig. 4: Mount for crankcase half 4-6 on engine support

6. Unscrew the star screw that fixes crankcase half 4-6 to the engine support -Arrow- . See Fig. 4.
Fig. 5: Separating the crankcase half

7. Tap the crankcase halves gently with a plastic hammer. Carefully lever the various cast lugs with a
screwdriver to separate the crankcase halves from one another.
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Fig. 6: Levering off crankcase half 4-6

CAUTION: Crankcase half 4-6 incorrectly levered off
 Damage to pistons, piston rings
--> Lever off crankcase half 4-6 only with the help of a second person.
8. Carefully lever off crankcase half 4-6 with the help of a second person to avoid damaging the pistons (e. g. by
tilting). Remove old shaft seals.
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Fig. 7: Auxiliary screws for securing gear carrier

9. For the following steps, fasten the gear carrier to crankcase housing half 1-3 with two cylinder-head screws
using spacer sleeves P 9613. --> Tightening torque: 20 (15 ftlb.) Nm
Removing pistons, side 4-6
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Fig. 8: Removing piston pins

10. Lever off the front piston-pin circlips of marked pistons 4-6 (from the viewpoint of the drive belt side) using
a small screwdriver, push out the piston pin -Arrow- and remove the pistons one by one. Assign the piston pins
again to the appropriate pistons. See Fig. 8.
Removing pistons and connecting rods, side 1-3
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Fig. 9: Connecting rod bolts

11. Remove marked pistons 1-3, including connecting rods. To do this, turn the crankshaft on the pulley until
the respective connecting rod bearing cover stands upwards. Undo and remove the connecting rod bolts (twelve-
edged socket wrench insert a/f 14), remove connecting rod bearing cap.
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Fig. 10: Removing connecting rod using plastic mandrel (shop-made)

NOTE:  Join connecting rod and connecting rod bearing cap together again
immediately after removal.
 Connecting rod bolts must be replaced.
12. Carefully press connecting rod and pistons downwards out of crankcase half 1-3 using a shop-made plastic
mandrel. Allocate a connecting rod cap immediately to the relevant connecting rod and screw on loosely. Pay
attention to the bearing shells.
13. Unscrew pulley fastening screw and remove washer.
14. To remove connecting rod 4-6, remove the gear carrier; see --> 134819 Removing and installing
crankshaft - section on "Preliminary work".
DISASSEMBLING PISTONS/CONNECTING RODS, CYLINDER 1-3
Disassembling pistons/connecting rods, cylinder 1-3
NOTE: When removing pistons, the piston-pin circlip always remains in the piston,
which is installed opposite the large assembly bore (no chamfer) for the piston
pin.
1. Remove piston/connecting rod unit. To do this, clamp the connecting rod to a vice with aluminum jaws, for
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example.
Fig. 11: Removing/installing piston rings

CAUTION: Over-extension of piston rings
 Damage or breakage
--> Using the piston ring pliers, spread open the piston rings only far enough so that the rings can be installed or
removed (without scratching the piston).
2. Remove piston ring groove 1 and groove 2 separately using a piston ring pliers Gr. 1 NR.58. Remove
piston ring groove 1 first. The piston rings must not be overstretched.
3. The three-piece oil scraper ring can be removed by hand. First, carefully remove both rings, then remove the
springs.
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Fig. 12: Piston assembly device 9597

4. Insert piston/connecting rod unit into the retaining device P 9597 in such a way that the twist lock in the
second piston ring groove faces the observer.
Fig. 13: Removing piston pin circlip

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5. Carefully press out piston-pin circlip with a screwdriver; while doing so, place a cloth over the piston so that
the circlip does not pop out.
Fig. 14: Pressing out piston pin

6. Turn piston/connecting rod unit through 180° on the assembly device and press out piston pin with the
plunger special tool assembly tool P 9500.
7. Repeat steps for removing pistons/connecting rods on cylinders 2 and 3.
ASSEMBLING PISTONS/CONNECTING RODS, CYLINDER 1-3
Assembling pistons/connecting rods, cylinder 1-3
NOTE: When removing pistons, the piston-pin circlip always remains in the piston,
which is installed opposite the large assembly bore (no chamfer) for the piston
pin.
The lug of the piston-pin circlip must always be touching the contact surface
facing the oil piston shank.
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Fig. 15: Piston assembly device 9597

Special tool retaining device P 9597 with spacer ring P 9597/1.
Fig. 16: Piston pin assembly bore

1. Insert the piston (without piston rings) into retaining device 9597 so that the deep assembly bore for the
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piston pin in the piston is facing the observer and the remaining circlip is located underneath (check: twist lock
of piston ring, second groove, is also pointing towards the observer -arrow- . arrow opposite piston crown). See
Fig. 16.
2. Place connecting rod in piston so that the twist lock of the connecting rod bearing shell is pointing
downwards in the connecting rod (i. e. in the direction of the arrow on the piston crown).
Fig. 17: Pressing in piston pin

3. Coat piston pin with new engine oil and press it in manually or using the plunger special tool assembly tool
P 9500.
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Fig. 18: Assembly sequence for piston-pin circlip

4. Insert new piston-pin circlip in the taper of the assembly aid P 9603/1. Position the cylindrical part on the
assembly tube of the special tool assembly tool P 9602/1.
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Fig. 19: Application of tool 9500/3

5. Press circlip into assembly tube using the assembly aid P 9500/3.
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Fig. 20: Assembling piston pin circlip

6. Position assembly tube on piston eye and press piston-pin circlip into the ring groove using the pressure pin
assembly tool P 9602/1. The circlip must audibly engage.
Fig. 21: Installation position of circlip

7. Check installation position and secure fit of circlip. The lug of the circlip must always be touching the contact
surface running in the direction of the oil piston shank opposite the piston ring grooves.
8. Repeat steps for pistons/connecting rods on cylinders 2 and 3 .
PISTON MARKINGS
Piston markings
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Fig. 22: Piston markings

Markings on piston crown: Replacement pistons are available from Porsche Parts Service only in dimensional
group X and in two weight groups + and - . The weight groups are listed in the table.
 Marking X appears as a large colored stamp in the middle of the piston crown, small as an engraved
feature Fig. 22 -1- .
 Marking + or - appears as a large colored stamp in the middle of the piston crown, small as an engraved
feature Fig. 22 -2- .
Complete Complete Complete

weight in g weight in g weight in g
Weight Complete weight in g (including piston (including (including (including
group rings) 987 2.7l - Ø 85.5 mm piston rings) piston rings) piston rings)
987 3.2l - Ø 93 Cayman S 2.7l Cayman S 3.4l
mm - Ø 85.5 mm - Ø 96 mm
- 460 - 466 535 - 541 462 - 468 524 - 530
+ 466 - 472 541 - 547 468 - 474 530 - 535
INSTALLING PISTONS
Installing pistons

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NOTE:  If the piston, piston pin or piston-pin circlip are incorrectly assembled, the
corresponding piston can be pulled out of the cylinder as follows.
Degrease center of piston crown with acetone. Coat suitable plastic
mandrel with instant adhesive, allow adhesive to cure, pull out piston,
remove plastic mandrel immediately.
NOTE:  All O-rings and seals (shaft seals) and micro-encapsulated screws or lock
nuts must be replaced.
NOTE:  Replace M9 x 1.25 connecting rod bolts and the piston-pin circlips that
have been removed.
NOTE:  With the help of a second person, carefully place crankcase half 4-6 in
position on crankcase half 1-3.
Piston/connecting rod assembly, cylinder 1-3:
1. Install gear carrier in crankcase half 1-3. --> 134819 Removing and installing crankshaft - section on
"Touching up"
2. Fit belt pulley with fastening screw. Turn the crankcase at the assembly support so that cylinders 1, 2 and 3
stand vertically upwards.
3. Turn crankshaft on pulley until the connecting-rod bearing from cylinder 1 stands vertically upwards. In
doing so, the bore marked 'U4' can be fixed with the bore in the crankcase using the fixing pin P 9595/1.
NOTE:  Observe information on aligning piston ring gaps at all times.
4. Prepare pre-assembled piston/connecting rod unit of cylinder 1 for installation. To do this, clamp the
connecting rod to a vice with aluminum jaws, for example. Align the gaps in the piston rings as follows:
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Fig. 23: Twist lock of piston ring, second groove

4.1. Align the second groove on the piston ring with the twist lock -Arrow- . See Fig. 23.
4.2. Turn gap of piston ring, groove 1, through 180°.
4.3. Turn the gaps of the oil scraper ring so that the gaps are located at the oil piston shank area. When doing so,
the gaps of both rings and the springs should not be on top of one another (they should be slightly offset with
respect to one another).
5. Coat piston and piston rings with plenty of new engine oil.
6. Insert connecting rod bearing in connecting rod and connecting rod cap. Coat sliding surface with Optimol
Optipit (available from Porsche Parts Service: 000.043.204.17).
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Fig. 24: Piston with restraining strap

7. Position clamping tool universal piston ring restraining strap, 75 - 125 mm NR.55 on the piston; when
doing so, ensure that the piston rings are positioned correctly. Adjust restraining strap to piston diameter, use
tensioning lever -1- and tensioning screw -2- to fine-tune the adjustments. See Fig. 24.
8. Coat cylinder bores 1-3 with plenty of new engine oil.
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Fig. 25: Piston in cylinder bore

9. Insert piston, together with connecting rod, into cylinder bore 1, universal piston ring restraining strap, 75-
125 mm NR.55 must lie evenly on cylinder surface.
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Fig. 26: Piston - installation position in crankcase

10. Pay attention to direction of assembly: arrow on piston crown always points to flywheel side
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Fig. 27: Pressing piston into cylinder bore

CAUTION: Incorrect and careless assembly of pistons.
 Component damage (pistons, piston rings, cylinder line)
--> Assemble pistons carefully and gently.
--> Stop process immediately if there is increased resistance during assembly; eliminate the cause of the
problem.
11. Hold the piston ring restraining strap firmly and press piston in a cable into the cylinder bore using a plastic
mandrel.
12. Check installation position of connecting rod: In the installation position, the recesses of the twist lock in
the connecting rod bearing point towards the oil pan.

13. Turn crankcase through 180° on assembly support, position marked connecting rod cap with new, greased
bearing shell and screw in two new connecting rod bolts.
14. First, screw in connecting rod bolts to the required torque and tighten to the specified torque angle. Then
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loosen the bolts again. The final tightening is performed again with an initial tightening per the torque and the
concluding tightening is performed with the torque angle wrench. --> Initial tightening: 20 (15 ftlb.) Nm ; -->
Torque angle, final tightening: 110 °
15. Repeat steps 3-14 for the pistons/connecting rods on cylinders 2 and 3. For the assembly of cylinder 2, bore
'U5' will be fixed with the fixing pin after the crankshaft is turned on the pulley; for the assembly of cylinder 3,
bore 'U6' will be fixed.
16. Remove the cylinder-head screw from crankcase 1-3 using the spacer sleeve P 9613.
Only the following sealants may be used to seal the engine:
 Loctite 5900
 Drei Bond 1209 (optional)
Fig. 29: Aligning timing chain and connecting rod

17. Prepare crankcase half 4-6 to fit it onto crankcase half 1-3. Carefully grease sealing faces of both halves
with acetone. Align connecting rods 4-6 vertically upwards and fold timing chain.
18. Apply sealant to the sealing face of crankcase half 4-6.
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Fig. 30: Application of sealant and tightening sequence for crankcase

19. With the help of a second person, place crankcase half 4-6 in position on crankcase half 1-3. Knock gently
on crankcase half 4 -6 using a plastic hammer. Pull timing chain out through chain space using a bent welding
wire.
Fig. 31: Coated screws for cross bolt connection

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20. Position four new, coated M6 x 35 Torx screws -1- on flywheel side. See Fig. 31.
Fig. 32: Cross bolt connection on belt side

21. Position seven M6 x 35 Torx screws on belt pulley side -1- ; then fit special tool centring mandrel P 9645
for the intermediate shaft. Position centring mandrel on the mounting point of the oil pump and turn the star
knob clockwise until it is braced in the crankcase. See Fig. 32.
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Fig. 33: Tightening sequence for crankcase

22. Position the remaining 13 M6 x 35 Torx screws on the crankcase. Tighten all screws in the cross bolt
connection to the required torque in accordance with the specified tightening sequence. --> Tightening torque:
13 (9.5 ftlb.) Nm
23. Carefully remove any remaining sealant on crankcase (particularly around the oil pan, intermediate-shaft
bearing and crankshaft sealing rings).
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Fig. 34: Additional screw for gear carrier, side 4-6

24. Fit inner Torx screw with M9 x 140 O-ring for gear carrier -Arrow- on crankcase half 4-6. --> Tightening
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Fig. 35: Mount for crankcase half 4-6 on engine support

25. Tighten third star screw for crankcase half 4-6 on engine support.
26. Remove belt pulley.
27. Fit crankshaft sealing ring on belt pulley side --> 137419 Removing and installing crankshaft sealing
ring - belt pulley side - section on "Installing" [987310 987311 987320 987321] --> 137419 Removing and
installing crankshaft sealing ring - belt pulley side - section on "Installing" [987120 987121].
28. Only position pulley with fastening screw (to turn the crankshaft).
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Fig. 36: Measuring mandrel 9699/1

29. Check the position of the crankshaft using the measuring mandrel P 9699/1.
30. Fit crankshaft sealing ring on flywheel side. Use the insertion device P 9699 for the assembly. --> 135919
Removing and installing crankshaft sealing ring - flywheel side - section on "Installing".
Piston assembly, cylinder side 4-6:
31. Turn the crankcase at the assembly support so that cylinder bank 4-6 stands upwards.
32. Move crankshaft of cylinder 6 to TDC by turning it on the pulley (in a clockwise direction). Bore U6 on the
pulley must be aligned with the fixing bore on the crankcase. Fix the crankshaft using a fixing pin P 9595/1.
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Fig. 37: Guide for piston pin assembly in 2.7l

33. Engine M96/25 2.7l: Fasten special tool centring aid P 9602/4 to crankcase using two countersunk screws.
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Fig. 38: Guide for piston pin assembly in 3,2l

34. Engine M96/26 3.2l: Fasten special tool centring aid P 9602/2 to crankcase using two countersunk screws.
NOTE:  Observe information on aligning piston ring gaps at all times.
35. Prepare pistons for installation in the same way as cylinder bank 1-3 (piston rings, oiling, piston ring
tensioning clamp).
Fig. 39: Aligning connecting rod

NOTE:  Leave the centring mandrel in the eye of the connecting rod until the
relevant piston (4-6) contacts the centring mandrel during assembly.
36. Align connecting rod using the centring mandrel P 9608 as required.
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Fig. 40: Piston in cylinder bore

37. Coat cylinder bore with new engine oil. Place piston 6 on cylinder bore 6 using the universal piston ring
restraining strap, 75-125 mm NR.55.
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Fig. 41: Piston - installation position in crankcase

38. Pay attention to direction of assembly: arrow on piston crown always points to flywheel side
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Fig. 42: Pressing piston into cylinder bore

problem.
39. Hold the piston ring restraining strap firmly and press piston into a cable into the cylinder bore using a
plastic mandrel until the piston touches the centring mandrel.
40. Check installation position of connecting rod: In the installation position, the recesses of the twist lock in
the connecting rod bearing point towards the oil pan.
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Fig. 43: Align piston connecting rod using the centring mandrel.
41. Align piston and connecting rod again using the centring mandrel P 9608 before fitting the piston pins.
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Fig. 44: Inserting piston-pin circlip into assembly tube

42. Insert piston-pin circlip into the assembly tube of the special tool assembly tool P 9602/1. Insert the lug of
the circlip so that it is aligned to the right in the groove.
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Fig. 45: Pressure pin in assembly tool

43. Insert pressure pin -1- carefully into assembly tube -2- , ensuring that the circlip does not pop out. See Fig.
45.
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Fig. 46: Assembly tool on piston pin

44. Oil piston pin -3- with new engine oil and place it in an upright position on a clean surface on the
workbench. Position assembly tube with circlip -1- and pressure pin on piston pin. See Fig. 46.
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Fig. 47: Moving piston-pin circlip into installation position

45. Press piston-pin circlip with pressure pin -1- onto piston pin; while doing so, press assembly tube -2- firmly
onto piston pin. This will move the piston-pin circlip into the correct installation position. See Fig. 47.
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Fig. 48: Installation position of piston-pin circlip in assembly tube

46. Check installation position of piston-pin circlip in assembly tube.
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Fig. 49: Piston pin and circlip on assembly tool 9602/1

47. Assembly tool P 9602/1 with piston pin circlip and piston pin must be inserted through the centring aid P
9602/5 into the crankcase. Press piston pin into assembly bore of piston/connecting rod eye.
Fig. 50: Position of assembly tube on centring aid 9602/5

48. Groove in assembly tube must sit on dowel pin of centring aid 9602/5.
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Fig. 51: Inserting piston-pin circlip in cylinder 6

49. Push the piston pin circlip to its installation position by briefly and forcefully striking the palm of your hand
against the star knob of the pressure pin.
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Fig. 52: Seating of piston-pin circlip

50. Using a mirror, check that the piston-pin circlip is seated correctly.
problem.
51. Repeat steps 35-49 carefully to assemble pistons 5 and 4. During this process, the crankshaft is fixed to the
crankcase through bore U5 for cylinder 5 and through bore U4 to the pulley. Convert the assembly tool P
9602/1 as described below.
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Fig. 53: Spacer sleeve for cylinder 5

52. Push a spacer sleeve onto the assembly tube for the assembly of pistons pins and circlip on cylinder 5.
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Fig. 54: Inserting piston-pin circlip for cylinder 5

53. Fit the piston-pin circlip for cylinder 5 using a sleeve.
Fig. 55: Spacer sleeves for cylinder 4

54. Push two spacer sleeve onto the assembly tube for the assembly of pistons pins and circlip on cylinder 4.
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Fig. 56: Inserting piston-pin circlip in cylinder 4

55. Fit the piston-pin circlip for cylinder 4 using two sleeves.
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Fig. 57: Screw plug for assembly bore in crankcase

56. Once the pistons have been installed, seal the bore for the piston pin and circlip assembly on the crankcase
using the aluminum screw plug and new sealing ring. --> Tightening torque: 80 (59 ftlb.) Nm
INSTALLING PISTONS, TOUCHING UP
Subsequent work for installing pistons
1. Assemble engine. Refer to 10 01 37 Disassembling and assembling engine - as of MY 2005 (All Models) ..
2. Refit transmission. Refer to 34 35 27 Removing and refitting transmission - as of MY 2005 (Boxster,

Boxster S RHD, Cayman S, Cayman S RHD) ..
3. Install engine. Refer to 10 01 19 Removing and installing engine - as of MY 2005 (Boxster, Boxster RHD,
Boxster S, Boxster S RHD) . Refer to 10 01 19 Removing and installing engine - as of MY 2005 (Cayman
S, Cayman S RHD) ..
13 44 IN MOUNTING SPECIFICATION FOR CONNECTING ROD BOLTS - AS

TOOLS

SECURING CONNECTING ROD BOLTS
CAUTION: Damage to engine caused by refitting of connecting rod bolts that have
already been fitted.
--> Always replace connecting rod bolts.

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--> New connecting rod bolts may be screwed in a maximum of four times during assembly.
1. Position the new connecting rod bolts with the associated connecting rod caps and tighten the screws by
hand.
2. Pre-tighten connecting rod bolts to the specified torque and retighten with a torque angle wrench. --> Initial
tightening: 15 ftlb. ; --> Torque angle: 110 °
3. Unscrew connecting-rod bolts.
4. Pre-tighten connecting rod bolts to the specified torque and perform the final tightening with a torque angle
wrench. --> Initial tightening: 15 ftlb. ; --> Final tightening - torque angle: 110 °
13 48 19 REMOVING AND INSTALLING CRANKSHAFT - AS OF MY 2005

(ALL MODELS)
TOOLS

Engine support special tool P 9589
mounting parts special tool P 9590
spacer sleeves special tool P 9613
PRELIMINARY WORK
Preliminary work
1. Disassemble engine to crankcase. Refer to 10 01 37 Disassembling and assembling engine - as of MY 2005

(All Models) ..
2. Remove piston --> 131020 Removing and installing pistons - section on "Removing".
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Fig. 58: Retaining device, gear carrier

3. Attach special tool retaining device P 9607 to the gear carrier with two M10 x 25 hexagon-head bolts -
Arrows- .
4. Unscrew cylinder-head screws with spacer sleeves P 9613.
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Fig. 59: Lifting gear carrier out of crankcase

5. Screw in retaining eyes on retaining device, lift gear carrier out of the crankcase half using a workshop crane
or engine lifter and secure in a vice.
6. Remove accessories on gear carrier.
Gear carrier components overview with intermediate shaft
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Fig. 60: Overview of gear carrier with intermediate shaft

Item
Designation Number Removal Fitting
No.
M6 x 40 fastening screw with Tightening torque: 10
1 3
captive washer Nm (7.5 ftlb.)
Visually inspect for scoring or
2 Guide rail 1
damage and replace if necessary
3 Snap ring 1 Replace
4 Shim 10 x 16 x 1.2 1
5 Tensioning rail 1
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Visually inspect for scoring or

5a Lining for tensioning rail 1
damage and replace if necessary
Check toothing for signs of
6 Intermediate shaft 1
damage
Chain for camshaft driving Check for visible damage,
7 1
mechanism, cylinder 1-3 replace if necessary
Chain for camshaft driving Check for visible damage,
8 1
mechanism, cylinder 4-6 replace if necessary
Chain for intermediate shaft Check for visible damage,
9 1
driving mechanism replace if necessary
Oil guide fastening screw Replace micro-
10 6
(Torx, M6 x 16) encapsulated screws
11 Seal for oil guide 2 Replace
12 Oil guide 1
Fit on retaining
13 Gear carrier 1 Fit on retaining device P 9607
device P 9607
Fig. 61: Chain guide, intermediate shaft

7. Remove tensioning rail and guide rail. Unscrew three M6 x 40 hexagon-head bolts and remove tensioning
rail -1- . Remove circlip and washer -2- , remove guide rail -3- . See Fig. 61.
8. Remove intermediate shaft with timing chains and place on a clean surface. Check timing chains and toothing
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on intermediate shaft for signs of damage, replace if necessary.
Fig. 62: Oil guide, intermediate shaft

9. Remove oil guide on gear carrier. Unscrew six M6 x 16 Torx screws -1- and remove guide with seals. See
Fig. 62.
REMOVING CRANKSHAFT
Removing crankshaft
CAUTION: Engine damage due to incorrect allocation of connecting rod and

connecting rod cap
--> Remove connecting rods one-by-one
--> When disassembling connecting rod cap, allocate it immediately to associated connecting rod
--> Mark installation position and cylinder allocation on connecting rod and connecting rod cap, using an
electric engraver, for example
--> Do not use prick punches or number embossing tools
Gear carrier components overview with crankshaft

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Fig. 63: Overview of gear carrier

Item
Designation Number Removal Fitting
No.
Connecting rod bolt,
1 6 Always replace
M9 x 1.25
Screw on immediately to associated
2 Connecting rod cap 3
connecting rod
Connecting rod Replace, grease (Optimol
3 6
bearing shell Optipit)
4 14
Crankshaft bearing Replace, coat with new engine
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shell oil
Press in right to the stop using
5 Oil spray jet 6 Clean, replace if damaged
a plastic mandrel (ø 4 mm)
Thrust-bearing
6 14 Tightening torque
screw, M9 x 127
Gear carrier half,
7 1
cylinder 1-3
8 Crankshaft 1
Position correctly, oil grooves
9 Thrust washer 2
always point outwards
Gear carrier half,
10 1
cylinder 4-6
Connecting rods, Immediately join with the associated
11 3
cylinder 4-6 connecting rod cap after removal
1. Fasten the special tool retaining device P 9607 onto the workbench using two screw clamps.
2. Mark connecting rod 4-6 in the installation position.
Fig. 64: Plastic mandrel

3. Remove connecting rods on cylinder side 4-6 one after another. Loosen the two connecting rod bolts on each
connecting rod, remove connecting rod cap. Using a plastic mandrel (possibly an in-house tool) push
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connecting rod down and out. Immediately after this, screw on loosely to associated connecting rod cap. Place
on a clean surface.
Fig. 65: Gear carrier

4. Loosen 14 M9 x 127 screws for the gear carrier in the opposite order to the tightening sequence, from the
outside inwards, and unscrew them.
NOTE: Watch out for bearing shells and oil spray jets that may fall out
5. Remove gear carrier half 1-3, possibly tapping it gently with a plastic hammer.
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Fig. 66: Oil spray jets in gear carrier half 1-3

6. Place gear carrier half on a clean surface, remove seven crankshaft bearing shells and three oil spray jets for
piston cooling.
7. Lever out crankshaft with timing chain and place on a soft, clean surface.
8. Remove seven crankshaft bearing shells and oil spray jets for piston cooling from gearing carrier half 4-6.
Unscrew gear carrier half from the retaining device and place on a clean surface.
INSTALLING CRANKSHAFT
Installing crankshaft
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Fig. 67: Connecting rod bearing position in gear carrier

Overview of connecting rod bearing position
Fig. 68: Gear carrier half 4-6 on device

1. Fit gearing carrier half 4-6 on special tool retaining device P 9607 using two M10 x 25 hexagon-head bolts.
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Fig. 69: Dowel sleeves, gear carrier 4-6

2. Ensure that the dowel sleeves are seated correctly in gear carrier half 4-6.
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Fig. 70: Oil spray jets for piston cooling

3. Insert three oil spray jets in the take-up bores in each of the gear carrier halves, press in gently to the stop
using a plastic mandrel (ø 4 mm).
Fig. 71: Thrust washer, thrust block

4. Insert two thrust washers onto the center thrust block (no. 4) of gear carrier half 4-6; when doing so, the oil
pockets -Arrows- must always point outwards (to the belt pulley side or flywheel side). See Fig. 71.
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Fig. 72: Oil spray jets and bearing shells in gear carrier half 1-3
5. Insert seven new bearing shells for the crankshaft and coat with new engine oil. Pay attention to the
installation position: the fixing lugs of the bearing shells in gear carrier half 4-6 point towards the dowel sleeve
side, the fixing lugs of the bearing shells in gear carrier half 1-3 face the opposite side.
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Fig. 73: Twist lock of bearing shell in gear carrier half 4-6
Twist lock of bearing shell
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Fig. 74: Seating of thrust washer with crankshaft

6. Insert crankshaft. Check that the thrust washers are seated properly.
7. Carefully position gear carrier half 1-3 on the crankshaft and gear carrier half 4-6. Fix the gear carrier halves
by tapping them carefully with a plastic hammer.
Fig. 75: Tightening sequence for gear carrier

8. Position 14 M9 x 127 thrust-bearing screws manually. Pre-tighten screws to the required tightening torque in
accordance with the tightening sequence. Then tighten to the required torque angle. --> Initial tightening: 15
(11 ftlb.) Nm ; --> Torque angle: 120 °
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Fig. 76: Dial gauge, crankshaft axial play

9. Check axial play of crankshaft. Fit dial gauge and dial gauge holder on gear carrier (flywheel side) and place
against crankshaft flange. Press crankshaft manually against probe of dial gauge and set dial gauge to '0' . Press
crankshaft away from dial gauge. Repeat process several times and note measured value.
Status Tolerance range Wear limit

First fitting 0.05 - 0.24 mm 0.28 mm
10. Insert connecting rod bearing in connecting rod and connecting rod cap. Coat sliding surface with Optimol
Optipit (available from Porsche Parts Service: 000.043.204.17).
NOTE: Connecting rod bolts must always be replaced.
11. Fit each of the connecting rods of cylinder 4-6 with the allocated connecting rod cap at the bearing surfaces
of cylinders 4, 5 and 6. Position new screws manually. Pay attention to the installation position of the
connecting rods: The recesses of the connecting-rod bearing twist lock face the oil pan (when the gear carrier
is installed in the crankcase).
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12. First, screw in connecting rod bolts to the required torque and tighten to the specified torque angle. Then
loosen the bolts again. The final tightening is performed again with an initial tightening per the torque and the
final tightening is performed with the torque angle wrench. --> Initial tightening: 20 (15 ftlb.) Nm ; -->
Torque angle: 110 °
SUBSEQUENT WORK
Subsequent work
1. Fit oil guide with new seals. Tighten six new M6 x 16 (micro-encapsulated) Torx screws. --> Tightening
torque: 10 (7.5 ftlb.) Nm
NOTE: Fix the intermediate shaft to the crankshaft using old O-rings, for example, to
secure it.
2. Insert intermediate shaft with timing chains.
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Fig. 78: Chain guide, intermediate shaft

3. Install tensioning rail and guide rail. Tighten three M6 x 40 hexagon-head bolts for guide rail -1- . Fit
tensioning rail -3- with new circlip and shim -2- . --> Tightening torque: 10 (7.5 ftlb.) Nm See Fig. 78.
4. Engine support P 9589 must be secured to the engine assembly support.
5. Fit crankcase half 1-3 with two mounting parts P 9590 to the engine support P 9589. Check sealing face to
gear carrier for damage. Carefully clean sealing face with a clean cloth soaked in solvent naphtha or acetone.
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Fig. 79: Dowel sleeves for gear carrier in crankcase

Use only dowel sleeves with dimension B = 26.5 mm for fixing the gear carrier.
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Fig. 80: Dowel sleeves, crankcase half 1-3

6. Check dowel sleeves to ensure that they are seated correctly or insert two new dowel sleeves in crankcase -
Arrows- . See Fig. 80.
Fig. 81: Seals for coolant ducts

7. Replace seals for coolant ducts -Arrows- . See Fig. 81.
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Fig. 82: Gear carrier in crankcase half 1-3

NOTE: It is advisable to get a second person to assist in inserting the gear carrier into
crankcase half 1-3.
8. Insert gear carrier in crankcase half 1-3 with retaining device.
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Fig. 83: Additional screws for gear carrier 1-3

9. Screw in and tighten two additional screws for fastening the gear carrier to cylinder side 1-3, replace O-ring. -
Arrows- . --> Tightening torque: 22 (16 ftlb.) Nm See Fig. 83.
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Fig. 84: Auxiliary screw with spacer sleeve 9613

10. Screw in and tighten another cylinder-head screw with spacer sleeve P 9613 -Arrow- on the belt pulley
side. --> Tightening torque: 20 (15 ftlb.) Nm See Fig. 84.
11. Unscrew special tool retaining device P 9607 from gear carrier.
12. Install piston --> 131020 Removing and installing pistons - section on "Installing".
13 59 19 REMOVING AND INSTALLING CRANKSHAFT SEALING RING -

FLYWHEEL SIDE - AS OF MY 2005 (ALL MODELS)
TOOLS

drift punch (1 mm tip) commercially NR.167
available tool
puller, model G for sealing commercially NR.168-1

rings available tool
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puller special tool P 9237 alternative

tool to puller
Mod. G (No.
168-1)
insertion tool special tool P 9699
measuring mandrel special tool P 9699/1
assembly aid special tool P 9699/2 Assembly of

PTFE sealing
ring
PRELIMINARY WORK FOR CRANKSHAFT SEALING RING ON FLYWHEEL SIDE
Preliminary work for crankshaft sealing ring on flywheel side
1. Remove manual transmission. Refer to 34 35 19 Removing and installing transmission - as of MY 2005

(All Models) ..
2. Remove clutch. Refer to 30 50 19 Removing and installing clutch - as of MY 2005 (All Models) ..
3. Remove double-mass flywheel --> 136019 Removing and installing double-mass flywheel - chapter on
"removing".
Tiptronic:
4. Remove automatic transmission. Refer to 37 35 19 Removing and installing automatic transmission - as of

MY 2005 (Cayman S, Cayman S RHD) . Refer to 37 35 19 Removing and installing automatic
transmission - as of MY 2005 (Boxster S, Boxster S RHD) . Refer to 37 35 19 Removing and installing
automatic transmission - as of MY 2005 (Boxster, Boxster RHD) ..
5. Remove drive plate for converter --> 136319 Removing and installing drive plate for converter - chapter
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on "removing".
REMOVING CRANKSHAFT SEALING RING ON FLYWHEEL SIDE
Removing crankshaft sealing ring on flywheel side
NOTE: Perform a visual inspection of the crankshaft flange and crankcase bore for
damage.
Ingress of dirt
 Risk of engine damage.
1. Carefully remove small edges or burrs on the chamfer of the crankshaft flange with an oilstone. Then,
carefully remove metal filings and any dirt remaining on the crankshaft journal and crankcase bore (using a
clean, lint-free cloth that has been soaked in solvent naphtha or acetone).
CAUTION: The crankshaft flange can be damaged if not cleaned correctly.
 Leaks
--> Never use an abrasive or polishing cloth or brushes with metal bristles.
--> Follow cleaning instructions.
2. If there are corroded spots on the crankshaft flange, clean them off using a metal-polishing pad (e. g. Nevr
Dull, available in car and motor bike accessory stores). Then, carefully rub off the flange (using a clean, lint-
free cloth that has been soaked in solvent naphtha or acetone).
3. Punch the installed sealing ring at a depression (round window in the ring) with a drift punch (1 mm tip)
NR.167.
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Fig. 85: Boring the sealing ring

4. Drill crankshaft sealing ring at the punched position with a greased drill bit (ø 3 mm) and carefully remove
the swarf (e. g. with compressed air).
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Fig. 86: Pulling out sealing ring

5. Screw extractor tip of the tool puller, model G for sealing rings NR.168-1 into the bore on the sealing ring
and pull out the sealing ring.
6. Alternatively, screw a sheetmetal screw with washer approx. 5 mm into the bore.
Fig. 87: Pulling out sealing ring

7. Pull out sealing ring using puller P 9237 at the tapping screw.
8. Check crankshaft flange and crankcase bore for damage.
9. If necessary, clean the crankshaft flange again using the metal-polishing pad. Then, carefully degrease the
flange and crankcase bore using a clean, lint-free cloth that has been soaked in solvent naphtha or acetone.
Ventilate this for at least three minutes to prevent the acetone vapours from destroying the new sealing ring.
INSTALLING CRANKSHAFT SEALING RING ON FLYWHEEL SIDE
Installing crankshaft sealing ring (PTFE) on flywheel side
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Fig. 88: Insert part 9699/2

New insert part assembly aid P 9699/2 for special tool insertion tool P 9699.
Component overview of insertion tool
Fig. 89: Individual parts of insertion tool


1 Screw For pulling in the sealing ring
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2 Sleeve Body of insertion tool 9699

For guiding the insert part -5- into the
3 Guide pin
sleeve. See Fig. 89.
For securing the insertion tool on the
4 Fastening screws
crankshaft flange
For fitting the PTFE sealing ring with
5 Assembly aid P 9699/2
supporting sleeve
1. Fit assembly aid P 9699/2 into the insertion tool P 9699. To do so, unscrew the hexagon-head bolt and
replace the insert parts.
CAUTION: Sharp tool edges and burrs.
 Damage to the sealing lip.
--> Always examine tools for signs of burrs and sharp edges.
2. Small burred spots or damaged areas on the tools can be eliminated with a nail file; then whet with an
oilstone, fine abrasive or polishing cloth. Remove residual dirt on the tools, e. g. using solvent naphtha or
acetone.
Fig. 90: Checking that crankshaft is centerd using measuring mandrel 9699/1
3. Check crankshaft installation position. To do this, insert special tool measuring mandrel P 9699/1 across the
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crankshaft flange into the fitted bore of the crankcase -figure- . The measuring mandrel must be placed with
slight resistance in the bore. If the measuring mandrel cannot be positioned, the engine must be replaced.
Fig. 91: Adjusting insertion part for positioning sealing ring

4. Adjust insertion tool in order to position the supporting sleeve of the sealing ring. Unscrew the hexagon-head
bolt until the groove of the assembly aid P 9699/2 is flush with the contact surface of the sleeve -arrow- . See
Fig. 91.
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Fig. 92: Sliding PTFE sealing ring with supporting sleeve onto tool
CAUTION: Damage to the sealing lip.
 Leaks
--> The crankshaft flange and tools must be perfectly clean and free of grease.
--> The sealing ring must be fitted dry, i. e. no oil, grease or other lubricants can be used.
--> The crankcase bore must not be oiled.
--> The sealing ring can only be positioned on the assembly tool using the supporting sleeve.
--> The new crankshaft sealing ring (PTFE) is supplied on a supporting sleeve as a spare part.
--> Do not remove the sealing ring from the supporting sleeve.
5. Slide new crankshaft sealing ring -1- with supporting sleeve onto the assembly aid P 9699/2 by pushing only
on the sleeve -2- . The collar of the sleeve must point away from tool -inset- . Make sure sealing ring is dry. See
Fig. 92.
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Fig. 93: Fit insertion tool on crankshaft flange (shown with engine removed)
6. Fit insertion tool P 9699 between the two internal M8 pan-head screws, (hexagon socket a/f 8) on the
crankshaft flange and fasten it. The crankshaft flange's dowel pin must sit in the bore of the device.
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Fig. 94: Inserting sealing ring using tool 9699

NOTE: After pulling in the sealing ring, leave assembly tool 9699 in place for about one
minute so that the sealing lip can settle into position on the crankshaft flange.
7. To position the crankshaft sealing ring correctly on the crankshaft flange, turn at the hexagon (a/f 19) of the
device in a clockwise direction as far as it will go -figure- . Let the tool in place for about one minute.
8. Remove tool. Loosen the large hexagon-head bolt and the two inner hexagon-head bolts alternately on the
crankshaft flange until the tool can be removed.
9. Check whether the sealing ring is properly seated and aligned. To do this, measure at four points, offset by
90°, from the flywheel attachment surface on the crankshaft flange to the sealing ring (outer radius). -->
Dimension: 13 mm
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Fig. 95: Support ring on insertion tool

10. Leave supporting sleeve on the tool following assembly to protect the edges of the tool. Carefully lift off the
sleeve at the bore with a small screwdriver to remove it.
SUBSEQUENT WORK FOR CRANKSHAFT SEALING RING ON FLYWHEEL SIDE
Subsequent work for crankshaft sealing ring on flywheel side
1. Install double-mass flywheel --> 136019 Removing and installing double-mass flywheel - chapter on
"installing".
2. Install clutch. Refer to 30 50 19 Removing and installing clutch - as of MY 2005 (All Models) ..
3. Install manual transmission. Refer to 34 35 19 Removing and installing transmission - as of MY 2005 (All
Models) ..
Tiptronic:
4. Install drive plate for converter --> 136319 Removing and installing drive plate for converter - chapter on
"installing".
5. Install automatic transmission. Refer to 37 35 19 Removing and installing automatic transmission - as of
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13 60 19 REMOVING AND INSTALLING FLYWHEEL - AS OF MY 2005 (ALL

MODELS)
TOOLS

toothed segment special tool P 9538/1
PRELIMINARY WORK
Preliminary work for double-mass flywheel

(All Models) ..
2. Remove clutch. Refer to 30 50 19 Removing and installing clutch - as of MY 2005 (All Models) ..
REMOVING DOUBLE-MASS FLYWHEEL
Removing double-mass flywheel
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Fig. 96: Overview of double-mass flywheel, 3.6 l

Component overview
 1 - Double-mass flywheel
 2 - Fastening screw for double-mass flywheel, (8 M10 x 50 screws)
 3 - Clutch plate
 4 - Clutch pressure plate
 5 - Fastening screw for clutch pressure plate, (6 M8 screws)
Fig. 97: Toothed segment 9538/1

NOTE: The toothed segment P 9538/1 must be bored to ø 15 mm to guarantee a perfect

fit and to avoid damaging the thread in the crankcase.
1. To counter, fit toothed segment P 9538/1 to the crankcase using an M12 x 50 hexagon-head bolt (fine
thread).
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Fig. 98: Flywheel

2. Loosen and unscrew fastening screws on flywheel. Carefully take off flywheel (watch the thread!). Undo
fastening screw for toothed segment.
NOTE: Check the friction surface of the flywheel. The flywheel must be replaced if it is
damaged or discolored.
3. Inspect the friction surface of the flywheel visually.
INSTALLING DOUBLE-MASS FLYWHEEL
Installing double-mass flywheel
NOTE: Before re-installation, clean the friction surface of the flywheel with a clean lint-
free cloth that has been soaked in solvent naphtha or acetone.
1. Position double-mass flywheel on the crankshaft's dowel pin and press on to the crankshaft flange. Insert all
fastening screws (8).
2. Align toothed segment P 9538/1 and tighten fastening screw again.
3. Screw in and tighten fastening screws in diagonally opposite sequence. --> Initial tightening: 19 ftlb. ; -->
Final tightening - torque angle: 120 °
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4. Remove toothed segment.
SUBSEQUENT WORK
Subsequent work for double-mass flywheel
1. Install clutch. Refer to 30 50 19 Removing and installing clutch - as of MY 2005 (All Models) ..
2. Install manual transmission. Refer to 34 35 19 Removing and installing transmission - as of MY 2005 (All
Models) ..
13 63 19 REMOVING AND INSTALLING DRIVE PLATE FOR CONVERTER -

TOOLS

PRELIMINARY WORK FOR REMOVING DRIVE PLATE FOR CONVERTER
Preliminary work for removing drive plate for converter

REMOVING DRIVE PLATE FOR CONVERTER
Removing drive plate for converter
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Fig. 99: Toothed segment 9538/1


1. To counter, fit toothed segment P 9538/1 to the crankcase using an M12 x 50 hexagon-head bolt (fine
thread).
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Fig. 100: Detaching drive plate

2. Loosen and unscrew eight M10 x 25 fastening screws on the drive plate. Remove drive plate.
3. Loosen fastening screw for toothed segment.
INSTALLING DRIVE PLATE FOR CONVERTER
Installing drive plate for converter
1. Position drive plate on the crankshaft's dowel pin and press on to the crankshaft flange. Insert all M10 x 25
fastening screws (8).
2. Align toothed segment P 9538/1 and tighten fastening screw again.
3. Screw in and tighten fastening screws in diagonally opposite sequence. --> Initial tightening: 25 (19) Nm
(ftlb.) ; --> Final tightening - torque angle: 120 °
4. Remove toothed segment.
SUBSEQUENT WORK AFTER INSTALLING DRIVE PLATE FOR CONVERTER
Subsequent work after installing drive plate for converter

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BELT PULLEY SIDE - AS OF MY 2005 (CAYMAN S, CAYMAN S RHD)
TOOLS

Assembly lever special tool P 9182
assembly sleeve special tool P 9610/1
PRELIMINARY WORK FOR CRANKSHAFT SEALING RING - BELT PULLEY SIDE
Preliminary work for crankshaft sealing ring - belt pulley side
1. Move driver and passenger seats to the front-most position and fold over the backrests.
2. Disconnect ground strap for battery.
3. Place protective covers in the car to prevent damage and soiling.
Fig. 101: Rear wall cover

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4. Remove rear wall lining of rear wall cover. Refer to 55 59 19 Removing and installing rear wall cover - as
of MY 2005 (All Models) ..

5. Remove drive belt. Mark the running direction of the belt with a colored pen. Slacken the belt; to do so, turn
tensioning roller (a/f 24) in a clockwise direction and at the same time, remove the belt from the tensioning
roller or the deflection roller, --> 137819 Removing and installing drive belt - chapter on "Removing".
6. Remove pulley --> 137619 Removing and installing pulley - chapter on "Removing".
REMOVING CRANKSHAFT SEALING RING - BELT PULLEY SIDE
Removing crankshaft sealing ring - belt pulley side
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1. Make a 3-mm hole at the front of the sealing ring using an angle drill. Grease the drill in order to bind the
chips caused by drilling. Screw a sheetmetal screw with a washer (5 x 2) approx. 5 mm into the bore hole.
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Fig. 104: Levering out the sealing ring

CAUTION: Ingress of dirt
2. Position a lever tool on the sheetmetal screw, (e. g. Assembly lever P 9182 ), place a wooden wedge between
the lever tool and the crankcase and lever out the sealing ring. Carefully remove any residual dirt on the
crankshaft flange.
 Leaks
Dull, available in car and motor bike accessory stores). Then, carefully degrease the flange and crankcase bore
using a clean, lint-free cloth that has been soaked in solvent naphtha or acetone.
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damage.
INSTALLING CRANKSHAFT SEALING RING - BELT PULLEY SIDE
Installing crankshaft sealing ring - belt pulley side
NOTE:  The standard shaft seal is pressed 12.5 mm in, measured from the end of
the flange. The new sealing ring is pressed 14.5 mm in using the special
tool
assembly sleeve P 9610/1 in order to generate a new running track.
1. Small burred spots or damaged areas on the tools can be eliminated with a nail file, then pull off with a fine
abrasive or polishing cloth. Remove residual dirt on the tools, e. g. using solvent naphtha or acetone.
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Fig. 105: Taper assembly sleeve, sealing ring

CAUTION: Grease on sealing ring can cause material damage
 Damage to micro-sealing lip
--> Do not oil or grease the crankshaft sealing ring
--> Only coat the crankshaft housing bore with new engine oil
2. Coat the crankshaft case bore with new engine oil and slide the new crankshaft sealing ring with the taper of
the assembly sleeve P 9610/1 special tool over the crankshaft flange.
Fig. 106: Insertion device for sealing ring

3. Fit sealing ring with the insertion device of the assembly sleeve P 9610/1.
4. Check that the sealing ring is seated correctly. To do this, measure at four points, offset by 90°, from the belt
pulley attachment surface on the crankshaft flange to the sealing ring (outer radius). --> Dimension: 14.5 mm

BELT PULLEY SIDE - AS OF MY 2005 (BOXSTER, BOXSTER RHD,
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TOOLS

Assembly lever special tool P 9182
assembly sleeve special tool P 9610/1
PRELIMINARY WORK FOR CRANKSHAFT SEALING RING - BELT PULLEY SIDE
Preliminary work for crankshaft sealing ring - belt pulley side

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6. Remove pulley --> 137619 Removing and installing pulley - chapter on "Removing".
REMOVING CRANKSHAFT SEALING RING - BELT PULLEY SIDE
Removing crankshaft sealing ring - belt pulley side
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1. Make a 3-mm hole at the front of the sealing ring using an angle drill. Grease the drill in order to bind the
chips caused by drilling. Screw a sheetmetal screw with a washer (5 x 2) approx. 5 mm into the bore hole.
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CAUTION: Ingress of dirt
2. Position a lever tool on the sheetmetal screw, (e. g. Assembly lever P 9182 ), place a wooden wedge between
the lever tool and the crankcase and lever out the sealing ring. Carefully remove any residual dirt on the
crankshaft flange.
 Leaks
Dull, available in car and motor bike accessory stores). Then, carefully degrease the flange and crankcase bore
using a clean, lint-free cloth that has been soaked in solvent naphtha or acetone.
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damage.
INSTALLING CRANKSHAFT SEALING RING - BELT PULLEY SIDE
Installing crankshaft sealing ring - belt pulley side
NOTE:  The standard shaft seal is pressed 12.5 mm in, measured from the end of
the flange. The new sealing ring is pressed 14.5 mm in using the special
tool
assembly sleeve P 9610/1 in order to generate a new running track.
1. Small burred spots or damaged areas on the tools can be eliminated with a nail file, then pull off with a fine
abrasive or polishing cloth. Remove residual dirt on the tools, e. g. using solvent naphtha or acetone.
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Fig. 111: Taper assembly sleeve, sealing ring

CAUTION: Grease on sealing ring can cause material damage
 Damage to micro-sealing lip
--> Do not oil or grease the crankshaft sealing ring
--> Only coat the crankshaft housing bore with new engine oil
2. Coat the crankshaft case bore with new engine oil and slide the new crankshaft sealing ring with the taper of
the assembly sleeve P 9610/1 special tool over the crankshaft flange.
Fig. 112: Insertion device for sealing ring

3. Fit sealing ring with the insertion device of the assembly sleeve P 9610/1.
4. Check that the sealing ring is seated correctly. To do this, measure at four points, offset by 90°, from the belt
pulley attachment surface on the crankshaft flange to the sealing ring (outer radius). --> Dimension: 14.5 mm
SUBSEQUENT WORK FOR CRANKSHAFT SEALING RING - BELT PULLEY SIDE
Subsequent work for crankshaft sealing ring - belt pulley side
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1. Install pulley --> 137619 Removing and installing pulley - chapter on "Installing".
Fig. 113: Installed position of drive belt

2. Fit drive belt --> 137819 Removing and installing drive belt - chapter on "Installing".
3. Connect the ground strap for the battery --> 27 06 IN WORK INSTRUCTIONS AFTER
4. Start the engine and allow it to warm up (operating temperature) and perform a visual inspection to check for
leaks.
5. Fit rear wall cover and rear wall lining, tighten screws and collar nuts. --> Tightening torque: 7.5 ftlb.
13 76 19 REMOVING AND INSTALLING BELT PULLEY - AS OF MY 2005

(ALL MODELS)
TOOLS

PRELIMINARY WORK
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Preliminary work for removing pulley

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Removing belt pulley - engine installed
NOTE: To release and tighten the belt pulley, a second person must counter with the
relevant retaining tool.
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Fig. 116: Belt pulley components

Component overview
 1 - Belt pulley
 2 - Washer
 3 - Fastening screw
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Fig. 117: Fastening screw for belt pulley

1. Position retaining device P 9593 and a large torque wrench on the belt pulley and loosen the fastening
screw. A second person must counter with the retaining tool.
2. Unscrew fastening screw and remove belt pulley.
INSTALLING BELT PULLEY
Installing belt pulley - engine installed
NOTE: Degrease the belt pulley before installation on the flange side of the crankshaft
using solvent naphtha or acetone.
1. Position belt pulley on crankshaft flange (dowel pin).
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Fig. 118: Fastening screw for belt pulley

NOTE: Replace belt pulley fastening screw.

To release and tighten the belt pulley, a second person must counter with the
relevant retaining tool.
2. Insert fastening screw and tighten in two stages. Counter at the same time with special tool retaining device
P 9593. --> Tightening torque: 37 ftlb. ; --> Torque angle: 90 ° ;
SUBSEQUENT WORK
Subsequent work for installing belt pulley
1. Install pulley --> 137619 Removing and installing pulley - chapter on "Installing".
Microsoft

2. Fit drive belt --> 137819 Removing and installing drive belt - chapter on "Installing".
3. Connect the ground strap for the battery --> 27 06 IN WORK INSTRUCTIONS AFTER
4. Start the engine and allow it to warm up (operating temperature) and perform a visual inspection to check for
leaks.
5. Fit rear wall cover and rear wall lining, tighten screws and collar nuts. --> Tightening torque: 7.5 ftlb.
13 78 19 REMOVING AND INSTALLING DRIVE BELT - AS OF MY 2005 (ALL

MODELS)
PRELIMINARY WORK
Preliminary work for removing drive belt
1. Put protective covers in the passenger compartment.
Models) ..
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REMOVAL
Removing drive belt
WARNING: Do not remove the drive belt when the engine is warm!
 Risk of damage or deformation!
--> Drive belts should only be removed when they have cooled down.

1. Turn the tensioning roller clockwise at the hexagon (a/f 24) and simultaneously remove the belt from the
deflection rollers.
NOTE:  To check drive belt for damage by the naked eye, it needs to have been
removed.
 Mark running direction of drive belt with a colored pen.
 Even minor damage means that the drive belt must be replaced (even if the
maintenance interval has not expired).
2. Take the drive belt off the belt pulleys and give it a detailed inspection. Examine it to see if it has picked up
foreign bodies, cracks or other damage and replace if necessary.
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3. Check the pulleys for damage, wear and soiling.
INSTALLATION
Installing drive belt
NOTE:  After installing the drive belt you should check again that the individual
belt pulleys and rollers are positioned correctly.
1. Install the drive belt as shown in the illustration. If you are reinstalling the old drive belt, it is absolutely
necessary to observe the previously marked rolling direction. Position the drive belt by taking the tension off the
tensioning roller in a clockwise direction, then allow the tensioning roller to slide back to its normal position.

REWORKING
Subsequent work for installing drive belt
Models) .
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ENGINE Cylinder head, valve drive
ENGINE
Cylinder head, valve drive
15 05 02 CHECKING CAMSHAFT TIMING - ENGINE INSTALLED - AS OF MY

TOOLS

locating pins special tool P 9595/1
adjusting gauge special tool P 9686
PRELIMINARY WORK FOR CHECKING CAMSHAFT TIMING
Preliminary work for checking camshaft timing
Models) .
Fig. 1: TDC marking

2. Turn the engine clockwise at the crankshaft pulley to the TDC marking of cylinder 1. Fix with special tool
locating pins P 9595/1 (short locating pin).
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3. Place jacks under the vehicle at the prescribed jacking points --> 40 LIFTING THE VEHICLE - AS OF
5. Drain engine oil. Refer to 17 01 55 Engine oil and oil filter change - as of MY 2005 (All Models) .

6. Remove ground strap by unscrewing the Torx screw (M8 x 30) -arrow- . See Fig. 2.
CHECKING CAMSHAFT TIMING
Checking camshaft timing
NOTE: Do not turn engine crankshaft against the rolling direction of the engine.
Ensure absolute cleanliness when working on the open engine. Make sure that
no dirt gets into the engine.
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Fig. 3: Cap
1. Remove all four green caps on the camshaft housing covers on both cylinder banks. To do this, press a small
screwdriver into the center of the piercing point of each cap -arrows- and lever off the caps. See Fig. 3.
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Fig. 4: Position of camshafts

2. Check the cylinder side that is at the overlapping TDC first (the smaller circular cutout at the milled grooves
of the inlet and exhaust camshafts is facing the cylinder head cover) using an adjusting gauge P 9686. Then
turn the engine a further 360° (as described above) and check the other cylinder side as well.
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Fig. 5: Camshaft adjusting gauge

Align camshafts.
SUBSEQUENT WORK FOR CHECKING CAMSHAFT TIMING
Subsequent work for checking camshaft timing
1. Fit two new green caps on the camshaft housing cover.
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2. Fit ground strap by inserting and tightening the Torx screw (M8 x 30) -arrow- . --> Tightening torque: 17
ftlb. . See Fig. 6.
4. Fill in engine oil. Refer to 17 01 55 Engine oil and oil filter change - as of MY 2005 (All Models) .
5. Remove special tool locating pins P 9595/1 (short locating pin).
Models) .
15 05 20 REMOVING AND INSTALLING CAMSHAFT - AS OF MY 2005

TOOLS

locating pin special tool P 9595/1
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retaining tool special tool P 9685

CAMSHAFT DESIGNATION M96.26
Camshaft designation M96.26
Fig. 7: Position of camshaft designation

Position of lettering: -arrows- . See Fig. 7.
Camshafts for cylinders 1 - 3
 Inlet camshaft: 996.105.049.00 3,2 IN 1-3

 Exhaust camshaft: 996.105.063.00 3,2 EX 1-3
Camshafts for cylinders 4 -6:

 Exhaust camshaft: 987.105.064.26 3,2 EX 4-6 (with aluminum plugs)
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Fig. 8: aluminum plugs in exhaust camshaft 4 - 6

Additional identifying feature for exhaust camshaft 4 - 6: aluminum plugs with lubrication bore -1- for tandem
pump. See Fig. 8.
ALLOCATION OF INLET CAMSHAFT ADJUSTMENT DEVICE
Allocation of inlet camshaft adjustment device
Camshaft adjustment device on inlet camshaft, cylinder bank 1 - 3
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Fig. 9: Designation of adjuster 1 - 3

NOTE:  Side 1 - 3: the arrow should be attached anti-clockwise
- Designation, side 1 - 3:
 Part number, cylinder bank, manufacturer information, direction of rotation of engine (arrow), production
date.
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Fig. 10: Designation of adjuster 4 -6

NOTE:  Side 4 - 6: the arrow should be attached clockwise
date.
ALLOCATION OF CHAIN TENSIONERS
Allocation of chain tensioners
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Fig. 11: Primary chain tensioner

- Primary chain tensioner on crankcase (oil filter area), identification: one ring -Arrow- . See Fig. 11.
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Fig. 12: Chain tensioner, cylinders 1 - 3

- Chain tensioner on cylinder head, cylinder bank 1 - 3, identification: two rings -Arrows- . See Fig. 12.
Fig. 13: Chain tensioner 4 - 6

- Chain tensioner on cylinder head, cylinder bank 4 - 6, no identification.
PRELIMINARY WORK FOR REMOVING CAMSHAFTS
Preliminary work for removing camshafts
2. For disassembling cylinder bank 1 - 3, undo the ground cable on the cylinder head by unscrewing a Torx
screw M8 and removing the cable. Unplug the cable plug for the oil pressure switch.
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Fig. 14: Hydraulic valve for camshaft adjustment and ignition coils
3. Remove ignition coils -1- . In each case, unscrew two M6 x 25 Torx socket screws and pull the ignition coil
out of the spark-plug recess.
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Fig. 15: Solenoid hydraulic valve for camshaft timing

4. Remove solenoid hydraulic valve -1- (for camshaft timing) --> 153719 Removing and installing solenoid
hydraulic valve for camshaft timing - chapter on "Removing". See Fig. 15.
Fig. 16: Oil suction pump for cylinders 1 - 3

6. Remove oil suction pump for cylinders 1 - 3. Unscrew four Torx screws M6 x 20 (micro-self-locking),
remove oil suction pump, and replace O-ring and screws.
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Fig. 17: Tandem pump side 4 - 6

7. Remove tandem pump for cylinders 4 - 6. Unscrew four Torx screws M6 (micro-self-locking) -1- . Pull off
the vacuum line on pump -2- . Remove pump and replace O-rings and micro-self-locking screws. See Fig. 17.
REMOVING CAMSHAFT - ENGINE REMOVED
Removing camshaft - engine removed
1. Remove the plastic caps on the cylinder head. Press a small screwdriver into the center of the piercing point
of each cap and lever out the cap.
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Fig. 18: TDC marking on pulley

2. Disassembling cylinder bank 1 - 3 Turn crankshaft at the pulley/vibration balancer clockwise to the
overlapping TDC of cylinder 1. Disassembling cylinder bank 4 -6 Turn crankshaft to the TDC for cylinder 4.
Using a locating pin P 9595/1 fix the pulley or vibration balancer.
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Fig. 19: Position of the camshafts in overlapping TDC of cylinders 1 or 4

3. If the camshafts of cylinder bank 1 - 3 are removed, the smaller circular cut-outs at the grooves of the inlet
and outlet camshafts -arrows- of cylinder 1 must point to the cylinder head cover. For cylinder bank 4 - 6 the
corresponding position is then on cylinder 4 . Check the position using the adjusting gauge P 9686. See Fig.
19.
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Fig. 20: Unscrew the central screw on the camshaft adjuster.

NOTE:  Before disassembling the cylinder head cover, it is essential to unscrew

the central screw on the camshaft adjustment device.
4. Unscrew the central screw on the camshaft adjustment device. Position retaining tool P 9685 on the hexagon
of the adapter and place the contact block as a counter on the fitting bore of the cylinder head cover for the oil
suction pump; if necessary, position the contact block by undoing and tightening the screw. If the special tool
cannot be positioned on the hexagon of the adapter in this way, the engine must be turned further in the
direction of rotation at the belt pulley of the crankshaft until the contact block comes into contact with the
central screw of the cylinder head cover, ready for unscrewing. Unscrew the central screw.
5. Remove cylinder head cover --> 158220 Removing and installing cylinder head cover - chapter on
"Removing".
6. Release the four Torx screws M6 x 16 on the sprocket of the respective exhaust camshaft. Do not remove the
sprocket.
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7. Remove chain tensioner for cylinders 1 - 3 or 4 - 6.
Cylinder side 4-6:
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8. Remove the chain tensioner for cylinders 4 - 6.
9. Unscrew the M6 guide rail screw on the pulley side (hexagon socket a/f 5).
10. Turn the engine at the assembly support so that cylinder bank to be worked on stands vertically upwards.
11. Unscrew four Torx screws for exhaust camshaft sprocket. Lift timing chain off sprocket and remove the
sprocket. Lay timing chain on the mounting tab for the sprocket.
12. Remove the four camshaft thrust bearings and the guide rail. Unscrew eight Torx screws, six M6 x 35, two
M6 x 40 (screws for guide rail). Lift the thrust bearing and the guide rail carefully off the mounting points or
timing chain.
13. Remove the camshafts. Remove exhaust camshaft, lift timing chain off the camshaft adjuster of the inlet
camshaft and remove the camshaft. Lay the timing chain in the chain housing in the cylinder head.
INSTALLING CAMSHAFT - ENGINE REMOVED
Installing camshaft - engine removed
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Fig. 23: Identification of camshaft housing:

Identification of housings of camshafts:
 Inlet camshaft:
 Thrust bearing: 'E' and matching number on cylinder head/cylinder head cover
 Housing of bearing sleeve: only matching number
 Outlet camshaft:
 Thrust bearing on sprocket: '1A' and matching number on cylinder head/cylinder head cover
 2nd Thrust bearing: '2A' and matching number on cylinder head/cylinder head cover
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Fig. 24: Pulley fixed at 60° before TDC

1. To remove the play from the timing chain drive, turn the crankshaft by means of the pulley or vibration
balancerclockwise (running direction of engine to 60° before TDC : marking U6 on pulley or vibration
balancer coincides with fixing bore in crankcase . Fix with locating pin P 9595/1.
Assembly of cylinder bank 4 - 6
2. Turn the engine on the assembly support until cylinder bank 4 - 6 stands vertically upwards.
3. Oil the bearing surfaces of the camshafts with new engine oil.
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Fig. 25: Cams of cylinder 4 pointing towards the bulkhead

4. Insert inlet camshaft 4-6. Pull the timing chain out of the chain housing of the cylinder head with a welding
wire and position on the ring gear of the camshaft adjuster, at the same time inserting the camshaft at
overlapping TDC of cylinder 4 (the cams of cylinder 4 point towards the bulkhead of the flat-base tappet
housing -arrows- ).
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Fig. 26: Position of bearing sleeve for inlet camshaft

NOTE:  Make sure that the bearing sleeve on the inlet camshaft is positioned
correctly.
5. The bearing sleeve of the inlet camshaft must be positioned so that the centrally bored blind hole points
vertically upwards -arrow- (the rib of the cylinder head should also be at the center in relation to the bearing
sleeve). In this position, the dowel pin in the bearing bore of the cylinder head will fit precisely into the opposite
off-center blind hole bore. Any other bores are through-holes for guiding the oil.
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Fig. 27: Exhaust camshaft 4 - 6

6. Insert exhaust camshaft 4-6. Lay the timing chain on the flange for the sprocket, then insert the camshaft at
overlapping TDC of cylinder 4 (the outlet cams of cylinder 4 point towards the cams of the inlet camshaft -
arrows- ). See Fig. 27.
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Fig. 28: Position of sprocket 4 - 6 at 60° before TDC

7. Insert exhaust camshaft sprocket in the timing chain and position on camshaft flange. The four threaded bores
in the camshaft flange must be covered approximately half way by the slots of the sprocket in the clockwise
running direction of the engine -arrows- . See Fig. 28.
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Fig. 29: Installation position of housing

NOTE:  Do not interchange the thrust bearings of the inlet and exhaust camshafts
during assembly; observe identification markings.
9. Insert three thrust bearings and one housing -arrows- for the bearing sleeve of the camshafts together with
the guide rail for the timing chain. See Fig. 29.
10. Insert eight housing screws (Torx): six M6 x 35 and two M6 x 40 for camshaft bearing and guide rail.
Tighten screws evenly and just hand-tight.
Adjust timing, cylinder bank 4 - 6
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Fig. 30: Slot position of camshafts at overlap

11. Align both camshafts. The small circular cut-outs must point upwards -arrows- . See Fig. 30.
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Fig. 31: Position of adjusting gauge 9689

12. Using special tool adjusting gauge P 9686, fix camshafts (if necessary with the gauge twisted) with an M8
screw (e. g. hexagon-head bolt M8 x 16). The flat tool face points upwards. Screw in fastening screw by hand.
Fig. 32: Housing screws and adjusting gauge

13. Screw the housing screws of the inlet and exhaust camshafts and the auxiliary screw of the adjustment
gauge alternately by approx. another 90° until the specified tightening torque is reached. --> Tightening
torque: 7.5 ftlb. ; --> Tightening torque: 17 ftlb.
14. Insert guide rail screw with a new O-ring and tighten (hexagon socket M6, a/f 5) Grease O-ring with
Optimol MP3. --> Tightening torque: 7.5 ftlb.
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15. Fit the chain tensioner, side 4-6 (hexagon socket a/f 14). Fit chain tensioner with new aluminum sealing ring
and tighten. --> Tightening torque: 59 ftlb.
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Fig. 34: Pulley fixed at TDC marking

NOTE:  Position crankshaft above the pulley or vibration balancer before final
adjustment of the timing to the TDC marking.
16. Turn the crankshaft by means of the pulley or vibration balancer clockwise (running direction of engine to
TDC mark : TDC marking on pulley or vibration balancer coincides with fixing bore in crankcase . Fix
with locating pin P 9595/1.
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Fig. 35: Exhaust camshaft sprocket tightened

17. Insert four Torx screws M6 to sprocket of exhaust camshaft and tighten evenly in diagonally opposite
sequence. --> Tightening torque: 10.5 ftlb.
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Fig. 36: Contact block at the fitting bore of the cylinder head
18. Tighten the central screw of the camshaft adjusting device. Fit special tool retaining tool P 9685 on
hexagon of intermediate piece of the central screw. Screw in the central screw gently by hand so that the loose
contact block just touches the fitting bore of the oil suction pump. Fix the hexagon-head bolt to the contact
block.
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Fig. 37: Tighten central screw of camshaft adjusting device.

NOTE:  Before final tightening (torque angle) of the central screw, the special tool
adjusting gauge P 9686 must be removed.
19. Tighten the central screw in two stages. Initial tightening to the specified torque. --> Initial tightening: 37
ftlb.
20. Remove special tool adjustment gauge P 9686. Undo the M8 screw and remove gauge.
21. Tighten central screw with torque angle wrench. --> Final tightening torque angle: 110 °
Assembly of cylinder bank 1-3
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23. Turn the crankshaft by means of the pulley or vibration balancer clockwise (running direction of engine
further still until the marking U6 on pulley or vibration balancer coincides with fixing bore in crankcase
(60° before TDC). Fix with locating pin P 9595/1.
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Fig. 39: Inlet camshaft 1-3 in overlap

25. Insert inlet camshaft 1-3. Pull the control chain out of the chain housing of the cylinder head with a welding
wire and position on the toothed ring of the camshaft adjuster. Then insert the camshaft at overlapping TDC of
cylinder 1 (the cams of cylinder 1 point diagonally downwards towards the outside of the cylinder head -arrow-
).
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correctly.
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Fig. 41: Exhaust camshaft 1-3 in overlap

27. Insert exhaust camshaft 1 - 3. Lay the control chain on the flange for the chain sprocket, then insert the
camshaft at overlapping TDC of cylinder 1 (the cams of cylinder 1 point diagonally downwards towards the
outside of the cylinder head).
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Fig. 42: Exhaust sprocket 1 - 3 at 60° before TDC

28. Insert exhaust camshaft sprocket in the timing chain and position on camshaft flange. The four threaded
bores in the camshaft flange must be fully visible on the left at the slotted curves of the sprocket -arrows- so
that the M6 x 12 Torx screws can still be positioned to fasten the sprocket. See Fig. 42.
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Fig. 43: Exhaust sprocket 1 - 3, all screws fitted


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Adjust timing, cylinder bank 1-3
31. Final timing adjustment for cylinder bank 1-3 is analogous to that for cylinder bank 4-6 ;.

32. Fit chain tensioner for side 1-3 (hexagon a/f 32) before turning crankshaft to the TDC mark. Fit chain
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tensioner with new sealing ring and tighten. --> Tightening torque: 59 ftlb.
After adjusting the timing, this should be re-checked.

33. Turn the engine 360° at the crankshaft and fix at the TDC mark. Check camshaft position of cylinder bank 4
- 6 using the adjusting gauge P 9686. Then turn a further 360° and check the camshaft position of cylinder
bank 1 - 3.
SUBSEQUENT WORK FOR INSTALLING CAMSHAFTS
Subsequent work for installing camshafts
Microsoft
Fig. 47: Spark plug recess gaskets and solenoid hydraulic valve for camshaft timing
1. Insert solenoid hydraulic valves and new gaskets for the spark-plug recesses. Fit new O-rings into the
solenoid hydraulic valves and insert into the bores in the cylinder head (if necessary replace oil strainer). Grease
O-rings with Optimol MP3 --> 153719 Removing and installing solenoid hydraulic valve for camshaft
timing - chapter on "Installing".
2. Install cylinder head cover --> 158220 Removing and installing cylinder head cover - engine removed -
chapter on "installing".
3. Fit oil suction pump (1 - 3) and tandem pump (4 - 6) with new, micro-self-locking Torx screws M6. Replace
O-rings and grease with Optimol MP3. Fit vacuum line with new O-rings at tandem pump. --> Tightening
torque: 7.5 ftlb.
4. Fit new plastic cap dry on cylinder head. Tap in with a plastic hammer.
5. Fit ground strap to cylinder head 1 - 3 with Torx screw M8 x 20 and tighten. --> Tightening torque: 17 ftlb.
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Fig. 48: Hydraulic valves for camshaft adjustment and ignition coils
6. Insert each ignition coil into its spark plug recess -1- , fit two M6 x 25 Torx socket screws and tighten. -->
Tightening torque: 7.5 ftlb. . See Fig. 48.
7. Fit new retainer plates and holder for the solenoid hydraulic valves -2- --> 153719 Removing and installing
solenoid hydraulic valve for camshaft timing - chapter on "Installing". --> Tightening torque: 7.5 ftlb. .
See Fig. 48.
8. Connect cable plugs to the oil temperature switch for cylinder bank 1 - 3.
15 05 20 REMOVING AND INSTALLING CAMSHAFT - AS OF MY 2005

(BOXSTER S, BOXSTER S RHD)
TOOLS

locating pin special tool P 9595/1
retaining tool special tool P 9685
Microsoft

Position of lettering: -arrows-

Camshafts for cylinders 4 - 6:

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pump. See Fig. 50.
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Position of lettering: -arrows- . See Fig. 51.

Camshafts for cylinders 4 -6:

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pump. See Fig. 52.
ALLOCATION OF INLET CAMSHAFT ADJUSTMENT DEVICE
Allocation of inlet camshaft adjustment device
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Fig. 53: Designation of adjuster 1 - 3

NOTE:  Side 1 - 3: the arrow should be attached anti-clockwise
date.
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Fig. 54: Designation of adjuster 4 -6

NOTE:  Side 4 - 6: the arrow should be attached clockwise
date.
ALLOCATION OF CHAIN TENSIONERS
Allocation of chain tensioners
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- Primary chain tensioner on crankcase (oil filter area), identification: one ring -Arrow- . See Fig. 55.
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- Chain tensioner on cylinder head, cylinder bank 1 - 3, identification: two rings -Arrows- . See Fig. 56.
Fig. 57: Chain tensioner 4 - 6

- Chain tensioner on cylinder head, cylinder bank 4 - 6, no identification.
PRELIMINARY WORK FOR REMOVING CAMSHAFTS
Preliminary work for removing camshafts
2. For disassembling cylinder bank 1 - 3, undo the ground cable on the cylinder head by unscrewing a Torx
screw M8 and removing the cable. Unplug the cable plug for the oil pressure switch.
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3. Remove ignition coils -1- . In each case, unscrew two M6 x 25 Torx socket screws and pull the ignition coil
out of the spark-plug recess.
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4. Remove solenoid hydraulic valve -1- (for camshaft timing) --> 153719 Removing and installing solenoid
hydraulic valve for camshaft timing - chapter on "Removing". See Fig. 59.
Fig. 60: Oil suction pump for cylinders 1 - 3

6. Remove oil suction pump for cylinders 1 - 3. Unscrew four Torx screws M6 x 20 (micro-self-locking),
remove oil suction pump, and replace O-ring and screws.
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7. Remove tandem pump for cylinders 4 - 6. Unscrew four Torx screws M6 (micro-self-locking) -1- . Pull off
the vacuum line on pump -2- . Remove pump and replace O-rings and micro-self-locking screws. See Fig. 61.
REMOVING CAMSHAFT - ENGINE REMOVED
Removing camshaft - engine removed
1. Remove the plastic caps on the cylinder head. Press a small screwdriver into the center of the piercing point
of each cap and lever out the cap.
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Fig. 62: TDC marking on pulley

2. Disassembling cylinder bank 1 - 3 Turn crankshaft at the pulley/vibration balancer clockwise to the
overlapping TDC of cylinder 1. Disassembling cylinder bank 4 -6 Turn crankshaft to the TDC for cylinder 4.
Using a locating pin P 9595/1 fix the pulley or vibration balancer.
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Fig. 63: Position of the camshafts in overlapping TDC of cylinders 1 or 4

3. If the camshafts of cylinder bank 1 - 3 are removed, the smaller circular cut-outs at the grooves of the inlet
and outlet camshafts -arrows- of cylinder 1 must point to the cylinder head cover. For cylinder bank 4 - 6 the
corresponding position is then on cylinder 4 . Check the position using the adjusting gauge P 9686. See Fig.
63.
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Fig. 64: Unscrew the central screw on the camshaft adjuster.

NOTE:  Before disassembling the cylinder head cover, it is essential to unscrew

the central screw on the camshaft adjustment device.
4. Unscrew the central screw on the camshaft adjustment device. Position retaining tool P 9685 on the hexagon
of the adapter and place the contact block as a counter on the fitting bore of the cylinder head cover for the oil
suction pump; if necessary, position the contact block by undoing and tightening the screw. If the special tool
cannot be positioned on the hexagon of the adapter in this way, the engine must be turned further in the
direction of rotation at the belt pulley of the crankshaft until the contact block comes into contact with the
central screw of the cylinder head cover, ready for unscrewing. Unscrew the central screw.
"Removing".
6. Release the four Torx screws M6 x 16 on the sprocket of the respective exhaust camshaft. Do not remove the
sprocket.
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7. Remove chain tensioner for cylinders 1 - 3 or 4 - 6.
Cylinder side 4-6:
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8. Remove the chain tensioner for cylinders 4 - 6.
9. Unscrew the M6 guide rail screw on the pulley side (hexagon socket a/f 5).
10. Turn the engine at the assembly support so that cylinder bank to be worked on stands vertically upwards.
11. Unscrew four Torx screws for exhaust camshaft sprocket. Lift timing chain off sprocket and remove the
sprocket. Lay timing chain on the mounting tab for the sprocket.
12. Remove the four camshaft thrust bearings and the guide rail. Unscrew eight Torx screws, six M6 x 35, two
M6 x 40 (screws for guide rail). Lift the thrust bearing and the guide rail carefully off the mounting points or
timing chain.
13. Remove the camshafts. Remove exhaust camshaft, lift timing chain off the camshaft adjuster of the inlet
camshaft and remove the camshaft. Lay the timing chain in the chain housing in the cylinder head.
INSTALLING CAMSHAFT - ENGINE REMOVED
Installing camshaft - engine removed
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Fig. 67: Identification of camshaft housing:

Identification of housings of camshafts:
 Inlet camshaft:
 Thrust bearing: 'E' and matching number on cylinder head/cylinder head cover
 Housing of bearing sleeve: only matching number
 Outlet camshaft:
 Thrust bearing on sprocket: '1A' and matching number on cylinder head/cylinder head cover
 2nd Thrust bearing: '2A' and matching number on cylinder head/cylinder head cover
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1. To remove the play from the timing chain drive, turn the crankshaft by means of the pulley or vibration
balancerclockwise (running direction of engine to 60° before TDC : marking U6 on pulley or vibration
balancer coincides with fixing bore in crankcase . Fix with locating pin P 9595/1.
Assembly of cylinder bank 4 - 6
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Fig. 69:
4. Insert inlet camshaft 4-6. Pull the timing chain out of the chain housing of the cylinder head with a welding
wire and position on the ring gear of the camshaft adjuster, at the same time inserting the camshaft at
overlapping TDC of cylinder 4 (the cams of cylinder 4 point towards the bulkhead of the flat-base tappet
housing -arrows- ).
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correctly.
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Fig. 71: Exhaust camshaft 4 - 6

6. Insert exhaust camshaft 4-6. Lay the timing chain on the flange for the sprocket, then insert the camshaft at
overlapping TDC of cylinder 4 (the outlet cams of cylinder 4 point towards the cams of the inlet camshaft -
arrows- ). See Fig. 71.
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Fig. 72: Position of sprocket 4 - 6 at 60° before TDC

7. Insert exhaust camshaft sprocket in the timing chain and position on camshaft flange. The four threaded bores
in the camshaft flange must be covered approximately half way by the slots of the sprocket in the clockwise
running direction of the engine -arrows- . See Fig. 72.
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Adjust timing, cylinder bank 4 - 6
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11. Align both camshafts. The small circular cut-outs must point upwards -arrows- . See Fig. 74.
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Fig. 75: Position of adjusting gauge 9689

12. Using special tool adjusting gauge P 9686, fix camshafts (if necessary with the gauge twisted) with an M8
screw (e. g. hexagon-head bolt M8 x 16). The flat tool face points upwards. Screw in fastening screw by hand.
Fig. 76: Housing screws and adjusting gauge

13. Screw the housing screws of the inlet and exhaust camshafts and the auxiliary screw of the adjustment
gauge alternately by approx. another 90° until the specified tightening torque is reached. --> Tightening
torque: 7.5 ftlb. ; --> Tightening torque: 17 ftlb.
14. Insert guide rail screw with a new O-ring and tighten (hexagon socket M6, a/f 5) Grease O-ring with
Optimol MP3. --> Tightening torque: 7.5 ftlb.
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15. Fit the chain tensioner, side 4-6 (hexagon socket a/f 14). Fit chain tensioner with new aluminum sealing ring
and tighten. --> Tightening torque: 59 ftlb.
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Fig. 78: Pulley fixed at TDC marking

16. Turn the crankshaft by means of the pulley or vibration balancer clockwise (running direction of engine to
TDC mark : TDC marking on pulley or vibration balancer coincides with fixing bore in crankcase . Fix
with locating pin P 9595/1.
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Fig. 79: Exhaust camshaft sprocket tightened

17. Insert four Torx screws M6 to sprocket of exhaust camshaft and tighten evenly in diagonally opposite
sequence. --> Tightening torque: 10.5 ftlb.
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Fig. 80: Contact block at the fitting bore of the cylinder head
18. Tighten the central screw of the camshaft adjusting device. Fit special tool retaining tool P 9685 on
hexagon of intermediate piece of the central screw. Screw in the central screw gently by hand so that the loose
contact block just touches the fitting bore of the oil suction pump. Fix the hexagon-head bolt to the contact
block.
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Fig. 81: Tighten central screw of camshaft adjusting device.

19. Tighten the central screw in two stages. Initial tightening to the specified torque. --> Initial tightening: 37
ftlb.
20. Remove special tool adjustment gauge P 9686. Undo the M8 screw and remove gauge.
21. Tighten central screw with torque angle wrench. --> Final tightening torque angle: 110 °
Assembly of cylinder bank 1-3
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23. Turn the crankshaft by means of the pulley or vibration balancer clockwise (running direction of engine
further still until the marking U6 on pulley or vibration balancer coincides with fixing bore in crankcase
(60° before TDC). Fix with locating pin P 9595/1.
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Fig. 83: Inlet camshaft 1-3 in overlap

25. Insert inlet camshaft 1-3. Pull the control chain out of the chain housing of the cylinder head with a welding
wire and position on the toothed ring of the camshaft adjuster. Then insert the camshaft at overlapping TDC of
cylinder 1 (the cams of cylinder 1 point diagonally downwards towards the outside of the cylinder head -arrow-
).
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correctly.
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Fig. 85: Exhaust camshaft 1-3 in overlap

27. Insert exhaust camshaft 1 - 3. Lay the control chain on the flange for the chain sprocket, then insert the
camshaft at overlapping TDC of cylinder 1 (the cams of cylinder 1 point diagonally downwards towards the
outside of the cylinder head).
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Fig. 86: Exhaust sprocket 1 - 3 at 60° before TDC

28. Insert exhaust camshaft sprocket in the timing chain and position on camshaft flange. The four threaded
bores in the camshaft flange must be fully visible on the left at the slotted curves of the sprocket -arrows- so
that the M6 x 12 Torx screws can still be positioned to fasten the sprocket. See Fig. 86.
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Fig. 87: Exhaust sprocket 1 - 3, all screws fitted


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Adjust timing, cylinder bank 1-3
31. Final timing adjustment for cylinder bank 1-3 is analogous to that for cylinder bank 4-6 ;.

32. Fit chain tensioner for side 1-3 (hexagon a/f 32) before turning crankshaft to the TDC mark. Fit chain
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tensioner with new sealing ring and tighten. --> Tightening torque: 59 ftlb.
After adjusting the timing, this should be re-checked.

33. Turn the engine 360° at the crankshaft and fix at the TDC mark. Check camshaft position of cylinder bank 4
- 6 using the adjusting gauge P 9686. Then turn a further 360° and check the camshaft position of cylinder
bank 1 - 3.
SUBSEQUENT WORK FOR INSTALLING CAMSHAFTS
Subsequent work for installing camshafts
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Fig. 91: Spark plug recess gaskets and solenoid hydraulic valve for camshaft timing
1. Insert solenoid hydraulic valves and new gaskets for the spark-plug recesses. Fit new O-rings into the
solenoid hydraulic valves and insert into the bores in the cylinder head (if necessary replace oil strainer). Grease
O-rings with Optimol MP3 --> 153719 Removing and installing solenoid hydraulic valve for camshaft
timing - chapter on "Installing".
2. Install cylinder head cover --> 158220 Removing and installing cylinder head cover - engine removed -
chapter on "installing".
3. Fit oil suction pump (1 - 3) and tandem pump (4 - 6) with new, micro-self-locking Torx screws M6. Replace
O-rings and grease with Optimol MP3. Fit vacuum line with new O-rings at tandem pump. --> Tightening
torque: 7.5 ftlb.
4. Fit new plastic cap dry on cylinder head. Tap in with a plastic hammer.
5. Fit ground strap to cylinder head 1 - 3 with Torx screw M8 x 20 and tighten. --> Tightening torque: 17 ftlb.
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6. Insert each ignition coil into its spark plug recess -1- , fit two M6 x 25 Torx socket screws and tighten. -->
Tightening torque: 7.5 ftlb. . See Fig. 92.
7. Fit new retainer plates and holder for the solenoid hydraulic valves -2- --> 153719 Removing and installing
solenoid hydraulic valve for camshaft timing - chapter on "Installing". --> Tightening torque: 7.5 ftlb. .
See Fig. 92.
8. Connect cable plugs to the oil temperature switch for cylinder bank 1 - 3.
15 21 19 REMOVING AND INSTALLING BEARING COVER FOR

INTERMEDIATE SHAFT - AS OF MY 2005 (BOXSTER, BOXSTER RHD,
TOOLS

socket wrench special tool P 9110
fixing pins special tool P 9595/1
puller special tool P 9673
Microsoft
PRELIMINARY WORK FOR BEARING COVER FOR INTERMEDIATE SHAFT
Preliminary work for bearing cover for intermediate shaft
NOTE:  Note the work instructions for disconnecting and reconnecting the battery.
1. Disconnect the battery --> 27 06 IN WORK INSTRUCTIONS AFTER DISCONNECTING THE

Tiptronic:

MY 2005 (Boxster S, Boxster S RHD) . Refer to 37 35 19 Removing and installing automatic transmission
- as of MY 2005 (Boxster, Boxster RHD) .

(All Models) .
7. Remove double-mass flywheel. Refer to 13 60 19 Removing and installing flywheel - as of MY 2005 (All
Models) .
REMOVING BEARING COVER FOR INTERMEDIATE SHAFT
Removing bearing cover for intermediate shaft
CAUTION: Timing chain may jump over.
 Risk of engine damage
--> Following removal of the chain tensioner, the crankshaft must not be turned under any circumstances.
NOTE:  For checking with the adjusting gauge, the timing adjustment must be
correct.
NOTE:  To make it easier to remove the bearing cover, spray the sealing surface
with anti-rust agent.
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NOTE:  Remove bearing cover using special tool

 After removing the bearing cover, do not press the threaded bolts of the
intermediate shaft.
puller P 9673. If this is not available, lever the bearing cover out carefully
with two screwdrivers so as not to damage the sealing surfaces. Turning
several times to the left and right loosens the bearing cover.
Bearing cover
Fig. 93: Bearing cover with sealing ring

1. Lever out two green closure caps on pulley side of cylinder bank 1 - 3.
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Fig. 94: Fixing pulley

2. Turn the engine at the hexagon-head bolt (a/f 24) of the crankshaft belt pulley clockwise to overlapping TDC
of cylinder bank 1 and fix it with special tool fixing pins P 9595/1.
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Fig. 95: Cam slot position at overlapping TDC of cylinder 1

3. To check the camshaft adjustment, insert adjusting gauge P 9686 for camshaft into the camshaft slots
(pulley side) (inscription on gauge and small circular cut-outs point towards cylinder head cover). If the gauge
cannot be inserted, rotate the crankshaft a further 360° and secure it again.
4. Unscrew two M6 x 12 hexagon-head bolts on the coolant pipe mount (Tiptronic) at cylinder side 1 - 3.
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5. Remove primary chain tensioner (hexagon socket a/f 32).
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6. Remove chain tensioner, cylinder bank 1 - 3 (hexagon socket a/f 32).
Fig. 98: Collar nut for bearing cover

7. Unscrew M8 hexagon collar nut on the housing of the intermediate shaft with special tool socket wrench P
9110, while at the same time countering the slotted threaded pin on the intermediate shaft with a screwdriver.
8. Unscrew the three M6 x 20 hexagon-head bolts (coated) on the intermediate-shaft flange. Replace coated
screws during installation and clean threaded bores.
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Fig. 99: Puller on bearing cover: View from intermediate shaft

9. Position special tool puller P 9673 at the housing grooves and secure by turning the locking lever anti-
clockwise.
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Fig. 100: Removing bearing cover

10. Pull the slide hammer on the puller a number of times against the stop nuts while countering the tool at the
same time with the other hand.
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Fig. 101: Levering out bearing cover

11. If the puller is not available, lever the bearing cover out carefully using two screwdrivers (or angle
screwdrivers), for example. Move the bearing cover frequently to the left and right to make the levering easier.
Do not damage the sealing surfaces.
INSTALLING BEARING COVER FOR INTERMEDIATE SHAFT
Installing bearing cover for intermediate shaft
NOTE:  Clean working area of bore for bearing cover and crankcase thoroughly
using acetone or solvent naphtha.
NOTE:  Replace bearing cover or sealing ring for bearing cover --> 152355
Replacing sealing ring for intermediate shaft.
1. Before installing the new bearing cover, check the fitted bore (axial attachment surface, bore chamfers) on
the crankcase for sharp edges and burrs. They should be removed with an oilstone or a polishing cloth. Remove
any existing residue and clean the bore with a clean cloth soaked in solvent naphtha or acetone.
2. Grease fitted bore in crankcase and new bearing cover (with new sealing ring) with special grease Optimoly
MP3 (available from Porsche Parts Service) and place bearing cover in position.
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NOTE:  Replace collar nut M8 x 1 and coated M6 screws for bearing cover.
3. Position three new, coated M6 x 20 screws on the crankcase and pull in the bearing cover by screwing in the
screws uniformly. Tighten screws --> Tightening torque: 7.5 ftlb. .

4. Position new M8 x 1 collar nut on the threaded pin of the intermediate shaft. Then tighten the nut using
special tool socket wrench P 9110. At the same time, counter with a screwdriver in the slotted threaded pin of
the intermediate shaft. --> Tightening torque: 9 ftlb. +0.5 ftlb.
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5. Insert primary chain tensioner with new aluminum sealing ring (hexagon a/f 32) and tighten to the specified
torque. --> Tightening torque: 59 ftlb.
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6. Insert chain tensioner for cylinder 1 - 3 with new aluminum sealing ring (hexagon a/f 32) and tighten to the
specified torque. --> Tightening torque: 59 ftlb.
7. Fasten coolant pipes on cylinder side 1 - 3 with two M6 x 12 hexagon-head bolts. --> Tightening torque: 7.5
ftlb.
8. Fit two new closure caps on cylinder head cover.
9. Pull fixing pin out of the crankshaft belt pulley.
SUBSEQUENT WORK FOR BEARING COVER FOR INTERMEDIATE SHAFT
Subsequent work for bearing cover for intermediate shaft
Tiptronic:

MY 2005 (Boxster S, Boxster S RHD) . Refer to 37 35 19 Removing and installing automatic transmission
Microsoft
3. Install clutch. Refer to 30 50 19 Removing and installing clutch - as of MY 2005 (All Models) .
4. Install double-mass flywheel. Refer to 13 60 19 Removing and installing flywheel - as of MY 2005 (All
Models) .
5. Install transmission. Refer to 34 35 19 Removing and installing transmission - as of MY 2005 (All

Models) .
All:
6. Filling in engine oil. Refer to 17 01 55 Engine oil and oil filter change - as of MY 2005 (All Models) .


INTERMEDIATE SHAFT - M96/25 - AS OF MY 2005 (BOXSTER, BOXSTER
RHD)
TOOLS


Microsoft
Tiptronic:

MY 2005 (Boxster, Boxster RHD) .

(All Models) .
Models) .
Removing bearing cover for intermediate shaft - up to engine number 61.504715
NOTE: Always observe specified engine number range.
Bearing covers
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of cylinder bank 1 and fix it with special tool locating pins P 9595/1.

correct.
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Microsoft


7. Unscrew M8 hexagon collar nut on the bearing cover of the intermediate shaft with special tool socket
wrench P 9110, while at the same time countering at the slotted threaded pin on the intermediate shaft with a
screwdriver.
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Fig. 111: Puller on bearing cover: view when removed


intermediate shaft.
9. Position special tool puller P 9673 at the bearing cover grooves and secure by turning the locking lever anti-
clockwise.
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Microsoft

Removing bearing cover for intermediate shaft - from engine number 61.504716
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NOTE:  The same sealing ring and installation/removal procedure applies as for
the "old" bearing cover.
 The new bearing cover can only be retrofitted along with the new
intermediate shaft up to model year 2003.
Overview of bearing covers for intermediate shaft.
Fig. 114: Differentiation of bearing covers for intermediate shaft

 A - Bearing cover 996.105.024.01

 B - Bearing cover 996.105.024.06
 C - Collar nut, M12 x 1.25
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Fig. 115: Rear view of bearing cover for intermediate shaft

Rear of bearing cover
 A - Rear of bearing cover 996.105.024.01

 B - Rear of bearing cover 996.105.024.06
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Fig. 116: Special tool 9673/1

Use the special tool assembly tool P 9673/1 for the M12 collar nut threaded joint.
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of cylinder bank 1 - 3 and fix it with special tool locating pins P 9595/1.
correct.
(pulley side) (inscription on gauge pointing towards cylinder head cover). If the gauge cannot be inserted, rotate
the crankshaft a further 360° and secure it again.
4. Unscrew two M6 x 12 hexagon-head bolts on the coolant pipe at cylinder side 1 - 3 (Tiptronic).
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Microsoft

Fig. 120: Threaded joint with collar nut on bearing cover for intermediate shaft
7. Loosen M12 hexagon collar nut (a/f 22) on bearing cover for intermediate shaft with special tool assembly
tool P 9673/1 and screw it off --> Threaded joint with collar nut on bearing cover for intermediate shaft . See
Fig. 120.
8. Unscrew the three M6 x 20 fastening screws (coated) on the intermediate-shaft flange. Replace screws during
installation and clean thread in crankcase.
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intermediate shaft.
clockwise.
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Microsoft

screwdrivers). Move the bearing cover a number of times to the left and right to make levering easier. Do not
damage the sealing surfaces.
Installing bearing cover for intermediate shaft - up to engine number 61.504715
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screws uniformly. Tighten the screws. --> Tightening torque: 10 (7.5 ftlb.) Nm

the intermediate shaft. --> Tightening torque: 12 (9 ftlb.) Nm +1 (0.5 ftlb.) Nm
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5. Insert primary chain tensioner with new sealing ring (hexagon a/f 32) and tighten to the specified torque. -->
Tightening torque: 80 (59 ftlb.) Nm
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6. Insert chain tensioner for cylinder 1 - 3 with new sealing ring (hexagon a/f 32) and tighten to the specified
torque. --> Tightening torque: 80 (59 ftlb.) Nm
7. Fasten coolant pipes on cylinder side 1 -3 with two M6 x 12 hexagon-head bolts. --> Tightening torque: 10
(7.5 ftlb.) Nm
9. Pull locating pin out of crankshaft belt pulley.
Installing bearing cover for intermediate shaft - from engine number 61.504716
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Fig. 127: New bearing cover for intermediate shaft

New bearing cover
 B - Bearing cover 996.105.024.06

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NOTE:  Replace collar nut M12 and coated M6 screws for bearing cover.
4. Position new M12 x 1.25 collar nut on the threaded pin of the intermediate shaft. Then tighten the nut using
special tool assembly tool P 9673/1. At the same time, counter with an angle screwdriver in the slotted threaded
pin of the intermediate shaft. --> Tightening torque : 20 (15 ftlb.) Nm +/-1 (0.5 ftlb.) Nm
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7. Secure coolant pipe on cylinder side 1 -3 with two M6 x 12 hexagon-head bolts. --> Tightening torque: 10
(7.5 ftlb.) Nm
8. Fit new closure caps on cylinder head cover.
Tiptronic:

Microsoft
Models) .

Models) .
All:


INTERMEDIATE SHAFT - M96/26 - AS OF MY 2005 (BOXSTER S, BOXSTER
S RHD)
TOOLS


Tiptronic:
Microsoft

MY 2005 (Boxster S, Boxster S RHD) .

(All Models) .
Models) .
Removing bearing cover for intermediate shaft - up to engine number 62.504094
Bearing covers
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Microsoft
of cylinder bank 1 and fix it with special tool locating pins P 9595/1.

correct.
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Microsoft


7. Unscrew M8 hexagon collar nut on the bearing cover of the intermediate shaft with special tool socket
wrench P 9110, while at the same time countering at the slotted threaded pin on the intermediate shaft with a
screwdriver.
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intermediate shaft.
clockwise.
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Microsoft

Removing bearing cover for intermediate shaft - from engine number 62.504095
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Overview of bearing covers for intermediate shaft.
Fig. 140: Differentiation of bearing covers for intermediate shaft

 A - Bearing cover 996.105.024.01

 B - Bearing cover 996.105.024.06
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Fig. 141: Rear view of bearing cover for intermediate shaft

Rear of bearing cover
 A - Rear of bearing cover 996.105.024.01

 B - Rear of bearing cover 996.105.024.06
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Fig. 142: Special tool 9673/1

Use the special tool assembly tool P 9673/1 for the M12 collar nut threaded joint.
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of cylinder bank 1 - 3 and fix it with special tool locating pins P 9595/1.
correct.
(pulley side) (inscription on gauge pointing towards cylinder head cover). If the gauge cannot be inserted, rotate
the crankshaft a further 360° and secure it again.
4. Unscrew two M6 x 12 hexagon-head bolts on the coolant pipe at cylinder side 1 - 3 (Tiptronic).
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Microsoft

7. Loosen M12 hexagon collar nut (a/f 22) on bearing cover for intermediate shaft with special tool assembly
tool P 9673/1 and screw it off --> Threaded joint with collar nut on bearing cover for intermediate shaft . See
Fig. 146.
8. Unscrew the three M6 x 20 fastening screws (coated) on the intermediate-shaft flange. Replace screws during
installation and clean thread in crankcase.
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intermediate shaft.
clockwise.
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Microsoft

screwdrivers). Move the bearing cover a number of times to the left and right to make levering easier. Do not
damage the sealing surfaces.
Installing bearing cover for intermediate shaft - up to engine number 62.504094
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the intermediate shaft. --> Tightening torque: 12 (9 ftlb.) Nm +1 (0.5 ftlb.) Nm
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7. Fasten coolant pipes on cylinder side 1 -3 with two M6 x 12 hexagon-head bolts. --> Tightening torque: 10
(7.5 ftlb.) Nm
Installing bearing cover for intermediate shaft - from engine number 62.504095
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Fig. 153: New bearing cover for intermediate shaft

New bearing cover
 B - Bearing cover 996.105.024.06

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NOTE:  Replace collar nut M12 and coated M6 screws for bearing cover.
4. Position new M12 x 1.25 collar nut on the threaded pin of the intermediate shaft. Then tighten the nut using
special tool assembly tool P 9673/1. At the same time, counter with an angle screwdriver in the slotted threaded
pin of the intermediate shaft. --> Tightening torque : 20 (15 ftlb.) Nm +/-1 (0.5 ftlb.) Nm
Microsoft

Microsoft

7. Secure coolant pipe on cylinder side 1 -3 with two M6 x 12 hexagon-head bolts. --> Tightening torque: 10
(7.5 ftlb.) Nm
8. Fit new closure caps on cylinder head cover.
Tiptronic:

MY 2005 (Boxster S, Boxster S RHD) .
Microsoft
Models) .

Models) .
All:

15 23 55 REPLACING SEALING RING FOR BEARING COVER FOR

INTERMEDIATE SHAFT - AS OF MY 2005 (BOXSTER, BOXSTER RHD,
PRELIMINARY WORK FOR BEARING COVER SEALING RING
Preliminary work for bearing cover sealing ring
1. Remove bearing cover for intermediate shaft --> 152119 Removing and installing bearing cover for
intermediate shaft - chapter on "removing" [987320 987321] --> 152119 Removing and installing bearing
cover for intermediate shaft - chapter on "removing" [987310 987311].
REPLACING SEALING RING FOR BEARING COVER FOR INTERMEDIATE SHAFT
Replacing sealing ring for bearing cover for intermediate shaft
Installation position of sealing ring
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Fig. 157: Sealing ring on bearing cover

Fig. 158: Levering off sealing ring

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NOTE: Do not use a sharp object to lever off the sealing ring.
1. Carefully lever off sealing ring with a small piece of wood or a plastic spatula in order to avoid damaging the
groove.
NOTE:  Before fitting the new sealing ring, check the edges of the bearing cover
for burred spots. Carefully remove these using an oilstone or polishing
cloth. Clean bearing cover (without sealing ring) thoroughly using acetone
or solvent naphtha.
2. Insert new sealing ring into the groove on the bearing cover by hand. The sealing ring can be fitted in any
direction since the sealing lips are facing vertically upwards and do not therefore have to be fitted in a specific
direction.
3. Before installation, grease the new sealing ring on the bearing cover and the fitting bore in the crankcase with
special grease Optimoly MP3 (available from Porsche Parts Service).
SUBSEQUENT WORK FOR BEARING COVER SEALING RING
Subsequent work for bearing cover sealing ring
1. Install bearing cover --> 152119 Removing and installing bearing cover for intermediate shaft - chapter
on "installing" [987320 987321] --> 152119 Removing and installing bearing cover for intermediate shaft
- chapter on "installing" [987310 987311].
15 37 19 REMOVING AND INSTALLING SOLENOID HYDRAULIC VALVE

(CAMSHAFT TIMING) - AS OF MY 2005 (BOXSTER, BOXSTER RHD,
TOOLS

relay puller special tool P 9235
REMOVING HYDRAULIC VALVE FOR CAMSHAFT TIMING
Removing hydraulic valve for camshaft timing
CAUTION: Risk of oil contamination and blocked oil bores
 Faulty engine parts, engine damage
--> Absolute cleanliness is essential when working on hydraulic valves.
Microsoft

1. Disconnect cable plug on hydraulic valve -1- by pressing the clip and pulling off the cable plug. See Fig. 159.
2. Unscrew two M6 x 20 inner Torx screws -2- at the valve holder and remove the holder along with the screws.
See Fig. 159.
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Fig. 160: Holder for solenoid hydraulic valve for camshaft timing
Fig. 161: Pulling out hydraulic valve with relay puller
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NOTE:  Handle the hydraulic valve with care; do not turn it at the valve tip or at the
safety contact.
 A seal against leaks cannot be ensured if there is damage in the area of
the retainer plate, therefore handle the pliers indicated with care.
3. Carefully pull the hydraulic valve out of the cylinder head using special tool relay puller P 9235. Before
using the puller, mask the valve body in fabric tape in order to prevent slippage or damage.
Fig. 162: Installation position of retainer plate for solenoid hydraulic valve for camshaft timing
4. Remove retainer plate with integrated seal -1- from the valve. See Fig. 162.
NOTE:  Handle the hydraulic valve with care; do not turn it at the valve tip or at the
safety contact.
 A seal against leaks cannot be ensured if there is damage in the area of
the retainer plate, therefore handle the pliers indicated with care.
5. Check the valve body for damage in the sealing area of the retainer plates. If necessary, the valve must be
replaced.
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Fig. 163: Oil strainer hydraulic valve NVS

6. Pull the oil strainer -1- out of the cylinder head bore using a bar magnet. Clean using solvent naphtha, check
for damage and soiling, and replace if necessary. Pay attention to the installation position. See Fig. 163.
INSTALLING HYDRAULIC VALVE FOR CAMSHAFT TIMING
Installing hydraulic valve for camshaft timing
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Fig. 164: Oil strainer hydraulic valve NVS

1. Using a bar magnet, fit a cleaned or new oil strainer into the cylinder bore -1- . Pay attention to the
installation position. See Fig. 164.
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Fig. 165: Groove on valve for camshaft timing

NOTE:  Replace O-ring on hydraulic valve and retainer plate with seal.
 Observe installation position of the hydraulic valve.
2. Replace O-ring on the hydraulic valve and coat new O-ring with engine oil. Insert hydraulic valve into the
cylinder head. Pay attention to installation position while doing this. The groove on the valve -arrow- points to
the dowel pin in the cylinder head. See Fig. 165.
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Fig. 166: Dowel pin for valve for camshaft timing

Position of dowel pin in cylinder head
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Fig. 167: Installation position of retainer plate for solenoid hydraulic valve for camshaft timing
3. Lightly coat seal of retainer plate with engine oil and slide it over the hydraulic valve.
Fig. 168: Holder for solenoid hydraulic valve for camshaft timing
4. Position two M6 x 20 inner Torx screws complete with holder -A- on the valve and tighten the screws.
Observe installation position of the cable terminal (to intake distributor). --> Tightening torque: 7.5 ftlb. . See
Fig. 168.
5. Push cable plug onto the hydraulic valve. Make sure that the plug engages audibly.
15 70 19 REMOVING AND INSTALLING CYLINDER HEAD - AS OF MY 2005

TOOLS

PRELIMINARY WORK FOR REMOVING CYLINDER HEAD
Microsoft
Preliminary work for removing cylinder head
1. Remove exhaust manifold. Remove old seal.
"Removing".
3. Remove camshafts --> 150520 Removing and installing camshaft - section on "Removing" [987320
987321] --> 150520 Removing and installing camshaft - section on "Removing" [987310 987311].
Fig. 169: Example of laying aside flat-base tappets

NOTE: There must be no visible signs of wear on the flat-base tappets and fitting bores
of the flat-base tappet housing.
4. Remove the flat-based tappets. Pull each of the components out of the flat-base tappet housing using a strong
Microsoft
magnet. Check running surfaces for signs of damage. To avoid confusing the individual flat-based tappets, lay
them on a labelled, clean surface --> Example of laying aside flat-base tappets and cover them. See Fig. 169.
Fig. 170: Flat-base tappet housing bolts

5. Remove flat-base tappet housing. Unscrew 11 Torx screws -1- from the outside to the inside. Remove
housing and check the fitting bores for damage. See Fig. 170.
6. Remove the old O-rings at the spark-plug recesses.
REMOVING CYLINDER HEAD
Removing cylinder head
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Cylinder head 1-3:
Fig. 171: Guide rail screw for cylinders 1-3

1. Unscrew M6 threaded bolt (hexagon socket) for guide rail (flywheel side) -1- . See Fig. 171.
2. Unscrew four Torx screws with M6 x 30 captive washers (10.9) -1-4- at the chain slot. Use of a magnetic bit
is recommended so that the screw to be fitted in the slot -Item 4- cannot fall into the crankcase. See Fig. 172.
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Fig. 172: External cylinder head screwed connection

3. Loosen and unscrew 12 M10 Torx cylinder-head screws from outside to inside.
4. Carefully lift off the cylinder head and remove the old cylinder-head gasket.
5. Carefully clean the sealing faces on the cylinder head and crankcase (e. g. using a nylon brush and a clean,
lint-free cloth soaked in acetone). Check the sealing face from cylinder head to crankcase for damage and
cracks, and rework the flat surface if necessary.
The removal of cylinder head 4-6 is the same as for side 1-3 with the following change
- The threaded bolt for guide rail 4-6 on the cylinder head (belt pulley side) -1- is removed even before the
camshaft timing gears are removed. See Fig. 173.
Microsoft

INSTALLING CYLINDER HEAD
Installing cylinder head
Fitting cylinder head side 1 - 3:
1. Turn the crankcase at the assembly support in such a way that side 1-3 stands vertically upwards.
2. Fit new cylinder head gasket. The marking 'OBEN/TOP' must be clearly visible.
3. Carefully position the cylinder head on the crankcase. Pay attention to the dowel sleeves.
Microsoft
4. Screw in 12 M10 Torx screws evenly and tighten according to the prescribed tightening sequence -1-12- . -->
Initial tightening: 30 (22 ftlb.) Nm , loosen all screws in reverse tightening sequence; --> Initial tightening:
20 (15 ftlb.) Nm ; --> Final tightening, 2 x torque angle: 70 ° . See Fig. 174.
Fig. 174: Tightening sequence for cylinder-head screws

5. Screw in and tighten four Torx screws with M6 x 30 captive washers (10.9) -1-4- at the chain slot. Use of a
magnetic bit is recommended so that the screw to be fitted in the slot -Item 4- cannot fall into the crankcase. -->
Tightening torque: 13 (9.5 ftlb.) Nm . See Fig. 175.
Microsoft
Fig. 175: External cylinder head screwed connection

Microsoft
6. Fit threaded bolt for guide rail -1- with a new O-ring at the cylinder head. --> Tightening torque: 10 (7.5
The installation of cylinder head side 4 -6 is carried out in the same way as the assembly sequence for side
1-3 with the following change:

- The threaded bolt for guide rail 4-6 on the cylinder head (belt pulley side) -1- is inserted only after the timing
chain has been fitted on the camshaft timing gears. See Fig. 177.
SUBSEQUENT WORK FOR INSTALLING CYLINDER HEAD
Subsequent work for installing cylinder head
Microsoft
Fig. 178: O-rings on spark-plug recess seal

1. Insert three new O-rings at the spark-plug recesses -Arrows- , lightly coat with high-pressure grease.
Microsoft
Fig. 179: Flat-base tappet housing bolts

NOTE: There must be no visible signs of wear on the flat-base tappets and fitting bores
of the flat-base tappet housing.
2. Fit flat-base tappet housing with 11 M6 x 35 Torx screws -1- and tighten screws from the inside out. -->
Fig. 180: Operating plunger position

3. Coat the flat-base tappets with new engine oil and insert them in their original position into the fitting bores
in the flat-base tappet housing. The operating plunger position (inlet side) is pre-set by the dowel pin -Arrow- .
4. Install camshaft and set timing --> 150520 Removing and installing camshafts - section on
"Installing" [987320 987321] --> 150520 Removing and installing camshafts - section on
Microsoft
"Installing" [987310 987311].
5. Install cylinder head cover --> 158220 Removing and installing cylinder head cover - chapter on
"Installing".
6. Fit exhaust manifold with new screws M8 x 26. Position new metal seal with the seam towards the cylinder
head. Tighten screws from the inside out --> Tightening torque: 23 (17 ftlb.) Nm .
15 70 37 DISASSEMBLING AND ASSEMBLING CYLINDER HEAD - AS OF

TOOLS

puller VW-tool 3364

Valve keys assembly- commercially NR.54
disassembly tool for available tool
Boxster + Carrera
assembly driver special tool P 9606
PRELIMINARY WORK FOR DISASSEMBLING CYLINDER HEAD
Preliminary work for disassembling cylinder head
RHD, Boxster S, Boxster S RHD) . Refer to 10 01 19 Removing and installing engine - as of MY 2005

Boxster S RHD, Cayman S, Cayman S RHD) . or. Refer to 37 35 27 Removing and refitting the automatic
transmission - as of MY 2005 (All Models) .
3. Remove cylinder head --> 157019 Removing and installing cylinder head - chapter on
"Removing" [987310 987311 987320 987321].
DISASSEMBLING CYLINDER HEAD
Microsoft
Disassembling cylinder head
The following tool is used and recommended for the described work: commercially available tool Valve
keys assembly- disassembly tool for Boxster + Carrera NR.54 (Sauer Co., Art. No. for standard case 600 50
00).
Fig. 181: Disassembling and assembling cylinder head tools


A Shaft (ø 20 x 450 mm) Art. No. 602 45 15
B aluminum supports, slotted, 2-piece Art. No. 602 36 20
C Lever arm Art. No. 602 35 30
E Joint with screw Art. No. 602 45 20
E Disassembly head with magnet Art. No. 602 46 50
F Assembly head 1b (for valve keys) Art. No. 600 01 02
G Pressure pieces Gr. 6a, 3-piece Art. No. 600 60 15
H Plates, 3-piece Art. No. 602 56 65
Microsoft
Not included in scope of delivery, article 600

Additional scope:
50 00
I Valve locating screws set, 4-piece Art. No. 609 64 50
J Screws with washer (4 ea.) M6 x 40
Component overview of cylinder head
Fig. 182: Cylinder head components

NOTE: Reusable inner parts of the cylinder head must always be cleaned thoroughly
and assigned to their original installation location.
Item Designation Removal Fitting

A second person should help Replacing cylinder-head
1 Cylinder head with removing and gasket; pay attention to the
positioning dowel pins
Check tilt play of valve guide
2 Intake valve if necessary; observe Lightly oil valve stem
assignment.
Replace; use 9606 assembly
3 Valve stem seal Use puller 3364
driver
Lower valve-spring plate
4
(intake)
5 Valve spring set (intake)
Upper valve-spring plate
6
(intake)
7 Valve collets
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Check tilt play of valve guide

8 Exhaust valve if necessary; observe Lightly oil valve stem
assignment.
Lower valve-spring plate
9
(exhaust)
10 Valve spring (exhaust)
Upper valve-spring plate
11
(exhaust)
1. Remove spark plugs, if not already done.
Fig. 183: Valve locating screws

2. Screw in the three valve locating screws -arrows- in the spark plug threads. See Fig. 183.
Microsoft
Fig. 184: Mounting aluminum supports

NOTE: Put the screw clamps for fixing the cylinder head only on the aluminum
supports, under no circumstances on the sealing surface.
3. Align aluminum supports on the cylinder head with fastening screws. Fix cylinder head to the workbench
with screw clamps. Slide on assembly shaft with the joint to the aluminum supports and fasten them.
4. Screw lever arm on joint and the disassembly head on the lever arm.
5. Place disassembly head on upper valve-spring plate and press together the valve springs with the lever arm.
The valve keys and the concave washer stick due to the magnetic insert on the disassembly head. Repeat this
process by moving the joint at the required valves.
Microsoft
Fig. 185: Pulling off the valve-stem seal (VW-special tool 3364)
6. Using the VW special tool puller 3364 pull off the valve-stem seal.
7. Check valve springs, valves, valve guides, and valve seats for damage.
8. Thoroughly clean cylinder head and all parts before assembling. Carry out repairs approved by PAG, if
necessary.
ASSEMBLING CYLINDER HEAD
Assembling cylinder head
NOTE: Reusable inner parts of the cylinder head must always be cleaned thoroughly
and assigned to their original installation location.
Microsoft
Fig. 186: Valve stem seal

NOTE: Replace valve-stem seal.
1. Insert lower valve-spring plate, oil valve stem lightly and position assembly sleeve (shim set for valve-stem
seals). Either set new valve-stem seal on the assembly sleeve or insert in the assembly driver P 9606.
Microsoft
Fig. 187: Valve-stem seal on valve stem

2. Press valve-stem seal with the assembly driver P 9606 up to the stop on the valve stem. Take off tool and
assembly sleeve.
Microsoft
Fig. 188: Pressing in valve-stem seal

3. Insert corresponding valve spring(s) and upper valve-spring plate.
Microsoft
Fig. 189: Assembly head for valve keys

4. Fasten assembly head to lever arm. Push sliding sleeve downward to the stop and insert the valve keys. In
order to ensure correct assembly, the wedges should be centered. Then push the sliding sleeve back again (valve
keys fixed).
Fig. 190: Mounting the valve keys

5. Position assembly head with the pressure piece over the valve stem and align the assembly head so that it is
aligned with the valve. Slowly press the assembly head downwards and guide it with your hand until a clicking
sound can be heard. The valve keys are then automatically pressed into the correct installation position.
6. Swivel out the lever with the assembly head and check the seat of the valve keys. Repeat the process if
necessary.
ASSEMBLING CYLINDER HEAD, TOUCHING UP
Assembling cylinder head, touching up
1. Install cylinder head --> 157019 Removing and installing side cylinder head - chapter on
"Installing" [987310 987311 987320 987321].
2. Mount transmission. Refer to 34 35 27 Removing and refitting transmission - as of MY 2005 (Boxster,

Microsoft
Boxster S RHD, Cayman S, Cayman S RHD) , or. Refer to 37 35 27 Removing and refitting the automatic
Boxster S, Boxster S RHD) . Refer to 10 01 19 Removing and installing engine - as of MY 2005 (Cayman
S, Cayman S RHD) .
15 70 49 MACHINING THE CYLINDER HEAD - AS OF MY 2005 (ALL

MODELS)
PRELIMINARY WORK
Preliminary work for machining cylinder head
"Removing" [987310 987311 987320 987321].
2. Disassemble cylinder head --> 157037 Disassembling and assembling cylinder head - chapter on
"Disassembling".
MACHINING THE CYLINDER HEAD
Machining the cylinder head
1. Measure cylinder head height on a level surface ( surface plate recommended).
Microsoft
Fig. 191: Cylinder head height

Standard dimension -X- : 142.0 ± 0.1 mm. See Fig. 191.
2. Check combustion chamber sealing face of the cylinder head for distortion (flatness) using a straight-edge
and feeler gauge.
Fig. 192: Flatness of sealing face of cylinder head (diagonal)

Permissible unevenness of parting surface for used cylinder head: 0.05 mm
Microsoft
Fig. 193: Flatness of cylinder head (longitudinal)

3. Cylinder heads with distorted or scored sealing surface can be repaired by plain-milling them. The following
machining criteria must be observed.
Permissible unevenness after machining: 0.03 mm
Permissible roughness profile (can be measured with contact stylus procedure): 15 pt 14
Permissible surface depth from standard dimension: 0.15 ± 0.05 mm
SUBSEQUENT WORK
Subsequent work for machining cylinder head
1. Assemble cylinder head --> 157037 Disassembling and assembling cylinder head - chapter on
"Assembling".
2. Install cylinder head --> 157037 Disassembling and assembling cylinder head - chapter on "Installing".
15 75 02 CHECKING VALVE GUIDE (VALVE LATERAL PLAY) - AS OF MY

2005 (ALL MODELS)
TOOLS
Microsoft

PRELIMINARY WORK
Preliminary work
CAUTION: Incorrect tray.
 Damaged and scratched sealing face.
--> Work on cylinder head only on a clean surface on the work bench.
"Removing" [987310 987311 987320 987321].
2. Disassemble cylinder head and clean components --> 157037 Disassembling and assembling cylinder head
- chapter on "Disassembling".
CHECKING VALVE GUIDE (VALVE LATERAL PLAY)
Checking valve guide (valve lateral play)
Microsoft
Fig. 194: Tool for fixing valve position

Special tool retaining device P 9739
Microsoft
Fig. 195: Special tool 9739 fitted

1. Fit special tool retaining device P 9739 in cylinder head (valve stem side). To do this, screw in the fastening
screws by hand into the spark plug thread.
Microsoft
Fig. 196: Checking valve tilt play of intake valve

NOTE: The permitted valve tilt play is 0.25 mm.
2. Check valve tilt play on intake valve. Adjust the dial gauge to the relevant angle of the valve to be checked
and set to '0' with preload. Press valve disc towards dial gauge and pull it back again. Read off value and note
it.
Fig. 197: Checking valve tilt play on exhaust valve

3. Check valve tilt play on exhaust valve. Adjust the dial gauge to the relevant angle of the valve to be checked
and set to '0' with preload. Press valve disc towards dial gauge and pull it back again. Read off value and note
it.
4. Check all valves.
SUBSEQUENT WORK
Subsequent work
1. When all valve guides are within the permitted tolerances, assemble cylinder head again. If the specification
is exceeded, the cylinder head must be replaced.
2. Install cylinder head --> 157019 Removing and installing side cylinder head - chapter on
"Installing" [987310 987311 987320 987321].
Microsoft
15 82 20 REMOVING AND INSTALLING CYLINDER HEAD COVER - ENGINE

REMOVED - AS OF MY 2005 (CAYMAN S, CAYMAN S RHD)
TOOLS

REMOVING CYLINDER HEAD COVER - ENGINE REMOVED
Removing cylinder head cover M97/21
NOTE: The coated screws for the bearing surfaces of the camshaft in the cylinder head
cover must be replaced when installing.
Replace O-ring on the oil suction pump (or tandem pump).
Cylinder row 1-3:
1. Disconnect oil pressure switch cable plug.
2. Disconnect and remove cable plugs for ignition coils. Remove ignition coils -1- . To do this, unscrew each of
the two Torx screws (M6 x 25) and remove the ignition coils from the spark-plug recess. See Fig. 198.
Microsoft
3. Remove support and retainer plates (with integrated seal) for the solenoid hydraulic valves (camshaft
adjustment and valve lift control) -2- , --> 153719 Removing and installing solenoid hydraulic valve for
camshaft timing - chapter on "Removing" . If the valves do not have to be replaced, these can remain in the
cylinder head (side 1-3 both, side 4-6 camshaft timing only). See Fig. 198.
Microsoft
Fig. 199: Oil strainer in hydraulic valve for camshaft adjustment

4. If the solenoid hydraulic valve for camshaft adjustment is removed, the oil strainer -1- must be checked for
damage and contamination, and replaced if necessary. See Fig. 199.
Microsoft
Fig. 200: Oil suction pump 1 - 3

5. Remove oil suction pump 1 - 3. Unscrew four M6 x 20 Torx screws (micro-self-locking), remove oil suction
pump, replace O-ring and screws.
6. Unclip oxygen sensor line from the brackets.
Microsoft
Fig. 201: Lifting cylinder head cover from above

CAUTION: Damage when levering off the cylinder head cover
 Cast lugs could break.
--> Perform work steps carefully and gently.
7. Remove cylinder head cover. Unscrew 20 M6 x 30 Torx screws from the cylinder head cover. To loosen the
cylinder head cover, raise the cover carefully at the two protruding cast edges with a screwdriver or mounting
lever. Remove cylinder head cover.
Microsoft
Fig. 202: Lifting cylinder head cover from below

8. Remove the plastic cap.
NOTE: Make sure that it is cleaned thoroughly and that residual sealing compound is
removed completely. Even the smallest particles can block up oil bores.
9. Clean the sealing faces on the cylinder head cover and cylinder head thoroughly (use a brass or nylon brush, a
clean and lint-free cloth soaked in acetone). All residual sealing compound in the cylinder head and on the
cover must be removed before assembly.
Additional work steps on cylinder row 4-6:
Microsoft
Fig. 203: Tandem pump side 4-6

- A tandem pump is installed on side 4-6 instead of the oil suction pump. Pull off the vacuum line on the pump -
2- . Replace O-rings and micro-self-locking screws -1- . See Fig. 203.
INSTALLING CYLINDER HEAD COVER - ENGINE REMOVED
Installing cylinder head cover M97/21
Microsoft
Fig. 204: Spark plug slot seals and solenoid hydraulic valves
1. Insert three new seals for the spark-plug recesses.
Only the following sealants may be used to seal the cylinder head cover:
 "Drei Bond" silicone - type 1209

 Loctite 5900
2. Prepare cylinder head cover for assembly. Apply a thin bead of sealant on the cylinder head cover (not more
than 1.5 mm high). --> Sealant application on cylinder head cover . See Fig. 205.
Microsoft
Fig. 205: Sealant application on cylinder head cover

Fig. 206: Screws for camshaft bearing surface

3. Coated screws on the camshaft bearing surfaces -1- must be replaced. See Fig. 206.
4. Place the cylinder head cover carefully onto the cylinder head. The bead of sealing compound must not be
Microsoft
wiped off or broken.
5. Position 20 Torx screws (eight of these should be new, coated screws -1-4 and 7-10- ) on the cylinder head
cover and tighten according to the specified tightening sequence. Only lightly screw in the two screws in the
area of the oil suction pump/tandem pump. They will be tightened after the pump is assembled. --> Tightening
torque: 13 (9.5 ftlb.) Nm . See Fig. 207.
Fig. 207: Tightening sequence for cylinder head cover

6. Position a new cap ø 45 mm (brown) on the bore of the intake camshaft on the pulley side and tap it gently
into place with a plastic hammer (dry mount).
7. Insert two new caps (green) into the small bores on the clutch side. Tap it in with a plastic hammer (dry
mount).
Microsoft
Fig. 208: Tandem pump side 4 -6

NOTE: Replace O-ring on the oil suction pump (or tandem pump).
8. Mount the oil suction pump or tandem pump with four new, micro-self-locking Torx screws -1- . Replace O-
rings on the pumps and the vacuum line -2- . Grease O-rings with Optimol MP3. --> Tightening torque: 10
(7.5 ftlb.) Nm . See Fig. 208.
9. Tighten the two screws on cylinder head cover in area of oil suction pump/tandem pump. --> Tightening
Microsoft
Fig. 209: Holder for solenoid hydraulic valves

10. Push new retainer plates (with integrated seal) onto solenoid hydraulic valves. Position support and tighten
with two Torx screws (M6 x 20). --> Tightening torque: 10 (7.5 ftlb.) Nm
 A: Support for camshaft adjustment valve (camshaft timing)

 B: Support for valve lift adjustment valve (valve lift control)
Microsoft
Fig. 210: Installation position for solenoid hydraulic valve retainer plates
 1 - Camshaft timing retainer plate

 2 - Valve lift control retainer plate
11. Insert ignition coils into the spark-plug recesses. Position and tighten two M6 x 25 Torx screws per ignition
coil. --> Tightening torque: 10 (7.5 ftlb.) Nm
12. Plug in cable plugs for ignition coils and solenoid hydraulic valves. Clip the cables of the hydraulic valves
into the brackets.
13. Connect cable plug to oil temperature switch.
14. Clip oxygen sensor lines into brackets.
15 82 20 REMOVING AND INSTALLING CYLINDER HEAD COVER - ENGINE

REMOVED - AS OF MY 2005 (BOXSTER, BOXSTER RHD, BOXSTER S,
BOXSTER S RHD)
TOOLS

Microsoft
PRELIMINARY WORK
Preliminary work
REMOVING CYLINDER HEAD COVER - ENGINE REMOVED
Removing cylinder head cover M96/25 and M96/26
Replace O-ring on the oil suction pump (or tandem pump).
Cylinder row 1-3:
1. Disconnect oil pressure switch cable plug.
2. Disconnect and remove cable plugs for ignition coils. Remove ignition coils -1- ; to do this, unscrew each of
the two Torx screws (M6 x 25) and remove the ignition coils from the spark-plug recess. See Fig. 211.
Microsoft
3. If necessary, remove camshaft adjustment valve -2- by unscrewing the Torx screws (M6 x 20). Remove
support and retainer plate (with integrated seal). Pull solenoid hydraulic valve for camshaft adjustment out of
the bore if this needs to be replaced. Replace retainer plate (with integrated seal) during installation. See Fig.
211.
Microsoft
Fig. 212: Oil strainer in hydraulic valve for camshaft adjustment

4. If the solenoid hydraulic valve is removed for camshaft timing, the oil strainer -1- must be checked for
damage and contamination, and replaced if necessary. See Fig. 212.
Microsoft
Fig. 213: Oil suction pump 1 - 3

5. Remove oil suction pump 1 - 3. Unscrew four M6 x 20 Torx screws (micro-self-locking), remove oil suction
pump, replace O-ring and screws.
6. Unclip oxygen sensor line from the brackets.
Microsoft
Fig. 214: Lifting cylinder head cover from above

CAUTION: Damage when levering off the cylinder head cover
 Cast lugs could break.
--> Perform work steps carefully and gently.
7. Remove the cylinder head cover. Unscrew 20 M6 x 30 Torx screws from the cylinder head cover. To loosen
the cylinder head cover, raise the cover carefully at the two protruding cast edges with a screw driver or
mounting lever. Remove cylinder head cover.
Microsoft
Fig. 215: Lifting cylinder head cover from below

8. Remove the plastic cap.
NOTE: Make sure that it is cleaned thoroughly and that residual sealing compound is
removed completely. Even the smallest particles can block up oil bores.
9. Clean the sealing faces on the cylinder head cover and cylinder head thoroughly (use a brass or nylon brush, a
clean and lint-free cloth soaked in acetone). All residual sealing compound in the cylinder head and on the
cover must be removed before assembling.
Additional work steps on the cylinder row 4-6:
Microsoft

- A tandem pump is installed on side 4-6 instead of the oil suction pump. Pull off the vacuum line on the pump -
2- . Replace O-rings and micro-self-locking screws -1- . See Fig. 216.
INSTALLING CYLINDER HEAD COVER - ENGINE REMOVED
Installing cylinder head cover M96/25 and M96/26
Microsoft
Fig. 217: Spark plug slot seals and solenoid hydraulic valves
1. Insert three new seals for the spark-plug recesses.
Only the following sealants may be used to seal the cylinder head cover:
 "Drei Bond" silicone - type 1209

 Loctite 5900
2. Prepare cylinder head cover for assembly. Apply a thin bead of sealant on the cylinder head cover (not higher
than 1.5 mm). --> Sealant application cylinder head cover . See Fig. 218.
Microsoft
Fig. 218: Sealant application cylinder head cover

Fig. 219: Screws for camshaft bearing surface

3. Coated screws on the camshaft bearing surfaces -1- must be replaced. See Fig. 219.
4. Place the cylinder head cover carefully onto the cylinder head. The bead of sealing compound must not be
Microsoft
wiped off or broken.
5. Position 20 Torx screws (eight of these should be new, coated screws -Item 1-4 and 7-10- ) on the cylinder
head cover and tighten according to the specified tightening sequence. Only lightly screw in the two screws in
the area of the oil suction pump/tandem pump. They will be tightened after the pump is assembled. -->
Fig. 220: Tightening sequence, cylinder head cover

6. Position a new cap ø 45 mm (brown) on the bore of the intake camshaft on the pulley side and tap it gently
into place with a plastic hammer (dry mount).
7. Insert two new caps (green) into the small bores on the clutch side. Tap it in with a plastic hammer (dry
mount).
Microsoft

NOTE: Replace O-ring on the oil suction pump (or tandem pump).
8. Mount the oil suction pump or tandem pump with four new, micro-self-locking Torx screws -1- . Replace O-
rings on the pumps and the vacuum line -2- . Lightly grease O-rings with Optimol MP3. --> Tightening
torque: 10 (7.5 ftlb.) Nm . See Fig. 221.
9. Tighten the two screws on cylinder head cover in area of oil suction pump/tandem pump. --> Tightening
Microsoft
Fig. 222: Holder for solenoid hydraulic valves

10. Push on new retainer plates (with integrated seal) onto solenoid hydraulic valves. Position support and
tighten with two Torx screws (M6 x 20). --> Tightening torque: 10 (7.5 ftlb.) Nm
Microsoft
Fig. 223: Installation position for solenoid hydraulic valve retainer plates
11. Insert ignition coils into the spark-plug recesses. Position and tighten two M6 x 25 Torx screws per ignition
coil. --> Tightening torque: 10 (7.5 ftlb.) Nm
12. Plug in cable plugs for ignition coils and solenoid hydraulic valves. Clip the cables of the hydraulic valves
into the brackets.
13. Connect cable plug to oil temperature switch.
14. Clip oxygen sensor lines into brackets.
SUBSEQUENT WORK
Subsequent work
15 84 19 REMOVING AND INSTALLING ACTUATOR FOR INLET CAMSHAFT

RHD)
TOOLS
Microsoft

pliers for circlips commercially NR.70
available tool
REMOVING ACTUATOR - CAMSHAFT REMOVED
Removing actuator - camshaft removed
NOTE:  During assembly and disassembly, absolute cleanliness is essential!

 The identification on the bearing sleeve should point towards the camshaft
(see illustration).
Component overview of inlet camshaft
Fig. 224: Component overview of inlet camshaft

Item Designation Qty. Removal Fitting

1 Central screw 1 Replace
2 Adapter 1
Camshaft adjustment
3 1
device
4 Friction washer 1 Replace
Pay attention to the
5 Bearing sleeve 1
installation position!
Check for visible signs of wear, taking care
6 Inlet camshaft 1 replace if necessary
not to damage rotor trim
Microsoft
Plain compression
7 2 Check for visible signs of wear replace if necessary
rings
1. Unscrew central screw -1- with adapter -2- .
2. Remove camshaft adjustment device -3- .
3. Remove washer -4- .
4. Pull bearing sleeve -5- carefully off the camshaft -6- .
NOTE:  Carry out disassembly and assembly of the plain compression rings
carefully and gently.
5. Check plain compression rings -7- for visible and perceptible signs of wear; replace if necessary. To remove
and install, use snap-ring pliers, e. g. pliers for circlips NR.70.
6. Check plain compression rings for visible and perceptible signs of wear; replace if necessary.
INSTALLING ACTUATOR - CAMSHAFT REMOVED
Installing actuator - camshaft removed
NOTE:  During assembly and disassembly, absolute cleanliness is essential!

 The identification on the bearing sleeve should point towards the camshaft
(see illustration).
Assemble inlet camshaft before inserting in cylinder head.
NOTE:  Carry out disassembly and assembly of the plain compression rings
carefully and gently.
1. Insert plain compression rings (if removed) carefully into the ring grooves. To remove and install, use snap-
ring pliers, e. g. pliers for circlips NR.70.
Microsoft
Fig. 225: Direction of installation of bearing sleeve - identification towards camshaft

2. Install bearing sleeve: lightly oil running surface with new engine oil. Press together the first piston ring and
carefully push up the bearing sleeve. Proceed in the same way with the second piston ring. Pay attention to
direction of installation.
NOTE:  Make sure that the new friction washer is inserted.
3. Position new friction washer and place the camshaft adjustment device in position. Insert the central screw
with the adapter and tighten gently by hand.
Microsoft
ENGINE Exhaust system
ENGINE
Exhaust system
26 01 TW TECHNICAL DATA, EXHAUST SYSTEM - AS OF MY 2005

TECHNICAL VALUES
Exhaust system and emission control
Exhaust system 987 987 S Cayman S

Two-pipe, three-way catalytic converter exhaust system, two parallel
Exhaust system structure rear mufflers with cross talk pipe and integrated catalytic converter
Merging in front of the center tailpipe
Emission control system
Oxygen sensor closed-loop control and 3-way catalytic converter
Euro 2 system, each with a primary and main catalytic converter on left + right
(RoW)
Three-way catalytic converter system, each with a primary and main
catalytic converter on left + right, oxygen sensor closed-loop control and
Euro 4
post-catalytic converter trim control (four probes), secondary air system
and EOBD
USA LEV / LEV II / CAL /
as Euro 4 except with OBD II + ORVR
Tier 2 / FEP
26 10 19 REMOVING AND INSTALLING EXHAUST MANIFOLD (WITH

PRIMARY CATALYTIC CONVERTER) - AS OF MY 2005 (ALL MODELS)
TOOLS

PRELIMINARY WORK
Preliminary work
Microsoft
WARNING: Parts of the exhaust system become extremely hot!
 Danger of burns
 Permanent scarring of the skin
--> Do not begin work until the exhaust system has cooled down completely.
--> If it is imperative that you work on the hot exhaust system, ensure that you wear fire-resistant and heat-
resistant protective gear.
2. Remove rear wheel. Use the specified special tool socket wrench insert P 300 to avoid damaging the wheel
rims Refer to 44 05 19 Removing and installing wheel - as of MY 2005 (All Models) .
3. Remove heat protection for brake hose. Unscrew two plastic nuts and one tapping screw and remove
component.
4. Remove oxygen sensors Refer to 24 69 20 Removing and installing oxygen sensor in front of catalytic
converter - as of MY 2005 (All Models) . Refer to 24 73 20 Removing and installing oxygen sensor behind
catalytic converter - as of MY 2005 (All Models) .
Microsoft
Fig. 1: Triangular flange of rear silencer

5. Unscrew three M8 lock nuts on the triangular flange of the exhaust manifold and remove metal seal.
REMOVING EXHAUST MANIFOLD
Removing exhaust manifold
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Fig. 2: Screws for exhaust manifold

1. Remove the exhaust manifold. Unscrew six hexagon-head bolts (M8 x 26) -Arrows- on the cylinder head.
Get another person to hold the component if necessary. See Fig. 2.
2. Remove exhaust manifold (with primary catalytic converter) -3- and flange gasket -2- . See Fig. 3.
Fig. 3: Exploded view of exhaust manifold

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INSTALLING EXHAUST MANIFOLD
Installing exhaust manifold
NOTE:  Always replace exhaust manifold screws during installation.

 Replace lock nuts.
 Replace gaskets.
1. Clean sealing surfaces on manifold flange and cylinder head using a brass wire brush for example.
2. Replace manifold seal -2- . Check that it is installed correctly - locating studs and beads must point to the
cylinder head. See Fig. 4.
3. Fit exhaust manifold (with primary catalytic converter) -3- on the cylinder head and triangular flange with
new metal seals. Get another person to help if necessary. See Fig. 4.
Fig. 4: Exploded view of exhaust manifold

 1 - Screw, M8 x 26
 2 - Metal seal
 3 - Exhaust manifold with primary catalytic converter
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Fig. 5: Screws for exhaust manifold

4. Position six new hexagon-head bolts (M8 x 26) -Arrows- by hand and tighten them from the inside outwards.
--> Tightening torque: 23 (17 ftlb.) Nm See Fig. 5.
SUBSEQUENT WORK
Subsequent work
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Fig. 6: Triangular flange of rear silencer

1. Secure triangular flange for exhaust manifold using three new M8 lock nuts. Tighten nuts evenly. -->
2. Install oxygen sensors. Refer to 24 69 20 Removing and installing oxygen sensor in front of catalytic
converter - as of MY 2005 (All Models) . Refer to 24 73 20 Removing and installing oxygen sensor behind
catalytic converter - as of MY 2005 (All Models) .
3. Fit heat protection for brake hose using two plastic nuts and one tapping screw. Tighten nuts and screw
carefully.
4. Fit rear wheel. Use the specified special tool socket wrench insert P 300 to avoid damaging the wheel rims.
Refer to 44 05 19 Removing and installing wheel - as of MY 2005 (All Models) .
26 33 19 REMOVING AND INSTALLING REAR SILENCER - AS OF MY 2005

TOOLS

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PRELIMINARY WORK
Preliminary work
1. Remove both rear wheels. Use the prescribed special tool socket wrench insert P 300 to avoid damaging the
component.
COMPONENT OVERVIEW
Components of the Cayman exhaust system
Overview
Microsoft
Fig. 7: Cayman exhaust system


Vehicle-specific version
1 Exhaust system support (Tiptronic, 5-speed/6-speed
manual transmission)
2 Hexagon-head bolt, M8 x 40
3 Fastening screws for transmission bracket (Tiptronic, 5-speed/6-speed
Right rear silencer with integrated catalytic
4
converter
Left rear silencer with integrated catalytic
5
converter
6 Clamp Replace following removal
7 Tailpipe
8 Cayman S tailpipe cover
9 Cayman tailpipe cover
REMOVING REAR SILENCER
Removing rear silencer
 Danger of burns
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NOTE: The main catalytic converters are integrated in the rear silencer.
The rear silencers can be replaced individually by disconnecting the system.
Fig. 8: Flange for right rear silencer

1. Unscrew three lock nuts (M8) -Arrows- on the right flange. See Fig. 8.
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Fig. 9: Flange for left rear silencer

2. Unscrew three lock nuts (M8) -Arrows- on the left flange. See Fig. 9.
3. Get another person to hold the rear silencer.
4. Remove two screws (M8) on the rear silencer holder -Arrows- . See Fig. 10.
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Fig. 10: Rear silencer holder

5. Remove the rear silencer with the help of another person.
INSTALLING REAR SILENCER
Installing rear silencer
1. Replace flange gaskets on the triangular flange and on the cylinder head.
2. Position rear silencer with the help of an assistant.
3. Fit and tighten two screws (M8) on the rear silencer holder -Arrows- . --> Tightening torque: 23 (17 ftlb.)
Nm . See Fig. 11.
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4. Fit and tighten three new lock nuts (M8) -Arrows- on the left flange. --> Tightening torque: 23 (17 ftlb.)
Nm . See Fig. 12.

5. Fit and tighten three new lock nuts (M8) -Arrows- on the right flange. --> Tightening torque: 23 (17 ftlb.)
Nm . See Fig. 13.
SUBSEQUENT WORK
Subsequent work
2. Fit both rear wheels. Use the prescribed special tool socket wrench insert P 300 to avoid damaging the rims.
26 33 19 REMOVING AND INSTALLING REAR SILENCER - AS OF MY 2005

TOOLS

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PRELIMINARY WORK
Preliminary work
1. Remove both rear wheels. Use the prescribed special tool socket wrench insert P 300 to avoid damaging the
component.
COMPONENT OVERVIEW
Components of the Boxster exhaust system
Overview
Microsoft
Fig. 14: Boxster exhaust system


1 Exhaust system support (Tiptronic, 5-speed/6-speed
2 Hexagon-head bolt, M8 x 40
3 Fastening screws for transmission bracket (Tiptronic, 5-speed/6-speed
Right rear silencer with integrated catalytic
4
converter
Left rear silencer with integrated catalytic
5
converter
6 Clamp Replace following removal
7 Tailpipe
8 Boxster S tailpipe cover
9 Boxster tailpipe cover
REMOVING REAR SILENCER
Removing rear silencer
 Danger of burns
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NOTE: The main catalytic converters are integrated in the rear silencer.
The rear silencers can be replaced individually by disconnecting the system.

1. Unscrew three lock nuts (M8) -Arrows- on the right flange. See Fig. 15.
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2. Unscrew three lock nuts (M8) -Arrows- on the left flange. See Fig. 16.
3. Get another person to hold the rear silencer.
4. Remove two screws (M8) on the rear silencer holder -Arrows- . See Fig. 17.
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5. Remove the rear silencer with the help of another person.
INSTALLING REAR SILENCER
Installing rear silencer
1. Replace flange gaskets on the triangular flange and on the cylinder head.
2. Position rear silencer with the help of an assistant.
3. Fit and tighten two screws (M8) on the rear silencer holder -Arrows- . --> Tightening torque: 23 (17 ftlb.)
Nm . See Fig. 18.
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4. Fit and tighten three new lock nuts (M8) -Arrows- on the left flange. --> Tightening torque: 23 (17 ftlb.)
Nm . See Fig. 19.

5. Fit and tighten three new lock nuts (M8) -Arrows- on the right flange. --> Tightening torque: 23 (17 ftlb.)
Nm . See Fig. 20.
SUBSEQUENT WORK
Subsequent work
2. Fit both rear wheels. Use the prescribed special tool socket wrench insert P 300 to avoid damaging the rims.
26 34 19 REMOVING AND INSTALLING TAILPIPE - AS OF MY 2005

REMOVING TAILPIPE
Removing tailpipe
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Fig. 21: Clamp for Boxster tailpipe cover

1. Loosen hexagon nut (M10) at the clamp on the tailpipe cover.
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Fig. 22: Clamp for Cayman tailpipe cover

2. Open up clamp.
3. Pull off tailpipe cover.
NOTE: The help of another person is required for removing and installing the rear
silencer.
4. Remove one rear silencer. To do so, loosen clamps on the tailpipe and clamping sleeve on the connecting
tube. Remove triangular flange for exhaust manifold and screws on silencer holder --> 263319 Removing and
installing rear silencer - section on "Removing".
REPLACING TAILPIPE CLAMP
Replacing the clamp
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Fig. 23: Clamp

The clamps on the tailpipe and tailpipe cover can be replaced if necessary. These can be obtained as a spare part
from the Porsche parts service.
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Fig. 24: Clamp spotweld on tailpipe

1. Cut spotweld on the defective clamp.
2. Slide on new clamp and secure it between the rear silencers after adjusting the tailpipe or connecting tube
(cross-coupling point). --> Tightening torque: 65 (48 ftlb.) Nm
26 34 19 REMOVING AND INSTALLING TAILPIPE - AS OF MY 2005

REMOVING TAILPIPE
Removing tailpipe


Microsoft

2. Open up clamp.
NOTE: The help of another person is required for removing and installing the rear
silencer.
4. Remove one rear silencer. To do so, loosen clamps on the tailpipe and clamping sleeve on the connecting
tube. Remove triangular flange for exhaust manifold and screws on silencer holder --> 263319 Removing and
installing rear silencer - section on "Removing".
REPLACING TAILPIPE CLAMP
Replacing the clamp
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Fig. 27: Clamp

The clamps on the tailpipe and tailpipe cover can be replaced if necessary. These can be obtained as a spare part
from the Porsche parts service.
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Fig. 28: Clamp spotweld on tailpipe

1. Cut spotweld on the defective clamp.
2. Slide on new clamp and secure it between the rear silencers after adjusting the tailpipe or connecting tube
(cross-coupling point). --> Tightening torque: 65 (48 ftlb.) Nm
INSTALLING TAILPIPE
Installing tailpipe
1. Clean tailpipe and flange on rear silencer with a wire brush for example. The connecting areas can be sprayed
with high-temperature grease for easier assembly.
2. Position clamping sleeve on connecting tube.
3. Position tailpipe.
4. Install rear silencer --> 263319 Removing and installing rear silencer - section on "Installing".
5. Secure clamps loosely to tailpipe with hexagon nuts. Also secure clamping sleeve to connecting tube.
6. Fit and adjust tailpipe cover --> 263519 Removing and installing decorative cover - section on
"Installing".
7. Tighten clamping sleeve on connecting tube. --> Tightening torque: 23 (17 ftlb.) Nm
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Fig. 29: Clamp for tailpipe cover (Boxster)

8. Tighten hexagon nuts (M10) -Arrow- on tailpipe clamps. --> Tightening torque: 65 (48 ftlb.) Nm See Fig.
29.
26 35 19 REMOVING AND INSTALLING TAILPIPE COVER - AS OF MY 2005

REMOVING TAILPIPE COVER
Removing tailpipe cover
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2. Open up clamp.
4. Clean tailpipe support with a wire brush. The connecting areas can be sprayed with high-temperature grease
for easier assembly.
INSTALLING TAILPIPE COVER
Installing tailpipe cover - Cayman
1. Push on tailpipe with clamp.
NOTE: When fitting the tailpipe cover for the first time, the dimension -a- must be
reduced by 1.5 mm.
2. Adjust tailpipe position as shown below.
Fig. 32: Cayman tailpipe position

a = Cayman, Cayman S - 20 mm
b = Cayman S - 22 mm
c = Cayman - 24 mm
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3. Slide the tailpipe cover onto the tailpipe until the edge is flush with the rear end.

4. Tighten hexagon nut (M10) -1- on clamp. --> Tightening torque: 65 (48 ftlb.) Nm See Fig. 33.
26 35 19 REMOVING AND INSTALLING TAILPIPE COVER - AS OF MY 2005

REMOVING TAILPIPE COVER
Removing tailpipe cover
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2. Open up clamp.
4. Clean tailpipe support with a wire brush. The connecting areas can be sprayed with high-temperature grease
for easier assembly.
INSTALLING TAILPIPE COVER
Installing tailpipe cover - Boxster
1. Push tailpipe cover with clamp onto the tailpipe.
NOTE: When fitting the tailpipe cover for the first time, set the dimension -a- and -b- to
26.5 mm .
2. Adjust tailpipe position as shown below.
Fig. 36: Assembly position for tailpipe (view of Boxster tailpipes)

a = Boxster S - 28 mm
b = Boxster - 28 mm
c = Boxster S - 34 mm
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d = Boxster - 29 mm
Fig. 37: Clamp for tailpipe

3. Tighten hexagon nut (M10) -Arrow- on clamp. --> Tightening torque: 65 (48 ftlb.) Nm See Fig. 37.
26 65 19 REMOVING AND INSTALLING SECONDARY AIR PUMP - AS OF MY

PRELIMINARY WORK FOR REMOVING SECONDARY AIR PUMP
Preliminary work for removing secondary air pump
2. Remove intake-air distributor 4-6 Refer to 24 46 20 Removing and installing intake-air distributor - as of
REMOVING SECONDARY AIR PUMP
Removing secondary air pump
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Fig. 38: Screw for cable duct

1. Loosen cable duct by unscrewing the Torx screw (M6 x 16) -arrow- . See Fig. 38.
Fig. 39: Screws for secondary air pump

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2. Carefully press cable duct down by hand and unscrew the three Torx screws (M6 x 50) -arrows- . See Fig.
39.
Fig. 40: Cable plug for secondary air pump

3. Unclip cable plug -1- with retaining clip and disconnect plug connection. See Fig. 40.
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Fig. 41: Hose for secondary air pump

4. Carefully lever off air hose -1- using a wooden or plastic spatula. See Fig. 41.
5. Lift secondary air pump from the bracket.
INSTALLING SECONDARY AIR PUMP
Installing secondary air pump
1. Position secondary air pump in installation position.
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Fig. 42: Hose for secondary air pump

2. Push on coolant hose -1- . See Fig. 42.
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Fig. 43: Cable plug for secondary air pump

3. Connect cable plug and clip it in -1- . See Fig. 43.
Fig. 44: Screws for secondary air pump

4. Carefully press cable duct down by hand and screw in and tighten the three Torx screws (M6 x 50) -arrows- .
--> Tightening torque: 7.5 ftlb. . See Fig. 44.
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Fig. 45: Screw for cable duct

5. Fasten cable duct by screwing in and tightening the Torx screw (M6 x 16) -arrow- . --> Tightening torque:
7.5 ftlb. See Fig. 45.
SUBSEQUENT WORK FOR INSTALLING SECONDARY AIR PUMP
Subsequent work for installing secondary air pump
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ENGINE Fuel system, Electronic injection
ENGINE
Fuel system, Electronic injection
24 24 19 REMOVING AND INSTALLING AIR CLEANER ELEMENT - AS OF

PRELIMINARY WORK
Preliminary work for air cleaner element
1. Apply protective covers to vehicle and in passenger compartment (Cayman).
2. Remove engine compartment cover. Refer to 55 78 19 Removing and installing engine compartment lid -
as of MY 2005 (Boxster, Boxster RHD, Boxster S, Boxster S RHD) . Refer to 55 78 19 Removing and
REMOVING AIR CLEANER ELEMENT
Removing air-cleaner element
NOTE: The air cleaner housing should not be cleaned on the outside with strong
cleaning agents.
1. If the air cleaner housing is dirty on the outside, clean only with a damp cloth and some washing-up liquid.
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Fig. 1: Air cleaner housing cover

2. Undo two sheetmetal screws -1- and lift air cleaner housing cover -2- up and off. See Fig. 1.
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Fig. 2: Fastening screw for air-cleaner element

3. Unscrew fastening screw -1- and remove the air-cleaner element -2- from the flange. See Fig. 2.
Fig. 3: Air-cleaner element in housing

4. Guide the air-cleaner element -1- into the front part of the air-cleaner housing -in direction of travel- . Then
turn the element in such a way that the opening is facing the observer. --> Removing and installing air-cleaner
element . See Fig. 4, Fig. 3.
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Fig. 4: Removing and installing air-cleaner element

- Pull air-cleaner element up and out.
5. Remove any dirt in air cleaner housing.
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Fig. 5: Air-cleaner element with holder

6. Unscrew screw -1- , release clips and remove holder -2- (only necessary when installing a new air-cleaner
element). See Fig. 5.
INSTALLING AIR CLEANER ELEMENT
Installing air-cleaner element
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Fig. 6: Air-cleaner element removed

1. Place holder -2- in position and screw in screw -1- (only necessary when installing a new air-cleaner
element). See Fig. 6.
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Fig. 7: Removing and installing air-cleaner element

2. Insert air-cleaner element -1- into the air-cleaner housing. See Fig. 8.
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Fig. 8: Air-cleaner element in housing

3. Place air-cleaner element -1- on the flange -2- . See Fig. 8.
Fig. 9: Air-cleaner element flange

- Air-cleaner element on flange
4. Screw in fastening screw for air-cleaner element -1- . See Fig. 10.
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Fig. 10: Air cleaner housing groove

5. Insert retaining lug of air cleaner housing cover into the groove -2- and fit air cleaner housing cover. See Fig.
10.
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Fig. 11: Air cleaner housing

6. Screw in screws -1- . See Fig. 11.
REWORKING
Rework on air cleaner element
1. Install engine compartment cover. Refer to 55 78 19 Removing and installing engine compartment lid - as
24 30 19 REMOVING AND INSTALLING FUEL RING PIPE - AS OF MY 2005

(ALL MODELS)
PRELIMINARY WORK FOR REMOVING FUEL RING PIPE
Preliminary work for removing fuel ring pipe

Microsoft
2. Disconnect battery ground lead. Refer to 27 06 IN External power connection, jump lead starting - as of
4. Remove air-cleaner element. --> 242419 Removing and installing air-cleaner element
REMOVING FUEL RING PIPE
Removing fuel ring pipe

 Damage to skin
1. Release and disconnect fuel lines -arrow- . Collect emerging fuel in a suitable container. See Fig. 12.
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Fig. 12: Fuel line

2. Unclip fuel line from the bracket -1- . See Fig. 12.
3. Disengage shift and selector cables or selector lever cable (Tiptronic) and place on the protective cover for
the luggage-compartment lid. Refer to 34 35 19 Removing and installing transmission - as of MY 2005 (All
Models) .
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Fig. 13: Shift and selector cables for 3.2-liter manual transmission
View of shift and selector cables for 3.2-liter manual transmission
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Fig. 15: Tiptronic selector lever cable

View of Tiptronic selector lever cable
4. Release and pull off cable plugs for fuel injectors -1- . See Fig. 16.
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Fig. 16: Left fuel gallery

5. Unscrew two Torx screws (M6 x 10) -2- on the fuel gallery. See Fig. 16.
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Fig. 17: Right fuel gallery

6. Pull fuel injectors with fuel gallery out of the bores in the intake-air distributor or intake pipe support.
Fig. 18: Fuel ring pipe

7. Pull out fuel ring pipe -arrow- between intake-air distributor and body. See Fig. 18.
8. Guide fuel ring pipe out of the engine compartment.
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Fig. 19: Fuel injector clips

9. Lever off safety clips -arrow- on fuel injectors. See Fig. 19.
10. Pull fuel injectors out of the fuel gallery.
INSTALLING FUEL RING PIPE
Installing fuel ring pipe
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Fig. 20: Fuel injector

1. Replace O-rings -arrows- on the fuel injectors. Lightly grease new O-rings with Optimol MP3. See Fig. 20.
2. Press fuel injectors into the fuel gallery.
3. Attach safety clips and make sure they are fitted correctly.
4. Position fuel ring pipe in the engine compartment.
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Fig. 21: Fuel ring pipe

5. Press fuel ring pipe -arrow- in between intake-air distributor and body. See Fig. 21.
6. Press fuel injectors with fuel gallery into the bores in the intake-air distributor or intake pipe support.
7. Secure fuel gallery with two Torx screws (M6 x 12) -2- . --> Tightening torque: 7.5 ftlb. . See Fig. 22.
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8. Connect cable plug for fuel injectors -1- . The plugs must engage audibly. See Fig. 22.
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Fig. 23: Right fuel gallery

9. Engage shift and selector cables or selector lever cable (Tiptronic). Refer to 34 35 19 Removing and
installing transmission - as of MY 2005 (All Models) .
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Fig. 26: Tiptronic selector lever cable

View of Tiptronic selector lever cable
10. Connect fuel line -arrow- . The connector must engage audibly. See Fig. 27.
Fig. 27: Fuel line

11. Clip fuel line into the bracket -1- . See Fig. 27.
SUBSEQUENT WORK FOR INSTALLING FUEL RING PIPE
Subsequent work for installing fuel ring pipe
2. Install air-cleaner element. --> 242419 Removing and installing air-cleaner element
3. Connect battery ground lead. Refer to 27 06 IN External power connection, jump lead starting - as of MY
2005 (All Models) .
4. Carry out an engine test run. Make sure that the fuel ring pipe is sealed properly, especially at the fuel
injectors.
Microsoft
24 40 20 REMOVING AND INSTALLING FUEL INJECTOR - AS OF MY 2005

(ALL MODELS)
PRELIMINARY WORK FOR REMOVING FUEL INJECTOR
Preliminary work for removing fuel injector
2. Disconnect battery ground lead. Refer to 27 06 IN External power connection, jump lead starting - as of
4. If a fuel injector from cylinder 1 to 3 is removed, the air-cleaner element must be removed. --> 242419
Removing and installing air-cleaner element
REMOVING FUEL INJECTOR
Removing fuel injector

 Damage to skin
- The following work procedure is shown on the fuel gallery of cylinders 1 - 3 as an example.
1. Release and pull off cable plug -1- . See Fig. 28.
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2. Unscrew two Torx screws (M6 x 10) -2- on the fuel gallery. See Fig. 28.
3. Pull fuel injectors with fuel gallery out of the bores in the intake-air distributor or intake pipe support.
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Fig. 29: Fuel injector clips

4. Lever off safety clips -arrow- . See Fig. 29.
5. Pull fuel injector out of the fuel gallery.
INSTALLING FUEL INJECTOR
Installing fuel injector
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Fig. 30: Fuel injector

1. Replace O-rings -arrows- . Lightly grease new O-rings with Optimol MP3. See Fig. 30.
2. Press fuel injector into the fuel gallery.
3. Fit safety clips.
4. Press fuel injectors with fuel gallery into the bores in the intake-air distributor or intake pipe support.
5. Secure fuel gallery with two Torx screws (M6 x 12) -2- . --> Tightening torque: 7.5 ftlb. . See Fig. 31.
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6. Connect fuel injector cable plug -1- . The plug must engage audibly. See Fig. 31.
SUBSEQUENT WORK FOR INSTALLING FUEL INJECTOR
Subsequent work for installing fuel injector
1. If a fuel injector from cylinder 1 to 3 was removed, the air-cleaner element must be installed. --> 242419
Removing and installing air-cleaner element
2. Connect battery ground lead. Refer to 27 06 IN External power connection, jump lead starting - as of MY
2005 (All Models) .
3. Carry out an engine test run. Make sure the fuel injectors are fully sealed.
24 42 19 REMOVING AND INSTALLING THROTTLE BODY - AS OF MY 2005

Microsoft
(ALL MODELS)
PRELIMINARY WORK FOR REMOVING THROTTLE BODY
Preliminary work for removing throttle body
REMOVING THROTTLE BODY
Removing throttle body
1. Remove hose for oil separator. To do this, disengage and remove rapid-action couplings -arrows- . See Fig.
32.

2. Undo four screw-type hose clamps -1- on distributor pipe. See Fig. 32.
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Fig. 33: Fastening for distributor pipe

3. Unscrew hexagon nut (M6) -arrow- . See Fig. 33.
4. Undo spring band clamp and pull off hose -2- . See Fig. 34.
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Fig. 34: Throttle body

5. Undo spring band clamp -1- on the rubber sleeve of the hot-film mass air flow meter. See Fig. 34.
6. Move rubber sleeves in the direction of the intake-air distributor.
7. Remove throttle housing and distributor pipe and turn upwards.
8. Release cable plug -2- on electronic throttle adjuster and remove it. See Fig. 35.
9. Unclip wire -3- . See Fig. 35.
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Fig. 35: Connector for throttle housing

10. Pull off vacuum line -1- on vacuum modulator. See Fig. 35.
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Fig. 36: Screws for throttle housing

11. Unscrew four Torx screws (M6 x 50) -arrows- on throttle housing. See Fig. 36.
INSTALLING THROTTLE BODY
Installing throttle body
Fig. 37: Sealing ring for throttle body

1. Replace sealing ring -arrow- . Coat sealing ring lightly with Optimol MP3 assembly grease. See Fig. 37.
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Fig. 38: Screws for throttle housing

2. Position four Torx screws (M6 x 50) -arrows- and tighten them. --> Tightening torque: 7.5 ftlb. See Fig.
38.
3. Connect vacuum line -1- on vacuum modulator. See Fig. 39.
4. Clip wire -3- into the cable holder. See Fig. 39.
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Fig. 39: Connector for throttle housing

5. Connect cable plug -2- on electronic throttle adjuster. See Fig. 39.
6. Position throttle housing between the intake-air distributors.
7. Push on rubber sleeves.
8. Push rubber sleeve from hot-film mass air flow meter pipe to throttle valve.
9. Tighten screw-type hose clamp -1- . See Fig. 40.
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Fig. 40: Throttle body

10. Push on hose -2- and tighten using the spring band clamp. See Fig. 40.
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Fig. 41: Fastening for distributor pipe

11. Position and tighten hexagon nut (M6) -arrow- . --> Tightening torque: 7.5 ftlb. See Fig. 41.
Fig. 42: Installation position for intake-air distributor screw-type hose clamps
12. Position and tighten four screw-type hose clamps -1- on rubber sleeves. See Fig. 43.
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13. Attach hose for positive crankcase ventilation on oil separator and distributor pipe.
WORK SUBSEQUENT TO INSTALLING THROTTLE BODY
Work subsequent to installing throttle body
24 45 19 REMOVING AND INSTALLING AIR FLOW SENSOR - AS OF MY

2005 (ALL MODELS)
PRELIMINARY WORK FOR REMOVING AIR FLOW SENSOR
Preliminary work for removing air flow sensor
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3. Remove throttle housing and distributor pipe --> 244219 Removing and installing throttle housing.
REMOVING AIR FLOW SENSOR
Removing air flow sensor
1. Remove rubber sleeve for intake-air distributor -1- . Unscrew the screw-type hose clamp -2- for this purpose.
See Fig. 44.
2. Release and disconnect cable plug for air flow sensor -3- . See Fig. 44.
Fig. 44: Hot-film mass air flow meter

3. Open clamps -arrows- . See Fig. 44.
4. Pull air flow sensor out of air cleaner housing flange.
INSTALLING AIR FLOW SENSOR
Installing air flow sensor
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Fig. 45: O-ring for hot-film mass air flow meter

1. Replace O-ring if necessary -arrow- . Grease O-ring to be used for assembly lightly with Optimol MP3
assembly grease and insert it correctly. See Fig. 45.
2. Push air flow sensor into air cleaner housing flange. Ensure correct seating of the O-ring.
3. Clip clamps -arrows- into place. See Fig. 46.
4. Connect cable plug for air flow sensor -3- . See Fig. 46.
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Fig. 46: Hot-film mass air flow meter

5. Fit rubber sleeve for intake-air distributor -1- . Tighten screw-type hose clamp -2- . See Fig. 46.
WORK SUBSEQUENT TO INSTALLING AIR FLOW SENSOR
Work subsequent to installing air flow sensor
1. Install throttle housing and distributor pipe. See: --> 244219 Removing and installing throttle body
24 46 TW TECHNICAL DATA, INTAKE SYSTEM - AS OF MY 2005 (ALL

MODELS)
TECHNICAL VALUES
Intake system
Microsoft

Variable dual-chamber tuning intake system (plastic) with double-flow
Intake system
intake air distributor pipe
Switching speeds, tuning flap
5000 - 7200 rpm 4500 - 7200 rpm 4900-7300 rpm
open
Switching speeds, distributor 3000 - 5000 rpm 3500 - 4700 rpm 3500-4800 rpm
pipe open 5600 - 7200 rpm 5500 - 7200 rpm 5000-7300 rpm
Timing ME 7.8-40, mass air flow measurement with hot film, electronic throttle
rpm limitation E-gas, ignition engagement, cylinder cut-out injection
24 46 20 REMOVING AND INSTALLING INTAKE-AIR DISTRIBUTOR - AS OF

PRELIMINARY WORK FOR REMOVING INTAKE-AIR DISTRIBUTOR
Preliminary work for removing intake distributor
3. Remove throttle housing and distributor pipe --> 244219 Removing and installing throttle housing.
4. If the intake-air distributor for cylinders 4-6 is removed, the air-cleaner element must also be removed -->
242419 Removing and installing air cleaner element.
REMOVING INTAKE-AIR DISTRIBUTOR
Removing intake distributor
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Fig. 47: Intake-air distributor

1. Undo four screw-type hose clamps -arrows- on resonance tube. See Fig. 47.
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2. Pull engine compartment temperature sensor and rubber sleeve from the bracket (only if removing intake-air
distributor on cylinders 1-3).
3. Disconnect and remove cable plug -1- from solenoid valve -2- . See Fig. 49.
4. Unclip solenoid valve -2- from intake-air distributor. The vacuum lines need not be removed. See Fig. 49.
Fig. 49: Solenoid valve

5. Unscrew two Torx screws (M6 x 12) -arrows- on fuel collection pipe. See Fig. 49.
6. Pull fuel injectors with collection pipe out of the bores in the intake-air distributor.
7. Disconnect plug connection for supply lead to air-conditioning compressor (only if intake-air distributor for
cylinders 4-6 is removed).
8. Unscrew six Torx screws on intake-air distributor (M6 x 35).
9. Pull intake-air distributor out of rubber sleeve on resonance tube.
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Fig. 50: Support for cycle valve

10. Lift intake-air distributor and unscrew tapping screw -arrow- (only if intake-air distributor on cylinders 4-6
is removed). See Fig. 50.
11. Guide intake-air distributor out of the engine compartment.
INSTALLING INTAKE-AIR DISTRIBUTOR
Installing intake-air distributor
1. Clean sealing surfaces on cylinder head and intake-air distributor (use a clean, lint-free cloth that has been
soaked in acetone or solvent naphtha).
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Fig. 51: Intake distributor gasket

2. Replace seals -arrows- . Observe position of sealing lugs! See Fig. 51.
3. Position intake-air distributor in engine compartment.
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Fig. 52: Support for cycle valve

4. Lift intake-air distributor and screw in tapping screw -arrow- (only if intake-air distributor on cylinders 4-6
is installed). See Fig. 52.
5. Position six Torx screws (M6 x 35) of the intake-air distributor and tighten them. --> Tightening torque: 7.5
ftlb.
6. Plug in cable plug of supply lead for air-conditioning compressor and clip connector housing into the bracket
provided (only if intake-air distributor on cylinders 4-6 is installed).
7. Replace O-rings on fuel injectors.
8. Push fuel injectors with collection pipe into the bores in the intake-air distributor.
9. Position and tighten Torx screws (M6 x 12) -arrows- . --> Tightening torque: 10 (7.5 ftlb.) Nm See Fig.
53.
10. Clip solenoid valve -2- into intake-air distributor. See Fig. 53.
Microsoft
Fig. 53: Solenoid valve

11. Connect cable plug -1- to solenoid valve -2- . See Fig. 53.
Microsoft

12. Push engine compartment temperature sensor and rubber sleeve into bracket (only if removing intake-air
distributor on cylinders 1-3). Grease rubber sleeve lightly with Optimol MP0 or silicon spray.
13. Position rubber sleeves with screw-type hose clamps.
Microsoft

14. Tighten screw-type hose clamps -arrows- on resonance tube. See Fig. 56.
WORK SUBSEQUENT TO INSTALLING INTAKE-AIR DISTRIBUTOR
Subsequent work for installing intake distributor
1. If the intake-air distributor for cylinders 4-6 was removed, install the air-cleaner element again --> 242419
Removing and installing air cleaner element.
2. Install throttle housing with distributor pipe --> 244219 Removing and installing throttle housing.
24 46 37 DISASSEMBLING AND ASSEMBLING INTAKE-AIR DISTRIBUTOR -

RHD)
Microsoft
DISASSEMBLING INTAKE-AIR DISTRIBUTOR
Disassembling intake-air distributor
Fig. 57: Screw for fuel ring pipe

1. Remove fuel ring pipe by unscrewing the four Torx screws (M6 x 12) --> Screw for fuel ring pipe and pull
the fuel rail with fuel injectors from the seats. See Fig. 57.
2. Loosen spring band clamp -1- and pull off hose -2- on throttle body. See Fig. 58.
Microsoft
Fig. 58: View of tank ventilation solenoid valve

3. Remove cycle valve on intake distributor by unscrewing the tapping screw -arrow- . See Fig. 58.
Microsoft
Fig. 59: View of vacuum units

4. Unscrew fastening screws -arrows- for vacuum units. See Fig. 59.
Microsoft
Fig. 60: View of ball joints

5. Lever ball sockets from the ball heads.
6. Unclip solenoid valves from brackets and remove the entire hose assembly.

7. Remove intake-air distributor gaskets.
Microsoft
Fig. 62: Screws for throttle body

8. Remove throttle body by unscrewing the four Torx screws (M6 x 50) -arrows- . See Fig. 62.
Microsoft

9. Pull off the seal -arrow- from the throttle body. See Fig. 63.
Fig. 64: Cap of intake-air distributor

10. Remove cap by unscrewing the two plastic screws.
Microsoft
Fig. 65: Screw-type hose clamps for intake-air distributor

11. Loosen screw-type hose clamps -arrows- and disconnect intake-air distributor. See Fig. 65.
12. Thoroughly clean components before assembly. Do not treat the surface with strong cleaning agents.
ASSEMBLING INTAKE-AIR DISTRIBUTOR
Assembling intake-air distributor
NOTE: Always replace O-rings and gaskets.
Microsoft
Fig. 66: Installation position of screw-type hose clamps

1. Join intake-air distributor with the rubber sleeves, then position and tighten the screw-type hose clamps -
arrows- . See Fig. 67.
Microsoft
Fig. 67: Screw-type hose clamps for intake-air distributor

Fig. 68: O-ring for cap
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2. Replace O-rings -arrow- of cap and lightly grease with Optimol MP3. See Fig. 68.
Fig. 69: Cap of intake-air distributor

3. Fit cap by screwing in the two plastic screws -arrows- . See Fig. 69.
Microsoft

4. Lightly grease and fit new seal for throttle body with Optimol MP3.
Microsoft
Fig. 71: Screws for throttle body

5. Fit throttle body by screwing in and tightening the four Torx screws (M6 x 50) -arrows- . --> Tightening
torque: 7.5 ftlb. . See Fig. 71.

6. Lightly grease and fit new molded seals --> Intake distributor gasket for intake-air distributor with Optimol
MP3. See Fig. 72.
7. Clip solenoid valves into the brackets.
8. Clip ball sockets onto ball heads; if necessary, lightly grease with Optimol MP3 beforehand.
Microsoft
Fig. 73: View of vacuum units

9. Screw in fastening screws -arrows- . See Fig. 73.
10. Fasten cycle valve with tapping screw -arrow- . See Fig. 74.
Microsoft
Fig. 74: View of tank ventilation solenoid valve

11. Push on hose -2- and position clamp -1- . See Fig. 58.
12. Replace O-rings on fuel injectors and apply a light coat of silicone spray to ease fitting.
Microsoft
Fig. 75: Screw for fuel ring pipe

13. Fit fuel ring pipe by pressing the fuel injectors into the seats in the intake-air distributor and tightening the
four Torx screws (M6 x 12) -arrow- . --> Tightening torque: 7.5 ftlb. . See Fig. 75.
24 69 20 REMOVING AND INSTALLING OXYGEN SENSOR IN FRONT OF

CATALYTIC CONVERTER - AS OF MY 2005 (ALL MODELS)
TOOLS

accessory for torque commercially NR.96-3
wrench: Open ring wrench available tool
(angled)
PRELIMINARY WORK FOR REMOVING OXYGEN SENSOR IN FRONT OF CATALYTIC

CONVERTER
Microsoft
Preliminary work for removing oxygen sensor in front of catalytic converter
1. Remove respective rear wheel. Use the prescribed special tool Socket wrench insert P 300 (Tools) to avoid
damaging the rims. Refer to 44 05 19 Removing and installing wheel - as of MY 2005 (All Models) .
REMOVING OXYGEN SENSOR IN FRONT OF CATALYTIC CONVERTER
Removing oxygen sensor in front of catalytic converter
 Danger of burns
CAUTION: The oxygen sensor may be damaged if handled incorrectly.
--> Do not remove the plastic cap on the thread until just prior to fitting the oxygen sensor. The thread grease
must never come into contact with the connector.
--> Protect sensors - before and after fitting - against mechanical shocks.
--> Sensors that were dropped on the floor must not be used owing to the risk of a broken ceramic insulator.
--> The cables must not be twisted or kinked when the sensors are screwed in. Avoid pulling on the cable and
connector.
--> Cleanliness in the housing of the plug connections is of utmost importance for the oxygen sensor to function
properly. Particles of dirt can impair the function of the oxygen sensor. The connector must therefore be
protected against any and all types of soiling.
Microsoft
--> Sensors with a soiled or damaged connector must no longer be used.
--> Protect the cables and plugs when carrying or moving the exhaust system with the sensors already fitted.
--> High-pressure cleaning equipment must not be used in the area of the sensors and plug connections.
--> Contact and corrosion agents, e. g. Stabilant, must not be applied to the plug contacts of the oxygen sensors.

1. Unclip cable plug -1- and connecting cable -2- from the support. Release and disconnect cable plug -1- . See
Fig. 76.
2. Expose connecting cable (blue) up to oxygen sensor.
Microsoft
Fig. 77: Oxygen sensor in front of catalytic converter

3. Loosen the oxygen sensor -arrow- using an open-ended wrench (a/f 22). The connecting cable must also pull
out when the oxygen sensor is removed. See Fig. 77.
INSTALLING OXYGEN SENSOR IN FRONT OF CATALYTIC CONVERTER
Installing oxygen sensor in front of catalytic converter
Microsoft
Fig. 78: Sealing washer for oxygen sensor

1. Replace sealing ring -arrow- . See Fig. 78.
2. Position oxygen sensor by hand and screw it in using Accessory for torque wrench: Open ring wrench
(angled) NR.96-3 (Tools). The connecting cable must also push in when the oxygen sensor is pushed into
position.

value 1 2
Oxygen sensor in front of catalytic Tightening
41 ftlb.
converter torque
3. Clip connecting cable (blue) into the brackets. Ensure that wire is guided in correctly.
Microsoft

4. Insert and lock cable plug -1- . Clip cable plug -1- and connecting cable -2- into the support. See Fig. 79.
SUBSEQUENT WORK FOR INSTALLING OXYGEN SENSOR IN FRONT OF CATALYTIC

CONVERTER
Subsequent work for installing oxygen sensor in front of catalytic converter
2. Fit the rear wheel that was removed. Use the prescribed special tool Socket wrench insert P 300 (Tools) to
avoid damaging the rims. Refer to 44 05 19 Removing and installing wheel - as of MY 2005 (All Models) .
24 69 AW PRECAUTIONARY MEASURES WHEN HANDLING OXYGEN

SENSORS - AS OF MY 2005 (ALL MODELS)
PRECAUTIONARY MEASURES WHEN HANDLING OXYGEN SENSORS
CAUTION: Improper handling of oxygen sensors.

Microsoft
 Material damage
connector.
24 70 19 REMOVING AND INSTALLING DME CONTROL MODULE - AS OF

TOOLS

PRELIMINARY WORK
Preliminary work on DME control unit 987
If a new DME control unit is installed, then read out the vehicle data from the DME control unit and transfer
them to the new one.
continue.
Microsoft
4. Select DME with the cursor keys and press the >> key.
5. Select Program control unit with the cursor keys and press the >> key.
6. Select Read out vehicle data (Vehicle data) using the cursor keys and press >>.
7. The message Reading vehicle data will appear on the tester screen.
8. After replacement of the DME control unit, the vehicle data is uploaded from the Program control unit
menu option.
General warning notes for control units
REMOVING DME CONTROL MODULE
Removing DME control module

destroyed.
Microsoft

Fig. 81: Loosening the carpet lining

1. Open rear luggage compartment lid and lever out the clips for the carpet lining using the removal tool.
Microsoft

2. Fold over the carpet lining and unscrew the three fastening nuts for the DME control unit.
Microsoft
Fig. 83: Releasing and removing connector

3. Remove the control unit, release the connectors -A, B- and pull them off. See Fig. 83.
4. Take out the control module.
INSTALLING DME CONTROL MODULE
Installing DME control module
Microsoft
Fig. 84: Connecting plug on control module

1. Push in plug for DME control module and secure with the latching lever.
2. Press in connectors on the control module until they click into place.
Microsoft
Fig. 85: Securing control module

3. Position control module and secure with the fastening nuts. --> M6: 7.5 ftlb.
SUBSEQUENT WORK
Subsequent work on DME control unit
1. Place carpet lining in position, paying attention to the fitted shape.
2. The DME control unit can be programmed using the PIWIS Tester P 9718.
PROGRAMMING DME CONTROL MODULE
Programming new DME control module
Microsoft
NOTE: If a new DME control module is to be installed in a vehicle, the DME code
specified in IPAS and the immobilizer code must be entered in the DME control
module.
The codes are available from IPAS or via the importer.
Follow the instructions on the Tester.
 During programming, the electric radiator fans may start.
NOTE: Depending on the software version of the PIWIS Tester, a new DME control
module can be interrogated for the "old DME programming code". In this case,
enter the code from IPAS which is also used for the "new DME programming
code".
In some countries (currently USA, Canada) the Ready status must be obtained following a test drive or by using
the Porsche System Tester after the DME control module has been programmed. If in doubt about this, contact
the relevant importer.
continue.
2. Select vehicle type. Press >> to continue.
Read out vehicle data. --> 247019 Removing and installing DME control module - "Preliminary work"
section
8. Select Program control module with the cursor keys and press the >> key. Observe the information
displayed by the Tester.
9. Enter Vehicle Ident. No. , >> confirm with F7.

Microsoft
10. Enter the DME programming code (IPAS), >> confirm with F7.
11. Enter the new immobilizer code (IPAS), >> confirm with F7.
12. Specify vehicle type >>.
13. Specify transmission type >>.
14. Specify exhaust standard >>.
15. Start Programming with F8. The data and programming status is then loaded on to the DME control
module. Do not interrupt the programming sequence. Observe Tester instructions.
16. For the learning and adaptation routine of the throttle valve (electronic throttle), switch the ignition off,
remove ignition key, insert ignition key and switch on ignition for at least 40 seconds without starting the
engine. Do not actuate accelerator pedal. This completes the adaptation of the throttle adjusting unit and the
programming sequence is complete.
17. In the DME menu go to Coding , code Cruise control present, not present.
18. Go to Vehicle data and, if necessary, enter the vehicle-specific data.
19. Read out the fault memories of all control units and delete the DME control module fault on every control
unit connected to the CAN.
20. Start engine.
Programming DME control module
module.
Microsoft
If a DME control module from a different vehicle with ME 7.8 is being used, proceed as follows. As a check,
the immobilizer code of the vehicle in which the control module is being installed (NEW) and of the vehicle
from which the control module has been removed (OLD) is required.
continue.
3. Read out vehicle data. --> 247019 Removing and installing DME control module - "Preliminary work"
section
7. Select Program control modules with the cursor keys and press the >> key. Observe the information
9. Enter the old DME programming code (IPAS) , >> confirm with F7.
10. Enter the new DME programming code (IPAS) , >> confirm with F7.
11. Enter the old immobilizer code (IPAS) , >> confirm with F7.
12. Enter the new immobilizer code (IPAS) , >> confirm with F7.
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21. Start engine.
Exhaust-gas standard
ME 7.8
Type Exhaust-gas standard Explanation
LEV, manual transmission Low Emission Vehicle, USA As of model
OBD 2
LEV, Tiptronic year `03.
EU2, manual transmission
RoW Rest of world As of model year `03.
EU2, Tiptronic
EU4, manual transmission European On-Board Diagnosis. As of model
EOBD
EU4, Tiptronic year `05.
Corea For Corea, as of model year '05.
EU4, Tiptronic
Japan For Japan, as of model year '05.
EU4, Tiptronic
24 70 19 REMOVING AND INSTALLING DME CONTROL MODULE - AS OF

TOOLS

Microsoft
PRELIMINARY WORK
Preliminary work on DME control unit 987
If a new DME control unit is installed, then read out the vehicle data from the DME control unit and transfer
them to the new one.
continue.
6. Select Read out vehicle data (Vehicle data) using the cursor keys and press >>.
7. The message Reading vehicle data will appear on the tester screen.
8. After replacement of the DME control unit, the vehicle data is uploaded from the Program control unit
menu option.
REMOVING DME CONTROL MODULE
Microsoft
Removing DME control module

destroyed.

Microsoft
Fig. 87: Loosening the carpet lining

1. Open rear luggage-compartment lid, undo the carpet lining and place to one side.
Microsoft

2. Unscrew the three fastening nuts for the DME control module.
Microsoft

3. Remove the control module, release the connectors -A, B- and pull them off. See Fig. 89.
INSTALLING DME CONTROL MODULE
Installing DME control module
Microsoft
Fig. 90: Connecting plug on control module

1. Push in plug for DME control module and secure with the latching lever.
2. Press in connectors on the control module until they click into place.
Microsoft
Fig. 91: Securing control module

3. Position control module and secure with the fastening nuts. --> M6: 7.5 ftlb.
SUBSEQUENT WORK
Subsequent work on DME control unit
1. Place carpet lining in position, paying attention to the fitted shape.
2. The DME control unit can be programmed using the PIWIS Tester P 9718.
PROGRAMMING DME CONTROL MODULE
Programming new DME control module
Microsoft
module.
NOTE: Depending on the software version of the PIWIS Tester, a new DME control
module can be interrogated for the "old DME programming code". In this case,
enter the code from IPAS which is also used for the "new DME programming
code".
continue.
Read out vehicle data. --> 247019 Removing and installing DME control module - "Preliminary work"
section
8. Select Program control module with the cursor keys and press the >> key. Observe the information

Microsoft
10. Enter the DME programming code (IPAS), >> confirm with F7.
11. Enter the new immobilizer code (IPAS), >> confirm with F7.
20. Start engine.
module.
Microsoft
continue.
section
9. Enter the old DME programming code (IPAS) , press >> and confirm with F7.
12. Enter the new immobilizer code (IPAS) , press >> and confirm with F7.
Microsoft
21. Start engine.
22. Carry out a test drive and read out the fault memory again.
Exhaust-gas standard
ME 7.8
Type Exhaust-gas standard Explanation
LEV, manual transmission Low Emission Vehicle, USA As of model
OBD 2
LEV, Tiptronic year `06.
RoW Rest of world As of model year `06.
EU2, Tiptronic
EU4, manual transmission European On-Board Diagnosis. As of model
EOBD
EU4, Tiptronic year `06.
Korea For Korea, as of model year '06.
EU4, Tiptronic
Japan For Japan, as of model year '06.
EU4, Tiptronic
Microsoft
module.
continue.
section
9. Enter the old DME programming code (IPAS) , >> confirm with F7.
Microsoft
12. Enter the new immobilizer code (IPAS) , >> confirm with F7.
21. Start engine.
24 73 20 REMOVING AND INSTALLING OXYGEN SENSOR BEHIND

CATALYTIC CONVERTER - AS OF MY 2005 (ALL MODELS)
TOOLS

accessory for torque commercially NR.96-3
wrench: Open ring wrench available tool
(angled)
Microsoft
PRELIMINARY WORK FOR REMOVING OXYGEN SENSOR BEHIND THE CATALYTIC

CONVERTER
Preliminary work for removing oxygen sensor behind the catalytic converter
1. Remove respective rear wheel. Use the prescribed special tool Socket wrench insert P 300 (Tools) to avoid
damaging the rims. Refer to 44 05 19 Removing and installing wheel - as of MY 2005 (All Models) .
REMOVING OXYGEN SENSOR BEHIND THE CATALYTIC CONVERTER
Removing oxygen sensor behind the catalytic converter
 Danger of burns
CAUTION: The oxygen sensor may be damaged if handled incorrectly.
Microsoft
connector.

1. Unclip cable plug -1- and connecting cable -2- (black) from the support. Release and disconnect cable plug -
1- . See Fig. 92.
2. Expose connecting cable (black) up to oxygen sensor.
Microsoft
Fig. 93: Oxygen sensor behind catalytic converter

3. Loosen the oxygen sensor -arrow- using an open-ended wrench (a/f 22). The connecting cable must also pull
out when the oxygen sensor is removed. See Fig. 93.
INSTALLING OXYGEN SENSOR BEHIND THE CATALYTIC CONVERTER
Installing oxygen sensor behind the catalytic converter
Microsoft
Fig. 94: Sealing washer for oxygen sensor

1. Replace sealing ring -arrow- . See Fig. 94.
2. Position oxygen sensor by hand and screw it in using Accessory for torque wrench: Open ring wrench
(angled) NR.96-3 (Tools). The connecting cable must also pull out when the oxygen sensor is removed.
3. Clip connecting cable (black) into the brackets. Ensure that wire is guided in correctly.

value 1 2
Oxygen sensor behind catalytic Tightening
41 ftlb.
converter torque
Microsoft

4. Insert cable plug -1- . Clip cable plug -1- and connecting cable -2- into the support. See Fig. 95.
SUBSEQUENT WORK FOR INSTALLING OXYGEN SENSOR BEHIND THE CATALYTIC

CONVERTER
Subsequent work for installing oxygen sensor behind the catalytic converter
2. Fit the rear wheel that was removed. Use the prescribed special tool Socket wrench insert P 300 (Tools) to
avoid damaging the rims. Refer to 44 05 19 Removing and installing wheel - as of MY 2005 (All Models) .
Microsoft
ENGINE Fuel, actuation
ENGINE
Fuel, actuation
20 01 AW BASIC SAFETY INSTRUCTIONS FOR WORKING WITH THE FUEL

INFORMATION
Safety instructions when working on fuel system
WARNING: Lethal danger of explosion and fire from escaping fuel and vapors.
--> Ensure adequate ventilation and extract all fuel vapors.
--> Do not work on fuel system when engine is hot.
--> No welding or grinding work when the fuel system is open.
--> Smoking prohibited and no naked lights.
--> Secure vehicle clearly, e. g with warning signs.
--> Wear a breathing mask with active charcoal filter; do not breathe in any fuel vapors.
--> Pay attention to cleanliness when working on the fuel system.
--> Before opening fuel lines or fuel hoses, relieve the fuel pressure.
--> Collect escaping fuel, absorb it if necessary with a suitable binding material and dispose of properly.
WARNING: Skin and eye damage from toxic and caustic effects of fuel.
--> In case of contact with skin or eyes wash immediately with plenty of warm water and acid-free soap.
--> Consult a doctor as soon as possible.
20 01 TW TECHNICAL DATA, FUEL SYSTEM - AS OF MY 2005 (ALL

MODELS)
Microsoft
TECHNICAL VALUES
Fuel supply

Digitale Motor-Elektronik ME 7.8-40 (DME engine control module,
Injection
ECM); injection valves controlled sequentially
Fuel delivery One two-stage flow pump
Fuel system Returnless fuel
Fuel quality/type ROZ 98, unleaded
Tank contents 64 / 65 liters
Reserve tank capacity 10 liters
20 02 01 CHECKING FUEL PRESSURE - AS OF MY 2005 (BOXSTER,

TOOLS

pressure gauge special tool P 378a
Connecting cable special tool P 9559

PRELIMINARY WORK
Preliminary work
1. Install protective supports.
Microsoft

Microsoft
Fig. 2: Engine compartment cover

3. Remove engine compartment cover. Refer to 55 78 19 Removing and installing engine compartment lid -
4. Relieve fuel pressure in fuel system --> 206601 Checking the fuel pump delivery rate.
CHECKING FUEL PRESSURE
Checking fuel pressure
NOTE:  The battery voltage must not fall below 12 volts during the fuel pressure
check.
1. Check the battery charge state using a voltmeter or the Porsche PIWIS Tester. The battery voltage must not
fall below 12 volts during the check.
Microsoft
Fig. 3: Example of warning sign on 911

WARNING: Risk of fire from escaping fuel.
 Danger of fatal injury and damage to property.
--> Observe basic safety instructions when working on the fuel system, --> 2001AW Basic safety instructions
when working on the fuel system.
--> Secure working area.
2. Attach or mount a warning sign in a clearly visible position on the vehicle.
Microsoft
Fig. 4: Fuel collection pipe metal cap

NOTE:  Use the brass cap on the test connection of the fuel supply line only once
as the sealing ring cannot be replaced. To avoid possible leaks, the cap
must be replaced after removal.
3. Release metal cap on test connection at fuel collection pipe -Arrow- and screw it off by hand (a/f 13 mm).
See Fig. 4.
Microsoft
Fig. 5: Pressure gauge for fuel pressure check

4. Connecting cable P 9559 must be connected using the pressure gauge P 378a (union nut a/f 17).
 A - Connection line (9559)

 B - Pressure gauge (378a)
Microsoft
Fig. 6: Pressure gauge to fuel collection pipe (view of Boxster)

5. Tighten the knurled union nuts of the connecting cable by hand on the test connection of the fuel collection
pipe -Arrow- . Collect emerging fuel with a cloth. See Fig. 6.
Procedure when the engine is standing still:
6. Connect the Porsche PIWIS Tester PIWIS Tester P 9718 to the input socket in the vehicle using the adapter
lead and switch on the ignition. Switch on the Tester and select the vehicle (option: Diagnostics).
Microsoft
Fig. 7: Piwis Tester: Control unit search

7. Run the individual control unit search for DME using the Porsche PIWIS Tester. To do this, select DME with
the tracer pen and press F12 >>.
Microsoft
Fig. 8: Activating drive link for fuel pump relay

8. Once the individual control unit search for DME is complete, select the Drive links item, then select the fuel
pump relay and activate it by pressing F8 - Start.
9. Read value on pressure gauge. --> Fuel pressure - engine not running: 3.8 bar +/-0.2 bar
Microsoft
Fig. 9: Deactivating drive link for fuel pump relay

10. Deactivate the fuel pump relay on the PIWIS Tester by pressing F8 - Stop. Then, press F11 << to return to
the start screen and switch off the Tester.
11. Switch off the ignition and remove PIWIS Tester adapter lead in the vehicle.
12. Checking the engine at idle speed: connect the pressure gauge P 378a as described above and start the
engine. Switch off the engine after reading the fuel pressure. --> Fuel pressure - idle speed: 3.8 bar +/-0.2 bar
13. Loosen the union nut on the connecting cable P 9559 for the pressure gauge P 378a on the test connection
and remove special tool. Collect escaping fuel with a cloth.
Microsoft
14. Position new closure cap on test connection and tighten (a/f 13 mm). --> Tightening torque: 2.5 (2 ftlb.)
Nm +/-0.5 (0.5 ftlb.) Nm
SUBSEQUENT WORK
Subsequent work
1. Mount engine compartment cover. Refer to 55 78 19 Removing and installing engine compartment lid - as
20 02 01 CHECKING FUEL PRESSURE - AS OF MY 2005 (CAYMAN S,

CAYMAN S RHD)
TOOLS

pressure gauge special tool P 378a
Connecting cable special tool P 9559

PRELIMINARY WORK
Preliminary work
1. Fit protective covers to vehicle and in luggage compartment.
Microsoft

2. Remove engine cover. Refer to 55 78 19 Removing and installing engine compartment lid - as of MY
CHECKING FUEL PRESSURE
Checking fuel pressure
NOTE:  The battery voltage must not fall below 12 volts during the fuel pressure
check.
Microsoft
Fig. 11: Example of warning sign on 911

Microsoft
Fig. 12: Fuel collection pipe metal cap

3. Release metal cap on test connection at fuel collection pipe -Arrow- and screw it off by hand (a/f 13 mm).
See Fig. 12.
Microsoft
Fig. 13: Pressure gauge for fuel pressure check

4. Connecting cable P 9559 must be connected using the pressure gauge P 378a (union nut a/f 17).
 A - Connection line (9559)

 B - Pressure gauge (378a)
Microsoft
Fig. 14: Pressure gauge to fuel collection pipe (view of Boxster)

5. Tighten the knurled union nuts of the connecting cable by hand on the test connection of the fuel collection
pipe -Arrow- . Collect emerging fuel with a cloth. See Fig. 14.
Procedure when the engine is standing still:
lead and switch on the ignition. Switch on the Tester and select the vehicle (option: Diagnostics).
Microsoft
Fig. 15: Piwis Tester: Control unit search

Microsoft
Fig. 16: Activating drive link for fuel pump relay

8. Once the individual control unit search for DME is complete, select the Drive links item, then select the fuel
pump relay and activate it by pressing F8 - Start.
9. Read value on pressure gauge. --> Fuel pressure - engine not running: 3.8 bar +/-0.2 bar
Microsoft
Fig. 17: Deactivating drive link for fuel pump relay

10. Deactivate the fuel pump relay on the PIWIS Tester by pressing F8 - Stop. Then, press F11 << to return to
the start screen and switch off the Tester.
11. Switch off the ignition and remove PIWIS Tester adapter lead in the vehicle.
12. Checking the engine at idle speed: connect the pressure gauge P 378a as described above and start the
engine. Switch off the engine after reading the fuel pressure. --> Fuel pressure - idle speed: 3.8 bar +/-0.2 bar
13. Loosen the union nut on the connecting cable P 9559 for the pressure gauge P 378a on the test connection
and remove special tool. Collect escaping fuel with a cloth.
Microsoft
14. Position new closure cap on test connection and tighten (a/f 13 mm). --> Tightening torque: 2.5 (2 ftlb.)
Nm +/-0.5 (0.5 ftlb.) Nm
SUBSEQUENT WORK
Subsequent work
1. Mount engine compartment cover. Refer to 55 78 19 Removing and installing engine compartment lid - as
SUBSEQUENT WORK
Subsequent work
Fig. 18: Installing engine compartment lid

1. Install engine cover. Refer to 55 78 19 Removing and installing engine compartment lid - as of MY 2005
Microsoft
20 15 IN CALIBRATING FUEL-LEVEL SENSOR SYSTEM - AS OF MY 2005

(ALL MODELS)
CALIBRATING FUEL-LEVEL SENSOR SYSTEM
WARNING: Danger of fire and injury!
 Danger of fire and injury!
--> Observe general safety regulations on the fuel system!
--> Wear protective gloves!
WARNING: Lethal danger of explosion and fire from escaping fuel and vapors.
--> Ensure adequate ventilation and extract all fuel vapors.
--> Do not work on fuel system when engine is hot.
--> No welding or grinding work when the fuel system is open.
--> Smoking prohibited and no naked lights.
--> Secure vehicle clearly, e. g with warning signs.
--> Wear a breathing mask with active charcoal filter; do not breathe in any fuel vapors.
--> Pay attention to cleanliness when working on the fuel system.
--> Before opening fuel lines or fuel hoses, relieve the fuel pressure.
--> Collect escaping fuel, absorb it if necessary with a suitable binding material and dispose of properly.
WARNING: Skin and eye damage from toxic and caustic effects of fuel.
--> In case of contact with skin or eyes wash immediately with plenty of warm water and acid-free soap.
--> Consult a doctor as soon as possible.

Microsoft
NOTE:  Tank calibration is necessary after replacement of the fuel tank, fuel-level
sensor or instrument cluster. Calibrate the fuel-level sensor system - after
replacing the instrument cluster - only if the function
 The fuel-level sensor system need not be calibrated if the battery was
disconnected or a plug connection on the instrument cluster or fuel-level
sensor was removed. The values remain stored in the instrument cluster.
 A range on remaining fuel of less than 15 km is not displayed in the
instrument cluster.
Read out values cannot be performed!
Empty the fuel tank, e. g. see Checking quantity delivered by fuel system. --> 206601 Checking fuel delivery
rate
1. Fill the fuel tank with 13 liters of fuel, metered by volume.
2. Wait for a short time to allow the tank sensor to settle down to the level.
Continue.
4. Select vehicle type, then go to the list of control units.
5. Select Instrument cluster control unit, then press >>.
6. Select the Special functions menu, then press >>.
7. Select the Tank check menu, then press >>.
8. Carry out the tank calibration; the tester gives a reading in liters, which is then synchronized to 13 liters .
9. Check position of tank needle in instrument cluster. Tank needle in lower third.
10. Fill vehicle with fuel and check position of tank needle in instrument cluster. Wait for a few minutes. Tank
needle shows full.
20 25 19 REMOVING AND INSTALLING CARBON CANISTER - AS OF MY

TOOLS

socket-wrench insert special tool P 300
PRELIMINARY WORK FOR CARBON CANISTER

Microsoft
Preliminary work for carbon canister
1. Disconnect ground connection from battery. Refer to 27 06 IN External power connection, jump lead
starting - as of MY 2005 (All Models) .
Fig. 19: Luggage-compartment cover

2. USA version: Remove luggage-compartment lining -2- by unscrewing the eight sheetmetal screws -1- (Refer
to 70 30 19 Removing and installing front luggage compartment cover - as of MY 2005 (All Models) ). See
Fig. 19.
Microsoft
Fig. 20: CD changer support for USA

3. Unscrew fastening screws for CD changer support -1- . The support is also fixed on the body side by two
retaining clips -Arrows- . See Fig. 20.
Microsoft
Fig. 21: CD changer support at plenum panel

4. Lift up support together with CD changer and disengage retaining clips at the plenum panel -Arrows- . See
Fig. 21.
5. Disconnect cable plug to CD changer.
6. RoW Version: Remove right front wheel using socket-wrench insert P 300. Refer to 44 05 19 Removing
and installing wheel - as of MY 2005 (All Models) .
REMOVING CARBON CANISTER
Removing carbon canister - RoW Version
Microsoft
Fig. 22: Carbon canister for RoW

1. Unscrew collar nut M6 -1- . Carefully pull carbon canister out of body mounting points in direction of travel.
See Fig. 22.
2. Release and remove plug-in couplings on the underside of the canister -2- . Unclip lines from the mountings
on the canister -3- . See Fig. 22.
Removing carbon canister - USA Version
Microsoft
Fig. 23: Carbon canister for USA

1. Unclip cable plug from canister -1- and then disconnect. See Fig. 23.
2. Unscrew two Torx screws M6 -2- from plastic holder for the carbon canister and press holder -3- from guide
in direction of travel. See Fig. 23.
Microsoft
Fig. 24: Small plug-in coupling

3. Lift carbon canister, release the small plug-in coupling -2- and pull it down and off. See Fig. 24.
Fig. 25: Large plug-in coupling

Microsoft
4. Lift carbon canister, release the large plug-in coupling -1- and pull it down and off. See Fig. 25.
INSTALLING CARBON CANISTER
Installing carbon canister - RoW Version
Fig. 26: Body mounting point for RoW canister

1. Wet rubber sleeves with water. Press canister into the body bores -1- . See Fig. 26.
Microsoft
Fig. 27: Carbon canister for RoW

2. Connect plug-in couplings to the underside of the canister and clip in the lines. Screw in collar nut M6 on the
holder and tighten. --> Tightening torque: 7.5 ftlb.
Installing carbon canister - USA Version
Microsoft
Fig. 28: View of plug-in couplings

Plug-in couplings in the vehicle
1. Insert canister and connect the plug-in couplings which must engage audibly.
Microsoft
Fig. 29: Carbon canister for USA

2. Slide plastic holder for the canister -3- into the guide and fix to the plenum panel. Screw in two Torx screws
M6 -2- and tighten. --> Tightening torque: 7.5 ftlb. See Fig. 29.
3. Connect cable plug and clip into the cable guide on the canister -1- . See Fig. 29.
SUBSEQUENT WORK FOR CARBON CANISTER
Subsequent work for carbon canister
1. USA version: Disconnect cable plug from CD changer.
Microsoft
Fig. 30: CD changer support at plenum panel

2. Engage support together with CD changer on the plenum panel by means of the retaining clips -Arrows- .
See Fig. 30.
Microsoft
Fig. 31: CD changer support for USA

3. Screw in and tighten fastening screws M6 -1- for CD changer support. --> Tightening torque: 10 (7.5 ftlb.)
Nm See Fig. 31.
Microsoft
Fig. 32: Luggage-compartment cover

4. Install luggage-compartment lining -2- by screwing in the eight sheetmetal screws -1- (Refer to 70 30 19
Removing and installing front luggage compartment cover - as of MY 2005 (All Models) ). See Fig. 32.
5. RoW Version: Remove rear part of right front wheel housing liner. Refer to 50 56 19 Removing and
6. Fit right front wheel using socket-wrench insert P 300. Refer to 44 05 19 Removing and installing wheel -
7. Connect ground connection to battery. Refer to 27 06 IN External power connection, jump lead starting -
20 66 01 CHECKING QUANTITY DELIVERED BY FUEL PUMP - AS OF MY

2005 (ALL MODELS)
TOOLS

measurement adapter special tool P 9705
Microsoft
PRELIMINARY WORK FOR QUANTITY DELIVERED BY FUEL PUMP
Preliminary work for quantity delivered by fuel pump
NOTE:  The battery voltage must not fall below 12 volts during the fuel delivery
rate check.
2. Remove rear cover for underbody. Refer to 51 94 19 Removing and installing cover for rear underbody -
CHECKING QUANTITY DELIVERED BY FUEL PUMP
Checking quantity delivered by fuel pump
NOTE:  The battery voltage must not fall below 12 volts during the fuel delivery
rate check.
Microsoft
Fig. 33: Example of warning sign on Carrera

2. Reduce fuel pump supply pressure. To do this, remove the cover of the fuse carrier in the left footwell and
take out the fuse for the fuel pump - level D, fuse F1 (No. 1 from left) . Then start the engine for several
seconds. This procedure does not cause an entry to be made in the fault memory. Insert the fuse again and
replace the cover.
lead, switch on the ignition and switch off all loads, such as the radio and air conditioning. Switch on the Tester
and select the vehicle (option: Diagnostics).
Microsoft
Fig. 34: Piwis Tester control unit search

5. Select the Drive links item and then select the fuel pump relay.
Microsoft
Fig. 35: Measuring adapter 9705 (A)

6. Have a measurement adapter P 9705, a fuel-resistant container, a measuring cup and a stopwatch to hand
for measuring.
Microsoft
Fig. 36: Fuel line

7. Disconnect rapid-action coupling on the fuel supply line -1- by pressing in the locking lug and pulling off the
coupling. Clean up emerging residual fuel with a cloth, for example. See Fig. 36.
Microsoft
Fig. 37: Connection for measurement adapter 9705

8. Connect the measuring adapter P 9705 special tool to the rapid-action coupling on the fuel line. Make sure
that the plug-in coupling is fitted correctly (must engage audibly) by pulling the line apart.
Microsoft
Fig. 38: Container for fuel collection

9. Place the drainage hose after the pressure regulator into a petrol-resistant container. Make sure that the
container does not tip over.
Microsoft
Fig. 39: PIWIS Tester step 2

10. Activate the fuel pump relay on the Porsche PIWIS Tester. Press F8 - Start until fuel emerges at the
drainage hose. Deactivate the fuel pump relay by pressing F8 - Stop and pour any leaked fuel from the container
into a petrol-resistant container or into the fuel tank. Keep a stopwatch to hand for the following measurement.
Microsoft
Fig. 40: PIWIS Tester step 3

11. Then, activate the fuel pump relay again by pressing F8 - Start and keep it going for 60 seconds. Start the
stopwatch at the same time. Collect emerging fuel in an available container. Deactivate the fuel pump relay after
60 seconds by pressing F8 - Stop.
12. Pour the collected fuel into the measuring cup and compare the quantity with the vehicle-specific nominal
values listed below. --> Volume: 2.0 l/min ; --> Volume: 2.3 l/min
13. Remove measurement adapter P 9705 and attach rapid-action coupling to fuel supply line. Collect
escaping fuel. Make sure that the plug-in coupling is fitted correctly (must engage audibly) by pulling the line
apart.
14. Switch off ignition, switch off the Porsche PIWIS Tester and disconnect adapter lead to the vehicle.
SUBSEQUENT WORK FOR QUANTITY DELIVERED BY FUEL PUMP
Subsequent work for quantity delivered by fuel pump
1. Install rear cover for underbody. Refer to 51 94 19 Removing and installing cover for rear underbody - as
Microsoft
ENGINE Ignition System
ENGINE
Ignition System
28 TW TECHNICAL DATA, IGNITION SYSTEM - AS OF MY 2005 (BOXSTER,

TECHNICAL VALUES
Ignition system
Designation 987 987 S

Spark plugs Bosch FRG 5KQEO
28 TW TECHNICAL DATA, IGNITION SYSTEM - AS OF MY 2005 (CAYMAN S,

CAYMAN S RHD)
TECHNICAL VALUES
Ignition system, engine control
Designation Cayman S
Engine control module Bosch ME 7.8 - 40
Spark plugs Bosch FRG 5KQEO
USA-LEV trim OBD II LEV II
Legal specifications for Europe EU4
Legal specifications for RoW (not including USA, Europe) EU2
28 04 19 REMOVING AND INSTALLING IGNITION SWITCH - AS OF MY 2005

(ALL MODELS)
TOOLS

wrench VW-tool T10152
Microsoft
REMOVING IGNITION SWITCH
Removing ignition switch
Microsoft
Fig. 2: Removing detachable cover

1. Carefully lift up rubber sleeve on the ignition switch using a plastic spatula, for example, and remove it.
Microsoft
Fig. 3: Unscrewing union nut from ignition switch

2. Turn union nut using a narrow plastic spatula, for example, or using the special wrench T10152 tool and
unscrew the ring from the ignition switch.
3. Press ignition switch inwards and remove towards the bottom.
Microsoft
Fig. 4: Releasing and pulling off electric plug

4. Release electric plug -a- and pull it off the ignition switch. See Fig. 4.
INSTALLING IGNITION SWITCH
Installing ignition switch
Microsoft

1. Connect plug on ignition switch until it clicks into place.
Microsoft
Fig. 6: Turning union nut on ignition switch

2. Position ignition switch in the instrument panel from below. Position union nut, re-adjust switch and tighten
union nut using wrench T10152. --> Tightening torque: 1.1 ftlb.
3. Place cover in position and slide it over the ignition switch, paying attention to the fitted shape.
INFORMATION
Emergency operation of the ignition key lock
NOTE:  In the event of insufficient or non-existent battery positive voltage, the

ignition key can be removed using the emergency operation.
1. Lever out the small cover, at the top right next to the ignition key, at the ignition switch using a screwdriver.
2. Then, push a pen, for example, into the opening next to the key, turn the ignition key to position 0 and pull it
out.
28 20 19 REMOVING AND INSTALLING IGNITION COILS - AS OF MY 2005

(ALL MODELS)
PRELIMINARY WORK
Microsoft
Preliminary work
1. Remove rear cover Refer to 51 94 19 Removing and installing cover for rear underbody - as of MY 2005
(All Models) .
REMOVAL
Removing ignition coils
1. Slide rubber sleeves of ignition coil plug connections upwards.
2. Release and pull off plugs on each ignition coil.
Fig. 7: Screws for ignition coils

3. Unscrew two M6 x 25 fastening screws -arrow- each per ignition coil and remove the six ignition coils
individually. See Fig. 7.
INSTALLATION
Installing ignition coils
Microsoft

1. Insert ignition coils into the spark-plug recesses and tighten using two M6 x 25 fastening screws each. -->
Tightening torque: 10 (7.5 ftlb.) Nm
2. Mount cable plug to the individual ignition coils. The connectors must engage audibly.
3. Slide rubber sleeves over the connectors.
SUBSEQUENT WORK
Subsequent work
1. Install rear cover Refer to 51 94 19 Removing and installing cover for rear underbody - as of MY 2005
(All Models) .
28 39 20 REMOVING AND INSTALLING HALL SENDER - AS OF MY 2005

PRELIMINARY WORK FOR REMOVING HALL SENDER
Preliminary work for removing hall sender
1. If the hall sender for cylinder bank 1 -3 is removed, the rear wall cover must be removed Refer to 55 59 19
Microsoft
Removing and installing rear wall cover - as of MY 2005 (All Models) .
REMOVING HALL SENDER
Removing hall sender
Fig. 9: View of hall sender for cyl.1-3

2. Remove hall sender -3- by unscrewing the Torx screw (M6 x 16) -2- . See Fig. 9.
Microsoft
Fig. 10: View of hall sender for cyl. 4-6

INSTALLING HALL SENDER
Installing hall sender
Microsoft
Fig. 11: O-ring for hall sender

1. Replace O-ring. Lightly grease O-ring -arrow- with Optimol MP3. See Fig. 11.
2. Fit hall sender -3- by screwing in and tightening the Torx screw (M6 x 16) -2- . --> Tightening torque: 7.5
ftlb. See Fig. 9.
Microsoft
Fig. 12: View of hall sender for cyl.1-3

Microsoft
Fig. 13: View of hall sender for cyl. 4-6

SUBSEQUENT WORK FOR INSTALLING HALL SENDER
Subsequent work for installing hall sender
1. If the hall sender for cylinder bank 1-3 has been removed, the rear wall cover must be installed Refer to 55 59
19 Removing and installing rear wall cover - as of MY 2005 (All Models) .
28 70 20 REMOVING AND FITTING SPARK PLUGS - AS OF MY 2005 (ALL

MODELS)
TOOLS

spark plug socket wrench special tool NR.14
3/8" extension, 16° special tool NR.15

moveable
PRELIMINARY WORK FOR REMOVING SPARK PLUGS
1. Remove rear cover Refer to 51 94 19 Removing and installing cover for rear underbody - as of MY 2005
(All Models) .
REMOVAL
Removing spark plugs
1. Slide rubber sleeves of ignition coil plug connections upwards.
2. Release and pull off plugs on each ignition coil.
Microsoft

3. Unscrew two M6 x 25 fastening screws -arrow- each per ignition coil and remove the six ignition coils
individually. See Fig. 14.
CAUTION: Incorrect tool for changing the spark plugs!
 Ceramic body breaks!
--> Only use the approved tool spark plug socket wrench NR.14 and 3/8" extension, 16° moveable NR.15.
4. Unscrew spark plugs using the tool spark plug socket wrench NR.14 with 3/8" extension, 16° movable
NR.15.
INSTALLATION
Installing spark plugs
CAUTION: Incorrect tool for changing the spark plugs!
 Ceramic body breaks!
--> Only use the approved tool spark plug socket wrench NR.14 and 3/8" extension, 16° moveable NR.15.
Microsoft
1. Install spark plugs using spark plug socket wrench NR.14 and 3/8" extension, 16° moveable NR.15. The
tightening torque is reduced if the spark plugs are removed and installed again for another activity. Do not get
spark plugs mixed up during reinstallation.

Spark plugs Using new spark plugs Tightening torque 22 ftlb.
Spark plugs Re-using old spark plugs Tightening torque 19 ftlb.

2. Insert ignition coils into the spark-plug recesses and tighten using two M6 x 25 fastening screws each. -->
Tightening torque: 7.5 ftlb.
3. Attach connector for each ignition coil (connector must engage audibly).
4. Slide on rubber sleeves for ignition coil plug connections.
Subsequent work for installing spark plugs
1. Install rear cover Refer to 51 94 19 Removing and installing cover for rear underbody - as of MY 2005
(All Models) .
28 72 20 REMOVING AND INSTALLING KNOCK SENSOR - AS OF MY 2005

Microsoft
PRELIMINARY WORK FOR REMOVING KNOCK SENSOR
Preliminary work for removing knock sensor
2. Remove intake-air distributor Refer to 24 46 20 Removing and installing intake-air distributor - as of MY

2005 (All Models) .
REMOVING KNOCK SENSOR
Removing knock sensor
2. Mark installation position of knock sensor so that cable plug can be reconnected after installation.
Fig. 16: View of knock sensor

3. Remove knock sensor -3- by unscrewing the Torx screw (M8 x 35) -2- . See Fig. 16.
INSTALLING KNOCK SENSOR
Installing knock sensor
Microsoft
1. Insert knock sensor -3- in the original position and then screw in and tighten the Torx screw (M8 x 35) -2- . --
> Tightening torque: 15 ftlb. . See Fig. 17.
Fig. 17: View of knock sensor

SUBSEQUENT WORK FOR INSTALLING KNOCK SENSOR
Subsequent work for installing knock sensor
1. Install intake-air distributor for the relevant cylinder bank Refer to 24 46 20 Removing and installing
intake-air distributor - as of MY 2005 (All Models) .
Microsoft
ENGINE Lubrication
ENGINE
Lubrication
17 01 TW TECHNICAL DATA, LUBRICATION SYSTEM - AS OF MY 2005

(ALL MODELS)
TECHNICAL VALUES
Engine lubrication

Type Integrated dry sump lubrication
Oil cooling via oil-water heat exchanger
Installation location of oil filter on pressure side behind oil pump
Oil pressure at 5000 rpm and 90 (C 5 bar
Oil pressure indicator light plus oil Oil pressure indicator
Oil pressure indicator
temperature lamp
ACEA A3-02 and special Porsche requirements (refer to Technical
Engine oil specification - Europe
Information notice about engine oils)
Engine oil specification - API SJ and SL and special Porsche requirements (refer to Technical
USA/RoW Information notice about engine oils)
Max. oil consumption at 1,000 km 1.0 liters
Quantity of oil for new engine 9.7 l 10.4 liters
Oil change quantity without oil
7.5 liters
filter
Oil change quantity with oil filter 7.75 liters
Engine oil level check without dipstick, display in instrument cluster
17 01 01 CHECKING ENGINE OIL LEVEL - AS OF MY 2005 (ALL MODELS)

CHECKING ENGINE OIL LEVEL
Checking engine oil level
WARNING: Incorrect oil level!
 Engine or catalytic converter damage
--> Check oil level regularly (if possible at every refuelling).
--> Oil level must not fall below the minimum mark or rise above the maximum mark.
--> Only use engine oils tested and approved by Porsche AG.
Microsoft
ENGINE Lubrication
NOTE:  The engine oil level can only be checked with the display in the instrument
cluster.
 Any malfunctions in the oil level indicator show up via a warning in the
instrument cluster.
 Use the Info function to display the requirements for oil level
measurement.
NOTE:  If the oil level drops below the minimum mark, the segment below starts
flashing!
 The difference between the minimum and maximum marks is approx. 1.2
liters, one segment of the display corresponding to approx. 0.4 liters of oil.
 Never fill or top up with engine oil above the maximum mark.
Requirements for correct oil level measurement (not during refuelling)
 Vehicle is parked horizontally.

 Engine is off.
 Ignition switched on.
Oil return time: Before measuring the oil level, the engine oil must have returned to the oil pan. The duration
depends on the temperature and the time the engine has been stationary.
Starting measurement:
Microsoft
ENGINE Lubrication
Fig. 1: Oil level measurement

NOTE:  The waiting time for the oil level measurement is indicated by a countdown
time display and cycling segments on the oil level indicator.
 Short waiting times when measuring the engine oil level are obtained after
the vehicle has been idle for a long period or if the engine is at operating
temperature.
1. Switch on the ignition (do not start the engine). Measurement starts automatically. The display for the oil
level measurement appears on the on-board computer.
Microsoft
ENGINE Lubrication
Fig. 2: Oil level indicator (maximum mark)

NOTE:  The oil level must be between the minimum and maximum marks.
 Adjust the engine oil level if necessary (pour engine oil in slowly) and
check the level again.
2. The oil level can be read off from the segment display after measurement is completed (at end of waiting
time). The permitted oil level lies between the minimum and maximum marks.
Microsoft
ENGINE Lubrication
Fig. 3: Minimum oil level

3. If the lowest segment of the oil level indicator is filled --> Minimum oil level , the minimum oil level has
been reached and the oil must be topped up immediately --> 17 01 55 Engine oil and oil filter change - as of
MY 2005 (All Models). See Fig. 3.
Oil level measurement in the "OIL" menu (requirements as above):
Microsoft
ENGINE Lubrication
Fig. 4: Operating lever for on-board computer (example 986)

4. Switch on selection field "D" . Push operating lever forwards.
Microsoft
ENGINE Lubrication
Fig. 5: Menu item" OIL"

5. Use the operating lever to select the menu item OIL and press the operating lever.
Microsoft
ENGINE Lubrication
Fig. 6: Starting the oil level measurement

NOTE:  The waiting time for the oil level measurement is indicated by a countdown
time display and cycling segments on the oil level indicator.
 Short waiting times when measuring the engine oil level are obtained after
the vehicle has been idle for a long period or if the engine is at operating
temperature.
6. Start measurement by pressing the operating lever.
Oil level measurement during refuelling:
7. The oil level is measured in the background when the vehicle is being refuelled. If the oil level is too low, the
message Check oil level appears on the on-board computer display.
Requirements
 Vehicle is parked horizontally.

 Engine is at operating temperature.
 Ignition switched off.
 There must be at least 5 minutes between switching off and starting the engine.
 Refuelling completed within the last 15 minutes .
8. If these requirements are not satisfied, the measurement is interrupted.
9. If the oil level measurement cannot be carried out for two refuellings, the message "Check oil level" appears
in the display of the instrument cluster.
17 01 55 ENGINE OIL AND OIL FILTER CHANGE - AS OF MY 2005 (ALL

MODELS)
TOOLS

oil filter spanner special tool P 9204
DRAINING ENGINE OIL
Draining engine oil
WARNING: Danger due to oil draining out and spraying when the engine is hot!
 Danger of scalding and injury

Microsoft
ENGINE Lubrication
--> Allow the engine to cool
--> Wear specified protective gear.
1. Apply protective covers to vehicle and in luggage compartment.
2. Open cap in the service tray in luggage compartment.
3. Jack up the vehicle at the take-up points provided --> 40 LIFTING THE VEHICLE - AS OF MY 2005
(ALL MODELS) .

NOTE:  To be able to fill the correct quantity of oil after draining the old oil, a time
of 20 minutes should be allowed for the oil to drip out.
 Dispose of waste oil in accordance with legal requirements in your
country.
4. Unscrew oil drain plug on the oil sump (a/f 8 hexagon) and allow the oil to drain into a collecting basin.
5. Clean the oil drain plug and screw it back in with a new aluminum sealing ring. --> Tightening torque: 37
ftlb.
CHANGING OIL FILTER

Microsoft
ENGINE Lubrication
Changing oil filter
1. Loosen oil filter using special tool oil filter spanner P 9204.
Fig. 8: Oil filter housing

2. Remove oil filter housing by pulling it straight downwards -arrow- . Drain remaining oil into an oil
collection container. Dispose of waste oil in accordance with legal requirements. See Fig. 8.
Microsoft
ENGINE Lubrication
Fig. 9: Oil filter cartridge

3. Remove the paper filter downwards and dispose of in accordance with legal requirements.
Microsoft
ENGINE Lubrication
Fig. 10: O-ring for oil filter housing

NOTE:  Never remove and install O-ring for oil filter with a sharp object!
 Do not scratch the sealing surface of the oil filter housing.
4. Carefully lever off the old O-ring on the housing groove with a small screwdriver in order not to damage the
thread.
Fig. 11: Oil filter components

5. Clean oil filter housing -1- thoroughly both inside and outside. Replace O-ring -3- with a new one and smear
Microsoft
ENGINE Lubrication
lightly with white Optimoly MP3 lubricant (available from the Porsche Parts Catalogue). See Fig. 11.
 1 - Oil filter housing

 2 - Oil filter cartridge
 3 - O-ring
6. Insert a new filter element.
7. Screw in the oil filter housing with the special release key P 9204 and tighten it. --> Tightening torque: 19
ftlb.
REFILLING ENGINE OIL
Filling in engine oil
CAUTION: Incorrect oil level
 Damage to engine and catalytic converter.
--> Specification of correct oil level must be adhered to under all circumstances.
NOTE: Use only engine oils tested and approved by Porsche AG.
Engine oil lid-filler neck loose.
 Warning light in instrument cluster (check engine).

 Spinning oil in engine or luggage compartment
--> Close the lid carefully.
1. Fill the engine oil slowly using a suitable filler container in order to avoid the oil overflowing at the filler
neck. Don't forget to screw the cap on again tightly.
Engine oil filling capacities:

value 1 2
Engine Top-up quantity for 987, 987 S with filter Filling 7.75
oil change capacity liters
Engine Top-up quantity for 987, 987 S engine oil Filling
7.5 liters
oil without filter change capacity
REWORKING
Subsequent work - topping up engine oil
Microsoft
ENGINE Lubrication
1. Check engine oil level display in instrument cluster and correct if necessary --> 170101 Checking engine oil
level.
17 09 19 REMOVING AND INSTALLING OIL-LEVEL SENDER - AS OF MY

PRELIMINARY WORK FOR REMOVING OIL-LEVEL SENDER
Preliminary work for removing oil-level sender
1. Remove intake-air distributor 1-3 Refer to 24 46 20 Removing and installing intake-air distributor - as of
REMOVING OIL-LEVEL SENDER
Removing oil-level sender
Fig. 12: View of oil-level sender

2. Unscrew two Torx screws (M6 x 20) -2- on the flange of the secondary air line -3- . See Fig. 12.
Microsoft
ENGINE Lubrication
3. Carefully press flange to one side and unscrew oil-level sender with an open-ended wrench (a/f 19).
INSTALLING OIL-LEVEL SENDER
Installing oil-level sender
1. Insert oil-level sender together with a new sealing ring and tighten. --> Tightening torque: 15 ftlb. .
2. Position flange of secondary air line -3- together with a new seal. See Fig. 13.
3. Insert and tighten two Torx screws (M6 x 20) -2- . --> Tightening torque: 7.5 ftlb. . See Fig. 13.
Fig. 13: View of oil-level sender

SUBSEQUENT WORK FOR INSTALLING OIL-LEVEL SENDER
Subsequent work for installing oil-level sender
Microsoft
HVAC Air conditioning
HVAC
Air conditioning
87 AW SAFETY REGULATIONS FOR WORKING ON AIR-CONDITIONED

VEHICLES AND DEALING WITH REFRIGERANT R134A - AS OF MY 2005
(ALL MODELS)
GENERAL SAFETY REGULATIONS FOR REFRIGERANTS
CAUTION: Extreme heating of air-conditioning system e. g. from sunlight shining into

the vehicle or as a result of welding and soldering work.
 Danger of fire due to excessive heating of air conditioning.

 Danger of environmental pollution due to emerging refrigerant.
--> When carrying out repairs on the air-conditioning system, the system must be emptied by suction and the
refrigerant must be purified. Chlorine-free refrigerants must also not be allowed to escape into the atmosphere
and must be disposed of correctly.
--> Due to their chemical composition, different refrigerants must not be mixed with each other! This also
applies for smaller quantities.
--> No welding, soldering or hot-air heating may take place on parts of the filled air-conditioning system or in
its immediate vicinity.
--> While drying after painting work, the temperature burden on the vehicle must not exceed two hours at a
maximum temperature of 80°C.
--> Whether or not the system is filled with refrigerant, the heating causes a very strong overpressure which can
cause damage to the system or even lead to an explosion.
--> R134a is completely non-toxic at normal temperatures, but it decomposes upon contact with a flame or at
high temperatures.
--> Refrigerant bottles must not be thrown and must not be subjected to direct sunlight or other heat sources for
an extended period when full.
--> The maximum permissible temperature of a filled refrigerant bottle must not exceed 45 °C.
--> Risk of injury! High temperatures from open flames or hot solids causes chemical breakdown of refrigerant
gas. Inhalation of the resulting breakdown products leads to coughing and nausea.
WARNING: Contact with liquid or gaseous refrigerant.
Microsoft
 The refrigerant attacks the skin and damages the skin's surface.
--> Wear rubber gloves to protect your hands.
--> Treat affected skin in the same way as in the case of freezing. Rinse immediately and then consult a
physician.
--> Wear safety goggles to protect your eyes.
--> If refrigerant still gets in your eyes, consult a physician immediately.
WARNING: The intensive effect of refrigerant on unprotected body parts can cause
freezing.
--> Keep an eye-rinse bottle with clear water at hand.
--> If liquid refrigerant gets into your eyes, rinse them thoroughly with water for about 15 minutes.
--> Then consult a doctor immediately.
--> The physician must be informed which refrigerant has caused the freezing.
NOTE:  The following safety measures should be followed for refrigerant R134a
(additional regulations may apply in certain countries).
If repair work necessitates opening the refrigerant circuit, the refrigerant circuit is first to be emptied. Avoid all
contact with liquid or gaseous refrigerants. If refrigerant should escape despite all safety measures having been
taken, the resulting refrigerant/air mixture should not be breathed in. Therefore, switch on extraction systems,
protect hands with rubber gloves and protect eyes with protective goggles.
If refrigerant gets onto any other body parts despite all safety measures having been taken, these should also be
rinsed immediately and thoroughly with water for at least 15 minutes.
Although refrigerant R134a is non-flammable, smoking, welding, soldering and hard-soldering is prohibited in
a room containing refrigerant.
EMPTYING THE REFRIGERANT CIRCUIT
NOTE: Refrigerant R134a contributes to the greenhouse effect as soon as it is released

into the Earth's atmosphere.
Refrigerant should not be released into the environment but is to be extracted

from the refrigerant circuit using an extraction or service station. The extracted
refrigerant is then prepared again on-site or returned to the manufacturer for
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environmentally-friendly disposal (varying or additional regulations may apply

in certain countries).
WORKING ON THE REFRIGERANT CIRCUIT
CAUTION: Emerging refrigerant in poorly ventilated rooms and erection pits.
 Danger of suffocation from odorless refrigerant.
--> The leaking refrigerant is not only colorless and odorless, but is also heavier than air and therefore displaces
oxygen. In poorly ventilated rooms and erection pits there is therefore an undetectable risk of suffocation.
--> The gas/air mixture formed when refrigerant escapes should not be breathed in but rather extracted via
suitable extraction systems (workshop extraction system).
--> There should be no erection pits, shafts or cellar stairs within a radius of 5 meters.
PAINTING WORK ON VEHICLES WITH AIR-CONDITIONING
WARNING: Painting work on vehicles with air-conditioning
 Material damage due to the air-conditioning system bursting.
--> When carrying out repairs involving painting work, object temperatures in the drying oven or its preheating
zone should not exceed 80 °C.
NOTES ON GENERAL REPAIRS
The refrigerant circuit of the air-conditioning is only to be emptied and opened if this is necessary due to safety
measures or if components of the refrigerant circuit have to be replaced.
The air-conditioning refrigerant circuit also remains closed during all other standard vehicle repair work.
Contact corrosion!
For this reason, the manufacturer only fits connecting elements with a special surface coating.
Contact corrosion can occur if unsuitable connecting elements (screws, nuts, washers, rivets, plugs, adhesives,
etc.) are used.
Only use original Porsche parts!
87 AW SAFETY REGULATIONS FOR EXTRACTION AND FILLING SYSTEMS

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SAFETY REGULATIONS FOR EXTRACTION AND FILLING SYSTEMS
WARNING: Improper handling of the filling system for the air conditioning.
 Unnecessary damage to the environment due to emerging

refrigerant.
--> Before connecting the filling system to the air-conditioning, make sure that the manual shut-off valves are
closed.
--> Before disconnecting the filling system from the air-conditioning, make sure that the process is complete so
that no refrigerant can escape into the atmosphere.
--> After the purified refrigerant has been filled into an external compressed gas bottle from the filling system,
the manual shut-off valves on the bottle and on the filling system should be closed.
--> Do not expose the filling system to moisture or use in a damp environment.
--> Shut off the power supply at the filling system before carrying out maintenance work.
--> An extension cable with cross-sectional area of at least 2.5 mm 2 should be used only when absolutely
necessary.
--> In the case of fire, the external bottle should be removed.
--> Fill the oil extracted from the air-conditioning system into a suitable closable container (the refrigerant oil
contains small quantities of refrigerant).
--> The filling system must be secured to prevent rolling.
87 02 IN TECHNICAL DATA, AIR-CONDITIONING SYSTEM - AS OF MY 2005

(ALL MODELS)
TECHNICAL DATA FOR AIR-CONDITIONING SYSTEM
Air conditioning Refrigerant quantity Filling capacity of refrigerant oil

Climatronic 900g R134a 195 +/- 15 cm3 ND 8
General pressures bar

High-pressure cut-off 32
Low-pressure cut-off at ambient temperature > 5 °C 1.4 (1.0)
High-pressure cut-off at ambient temperature < 5 °C 0,5
Pressure relief valve purge pressure 40
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Refrigerant distribution in circuit approx. cm3

Compressor 50
Condenser (2 x 20 cm 3 ) 40
Evaporator 30
Fluids with containers 30
Circulating oil quantity in the refrigerant circuit 60
TIGHTENING TORQUES FOR AIR-CONDITIONING SYSTEM
NOTE: When installing the refrigerant lines, the screw connections must always be wet
with refrigerant oil.
The extracted refrigerant oil must be disposed of as special-category waste.
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Fig. 1: Overview, shown on the 911

-A- - --> M5: 4.5 ftlb. . See Fig. 1.
-B- - --> M6: 6.5 ftlb. . See Fig. 1.
-C- - --> M8: 10.5 ftlb. . See Fig. 1.
-D- - --> M8: 10.5 ftlb. . See Fig. 1.
-E- - --> M6: 4.5 ftlb. . See Fig. 1.
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-F- - --> M8: 10.5 ftlb. . See Fig. 1.
-G- - --> M8: 17 ftlb. . See Fig. 1.
-H- - --> M10: 19 ftlb. . See Fig. 1.
-I- - --> M8: 17 ftlb. . See Fig. 1.
87 01 IN INSTRUCTIONS FOR REPAIRING AIR-CONDITIONING SYSTEMS

AND STORING SPARE PARTS - AS OF MY 2005 (ALL MODELS)
INSTRUCTIONS FOR REPAIRING AIR-CONDITIONING SYSTEMS AND STORING SPARE
PARTS
NOTE: Close all openings immediately upon starting work on the refrigerant circuit.
Store all spare parts in a dry and sealed-off area.
Blast air-conditioning components with nitrogen before refitting.
When fitting parts, do not remove plugs until shortly before installation. Do not
remove the protective foil from the dryer until shortly before installation. The
dryer absorbs moisture from the air and is then useless.
Do not carry out repairs in the open in damp weather.
Replace the dryer after each occasion of working on the refrigerant circuit.
Moisture in the refrigerant circuit not only leads to poor cooling.

Supersaturation can also cause the dryer to disintegrate and contaminate the
air-conditioning from inside. This may lead to expensive and complicated
repairs.
Replace the dryer every 3-4 years.
Evacuate the refrigerant circuit according to regulations.
Use a pressure reducer when working with nitrogen.
87 02 19 REMOVING AND INSTALLING AIR-CONDITIONING SYSTEM

REGULATOR - AS OF MY 2005 (ALL MODELS)
Microsoft
TOOLS

PRELIMINARY WORK
Preliminary work for removing and installing air-conditioning system regulator
1. Remove left and right cover for the center console. --> 68 14 19 REMOVING AND INSTALLING
CENTRE CONSOLE COVER - AS OF MY 2005 (ALL MODELS) .
2. Move gear-shift lever to rear position.
REMOVING AIR-CONDITIONING SYSTEM REGULATOR
Removing air-conditioning system regulator
Fig. 2: Installation position shown on the 911 Cockpit
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Fig. 3: Levering out air-conditioning system regulator

1. Insert a screwdriver behind the air-conditioning system regulator and press out.
2. Pull air-conditioning system regulator out of the installation slot.
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Fig. 4: Unlocking electric plugs

3. Release and pull off electric plugs -a- . See Fig. 4.
INSTALLING AIR-CONDITIONING SYSTEM REGULATOR
Installing air-conditioning system regulator
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Fig. 5: Inserting electric plugs

1. Insert electric plugs into the air-conditioning system regulator until they are felt to engage.
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Fig. 6: Sliding in air-conditioning system regulator

2. Slide the air-conditioning system regulator into the installation slot until it clicks into place.
SUBSEQUENT WORK
Subsequent work for the air-conditioning system regulator
1. Install left and right side cover for center console. --> 68 14 19 REMOVING AND INSTALLING
CENTRE CONSOLE COVER - AS OF MY 2005 (ALL MODELS) .
CODING AIR-CONDITIONING REGULATOR
Coding the air-conditioning control
NOTE: If the control unit for the air-conditioning control is replaced, it must be
programmed using the PIWIS Tester P 9718. This is to adapt the control unit to
the vehicle and equipment.
During coding, it is essential to guarantee the power supply for the PIWIS
Tester P 9718. It is essential to connect a battery charger with a current rating of
at least 40 A to the vehicle battery.
The PIWIS Tester P 9718 instructions take precedence and in the event of a
1. Connect the PIWIS Tester P 9718 to the vehicle and start the System Tester. Switch on ignition. >>
continue.
2. Select vehicle type using the cursor keys. >> continue.
3. Select air conditioner with the cursor keys and press the >> key.
7. Switch off ignition, replace air conditioning control.
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13. Select System test with the cursor keys and press the >> key.
14. The Tester starts the system test , follow the instructions on the Tester.
15. Quit menu, carry out a test drive, and check operation of the air conditioning control. Read out fault
memory.
87 03 17 DRAINING AND FILLING IN REFRIGERANT - AS OF MY 2005 (ALL

MODELS)
TOOLS

Air-conditioning recycling commercially
unit available tool
Warning notes for handling refrigerant
CAUTION: Danger of injury when working on air-conditioned vehicles!
--> Observe safety regulations for working on air-conditioned vehicles and dealing with refrigerant R134a. -->
87 AW Safety regulations for working on air-conditioned vehicles and dealing with refrigerant R134a - as
--> Observe safety regulations for working with extraction and filling systems. --> 87 AW Safety regulations
for extraction and filling systems - as of MY 2005 (All Models) .
--> Observe instructions for repairing air-conditioning systems and storing spare parts. --> 87 01 IN
Instructions for repairing air-conditioning systems and storing spare parts - as of MY 2005 (All Models).
TECHNICAL VALUES
Microsoft
Servicing equipment
Air-conditioning recycling unit, --> " Gr. 2.5; Handbuch Werkstatteinrichtung"
DRAINING AND FILLING IN REFRIGERANT
Assembly work involving the refrigerant system
NOTE: During all work on the air-conditioning system which necessitates opening the
refrigerant system, the system contents must first be disposed of correctly!
Dirt and moisture must be kept out of the air-conditioning system's pipe
system!
Thorough cleanliness must be ensured during all work!
System components must never be cleaned on the inside with hot steam!
Use only nitrogen for cleaning purposes!
When replacing a component, all openings must be closed off with suitable
plugs!
General assembly sequence
The charging valves are located in the radiator tank at the front right.
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Fig. 7: Protective caps on charging valves

1. Screw off the protective caps on the charging valves.
Pay attention to sealing rings when disconnecting or connecting the hose connections!
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Fig. 8: Service connection

Before connecting the high-pressure -2- and low-pressure lines -1- to the vehicle, remove any refrigerant
remaining in the lines by suction. See Fig. 8.
2. Connecting the high-pressure and low-pressure lines of the air-conditioning unit
NOTE: In the case of service units with transparent oil separator, read and take note of
the oil level before removing the refrigerant.
Do not carry out this step with empty air-conditioning systems (pressure gauge
approx. 0 bar), otherwise air will get into the refrigerant bottle.
In the case of cold vehicles, it may be necessary to repeat the suction

procedure until all refrigerant has been removed from the air-conditioning
system. This step is carried out automatically with some units.
2.1.
2.2. Let the engine run for a short while with the air-conditioning on, then connect the high-pressure and low-
pressure lines of the air-conditioning unit.
2.3. Open the valves of the high-pressure and low-pressure lines.

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3. Remove refrigerant by suction.
3.1. In the case of cold vehicles, it may be necessary to repeat the suction procedure until all refrigerant has
been removed from the air-conditioning system. This step is carried out automatically with some units.
3.2. Wait for approx. 2 minutes after the service unit has switched itself off. If the pressure gauge reading rises
above 0 bar, repeat the suction process.
3.3. The vehicle air-conditioning system is now completely empty. Necessary repairs, such as removing and
fitting the dryer, can now be carried out.
3.4. The open air-conditioning system should not be left open unnecessarily, but must be closed again as
quickly as possible after being opened.
3.5. Drain the extracted refrigerant oil into a measuring cup on the service unit and determine the volume.
4. Carrying out repairs
4.1. If the air-conditioning system has been open for a long time, a new dryer must be fitted. --> 875519
Removing and installing dryer
4.2. If necessary, reconnect high-pressure and low-pressure lines.
5. Evacuate the system and check it for leaks.
5.1. If the air-conditioning system has been opened, evacuation should last at least 20 minutes so that the
moisture can evaporate and be removed by suction.
5.2. If the air-conditioning system has been open for a long time, evacuation can be carried out for up to 120
minutes.
5.3. Observe the pressure gauge for approx. 2 minutes. If the pressure rises, air is entering the vehicle air-
conditioning system. The leak must be located and repaired. If the pressure remains constant, add refrigerant oil.
6. Adding refrigerant oil
6.1. For units without oil filling system:
6.2. Start the vacuum pump. At the start of this vacuum phase, add the measured quantity of refrigerant oil
using an oil injector or a hose disconnected from the service unit. Reconnect the hose to the service unit
immediately after adding the oil.
6.3. For units with oil filling system: Add the measured quantity of refrigerant oil and wait for it to be taken in.
6.4. Do not allow any air to be taken in, otherwise point 5 must be repeated.
7. Evacuate.
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7.1. If the air-conditioning system has been opened, evacuation should last at least 20 minutes so that the
moisture can evaporate and be removed by suction.
7.2. If the air-conditioning system has been open for a long time, evacuation can be carried out for up to 120
minutes.
7.3. In the case of units with fitted oil filling system, add refrigerant oil now.
8. Filling the air-conditioning system
8.1. Using the service unit, add the refrigerant quantity stated in the manual into the air-conditioning lines. -->
Technical data for air-conditioning system.
8.2. As refrigerant usually flows instead of being pumped, it may not be possible - especially if the vehicle is
warm and the service unit cold - to add the entire quantity. If this is the case, switch the engine and the air-
conditioning on. Wait for the suction pressure to fall below 2 bar. Now open the low-pressure valve on the unit
slowly and carefully until the remaining quantity has been added.
CAUTION: Low-pressure reading too high in refrigerant circuit.
 Destruction of air-conditioning compressor.
--> Do not allow the low-pressure gauge to exceed 3 bar, otherwise liquid refrigerant can get onto the suction
side of the compressor and destroy it.
8.3.
9. Add the refrigerant from both connection hoses to the air-conditioning system in the vehicle.
9.1. The refrigerant in the high-pressure and low-pressure lines belongs to the filling capacity of the refrigerant
in the air-conditioning system in the vehicle.
9.2. Close the valve on the high-pressure line and disconnect it from the vehicle.
9.3. Start the engine and air-conditioning system. When the pressure on both pressure gauges sinks below 2 bar,
close the valve on the low-pressure line and disconnect it from the vehicle.
87 14 19 REMOVING AND INSTALLING SUN SENSOR. - AS OF MY 2005

(ALL MODELS)
REMOVING SUN SENSOR
Remove sun sensor
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1. Lift cover on dashboard using plastic spatula and unclip.
2. Unplug electrical plug connection.
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Fig. 11: Removing sun sensor

3. Carefully pull the three tabs out of the cover and remove the sun sensor.
Installing sun sensor
1. Press sensor into the holder until the sensor lugs engage.
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Fig. 12: Engaging sensor in holder

2. Connect the electric plug connection.
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Fig. 13: Clipping in cover

3. Position cover and clip into dashboard.
87 20 19 REMOVING AND INSTALLING SERVO MOTOR FOR

TEMPERATURE MIXING FLAP (PINK) - AS OF MY 2005 (ALL MODELS)
PRELIMINARY WORK
Preliminary work - servo motor for temperature mixing valve
2. Remove front footwell outlet vent. Refer to 80 55 19 Removing and installing front footwell outlet vent -
REMOVING SERVO MOTOR FOR TEMPERATURE MIXING FLAP
Removing servo motor for temperature mixing flap
Microsoft
Microsoft

2. First unscrew the two accessible fastening screws -1- , then shift the servo motor and unscrew the third
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Fig. 16: Releasing the electric connector

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Fig. 17: Disengaging actuating lever

4. Turn the servo motor out until the actuating lever -A- can be disengaged. See Fig. 17.
5. Remove servo motor.
INSTALLING SERVO MOTOR FOR TEMPERATURE MIXING FLAP
Installing servo motor for temperature mixing flap
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Fig. 18: Engaging actuating lever on servo motor

1. Position servo motor and engage actuating lever -A- on the servo motor. See Fig. 18.
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Fig. 19: Connecting electric plugs

2. Connect electric connector to servo motor until the connector is felt to engage.
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Fig. 20: Securing servo motor

3. Position servo motor on heater/air-conditioning unit and tighten with the three fastening screws -1- . -->
Tightening torque: 1.2 (1.0 ftlb.) Nm +/-0.5 (0.5 ftlb.) Nm . See Fig. 20.
3.1. First screw in one fastening screw.
3.2. Turn the servo motor and screw in the remaining two fastening screws.
4. Switch on ignition and check function of servo motor by adjusting the air conditioning control.
SUBSEQUENT WORK
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Subsequent work - servo motor for temperature mixing valve
1. Install front footwell outlet vent. Refer to 80 55 19 Removing and installing front footwell outlet vent - as
87 20 19 REMOVING AND INSTALLING SERVO MOTOR FOR CENTRAL

DISTRIBUTOR FLAP (GREEN) - AS OF MY 2005 (ALL MODELS)
PRELIMINARY WORK
Preliminary work - servo motor for central distributor flap
2. Remove front footwell outlet vent. Refer to 80 55 19 Removing and installing front footwell outlet vent -
REMOVING SERVO MOTOR FOR CENTRAL DISTRIBUTOR FLAP
Removing servo motor for central distributor flap
Microsoft
Microsoft

2. First unscrew the two accessible fastening screws -1- , then shift the servo motor and unscrew the third
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Fig. 23: Releasing the electric connector

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4. Turn the servo motor out until the actuating lever -A- can be disengaged. See Fig. 24.
INSTALLING SERVO MOTOR FOR CENTRAL DISTRIBUTOR FLAP
Installing servo motor for central distributor flap
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1. Position servo motor and engage actuating lever -A- on the servo motor. See Fig. 25.
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Fig. 26: Connecting electric plugs

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3. Position servo motor on heater/air-conditioning unit and tighten with the three fastening screws -1- . -->
Tightening torque: 1.2 (1.0 ftlb.) Nm +/-0.5 (0.5 ftlb.) Nm . See Fig. 27.
3.1. First screw in one fastening screw.
3.2. Turn the servo motor and screw in the remaining two fastening screws.
SUBSEQUENT WORK
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Subsequent work - servo motor for central distributor flap
1. Install front footwell outlet vent. Refer to 80 55 19 Removing and installing front footwell outlet vent - as
87 20 19 REMOVING AND INSTALLING FOOTWELL/DEFROST (YELLOW)

SERVO MOTOR - AS OF MY 2005 (ALL MODELS)
PRELIMINARY WORK
Preliminary work for footwell/defrost servo motor
1. Remove dashboard trim panel. Refer to 70 19 19 Removing and installing trim under dashboard - as of
2. Remove left console cover. Refer to 68 14 19 Removing and installing center console cover - as of MY
2005 (All Models) .
REMOVING FOOTWELL/DEFROST SERVO MOTOR
Removing footwell/defrost servo motor
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Microsoft

2. Unscrew the three fastening screws.
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Microsoft

4. Pull the servo motor out further until the actuating lever -A- can be disengaged. See Fig. 31.
INSTALLING FOOTWELL/DEFROST SERVO MOTOR
Installing footwell/defrost servo motor
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1. Position servo motor and engage actuating lever on the servo motor.
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Fig. 33: Connecting electric connector

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3. Position servo motor on heater/air-conditioning unit and tighten with fastening screws -1- . --> Tightening
torque: 1.2 (1.0 ftlb.) Nm +/-0.5 (0.5 ftlb.) Nm . See Fig. 34.
SUBSEQUENT WORK
Subsequent work for footwell/defrost servo motor
1. Install left console cover. Refer to 68 14 19 Removing and installing center console cover - as of MY 2005
(All Models) .
2. Install dashboard cover. Refer to 70 19 19 Removing and installing trim under dashboard - as of MY
2005 (All Models) .
87 27 19 REMOVING AND INSTALLING MAGNETIC COUPLING - AS OF MY

PRELIMINARY WORK
Preliminary work for magnetic clutch
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1. Move convertible top to service position Refer to 61 01 IN Diagram of convertible top - as of MY 2005

2. Remove engine compartment lid Refer to 55 78 19 Removing and installing engine compartment lid - as
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3. Remove rear wall cover Refer to 55 59 19 Removing and installing rear wall cover - as of MY 2005 (All
Models) .
4. Remove drive belt. --> 13 78 19 Removing and installing drive belt - as of MY 2005 (All Models) .

5. Remove Pentosin from the power-steering reservoir by suction and pour it into a suitable container.
Microsoft
Fig. 37: Servo-tank

6. Release bayonet lock -arrow- on the power-steering reservoir and remove power-steering reservoir. See Fig.
37.
REMOVING THE MAGNETIC COUPLING
Removing the magnetic coupling
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Fig. 38: Overview

A - Thrust plate
B - Spacer washer
C - Belt pulley
D - Solenoid coil
E - Seeger circlip ring for pulley
F - Seeger circlip ring for solenoid coil
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Fig. 39: Loosen pressure plate mount

1. Use a commercially available strap wrench to securely hold the pressure plate -A- on the air-conditioning
compressor, and undo the fastening screw -1- . See Fig. 39.
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Fig. 40: Removing pressure plate

2. Screw in an M8 screw -2- into the thread of the pressure plate until the pressure plate -A- can be removed by
hand. See Fig. 40.
3. Take off spacers -B- behind the pressure plate. See Fig. 40.
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Fig. 41: Removing Seeger circlip ring for pulley

4. Use a Seeger circlip ring pliers to remove the Seeger circlip ring -E- on the pulley -C- . See Fig. 41.
5. Remove pulley -C- on the compressor. See Fig. 41.
6. Unscrew electric line of solenoid coil on the compressor:
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6.1. Unscrew rear Torx screw for air-conditioning compressor (M8 x 120) -1- between the pipes of the intake
system. See Fig. 42.
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6.2. Unscrew front Torx screws for air-conditioning compressor (M8 x 90) -1- and -2- . See Fig. 43.
6.3. Disconnect electric plug connection on the air-conditioning compressor's electrical line.
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Fig. 44: Removing solenoid coil

7. Remove Seeger circlip ring -F- for the solenoid coil with the Seeger circlip ring pliers. Remove the magnetic
coil from the compressor housing. See Fig. 44.
INSTALLING THE MAGNETIC COUPLING
Installing the magnetic coupling
NOTE: If a new magnetic clutch is installed, the air gap between pressure plate and
pulley must be checked with a depth gauge. --> 872719 Removing and installing
magnetic clutch - chapter on "Checking"
Microsoft
Fig. 45: Engaging lock pin on compressor

1. Place the magnetic coil -D- on the compressor housing. The locking pin -G- must engage in the locking hole
-H- . See Fig. 45.
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Fig. 46: Seeger circlip ring installation position

NOTE: When installing the Seeger circlip ring, the slanted surface of the Seeger circlip
ring must point forward.
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Fig. 47: Installing Seeger circlip ring for solenoid coil

2. Position Seeger circlip ring -F- for solenoid coil -D- and install with Seeger circlip ring pliers. See Fig. 47.
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Fig. 48: Installing belt pulley

3. Position pulley -C- and install with the Seeger circlip ring -E- . See Fig. 48.
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Fig. 49: Screwing down electric line to compressor.

4. Secure the electric line with the fastening screw -4- on the compressor. See Fig. 49.
5. Position compressor on engine again and screw down the fastening screws:
5.1. Clip in connector for air-conditioning compressor supply line and clip connector housing into the holder
provided.
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5.2. Screw in front Torx screws for air-conditioning compressor (M8 x 90) -1- and -2- . See Fig. 50.
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5.3. Screw in rear Torx screw for air-conditioning compressor (M8 x 120) -1- and tighten all three screws for
air-conditioning compressor. --> Tightening torque: 23 (17 ftlb.) Nm . See Fig. 51.
6. Position the pressure plate-A- and tighten with the fastening screw -1- . --> Tightening torque: 14 (10.5
ftlb.) Nm . See Fig. 52
Fig. 52: Screw down pressure plate

SUBSEQUENT WORK
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Subsequent work for magnetic clutch
Fig. 53: Servo-tank

steering reservoir.
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4. Check Pentosin level in power-steering reservoir Refer to 48 02 01 Checking the fluid level for the power-
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6. Install rear wall cover Refer to 55 59 19 Removing and installing rear wall cover - as of MY 2005 (All
Models) .
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7. Install engine compartment lid Refer to 55 78 19 Removing and installing engine compartment lid - as of
8. Assemble convertible top. Refer to 61 01 IN Diagram of convertible top - as of MY 2005 (Boxster,

steering system.
10. Check operation of air-conditioning compressor.
CHECKING THE MAGNETIC COUPLING
Check air gap of magnetic clutch
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Fig. 57: Overview

A - Thrust plate
B - Spacer washer
C - Pulley
D - Solenoid coil
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Fig. 58: Check air gap of magnetic clutch

1. Check the air gap between the pressure plate and belt pulley with a depth gauge.
2. Place a rule on the outer edge of the belt pulley. Use a depth gauge to measure up to the pressure plate. Apply
battery voltage to the magnetic coupling and measure the distance (air gap) to the attracted pressure plate.
Always measure at least three points on the pressure plate in order to obtain a mean value. Distance: 0.5 mm ±
0.15 mm
3. If the air gap is not in the tolerance range, it must be adjusted with the aid of the spacer washers -B- . See Fig.
57.
87 27 19 REMOVING AND INSTALLING MAGNETIC COUPLING - AS OF MY

PRELIMINARY WORK
Preliminary work for magnetic clutch
Microsoft

Microsoft

Models) .
3. Remove drive belt. --> 13 78 19 REMOVING AND INSTALLING DRIVE BELT - AS OF MY 2005
(ALL MODELS) .

Microsoft
Fig. 61: Servo-tank

61.
REMOVING THE MAGNETIC COUPLING
Removing the magnetic coupling
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Fig. 62: Overview

A - Thrust plate
B - Spacer washer
C - Belt pulley
D - Solenoid coil
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Fig. 63: Loosen pressure plate mount

1. Use a commercially available strap wrench to securely hold the pressure plate -A- on the air-conditioning
compressor, and undo the fastening screw -1- . See Fig. 63.
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Fig. 64: Removing pressure plate

2. Screw in an M8 screw -2- into the thread of the pressure plate until the pressure plate -A- can be removed by
hand. See Fig. 64.
3. Take off spacers -B- behind the pressure plate. See Fig. 64.
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Fig. 65: Removing Seeger circlip ring for pulley

4. Use a Seeger circlip ring pliers to remove the Seeger circlip ring -E- on the pulley -C- . See Fig. 65.
5. Remove pulley -C- on the compressor. See Fig. 65.
6. Unscrew electric line of solenoid coil on the compressor:
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6.1. Unscrew rear Torx screw for air-conditioning compressor (M8 x 120) -1- between the pipes of the intake
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6.2. Unscrew front Torx screws for air-conditioning compressor (M8 x 90) -1- and -2- . See Fig. 67.
6.3. Disconnect electric plug connection on the air-conditioning compressor's electrical line.
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Fig. 68: Removing solenoid coil

7. Remove Seeger circlip ring -F- for the solenoid coil with the Seeger circlip ring pliers. Remove the magnetic
coil from the compressor housing. See Fig. 68.
INSTALLING THE MAGNETIC COUPLING
Installing the magnetic coupling
NOTE: If a new magnetic clutch is installed, the air gap between pressure plate and
pulley must be checked with a depth gauge. --> 872719 Removing and installing
magnetic clutch - chapter on "Checking"
Microsoft
Fig. 69: Engaging lock pin on compressor

1. Place the magnetic coil -D- on the compressor housing. The locking pin -G- must engage in the locking hole
-H- . See Fig. 69.
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Fig. 70: Seeger circlip ring installation position

NOTE: When installing the Seeger circlip ring, the slanted surface of the Seeger circlip
ring must point forward.
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Fig. 71: Installing Seeger circlip ring for solenoid coil

2. Position Seeger circlip ring -F- for solenoid coil -D- and install with Seeger circlip ring pliers. See Fig. 71.
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Fig. 72: Installing belt pulley

3. Position pulley -C- and install with the Seeger circlip ring -E- . See Fig. 72.
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Fig. 73: Screwing down electric line to compressor.

4. Secure the electric line with the fastening screw -4- on the compressor. See Fig. 73.
5. Position compressor on engine again and screw down the fastening screws:
5.1. Clip in connector for air-conditioning compressor supply line and clip connector housing into the holder
provided.
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5.2. Screw in front Torx screws for air-conditioning compressor (M8 x 90) -1- and -2- . See Fig. 74.
Microsoft

5.3. Screw in rear Torx screw for air-conditioning compressor (M8 x 120) -1- and tighten all three screws for
air-conditioning compressor. --> Tightening torque: 23 (17 ftlb.) Nm . See Fig. 75.
6. Position the pressure plate-A- and tighten with the fastening screw -1- . --> Tightening torque: 14 (10.5
ftlb.) Nm. See Fig. 76.
Fig. 76: Screw down pressure plate

SUBSEQUENT WORK
Microsoft
Subsequent work for magnetic clutch
Fig. 77: Servo-tank

steering reservoir.
Microsoft

Microsoft

Models) .
Microsoft

steering system.
9. Check operation of air-conditioning compressor.
CHECKING THE MAGNETIC COUPLING
Check air gap of magnetic clutch
Microsoft
Fig. 81: Overview

A - Thrust plate
B - Spacer washer
C - Pulley
D - Solenoid coil
Microsoft
Fig. 82: Check air gap of magnetic clutch

1. Check the air gap between the pressure plate and belt pulley with a depth gauge.
2. Place a rule on the outer edge of the belt pulley. Use a depth gauge to measure up to the pressure plate. Apply
battery voltage to the magnetic coupling and measure the distance (air gap) to the attracted pressure plate.
Always measure at least three points on the pressure plate in order to obtain a mean value. Distance: 0.5 mm ±
0.15 mm
3. If the air gap is not in the tolerance range, it must be adjusted with the aid of the spacer washers -B- . See Fig.
81.
87 34 19 REMOVING AND INSTALLING AIR-CONDITIONING COMPRESSOR

RHD)
PRELIMINARY WORK
Preliminary work for compressor
1. Drain refrigerant for air-conditioning system with one air-conditioning unit. --> 870317 Draining and filling
in refrigerant - chapter on "Draining"
2. Move convertible top to service position Refer to 61 01 IN Diagram of convertible top - as of MY 2005
Microsoft

Microsoft

Models) .
5. Remove drive belt. --> 13 78 19 Removing and installing drive belt - as of MY 2005 (All Models) .
REMOVING THE COMPRESSOR
Removing compressor

Microsoft
Fig. 85: Servo-tank

85.
Microsoft

3. Unscrew rear Torx screw for air-conditioning compressor (M8 x 120) -1- between the pipes of the intake
Microsoft

5. Disconnect electric plug connection on the air-conditioning compressor's electrical line.
Microsoft

Microsoft

NOTE:  After removal, place the air-conditioning compressor on a suitable

tunnel.

8. Unscrew both fastening screws -1, 2- , pull out the refrigerant lines carefully and close them immediately
INSTALLING THE COMPRESSOR
Installing compressor
CAUTION: Risk of damaging the air-conditioning compressor.
--> The engine must not be started until the air-conditioning system has been filled.
Microsoft
NOTE:  New compressors are pressurized and are filled with the required amount
of oil for the refrigerant circuit!
 The remaining oil quantity in the individual components must therefore be
taken into account!
 Refrigerant oil from the compressor or refrigerant oil removed by suction
from a previously run air-conditioning system may no longer be used
(special-category waste)!
1. If a new compressor is installed, first correct the refrigerant oil quantity in the air-conditioning compressor. --
> 873419 Removing and installing compressor - chapter on "Checking"
2. Replace O-rings for the refrigerant lines and wet the new rings with refrigerant oil.
3. Do not remove the plugs for the lines and compressor connection until shortly before installation.
Fig. 91: Connection point for compressor line

4. Connect the lines and secure with the fastening screws -1, 2- . --> Tightening torque: 20 (15 ftlb.) Nm -->
Microsoft

7. Clip in connector for air-conditioning compressor supply line and clip connector housing into the holder
provided.
Microsoft

Microsoft

Fig. 95: Servo-tank

steering reservoir.
Microsoft

SUBSEQUENT WORK
Subsequent work for compressor
Microsoft

Models) .
Microsoft

5. Fill refrigerant on the air-conditioning system in accordance with regulations. --> 870317 Draining and
filling in refrigerant
6. Open air exhaust nozzles on the dashboard, and set fan to at least 75 %.
7. After allowing the system to stabilize at idle speed (approx. 5 sec.), switch on air conditioner and allow the
engine to run uninterrupted for at least 2 minutes at 1500 rpm.
8. Switch off the air conditioner again. Do not drive until the air conditioner has been filled.
steering system.
CHECKING REFRIGERANT OIL IN "NEW" AIR-CONDITIONING COMPRESSOR
Correct the refrigerant oil level in the "new" air-conditioning compressor
WARNING: A new air-conditioning compressor contains the oil quantity for the
complete air-conditioning circuit.
Microsoft
 Risk of damaging the air-conditioning compressor by excessive

refrigerant oil in the air-conditioning circuit.
--> If a new air-conditioning compressor or a component in the circuit is replaced, the oil quantity must be
determined and adjusted.
--> Insufficient refrigerant oil causes a lack of lubrication, resulting in the failure of the air-conditioning
compressor.
--> Too much refrigerant oil results in reduced refrigerant performance.
NOTE: All connection points must be completely dirt-free.
The air-conditioning compressor must be dry (washing the vehicle) and the air-
conditioning compressor and lines must be free of moisture.
The connection points must be closed after they have been opened. Use the
original transport caps.
A clean measuring cylinder with a capacity of approx. 300 ml is required.
Determining oil quantity on the "old" air-conditioning compressor
Fig. 99: Caps

Microsoft
1. First, open the cap on the high-pressure side and relieve the pressure from the compressor -A- . See Fig. 99.
2. Open the oil filler screw -B- on the compressor. See Fig. 99.
3. Fill the refrigerant oil from the air-conditioning compressor into the measuring cylinder. Turn the pressure
plate on the air-conditioning compressor (not the belt pulley) when emptying the refrigerant oil.
The amount of refrigerant oil is referred to as "Vold " in the formula below.
4. Always replace the sealing ring for the oil filler plug.
5. Screw oil filler plug -B- into the compressor. --> Tightening torque: 30 (22 ftlb.) Nm . See Fig. 99.
Fig. 100: Oil filler screw

Determining the oil quantity at the "new" oil filler screw of the air-conditioning compressor
1. To drain refrigerant oil:
1.1. First, open the cap on the high-pressure side and relieve the pressure from the compressor -A- . See Fig.
100.
Microsoft
1.2. Open the oil filler screw -B- on the compressor. See Fig. 99.
1.3. Drain the refrigerant oil from the air-conditioning compressor.
The refrigerant oil must not be re-used, but must be disposed of properly.
2. To determine the refrigerant oil quantity:
2.1. Vtotal = "Vremoved " + "Vold " + 20 cm3
2.2. Vtotal = Total volume for the new air-conditioning compressor
2.3. Vremoved = Volume of refrigerant oil removed by suction
2.4. Vold = Volume of refrigerant oil in the old air-conditioning compressor
2.5. 20 cm3 = Additional safety volume
3. To fill the air-conditioning compressor:
3.1. Fill the determined refrigerant oil volume Vtotal into the air-conditioning compressor.
3.2. Always replace the sealing ring for the oil filler plug.
3.3. Screw oil filler plug -B- onto the compressor. --> Tightening torque: 30 (22 ftlb.) Nm . See Fig. 99.
3.4. Install air-conditioning compressor. --> 873419 Removing and installing compressor - Installing
87 34 19 REMOVING AND INSTALLING COMPRESSOR - AS OF MY 2006

PRELIMINARY WORK
Preliminary work for air-conditioning compressor
1. Drain refrigerant for air-conditioning system with a refrigerant pump.
Models) .
Microsoft
General warning notes for air-conditioning compressor
WARNING: Safety regulations should be strictly observed when working on air-

conditioned vehicles and dealing with refrigerant.
 Danger of injury.
--> 87 AW Safety regulations for working on air-conditioned vehicles and dealing with refrigerant R134a
- as of MY 2005 (All Models)
--> 87 AW Safety regulations for extraction and filling systems - as of MY 2005 (All Models) .
--> 87 01 IN Instructions for repairing air-conditioning systems and storing spare parts - as of MY 2005
(All Models).
TOOLS AND MATERIALS
Tool for air-conditioning system
Air-conditioning service unit, refer to Special Tools, Commercially Available Tools, Chapter 2.4, No. 96-2)
REMOVING AIR-CONDITIONING COMPRESSOR
Removing the air-conditioning compressor

Microsoft

2. Release bayonet lock -Arrow- on the power-steering reservoir and remove power-steering reservoir. See Fig.
101.
Microsoft

3. Unscrew rear Torx screw for air-conditioning compressor (M8 x 120) -1- between the pipes of the intake
Microsoft

5. Disconnect electric plug connection on the air-conditioning compressor's electric line.
Microsoft

Microsoft

NOTE:  After removal, place the air-conditioning compressor on a suitable

tunnel.

8. Unscrew both fastening screws -1, 2- , pull out the refrigerant lines carefully and close them immediately
INSTALLING THE COMPRESSOR
Installing compressor
CAUTION: Risk of damaging the air-conditioning compressor.
--> The engine must not be started until the air-conditioning system has been filled.
Microsoft
NOTE:  New compressors are pressurized and are filled with the required amount
of oil for the refrigerant circuit!
 The remaining oil quantity in the individual components must therefore be
taken into account!
 Refrigerant oil from the compressor or refrigerant oil removed by suction
from a previously run air-conditioning system may no longer be used
(special-category waste)!
1. If a new compressor is installed, first correct the refrigerant oil quantity in the air-conditioning compressor. --
> 873419 Removing and installing compressor - section on "Checking"
2. Replace O-rings for the refrigerant lines and wet the new rings with refrigerant oil.
3. Do not remove the plugs for the lines and compressor connection until shortly before installation.

4. Connect the lines and secure with the fastening screws -1, 2- . --> Tightening torque: 20 (15 ftlb.) Nm -->
Microsoft

7. Clip in connector for air-conditioning compressor supply line and clip connector housing into the holder
provided.
Microsoft

Microsoft


10. Position power-steering reservoir. Lock bayonet lock -Arrow- on power-steering reservoir. See Fig. 111.
steering reservoir.
Microsoft

SUBSEQUENT WORK
Subsequent work on compressor
Microsoft

Models) .
5. Fill refrigerant on the air-conditioning system in accordance with regulations. --> 870317 Draining and
filling in refrigerant
6. Open air exhaust nozzles on the dashboard, and set fan to at least 75 %.
7. After allowing the system to stabilize at idle speed (approx. 5 sec.), switch on air conditioner and allow the
engine to run uninterrupted for at least 2 minutes at 1500 rpm.
8. Switch off the air conditioner again. Do not drive until the air conditioner has been filled.
steering system.
CHECKING REFRIGERANT OIL IN "NEW" AIR-CONDITIONING COMPRESSOR
Correct the refrigerant oil level in the "new" air-conditioning compressor
Microsoft
WARNING: A new air-conditioning compressor contains the oil quantity for the
complete air-conditioning circuit.
 Risk of damaging the air-conditioning compressor by excessive

refrigerant oil in the air-conditioning circuit.
--> If a new air-conditioning compressor or a component in the circuit is replaced, the oil quantity must be
determined and adjusted.
--> Insufficient refrigerant oil causes a lack of lubrication, resulting in the failure of the air-conditioning
compressor.
--> Too much refrigerant oil results in reduced refrigerant performance.
NOTE: All connection points must be completely dirt-free.
The air-conditioning compressor must be dry (washing the vehicle) and the air-
conditioning compressor and lines must be free of moisture.
The connection points must be closed after they have been opened. Use the
original transport caps.
A clean measuring cylinder with a capacity of approx. 300 ml is required.
Determining oil quantity on the "old" air-conditioning compressor
Microsoft
Fig. 114: Caps

1. First, open the cap on the high-pressure side and relieve the pressure from the compressor -A- . See Fig. 114.
2. Open the oil filler screw -B- on the compressor. See Fig. 114.
3. Fill the refrigerant oil from the air-conditioning compressor into the measuring cylinder. Turn the pressure
plate on the air-conditioning compressor (not the belt pulley) when emptying the refrigerant oil.
The amount of refrigerant oil is referred to as "Vold " in the formula below.
4. Always replace the sealing ring for the oil filler plug.
5. Screw oil filler plug -B- into the compressor. --> Tightening torque: 30 (22 ftlb.) Nm . See Fig. 114.
Microsoft

Determining the oil quantity at the "new" oil filler screw of the air-conditioning compressor
1. To drain refrigerant oil:
1.1. First, open the cap on the high-pressure side and relieve the pressure from the compressor -A- . See Fig.
115.
1.2. Open the oil filler screw -B- on the compressor. See Fig. 114.
1.3. Drain the refrigerant oil from the air-conditioning compressor.
The refrigerant oil must not be re-used, but must be disposed of properly.
2. To determine the refrigerant oil quantity:
2.1. Vtotal = "Vremoved " + "Vold " + 20 cm3
2.2. Vtotal = Total volume for the new air-conditioning compressor
2.3. Vremoved = Volume of refrigerant oil removed by suction
Microsoft
2.4. Vold = Volume of refrigerant oil in the old air-conditioning compressor
2.5. 20 cm3 = Additional safety volume
3. To fill the air-conditioning compressor:
3.1. Fill the determined refrigerant oil volume Vtotal into the air-conditioning compressor.
3.2. Always replace the sealing ring for the oil filler plug.
3.3. Screw oil filler plug -B- onto the compressor. --> Tightening torque: 30 (22 ftlb.) Nm . See Fig. 114.
3.4. Install air-conditioning compressor. --> 873419 Removing and installing compressor - Installing
87 42 19 REMOVING AND INSTALLING CONDENSER-CONDENSER LINE -

PRELIMINARY WORK
Preliminary work for line condenser-condenser
Models) .
Draining refrigerant. --> 870317 Draining and filling in refrigerant - chapter on "draining"
REMOVING THE CONDENSER-CONDENSER LINE
Removing the condenser-condenser line
Microsoft
Fig. 116: Installation location for line condenser-condenser

Fig. 117: Air guide for condenser

1. Unscrew the two fastening screws -1- holding the air guide for the condenser. See Fig. 117.
Microsoft
2. Pull the air guide forward and disengage it at the condenser -A- . See Fig. 117.
Fig. 118: Releasing and opening up the mount

3. Unscrew the fastening nuts for both holders line, open the holder and take out the line.
NOTE:  When loosening or tightening the M8 refrigerant lines on the condenser,

always counter with a 21-mm open-ended wrench.
NOTE: Before re-installing the component, check the O-rings of the refrigerant lines for
damage and replaced them if necessary.
Wet the O-rings of the refrigerant lines with refrigerant oil.
Do not open the plugs for the lines and connections until shortly before
installation.
Close off all lines and connections using suitable plugs during removal.
Microsoft
Fig. 119: Unscrew condenser fastening screw

4. Unscrew the fastening screws -1- of the line condenser-condenser and pull the line out of both condensers.
See Fig. 119.
INSTALLING THE CONDENSER-CONDENSER LINE
Installing the condenser-condenser line

installation.
Microsoft
Fig. 120: Position and secure line

1. Carefully push the lines into the condensers and screw tight with the fastening screws. --> Tightening
Microsoft
Fig. 121: Close and secure holder

2. Attach line to both holders, close holders and secure with fastening screws.
Microsoft

3. Engage air guide on condenser -A- and screw down using the two fastening screws -1- . --> Tightening
torque: 4 (3 ftlb.) Nm . See Fig. 122.
SUBSEQUENT WORK
Subsequent work for line condenser-condenser
Filling in refrigerant. --> 870317 Draining and filling in refrigerant
Install front apron. --> 63 10 19 REMOVING AND INSTALLING FRONT BUMPER - AS OF MY 2005
(ALL MODELS) .
87 43 19 REMOVING AND INSTALLING COMPRESSOR/CONDENSER LINE

AROUND THE ENGINE - AS OF MY 2005 (ALL MODELS)
PRELIMINARY WORK
Preliminary work for compressor/condenser line
Remove air-conditioning compressor from engine. --> 873419 Removing and installing compressor - chapter
Microsoft
on "Removing" [987310 987311 987320 987321] --> 873419 Removing and installing compressor -
chapter on "Removing" [987120 987121]
REMOVING COMPRESSOR/CONDENSER LINE
Removing compressor/condenser line
NOTE: Close off all lines and connections using suitable plugs during removal.
Before re-installing the component, check the O-rings of the refrigerant lines for

A - Compressor/condenser line
Microsoft

1. Unscrew fastening screw -1- on compressor, pull out line on compressor and remove it from support -7- . See
Fig. 124.
Microsoft
Fig. 125: Removing line

2. Unscrew fastening nut -5- on cable holder, open cable holder and pull line out of rubber mounting -6- . See
Fig. 124.
3. Unscrew fastening screw -3- on connection point and pull out line. See Fig. 124.
4. Remove line downwards from the engine area.
INSTALLING COMPRESSOR/CONDENSER LINE
Installing compressor/condenser line
installation.
Microsoft
Fig. 126: Installing lead

1. Insert line from below into engine compartment.
2. Insert line into evaporator line and secure using the fastening screw -3- . --> Tightening torque: 14 (10.5
Microsoft

3. Push line into the compressor, secure with the fastening screw -1- and clip line into the support. -->
Microsoft
Fig. 128: Clipping in line and securing it

4. Insert line in underbody area into rubber mount -6- , close support and secure with fastening nut -5- . See Fig.
128.
SUBSEQUENT WORK
Subsequent work for compressor/condenser line
Install air-conditioning compressor on engine. --> 873419 Removing and installing compressor - chapter on
"Installing" [987310 987311 987320 987321] --> 873419 Removing and installing compressor - chapter on
"Installing" [987120 987121]
Fill in refrigerant. --> 870317 Draining and filling in refrigerant - chapter on "Filling in"
87 43 19 REMOVING AND INSTALLING COMPRESSOR-CONDENSER LINE

AT FRONT - AS OF MY 2005 (ALL MODELS)
PRELIMINARY WORK
Preliminary work on compressor-condenser line
Remove front right wheel. Refer to 44 05 19 Removing and installing wheel - as of MY 2005 (All Models) .
Microsoft
Remove front right wheel housing liner. Refer to 50 56 19 Removing and installing front wheel housing liner
Drain refrigerant. --> 870317 Draining and filling in refrigerant - chapter on "draining"
REMOVING COMPRESSOR-CONDENSER LINE
Removing compressor-condenser line
installation.
Fig. 129: Installation location for compressor-condenser line

NOTE: When loosening or tightening the M8 refrigerant lines on the condenser, always
counter with a 21-mm open-ended wrench.
Microsoft
Fig. 130: Unscrewing condenser fastening screws

1. Unscrew the fastening screw -1- for the condenser line and pull the line out of the condenser. See Fig. 130.
Microsoft
Fig. 131: Unscrewing the compressor line fastening screw

2. Unclip holder for line and remove the line.
3. Unscrew the fastening screw -2- for the line to the compressor and pull the line out of the compressor line.
See Fig. 131.
4. Pull the line out of the line holder and take it out.
INSTALLING COMPRESSOR-CONDENSER LINE
Installing compressor-condenser line
Microsoft
Fig. 132: Pulling line out of holder

1. Clip line into the line holder at the top and engage it in the rubber mounting.
installation.
2. Insert compressor-condenser line into the line to the compressor and fasten with the fastening screw -2- . -->
3. Close and engage holder for rubber mounting.
Microsoft
Fig. 133: Inserting and screwing down refrigerant line

4. Insert compressor-condensor line into the condenser and fasten it with the fastening screw -1- . -->
SUBSEQUENT WORK
Subsequent work on compressor-condenser line
Fill in refrigerant. --> 870317 Draining and filling in refrigerant
Install front right wheel housing liner. Refer to 50 56 19 Removing and installing front wheel housing liner -
Install front right wheel. Refer to 44 05 19 Removing and installing wheel - as of MY 2005 (All Models) .
87 43 IN LAYING COMPRESSOR/CONDENSER LINE - AS OF MY 2005 (ALL

MODELS)
LAYING COMPRESSOR/CONDENSER LINE
Microsoft

A - Compressor/condenser line
Remove the compressor/condenser line and the compressor/evaporator line together.
Microsoft
Fig. 135: Laying and securing the compressor/condenser line

1 - Fastening nut for both holders
2 - Grommet for continuity to plenum panel
87 45 19 REMOVING AND INSTALLING COMPRESSOR/EVAPORATOR LINE

PRELIMINARY WORK
Preliminary work for compressor/evaporator line
Remove air-conditioning compressor from engine. --> 873419 Removing and installing compressor - chapter
on "Removing" [987310 987311 987320 987321] --> 873419 Removing and installing compressor -
chapter on "Removing" [987120 987121]
REMOVING COMPRESSOR/EVAPORATOR LINE
Removing compressor/evaporator line
Microsoft

B - Compressor/evaporator line
Microsoft

1. Unscrew fastening screw -2- on compressor, pull out line on compressor and remove it from support -7- . See
Fig. 137.
Microsoft
Fig. 138: Removing line

2. Unscrew fastening nut -5- on cable holder, open cable holder and pull line out of rubber mounting -6- . See
Fig. 138.
3. Unscrew fastening screw -4- on connection point and pull out line. See Fig. 137.
4. Remove line downwards from the engine area.
INSTALLING COMPRESSOR/EVAPORATOR LINE
Installing compressor/evaporator line
installation.
Microsoft
Fig. 139: Installing lead

1. Insert line from below into engine compartment.
2. Insert line into evaporator line and secure using the fastening screw -4- . --> Tightening torque: 14 (10.5
Microsoft

3. Push line into the compressor, secure with the fastening screw -2- and clip line into the support -7- . -->
Tightening torque: 21 (16 ftlb.) Nm . See Fig. 140, Fig. 141.
Microsoft
Fig. 141: Clipping in line and securing it

4. Insert line in underbody area into rubber mount -6- , close support and secure with fastening nut -5- . See Fig.
141.
SUBSEQUENT WORK
Subsequent work for compressor/evaporator line
Install air-conditioning compressor on engine. --> 873419 Removing and installing compressor - chapter on
"Installing" [987310 987311 987320 987321] --> 873419 Removing and installing compressor - chapter on
"Installing" [987120 987121]
Fill in refrigerant. --> 870317 Draining and filling in refrigerant - chapter on "Filling in"
87 45 IN LAYING COMPRESSOR/EVAPORATOR LINE - AS OF MY 2005

(ALL MODELS)
LAYING COMPRESSOR/EVAPORATOR LINE
Microsoft

B - Compressor/evaporator line
Remove the compressor/evaporator line and the compressor/condenser line together.
Microsoft
Fig. 143: Laying and securing the compressor/condenser line

1 - Fastening nut for both holders
2 - Grommet for continuity to plenum panel
87 46 19 REMOVING AND INSTALLING CONDENSER-FLUID TANK LINE -

PRELIMINARY WORK
Preliminary work for line condenser-fluid tank
Removing left front wheel. Refer to 44 05 19 Removing and installing wheel - as of MY 2005 (All Models) .
Remove front left wheel housing liner. Refer to 50 56 19 Removing and installing front wheel housing liner -
REMOVING THE CONDENSER-FLUID TANK LINE
Removing the condenser-fluid tank line
Microsoft
Fig. 144: Installation location for line condenser-fluid tank

Microsoft
Fig. 145: Unscrew condenser fastening screw

1. Unscrew the fastening screw -1- for the line condenser and pull the line out of the condenser. See Fig. 145.
2. Pull the line out of the line holder.
Fig. 146: Open threaded joint

3. Counter the fastening nuts -2- and open carefully. See Fig. 146.
installation.
Microsoft
Fig. 147: Remove line

4. Pull the line and the rubber sleeve out of the passage to the plenum panel over the wheel housing.
INSTALLING THE CONDENSER-FLUID TANK LINE
Installing the condenser-fluid tank line
Microsoft
Fig. 148: Insert line

1. Push line into the plenum panel via the wheel housing and press rubber sleeve into place. Ensure that rubber
sleeve is fitted correctly.
Microsoft
Fig. 149: Screw down line on the condenser

2. Clip line into the line holder at the top, insert line into the condenser and screw down with -2- fastening
screw. --> Tightening torque: 14 (10.5 ftlb.) Nm . See Fig. 149.
installation.
Microsoft
Fig. 150: Screw on line

3. Push together line in plenum panel and screw on with the -1- fastening screws. --> Tightening torque: 20
(15 ftlb.) Nm . See Fig. 150.
SUBSEQUENT WORK
Subsequent work for line condenser-fluid tank
Install front left wheel housing liner. Refer to 50 56 19 Removing and installing front wheel housing liner -
Installing front wheel. Refer to 44 05 19 Removing and installing wheel - as of MY 2005 (All Models) .
87 47 19 REMOVING AND INSTALLING EVAPORATOR-FLUID TANK LINE -

PRELIMINARY WORK
Preliminary work line condenser-fluid tank
Microsoft
Removing cowl panel cover. Refer to 50 87 19 Removing and installing cowl panel cover - as of MY 2005
(All Models) .
Removing the battery. Refer to 27 06 19 Removing and installing battery - as of MY 2005 (All Models) .
REMOVING THE CONDENSER-FLUID TANK LINE
Removing the condenser-fluid tank line
installation.
Fig. 151: Installation location line condenser-fluid tank

Microsoft

1. Unscrew fastening nut -1- . See Fig. 152.
2. Remove the holder for the two refrigerant lines and pull the refrigerant line condenser-fluid tank out of the
expansion valve.
Microsoft
Fig. 153: Taking out refrigerant line

3. Unscrew the fastening nut -2- for the refrigerant line condenser-fluid tank in front of the fluid tank, detach the
line from the holder and pull out from under the water hoses for the heat exchanger. See Fig. 153.
INSTALLING THE CONDENSER-FLUID TANK LINE
Installing the condenser-fluid tank line
installation.
Microsoft
Fig. 154: Fastening nut on line fluid tank

1. Lay the refrigerant line under the heat exchanger hoses and screw down on line to fluid tank -2- with
fastening nut. --> Tightening torque: 20 (15 ftlb.) Nm . See Fig. 154.
2. Clip line into the holder.
Microsoft
Fig. 155: Screwing in fastening nuts

3. Position holder for refrigerant lines and secure with the fastening nut -1- . --> Tightening torque: 6 (4.5
SUBSEQUENT WORK
Subsequent work line condenser-fluid tank
Installing battery. Refer to 27 06 19 Removing and installing battery - as of MY 2005 (All Models) .
Installing cowl panel cover. Refer to 50 87 19 Removing and installing cowl panel cover - as of MY 2005
(All Models) .
87 50 19 REMOVING AND INSTALLING CONDENSER - AS OF MY 2005 (ALL

MODELS)
PRELIMINARY WORK
Preliminary work for condenser
--> 870317 Draining and filling in refrigerant
Microsoft
--> 63 10 19 REMOVING AND INSTALLING FRONT BUMPER - AS OF MY 2005 (ALL MODELS) .
REMOVING THE CONDENSER
Removing the condenser

Microsoft

1. Unscrew the two fastening screws -1- holding the air guide for the condenser. See Fig. 157.
2. Pull the air guide forward and disengage it at the condenser -A- . See Fig. 157.
Microsoft
Fig. 158: Refrigerant lines on condenser


3. Unscrew the two fastening screws -2- for the refrigerant lines. See Fig. 158.
4. Unscrew fastening screw -3- , lift the condenser and disengage from radiator bracket. See Fig. 158.
Microsoft
Fig. 159: Unclipping condenser

installation.
Microsoft
5. Unclip the condenser from the four brackets -A- and lift it out of the retaining bracket -arrow- . See Fig. 159.
INSTALLING THE CONDENSER
Installing the condenser
Fig. 160: Clipping in condenser

1. Insert condenser into the retaining bracket and clip it into place -A- . See Fig. 160.
Microsoft
Fig. 161: Refrigerant lines on condenser

2. Engage the condenser on the radiator bracket and secure with the fastening screw -3- . --> tightening torque:
4 (3) Nm (ftlb.) . See Fig. 161.


Microsoft
installation.
3. Carefully insert refrigerant lines into the condenser and secure with the fastening screws -2- . --> tightening
torque: 14 (10.5) Nm (ftlb.) . See Fig. 161.

4. Engage air guide on condenser -A- and screw down using the two fastening screws -1- . --> tightening
torque: 4 (3) Nm (ftlb.) . See Fig. 162.
SUBSEQUENT WORK
Rework on condenser
--> 63 10 19 REMOVING AND INSTALLING FRONT BUMPER - AS OF MY 2005 (ALL MODELS) .
87 55 19 REMOVING AND INSTALLING DESICCATOR - AS OF MY 2005

Microsoft
(ALL MODELS)
PRELIMINARY WORK
Preliminary work for dryer
1. Remove cover on left for plenum chamber. Refer to 85 22 19 Removing and installing cover - as of MY
2005 (All Models) .
2. Drain refrigerant for air-conditioning system with one air-conditioning unit. --> 870317 Draining and filling
in refrigerant - draining
General safety regulations for work on the air-conditioning systems.
CAUTION: Danger of injury when working on air-conditioned vehicles!
--> Observe safety regulations for working on air-conditioned vehicles and dealing with refrigerant R134a. -->
87 AW Safety regulations for working on air-conditioned vehicles and dealing with refrigerant R134a - as
--> Observe safety regulations for working with extraction and filling systems. --> 87 AW Safety regulations
for extraction and filling systems - as of MY 2005 (All Models) .
--> Observe instructions for repairing air-conditioning systems and storing spare parts. --> 87 01 IN
Instructions for repairing air-conditioning systems and storing spare parts - as of MY 2005 (All Models).
TOOLS AND MATERIALS
Tools for air-conditioning compressor
Air-conditioning service unit, refer to Special Tools, Commercially Available Tools, Chapter 2.4, No. 96-2)
REMOVING DRYER (FLUID TANK)
Removing desiccator (fluid tank)
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The desiccator (fluid tank) is located under the left plenum chamber cover.
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Fig. 164: Removing desiccator

1. Unscrew the fastening nuts -1- on the fluid tank. See Fig. 164.
3. Unscrew the fastening clamp -3- and remove the fluid tank upwards. See Fig. 164.
4. In any case, replace the desiccator.
INSTALLING DRYER (FLUID TANK)
Installing desiccator (fluid tank)

Microsoft
In any case, replace O-rings for the refrigerant lines and wet the new rings with refrigerant oil.
Only install a new desiccator.
Fig. 165: Installing desiccator

1. Position the fluid tank, connect the refrigerant lines and secure with the fastening screws -2- . --> M6: 4.5
ftlb. . See Fig. 165.
2. Connect the air-conditioning line -1- and tighten with fastening nut. See Fig. 165.
3. Tighten the hose clamp -3- . See Fig. 165.
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4. Determine the quantity of refrigerant oil. --> Technical data for air-conditioning system, volume removed
by suction + 30 cm3 .
SUBSEQUENT WORK
Subsequent work for the dryer
1. Fill in refrigerant correctly. --> 870317 Draining and filling in refrigerant - filling in
2. Install cover on left for plenum chamber. Refer to 85 22 19 Removing and installing cover - as of MY 2005
(All Models) .
87 58 19 REMOVING AND INSTALLING TEMPERATURE SENSOR - AS OF

REMOVING TEMPERATURE SENSOR
Removing temperature sensor


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2. From the driver's side, reach around to the "driver's footwell" air vent to release and disconnect the electrical
connector -a- . See Fig. 167.
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Fig. 168: Removing temperature sensor

3. Turn temperature sensor through 90° and pull it out of the heating/air conditioner unit.
INSTALLING TEMPERATURE SENSOR
Installing temperature sensor
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Fig. 169: Installing temperature sensor

2. From the driver's side, reach around the "driver's footwell" air vent to insert the temperature sensor into the
heater/air-conditioning unit and turn it through 90°.
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3. Plug in the electric connector until it clicks into place.
87 59 19 REMOVING AND INSTALLING OUTSIDE TEMPERATURE SENSOR

PRELIMINARY WORK
Preliminary work for outside temperature sensor
Refer to 85 15 19 Removing and installing heating/fresh air unit - as of MY 2005 (All Models) .
REMOVING OUTSIDE TEMPERATURE SENSOR
Removing outside temperature sensor
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Fig. 172: Unplugging electrical connector.

2. Release electrical connector to the temperature sensor -a- and unplug it. See Fig. 172.
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Fig. 173: Removing temperature sensor

3. Turn temperature sensor through 90° and pull it out of the heating/fresh-air unit.
INSTALLING OUTSIDE TEMPERATURE SENSOR
Installing outside temperature sensor
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Fig. 174: Installing temperature sensor

2. Insert temperature sensor into the heating/fresh air unit and turn through 90°.
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3. Push electrical connector into temperature sensor until it clicks into place.
SUBSEQUENT WORK
Subsequent work for outside temperature sensor
Refer to 85 15 19 Removing and installing heating/fresh air unit - as of MY 2005 (All Models) .
87 70 19 REMOVING AND INSTALLING EXPANSION VALVE - AS OF MY

2005 (ALL MODELS)
PRELIMINARY WORK
Preliminary work for expansion valve
Refer to 85 22 19 Removing and installing cover - as of MY 2005 (All Models) .
REMOVING EXPANSION VALVE
Removing expansion valve

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2. Remove the bracket for the two refrigerant lines and pull the refrigerant lines out of the expansion valve.
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Fig. 177: Fastening screws on expansion valve

3. Undo the two fastening screws on the expansion valve and remove expansion valve.
INSTALLING EXPANSION VALVE
Installing expansion valve
installation.
1. Carefully push expansion valve onto refrigerant lines from evaporator - do not tilt.
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Fig. 178: Fastening screws on expansion valve

2. Insert and tighten the two fastening screws. --> tightening torque: 9 (6.5) Nm (ftlb.)
3. Position refrigerant lines on expansion valve and press into place - do not tilt.
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Fig. 179: Screwing in fastening nuts

4. Position bracket for refrigerant lines and secure with the fastening nuts -1- . --> tightening torque: 6 (4.5)
Nm (ftlb.) . See Fig. 179.
SUBSEQUENT WORK
Rework on expansion valve
Refer to 85 22 19 Removing and installing cover - as of MY 2005 (All Models) .
87 78 19 REMOVING AND INSTALLING BLOWER REGULATOR - AS OF MY

2005 (ALL MODELS)
PRELIMINARY WORK
Preliminary work for blower regulator
(All Models) .
Remove air guide C . Refer to 85 34 19 Removing and installing air guide - as of MY 2005 (All Models) .
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REMOVING BLOWER REGULATOR
Removing blower regulator

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2. Release electrical connector and unplug it from blower regulator.
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3. Undo fastening screw.
4. Lift blower regulator and detach at the top side.
INSTALLING BLOWER REGULATOR
Installing blower regulator
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Fig. 183: Engage and screw down the blower regulator.

2. Engage blower regulator and insert into the heating/air-conditioning unit.
3. Secure the blower regulator with the fastening screw. --> Tightening torque: 1.5 (1.0 ftlb.) Nm
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Fig. 184: Inserting electric connector

4. Insert electrical connector into blower regulator until it clicks into place.
SUBSEQUENT WORK
Subsequent work for blower regulator
Install air guide C . Refer to 85 34 19 Removing and installing air guide - as of MY 2005 (All Models) .
(All Models) .
87 83 19 REMOVING AND INSTALLING PRESSURE SWITCH - AS OF MY

2005 (ALL MODELS)
PRELIMINARY WORK
Preliminary work for pressure switch
--> 870317 Draining and filling in refrigerant - chapter on "draining"
REMOVING PRESSURE SWITCH
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Removing pressure switch
The pressure switch is located in the radiator tank, right side in the direction of travel, under the cowl panel
cover.

1. Press release on electrical connector and disconnect from pressure switch.
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Fig. 186: Removing switch

2. Place one open-ended wrench on the hexagon of the pressure switch and a second open-ended wrench on the
hexagon of the refrigerant line.
3. Unscrew pressure switch from refrigerant line and remove.
INSTALLING PRESSURE SWITCH
Installing pressure switch
Replace the O-ring on the pressure switch and wet it with refrigerant oil.
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Fig. 187: Installing switch

1. Screw pressure switch onto refrigerant line and tighten with an open-ended wrench. Counter with a second
open-ended wrench. --> Tightening torque: 3.5 ftlb.
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2. Push electrical plug onto pressure switch until it clicks into place.
SUBSEQUENT WORK
Subsequent work for pressure switch
--> 870317 Draining and filling in refrigerant - chapter on "filling in"
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HVAC Heating
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Heating
80 23 19 REMOVING AND INSTALLING HEAT EXCHANGER - AS OF MY

2005 (ALL MODELS)
PRELIMINARY WORK
Preliminary work for heat exchanger
Refer to 19 38 17 Draining and filling in coolant - as of MY 2005 (All Models) .
Refer to 92 19 19 Removing and installing wiper link - as of MY 2005 (All Models) .
Remove left and right dome strut.
REMOVING HEAT EXCHANGER
Removing heat exchanger
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HVAC Heating
Fig. 1: Disconnecting coolant hoses of heat exchanger

1. Release the two fastening clamps for the coolant hoses of the heat exchanger and slide them back over the
hoses.
2. Carefully lift off the cover of the heat exchanger and remove from the body.
NOTE: If the cover of the heat exchanger is damaged during removal, it must be
replaced.
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HVAC Heating
Fig. 2: Removing the heat exchanger.

3. Undo the two fastening screws -1- and carefully lift the heat exchanger up and out. See Fig. 2.
INSTALLING HEAT EXCHANGER
Installing heat exchanger
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HVAC Heating
Fig. 3: Inserting heat exchanger into the heating/air-conditioning unit.

1. Carefully insert heat exchanger from above into the heating/air-conditioning unit and secure with the
fastening screws -1- . --> Tightening torque: 1.0 ftlb. . See Fig. 3.
NOTE: If the cover of the heat exchanger is damaged during removal, it must be
replaced.
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HVAC Heating
Fig. 4: Seal of heat exchanger cover

2. Check the seal at the cover of the heat exchanger and repair using a commercially available butyl adhesive or
replace if necessary.
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HVAC Heating
Fig. 5: Securing coolant hoses of heat exchanger

3. Push the cover over the connections of the heat exchanger and press into place against the body, making sure
it fits securely.
4. Push coolant hoses onto the heat exchanger and secure with fastening clamps.
SUBSEQUENT WORK
Subsequent work for heat exchanger
Refer to 19 38 17 Draining and filling in coolant - as of MY 2005 (All Models) .
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HVAC Heating
Refer to 92 19 19 Removing and installing wiper link - as of MY 2005 (All Models) .
Install left and right dome strut.
80 32 19 REMOVING AND INSTALLING HEAT EXCHANGER HOSE - AS OF

TOOLS

assembly tool for spring- commercially NR.72
band clamps available tool
PRELIMINARY WORK
Preliminary work for heat exchanger hose
Drain coolant. Refer to 19 38 17 Draining and filling in coolant - as of MY 2005 (All Models) .
Remove battery cover. Refer to 27 12 19 Removing and installing battery cover - as of MY 2005 (All
Models) .
Removing the battery. Refer to 27 06 19 Removing and installing battery - as of MY 2005 (All Models) .
REMOVING HEAT EXCHANGER HOSE
Removing heat exchanger hose
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HVAC Heating
Fig. 6: Disconnecting coolant hoses of heat exchanger

1. Release the two top fastening clamps for the coolant hoses of the heat exchanger and slide them back over the
hoses.
2. Remove the two bottom spring-band clamps using the assembly tool for spring-band clamps NR.72.
INSTALLING HEAT EXCHANGER HOSE
Installing heat exchanger hose
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HVAC Heating
Fig. 7: Securing coolant hoses of heat exchanger

1. Push coolant hoses onto the heat exchanger and secure with the two fastening clamps.
2. Fit the two bottom spring-band clamps using the assembly tool for spring-band clamps NR.72.
SUBSEQUENT WORK
Subsequent work for heat exchanger hose
Installing battery. Refer to 27 06 19 Removing and installing battery - as of MY 2005 (All Models) .
Fill in coolant. Refer to 19 38 17 Draining and filling in coolant - as of MY 2005 (All Models) .
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HVAC Heating
Install battery cover. Refer to 27 12 19 Removing and installing battery cover - as of MY 2005 (All
Models) .
Carry out work instruction after disconnecting the battery. Refer to 27 06 IN External power connection,
80 55 19 REMOVING AND INSTALLING FRONT FOOTWELL OUTLET VENT -

PRELIMINARY WORK
Preliminary work for front footwell outlet vent
Remove the small front covers for the center console at the left and right. Refer to 68 14 19 Removing and
installing center console cover - as of MY 2005 (All Models) .
REMOVING FRONT FOOTWELL OUTLET VENT
Removing front footwell outlet vent
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HVAC Heating
Fig. 8: Installation position of air guide

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HVAC Heating

1. Unscrew the fastening screw at the left -1- and right -2- of the heater/air-conditioning unit. See Fig. 9.
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HVAC Heating
Fig. 10: Removing footwell outlet vent

2. Pull the footwell outlet vent down out of the heater/air-conditioning unit and remove through the driver's
side.
INSTALLING FRONT FOOTWELL OUTLET VENT
Installing front footwell outlet vent
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HVAC Heating
Fig. 11: Inserting footwell outlet vent

1. Slide the footwell outlet vent in under the heater/air-conditioning unit through the driver's side and push it
onto the heater/air-conditioning unit.
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HVAC Heating
Fig. 12: Screw down the footwell outlet vent

2. Screw the footwell outlet vent to the heater/air-conditioning unit with the two fastening screws at the left -1-
and right -2- . --> Tightening torque: 1 (0.5 ftlb.) Nm . See Fig. 12.
SUBSEQUENT WORK
Subsequent work for front footwell outlet vent
Fit the small front covers for the center console at the left and right. Refer to 68 14 19 Removing and installing
center console cover - as of MY 2005 (All Models) .
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HVAC Ventilation
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85 15 19 REMOVING AND INSTALLING HEATING/FRESH AIR UNIT - AS OF

PRELIMINARY WORK
Preliminary work for heating/fresh air unit
1. Drain refrigerant. Refer to 87 03 17 Draining and filling in refrigerant - as of MY 2005 (All Models) .
2. Drain engine coolant. Refer to 19 38 17 Draining and filling in coolant - as of MY 2005 (All Models) .
Models) .
4. Remove tunnel support.
5. Remove passenger's airbag unit. Refer to 69 59 19 Removing and installing passenger's airbag unit - as of
7. Remove right plenum panel cover. --> 852219 Removing and installing cover - chapter on "Removing"
8. Remove heat exchanger. Refer to 80 23 19 Removing and installing heat exchanger - as of MY 2005 (All
Models) .
REMOVING HEATING/FRESH AIR UNIT
Removing heating/fresh air unit
NOTE:  Make sure not to damage the insulation of the main wiring harness.
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1. Immediately seal the openings of air-conditioning lines with suitable plugs.
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Fig. 2: Opening pressure line

2. Unscrew fastening screw -1- for refrigerant line -C- and open the pressure line. See Fig. 2, Fig. 1.
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Fig. 3: Removing expansion valve

3. Unscrew fastening screws -2- and remove expansion valve. Refer to 87 70 19 Removing and installing
expansion valve - as of MY 2005 (All Models) . See Fig. 3.
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Fig. 4: Fastening nuts for heater/air-conditioning unit

4. Unscrew the fastening nuts -6- for the heater/air-conditioning unit in the area of the plenum panel/firewall.
See Fig. 4.
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Fig. 5: Fastening screw to dashboard bracket

5. Unscrew fastening screw -3- for securing holder of the heater/air-conditioning unit to right side of dashboard
bracket (next to A-pillar). See Fig. 5.
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Fig. 6: Fastening screw to dashboard bracket

6. Unscrew fastening screw -4- for securing heater/air-conditioning unit to right side of dashboard bracket
(passenger's side). See Fig. 6.
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Fig. 7: Fastening screws on dashboard bracket

7. Unscrew the two fastening screws -5- for dashboard bracket to right side of body. See Fig. 7.
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Fig. 8: Unclipping wire harness at dashboard bracket.

8. Unclip holder for electric harness with a screwdriver from right side of dashboard bracket.
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Fig. 9: Pulling dashboard bracket forward

9. Now pull dashboard bracket a few centimeters forward on the right side.
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Fig. 10: Removing cotter pin

10. Pull out cotter pin -A- for holder of the heater/air-conditioning unit. See Fig. 10.
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Fig. 11: Pull out holder

11. Turn holder -B- for heater/air-conditioning unit by 90° and pull up and out. See Fig. 11.
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Fig. 12: Pulling off water drain hose

12. Lay down the air conditioner, release clamp for water drain hose -C- and pull off the water drain hose from
the heater/air-conditioning unit. See Fig. 12.
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Fig. 13: Lifting heater/air-conditioning unit forward under the dashboard bracket
13. Carefully lift heater/air-conditioning unit forward with a screwdriver under the right side of the dashboard
bracket.
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14. Release lower plug connection on heater/air-conditioning unit -a- and unplug. See Fig. 14.
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15. Release upper plug connection on heater/air-conditioning unit -a- and unplug. See Fig. 15.
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16. Cut tie-wraps of electric line (vehicle wire harness to heater/air-conditioning unit wire harness) with side
cutters. Remove vehicle wire harness.
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Fig. 17: Unscrewing holder for B+ line

17. Pull air conditioner forward on the right side, unscrew fastening screw -7- for B+ line holder and remove
holder for heater/air-conditioning unit. See Fig. 17.
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Fig. 18: Pulling out heater/air-conditioning unit

18. Pull/push heater/air-conditioning unit as far as possible in direction of passenger's seat.
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Fig. 19: Heating/air-conditioning unit

19. Remove heater/air-conditioning unit from passenger compartment via passenger's door.
INSTALLING HEATING/FRESH AIR UNIT
Installing heating/fresh air unit
NOTE: Do not remove the plugs until just before installing the expansion valve.
Check the condition of foam parts for damage; if in doubt replace.
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Fig. 20: Placing heater/air-conditioning unit in the vehicle

1. Insert heater/air-conditioning unit in the vehicle over the passenger's side.
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Fig. 21: Positioning heater/air-conditioning unit

2. Lift heater/air-conditioning unit over the center console and position under dashboard bracket.
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Fig. 22: Tightening holder for B + lead

3. Position holder for the B+ line on the heater/air-conditioning unit and tighten with the fastening screw -7- . --
> Tightening torque: 1.7 (1.5 ftlb.) Nm . See Fig. 22.
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4. Lay electric line from vehicle wire harness to heater/air-conditioning unit wire harness and fix with a tie-
wrap.
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5. Connect upper electric plug connection at heater/air-conditioning unit until it is felt to engage.
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6. Connect upper electric plug connection at heater/air-conditioning unit until it is felt to engage.
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Fig. 26: Fixing water drain hose

7. Check water drain hose for damage; if drain hose shows no sign of damage, connect hose to the drain on
heater/air-conditioning unit and fix with the clamp -C- . See Fig. 26.
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Fig. 27: Positioning heater/air-conditioning unit

8. Push heater/air-conditioning unit into position under right side of dashboard bracket in the direction of
firewall.
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Fig. 28: Positioning holder for heater/air-conditioning unit

9. Guide holder -B- for the heater/air-conditioning unit over the dashboard bracket, push through the mounting
of the heater/air-conditioning unit and turn through 90°. See Fig. 28.
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Fig. 29: Holder for heater/air-conditioning unit

10. Fix holder for heater/air-conditioning unit with cotter pin -A- . See Fig. 29.
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Fig. 30: Pushing dashboard bracket forwards

11. Push dashboard bracket forwards while lifting the heater/air-conditioning unit and taking care that no
electric lines get trapped.
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Fig. 31: Securing dashboard bracket

12. Screw down dashboard bracket with the two fastening screws -5- . --> Tightening torque: 23 (17 ftlb.)
Nm . See Fig. 31.
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Fig. 32: Clipping in plastic holders

13. Clip in the plastic holders for the electric main wire harness to the dashboard bracket.
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Fig. 33: Securing dashboard bracket

14. Secure dashboard bracket with the fastening screw -4- . --> Tightening torque: 9.7 (7.0 ftlb.) Nm . See
Fig. 33.
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Fig. 34: Securing holder for heater/air-conditioning unit

15. Screw down holder of heater/air-conditioning unit with the fastening screw -3- . --> Tightening torque: 3.5
(2.5 ftlb.) Nm . See Fig. 34.
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Fig. 35: Securing heater/air-conditioning unit to firewall

16. Slide the fastening bolts of the heater/air-conditioning unit through the firewall lid and tighten with the three
fastening nuts -6- . --> Tightening torque: 9.7 (7.0 ftlb.) Nm . See Fig. 35.
NOTE: Do not remove the plugs until just before installing the expansion valve.
Check the condition of foam parts for damage; if in doubt replace.
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Fig. 36: Installing expansion valve

17. Install expansion valve and tighten with the two fastening screws -2- , replace sealing rings for refrigerant
lines and wet them with refrigerant. Refer to 87 70 19 Removing and installing expansion valve - as of MY
2005 (All Models) . --> Tightening torque: 9 (6.5 ftlb.) Nm . See Fig. 36.
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Fig. 37: Positioning and securing refrigerant lines

18. Replace sealing rings for refrigerant lines and wet with refrigerant. Position refrigerant line and tighten with
fastening screw -1- . --> M8: 14 (10.5 ftlb.) Nm . See Fig. 37.
SUBSEQUENT WORK
Subsequent work for heater/air-conditioning unit
1. Install heat exchanger Refer to 80 23 19 Removing and installing heat exchanger - as of MY 2005 (All
Models) .
2. Install passenger's airbag unit. Refer to 69 59 19 Removing and installing passenger's airbag unit - as of
3. Install tunnel support.
Models) .
5. Install and connect the battery. Refer to 27 06 19 Removing and installing battery - as of MY 2005 (All
Models) . --> 27 06 IN WORK INSTRUCTIONS AFTER DISCONNECTING THE BATTERY - AS OF
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HVAC Ventilation
6. Fill in refrigerant. Refer to 87 03 17 Draining and filling in refrigerant - as of MY 2005 (All Models) .
7. Top up engine coolant. Refer to 19 38 17 Draining and filling in coolant - as of MY 2005 (All Models) .
8. Install right cover for plenum panel. --> 852219 Removing and installing cover - chapter on "Installing"
85 22 19 REMOVING AND INSTALLING COVER - AS OF MY 2005 (ALL

MODELS)
REMOVING COVER
Installing cover
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Fig. 39: Remove cover

1. Lift rubber lip of luggage compartment seal to one side, lift up the cover and disengage it from cowl panel
cover.
2. Check condition of Velcro strip -1- on the body and on the cover; replace if necessary. See Fig. 39.
INSTALLING COVER
Installing cover
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Fig. 40: Install cover

1. Check condition of Velcro strip -1- on the body and on the cover; replace if necessary. See Fig. 40.
2. Engage cover in cowl panel cover, lift rubber lip of luggage compartment seal to one side and press the cover
onto the Velcro strip -1- . See Fig. 40.
85 18 19 REMOVING AND INSTALLING PARTICLE FILTER - AS OF MY 2005

(ALL MODELS)
PRELIMINARY WORK
Preliminary work for the particle filter

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HVAC Ventilation
1. Remove battery cover.
2. Remove cover on right for plenum chamber.
REMOVING PARTICLE FILTER
Removing particle filter
1. In conjunction with telephone preparation, loosen the antenna at the two top fastening screws and unscrew
the two bottom fastening screws. Remove antenna part.
Fig. 41: Removing particle filter

2. Open the lock -1- on the filter housing. See Fig. 41.
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Fig. 42: Removing particle filter from housing

3. Remove the particle filter upwards and to the side -2- out of the housing guide. See Fig. 42.
INSTALLING PARTICLE FILTER
Installing particle filter
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Fig. 43: Inserting particle filter into housing

1. Insert a new particle filter into the housing guide -2- . See Fig. 43.
2. Ensure correct seating and installation position.
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Fig. 44: Lock filter housing

3. Close the lock -1- on the filter housing. See Fig. 44.
4. For vehicles with telephone preparation, insert antenna part at the top. Secure the antenna with the four
fastening screws.
SUBSEQUENT WORK
Work subsequent to installing particle filter
1. Install cover on right for plenum chamber.
2. Install battery cover.
85 30 19 REMOVING AND INSTALLING FAN - AS OF MY 2005 (ALL

MODELS)
PRELIMINARY WORK
Preliminary work for heating and fresh air blower motor
1. Refer to 68 15 19 Removing and installing glove compartment - as of MY 2005 (All Models) .
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REMOVING HEATER/FRESH-AIR BLOWER MOTOR
Removing heater/fresh-air blower motor
Set blower to position 0 on climate control and remove ignition key.
Fig. 45: Support strut

1. Unscrew the two fastening screws -1- of support strut and remove support strut. See Fig. 45.
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Fig. 46: Removing connector plug

2. Squeeze the plug -a- on the blower motor and pull off. See Fig. 46.
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Fig. 47: Blower motor cover fasteners

3. Unscrew the two fastening screws -2- holding the blower motor cover. See Fig. 47.
Fig. 48: Removing blower motor cover

4. Remove the cover -3- for the blower motor and pull out the blower motor downwards. See Fig. 48.
INSTALLING HEATER/FRESH-AIR BLOWER MOTOR
Installing heater/fresh-air blower motor
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Fig. 49: Installing blower motor cover

1. Insert the heater/fresh-air blower motor from below into the heater/ A/C unit and position the cover -3- . See
Fig. 49.
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Fig. 50: Blower motor cover fasteners

2. Secure cover -3- with the two fastening screws. See Fig. 49.
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Fig. 51: Inserting electrical plug connection

3. Insert the electrical plug connection until the plug can be felt to engage.
Fig. 52: Support strut

4. Install support strut and tighten with the two fastening screws -1- . See Fig. 52.
5. Switch on ignition and the blower in stages on the heating and fresh-air control. Check the function of the
blower.
SUBSEQUENT WORK
Subsequent work for heater blower motor
Refer to 68 15 19 Removing and installing glove compartment - as of MY 2005 (All Models) .
85 34 19 REMOVING AND INSTALLING AIR GUIDE - AS OF MY 2005 (ALL

MODELS)
OVERVIEW OF AIR GUIDE
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Fig. 53: Overview of air guide, shown on the 911

PRELIMINARY WORK
Preliminary work for defrost air guide
Remove dashboard. Refer to 70 18 19 Removing and installing instrument panel - as of MY 2005 (All
Models) .
Preliminary work for left air guide
Remove air vent for left door window. --> 855919 Removing and installing air vent at door - section on
"Removing"
Remove instrument panel trim. Refer to 70 19 19 Removing and installing trim under dashboard - as of MY
2005 (All Models) .
Preliminary work for right air guide
(All Models) .
REMOVING AIR GUIDE
Removing defrost air guide
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Fig. 54: Defrost air guide

1. Pull defrost air guide -2- up out of the heater/air-conditioning unit. See Fig. 54.
Removing left air guide
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Fig. 55: Disengaging air guide

1. Disengage air guide -A- for air vent at left door window by pulling it upward at the mounting bracket, then
pull to the left out of the air guide slot -B- to remove it in a downward direction. See Fig. 55.
If the air guide -B- is to be removed, first remove the dashboard. Refer to 70 18 19 Removing and installing
instrument panel - as of MY 2005 (All Models) . See Fig. 55.
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Fig. 56: Removing air guide

2. Pull the air guide -B- up out of the heater/air-conditioning unit. See Fig. 56.
Removing right air guide
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HVAC Ventilation

1. Disengage air guide -C- at the heater/air-conditioning unit and at the air guide -D- . See Fig. 57.
2. If the air guide -D- has to be removed, first remove the air vent at the right door window. --> 855919
Removing and installing air vent at door - section on "Removing"See Fig. 57.
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3. Disengage air guide -D- by pulling it upward at the mounting bracket, and pull it out in a downward direction
to remove it. See Fig. 58.
INSTALLING AIR GUIDE
Installing defrost air guide
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Fig. 59: Securing intermediate piece for defroster cover

1. Push defrost air guide -2- onto the connection on the heater/air-conditioning unit. Ensure it is seated properly.
See Fig. 59.
Installing left air guide
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Fig. 60: Inserting air guide

1. Insert the air guide -B- into the heating/air-conditioning unit and check that it is secure. See Fig. 60.
2. Install the dashboard if necessary. Refer to 70 18 19 Removing and installing instrument panel - as of MY
2005 (All Models) .
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HVAC Ventilation
Fig. 61: Engaging air guide

3. Slide the air guide -A- into the air guide slot -B- and engage air guide -A- at the mounting bracket. See Fig.
61.
Installing right air guide
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HVAC Ventilation
Fig. 62: Engaging air guide

1. Engage the air guide -D- at the mounting bracket. See Fig. 62.
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Fig. 63: Connecting air guide

2. Connect air guide -C- at the heater/air-conditioning unit and at the air guide -D- . See Fig. 63.
3. Install air vent at door window if necessary. --> 855919 Removing and installing air vent at door - section
on "Installing"
SUBSEQUENT WORK
Subsequent work for defrost air guide
Install dashboard. Refer to 70 16 19 Removing and installing dashboard cover - as of MY 2005 (All
Models) .
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HVAC Ventilation
Subsequent work for left air guide
Install air vent for left door window. --> 855919 Removing and installing air vent at door - section on
"Installing"
Install trim under instrument panel. Refer to 70 19 19 Removing and installing trim under dashboard - as of
Subsequent work for right air guide
(All Models) .
85 53 19 REMOVING AND INSTALLING MIDDLE AIR VENT - AS OF MY 2005

(ALL MODELS)
PRELIMINARY WORK
Preliminary work for central air vent
Remove PCM/radio. Refer to 91 10 19 Removing and installing PCM display and control unit - as of MY
2005 (All Models) .; Refer to 91 24 19 Removing and installing car radio CD player - as of MY 2005 (All
Models) .
REMOVING MIDDLE AIR VENT
Removing middle air vent
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NOTE: The air vent is installed in the dashboard using three locking tabs.
Fig. 65: Raising bottom locking tabs

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The two bottom locking tabs can be raised using a small screwdriver.
Fig. 66: Releasing top locking tab

The top locking tab must be levered downwards using a thin screwdriver.
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1. Using a size one screwdriver, raise the two bottom locking tabs, pulling out the air vent underneath at the
same time.
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Fig. 68: Releasing top locking tab using a screwdriver

2. Hold the bottom air vent under tension and push a size one screwdriver through the ventilation slats and the
slot for the top locking tab.
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Fig. 69: Turning screwdriver through 90°

3. Turn the screwdriver to the left through 90° so that the locking tab is pushed down.
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Fig. 70: Levering out top air vent

4. Hold the screwdriver and carefully lever out the top air vent from the dashboard using a plastic spatula.
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Fig. 71: Electrical line routing

5. Disengage electric plug connection on device carrier and pull apart plug connection.
INSTALLING MIDDLE AIR VENT
Installing middle air vent
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Fig. 72: Electrical line routing

1. Connect electric line for air vent with the harness and attach to device carrier.
2. Push air vent into dashboard and ensure that the air vent is pushed into the air guide on the heating/air-
conditioning unit.
3. Push air vent into dashboard right up to the stop. Check adjustment options and illumination of air vent to
ensure that everything is operating correctly.
SUBSEQUENT WORK
Subsequent work for central air vent
Install PCM/radio. Refer to 91 10 19 Removing and installing PCM display and control unit - as of MY
2005 (All Models) .; Refer to 91 24 19 Removing and installing car radio CD player - as of MY 2005 (All
Models) .
85 59 19 REMOVING AND INSTALLING AIR VENT AT DOOR - AS OF MY

2005 (ALL MODELS)
REMOVING AIR VENT AT DOOR
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HVAC Ventilation
Removing air vent at door
NOTE: The air vent is installed in the dashboard using three locking tabs.

The two bottom locking tabs can be raised using a small screwdriver.
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Fig. 74: Releasing top locking tab

The top locking tab must be levered downwards using a thin screwdriver.
Fig. 75: Installation position for air vent at door

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1. Using a size one screwdriver, raise the two bottom locking tabs, pulling out the air vent underneath at the
same time.
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Fig. 77: Releasing top locking tab using a screwdriver

2. Hold the bottom air vent under tension and push a size one screwdriver through the ventilation slats and the
slot for the top locking tab.
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Fig. 78: Turning screwdriver through 90°

3. Turn the screwdriver to the left through 90° so that the locking tab is pushed down.
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Fig. 79: Levering out air vent, diagram shows central air vent
4. Carefully lever out the top air vent from the dashboard using a plastic spatula.
5. Unclip the side panel on the dashboard using a plastic spatula and disengage the electrical plug connection on
the mounting bracket and pull apart the plug connection.
6. Pull out air vent.
INSTALLING AIR VENT AT DOOR
Installing air vent at door
1. Connect electric line for air vent with the harness and attach to mounting bracket. Attach the side panel to the
dashboard and clip it in.
2. Push air vent into dashboard and ensure that the air vent is pushed into the air guide on the heating/air-
conditioning unit.
3. Push air vent into dashboard right up to the stop. Check adjustment options and illumination of air vent to
ensure that everything is operating correctly.
85 78 19 INSTALLING AND REMOVING FRESH/RECIRC. AIR SERVO

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MOTOR - AS OF MY 2005 (ALL MODELS)

PRELIMINARY WORK
Preliminary work for fresh/recirc. air servo motor
1. Remove heater/air-conditioning unit. --> 851519 Removing and installing heating/fresh-air unit - chapter
on "Removing"
REMOVING FRESH/RECIRC. AIR SERVO MOTOR
Removing fresh/recirc. air servo motor

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2. Unscrew fastening screw -1- from below -arrow- . See Fig. 81.
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4. Press the locking mechanism of the servo motor actuating lever and press it out from the deflector of the
recirculation flap.
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Fig. 84: Removing servo motor

5. Swing down the servo motor and remove from the heater/air-conditioning unit.
INSTALLING FRESH/RECIRC. AIR SERVO MOTOR
Installing fresh/recirc. air servo motor
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Fig. 85: Inserting servo motor into heater/air-conditioning unit

1. Slide servo motor into heater/air-conditioning unit as far as it will go and then swing it upwards.
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Fig. 86: Engaging actuating lever

2. Clip the servo motor actuating lever onto the deflection lever of the heater/air-conditioning unit.
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3. Lay electric line to the servo motor -A- and connect the electric connector to servo motor until it is felt to
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HVAC Ventilation

4. Secure servo motor with the fastening screw -1- . --> Tightening torque: 1.2 (1.0 ftlb.) Nm +/-0.5 (0.5 ftlb.)
Nm . See Fig. 88.
SUBSEQUENT WORK
Subsequent work for fresh/recirc. air servo motor
1. Install heating/air-conditioning unit. --> 851519 Removing and installing heating/fresh-air unit - chapter
on "Installing"
85 65 19 REMOVING AND INSTALLING VENTILATION COVER - AS OF MY

2005 (ALL MODELS)
PRELIMINARY WORK
Preliminary work for ventilation cover
Remove rear apron. Refer to 63 55 19 Removing and installing rear spoiler - as of MY 2005 (Boxster S,
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Boxster RHD) .
Remove rear luggage compartment carpet.
REMOVING VENTILATION COVER
Removing ventilation cover
The ventilation covers are located laterally, underneath, and in front of the tail lights on the left and right.

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Fig. 90: Removing the electric line

1. Pull the support for the electric line through the luggage compartment to the ventilation cover.
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Fig. 91: Removing the ventilation cover

NOTE: Removing the ventilation covers destroys the air boxes. The air boxes must be
replaced.
2. Unclip the ventilation cover on the body from the inside (luggage compartment area) and take off toward the
outside.
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Fig. 92: Removing air box with ventilation cover

3. Take off the air box from the body and remove any remaining adhesive with cleaning agents.
INSTALLING VENTILATION COVER
Installing ventilation cover
NOTE: Removing the ventilation covers destroys the air boxes. The air boxes must be
replaced.
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Fig. 93: Inserting ventilation cover in the air box

1. Move and position the ventilation cover through the air box, and pull off the protective film of the air box for
the butyl cord. The air boxes have a butyl cord attached in the sealing area.
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Fig. 94: Installing ventilation cover with air box

2. Position the ventilation cover together with the air box on the body and clip in the ventilation cover. Press on
the air box in the sealing area to the body again.
3. Push on electric line to the ventilation cover.
SUBSEQUENT WORK
Subsequent work for ventilation cover
Insert rear luggage compartment carpet.
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Install rear apron. Refer to 63 55 19 Removing and installing rear spoiler - as of MY 2005 (Boxster S,
Boxster RHD) .
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STEERING Steering
STEERING
Steering
48 TW TIGHTENING TORQUES FOR STEERING - AS OF MY 2005 (ALL

MODELS)
TIGHTENING TORQUES FOR STEERING
Tightening torques for power-steering gear

value 1 2
Steering gear to cross member M10 x Replace screws after Tightening
48 ftlb.
45 each removal. torque
Universal joint (steering shaft) to Replace fit bolt after Tightening
17 ftlb.
steering gear M8 x 35 each removal. torque
Tie rod (axial joint) to steering rack Tightening
59 ftlb.
M16 x 1.5 torque
Aluminum tie rod to axial joint (lock Tightening
37 ftlb.
nut) M14 x 1.5 torque
Tie rod (ball joint) to wheel carrier Tightening
56 ftlb.
(at steering arm) M12 x 1.5 torque
Steering line to upper steering gear Tightening 7.5
(union nut) M10 torque ftlb.
Steering line to lower steering gear Tightening 7.5
(union nut) M10 torque ftlb.
Combination holder for pressure and Tightening 7.5
return lines to engine M6 x 12 torque ftlb.
Pressure and return lines to steering Tightening
17 ftlb.
gear (tension shackle) M10 x 20 torque
Threaded connection, plug-in
a/f = width across flats Tightening
couplings for steering hydraulics 22 ftlb.
a/f 15 pressure line torque
M16 x 1.5 (a/f 15)
Threaded connection, plug-in
a/f = width across flats Tightening
couplings for steering hydraulics 30 ftlb.
a/f 19 return line torque
M20 x 1.5 (a/f 19)
Tightening torques for steering train/steering wheel

value 1 2
Upper universal joint to steering Replace fit bolt after Tightening
17 ftlb.
shaft M8 x 35 each removal. torque
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STEERING Steering
Steering train to upper pedal block Tightening

34 ftlb.
M10 x 100 torque
Steering train to lower pedal block Tightening 6 to 7.5
(pedal bearing axle in pedal block) torque ftlb.
Steering train to lower pedal block
Tightening 7.5
(locknut pedal bearing axle to pedal
torque ftlb.
block right M8)
Steering train to lower pedal block
Tightening
(locknut pedal bearing axle to pedal 34 ftlb.
torque
block left M8)
Locking-mechanism housing to
Tightening 5.5
steering outer tube upper and lower
torque ftlb.
M6 x 18
Tightening 4.5
Steering lock to steering train
torque ftlb.
Transverse support to retaining Tightening 7.5
frame M6 torque ftlb.
Replace internal
Steering wheel to steering shaft Tightening
serration screw after 37 ftlb.
M18 x 26 torque
each removal.
Tightening 4.5
Tab washer to steering wheel M6
torque ftlb.
48 02 01 CHECKING THE FLUID LEVEL FOR THE POWER-ASSISTED

STEERING - AS OF MY 2005 (ALL MODELS)
CHECKING THE FLUID LEVEL FOR THE POWER-ASSISTED STEERING
Notes on power-steering fluid
Damage to the power-assisted steering is caused by a shortage of oil in the hydraulic system. Even small leaks
can cause the fluid to escape and damage the servo pump as a result of the high oil pressure occurring in the
hydraulic circuit.
Grunt-like noises that can be heard when the steering is locked, or foam formation in the reservoir indicate a
shortage of oil and/or that air has also been sucked in. Before filling the reservoir, any existing leaks must be
eliminated on the suction side. Alternatively, the defective part on the pressure side should be replaced.
Only Pentosin CHF 11 S may be used in the reservoir. Pentosin CHF 11 S can be ordered under the following
part number:
Quantity supplied 1 liter = 000.043.203.33.
Checking fluid level for power-assisted steering
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STEERING Steering
The reservoir is located in the engine compartment.
Fig. 1: Checking steering fluid

There are 2 marks on the dipstick located on the cap. There is a "Cold" mark for when the engine is cold -->
Cold mark: approx. 20 °C and on the other surface for when the engine is hot, "Hot" --> Hot mark: approx.
80 °C .
Check the fluid level (Pentosin CHF 11 S) when the engine is off and cold --> Cold mark: approx. 20 °C .
1. Start engine and --> duration: approx. 20 s allow to run at idle speed. Switch off engine.
2. Open engine cover. Open reservoir cap.
3. Wipe off the dipstick. Close and then reopen the cap. The fluid level should lie in the hatched area beneath
the "Cold" mark (mark = maximum level) at --> Cold mark: approx. 20 °C . Top up with Pentosin if
necessary. The upper "Hot" mark is intended for a fluid temperature of --> Hot mark: approx. 80 °C .
Do not add too much Pentosin! The respective marks are for the maximum fluid level at the "COLD" or "HOT"
temperature.
If assembly work was performed previously, check fluid level with the engine idling and without operating the
steering.
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STEERING Steering
Multiple steering movements (maneuvering) with the engine switched off change the fluid level in the reservoir
- fluid level rises. In this case, the engine must be run for at least 20 seconds immediately prior to the fluid level
check.
When topping up or filling in Pentosin, make sure that it does not come into contact with the coolant hoses! If
coolant hoses come into contact with Pentosin, thoroughly clean them with water IMMEDIATELY! Replace
visibly swollen coolant hoses!
Checking the steering system for leaks (visual check)
With engine idling, turn steering wheel as far as the stop and hold still. The maximum possible line pressure
results in this way.
In this position, check all pipe connections for leaks.
Carry out testing for a maximum of --> Period: 10 s . A longer check should always be interrupted by a brief
pause after approximately --> Period: 10 s .
Bleeding the steering system
1. To fill the whole system after the installation of new steering components or lines or after a substantial loss of
hydraulic fluid, briefly start the engine a few times and, when it fires, switch it off again immediately. This
procedure causes the fluid level in the reservoir to fall rapidly, so constantly add Pentosin CHF 11 S. The
reservoir must not be sucked dry.
2. If the fluid level in the reservoir does not fall any further when the engine is briefly turned over, start the
engine and let it run at idling speed.
3. Rapidly turn the steering wheel from full-lock to full-lock several times so that the air can escape from the
cylinders. At the end positions of the piston, do not pull the steering wheel with more force than is necessary in
order to turn the steering (to prevent unnecessary build-up of pressure initially).
4. Observe fluid level during this procedure. If it continues to fall, add fluid until the level in the reservoir
remains constant and no more air bubbles rise in the reservoir when the steering wheel is turned.
5. Correct the fluid level with the engine at idling speed and without moving the steering.
48 10 19 REMOVING AND INSTALLING STEERING WHEEL - AS OF MY 2005

(ALL MODELS)
PRELIMINARY WORK
Warning notes for removing and installing steering wheel
Refer to 27 06 IN External power connection, jump lead starting - as of MY 2005 (All Models) .
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STEERING Steering
Warning notes for removing and installing steering wheel
WARNING: Danger of injury and damage to property as a result of incorrect handling

of airbag units! Always observe the safety regulations for handling airbag
units. Refer to 69 AW Disposal of airbag and belt tensioner units - as of
 In the case of incorrect handling, system faults may occur resulting

in the triggering of the airbag or failure to do so.
--> The airbag unit must always be placed so that the airbag opening faces upwards.
--> If removed for an extended period, the airbag unit must be kept in a locked place.
--> Switch off ignition and leave ignition key inserted (steering must not be locked). Disconnect the battery.
Route or isolate ground strap so that all contact with a ground carrier (e. g. body, seat frame) is avoided. Refer
to 27 06 IN External power connection, jump lead starting - as of MY 2005 (All Models) .
--> After the battery is disconnected, always wait for 1 minute before disconnecting the airbag connectors.
REMOVAL

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STEERING Steering
Fig. 2: Releasing driver's airbag unit

2. Remove steering wheel airbag unit --> 69 58 19 REMOVING AND INSTALLING DRIVER'S AIRBAG
UNIT - AS OF MY 2005 (CARRERA 2, CARRERA 2S, CABRIO 2, CABRIO 2S, CARRERA 4,
CABRIO 4) .
3. Turn wheels to straight-ahead position. Before removing steering wheel, put a mark (e. g. color marking) on
steering wheel and steering column (centering of airbag spiral spring).
4. Remove steering wheel by releasing multiple-tooth screw.
INSTALLATION
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STEERING Steering
NOTE:  The steering wheel is made of magnesium alloy. The tightening torques
must be strictly observed.
 Wheels straight ahead and observe the previously-applied marking.
 Replace multiple-tooth screw after each removal (micro-encapsulated
thread).
 Observe tightening torque. --> Tightening torque: 50 (37 ftlb.) Nm
 Airbag unit must lock with an audible click! Check by pulling at airbag
unit.
Installation of the steering wheel takes place in reverse order.
48 15 19 REMOVING AND INSTALLING STEERING COLUMN CENTER - AS

PRELIMINARY WORK
Preliminary work
1. Ignition key in position 1. Then ignition key in position 0 = (switch ignition off but do not remove key so that
electronic steering wheel locking does not lock). Then disconnect battery.
2. Remove airbag unit for driver. Refer to 69 58 19 Removing and installing driver's airbag unit - as of MY
2005 (All Models) .
3. Turn steering wheel to a straight-ahead position and remove it --> 481019 Removing and installing steering
wheel.
NOTE:  For better accessibility, move the height adjustment (steering wheel) of the
steering column to the appropriate position and close the locking lever.
4. Remove main headlight switch. To do this, press in rotary knob on the light switch (not to the stop) and turn
the switch clockwise. Pull out the light switch in this position. Release and remove connector.
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STEERING Steering
Fig. 3: Removing trim panel (lower part of dashboard)

5. Remove trim panel (lower part of dashboard) --> 70 19 19 REMOVING AND INSTALLING TRIM
UNDER DASHBOARD - AS OF MY 2005 (ALL MODELS) . Unscrew the fastening screws -1- and swivel
the cover under the dashboard on the driver's side -2- downwards -Arrow A- . See Fig. 3.
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STEERING Steering
Fig. 4: Disconnecting the electrical plug connections

6. Release plug connections -1, 2, 3- and remove -Arrows A- . See Fig. 4.
7. Remove clutch pedal on vehicles with manual transmission Refer to 30 05 19 Removing and installing the
clutch pedal - as of MY 2005 (All Models) .
REMOVING STEERING COLUMN CENTER
CAUTION: Increase risk when handling airbag modules.
 Injury and material damage may occur if airbag units are not handled
correctly. Refer to 69 AW Disposal of airbag and belt tensioner units -
--> Observe safety regulations for handling airbag modules.
NOTE:  The height adjustment (steering wheel) of the steering column must be in
the lower stop and the locking lever closed.
 The electronic locking unit (ELV) must be open (ignition key plugged in,
then disconnect battery).
As a spare part, the steering column -A- is delivered complete with steering shaft. See Fig. 5.
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STEERING Steering
Fig. 5: Overview, steering column

A - Steering column with steering shaft
1. Remove trim panel of steering column switch and remove steering column switch --> 94 50 19 REMOVING
AND INSTALLING STEERING-COLUMN SWITCH - AS OF MY 2005 (ALL MODELS) .
Fig. 6: Strut on steering column

2. Loosen strut on retaining frame (arrow shows mount on steering column). --> Strut on steering column . See
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STEERING Steering
Fig. 6.
3. Remove KESSY/PAS control unit.
Fig. 7: Steering column mounting

4. Loosen lower steering column mount. To do this, loosen the lock nut -1- approx. 3 turns. Then unscrew the
pedal bearing axle on the hexagon -2- approx. 2 turns (anti-clockwise). See Fig. 7.
5. Loosen upper steering column mount (loosen lock nut -3- /remove hexagon-head bolt -4- ) and extend the
steering column. See Fig. 8, Fig. 7.
6. Remove front underbody panel.
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STEERING Steering
Fig. 8: Steering shaft to steering gear

7. Loosen fastening screw -Arrow- and pull off steering shaft (universal joint) on the steering gear. See Fig. 8.
INSTALLING STEERING COLUMN CENTER
CAUTION: Increase risk when handling airbag modules.
 Injury and material damage may occur if airbag units are not handled
correctly Refer to 69 AW Disposal of airbag and belt tensioner units -
--> Observe safety regulations for handling airbag modules.
NOTE:  Observe the tightening sequence on the mounting bracket.

 Once the battery is disconnected, perform the work required for full
restoration of normal driving. Refer to 27 06 IN External power connection,
 Calibrate steering-angle sensor. Refer to 45 60 Initializing and calibrating
steering-angle sensor - as of MY 2005 (All Models) .
 If the steering column is replaced (new steering column), the electric
steering column locking mechanism (ELV) must be taught with the PIWIS
Tester in the PAS system, menu Learning functions >> Teach ELV << . You
can get the necessary Teach Enable Code (TEC code) from IPAS or from
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STEERING Steering
your importer using the vehicle identification number.

 Always replace the fastening screw for the universal joint of the steering
column.
 Replace locking screws and nuts.
 Replace the clamping washer (strut mount to steering column).
 Carry out a visual inspection of all parts.
 Observe correct tightening torques --> 4800TW Tightening torques for
steering.
Individual components cannot be disassembled and/or replaced.
Fig. 9: Strut to steering column

1. Before installing the steering column, mount the strut -Arrow- without play on the steering column. See Fig.
9.
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STEERING Steering
Fig. 10: Steering shaft to steering gear

2. Put steering gear in center position. Make sure that the clip for steering gear pinion is present (steering shaft
assembly aid). Mount the steering shaft (universal joint) to the steering gear in the correct position using new
hexagon-head bolt -Arrow- . See Fig. 10.
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Fig. 11: Steering column tightening sequence

3. Insert the steering column and pay attention to the block teeth of the steering shaft (the steering shaft can only
paired be in one position! 2. worker required). Tightening sequence for mounting:
1. - Pedal bearing axle on a/f 10 mm hexagon -2- (tightening torque 8 + 2 Nm (6 + 1.5 ftlb.)). See Fig. 11.
2. - Lock nut right -1a- (tightening torque 10 Nm (7.5 ftlb.)). Then lock nut for steering column -1b- (tightening
torque 46 Nm (34 ftlb.)). See Fig. 11.
3. - Lock nut of upper mount -3- (tightening torque 46 Nm (34 ftlb.)) See Fig. 11.
4. Install front underbody panel.
5. Install KESSY/PAS control unit.

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STEERING Steering
6. Put steering column in the lowermost adjustment position and close the locking lever again. In this position,
fasten the strut to the structure (this allows the adjustment range to move smoothly in all positions).
7. Install the steering-column switch and the trim panel from the steering-column switch --> 94 50 19
REMOVING AND INSTALLING STEERING-COLUMN SWITCH - AS OF MY 2005 (ALL
MODELS) .
SUBSEQUENT WORK
Subsequent work
1. Install clutch pedal on vehicles with manual transmission Refer to 30 05 19 Removing and installing the
clutch pedal - as of MY 2005 (All Models) .
Fig. 12: Installing lining

2. Mount linings under dashboard --> 70 19 19 REMOVING AND INSTALLING TRIM UNDER
DASHBOARD - AS OF MY 2005 (ALL MODELS) .
3. Install main headlight switch. To do this, insert the connector until it is felt to engage. Push in the light switch
to the stop and turn the rotary switch anti-clockwise.
4. Install steering wheel --> 48 10 19 Removing and installing steering wheel - as of MY 2005 (All Models).
5. Install airbag unit for driver --> 69 58 19 Removing and installing driver's airbag unit - as of MY 2005
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STEERING Steering
(All Models) .
(All Models) .
NOTE: If the steering column is replaced (new steering column), the electric steering
column locking mechanism (ELV) must be taught with the PIWIS Tester in the
PAS system , menu Learning functions >> Teach ELV << . You can get the
necessary Teach Enable Code (TEC code) from IPAS or from your importer
using the vehicle identification number.
7. Read out all fault memories and delete them, if necessary.
8. Carry out suspension alignment.
9. After the suspension alignment, with the position of the wheels >> straight ahead << calibrate the steering-
angle sensor on the measuring platform.
10. Carry out a test drive and check the operation (continuous easy steering movements, steering column
adjustment, electronic steering column lock).
48 90 19 REMOVING AND INSTALLING POWER-STEERING GEAR - AS OF

TOOLS

screwdriver special tool P 9546
press-out tool special tool P 9560
PRELIMINARY WORK
Preliminary work
1. Raise the vehicle Refer to 40 Tightening torques for front axle - as of MY 2005 (All Models) .
2. Remove front wheels Refer to 44 05 19 Removing and installing wheel - as of MY 2005 (All Models) .
3. Remove front underbody panel Refer to 51 92 19 Removing and installing cover for front underbody - as
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STEERING Steering
CAUTION: Increased risk of accidents if too much Pentosin is used or if Pentosin

comes into contact with the coolant hoses when filling or topping up.
 Possible danger of injury or damage.
--> Multiple steering operations (maneuvering) with the engine switched off change the fluid level in the
reservoir. In this case, the engine must be running immediately prior to the fluid level check.
--> If coolant hoses come into contact with Pentosin, clean them thoroughly with water IMMEDIATELY.
--> Replace visibly swollen coolant hoses.
NOTE:  Before the feed and return lines are loosened, place a suitable container
underneath to collect steering fluid.
 Wear protective goggles and gloves.
REMOVAL
Removing
NOTE: Fix the steering wheel with the wheels in straight-ahead position or remove the
steering wheel with the wheels in straight-ahead position. If this is not done, the
airbag contact unit will have to be put in center position after installation of the
steering gear.
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STEERING Steering
Fig. 13: Universal joint

1. Loosen universal joint (steering shaft) at steering gear -Arrow- . For this purpose, take out the clamping
screw and slide the joint upwards. See Fig. 13.
2. Press tie-rod end out of steering arm. Use press-out tool P 9560 (ball-joint extractor). When loosening the
lock nut, counter with a screwdriver P 9546 (Torx screwdriver).
3. Repeat procedure on the other side.
Fig. 14: Retainer plate

4. Loosen feed and return lines at the steering gear. To do this, loosen the hexagon socket-head bolt -Arrow-
and remove the retainer plate. Plug lines or use collecting container. Cover lines if necessary (danger of soiling).
See Fig. 14.
5. Loosen the two steering-gear fastening screws (on the underside of the cross member).
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STEERING Steering
Fig. 15: Cross member with diagonal brace to body

6. Loosen screws -1+2- on the two (front) diagonal braces. See Fig. 15.
Fig. 16: Supporting cross member

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STEERING Steering
7. Lower vehicle to working height (lower platform lift) and support cross member with a hydraulic lift (use
hard rubber base or wooden block: See Fig. 16).

8. Loosen threaded connections -3+4- securing cross member to body (front) and threaded connections -5+6-
securing cross member with diagonal arm to body (front) (screws -1+2- have already been removed). See Fig.
15.
9. Loosen threaded connections securing cross member to body (rear) -7+8- and screw out -9+10- by approx. 10
mm. See Fig. 15.
10. Lower front cross member slightly (approx. 50 to 60 mm).
11. Pull out steering gear to the left (to the right for right-hand drive vehicles).
NOTE: Ensure that no damage (scoring) is caused to the steering rack. To loosen and
tighten the tie rods, secure the steering gear on a suitable plate.
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STEERING Steering
Fig. 18: Tie rod on steering gear

12. If necessary, loosen and remove right and left tie rods at steering gear.
INSTALLATION
Installing
NOTE: When topping up or filling in Pentosin, make sure that it does not come into
contact with the coolant hoses. Observe the specifications in order to avoid
overfilling, and thus overflowing.
 If coolant hoses come into contact with Pentosin, clean them thoroughly
with water IMMEDIATELY.
 Replace visibly swollen coolant hoses.
 Tighten all threaded connections to the specified tightening torque.
Install in reverse order. It is essential to observe the following points while doing so:
- Replace steering-gear fastening screws, the fit bolt of the steering shaft and the steering-wheel fastening screw
whenever they have been removed. Screw threads must be clean and free of grease.
- Ensure that no damage (scoring) is caused to the steering rack.
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STEERING Steering
Fig. 19: Tie rod on steering gear

- Mount the tie rods on the steering gear. Then secure the respective bellows with new clamping rings --> Tie
rod on steering gear . See Fig. 19.
- Position red plastic clip on steering-gear pinion. The plastic clip ensures that the fastening screw between the
universal joint and steering pinion sits into the groove on the steering pinion.
- Push on universal joint (steering shaft) with the steering gear and steering wheel or airbag contact unit (spring)
in center position. For ease of assembly, just insert steering-gear fastening screws.
- Observe following notes for sliding piece and airbag contact unit!
Notes for sliding piece and airbag contact unit
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STEERING Steering
Fig. 20: Sliding piece

1. If sliding piece -1- was pulled off the steering shaft -4- , the notch -2- must point towards the tooth gap -3-
during assembly. See Fig. 20.
2. If the steering wheel was not fixed before the steering gear was removed, the position of the contact unit
(spring) may no longer be correct. In this case, remove steering wheel and move contact unit to center position
because otherwise the spring will be damaged.
Contact unit in center position
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STEERING Steering
Fig. 21: Contact unit

- To position the airbag contact unit in center position, press the latch -D- and turn the rotor -A- carefully to the
left as far as it will go. See Fig. 21.
- Then (from the furthest left position) turn the rotor -A- carefully to the right, approx. 3.5 to 3.75 turns, until
the band printed on one side is visible in the window. See Fig. 21.
3. Turn front wheels to straight-ahead position before fitting the steering wheel (steering shaft mounted on
steering gear).
SUBSEQUENT WORK
Subsequent work
1. After fitting the pressure lines, fill steering hydraulics with Pentosin and bleed the steering system.
2. Fit front underbody panel Refer to 51 92 19 Removing and installing cover for front underbody - as of
3. Fit front wheels Refer to 44 05 19 Removing and installing wheel - as of MY 2005 (All Models) .
4. Adjust toe Refer to 44 95 03 Suspension alignment, complete - as of MY 2005 (All Models) . Calibrate
steering-angle sensor if necessary.
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STEERING Steering
48 98 19 REMOVING AND INSTALLING HYDRAULIC PUMP - AS OF MY 2005

(ALL MODELS)
TOOLS

Disassembly tool, universal commercially NR.21
available tool
INFORMATION
Information
Fig. 22: Overview of hydraulic pump

1 - Throttle housing with distributor pipe
2 - Resonance tube
3 - Intake distributor cylinders 4-6
4 - Air-conditioning compressor
5 - Supply tank
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STEERING Steering
6 - Sealing rings
7 - Pulley
8 - Screw
9 - Hydraulic pump
PRELIMINARY WORK
Preliminary work
1. Remove left front seat. Refer to 72 01 19 Removing and installing front seat - as of MY 2005 (All LHD
Models) .
3. Remove engine compartment cover.
REMOVING HYDRAULIC MOUNT
Removing
Fig. 23: Overview of hydraulic pump

1 - Throttle housing with distributor pipe
2 - Resonance tube
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STEERING Steering
3 - Intake distributor cylinders 4-6
4 - Air-conditioning compressor
5 - Supply tank
6 - Sealing rings
7 - Pulley
8 - Screw
9 - Hydraulic pump
1. Remove throttle housing and distributor pipe.
Refer to 24 42 19 Removing and installing throttle body - as of MY 2005 (All Models) .
2. Remove resonance tube.

Loosen screw-type hose clamps, see -Arrows- , and remove resonance tube -2- . See Fig. 24, Fig. 23.
3. Remove left intake-air distributor.

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STEERING Steering
Refer to 24 46 20 Removing and installing intake-air distributor - as of MY 2005 (All Models) .
4. Loosen belt pulley.
Loosen screws on pulley, see -Arrows- . See Fig. 25.
Fig. 25: Belt pulley

5. Remove drive belt and pulley.
Refer to 13 78 19 Removing and installing drive belt - as of MY 2005 (All Models) .
Unscrew screws on pulley, see -Arrows- , and remove pulley. See Fig. 25.
6. Drain hydraulic fluid at underbody connection point.
The following steps must be completed in order to drain the hydraulic fluid:
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STEERING Steering

6.1. Remove rear underbody panel.
Replace fastening nuts -2- following removal . See Fig. 26.
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STEERING Steering

6.2. Remove underbody panel at the left side.
Replace fastening nuts -3- following removal. See Fig. 27.
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STEERING Steering
Fig. 28: Supply and return line

6.3. Disconnect supply and return line at underbody.
Disconnect supply and return line and collect hydraulic fluid.
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STEERING Steering
Fig. 29: Supply tank

7. Remove the supply tank.
Remove hydraulic fluid from supply tank by suction. Open bayonet lock and remove the supply tank.
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STEERING Steering
Fig. 30: Return line at hydraulic pump

8. Disconnect return line at the supply tank/hydraulic pump.
Disassembly tool, universal NR.21, Tools.
If you do not have a special tool to hand, press the red circlip forward using two plastic spatulas and pull the
return line out at the same time.
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STEERING Steering

9. Loosen air-conditioning compressor.
Unscrew screws -2- and move air-conditioning compressor -1- so that the screw -3- can be removed. See Fig.
31.
Fig. 32: Feed line at hydraulic pump

10. Disconnect feed line at the hydraulic pump.
Loosen feed line -1- (a/f 16). Counter at the connection piece while doing so (a/f 24). See Fig. 32.
11. Remove hydraulic pump.
NOTE: When you remove the drive belt, the drive belt tensioner is lying on the
hydraulic pump. The increased strain prevents the hydraulic pump from being
removed and inserted, so the tensioner must be turned accordingly. Get
another person to help you do this.
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STEERING Steering
Fig. 33: Back of hydraulic pump

11.1. Unscrew the screw at the back of the hydraulic pump.
Remove screw -3- . See Fig. 33.
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STEERING Steering
Fig. 34: Loosening and securing hydraulic pump

11.2. Unscrew the screws at the front of the hydraulic pump.
Remove screws -2- and press the drive belt tensioner back at the same time. Remove hydraulic pump. See Fig.
34.
INSTALLING HYDRAULIC PUMP
Installing
1. Install hydraulic pump.
Press drive belt tensioner back with the help of another person and insert the hydraulic pump.
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STEERING Steering
Fig. 35: Loosening and securing hydraulic pump

1.1. Screw in and tighten the screws at the front of the hydraulic pump.
Tighten screws -2- at the housing. See Fig. 35.
--> Tightening torque: +23 (17 ftlb.) Nm
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STEERING Steering
Fig. 36: Hydraulic pump

1.2. Screw in and tighten screw at the back of the hydraulic pump.
Tighten screw -3- at the housing. See Fig. 36.
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STEERING Steering
Fig. 37: Feed line at hydraulic pump

2. Secure feed line at the hydraulic pump.
Secure feed line -1- (a/f 16). Counter at the connection piece while doing so (a/f 24). See Fig. 37.
Fig. 38: Return line at hydraulic pump

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STEERING Steering
3. Connect return line at the supply tank/hydraulic pump.

4. Secure air-conditioning compressor.
Tighten screws -2- on air-conditioning compressor. See Fig. 39.
--> Tightening torque: 23 (17 ftlb.) Nm
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STEERING Steering
Fig. 40: Supply tank

5. Install supply tank.
Pay attention to markings on the catch and on the supply tank, see -Arrow- ! See Fig. 40.
6. Connect supply and return line at underbody.
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STEERING Steering
Fig. 41: Supply and return line

6.1. Connect supply and return line at underbody.
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STEERING Steering

6.2. Install underbody panel at the left side.
Replace fastening nuts -3-. See Fig. 42.

6.3. Install rear underbody panel.
Replace fastening nuts -2-. See Fig. 43.
Tighten fastening screws -1- . See Fig. 43.
--> Tightening torque: 2 (1.5 ftlb.) Nm +/-1 (0.5 ftlb.) Nm
Tighten fastening nuts -2- . See Fig. 43.
--> Tightening torque: 1.5 (1 ftlb.) Nm +/-1 (0.5 ftlb.) Nm
Tighten fastening nuts -4- . See Fig. 43.
--> Tightening torque: 5 (3.5 ftlb.) Nm +/-1 (0.5 ftlb.) Nm
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STEERING Steering
7. Install drive belt.
Fig. 44: Drive belt

Refer to 13 78 19 Removing and installing drive belt - as of MY 2005 (All Models) .
8. Secure belt pulley.
Tighten screws -Arrows- . See Fig. 44.
9. Install left intake-air distributor.
Refer to 24 46 20 Removing and installing intake-air distributor - as of MY 2005 (All Models) .
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STEERING Steering
10. Install resonance tube and throttle housing with distributor pipe.
Tighten screw-type hose clamps in correct position. Refer to 24 42 19 Removing and installing throttle body -
11. Fill in hydraulic fluid, bleed the power steering and check for leaks.
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STEERING Steering
Fig. 46: Checking steering fluid

Subsequent work
1. Install engine compartment cover.
Models) .
3. Install left front seat. Refer to 72 01 19 Removing and installing front seat - as of MY 2005 (All LHD
Microsoft
SUSPENSION Front wheel suspension, drive shafts
SUSPENSION
Front wheel suspension, drive shafts
40 LIFTING THE VEHICLE - AS OF MY 2005 (ALL MODELS)

PRELIMINARY WORK
Lifting the vehicle
WARNING: Inappropriate raising of the vehicle or inaccuracy driving onto the

platform.
 Risk of damage to property, e. g. damage to door sills and side

member panels.
--> Lift vehicle only at the take-up points shown .
--> Make sure the screw connections for the diagonal braces are accessible.
--> When driving onto a lifting platform, ensure that there is sufficient distance between the lifting platform and
the vehicle.
--> In order to avoid damage to the side members and side member panels, the mounting plates of the platform
lift must be raised.
--> Under no circumstances should the vehicle be lifted by the engine, transmission or axles.
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Fig. 1: Mounting point front

Align the platform of the platform lift so that it lines up with the illustrated jacking point -arrow- . Repeat
procedure on the other side. See Fig. 1.
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Fig. 2: Jacking point rear

Align the platform of the platform lift so that it lines up with the illustrated jacking point -arrow- . Repeat
procedure on the other side. See Fig. 2.
40 TIGHTENING TORQUES FOR FRONT AXLE - AS OF MY 2005 (ALL

MODELS)
TIGHTENING TORQUES FOR FRONT AXLE
Tightening torques for cross member/side member (one component)

value 1 2
Caution: Do not grease
Threaded connection, cross
threaded connection in tightening 74
member to body (front) M12 x
Dacromet finish - aluminum torque ftlb.
1.5
color.
Threaded connection, cross
threaded connection in Tightening 118
member with diagonal arm to
body (front) M 14 x 1.5
color.
Threaded connection, cross threaded connections in Tightening 118
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member to body rear (two Dacromet finish - aluminum torque ftlb.

screws each side) M 14 x 1.5 color.
Tightening torques for diagonal brace

value 1 2
Caution: Do not grease screw
Diagonal brace to body screw tightening
connection with Dacromet 74 ftlb
connection M12 x 1.5 torque
finish - aluminum color.
Diagonal brace to cross
Caution: Do not grease screw
member / side member tightening
connection with Dacromet 74 ftlb
hexagon nut screw connection torque
M12
Tightening torques for axle strut

value 1 2
Please note: Do not grease
Control arm to cross 120 (89
threaded connections in Tightening
member/side member, M12 x ftlb.)
Dacromet finish - aluminum torque
1.5 Nm
color.
Please note: Do not grease 160
Control arm to diagonal arm, threaded connections in Tightening (118
M14 x 1.5 Dacromet finish - aluminum torque ftlb.)
color. Nm
Control arm to wheel carrier 75 (56
(ball joint), M12 x 1.5 (also ftlb.)
applicable for 911 GT3) Nm
color.
Camber basic setting on two- 27 (20
part trailing arm, M8 (911 ftlb.)
GT3) Nm
color.
Tightening torques for spring strut

value 1 2
Spring strut to wheel carrier 85 (63
threaded connection in Tightening
(anti-roll-bar mount to shock ftlb.)
absorber pipe), M12 x 1.5 Nm
color.
Please note: Do not grease 33 (24
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threaded connection in ftlb.)

Spring-strut mount to body, Tightening
Dacromet finish - aluminum Nm
M8 torque
color.
80 (59
Spring-strut mount to piston threaded connection in Tightening
ftlb.)
rod, M14 x 1.5 Dacromet finish - aluminum torque
Nm
color.
Tightening torques for wheel carrier

value 1 2
Please note: Do not grease threaded 10 (7.5
Brake cover plate to Tightening
connections in Dacromet finish - ftlb.)
wheel carrier, M6 torque
aluminum color. Nm
Brake disc to wheel Tightening
hub, M6 torque
aluminum color. Nm
Please note: Do not grease threaded
Brake calliper to connections in Dacromet finish - 85 (63
Tightening
wheel carrier, M12 x aluminum color! Replace screws on ftlb.)
torque
1.5 front and rear axle whenever they have Nm
been removed.
Speed sensor to Tightening
wheel carrier, M6 torque
aluminum color. Nm
Combination Please note: Do not grease threaded 10 (7.5
Tightening
coupling to wheel connections in Dacromet finish - ftlb.)
torque
carrier, M6 aluminum color. Nm
Brake hose bracket Tightening
to wheel carrier, M6 torque
aluminum color. Nm
Cable holder to Please note: Do not grease threaded 46 (34
Tightening
wheel carrier, M10 connections in Dacromet finish - ftlb.)
torque
(911 GT3) aluminum color. Nm
Retainer plate for Please note: Do not grease threaded 37 (27
Tightening
wheel bearing to connections in Dacromet finish - ftlb.)
torque
wheel carrier, M8 aluminum color. Nm
Please note: Do not grease threaded 460
Wheel hub to wheel
connections in Dacromet finish - Tightening (340
carrier (tension
aluminum color! Replace lock nut torque ftlb.)
bolt), M22 x 1.5
following removal. Nm
Tightening torques for anti-roll bar
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value 1 2
Please note: Do not
Anti-roll bar to cross 65 (48
grease threaded
member/side member, Tightening torque ftlb.)
connection in Dacromet
M10 x 60 Nm
3-stage tightening
Please note: Observe 3-
procedure (Stage 1:
stage tightening
tighten to 50 Nm (37 65 (48
Suspension/stabilizer to procedure! Do not
ftlb.). Stage 2: loosen by ftlb.)
anti-roll bar, M10 grease threaded
90 degree angle. Stage 3: Nm
connection in Dacromet
tighten to 65 Nm (48
ftlb.)).
Suspension/stabilizer to Please note: Do not
85 (63
shock-absorber grease threaded
Tightening torque ftlb.)
pipe/wheel carrier, M12 x connection in Dacromet
Nm
1.5 finish - aluminum color.
Tightening torques for steering

value 1 2
Tie rod (ball- 75 (56
Caution: Do not grease screwed connections Tightening
joint pin) on ftlb.)
in Dacromet finish - aluminum color. torque
lever M12 x 1.5 Nm
Caution: When using special tool P9730
aluminum tie rod
(socket wrench insert), observe the changed 50 (37
to axial joint Tightening
tightening torque! 50 Nm (37 ftlb.) at the ftlb.)
(lock nut) M14 x torque
lock nut corresponds to a setting of approx. Nm
1.5
32.5 Nm (24 ftlb.) on the torque wrench.
Universal joint
Caution: Do not grease threaded connection 23 (17
(steering shaft) to Tightening
in Dacromet finish - aluminum color! ftlb.)
steering gear M8 torque
Replace fit bolt after each removal. Nm
x 35
Steering gear to Caution: Do not grease threaded connection 65 (48
Tightening
cross member in Dacromet finish - aluminum color! ftlb.)
torque
M10 x 1.5 Replace fastening screws after each removal. Nm
Tightening torques for wheel mounting

value 1 2
Caution: Do not grease threaded connection in

Dacromet finish - aluminum color! Thinly grease
thread, shank and under head (between screw
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head bearing surface and spherical cap ring) of

the wheel bolts with Optimoly TA (aluminum
Threaded
paste). Do not grease bearing surface of the
connection, Tightening 96
spherical cap facing the wheel. If heavily
wheel to wheel torque ftlb.
contaminated, clean bolts first with a lint-free
hub M14 x 1.5
cloth. Replace damaged wheel bolts (no rework
permitted).
40 09 19 REMOVING AND INSTALLING FRONT-AXLE CROSS MEMBER - AS

PRELIMINARY WORK
Preliminary work
1. Put steering wheel with wheels in straight ahead position and remove ignition key (steering wheel fixed.)
2. Raise the vehicle --> 400000 Lifting the vehicleand remove front wheels Refer to 44 05 19 Removing and
3. Remove front cover (underbody protection) Refer to 51 92 19 Removing and installing cover for front
REMOVING AND INSTALLING FRONT-AXLE CROSS MEMBER
Removing
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Fig. 3: HBA sensor

1. Pull connector -A- from sensor for HBA and loosen threaded joint -B- on control lever. See Fig. 3.
Fig. 4: Support for coolant pipes

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2. Loosen support for coolant pipes (screwed on 4x) and press together the support for coolant pipes in the
center -arrows- and unclip. See Fig. 4.
Fig. 5: Front anti-roll-bar mount

3. Loosen anti-roll-bar mount -arrows- and allow anti-roll bar to hang. See Fig. 5.
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Fig. 6: Trailing arm mount for axle cross member

4. Loosen trailing arm on front-axle cross member -arrow - and pull out of the mount. See Fig. 6.
Fig. 7: Universal joint

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5. Remove screw -arrow- from universal joint (steering column). Carefully push steering column upward until
the universal joint loosens from the steering gear. See Fig. 7.
6. Remove the steering mount (2 M10 screws on front-axle cross member).
7. Remove diagonal braces (2 screws -1 + 2- and 2 M12 nuts on front-axle cross member). See Fig. 8.
Remove protective plate (cover under tank). To do so, loosen the screw from the right and left tank restraining
strap.
Remove the mounts -3 to 10- and carefully lower the front-axle cross member (two workers required!). See Fig.
8.

Installing
NOTE: Always replace the screw for the universal joint of the steering column.
Installation is in reverse order.
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SUBSEQUENT WORK
Subsequent work
Fit the front cover (underbody protection) Refer to 51 92 19 Removing and installing cover for front
Fit front wheels Refer to 44 05 19 Removing and installing wheel - as of MY 2005 (All Models) .
NOTE: Check the steering-angle sensor setting.
Adjust toe Refer to 44 95 03 Suspension alignment, complete - as of MY 2005 (All Models) . Calibrate
steering-angle sensor if necessary.
40 57 19 REMOVING AND INSTALLING FRONT WHEEL BEARING - AS OF

TOOLS

separating device (ø = 12 - commercially NR.111
115 mm) available tool
press-out mandrel special tool P 297a
pressure piece (4 x) special tool P 9247
tubular piece VW-tool VW 415 A
pressure piece VW-tool VW 433
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INFORMATION
Information
NOTE: The wheel bearings adopt the function of the former ABS pulse rings. They are
fitted with a so-called multipole seal. This is a seal with a magnetized layer,
which generates the torque impulses for the ABS RPM sensors.
The multipole seal must not come into contact with highly magnetic parts.
During installation, make sure that the magnetic side is facing the ABS sensor.
Use test card 147-2 for this.
Fig. 9: Wheel bearing

PRELIMINARY WORK
Preliminary work
- Remove front wheel bearing housing (wheel carrier). First, loosen the tension bolt on the wheel hub (lock nut
on wheel hub/wheel bearing threaded joint).
REMOVING FRONT WHEEL BEARING
Removing front wheel bearing
The following tools are required for removing the rear wheel bearing.
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Press-out mandrel P 297a For pressing out the wheel hub.

Tubular piece VW 415 A For pressing the wheel bearing out and in.
Used as a support when pressing out the wheel hub
Separating device, 12 - 115
No. 111 and when pressing the wheel bearing inner race off
mm ø
the wheel hub.
1. Take off brake cover plate on the wheel bearing housing.
Fig. 10: Wheel bearing housing

2. Press out wheel hub.
Press the wheel hub out using a press-out mandrel P 297a. A separating device (ø = 12 - 115 mm) NR.111
and a suitable support must be used for countering.
3. Remove lid for the wheel bearing on the wheel bearing housing (4 screws).
4. Heat wheel bearing housing to approx. 100 °C (max. 120 °C).
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Fig. 11: Pressing out wheel bearing

5. Press out wheel bearing using a tubular piece VW 415 A.
WARNING: Hot wheel bearing housing!
 Danger of burns
--> Wear heat-resistant gloves!
6. Press out wheel bearing inner race.
NOTE: To press out the inner bearing race of the old wheel bearing, pull the inner
bearing race several millimeters off the wheel hub using a two-claw puller so
that the separator can be put into place. To do this, use a two-claw puller
together with a pressure piece VW 433, for example.
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Fig. 12: Pressing out bearing race

Pull inner bearing race several millimeters off the wheel hub using a two-claw puller.
Press out inner bearing race using a press-out mandrel P 297a together with the separating device (ø = 12 -
115 mm) NR.111.
INSTALLING FRONT WHEEL BEARING
Installing front wheel bearing
Before installation, clean the bore in the wheel bearing housing and remove edges with a polishing cloth.
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The following tools are required for installing the rear wheel bearing.

Use together with the tubular piece VW 415 A
Pressure pieces P9247 (4x) P 9247/4
for pressing in the wheel bearing P9247/4.
1. Press in wheel bearing.
which generates the torque impulses for the ABS RPM sensors.
Fig. 13: Pressing in wheel bearing

Heat up wheel bearing housing before pressing in the wheel bearing.
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 Danger of burns
Preparatory condition: --> Temperature: 100 °C +20 °C
Insert wheel bearing at the correct position, then press again on the wheel bearing housing with only slight force
using a suitable pressure piece (9247/4), see pressure piece (4 x) P 9247 and tubular piece VW 415 A.
2. Fit lid for the wheel bearing on the wheel bearing housing (4 M8 screws). --> Tightening torque: 37 (27
ftlb.) Nm .
Fig. 14: Pressing in wheel hub

3. Press in wheel hub.
Position wheel bearing housing on wheel hub and press on wheel bearing inner race using a tubular piece VW
415 A.
4. Fit brake cover plate on wheel carrier.
Screw in and tighten screws on brake cover plate.
--> Tightening torque: 10 (7.5 ftlb.) Nm

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SUBSEQUENT WORK
Subsequent work
1. Install wheel bearing housing.
1.1. Tighten tension bolt on the wheel hub (wheel hub/wheel bearing threaded joint). Use a new lock nut (M22
x 1.5). Tightening torque: 460 Nm (340 ftlb.).
40 78 19 REMOVING AND INSTALLING CONNECTING LINK

(SUSPENSION/STABILIZER) - AS OF MY 2005 (ALL MODELS)
REMOVING FRONT CONNECTING LINK (SUSPENSION/STABILIZER)
Removing front connecting link (suspension/stabilizer)
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Fig. 15: Connecting link (suspension/stabilizer)

1. Remove wheel. Refer to 44 05 19 Removing and installing wheel - as of MY 2005 (All Models) . Then
loosen the lock nuts -arrows- on the suspension/stabilizer. When loosening, counter with Torx T30 or open-
ended wrench. See Fig. 15.
2. Support wheel suspension on wheel carrier with suitable jack, and remove suspension/stabilizer.
INSTALLING FRONT CONNECTING LINK (SUSPENSION/STABILIZER)
Installing front connecting link (suspension/stabilizer)
Up to approx. the middle of April 2005 (the exact date can be taken from the Technical Information if
necessary), the lock nut can become loose on the threaded connection of the stabilizer/suspension/stabilizer on
the front and rear axle due to a loss in preload. Suspension/stabilizers are therefore installed with a pin extended
by 10 mm and an appropriately extended hexagon nut on the front and rear axle as of the time mentioned.
Suspension/stabilizers with extended pins (extended threads) of the fastening bolt can be installed retroactively.
In the event of a claim (noise problem caused by the stabilizer), all 4 suspension/stabilizers are to be replaced by
the modified version. On assembly work in the stabilizer area or on the wheel suspension, install the modified
version on the right and left side.
1. Install connecting link (suspension/stabilizer).
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NOTE:  Use the new fastening nuts, which are 10 mm longer (Part No.
999.084.123.09), to secure the modified connecting links.
 Use the old fastening nuts (Part No. 999.084.643.09) to secure the old
connecting links.
 The old connecting link (short threaded pin) must not be used together
with the new lock nut because the threaded pin is not long enough for the
lock nut. If this incorrect combination is used, the safety effect could not
be assured or would only be provided conditionally.
2. Use new fastening nuts. Fit the assigned lock nut -Down arrow- to the connection from the
suspension/stabilizer to the stabilizer depending on the version (longer or shorter pin). See Fig. 16.
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3. Observe prescribed tightening torques. Tighten the lower lock nut (M10) in three stages --> 400000
Tightening torques for front axle.
4. Fit wheel Refer to 44 05 19 Removing and installing wheel - as of MY 2005 (All Models) .
40 85 19 REMOVING AND INSTALLING SPRING STRUT - AS OF MY 2005

(ALL MODELS)
TOOLS

REMOVING AND INSTALLING SPRING STRUT - PRELIMINARY WORK
Removing and installing spring strut - preliminary work
1. Raise the vehicle --> 400000 Lifting the vehicleand remove front wheel Refer to 44 05 19 Removing and
REMOVING FRONT SPRING STRUT
Removing front spring strut
1. Loosen stabilizer mount at stabilizer (counter with Torx T30).
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Fig. 17: Loosening tie rod

2. Loosen tie rod and control arm at wheel carriers and press off the ball joints with special tool press-out tool
P 9560. When loosening the lock nuts, counter at the ball-joint pins with special tool screwdriver P 9546 (Torx
screwdriver).
3. Disconnect plug connection at wheel carrier and pull out plugs. Undo plug connection at wheel carrier and
unclip electric wires at the spring strut.
4. Loosen holder for brake line/brake hose at wheel carrier. Loosen brake calliper from wheel carrier and attach
in wheel arch.
5. Open luggage compartment and remove the relevant design cover over the spring strut.
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Fig. 18: PASM bracket and connector

6. Loosen cover over piston rod (at spring strut). For PASM spring struts, carefully disconnect connecting cable
at the connector and unclip it from the bracket -Arrows- . See Fig. 18.
7. Mark the installation position of the spring-strut mount (position of the three collar nuts). Loosen fastening
nuts (3 ea. M8) at spring-strut mount.
8. Pull out spring strut with wheel carrier.
9. Loosen clamped connection between spring strut/wheel carrier (ball joint of stabilizer mount). Counter with
open-ended wrench. Pull spring strut out of wheel carrier.
INSTALLING FRONT SPRING STRUT
Installing front spring strut
NOTE:  If assembly work was performed or parts replaced that affect the vehicle
height, a complete wheel alignment is necessary.
1. Install in reverse order. Before installing, do a visual check on the parts. Replace brake calliper fastening
screws.
2. Do not grease threaded connections in Dacromet finish - aluminum color. Observe correct tightening torques.
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3. Place the spring-strut/wheel-carrier assembly into the vehicle. Note installation position of the spring-strut
mount. The arrow markings must point to the outer side of the vehicle. The shock-absorber piston rod is thereby
shifted outwards. Use new lock nuts. Before tightening the lock nuts, align spring-strut mount in accordance
with the applied marking (position of the three collar nuts).
REMOVING AND INSTALLING SPRING STRUT - SUBSEQUENT WORK
Removing and installing spring strut - subsequent work
1. Fit front wheel Refer to 44 05 19 Removing and installing wheel - as of MY 2005 (All Models) .
2. Check wheel alignment values on front axle and adjust if necessary Refer to 44 95 03 Suspension alignment,
complete - as of MY 2005 (All Models) .
40 85 37 DISASSEMBLING AND ASSEMBLING FRONT SPRING STRUT - AS

TOOLS

spring clamp for spring commercially NR.121
struts available tool
arm bracket special tool P 9630
retaining tool special tool P 9630/1
socket-wrench insert special tool P 9630/2
INFORMATION
Component and assembly overview (with and without PASM)
There are two different types of running gear: standard running gear, and PASM running gear.
The Boxster S comes with the PASM chassis as standard.
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Fig. 19: Spring strut, exploded view

No. Designation Qty. Removal Fitting

Tension the coil springs
using spring clamp. Then
loosen the lock nut using
Use a new fastening nut.
the socket-wrench insert
Tighten to 80 Nm (59
P 9630/2 . Counter when
ftlb.).
loosening at the piston
On PASM spring struts,
-1- See Fig. rod or stop plate -2- . See
Lock nut M14 x 1.5 1 first align the stop plate -
19. Fig. 19.
2- with the supporting
To do this for PASM
mount -3- (offset 45°
spring struts, use
from direction of travel
retaining tool P 9630/1
marking). See Fig. 19.
and for conventional
spring struts arm bracket
P 9630.
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Stop plate
Fit dome upwards,
(2 versions).
towards lock nut.
PASM version: With two
-2- See Fig. On PASM spring struts,
grooves (two cut-outs), 1
19. align (position) the stop
for countering when
plate with the supporting
loosening and tightening
mount.
lock nut -1- . See Fig. 19.
-3- See Fig.
Spring strut mount 1
19.
Make sure it is seated
-4- See Fig.
Bearing with housing 1 properly in the spring
19.
strut mount
-5- See Fig.
Support ring 1
19.
Observe allocation
-6- See Fig. Spring plate
1 according to the coil
19. (compensating plate)
spring tolerance range.
-7- See Fig.
Stop plate 1 Fit dome downwards.
19.
-8- See Fig. Mount in correct
Conical washer 1
19. position.
-9- See Fig. Additional spring (rubber
1 Replace if necessary.
19. stop)
If necessary, replace. Fit
-10- See Fig.
Bellows 1 on additional spring -9- .
19.
See Fig. 19.
Observe allocation as per
-11- See Fig. Spare Parts Catalogue.
Coil spring 1
19. Replace coil springs only
in pairs.
Observe allocation as per
Spare Parts Catalogue.
-12- See Fig.
Vibration damper 1 The item number is
19.
shown on the damper
tube.
-13- See Fig. Mount for clip (vibration
1
19. balancer)
Not always present.
-14- See Fig.
Clip (vibration balancer). 1 See Spare Parts
19.
catalogue.
DISASSEMBLING AND ASSEMBLING SPRING STRUT
Disassembling spring strut
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CAUTION: Increased risk of accidents due to spring tensioning.
 Danger of injury and damage from springs jumping out.
--> Never use an impact bolter to loosen or tighten the fastening nut.
--> Use a commercially available changeover ratchet.
1. To prevent damage (deformation), clamp the spring strut in a suitable clamping block (tensioning device for
MacPherson spring struts). Alternatively, the spring clamp can also be held in a retaining device.
Fig. 20: Tensioning front spring

2. Pre-tension the coil spring using spring clamp for spring struts NR.121 until the piston rod is relieved. The
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appropriate forks must be inserted into the spring clamp.
Fig. 21: Spring strut supporting mount (PASM version)

3. To loosen the lock nut (piston rod to spring-strut mount) use socket-wrench insert P 9630/2.
When loosening the nut, counter it at the piston rod (for conventional spring struts) or at the two grooves (cut-
outs) of the stop plate (for PASM spring struts). Tools required: retaining tool P 9630/1 and for conventional
spring struts arm bracket P 9630.
4. Remove all parts from the piston rod.
Coil spring/compensating plate allocation
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Fig. 22: color marking of spring/damper

Identification marking -A- comprising two colored lines is for the spring constant and spring length (depending
on vehicle version and equipment). See Fig. 22.
Identification marking -B- comprising one colored line (white or green) is for the coil spring tolerance range
(load group) and determines the thickness of the spring plate (compensating plate). See Fig. 22.
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Fig. 23: Spring plate (compensating plate)

The spring plate (compensating plate) comes in two thicknesses -arrows- . See Fig. 23.
color identification A of coil

Vehicle version and equipment
spring
Example Standard running gear Boxster and Boxster S RoW/USA with manual
rape yellow/blue transmission and Tiptronic
Example PASM running gear Cayman S RoW/USA with manual transmission and
green/yellow Tiptronic
Spring plate
color identification B of coil spring (compensating
plate) ()
Thickness 3.5 mm
One white line (color identification B) ()
Thickness 6.5 mm
One green line (color identification B) ()
() If you are installing new coil springs, then order the 3.5 mm and 6.5 mm spring
plates (compensating plate) at the same time. As coil springs of load group 1 or 2
will be supplied, the correct spring plates (compensating plates) will then be
present for installation.
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() In production there have been deviations from the general allocation of spring
plates (thickness of compensating plate), in some cases different spring plates
(compensating plates) have been installed. This was necessary due to the tolerances
of the coil springs. This means that in the event of replacement: If the coil spring is
to be re-used, then install the spring plate (compensating plate) with the same
thickness. If the coil springs are to be replaced (only replace in pairs) then the
allocation given above applies.
Allocation of vibration dampers
See allocation in Spare Parts Catalogue.
Fig. 24: Color marking of spring/damper

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The marking, item number and color dot coding -C- are shown on the damper tube. See Fig. 24.
Assembling spring strut
CAUTION: Increased risk of accidents due to spring tensioning.
 Danger of injury and damage from springs jumping out.
--> Never use an impact bolter to loosen or tighten the fastening nut.
--> Use a commercially available changeover ratchet.
NOTE:  Observe the correct allocation (vehicle version and equipment) when
installing new coil springs and/or shock absorbers.
 Observe allocation of compensating plate according to the coil spring
tolerance range.
 Coil springs are only available in pairs.
1. Clamp the spring strut in a suitable clamping block (tensioning device for MacPherson spring struts).
Alternatively, the spring clamp can also be held in a retaining device.
2. Slide the bellows/additional spring assembly onto the piston rod.
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Fig. 25: Cone washer

3. Mount cone washer -8- and stop plate -7- in correct position. See Fig. 25.
4. Push the pretensioned coil spring onto the vibration damper so that the end of the coil spring rests against the
stop of the spring plate.
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Fig. 26: Supporting mount assembly

5. Completely assemble the spring plate (compensating plate) -6- , support ring -5- and bearing with its housing
-4- with the spring strut supporting mount -3- . Then slide the assembly onto the piston rod. See Fig. 26.
6. Place spring strut supporting mount assembly onto the piston rod so that the end of the coil spring is located
inside the spring plate.
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Fig. 27: Supporting mount (correct seat)

7. Fit stop plate in the correct position (domed side upwards) and screw a new fastening nut onto the piston rod.
Important: For PASM spring struts, place the lug of the stop plate (in area of spring strut mount) in the groove
of the piston rod (twist lock of piston rod opposite the supporting mount). Make sure that the plastic part of the
bearing sits correctly in the recess of the supporting mount -arrows- . See Fig. 27.
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Fig. 28: Stop plate position (PASM only)

8. On PASM spring struts, before tightening the lock nut, align the stop plate -2- offset 45° from direction of
travel marking -Arrows A- of the supporting mount. See Fig. 28.
The value: 45° + - 2° is necessary so that the two grooves of the stop plate (cut-outs for countering) are
positioned over or between the recesses (pockets in the rubber part) which lie below.
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Fig. 29: Spring strut mount

9. Tighten fastening nut to the specified tightening torque. For PASM spring struts, counter at the stop plate
using retaining tool P 9630/1. For conventional spring struts, counter at the hexagon socket of the piston rod
using special tool P 9630.
10. If present, push on clip (vibration balancer) at damper tube of vibration damper. Final assembly (tightening)
only on completion of wheel carrier.
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SUSPENSION Level control
SUSPENSION
Level control
43 16 19 REMOVING AND INSTALLING PASM CONTROL UNIT - AS OF MY

2005 (ALL MODELS)
TOOLS

REMOVING PASM CONTROL UNIT
Removing PASM control unit
NOTE: If the control unit has to be replaced, read out the values saved in the control
unit before starting the removal. --> 431619 Removing and installing PASM
control unit - chapter on "Programming".

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Fig. 2: Unscrewing cover for passenger's footwell

1. Pull carpet on right-hand side to the side.
2. Unscrew the two fastening nuts -1- and remove the cover -2- . See Fig. 2.
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Fig. 3: Disconnecting control unit

3. Unclip control unit from the support and pull it out and down.
4. Release -A- and pull off electric connector. See Fig. 3.
INSTALLING PASM CONTROL UNIT
Installing PASM control unit
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1. Connect the electric plug connection until the plug clicks into place.
2. Push in control unit into the support and clip it in.
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Fig. 5: Screwing on cover for passenger's footwell

3. Fit cover -2- and secure with the two fastening nuts -1- . See Fig. 5.
4. Stick on carpet at side again onto cover.
PROGRAMMING PASM CONTROL UNIT
Reading out and writing values for PASM control unit
NOTE:  During coding, there should be a guaranteed power supply for the PIWIS
different text or additions may appear in thePIWIS tester P 9718 .
PIWIS tester P 9718. It is essential to connect a battery charger with a

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4. Select PASM and press >>.
5. In the PASM menu, select Control unit replacement and press >>.
6. Select Read codes and press >>.
7. On the screen of the PIWIS tester appears the message Coding read-out complete >>.
11. Switch on ignition. Once the control unit has been replaced, the vehicle data is uploaded under the Write in
data menu (see Section 7). Press >>.
12. PIWIS tester displays Coding write-in complete >>.
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SUSPENSION Rear wheel suspension, drive shafts
SUSPENSION
Rear wheel suspension, drive shafts
42 TIGHTENING TORQUES FOR REAR AXLE - AS OF MY 2005 (ALL

MODELS)
TIGHTENING TORQUES FOR REAR AXLE
Tightening torques for carrier side section/cross member

value 1 2
Carrier side section to body
(front and rear) M10 x 1.5 x 48 ftlb.
80
color.
Cross member to carrier side
section (upper and lower) 48 ftlb.
M10 x 1.5 x 45
color.
Support plate to cross threaded connections in Tightening
48 ftlb.
member M10 x 1.5 Dacromet finish - aluminum torque
color.
Support plate to V-strut
(transverse strut rear) collar 48 ftlb.
nut M10 x 1.5
color.
V-strut (transverse strut rear) threaded connections in Tightening
48 ftlb.
to body M10 x 1.5 Dacromet finish - aluminum torque
color.
Diagonal brace to carrier side threaded connections in Tightening
48 ftlb.
section (collar nut) M10 x 1.5 Dacromet finish - aluminum torque
color.
Diagonal brace with support
plate to carrier side section 48 ftlb.
(collar nut) M10 x 1.5
color.
Diagonal brace to body M10 threaded connections in Tightening
48 ftlb.
x 1.5 x 45 Dacromet finish - aluminum torque
color.
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Restraining cable to cross threaded connections in Tightening
17 ftlb.
member M8 Dacromet finish - aluminum torque
color.
Restraining cable to engine threaded connections in Tightening
17 ftlb.
M8 Dacromet finish - aluminum torque
color.
Tightening torques for axle strut

value 1 2
Control arm 2 (toe control arm)
threaded connections in Tightening 56
to wheel carrier (taper) M12 x
1.5
color.
Control arm 2 (toe control arm)
to wheel carrier (toe eccentric)
M12 x 1.5
color.
Control arm (lower control
arm) to wheel carrier (taper)
M12 x 1.5
color.
Control arm (lower control Caution: Do not grease
arm) to carrier side section threaded connections in Tightening 74
eccentric (camber eccentric) Dacromet finish - aluminum torque ftlb.
M12 x 1.5 color.
Diagonal brace to control arm
(lower control arm) M14 x 1.5
x 75
color.
Diagonal brace to body M14 x threaded connections in Tightening 118
1.5 x 90 Dacromet finish - aluminum torque ftlb.
color.
Tightening torques for wheel carrier

value 1 2
Caution: Do not grease threaded
Wheel bearing to Tightening 27
connections in Dacromet finish -
wheel carrier (lid) M8 torque ftlb.
aluminum color.
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Speed sensor to wheel Tightening 7.5
carrier M6 torque ftlb.
aluminum color.
Brake cover plate to Tightening 7.5
wheel carrier M6 torque ftlb.
aluminum color.
Brake disc to wheel Tightening 7.5
hub M6 torque ftlb.
aluminum color.
Caution: Do not grease screwed
Brake caliper to wheel
connections in Dacromet finish - Tightening 63
carrier (cheese head
aluminum color! Replace screws at torque ftlb.
screw) M12 x 1.5
front and rear axle after each removal.
Brake hose bracket to Tightening 7.5
aluminum color.
Combination line to Tightening 7.5
aluminum color.
Tightening torques for spring strut

value 1 2
Spring strut cable to engine M8
Dacromet finish - torque ftlb.
aluminum color.
Spring strut to wheel carrier threaded connections in Tightening 63
(suspension/stabilizer) M12 x 1.5 Dacromet finish - torque ftlb.
aluminum color.
Shock absorber to mount (piston
rod) conventional without PASM,
M14 x 1.5
aluminum color.
Shock absorber to mount (piston
rod) variable with PASM, M14 x
1.5
aluminum color.
Tightening torques for stabilizer

value 1 2
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Stabilizer to side section threaded connections in 17
Tightening torque
M8 Dacromet finish - ftlb.
aluminum color.
Caution: Observe three- Three-stage tightening
stage tightening procedure (1st stage:
Suspension/stabilizer to
procedure! Do not grease tighten to 37 ftlb. 2nd 48
stabilizer (collar nut
screwed connections in stage: loosen 90 ftlb.
M10)
Dacromet finish - degrees. 3rd stage:
aluminum color. tighten to 48 ftlb.).
Suspension/stabilizer to
threaded connections in 63
spring strut/wheel carrier Tightening torque
Dacromet finish - ftlb.
M12 x 1.5
aluminum color.
Tightening torques for unit mount

value 1 2
Engine carrier to body Tightening
connections in Dacromet finish - 48 ftlb.
M10 x 1.5 torque
aluminum color.
Stud for engine carrier to Tightening
body M8 torque
aluminum color.
Engine mounting to engine Tightening
carrier M10 x 1.5 torque
aluminum color.
Engine bracket to engine Tightening
M10 x 1.5 torque
aluminum color.
Transmission bracket to Caution: Do not grease threaded
Tightening
manual transmission M10 connections in Dacromet finish - 48 ftlb.
torque
x 1.5 aluminum color.
Transmission bracket to Caution: Do not grease threaded
Tightening
Tiptronic transmission connections in Dacromet finish - 48 ftlb.
torque
M10 x 1.5 aluminum color.
Hydraulic mount to Caution: Do not grease threaded
Tightening
transmission bracket M12 connections in Dacromet finish - 63 ftlb.
torque
x 1.5 aluminum color.
Hydraulic mount to rear Caution: Do not grease threaded
Tightening
axle carrier side section connections in Dacromet finish - 24 ftlb.
torque
M8 aluminum color.
Tightening torques for drive shaft
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value 1 2
Drive shaft to Caution: Do not grease threaded
Tightening 60
transmission M10 connections in Dacromet finish -
torque ftlb.
(manual transmission) aluminum color.
Tightening 60
torque ftlb.
(Tiptronic) aluminum color.
Tightening 29
torque ftlb.
(Tiptronic) aluminum color.
Caution: Do not grease screwed
Drive shaft to wheel connections in Dacromet finish - tightening 340
hub M22 x 1.5 aluminum color! Replace lock nut torque ftlb.
after each removal.
Tightening torques for plug-in couplings for steering hydraulics

Steering pressure line M16 x 1.5 Wrench size 15 Tightening torque 22 ftlb.
Steering return line M20 x 1.5 Wrench size 19 Tightening torque 30 ftlb.
Tightening torques for plug-in couplings for clutch hydraulic system

Clutch line M16 x 1.5 Wrench size 15 Tightening torque 22 ftlb.
Tightening torques for wheel mounting

value 1 2
Thinly grease thread, shank and under head (between
screw head bearing surface and spherical cap ring) of
Wheel to the wheel bolts with Optimoly TA (aluminum paste).
Tightening 96
wheel hub Do not grease bearing surface of the spherical cap
torque ftlb.
M14 x 1.5 facing the wheel. If heavily contaminated, clean bolts
first with a lint-free cloth. Replace damaged wheel
bolts (no rework permitted).
42 21 19 REMOVING AND INSTALLING DRIVE SHAFT - AS OF MY 2005

(ALL MODELS)
TOOLS
Microsoft

universal drive shaft/wheel special tool NR.87-1
hub extractor as of model
'86
PRELIMINARY WORK FOR REMOVING DRIVE SHAFT
Preliminary work for removing drive shaft
1. Release axle nut (vehicle on ground) while operating the brake (2 fitters required).
2. Raise the vehicle Refer to 40 Tightening torques for front axle - as of MY 2005 (All Models) . and remove
the required rear wheel Refer to 44 05 19 Removing and installing wheel - as of MY 2005 (All Models) .

3. Remove support plate -A- (this also involves removing diagonal braces -B- ) --> 421419 Removing and
installing support plate. See Fig. 1.
REMOVING DRIVE SHAFT
Removing drive shaft
NOTE:  Removal and installation applies to Tiptronic and all manual

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transmissions.
Fig. 2: Drive shaft

1. Fit protective tube for drive shaft (shop-made tube to protect against mechanical damage).
Remove drive shafts at transmission side (six hexagon socket head bolts).
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Fig. 3: Pressing out drive shaft

2. Use universal drive shaft/wheel hub extractor as of model '86 NR.87-1 to carefully press out the pin of
the drive shaft until the shaft can be moved by hand. --> Pressing out drive shaft , See Fig. 3.
3. Remove (pull out) drive shaft.
INSTALLING DRIVE SHAFT
Installing drive shaft
NOTE:  Screws are Dacromet-coated and must not be greased.

 Grease the toothing of the drive shaft lightly with Optimoly HT.
 To prevent damage to the drive shaft, slide a protective tube (shop-made)
over the drive shaft.
 Use new screws and lock nuts.
 Observe correct tightening torques --> 420000 Tightening torques for rear
axle.
 Always check the bellows for damage and replace them if necessary if you
intend to continue using the drive shaft.
1. Insert drive shaft and fit the axle nut.
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2. Fit drive shafts at transmission side (six hexagon socket head bolts).
3. Remove protective tube for drive shaft.
SUBSEQUENT WORK AFTER INSTALLING DRIVE SHAFT
Subsequent work after installing drive shaft

1. Install support plate -A- with diagonal braces -B- . --> 421419 Removing and installing support plate. See
Fig. 4.
2. Fit wheel, Refer to 44 05 19 Removing and installing wheel - as of MY 2005 (All Models) .
3. Tighten axle nut (vehicle on ground) whilst operating the brake (2 fitters required).
42 14 19 REMOVING AND INSTALLING SUPPORT PLATE - AS OF MY 2005

(ALL MODELS)
INFORMATION
Important notes about the support plate
Microsoft

Remove and install the support plate -A- only under the following conditions. See Fig. 5.
 All wheels must be lifted (freely suspended).

 Always lift the vehicle at the specified jacking points with the lifting platform set up evenly. (Align lifting
arms evenly to avoid distortion.)
 Suspension alignment is not necessary if the support plate -A- is removed and installed under these
conditions. In the worst case, the rear-axle wheel alignment values may change slightly. This could cause
a slight change in the steering wheel position from that prior to removal when driving straight ahead. See
Fig. 5.
REMOVING AND INSTALLING SUPPORT PLATE
Removing support plate
1. Raise the vehicle at the prescribed jacking points Refer to 40 Tightening torques for front axle - as of MY
2005 (All Models) .
2. Remove rear underbody panel.
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3. Remove right and left diagonal braces -B- and the support plate -A- ( --> 421419 Removing and installing
support plate - section on "Information"). Pull out the support plate -A- without undue force. See Fig. 6.
Installing support plate
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1. Insert support plate -A- without undue force --> 421419 Removing and installing support plate - section
on "Information". See Fig. 7.
2. right and left diagonal braces -B- . See Fig. 7.
3. Tighten screws and nuts to the specified torque --> 420000 Tightening torques for rear axle.
4. Fit rear underbody panel.
42 38 19 REMOVING AND INSTALLING REAR-AXLE CARRIER SIDE

SECTION - AS OF MY 2005 (ALL MODELS)
INFORMATION
Information
NOTE: Pay attention to the following in order to remove the support plate without
tension:
Lift the vehicle only at the jacking points provided using a uniformly adjusted
platform lift. Align lifting arms evenly (in order to avoid distortion).
Microsoft
Fig. 8: Overview of rear-axle carrier side section

1 - Rear-axle carrier side section
2 - Diagonal brace
3 - Support plate
4 - Cross member
7 - V-brace
Preliminary work
1. Raise vehicle at the specified jacking points --> 40 LIFTING THE VEHICLE - AS OF MY 2005 (ALL
MODELS) .
3. Remove rear underbody panel Refer to 51 94 19 Removing and installing cover for rear underbody - as of
Removing
NOTE: Pay attention to the following in order to remove the support plate without
tension:
Lift the vehicle only at the jacking points provided using a uniformly adjusted
platform lift. Align lifting arms evenly (in order to avoid distortion).
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Fig. 9: Rear-axle carrier side section disassembled

2 - Diagonal brace
3 - Support plate
4 - Cross member
5 - Sensor
6 - Restraining cable
7 - V-brace
1. Remove the diagonal braces.
Unscrew nuts -2a- and bolts -2b- and remove diagonal braces at the left and right. See Fig. 9.
2. Remove support plate.
Unscrew nuts -3a- and bolts -3b- and take off support plate. See Fig. 9.
3. Remove transmission bracket with hydraulic mount.
A - Transmission bracket
B - Hydraulic mount
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C - Fastening nut (never loosen)
Support transmission before removing the transmission bracket! When supporting the transmission,
ensure that there is no tension on the screws on the transmission bracket -A- . See Fig. 10.
Fig. 10: Hydraulic mount

Unscrew nuts -Arrows- on hydraulic mount -B- . See Fig. 10.
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Fig. 11: Mount for transmission bracket

Unscrew screws -Arrows- on transmission bracket -A- and remove transmission bracket -A- together with
hydraulic mount. See Fig. 11, Fig. 10.
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4. Remove cross member -4- together with sensor -5- . See Fig. 9.
Sensor:
Unscrew M6 nut securing sensor to control arm and disengage linkage.
Pull off electric connection.
Cross member:
Pull electric plug connections and lines out of the holders.
Unscrew screws -4a- and remove cross member -4- . See Fig. 9.
5. Remove stabilizer on rear-axle carrier side section.
Unscrew screws -2a- and remove stabilizer -2- by tilting it backwards. See Fig. 13.
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Fig. 13: Eccentric threaded joint, rear-axle carrier side section

6. Remove eccentric threaded joints (toe and transverse control arm) at rear-axle carrier side section.
6.1. Remove toe eccentric threaded joint between transverse strut and rear-axle carrier side section.
Mark the basic position of the toe eccentrics on the rear-axle carrier side section -see Arrow- . See Fig. 13.
6.2. Remove camber eccentric threaded joint between toe control arm and rear-axle carrier side section.
Mark the basic position of the camber eccentrics on the rear-axle carrier side section -see Arrow- . See Fig. 13.
7. Remove rear-axle carrier side section.
Unscrew screws -3- and remove rear-axle carrier side section. See Fig. 13.
Installing
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Fig. 14: Rear-axle carrier side section disassembled

2 - Diagonal brace
3 - Support plate
4 - Cross member
5 - Sensor
6 - Restraining cable
7 - V-brace
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Fig. 15: Rear-axle carrier side section

1. Install rear-axle carrier side section.
Tighten screws -3- only slightly. See Fig. 13.
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2. Install cross member together with sensor.
Tighten screws -4a- only slightly. See Fig. 16.
Sensor
Fit sensor on control arm and connect electric plug connection.
Cross member
Insert electric plug connection in holder -Arrows- . See Fig. 16.
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Fig. 17: Rear-axle carrier side section

3. Install eccentric threaded joints (toe and transverse control arm) at rear-axle carrier side section.
3.1. Install toe eccentric threaded joint between transverse strut and rear-axle carrier side section.
Set the basic position of the toe eccentrics at the marked position -see Arrow- on the rear-axle carrier side
section and tighten nuts. See Fig. 13.
3.2. Install camber eccentric threaded joint between toe control arm and rear-axle carrier side section.
Set the basic position of the toe eccentrics at the marked position -see Arrow- on the rear-axle carrier side
section and tighten nuts. See Fig. 13.
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Fig. 18: Securing support plate

4. Insert support plate and align rear-axle carrier side section.
Insert the support plate and secure it to the following components, see -Arrows- : See Fig. 18.
Rear-axle carrier side section, cross member, V-brace
Align rear-axle carrier side section as required until the hole patterns are perfectly matched. It must be possible
to insert the support plate without tension.
5. Tighten screws on rear-axle carrier side section and cross member.
5.1. Tighten screws securing rear-axle carrier side section to body. --> Tightening torque: 65 (48 ftlb.) Nm
5.2. Tighten screws securing cross member to rear-axle carrier side section. --> Tightening torque: 65 (48
ftlb.) Nm
6. Install transmission bracket with hydraulic mount.
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6.1. Tighten screws securing transmission bracket to transmission.
6.1.1. Transmission bracket to Tiptronic transmission
6.1.2. Transmission bracket to manual transmission
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6.2. Tighten nuts securing hydraulic mount -Arrows- to rear-axle carrier side section. See Fig. 20.
B - Hydraulic mount
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Fig. 21: Support plate/diagonal brace

7. Fit support plate with diagonal brace.
A - Support plate
B - Diagonal brace
Insert and tighten bolts and nuts for the support plate -A- and diagonal braces -B- . See Fig. 21.
Support plate to cross member:
Support plate to V-brace:
Diagonal braces with support plate to rear-axle carrier side section:
Diagonal brace to body:

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Subsequent work
1. Install rear underbody panel Refer to 51 94 19 Removing and installing cover for rear underbody - as of
2. Fit rear wheels Refer to 44 05 19 Removing and installing wheel - as of MY 2005 (All Models) .
3. Align the vehicle Refer to 44 95 03 Suspension alignment, complete - as of MY 2005 (All Models) .
Camber eccentric to control arm --> Tightening torque: 100 (74 ftlb.) Nm
Toe eccentric to toe control arm --> Tightening torque: 100 (74 ftlb.) Nm
42 52 19 REMOVING AND INSTALLING REAR WHEEL BEARING HOUSING

(WHEEL CARRIER) - AS OF MY 2005 (ALL MODELS)
TOOLS

universal drive shaft/wheel special tool NR.87-1
hub extractor as of model
'86
PRELIMINARY WORK
Preliminary work
1. If the wheel bearing needs to be replaced, loosen axle nut (vehicle on ground) whilst operating the brake (2
fitters required).
2. Raise the vehicle, Refer to 40 LIFTING THE VEHICLE - AS OF MY 2005 (ALL MODELS)
3. Remove rear wheel, Refer to 44 05 19 Removing and installing wheel - as of MY 2005 (All Models) .
REMOVING REAR WHEEL BEARING HOUSING
Removing
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Fig. 22: Wheel bearing housing/wheel bearing


1. Disengage the parking-brake cable at the parking-brake lever.
Release the parking-brake lever (do not operate again until fitting is complete; self-adjusting).
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Open cover of oddments tray in center console.
Remove bottom of oddments tray in center console.
Remove the relevant parking-brake cable sideways out of the turnbuckle.
Fig. 24: Combination wire

2. Disconnect and remove electric connections (combination wire) on the wheel bearing housing.
Open safety clip on combination wire for ABS and brake pad wear indicator on the wheel bearing housing and
pull out the connectors.
Screw out screw -1- on combination wire. See Fig. 22.
Remove line for brake pad wear indicator from the support on the spring strut.
3. Remove speed sensor .
4. Loosen holder for brake line/brake hose at the wheel bearing housing.
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Fig. 25: Brake calliper/brake pads

5. Remove brake calliper.
Release brake calliper from wheel bearing housing (do not open brake system) and suspend it in the wheel arch.
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6. Remove brake disc and parking-brake shoes.
6.1. Remove parking-brake shoes Refer to 46 83 20 Removing and installing brake shoes - as of MY 2005
(All Models) .
6.2. Disengage parking-brake cable at the actuating lever -7- and pull it out of the guide on the wheel bearing
housing. See Fig. 26.
7. Loosen the drive shaft at the transmission and wheel bearing housing (only at the wheel bearing housing if
the wheel bearing or wheel bearing housing needs to be replaced).

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7.1. Loosen the drive shaft at the transmission.
Slide a protective hose over the drive shaft to prevent damage to the drive shaft.
Fig. 28: Pressing out drive shaft

7.2. Loosen the drive shaft at wheel bearing housing (only if the wheel bearing or wheel bearing housing needs
to be replaced).
Use universal drive shaft/wheel hub extractor as of model '86 NR.87-1 to carefully press out the pin of the
drive shaft until the shaft can be moved by hand.
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Fig. 29: Rear toe and transverse control arm

8. Remove connecting link (suspension/stabilizer), toe and transverse control arm at the wheel bearing housing.
8.1. Remove toe and transverse control arm -1, 2- at the wheel bearing housing. See Fig. 29.
Use the press-out tool P 9560 for pressing out the ball joint. When loosening the lock nuts, counter at the ball-
joint pin with a screwdriver P 9546 (Torx screwdriver).
8.2. Remove connecting link (suspension/stabilizer) -3- at the wheel bearing housing (connection between
wheel bearing housing and spring strut). See Fig. 29.
Counter at the connecting link -3- (a/f 18) while loosening the nut (a/f 18). See Fig. 29.
9. Remove wheel bearing housing together with drive shaft.
To pull the ball-joint pin out of the wheel bearing housing, pull the transverse control arm down evenly with
both hands while swivelling the wheel bearing housing outwards. Get another person to help you with this.
INSTALLING REAR WHEEL BEARING HOUSING
Installing
1. Insert wheel bearing housing together with drive shaft.
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To insert the ball-joint pin into the wheel bearing housing, pull the transverse control arm down evenly with
both hands while swivelling the wheel bearing housing inwards. Get another person to help you with this.
Fig. 30: Rear toe and transverse control arm

2. Fit connecting link (suspension/stabilizer), toe and transverse control arm at the wheel bearing housing.
2.1. Tighten nut on connecting link.
Counter at the connecting link while tightening.
2.2. Tighten nut on toe control arm -1b- . See Fig. 30.
2.3. Tighten nut on transverse control arm -1a- . See Fig. 30.
2.4.
3. Fit the drive shaft on the transmission.
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4. Install parking-brake shoes.
4.1. Press parking-brake cable into guide on wheel bearing housing and engage it on the actuating lever -7- . See
Fig. 31.
4.2. Install parking-brake shoes Refer to 46 83 20 Removing and installing brake shoes - as of MY 2005 (All
Models) .
5. Secure brake hose bracket to wheel bearing housing.
6. Install speed sensor .
7. Secure brake calliper on wheel bearing housing.
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Fig. 32: Combination wire

8. Connect electric connections (combination wire) on wheel bearing housing.
Tighten screw -1- on combination wire. See Fig. 32.
Secure line for brake pad wear indicator on spring strut support.
Connect electric connectors for combination wire for ABS and brake pad wear indicator and lock using a safety
clip.
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9. Engage the parking-brake cable at the parking-brake lever and adjust parking-brake shoes.
9.1. Engage the parking-brake cable at the parking-brake lever.
9.2. Check parking brake adjustment.
Check basic setting of parking-brake shoes. The parking brake cannot be adjusted at the parking-brake cable
since it is self-adjusting.
Refer to 46 83 16 Adjusting the parking-brake shoes - as of MY 2005 (All Models) .
SUBSEQUENT WORK
Subsequent work
2. Tighten axle nut on drive shaft (if it was removed).
Tighten axle nut securing drive shaft to wheel hub: --> Tightening torque: 460 (340 ftlb.) Nm
42 58 19 REMOVING AND INSTALLING REAR WHEEL BEARING - AS OF MY

Microsoft
2005 (ALL MODELS)

TOOLS

A separating device (ø = 12 commercially NR.111
- 115 mm) available tool
press-out mandrel special tool P 297a
pressure piece (4 x) special tool P 9247
tubular piece VW-tool VW 415 A
pressure piece VW-tool VW 433
INFORMATION
Information
which generates the torque impulses for the ABS rpm sensors.
Microsoft
Fig. 34: Wheel bearing

PRELIMINARY WORK
Preliminary work
1. Remove rear wheel bearing housing --> 425219 Removing and installing rear wheel bearing housing.
REMOVING REAR WHEEL BEARING
Removing
The following tools are required for removing the rear wheel bearing.

Press-out mandrel P 297a For pressing out the wheel hub.
Used as a support when pressing out the wheel hub
Separating device, 12 - 115
No. 111 and when pressing the wheel bearing inner race off
mm ø
the wheel hub.
1. Take off brake cover plate on the wheel bearing housing.
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Fig. 35: Wheel bearing housing

2. Press out wheel hub.
Press the wheel hub out using a press-out mandrel P 297a. A separating device (ø = 12 - 115 mm) NR.111
and a suitable support must be used for countering.
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3. Remove bearing cover.
Unscrew screws -1- and remove bearing cover. See Fig. 36.
4. Heat wheel bearing housing to approx. 100 °C (max. 120 °C).
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Fig. 37: Pressing out wheel bearing

5. Press out wheel bearing using a tubular piece VW 415 A.
 Danger of burns
6. Press out wheel bearing inner race.
NOTE: To press out the inner bearing race of the old wheel bearing, pull the inner
bearing race several millimeters off the wheel hub using a two-claw puller so
that the separator can be put into place. To do this, use a two-claw puller
together with a pressure piece VW 433, for example.
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Fig. 38: Pressing out bearing race

Pull inner bearing race several millimeters off the wheel hub using a two-claw puller.
Press out inner bearing race using a press-out mandrel P 297a together with the separating device (ø = 12 -
115 mm) NR.111.
INSTALLING REAR WHEEL BEARING
Installing
Before installation, clean the bore in the wheel bearing housing and remove edges with a polishing cloth.
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The following tools are required for installing the rear wheel bearing.

Use together with the tubular piece VW 415 A
Pressure pieces P9247 (4 x) P 9247/4
for pressing in the wheel bearing P9247/4.
1. Press in wheel bearing.
which generates the torque impulses for the ABS rpm sensors.
Fig. 39: Pressing in wheel bearing

Heat up wheel bearing housing before pressing in the wheel bearing.
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 Danger of burns
Preparatory condition: --> Temperature: 100 °C +20 °C
Insert wheel bearing at the correct position, then press again on the wheel bearing housing with only slight force
using a suitable pressure piece (9247/4), see pressure piece (4 x) P 9247 and tubular piece VW 415 A.
Fig. 40: Installing bearing cover

2. Install bearing cover -2- . See Fig. 40.
Screw in and tighten screws -1- . --> Tightening torque: 37 (27 ftlb.) Nm See Fig. 40.
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Fig. 41: Pressing in wheel hub

3. Press in wheel hub.
Position wheel bearing housing on wheel hub and press on wheel bearing inner race using a tubular piece VW
415 A.
4. Fit brake cover plate on wheel carrier.
Screw in and tighten screws on brake cover plate.
SUBSEQUENT WORK
Subsequent work
1. Install rear wheel bearing housing --> 425219 Removing and installing rear wheel bearing housing.
42 71 19 REMOVING AND INSTALLING REAR SPRING STRUT - AS OF MY

2005 (ALL MODELS)
TOOLS
Microsoft

PRELIMINARY WORK FOR REMOVING SPRING STRUT
Preliminary work for removing spring strut
1. Find an access point to where the upper spring strut is attached to the body (three M8 lock nuts).
On the Boxster , this involves moving the convertible top to service position Refer to 61 01 IN Diagram of
convertible top - as of MY 2005 (Boxster, Boxster RHD, Boxster S, Boxster S RHD) .
Procedure on the Cayman: Remove trim panel for spring strut mount Refer to 70 23 19 Removing and
installing trim panel for spring strut mount - as of MY 2006 (Cayman S, Cayman S RHD) . This includes:
trim panel for rear Refer to 70 53 19 Removing and installing rear cover. - as of MY 2006 (Cayman S,
Cayman S RHD) and C-pillar Refer to 70 68 19 Removing and installing C-pillar trim panel - as of MY
2. Raise the vehicle Refer to 40 Tightening torques for front axle - as of MY 2005 (All Models) .
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Models) .
REMOVING SPRING STRUT
Removing spring strut
1. Disconnect plug connections at the wheel carriers and pull out the plugs. Undo plug connection at the wheel
carrier (M6 screw) and unclip electric wires at the spring strut.
2. Loosen holder for brake line/brake hose at the wheel carrier. Undo brake calliper from wheel carrier (do not
open brake system) and suspend it in the wheel arch.
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3. Loosen the drive shaft at the transmission. Slide a protective hose over the drive shaft to prevent damage to
the drive shaft.
Fig. 45: Control arm at wheel carrier

4. Loosen suspension/stabilizer -1- at the anti-roll bar. See Fig. 45.
Loosen toe and control arm -2 and 3- on the wheel carrier. Use the press-out tool P 9560 for pressing out the
ball joint. When loosening the lock nuts, counter at the ball-joint pin with a screwdriver P 9546 (Torx
screwdriver). See Fig. 45.
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To pull the ball-joint pin out of the wheel carrier, pull the control arm down evenly with both hands while
swivelling the wheel carrier outwards. Enlist the assistance of a second person for this step.
5. The parking-brake cable must be disengaged at the parking brake lever in the passenger compartment in order
to remove the spring strut. Disengaging the parking-brake cable includes:
Releasing the parking-brake lever (do not operate again until fitting is complete! Self-adjusting!).
Opening cover of oddments tray in center console.
Removing bottom of oddments tray in center console.

Removing the relevant parking-brake cable sideways out of the turnbuckle.
6. Open clip for parking-brake cable (at the rear wall) and take the parking-brake cable out of the deflector box.
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Fig. 47: Attachment of spring strut to body

7. Mark the installation position of the spring strut mount (position of the three M8 lock nuts). Undo M8 lock
nuts on the spring strut mount -Arrows- . See Fig. 47.
8. Pull out spring strut with wheel carrier and drive shaft. Make sure that the ball joint boots and drive shaft
boots are not damaged during removal and installation.
Fig. 48: Clamped connection between spring strut and wheel carrier
9. Remove lock nut on suspension/stabilizer -1 and 2- (clamped connection between spring strut and wheel
carrier). Pull spring strut -3- out of the wheel carrier -4- . See Fig. 48.
INSTALLING SPRING STRUT

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Installing spring strut
NOTE:  Always check the parts visually before installation.

 Replace brake calliper fastening screws.
 Do not grease screwed connections in Dacromet finish - aluminum color!
 Observe correct tightening torques.
2. Insert spring strut into vehicle. Before tightening the fastening nuts, adjust spring strut mount in accordance
with the applied marking (position of the three fastening nuts).
Fig. 49: Correct position for support ring

Then double-check that the support ring is still positioned correctly on the spring strut mount --> Correct
position for support ring . The cut-outs in the support ring must be positioned between the collars of the three
fastening bolts -Arrows- . Re-establish the correct position if necessary. See Fig. 49.
3. Insert parking-brake cable into the deflector box and into the clip at the rear wall.
4. Engage brake cable sideways into the turnbuckle --> Removing/fitting parking-brake cable . Fit floor in
oddments tray of the center console. See Fig. 50.
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The handbrake does not have to be adjusted (self-adjusting).
5. Fit brake calliper and holder for brake line/brake hose at the wheel carrier.
6. Connect and clip in all electric plugs.
SUBSEQUENT WORK AFTER INSTALLING SPRING STRUT
Subsequent work after installing spring strut
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Models) .
3. On the Boxster , move convertible top out of service position Refer to 61 01 IN Diagram of convertible top
- as of MY 2005 (Boxster, Boxster RHD, Boxster S, Boxster S RHD) .
On the Cayman: Install trim panel for spring strut mount Refer to 70 23 19 Removing and installing trim
panel for spring strut mount - as of MY 2006 (Cayman S, Cayman S RHD) . This includes installing the
following: trim panel for rear Refer to 70 53 19 Removing and installing rear cover. - as of MY 2006
(Cayman S, Cayman S RHD) and C-pillar Refer to 70 68 19 Removing and installing C-pillar trim panel -
4. If new parts are installed that affect vehicle height, suspension alignment must always be carried out Refer to
44 95 03 Suspension alignment, complete - as of MY 2005 (All Models) .
42 91 19 REMOVING AND INSTALLING CONNECTING LINK

(SUSPENSION/STABILIZER) - AS OF MY 2005 (ALL MODELS)
REMOVING REAR CONNECTING LINK (SUSPENSION/STABILIZER)
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Removing rear connecting link (suspension/stabilizer)

1. Remove wheel Refer to 44 05 19 Removing and installing wheel - as of MY 2005 (All Models) . Then
loosen the lock nuts -Arrows- on the suspension/stabilizer. Counter with a Torx T30 or open-ended wrench
when loosing the nuts. See Fig. 52.
2. Support wheel suspension at the wheel carrier with a suitable jack and remove suspension/stabilizer.
INSTALLING REAR CONNECTING LINK (SUSPENSION/STABILIZER)
Installing rear connecting link (suspension/stabilizer)
Up to around mid-April 2005 (see Technical Information for exact date of introduction, if necessary), the lock
nuts on the threaded connection between the anti-roll bar and suspension/stabilizer on the front and rear axle
can become loose due to reduced preload. As of the specified date, suspension/stabilizers with a pin that is 10
mm longer and a correspondingly lengthened hexagon nut must be fitted on the front and rear axle.
Suspension/stabilizers with a longer fastening pin (longer thread) can be retrofitted. In the event of a complaint
(problem with noises caused by the anti-roll bar), replace all four suspension/stabilizers with the modified
version. When carrying out assembly work close to the anti-roll bar or on the wheel suspension, install the
modified version on the right and left-hand side.
1. Fit connecting link (suspension/stabilizer).
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NOTE:  Use the new fastening nuts, which are 10 mm longer (Part No.
999.084.123.09), to secure the modified connecting links.
 Use the old fastening nuts (Part No. 999.084.643.09) to secure the old
connecting links.
 The old connecting link (short threaded pin) must not be used together
with the new lock nut because the threaded pin is not long enough for the
lock nut. If this incorrect combination is used, the safety effect could not
be assured or would only be provided conditionally.
2. Use new fastening nuts. Fit the correct lock nut -Down arrow- on the connection between the
suspension/stabilizer and anti-roll bar, depending on the version used (long or short pin). See Fig. 53.
3. Observe prescribed tightening torques. Tighten the lower lock nut (M10) in three stages --> 420000
Tightening torques for rear axle.
4. Fit wheel Refer to 44 05 19 Removing and installing wheel - as of MY 2005 (All Models) .
Microsoft
Suspension Wheels, Tires, Alignment
Suspension
Wheels, Tires, Alignment
44 WHEELS AND TIRES/TIRE PRESSURE - AS OF MY 2005 (ALL MODELS)

WHEELS AND TIRES/TIRE PRESSURE
Wheels, Tires: visual inspection for damage
Check Tires for sufficient tread depth, foreign bodies, pricks, cracks and bulges in the sidewall (ply breakage).
Check age of the Tires. Replace Tires if necessary.
Checking wheel mounting
Use suitable commercially available tools (wrench size 19 mm) together with a tested torque wrench, covering
the range up to 130 Nm (96 ftlb.). Never use an impact bolter.
Do not undo the wheel bolts to check whether they are secure. Tighten the wheel bolts to 130 Nm (96 ftlb.) and
check that they fit securely.
Tire pressure for cold Tires (approx. 20 °C) - all Boxster and Cayman models
WARNING: Tire damage due to insufficient Tire pressure in conjunction with driving
at high speeds, due to Tires that are too old and/or Tires which do not
meet Porsche requirements.
 Increased risk of accidents.
--> Adjust the Tire pressure according to specifications. Never allow the pressure to fall below the minimum
pressure.
--> Carry out a visual inspection and check Tire age. Replace Tires older than 6 years.
--> Use only Tires recommended by Porsche.
NOTE:  Valve caps protect the valve from dust and dirt and therefore from leaks!
Always screw caps tight and replace any missing caps.
17-inch/18-inch wheels, summer and winter tires
17 and 18-inch wheels, front --> : 2,0 bar

17 and 18-inch wheels, rear --> : 2,5 bar
19-inch wheels, summer and winter tires
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19-inch wheels, front --> : 2,2 bar

19-inch rear wheels --> : 2,5 bar
 Spare wheel/collapsible wheel not available! However there is a tire repair kit in the luggage
compartment which can be used to repair the damaged tire in the event of damage!
 For repairs in the event of damage, observe without fail the safety and operating instructions !
The chart of Tires and wheels for summer and winter should be taken from Technical Information (TI).
When replacing summer Tires, pay close attention to the Tire specification number! The specification characters
N1, N2, N3 or N0 distinguish the summer Tires specially authorized by Porsche from other models of the same
Tire type and size!
Notes on mounting Tires
 When fitting Tires, the direction of rotation and the inner and outer sides should be noted!
 If there are no mounting instructions on the Tire sidewall, the Tire must be mounted so that the DOT code
is visible from the outside.
44 ADJUSTMENT VALUES FOR SUSPENSION ALIGNMENT - AS OF MY

2005 (ALL MODELS)
VEHICLE HEIGHT
NOTE:  The following values relate to the empty weight, i. e. full fuel tank, vehicle
with tools, but without driver and without additional weights!
All Boxster and Cayman All Boxster and Cayman

Vehicle height
RoW/USA: Standard RoW/USA: PASM
Front axle
--> Control value: 143 mm +/-10 --> Control value: 133 mm +/-10
Height with 17-inch wheels
mm mm
mm mm
mm mm
From road contact surface to lower edge of hexagon-head bolt of cross-member screw connection to the
body.
Rear axle
mm mm
Height with 18-inch wheels --> Control value: 155 mm +/-10 --> Control value: 145 mm +/-10
Microsoft
mm mm
mm mm
From wheel contact area up to lower edge of diagonal brace (at control arm fastening point).
WHEEL ALIGNMENT VALUES
WARNING: Risk of accident due to incorrect functioning of steering angle sensor if it

is uncalibrated or incorrectly calibrated.
 There is a risk of accidents causing physical damage to persons or

objects in the PSM testing area.
--> After working on wheel suspension parts, when replacing the steering-angle sensor and after changing the
wheel alignment values, calibrate the steering angle sensor with the front wheels in straight-ahead position
using the PIWIS tester.
--> Check the actual value of the steering angle sensor after a suspension alignment where no changes were
made to the wheel alignment values.
NOTE:  The following values relate to the empty weight, i. e. full fuel tank, vehicle
with tools but without driver or additional weights.
 The toe-difference angle value is also influenced by the vehicle height. For
this reason the measured result must be evaluated accordingly. No action
is necessary in the case of small deviations from the toe-difference angle's
required value as long as the value to the right and left is almost the same.
All Boxster and Cayman All Boxster and Cayman

Wheel alignment values
RoW/USA: Standard RoW/USA: PASM
Front axle
Toe unpressed (total) + 5' ± 5' + 5' ± 5'
Toe difference angle at 20° lock - 1° 40' ± 30' - 1° 50' ± 30'
Camber (with wheels in straight-

- 10' ± 15' - 15' ± 15'
ahead position)
max. difference, left to right 20' 20'
Caster 8° ± 30' 8° ± 30'

Rear axle
Toe per wheel + 5' ± 5' + 5' ± 5'
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Camber - 1° 20' ± 15' - 1° 30' ± 15'

44 05 19 REMOVING AND INSTALLING WHEEL - AS OF MY 2005 (ALL

MODELS)
INFORMATION
Wheel mounting
Fig. 1: Wheel bolt length

The wheels of the Boxster (987) are secured with standard wheel bolts (M14 x 1.5) the same as for the Boxster
(986). Length: dimension -X- --> screw length: approx. 45 mm . See Fig. 1.
REMOVING WHEEL
Removing wheel
NOTE:  Use suitable commercially available tools (wrench size 19 mm)! Never use
an impact bolter to tighten the wheel bolts.
 Before the wheel is placed on the wheel hub, re-grease the centring
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surface of the wheel hub (if required) as necessary with a very thin coat of
Optimoly TA (aluminum paste).
 The wheel bolt consists of two parts that are permanently joined together.
Other wheel bolts must not be used.
CAUTION: Removing/fitting the wheels for vehicles with PCCB (Porsche Ceramic
Composite Brake).
 Risk of damage to the brake discs.
--> Use assembly aids (assembly pins) in order to exclude any possibility of heavy contact of the wheel with the
brake disc. The assembly aids (2 assembly pins) are located in the luggage compartment.
Fig. 2: Assembly pins for vehicles with PCCB brakes

NOTE:  The assembly pins for removing / mounting the wheel for vehicles with
PCCB can be ordered separately as a spare part. Part No.: 999 571 074 30.
- In the case of vehicles with PCCB (Porsche Ceramic Composite Brake), screw the two assembly aids
(assembly pins), instead of two wheel bolts, into the wheel hub before removing the wheel. Only then remove
the three remaining wheel bolts and remove the wheel carefully, without touching the brake discs.
INSTALLING WHEEL
Microsoft
Installing wheel
NOTE:  Use suitable commercially available tools (wrench size 19 mm)! Never use
an impact bolter to tighten the wheel bolts.
 Before the wheel is placed on the wheel hub, re-grease the centring
surface of the wheel hub (if required) as necessary with a very thin coat of
Optimoly TA (aluminum paste).
 The wheel bolt consists of two parts that are permanently joined together.
Other wheel bolts must not be used.
NOTE:  The assembly pins for removing / mounting the wheel for vehicles with
PCCB can be ordered separately as a spare part. Part No.: 999 571 074 30.
CAUTION: Removing/fitting the wheels for vehicles with PCCB (Porsche Ceramic
Composite Brake).
 Risk of damage to the brake discs.
--> Use assembly aids (assembly pins) in order to exclude any possibility of heavy contact of the wheel with the
brake disc. The assembly aids (2 assembly pins) are located in the luggage compartment.
Fig. 3: Assembly pins for vehicle with PCCB brakes

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1. In the case of vehicles with PCCB (Porsche Ceramic Composite Brake), screw the 2 assembly aids (assembly
pins) into the wheel hub before mounting wheel.
2. In the case of heavy soiling, clean the wheel bolts and the concavities in the wheel with a lint-free cloth.
Fig. 4: Wheel bolt

3. Always apply a thin coat of Optimoly TA (aluminum paste) on the thread of the wheel bolts, on the shank
and between the bolt head bearing surface and spherical cap ring (under the head) -arrows- . Do not grease the
spherical cap bearing surface -X- of the wheel bolts that face the wheel.
-A- - Spherical cap ring (permanently connected with the wheel bolt). See Fig. 4.
-X- - Spherical cap bearing surface facing the wheel (do not grease). See Fig. 4.
NOTE:  Rework on wheel bolts is impermissible.
4. Always replace damaged wheel bolts.
This damage includes mechanical damage to the thread, the spherical cap and damage resulting from seizure of
the bolt head bearing surface and spherical cap ring. It must be possible to rotate the spherical cap ring on the
bolt shank and to move it in axial direction.
NOTE:
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 Always observe the specified tightening torque of 130 Nm (96 ftlb.).
5. Screw in wheel bolts by hand and then tighten evenly. Start at the top when tightening.
44 05 94 BALANCING/OPTIMIZING WHEELS - AS OF MY 2005 (ALL

MODELS)
TOOLS

measuring gauge commercially NR.136
available tool
BALANCING/OPTIMIZING WHEELS
General
Excessive wheel imbalance not only produces vibrations and causes the steering wheel to shake, but also results
in increased wear on various parts of the running gear.
Even if the wheels are correctly balanced, excessive geometry errors (radial and axial runout) and misshapen
Tires, e. g. accumulation of material at one point in the Tire structure (spring action of Tire changes as the Tire
rolls), can cause rolling and steering imbalance.
NOTE:  Achieving a good result requires utmost care, observance of the

instructions and procedure, and attempting to eliminate even the very last
gram of imbalance.
Recommendations/requirements
 Wheel suspension elements must be in good technical order.

 The wheels must be clean with no foreign objects in the Tire.
 Use a Tire measuring gauge, e. g. measuring gauge NR.136 to check radial and lateral runout values on
wheels without flat spots. Values of less than 1.0 mm are desirable - around 0.5 mm would be better.
 To limit the number of radial runout errors and to optimism smoothness of rolling, it is a good idea - and
even necessary in individual cases - to match the Tire (i. e. to fit it in a favorable position with respect to
the wheel). Follow tips and fitting instructions as well as information on Tire mounting paste for Tires.
 If the rims (wheels without Tires) are perfect but the complete wheels have large axial and radial runout
values (due to ply breakage or other damage), it may be necessary to replace the Tire.
 Balance used wheels only after they have been warmed up by driving, otherwise flat spots will simulate
imbalance. Never perform matching in the case of flat spots.
 Correct Tire pressure is an important prerequisite.
 Place the balancing weights at the prescribed position.
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Explanation of terms
Geometry error (radial and lateral runout)
Radial and lateral runout of the rim and/or rim/Tire assembly.
Flat spots
Flat spots can occur on the Tires if the vehicle is idle for extended periods.
Radial force variations
Fig. 5: Radial force variations

The radial force is a force that compresses a Tire. Based on its size, a Tire has softer ( -item A- ) and more rigid
areas ( -item B- ) due to design and production-related factors. Given this, the Tire compresses to various
extents at a constant wheel load ( -arrows 1- ) and a constant Tire pressure ( -arrows 2- ). This varying spring
action ( -X- ) in the Tire can cause vibrations in the chassis on even road surfaces and the driver may notice this
as shaking in the steering wheel, for example. Measuring the radial force variation involves running the Tire on
a wheel balancer that measures radial force variation while applying a constant load to the Tire. This simulates
the rolling of the Tire on a driving surface. Variations in radial force occur independently of the direction of
rotation of the Tire and are measured as the difference between the maximum and minimum radial force ("peak
to peak" value). See Fig. 5.
1st Harmonic
The changes in radial force variation can be broken down mathematically into individual variations. Porsche
uses the value of the 1st Harmonic Variation (basic variation) to assess the Tire from the point of view of
rigidity. The 1st Harmonic Variation relates to the changes in radial force that cause the strongest vibrations.
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Other harmonic variations (2nd - 4th Harmonic) can also be seen in the changes in radial force. These relate to
the changes in radial force that cause weaker vibrations.
Uncontrolled matching
Turn the Tire on the wheel by 90° or 180° if necessary in order to achieve an acceptable value with regard to
rolling smoothness (true running, imbalance and distribution of balance weights).
Controlled matching
With a balancing machine with matching program. In most cases, this produces an even better result with regard
to the rolling smoothness (true running, imbalance and distribution of the balance weights) than can be achieved
with uncontrolled matching.
Tire seating pressure
This is the filling pressure after the Tire has been fitted on the rim at which the Tire bead, coming out of the
deep bed, must pop over the hump of the rim bead.
Balancing/optimizing wheels
The entire process is divided into three operations.
1. Fitting the Tire on the rim.
2. A - Measure radial force variations and optimism the wheels if necessary. Afterwards, balance the wheels.
B - As an alternative to item 2 A, if there is no device available to measure radial force variations: Stationary
balancing of the wheel (eliminating static and dynamic imbalance) with optimization of rolling smoothness.
3. Fitting the wheel on the vehicle.
Further to 1: Fitting the Tire on the rim
- Remove rubber residues and dried-on Tire paste from the rim, especially from the rim bead and the hump.
- Examine rim for damage; remove old balancing weights.
- Use the prescribed Tire mounting paste (only TIP TOP Universal, order no. 593 0601, 3.5 kg bucket, or
Contifix) so that the Tire does not turn on the rim the first time the car is driven, thereby counteracting all your
careful work. If the Tire turns by as little as 20 mm with respect to the rim, this can worsen an optimum
balancing result.
- Fit Tire on the rim. When doing so, it is a good idea - and even necessary in individual cases - to fit the Tire in
a favorable position with respect to the wheel (matching). Compare Controlled and Uncontrolled matching
below.
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Fig. 6: Tire filling cage

WARNING: If the Tire seating pressure is too high (max. 4.0 bar permissible),
personal injuries are possible in the event of Tire or wheel destruction.
--> Maximum Tire seating pressure 4 bar! This value must not be exceeded.
--> For Tire seating pressure over 3.3 bar (possible in the event that several unfavorable factors should occur
simultaneously / max. 4.0 bar permissible) use a Tire filling cage.
- Fill Tire. Important: At the latest when the pressure reaches 3.3 bar (max. 4.0 bar in Tire filling cage), the Tire
beads (coming out of the deep bed) must pop over the hump of the rim bead in order to avoid fractures of the
bead core. If necessary, interrupt the process and generously coat all necessary surfaces with recommended
lubricant (Tire mounting paste). Then repeat the process.
 Important: Damage to the bead core resulting from incorrect Tire assembly/disassembly will cause an
increase in fluctuations in power (radial/lateral fluctuation in power). This is apparent when you roll the
Tire on the driving surface.
- Uncontrolled matching: Turn the Tire on the wheel by 90° or 180° if necessary in order to achieve an
acceptable value with regard to rolling smoothness (true running, imbalance and distribution of balance
weights).
- Controlled matching: With a balancing machine with matching program. In most cases, this produces an even
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better result with regard to the rolling smoothness (true running, imbalance and distribution of the balance
weights) than can be achieved with uncontrolled matching.
- Check the fit of the Tire on the rim using the bead centring line.
- Set the prescribed Tire pressure.
Further to 2A: Measuring radial force variations
- Tension wheel on balancing machine with radial force variation measurement (vibration monitoring system).
- Observe the operating instructions of the balancing machine (adjust the machine from time to time).
- The contact surfaces of the wheel on the balancing flange (levelling surface) and the centring surface must be
clean.
- The display disabling function must be switched off.
- Adjust Tire air pressure to 2.6 bar (best test pressure) when balancing and measuring radial force variations.
- Particular attention must be paid to the wheel mounting when measuring radial force variations and when
balancing. Using the special pressure pieces provided by the manufacturer of the balancing machine will ensure
that wheels are balanced accurately and there is the highest possible repeat accuracy. Observe the operating
instructions.
Maximum deviations permitted in radial force variation results:
Front wheels Rear wheels

Radial force variation (peak
max. 170 N max. 170 N
to peak vibrations)
1st Harmonic (variation) max. 125 N max. 150 N
If these values are exceeded, the Tire must be matched on the rim.
If these values are not reached, the wheel must be balanced.
NOTE: A new Tire must be fitted if the radial force variation cannot be reduced to the
values listed in the table.
Further to 2B: Stationary balancing with optimization of rolling smoothness
- Clamp wheel on stationary balancing machine.
- Observe the operating instructions for the balancing machine. Adjust the machine according to the
manufacturer's instructions (if necessary).
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- The contact surfaces of the wheel on the balancing flange (levelling surface) and the centring surface must be
clean.
- center (clamp) the wheel from the inside with centring clamping device - see Workshop Equipment Manual,
Chapter 3. This centring clamping device fits all wheel-balancing machines approved by Porsche.
Check radial and lateral runout during the first measuring run. Values of less than 1.0 mm are desirable - around
0.5 mm would be better.
Consider the size of the measured balancing weights and their distribution on the inner and outer planes (inner
and outer rim flanges) critically.
A uniform distribution with low values (e. g. 25/35 g) means that the Tire was fitted correctly and the quality of
the Tire and rim is good.
A value of 80g/80g (90g/90g using the Tire pressure monitoring system) should not be exceeded with interior
balancing behind wheel center. A considerably different distribution, e. g. 35/90 g is very unfavorable; this
usually indicates incorrect fitting. Problem wheels of this kind often have pronounced radial and axial runout
values.
This can be remedied by matching (use correct mounting paste). This can be improved with uncontrolled
matching (manual); significant improvement is possible in almost all cases using the rolling smoothness
optimization program (controlled matching).
Tire pressure during balancing at required pressure.
Permissible residual imbalance of less than 3 g, or max. 3 g per plane.
Further to 3: Fitting the wheel on the vehicle
NOTE:  Never use an impact bolter.

 Observe information on the two-piece wheel bolt. This is described in the
chapter on wheel removal and installation (fitting wheel on vehicle) -->
440519 Removing and installing wheel.
- Fit wheel using a suitable commercially available tool.
- Screw in wheel bolts by hand and then tighten evenly. Start at the top when tightening. Always observe the
specified tightening torque of 130 Nm (96 ftlb.).
- Tire pressure according to the specifications.
Balancing weights
Balancing weights: Balance stick-on weights (current version is a fine zinc alloy).
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Fig. 7: Attaching wheel weights

Attach both weights to the inner side.
NOTE:  Observe program selection and operating instructions of the balancing

machine.
Attaching the balance stick-on weights
NOTE:  Remove the protective film just before sticking on the weight, as
prolonged exposure to the air will reduce the bonding strength.
 Pay attention to cleanliness.
- Determine exact position of the balancing weights (if necessary, temporarily stick on the balancing weights
with a strip of adhesive tape until the correct position is determined).
- Prepare bonding surface on the rim. The bonding surface must be perfectly clean and free of grease.
- Remove protective paper from the bonding surface of the weight and press the weight firmly into place.
- The balance stick-on weight must be in uniform contact over the entire surface.
- Check the balancing weight is seated firmly. A weight freshly affixed weight must not detach itself from the
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rim under application of a shear load at right angles to its longitudinal axis.
44 12 02 CHECKING DISC WHEELS - AS OF MY 2005 (ALL MODELS)

CHECKING THE RADIAL AND LATERAL RUNOUT
NOTE:  Straightening and welding work on light alloy wheels is not permissible.
 The work is carried out initially with the wheel mounted on the vehicle.
 To measure wheels with Tires and wheels without Tires, use a Tire
measuring gauge, e. g. VAG. 1435, see Workshop Equipment Manual,
Chapter 3.4.2.
Fig. 8: Tire measuring gauge, e. g. VAG. 1435

Maximum permissible radial runout and lateral runout of the wheel with Tire = 1.25 mm. Values less than 1.0
mm - better around 0.5 mm - are desirable. For this purpose, match the Tire (turn the Tire on the rim) if
necessary).
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Fig. 9: Identifying radial runout and lateral runout

Maximum permissible radial runout and lateral runout -a- of the light alloy wheels = 0.7 mm. See Fig. 9.
If in isolated cases further measurements are necessary, carry out the following procedure.
1. To measure wheels without Tires, remove the wheel from the vehicle. --> 440519 Removing and installing
wheel
2. Remove the Tire from the light alloy wheel. --> 444019 Fitting Tires for vehicles with and without Tire
Pressure Monitoring (TPM)
3. Clamp the wheel on the balancing machine and measure at the points -a- . See Fig. 9.
44 32 19 REMOVING AND INSTALLING WHEEL ELECTRONICS - AS OF MY

2005 (ALL MODELS)
REMOVING WHEEL ELECTRONICS
General information on wheel electronics
The Tire pressure monitoring system is designed to constantly monitor the Tire pressure during driving and
when the vehicle is stopped. One set of electronics -A- per Tire is mounted in the rim well base. These measure
Tire pressure and temperature at regular intervals and transfer the values to a central control unit via a high-
frequency route. The control unit evaluates the information and transfers the data to the instrument cluster if
required. In this way, the driver is warned and informed if the Tire pressure needs to be adjusted. See Fig. 10.
There are two versions of the wheel electronics -A- . Wheel electronics with normal transmission power are
used on the Boxster (987) (while the version on the Cayenne has amplified transmission power). These transmit
on a high frequency range of: See Fig. 10.
 433 MHz or 315 MHz (while special wheel electronics with a frequency of 315 MHz are used for Japan).
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The following points can be used as distinguishing characteristics:
 the labelling, 433 MHz or 315 MHz

 the part number
 without 8 stars (figure shows 8 stars, four on the left and right of the slot respectively, wheel electronics
with amplified transmission power on the Cayenne)
 special wheel electronics - 315 MHz for Japan: marking with 14 diagonal lines
 and/or the color (black = 433 MHz/grey = 315 MHz).
Fig. 10: View of valve complete and wheel electronics

-A- - Wheel electronics
-B- - Valve complete (No. 2 to No. 7)
-1- - Self-locking (Torx) fastening screw
-2- - Valve cap (plastic)
-3- - Valve insert
-4- - Union nut
-5- - Washer chamfered on both sides
-6- - Bead seat sealing ring
-7- - Valve
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Removing wheel electronics
Fig. 11: Valve complete

NOTE:  For vehicles with a Tire pressure monitoring system, the valve and wheel
electronics are only replaced in exceptional cases! The following points
can make replacement necessary!
Valve complete with screw -1 to 7- has to be replaced if: See Fig. 11.
 The wheel electronics are removed.

 The self-locking -1- fastening screw is loose. See Fig. 11.
 The bead seat sealing ring -6- is porous or damaged. See Fig. 11.
 The valve body -7- is bent. See Fig. 11.
 The union nut -4- is loose. See Fig. 11.
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Fig. 12: Wheel electronics

The wheel electronics -A- must be replaced if: See Fig. 12.
 The housing is visibly deformed

 The filter surface (square, porous section on back of wheel electronics) is so badly soiled that it can no
longer be cleaned by wiping
 Tire sealant (Tire sealing liquid) has been used
 The service life of the battery has expired
 There is a fault within the wheel electronics.
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Fig. 13: Position of wheel electronics

After removal of the Tire, the wheel electronics -A- can be seen at the valve in the outer rim well base. See Fig.
13.
1. Release wheel electronics from valve using a Torx socket screwdriver T 20 (if necessary, counter with a
suitable assembly pin, e. g. steel pin Ø approx. 1.8 mm in bore at valve foot) and remove.
2. Then unscrew union nut and remove valve.
INSTALLING WHEEL ELECTRONICS
CAUTION: The wheel electronics must not come into contact with the Tire fitting
paste or solvent.
--> Do not apply compressed air, mounting paste, soap, solvents or any other cleaners to the wheel electronics
when fitting/removing Tires.
When replacing the wheel electronics, always use a completely new valve and a new fastening screw!
The tightening torque for wheel electronics/valve is 4 Nm (3 ftlb.)(± 0.5 Nm/0.4 ftlb.)!
Every Tire set or wheel change must be communicated to the control unit. In particular, this includes the case
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where wheel positions have been interchanged. For this purpose, always select the Tire type and Tire size under
Main menu > Tire pressure > Adjustments in the instrument cluster. The control unit then learns the wheel
positions again once the vehicle starts driving.
1. Install wheel electronics loosely at valve (do not tighten) and position in valve bore together with valve and
bead seat sealing ring.
CAUTION: Remove assembly pin after installing valve (required to counter).

Otherwise the Tire will be damaged during installation.
--> Carry out the tightening procedure for the valve in one step (tighten without interruption the prescribed
tightening torque is reached).
2. Position washer, chamfered on both sides, and screw union nut on as far as the mounting face. Visibly twist
bore at valve foot. If necessary, block with suitable assembly pin. The tightening torque is 4 Nm (± 0,5 Nm) (3
ftlb. ± (0.4 ftlb.)).

3. Push wheel electronics -A- slightly into rim well (this adjusts the angle of inclination of valve to wheel
electronics). See Fig. 14.
4. Carefully tighten self-locking (Torx) fastening screw T 20 to tightening torque 4 Nm (± 0.5 Nm (3 ftlb. (± 0.4
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ftlb.)). The wheel electronics should now be lying evenly against the rim.
44 34 19 REMOVING AND INSTALLING TIRE PRESSURE MONITORING

SYSTEM CONTROL MODULE - AS OF MY 2005 (ALL MODELS)
TOOLS

PRELIMINARY WORK
Preliminary work for Tire pressure monitoring system (RDK) control module
REMOVING TIRE PRESSURE MONITORING SYSTEM (RDK) CONTROL MODULE
Removing Tire pressure monitoring system (RDK) control module

destroyed.
The control module is located beside the brake booster in the luggage compartment.
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Fig. 15: Unscrew fastening nut -1-, loosen fastening nut -2-, release plug -3- and remove it.
2. Loosen fastening nut -2- and remove the control module. See Fig. 15.
3. Release the electrical plug -A- and fold up lock. See Fig. 15.
4. Remove control module.
INSTALLING TIRE PRESSURE MONITORING SYSTEM (RDK) CONTROL MODULE
Installing Tire pressure monitoring system (RDK) control module
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Fig. 16: Connecting and locking plug

1. Connect electrical plug to control module and lock plug -B- . See Fig. 16.
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Fig. 17: Positioning and securing control module

2. Position control module and secure with both fastening nuts.
SUBSEQUENT WORK
Rework on Tire pressure monitoring system (RDK) control module
PROGRAMMING TIRE PRESSURE MONITORING SYSTEM (RDK) CONTROL UNIT
Control units - reading and writing replacement values
If the control module for the Tire pressure monitoring system is replaced, it must be programmed using the
PIWIS Tester P 9718. This will ensure that the control module is taught for the relevant vehicle, country
version and equipment.
1. Connect the Porsche System Tester to the vehicle and start the System Tester. Switch on the ignition. Press
>> to continue.
4. Select RDK with the cursor keys and press the >> key.
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8. Switch off ignition and replace control unit. --> 443419 Removing and installing control unit for the Tire
pressure monitoring system - chapter on "Removing"
44 38 19 REMOVING AND INSTALLING TIRE PRESSURE MONITORING

SYSTEM ANTENNA - AS OF MY 2005 (ALL MODELS)
PRELIMINARY WORK
Preliminary work
1. Remove front wheel housing liner (Part A). Refer to 50 56 19 Removing and installing front wheel housing
2. Remove rear wheel housing liner (Part A). Refer to 53 69 19 Removing and installing rear wheel housing
REMOVING TIRE PRESSURE MONITORING SYSTEM ANTENNA
Removing antenna for Tire pressure monitoring system
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Fig. 18: Overview of Tire pressure monitoring system antenna

Fig. 19: Unscrewing fastening screw for Tire pressure monitoring system antenna

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3. Pull out antenna for Tire pressure monitoring system from holder -arrow A- and remove. See Fig. 19.
Fig. 20: Pulling plug from antenna of Tire pressure monitoring system
4. Release connector -arrow a- , pull off, and remove Tire pressure monitoring system antenna. See Fig. 20.
INSTALLING TIRE PRESSURE MONITORING SYSTEM ANTENNA
Installing antenna for Tire pressure monitoring system
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Fig. 21: Overview of Tire pressure monitoring system antenna

Fig. 22: Pushing plug onto antenna of Tire pressure monitoring system
1. Insert plug until it is felt to engage.
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Fig. 23: Securing antenna of Tire pressure monitoring system with fastening screw
2. Insert antenna of Tire pressure monitoring system into support -arrow A- and secure with fastening screw -1-
. --> Tightening torque: 1.5 ftlb. See Fig. 23.
SUBSEQUENT WORK
Subsequent work
1. Install front wheel housing liner (Part A). Refer to 50 56 19 Removing and installing front wheel housing
2. Install rear wheel housing liner (Part A). Refer to 53 69 19 Removing and installing rear wheel housing
44 40 19 FITTING TIRES FOR VEHICLES WITH AND WITHOUT TIRE

PRESSURE MONITORING (TPM) - AS OF MY 2005 (ALL MODELS)
NOTES ON REMOVING/MOUNTING TIRES
NOTE:  Before fitting, check whether a Tire Pressure Monitoring system (TPM) is
installed! The Tire valve serves as the distinguishing characteristic.
Without Tire Pressure Monitoring: rubber valve, with Tire Pressure
Monitoring: aluminum valve. If Tire pressure monitoring is used, observe
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the special instructions for the Tire Pressure Monitoring system. -->
444019 Mounting Tires for vehicles with and without Tire Pressure
Monitoring system (TPM), section on "Special notes for Tire Pressure
Monitoring system"
 The mounting machine described here is particularly suitable for large Tire
combinations, such as those used by Porsche.
 All parts in contact with the wheel and the Tires are made of plastic.
 No large point load for wheel and Tires.
Tools
Fig. 24: Tire Service Tools

A - Holding-down device 9539 - For holding down Tire bead, see Workshop Equipment Manual, Chapter
Special Tools
B - Assembly aid - commercially available; refer to Workshop Equipment Manual, Chapter 2.5
C - Adhesive weight remover - commercially available
D - Mounting lever - commercially available
Notes on removing/mounting Tires
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Fig. 25: Tire Service Tools

NOTE:  When fitting Tires, the direction of rotation and the inner and outer sides
should be noted.
 Use only TIP TOP Universal, order No. 593 0601 (3.5 kg bucket) or Contifix
as the mounting paste.
 Ensure that no damage (scoring, soiling) is caused to the assembly head
of the fitting machine during fitting. Such damage may result in paint
damage and pressure marks on the rim flange.
- Avoid slipping on to the rim flange. Use rim flange protection (assembly aid) -B- . See Fig. 25.
- Adhesive tape can be used to protect the rim flange in individual cases, in order to prevent any paint damage
during fitting. The mounting lever can also be covered with adhesive tape in order to avoid damaging the area
around the spokes during removal.
- The valve must always be replaced when changing a Tire.
- Check the wheel for damage.
Special notes for Tire pressure monitoring system (RDK)
NOTE:  If the previous wheels are still in the vicinity after assembly work (for
example changing winter Tires and/or wheels from another vehicle with
Tire pressure monitoring system), they might still be recognized by the
system. If one or more of these wheels has a minimum pressure of more
than 0.4 bar below the required pressure, this can trigger a warning in the
instrument cluster. In this case, remove the other wheels or use the PIWIS
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Tester to tune the vehicle to be outside the radio range of these wheels.
 The remaining life span can be read out with the PIWIS Tester. Where a
Tire change is about to be made, it is advisable to read out the remaining
life span of the wheel electronics (based on the battery capacity).
 For vehicles with a Tire pressure monitoring system, the valve and wheel
electronics -A- are only replaced in exceptional cases. The following
points can make replacement necessary. See Fig. 26.

The valve must be replaced if:
 The wheel electronics are removed

 The self-locking fastening screw is loose
 The union nut is loose
 The valve leaks at valve seat
 And the valve body is bent or broken.
The wheel electronics must be replaced if:
 The housing is visibly deformed

 The filter surface is so soiled that it cannot be cleaned by wiping
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 Tire sealant (Tire sealing liquid) has been used.
1. Install wheel electronics loosely at valve (do not tighten) and position in valve bore together with valve and
bead seat sealing ring.
CAUTION: Remove assembly pin after installing valve (required to counter).

Otherwise the Tire will be damaged during installation.
--> Carry out the tightening procedure for the valve in one work step (tighten without interruption up to
attaining the prescribed tightening torque).
2. Fit washer, chamfered on both sides, and screw on union nut until it seats. Visibly twist bore at valve foot. If
necessary, block with suitable assembly pin. The tightening torque is 4 Nm (3 ftlb.) (± 0.5 Nm (0.4 ftlb.)).

3. Push wheel electronics -A- slightly into rim well (this adjusts the angle of inclination of valve to wheel
electronics). See Fig. 27.
4. Carefully tighten self-locking Torx fastening screw T 20 with tightening torque 3 ftlb. (± 0.4 ftlb.). The wheel
electronics should now be lying evenly against the rim.
Removal
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1. Clamp wheel.
Fig. 28: Setting bead press-off tool

2. When pushing off the Tire, ensure that the bead press-off tool is set to the exact inch graduation. If this is not
the case, the rim flange may be damaged by the press-off rollers.
3. The wheel must be turned anti-clockwise when pressing the Tire off the rim. Otherwise, excessive forces
occur on the fastening bolts of the machine which can lead to bolt breakage. The Tire beads can be pressed off
at the same time or individually.
4. Before removing the Tire, coat the Tire beads with mounting paste to facilitate removal.
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Fig. 29: Tire removal

NOTE:  The mounting lever must be kept at a safe distance from the rim. This
prevents damage (scratches, pressure marks) to the rim spokes.
 In the case of vehicles with RDK, for the upper Tire bead the mounting
head must be positioned about 15 cm behind the valve in order to prevent
damage to the wheel electronics.
 In the case of vehicles with RDK, for the lower Tire bead the mounting
head must be positioned about 5 cm behind the valve.
5. Put the assembly head on the rim flange. Position the assembly aid. The mounting lever is pushed into the
deep bed underneath the first Tire bead, and then guided over the assembly shoe and pushed down.
6. Lift the Tire bead out of the rim bed by turning the wheel to the right.
7. Position the assembly aid for the second Tire bead approximately 5 - 10 cm to the right of the valve. Pull the
Tire upwards and push it into the rim bed underneath the second Tire bead using the mounting lever. Make sure
that the mounting lever is guided correctly (see Item 5). Turn the wheel to the right and remove the Tire.
Installation
NOTE:  Check the mounting head adjustment (must correspond with rim size).
 The wheel electronics must not be treated with compressed air, mounting
paste, cleaning agents or any other solvents.
 Rims must not be cleaned with high pressure before Tires have been
fitted.
 Do not scratch filter surface of wheel electronics clear! Remove soiling
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with a lint-free cloth. The wheel electronics must be free of Tire mounting
paste (observe when applying Tire mounting paste to the rim).
 During fitting, ensure that the Tire bead is not pressed against the wheel
electronics.
1. Free the wheel from the abraded rubber particles and check for damage.
2. A new valve must always be fitted.
3. Coat the wheel and Tire with Tire mounting paste - TIP TOP Universal, order No. 593 0601 - or Contifix.
Make sure that the wheel electronics are free of Tire mounting paste.
4. Place the Tire in the correct position on the wheel. Push in mounting arm and position on top of the rim
flange. The assembly head must be offset from valve by 180°.
5. Push the first part of Tire bead (lower Tire bead) partly over rim flange. Adjust mounting head on rim flange
and pull lower Tire bead onto the rim.
6. Position mounting head approx. 15 cm to the right of valve and pull the second Tire bead (upper Tire bead)
onto rim.
Fig. 30: Tire filling cage

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WARNING: If the Tire seating pressure is too high (max. 4 bar permissible), personal
injuries due to possible Tire or wheel destruction are possible.
--> Maximum Tire seating pressure 4 bar! This value must not be exceeded!
--> For Tire seating pressure over 3.3 bar (possible in the event that several unfavorable factors should occur
simultaneously / max. 4.0 bar permissible) use a Tire filling cage.
7. Remove entire wheel from Tire fitting unit. Without valve insert, fill Tire with air until Tire beads slide over
hump (to a maximum of 4.0 bar).
8. Screw in new valve insert and fill Tire to specified Tire pressure. Screw on valve cap.
44 95 03 SUSPENSION ALIGNMENT, COMPLETE - AS OF MY 2005 (ALL

MODELS)
TOOLS

INFORMATION
General procedure for wheel alignment
Performing wheel alignment using an electronic wheel alignment tester. Measurement procedures should be
taken from the operating instructions for the wheel alignment tester involved.
In order to exclude erroneous measurements, the following preconditions must be met before alignment
and the following points should be given special attention:
Empty weight of vehicle according to DIN 70020, i. e. vehicle in ready-to-drive condition with full tank and
including tools but without driver or additional weights.
Ball-joint and wheel-bearing play in order (wheel-bearing play cannot be adjusted).
Tire pressure in accordance with regulations, fairly uniform Tire tread.
Quick-clamping holder with adapter (for the measured-value pickups) correctly secured to the wheels.
Receiving surfaces for the quick-clamping holder on the wheels and the adapter surfaces must be clean and flat.
Always check the levelling surface on the wheels precisely in particular before fitting the quick-clamping
holders.
Strictly comply with maintenance intervals for measuring equipment and measuring platform. If the levelling of
the measuring platform or measuring station is done in-house, levelling equipment is required. A hose level
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gauge is not adequate.
Skilled handling of measuring equipment and measuring platform.
Sliding plates with transverse motion (rotary motion) at the rear axle are advisable.
Observe the Technical Literature of PAG, the manufacturer of the measuring equipment and the manufacturer
of the measuring platform.
Do not treat measured values as a whole, but very critically in regard to driving dynamics, high-speed strength
of the Tires, Tire wear and cost/benefit effects (time required for correction of insubstantial deviations). The toe
values are of decisive significance for driving dynamics and Tire wear.
If the vehicle is measured front and rear, check and adjust the wheel alignment values at the rear axle first.
Camber values at the front axle apply for the straight-ahead position of the wheels. Steering wheel and steering
gear in center position when toe is being adjusted.
Before wheel alignment values are adjusted at front and rear axles, it is recommended that the vehicle height be
checked at the DIN empty weight. Conclusions can then be drawn about wheel alignment values in the event of
any suspension alignment that becomes necessary later.
ALIGNING VEHICLE AT FRONT AND REAR
Vehicle height (height check)
General
The vehicle height at front and rear axle is not adjustable.
Preliminary work
For the height check, place the vehicle on a level surface or on the measuring platform (ready to drive, with a
full tank and tools but without driver or additional weights). Compress (push down) vehicle at front and rear
axles 2-3 times and allow it to spring back freely.
Front axle
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Fig. 31: Measuring height of front axle (left-hand side)

From road contact surface to hexagon-head bolt of cross-member screw connection to the body.
Nominal value for front and rear axles --> 440000 Adjustment values for wheel alignment.
Rear axle
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Fig. 32: Measuring the height of the rear axle (right-hand side)
Measure from wheel contact area up to lower edge of diagonal brace (at control arm fastening point).
Wheel alignment
WARNING: Risk of accident due to incorrect functioning of steering angle sensor if it

is uncalibrated or incorrectly calibrated.
 There is a risk of accidents causing physical damage to persons or

objects in the PSM testing area.
--> After working on wheel suspension parts, when replacing the steering-angle sensor and after changing the
wheel alignment values, calibrate the steering angle sensor with the front wheels in straight-ahead position
using the PIWIS tester.
--> Check the actual value of the steering angle sensor after a suspension alignment where no changes were
made to the wheel alignment values.
Notes
Only check or adjust wheel-alignment values when prescribed preconditions are met. --> 449503 Suspension
alignment complete - section on "Information"
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If the vehicle is measured front and rear, check and adjust the rear axle first. After adjustment, tighten the
appropriate screw connections to the prescribed tightening torque. Tables for this can be found in Repair group
40 Refer to 40 Tightening torques for front axle - as of MY 2005 (All Models) . and Repair group 42 Refer
to 42 Tightening torques for rear axle - as of MY 2005 (All Models) .
The steering-angle sensor must be calibrated if the previous wheel alignment values (on rear and/or front
axle) were changed!
Rear axle
Preliminary work
Prepare vehicle for checking and/or adjustment of wheel alignment values. Place front wheels on rotary table
and rear wheels on rotary / sliding plates. Compress vehicle at front and rear axles by approximately 25 mm 2-3
times and allow it to spring back freely.
Adjusting camber
Fig. 33: Toe and camber eccentrics

After loosening the lock nut, turn eccentric -B- appropriately. See Fig. 33.
NOTE:  Due to the restricted space, to tighten the lock nut of the left camber
eccentric, use a 3/8 inch torque wrench (covering the range of 100 Nm (74
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ftlb.)) together with a 18 mm socket-wrench insert.

 3/8 inch torque wrenches and 3/8 inch socket-wrench inserts have a
smaller height than tools of the same size in a 1/2 inch version.
Tighten lock nut from camber eccentric to the prescribed tightening torque Refer to 42 Tightening torques for
rear axle - as of MY 2005 (All Models) . To do this, use a 3/8 inch torque wrench (covering the range of 100
Nm (74 ftlb.)) together with an 18 mm socket wrench insert on the left side.
Adjusting toe
Fig. 34: Toe and camber eccentrics

After loosening the lock nut, turn eccentric -A- appropriately. See Fig. 33.
After adjusting, tighten the lock nut of the toe eccentric to the prescribed tightening torque Refer to 42
Tightening torques for rear axle - as of MY 2005 (All Models) .
Front axle
Adjusting camber
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Fig. 35: Adjusting camber

The camber is adjusted by moving the spring strut transversely. For this purpose, undo the three fastening nuts
on the spring-strut mount and, to move the spring strut, remove the covering cap on the piston rod.
Adjusting caster
The caster is not adjustable on standard vehicles.
Adjusting toe
Preliminary work: Check whether the steering wheel is displaced with respect to the steering gear. To do this,
center the steering gear as described below.
Turn wheels to the straight-ahead position.
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Fig. 36: Steering in center position

Then re-adjust the front wheel alignment, if necessary, until bolt -2- in driver -1- and the lug on the steering
gear housing -4- line up. See Fig. 37.
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Fig. 37: Steering in center position

No. 3 is the desired breaking point for bolts in new steering gears. The (new) bolt -2- is inserted into driver -1-
and lies with its underside in lug -4- . This locks the steering gear in the center position. After installation of a
new steering gear, the lower part of the bolt is sheared off (at desired breaking point -3- ) by turning the steering
wheel. The upper part of the bolt -2- remains in the driver. See Fig. 37, Fig. 36.
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Fig. 38: Mark for the center steering position

If necessary, reposition the steering wheel. When doing this, seek the best position.
WARNING: A triggering of the airbag (malfunction in the airbag system) caused by

improper work on airbag components cannot be ruled out. In the case of
such a malfunction, an unsuitable steering wheel holder could cause
injury or damage.
--> Use only steering wheel holders that do not project into the area of the airbag unit!
--> Observe safety regulations when working with airbag vehicles (see in Repair Group 69)!
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Fig. 39: Steering wheel holder

Clamp steering wheel in center position with steering wheel holder -A- . Use only steering wheel holders that
do not project into the area of the airbag unit -B- ! If necessary, shorten the guiding rod of the steering wheel
holder at top -Arrow- . See Fig. 39.
Fig. 40: Adjusting toe

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Loosen tie rod lock nut(s) -2- . When loosening and tightening the tie rod lock nut(s) counter on the square of
the tie rod -3- , with an open-ended wrench. Then adjust the toe on the hexagon -1- of the tie rod(s). Then
tighten the tie rod lock nut(s) -2- to the prescribed tightening torque. See Fig. 40.
Fig. 41: Loosening and tightening tie rod lock nuts

Use special tool (socket wrench insert) P 9730 -A- together with a torque wrench -B- to loosen and tighten the
tie rod lock nut(s). The tightening torque of 50 Nm (37 ftlb.) for the tie rod lock nut(s) corresponds to a value of
approx. 32.5 Nm (24 ftlb.) when using a socket wrench insert P 9730. See Fig. 41.
Toe-difference angle
The toe-difference angle is not adjustable.
The steering angle sensor must be calibrated if the previous wheel alignment values (on rear and/or front axle)
were changed.
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TRANSMISSION Clutch, control
TRANSMISSION
Clutch, control
30 05 01 CHECKING CLUTCH PEDAL (END POSITION) - AS OF MY 2005

(ALL MODELS)
CLUTCH PEDAL: CHECKING PLAY AND PEDAL END POSITION
Checking clutch free play
The clutch master cylinder has an inner stop. The push rod and the clutch pedal are always pressed against this
stop by the clutch power spring. Due to the automatic hydraulic adjustment of the clutch, it is not possible to
determine the clutch play by checking at the clutch pedal.
Clutch: Checking pedal end position (pedal return/return force)
NOTE: This work step only needs to be performed in the course of maintenance.
The pedal must not give way during the operation.
If it gives way, the fault is in the clutch power spring or in the pedals.
- Check that the pedal is in end position by pulling at the pedal (without the use of force) towards the driver's
seat.
The clutch push rod and the clutch power spring are not adjustable. The clutch power spring has two functions,
namely to provide pedal force assistance and to return the pedal. The following are some of the points which are
requirements for perfect clutch operation:
 Correct bleeding of the clutch hydraulic system.

 No leaks in the hydraulic system
 Pedal return to the starting position
 Installation position of the pedals corresponds to the standard condition
30 01 07 BLEEDING THE CLUTCH SYSTEM - AS OF MY 2005 (ALL

MODELS)
INFORMATION
Important notes on bleeding
The clutch hydraulics must always be filled or bled using a bleeding device. Furthermore, the bleeder valve
must be opened sufficiently and the gauge pressure at the bleeding device must be approx. 1.3 bar.
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Once the filling or bleeding process has started, the clutch pedal must be moved (extremely slowly) into the
"Pedal fully depressed" position.
As there is no system pressure, servo kinematic effects will cause the clutch pedal to move forward abruptly. In
order to avoid damage, the pedal must be guided manually.
In general, a minimum filling time of 90 seconds must be observed. Once this filling period has elapsed, check
that no more bubbles appear at the bleeder valve (use a collecting bottle with transparent hose). Only then close
the bleeder valve.
Filling/bleeding
NOTE: In general, a minimum filling time of 90 seconds must be observed.
Use only new Super DOT 4 class brake fluid. This brake fluid is available under
the following part numbers:
 Container quantity 1 litre = 000.043.203.66

 Container quantity 30 litres = 000.043.203.67
Fig. 1: Connecting bleeding device to the brake fluid reservoir

1. Remove the cover over the brake fluid reservoir. Fill reservoir to its top edge with new brake fluid. Connect
the bleeding device to the brake fluid reservoir. --> See Fig. 1.
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2. Switch on the bleeding device and set an overpressure of approx. 1.3 bar.
Fig. 2: Bleeding (graphic 5-speed transmission)

3. Open the bleeder valve -arrow- on the clutch slave cylinder. See Fig. 2.
4. Move pedal extremely slowly to the "Pedal fully depressed" position. When doing so, guide the pedal by
hand so that it does not move forward abruptly.
5. Allow the brake fluid to rinse through for 30 seconds.
6. Afterwards, activate complete pedal travel manually very slowly for a further 60 seconds. After about 10 to
15 pedal strokes, leave the pedal in its normal position. Once this filling period has elapsed, check that no more
bubbles appear at the bleeder valve (use a collecting bottle with transparent hose). Then close the bleeder valve.
7. Switch off and disconnect the bleeding device. Check the brake fluid level. It should not be above the MAX.
mark.
8. Activate the clutch pedal slowly, five times.
9. Fit the cover over the brake fluid reservoir.
30 30 19 REMOVING AND INSTALLING CLUTCH SLAVE CYLINDER - 6-

SPEED TRANSMISSION - AS OF MY 2005 (ALL MODELS)
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TOOLS

INFORMATION
Information
Fig. 3: Installation overview of clutch slave cylinder

Preliminary work
1. Raise the vehicle at the prescribed jacking points --> 40 LIFTING THE VEHICLE - AS OF MY 2005
(ALL MODELS) .
Removing
1. Remove left transmission bracket with hydraulic mount.
A - Transmission bracket
B - Hydraulic mount

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Support transmission before removing the transmission bracket! When supporting the transmission,
ensure that there is no tension on the screws on the transmission bracket -A-. See Fig. 4.

Unscrew nuts -Arrows- on hydraulic mount -B- . See Fig. 4.
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Unscrew screws -Arrows- on transmission bracket -A- and remove transmission bracket -A- together with
hydraulic mount. See Fig. 5, Fig. 4.
2. Lever off shift cable and connecting rods.
1 - Shift cable
2 - Connecting rod
3 - Connecting rod
4 - External shift mechanism
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Fig. 6: External shift mechanism

Lever off shift cable -1- and connecting rods -2, 3- at the external shift mechanism -4- . See Fig. 6.
3. Remove external shift mechanism.
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3.1. Unscrew nut -Arrow- . See Fig. 7.
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Fig. 8: Pulling off external shift mechanism

3.2. Pull external shift mechanism off the shifting shaft. Use the Puller P 9736 (Tools) to do this.
4. Disconnect clutch line on the clutch slave cylinder.
Seal off the clutch line with a plug.
Fig. 9: Clutch slave cylinder

5. Screw out screw -Arrow- and pull clutch slave cylinder out of the guide. See Fig. 9.
Installing
1. Install clutch slave cylinder.
NOTE: Before installing the clutch slave cylinder, grease the push rod with Kluberalfa
in the area of the release-lever ball socket. Part No. 000.043.304.02 (50g tube).
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2. Install external shift mechanism.
Insert external shift mechanism and tighten nut -Arrow- . See Fig. 10.
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Fig. 11: External shift mechanism

3. Press on shift cable and connecting rods.
1 - Shift cable
2 - Connecting rod
3 - Connecting rod
4 - External shift mechanism
4. Install transmission bracket with hydraulic mount.
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4.1. Tighten screws securing transmission bracket to transmission.
4.1.1. Transmission bracket to Tiptronic transmission
4.1.2. Transmission bracket to manual transmission
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4.2. Tighten nuts securing hydraulic mount to rear-axle carrier side section.
B - Hydraulic mount
SUBSEQUENT WORK
Subsequent work
1. Bleed the clutch system --> 300107 Bleeding the clutch system.
2. Clean the transmission in the work area.
30 05 19 REMOVING AND INSTALLING THE CLUTCH PEDAL - AS OF MY

2005 (ALL MODELS)
PRELIMINARY WORK
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Preliminary work
1. Remove center console cover (driver's side) Refer to 68 14 19 Removing and installing center console
Fig. 14: Removing trim panel (lower part of dashboard)

2. Remove trim panel (dashboard lower part). To do this, unscrew the fastening screws -1- and swivel the trim
panel under the dashboard on the driver's side -2- downwards -Arrow A- Refer to 70 19 19 Removing and
installing trim under dashboard - as of MY 2005 (All Models) . See Fig. 14.
CAUTION: Increased risk of accidents when removing/installing the clutch boost

spring.
 Possible risk of damage and injury (e. g. crushing).
--> The boost spring must be secured with a cotter pin when working near the clutch pedal (except for work on
the clutch pedal switch and interlock switch).
TECHNICAL VALUES
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Technical values

value 1 2
Tightening
Master cylinder 7.5 ftlb.
torque
Tightening
Pedal bearing axle 6 ftlb. +1.5 ftlb.
torque
Pedal bearing axle: right lock nut Tightening
7.5 ftlb.
(M8) torque
Pedal bearing axle: left lock nut Tightening
34 ftlb.
(M14) torque
Tightening
Bracket for clutch boost spring 7.5 ftlb.
torque
REMOVING CLUTCH PEDAL
Removing
1. Remove the cover and side trim panel for the fusebox in the left driver's footwell.
Fig. 15: Clutch pedal switch

2. Carefully pull off the connector from the clutch pedal switch (and interlock switch if necessary) -Arrows- .
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See Fig. 15.
3. Remove the relay carrier, vehicle electrical system control unit, and device support on the left above the
clutch pedal.
4. Secure clutch power spring with a cotter pin, for example. Press the clutch pedal lightly, unclip the clutch
power spring and remove.
Fig. 16: Clutch master cylinder

5. Loosen the clutch master cylinder -Arrows- (do not open the clutch system!) and remove the pin (master
cylinder valve pushrod). See Fig. 16.
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Fig. 17: Bracket for clutch power spring

6. Loosen bracket for clutch power spring (support for clutch pedal switch and remove interlock switch, if
necessary) --> Fig. 17. Carefully move bracket for clutch power spring approximately 2-4 mm to the left -A- .
Carefully turn bracket for clutch power spring clockwise on the pedal bearing axle approximately 10-15 degrees
-B- . See Fig. 17.
NOTE: When removing the bracket for the clutch power spring, carefully guide the
master cylinder valve pushrod past at the clutch pedal.
7. Pull out bracket for clutch power spring to the left and take out the clutch pedal.
INSTALLING CLUTCH PEDAL
Installing
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Fig. 18: Advanced grease specification

NOTE: Grease bracket in area of pedal bearing axle -Arrows- with Renocal (Glissando
VW 745). Part No. 000.043.206.21 (10g tube). See Fig. 18.
Important: By contrast with previous models, do not grease the pedal bearing axle in the area of the clutch pedal
-A- (due to plastic-coated bearing sleeves). See Fig. 18.
Also grease the following contact surfaces with Renocal (Glissando VW 745) (Part No. 000.043.206.21): The
clutch pedal switch (interlock switch) system -Arrow- . In addition, the contact surface between the clutch
pedal (inside of prongs) -Arrow- and the guiding rods of the clutch power spring -Arrow- . See Fig. 18.
Use new lock for bolts.
When installing the bracket for clutch power spring, insert the valve pushrod for the master cylinder carefully
into the specified position in the clutch pedal.
Fig. 19: Clutch master cylinder (push rod)

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If creaking noises (over approx. 2/3 of the lift area) are heard after installing the clutch pedal, these may be
coming from the connection between the ball head piston rod and piston seat of the clutch master cylinder -
Arrow- . In this case, spray a minimal amount of multipurpose oil on the connection point using a metering
tube -Arrow- . Important: The lubricant must only be applied to this connection point so make sure not to use
too much. This connection point cannot be taken apart without damaging it irreparably. See Fig. 19.
1. Insert bracket for clutch power spring with clutch pedal.
Fig. 20: Clutch pedal switch support

2. Position support for clutch pedal switch (and interlock switch, if necessary) in the correct position. Observe
the auxiliary bar! -Arrow- The auxiliary bar must be fitted in the correct position in the groove. See Fig. 20.
3. Install clutch power spring. Observe the installation position of the bolt for the clutch power spring
(hexagon!). After installation, remove the clutch power spring cotter pin.
NOTE: Insert pin. Screw in the fastening screws slightly so that the master cylinder can
still be moved. Have the clutch pedal not actuated at the limit stop. Press the
clutch master cylinder in the direction of travel and tighten (make sure the
return bore in the clutch master cylinder is not blocked!).
4. Mount the clutch master cylinder.
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Fig. 21: Adjustment for clutch pedal switch (interlock switch)

NOTE: If the clutch pedal switch adjustment (interlock switch) has been changed, the
adjustment must be checked or adjusted. The switch must switch when the
clutch pedal is actuated approx. 1-2 mm before the limit stop of the clutch
master cylinder.
5. Check adjustment for clutch pedal switch (and interlock switch, if necessary). --> Adjustment for clutch pedal
switch (interlock switch) Plug in connector. See Fig. 21.
6. Install device support, vehicle electrical system control unit and relay carrier.
7. Install the side trim panel for the fusebox and cover in the left driver's footwell.
SUBSEQUENT WORK
Subsequent work
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Fig. 22: Installing trim panel (lower part of dashboard)

1. Screw in the fastening screws -1- and swivel the trim panel under the dashboard on the driver's side -2-
upwards -arrow A- Refer to 70 19 19 Removing and installing trim under dashboard - as of MY 2005 (All
2. Install covers for center console Refer to 68 14 19 Removing and installing center console cover - as of
30 47 19 REMOVING AND INSTALLING GUIDE SLEEVE - AS OF MY 2005

(BOXSTER S, BOXSTER S RHD, CAYMAN S, CAYMAN S RHD)
PRELIMINARY WORK
Preliminary work
1. Remove transmission. Refer to 34 35 19 Removing and installing transmission - as of MY 2005 (All

Models) .
REMOVING GUIDE SLEEVE
Removing guide sleeve
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Fig. 23: Release mechanism

1. Remove release lever and release bearing.
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Fig. 24: Tab washer

2. Unscrew retaining screws for tab washer.
Fig. 25: Pulling off guide sleeve

3. Pull off guide sleeve.
INSTALLING GUIDE SLEEVE
Installing guide sleeve
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Fig. 26: Fitting guide sleeve

1. Fit guide sleeve and apply a thin coat of Optimol MP3.
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Fig. 27: Tab washer

2. Screwing in retaining screws for tab washer.

Tab washer Tightening torque 24 (18 ftlb.) Nm

3. Fit release lever and release bearing.
SUBSEQUENT WORK
Subsequent work

Models) .
30 47 19 REMOVING AND INSTALLING GUIDE SLEEVE - AS OF MY 2005

PRELIMINARY WORK
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Preliminary work

Models) .
REMOVING GUIDE SLEEVE

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Fig. 30: Guide sleeve

2. Unscrew fastening screws for guide sleeve and pull off guide sleeve.
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Fig. 32: Tab washer

2. Unscrew retaining screws for tab washer.
Fig. 33: Pulling off guide sleeve

3. Pull off guide sleeve.
INSTALLING GUIDE SLEEVE
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Fig. 34: Fitting guide sleeve

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Fig. 35: Tab washer

2. Screwing in retaining screws for tab washer.

Tab washer Tightening torque 24 (18 ftlb.) Nm

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Fig. 37: Guide sleeve


Guide sleeve Tightening torque 35 (26 ftlb.) Nm
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SUBSEQUENT WORK
Subsequent work

Models) .
30 50 19 REMOVING AND INSTALLING CLUTCH - AS OF MY 2005 (ALL

MODELS)
TOOLS

mandrel VW-tool 3176
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PRELIMINARY WORK
Preliminary work

Models) .
REMOVING CLUTCH
Removing clutch
Fig. 39: Toothed segment


1. Fasten toothed segment P 9538/1 to the crankcase with an M12 x 50 hexagon-head bolt.
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NOTE: To avoid deforming the clutch pressure plate, loosen and tighten the fastening
screws in at least five steps in diagonally opposite sequence.
2. Detach thrust plate.
3. Remove thrust plate and drive plate.
INSTALLING CLUTCH
Installing clutch
NOTE:  Clean the friction surfaces of the flywheel and pressure plate prior to
installation, e. g. with brake cleaner.
 Surfaces of friction linings must be free from contamination, especially oil
and grease.
1. Insert mandrel 3176 with the drive plate in the guide bearing (needle sleeve).
NOTE: To avoid deforming the clutch pressure plate, loosen and tighten the fastening
screws in at least five steps in diagonally opposite sequence.
2. Fit pressure plate.

value 1 2
Clutch pressure Fastening screws between pressure Tightening
17 ftlb.
plate plate and flywheel torque
3. Remove centring mandrel.
4. Remove toothed segment P 9538/1.
SUBSEQUENT WORK
Subsequent work

Models) .
30 56 01 CHECKING CLUTCH PLATE FOR WEAR - AS OF MY 2005 (ALL

MODELS)
PRELIMINARY WORK
Preliminary work
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1. Remove clutch. --> 305019 Removing and installing clutch - chapter on "Removing"
CHECKING CLUTCH PLATE FOR WEAR
Checking clutch plate for wear
NOTE: It should be noted that the clutch lining does not wear linearly over the service
life of the clutch. Due to the settling behavior of the clutch lining, wear can be
expected to be greater at the beginning. However, pad thickness wear will
become less as mileage increases.
Fig. 40: Measuring lining thickness

NOTE: Pad thickness measurement must only be done on the flanged side of the rivet
head.
1. Place a commercially available depth gauge on the clutch lining -1- and measure the distance to the rivet
head. See Fig. 41.
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Fig. 41: Sectional view

The wear dimension -X- measures 0.3 mm. If a smaller value is measured, the clutch drive plate must be
replaced. When new the measured value is more than 1mm. See Fig. 41.
SUBSEQUENT WORK
Subsequent work
1. Install clutch. --> 303019 Removing and installing clutch slave cylinder
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TRANSMISSION Final drive, differential, differential lock
TRANSMISSION
Final drive, differential, differential lock
39 08 15 ADJUSTING THE DRIVE SET - AS OF MY 2005 (BOXSTER,

BOXSTER RHD)
TOOLS

holder VW-tool 3177
engine support special tool P 9589
measuring mandrel VW-tool VW 385/ 1
gauge plunger VW-tool VW 385/14
final-dimension plate 50 VW-tool VW 385/17

mm
master gauge 35-85 mm VW-tool VW 385/30
final-dimension plate VW-tool VW 385/33
dial gauge holder VW-tool VW 387

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adjustable measuring lever VW-tool VW 388
clamping sleeve special tool VW 521/12
adjustment device VW-tool VW 521/4
engine and gear support VW-tool VW 540
PRELIMINARY WORK
Preliminary work

Models) .
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Fig. 1: Transmission on assembly support

2. Tighten the transmission using engine support P 9589 or engine and gear support VW 540 at the assembly
support.
3. Drain transmission oil. Refer to 34 01 55 Changing transmission oil - as of MY 2005 (Boxster, Boxster
RHD) .
4. Disassemble the transmission. Refer to 34 35 37 Disassembling and assembling transmission - as of MY

2005 (Boxster, Boxster RHD) .
INFORMATION
General information
NOTE: Careful adjustment of the output shaft and crown wheel are crucial to the
service life and smooth running of the final drive. Therefore, output shafts and
crown wheels are paired with each other as early as during production and are
checked by special machines to ensure a good position of the contact pattern
and that there is low noise in both rotation directions.
The deviation r referring to the master gauge Ro is measured for the drive sets
supplied as spare parts and is then recorded on the outer circumference of the
crown wheel. Every drive set (consisting of output shaft and crown wheel) must
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only be replaced as a complete unit.
Adjustment and labelling of the After Sales Service drive set
Fig. 2: After Sales Service drive set

1 - Code 0935 means: Oerlikon drive set with transmission ratio of 35 : 9
2 - Pairing number (312) of the drive set
3 - Deviation r refers to the master gauge of the special inspection machine used in production. The deviation r
is always given in 1/100 mm. For example: 25 means r=0.25 mm
R0 - Length of the master gauge used in the special inspection machine. Ro = 59.65 mm
R - Actual dimension between the crown wheel axis and the front side of the output shaft at the point of
maximum smooth running for this one drive set.
V0 - Hypoid offset
Adjustment and labelling of the standard drive set
NOTE: In the standard drive set, the position of the output shaft is determined by the
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dimension Po (center of the crown wheel to the rear of the output shaft head).
The dimension r on the crown wheel and the pairing number are not specified.
Therefore, before removing the output shaft, an actual measurement must be
made if parts which directly affect the installation position of the output shaft
are to be replaced.
Fig. 3: Standard drive set

X - These details are not required in the standard drive set.
P0 - Adjustment dimension for the standard drive set
Adjustment overview
NOTE: When carrying out assembly work on the final drive, re-adjustment of the output
shaft and crown wheel or drive set is necessary only if parts are being replaced
which directly influence the adjustment of the final drive. To avoid unnecessary
adjustment work, proceed according to the following table:
Crown Output Output shaft (S3 + Output shaft

Adjust: wheel (S1 shaft (S3 S ) via actual only adjusting
4
+ S2 ) + S4 ) shim S4
measurement
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Part replaced
Transmission housing () X X
Transmission cover X
Differential housing X
Taper roller bearing for the output shaft X
Taper roller bearing for the differential X
Drive set X X
Cover for final drive X
() If the transmission housing is replaced, the
drive shaft must also be adjusted. Refer to
35 40 15 Adjusting the drive shaft - as of
Sequence for re-adjusting the drive set
NOTE: The aim of the adjustment is to regain the position of maximum smooth running
which was determined on the testing machine.
The greatest possible care and cleanliness during all assembly work and
measuring procedures are essential requirements for perfect results.
Fig. 4: Setting
S1 - Adjusting shim for crown wheel
S2 - Adjusting shim for crown wheel
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S3 - Adjusting shim for output shaft
S4 - Adjusting shim for output shaft
If the output shaft and crown wheel have to be adjusted, it is best to follow the sequence below in the interest of
rational working:
1. Determine total disc thickness Stot (S1 + S2 ) for the preload of the taper roller bearings and differential in
accordance with regulations.
2. Calculate the total disc thickness Stot (S3 + S4 ).
3. Divide up the total disc thickness Stot (S3 + S4 ) so that the measurement from the crown wheel center to the
front of the output shaft corresponds to the installation dimension R measured during production.
4. Divide up the total disc thickness Stot (S1 + S2 ) so that the stipulated circumferential backlash is present
between the crown wheel and output shaft.
DETERMINING THE INSTALLATION POSITION OF THE OUTPUT SHAFT (ACTUAL

MEASUREMENT)
Determining the installation position of the output shaft
NOTE: This work must be carried out only if the deviation r is not given on the crown
wheel and if parts which directly influence the output shaft position are to be
replaced. These parts are: both taper roller bearings for the drive shaft and the
transmission housing.
1. Remove differential. --> 390919 Removing and installing differential - section on "Removing"
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Fig. 5: Preparing measuring mandrel

2. Prepare measuring mandrel VW 385/ 1. --> Fig. 5.
a - 40 mm
b - 55 mm
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Fig. 6: Completing the measuring mandrel

3. Complete measuring mandrel VW 385/ 1. A dial-gauge extension of approx. 12 mm in length must be fitted
in the gauge plunger VW 385/14.
4. Set the master gauge 35-85 mm VW 385/30 to the dimension R0 = 59.65 mm and place on the measuring
mandrel VW 385/ 1.
5. Zero the dial gauge with approx. 1 mm preload.
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Fig. 7: Final-dimension plate

6. Place final-dimension plate VW 385/33 on the output shaft head.
7. Remove master gauge 35-85 mm VW 385/30 and insert measuring mandrel VW 385/ 1 into the housing.
8. Put on the cover for the final drive and secure it with at least four screws.

1 2
Fastening screws for cover for final Tightening 25 (19 ftlb.)
drive torque Nm
9. Pull out the second centering screw via the movable setting collar far enough so that the measuring mandrel
can still just be turned manually.
NOTE: Record the measured value r .
After replacing the parts, adjust the output shaft as described. When doing so,
use the deviation r determined when measuring the adjusting shim S3 .
10. Turn the measuring mandrel until the dial gauge tip touches the end plate on the output shaft head and
displays the maximum deflection (reversing point). The measured value is the actual deviation r .
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CALCULATING DISC THICKNESS S3 AND S4
Calculating the total disc thickness "Stot" (S3 + S4)
NOTE: In practice, it has been shown that the disc thickness S3 often remains constant
when replacing the output shaft. Therefore, only the disc thickness S4 must be
calculated again. In any case, the result must be checked.
Before beginning adjusting and measuring work, the sealing surfaces of the
transmission housing and cover must be cleaned carefully.
1. Remove outer bearing ring from transmission cover Refer to 34 55 37 Disassembling and assembling
transmission cover - as of MY 2005 (Boxster, Boxster RHD) . The rubber washer remains in the transmission
cover.
2. Remove adjusting shims S4 from the transmission cover and fit the outer bearing ring again.
Fig. 8: Bearing on output shaft

NOTE: If the output shaft is already assembled, it is not necessary to disassemble it.
3. Fit the taper roller bearing on the output shaft, secure lower taper roller bearing and install output shaft. Refer
to 34 35 37 Disassembling and assembling transmission - as of MY 2005 (Boxster, Boxster RHD) .
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4. If the transmission cover has been removed, mount transmission cover and screw in screws.

1 2
Fastening screws for transmission Tightening 25 (19 ftlb.)
cover torque Nm
5. Turn the output shaft several times by hand so that the taper roller bearings settle.
Fig. 9: Measurement setup

6. Assemble measuring tool. --> Fig. 9.
7. Press output shaft completely in the direction of transmission cover.
9. Press output shaft with screwdriver in the direction of transmission housing.
10. Read dial gauge and record result.
Repeat the measurement procedure several times and compare the values read.
Example for value read: 0.70 mm

Microsoft
Because the disc thickness S3 has not been changed, the following particular disc thickness is installed
completely as adjusting shim S4 .
Stot = measured result + compression
Compression (constant value) 0.15 mm

Measured result +0.70 mm
Stot = S4 = 0.85 mm
11. Remove outer bearing ring from transmission cover, insert new disc S4 (0.85 mm in example) and fit outer
bearing ring again. Refer to 34 55 37 Disassembling and assembling transmission cover - as of MY 2005
(Boxster, Boxster RHD) .
Checking disc thickness S4
NOTE: The pre-tension of the taper roller bearing is determined using the disc
thickness S4 together with the disc thickness S3 , which was already calculated
and used correctly.
1. Place the transmission housing on the workbench, and insert the output shaft.
2. Position transmission cover and screw in screws.

1 2
cover torque Nm
3. Turn transmission and place on transmission cover.
NOTE: Pre-loading the taper roller bearing increases the force necessary to turn the
shaft. Therefore, a hexagon-head bolt can be inserted in the thread of the shaft
head to turn the output shaft, and turned at the hexagon.
4. Turn the output shaft several times so that the taper roller bearing settles.
Microsoft

5. Assemble measuring tool. --> Fig. 10.
7. Undo the screws of the transmission cover and read off the dial gauge. If the adjusting shims were selected
correctly, the dial gauge must display a value between 0.08 mm and 0.15 mm.
If the value read is not between 0.08 mm and 0.15 mm, the adjusting shim S4 must be changed accordingly and
the measurement taken again.
Checking disc thickness S3
NOTE: The disc thickness S3 , together with disc thickness S4 , determines the
distance between the output shaft and crown wheel as well as the pre-tension.
Using the master gauge, the setpoint dimension R is adjusted for the distance
from pinion to crown wheel. The setpoint dimension for the distance is
calculated from the total of the design dimension R0 = 59.65 mm and the
deviation r, which is either specified on the crown wheel or has been
determined by the actual value measurement (example: 0.40 mm).
1. Insert output shaft, position transmission cover and screw in screws.
Microsoft

1 2
cover torque Nm
NOTE: Pre-loading the taper roller bearing increases the force necessary to turn the
shaft. Therefore, a hexagon-head bolt can be inserted in the thread of the shaft
head to turn the output shaft, and turned at the hexagon.
2. Turn the output shaft several times so that the taper roller bearing settles.
Fig. 11: Preparing measuring mandrel

4. Prepare measuring mandrel VW 385/ 1. --> Fig. 11.
a - 40 mm
b - 55 mm
Microsoft
Fig. 12: Completing the measuring mandrel

5. Complete measuring mandrel VW 385/ 1. A dial-gauge extension of approx. 12 mm in length must be fitted
in the gauge plunger VW 385/14.
6. Set the master gauge 35-85 mm VW 385/30 to the dimension R0 + r (in the example: 59.65 mm + 0.40 mm
= 60.05 mm) and position measuring mandrel VW 385/ 1.
Microsoft
Fig. 13: Final-dimension plate

8. Place final-dimension plate VW 385/33 on the output shaft head.
9. Remove master gauge 35-85 mm VW 385/30 and insert measuring mandrel VW 385/ 1 into the housing.
10. Put on the cover for the final drive and secure it with at least four screws.

1 2
Fastening screws for cover for final Tightening 25 (19 ftlb.)
drive torque Nm
11. Pull out the second centering screw via the movable setting collar far enough so that the measuring mandrel
can still just be turned manually.
12. Turn the measuring mandrel until the dial gauge tip touches the end plate on the output shaft head and
displays the maximum deflection (reversing point). The measured value is the actual deviation R .
If the actual deviation R is outside the tolerance of ± 0.04 mm, or if the maximum deflection of the dial gauge
deviates from zero by more than 0.04 mm, the adjusting shim S3 must be changed accordingly and the
measurement repeated.
CALCULATING DISC THICKNESS S1 AND S2

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Calculating total disc thickness Stot (S1 + S2)
NOTE:  The output shaft must be removed in order to determine the preload of the
taper roller bearings on the differential. Refer to 34 35 37 Disassembling
and assembling transmission - as of MY 2005 (Boxster, Boxster RHD) .
 In practice, it has been shown that the disc thickness S2 often remains
constant when replacing the parts mentioned above. Therefore, only the
disc thickness S1 must be calculated again. In any case, the result must be
checked.
 When replacing the transmission housing, the adjusting shim S2 must be
removed from the old housing and installed in the new housing. Refer to
34 37 37 Disassembling and assembling transmission housing - as of MY
 Before beginning adjusting and measuring work, the sealing surfaces of
the transmission housing and cover must be cleaned carefully.
Re-adjustment of the crown wheel is necessary if any of the following parts is replaced:
 Transmission housing
 Cover for final drive
 Taper roller bearing for the differential
 Differential housing
 Drive set
1. Remove sealing ring, taper roller bearing outer ring and adjusting shim from the cover for the final drive.
Refer to 34 37 37 Disassembling and assembling transmission housing - as of MY 2005 (Boxster, Boxster
RHD) .
2. Install the taper roller bearing outer ring without adjusting shim. Refer to 34 37 37 Disassembling and
assembling transmission housing - as of MY 2005 (Boxster, Boxster RHD) .
3. Fit differential without speedometer-drive gear into the transmission housing and put on the cover. Refer to
34 37 37 Disassembling and assembling transmission housing - as of MY 2005 (Boxster, Boxster RHD) .
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4. Fit adjustment device VW 521/4 and clamping sleeve VW 521/12.
5. Place the final-dimension plate 50 mm VW 385/17 on the collar of the differential.
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6. Secure the dial gauge holder VW 387 with the dial gauge and extension to the housing, and set to 0 with 1
mm preload.
NOTE: Do not turn the differential when measuring, otherwise the measurement result
will be falsified.
7. Move the differential up and down on the adjustment device VW 521/4. Read off and record the play on the
dial gauge.
Example for value read: 0.75 mm
Because the disc thickness S2 has not been changed, the following particular disc thickness is installed
completely as adjusting shim S1 .
Stot = measured result + compression
Compression (constant value) 0.50 mm

Measured result + 0.75 mm
Stot = S1 = 1.25 mm
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8. Install disc S1 and fit cover for final drive. Refer to 34 37 37 Disassembling and assembling transmission
housing - as of MY 2005 (Boxster, Boxster RHD) .
Fig. 16: Torque gauge

9. Measure the friction torque with a commercially available torque gauge (measuring range 0...600 Ncm (0...
53 inlb.)). It must be 250...350 Ncm (22...31 inlb.) in the case of new taper roller bearings and it must be 30...60
Ncm (2.6...5.3 inlb.) in the case of run-in taper roller bearings (taper roller bearings filled with transmission oil).
When re-adjusting the drive set, also adjust the output shaft and perform a check. --> Calculating total disc
thickness "Stot" (S3 + S4) --> Checking disc thickness S4 --> Checking disc thickness S3
Checking disc thickness S1 and S2 via circumferential backlash
1. Install the output shaft with the adjusting shims S3 and S4 . Refer to 34 35 37 Disassembling and
assembling transmission - as of MY 2005 (Boxster, Boxster RHD) .
2. Insert differential and fit transmission cover. --> 390919 Removing and installing differential - section on
"Installing"
Microsoft

3. Screw together adjustable measuring lever VW 388 with adjustment device VW 521/4 and set the lever
length of the gauge plunger to -a = 72 mm- . See Fig. 17.
4. Insert adjustment device VW 521/4 and clamping bush VW 521/12 into the differential and clamp tightly.
5. Turn the differential several times in both directions so that the taper roller bearings can settle.
6. Fit the dial gauge holder with the dial gauge so that a right angle is produced between the dial gauge axis and
the measuring lever.
Microsoft
Fig. 18: Stop

If the friction coefficient of the output shaft for turning from stop to stop is too low, the holder 3177 -A- must
be fitted so that an exact circumferential backlash can be measured. The differential can only be inserted in such
a way that the aperture of the bevel gears faces the output shaft. See Fig. 18.
7. Turn the crown wheel to the stop and set the dial gauge to zero.
8. Turn back the crown wheel to the stop, read off the circumferential backlash on the dial gauge, and record
value.
NOTE:  If the measured values deviate from each other by more than 0.05 mm, the
installation of the crown wheel or the drive set itself is faulty. The
assembly work must then be checked, or if necessary, the drive set itself
must be replaced.
 The measured circumferential backlash must be between 0.12 mm and
0.22 mm. If the measured circumferential backlash is less than 0.12 mm,
the disc thickness S1 must be reduced and the disc thickness S2 must be
increased accordingly. If the circumferential backlash is greater than 0.22
mm, the disc thickness S2 must be reduced and the disc thickness S1
must be increased accordingly.
9. Further rotate crown wheel 90° each time, three times, repeating the measurement each time. With the holder
Microsoft
3177 fitted, install the differential offset by 180° and repeat the measuring procedure.
SUBSEQUENT WORK
Subsequent work
1. Assemble transmission. Refer to 34 35 37 Disassembling and assembling transmission - as of MY 2005

2. Fill with transmission oil. Refer to 34 01 55 Changing transmission oil - as of MY 2005 (Boxster, Boxster
RHD) .
3. Remove transmission from assembly support.

Models) .
39 09 19 REMOVING AND INSTALLING DIFFERENTIAL - AS OF MY 2005

(ALL MODELS)
TOOLS

Retaining device special tool P 9624/1
PRELIMINARY WORK
Preliminary work
1. Raise the vehicle at the specified jacking points. --> 40 LIFTING THE VEHICLE - AS OF MY 2005
(ALL MODELS) .
2. Remove rear right wheel. Refer to 44 05 19 Removing and installing wheel - as of MY 2005 (All Models) .
3. Remove support plate. Refer to 42 14 19 Removing and installing support plate - as of MY 2005 (All
Models) .
4. Unscrew fastening nuts for restraining cables and remove restraining cables from cross member.
Microsoft
Fig. 19: Special tool

5. Retaining device P 9624/1 must be screwed to cross member, then turn spindle upwards and support engine.
6. Drain oil for final drive. --> 399055 Changing oil for final drive
REMOVING DIFFERENTIAL
Removing differential
1. Remove cover for final drive.
NOTE: Note the whereabouts of the adjusting shims and outer bearing rings in the
differential cover and in the transmission housing. The adjusting shims are
calibrated and may not be modified or switched.
2. Remove final drive.
INSTALLING DIFFERENTIAL
Installing differential
1. If necessary, insert adjusting shims and outer bearing rings in transmission housing and differential cover.
The adjusting shims sit under the outer bearing rings.
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2. Insert final drive in transmission housing.
3. Coat new toroidal sealing ring on lid with oil and place onto lid.
4. Position cover for final drive.
Fig. 20: Tightening sequence

5. Screw in cover screws -1, 2 and 3- and tighten by hand. See Fig. 20.
6. Screw in cover screws in the following order -1 to 12- and tighten. See Fig. 20.

Cover screws Tightening torque 23 (17 ftlb.) Nm
SUBSEQUENT WORK
Subsequent work
1. Top up oil for final drive and perform all assembly work described. --> 399055 Changing oil for final drive
Microsoft

2. Retaining device P 9624/1 must then be removed from cross member.
3. Fit restraining cables to cross member.

1 2
Restraining Fastening nut between restraining Tightening 23 (17
cable cable and cross member torque ftlb.) Nm
4. Install support plate. Refer to 42 14 19 Removing and installing support plate - as of MY 2005 (All
Models) .
5. Install right wheel. Refer to 44 05 19 Removing and installing wheel - as of MY 2005 (All Models) .
6. Lower the vehicle.
39 09 19 REMOVING AND INSTALLING DIFFERENTIAL - AS OF MY 2005

TOOLS
Microsoft

PRELIMINARY WORK
Preliminary work

Models) .

support.
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RHD) .
REMOVING DIFFERENTIAL
Fig. 23: Overview

No. Designation Qty.

1 Flanged shaft 2
2 Circlip 2
3 Torx screw 10
4 Cover for final drive 1
5 Differential 1
6 Speedometer-drive gear 1
7 Tachometer sensor 1
8 O-ring 1
9 Transmission housing 1
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Fig. 24: Removing flanged shaft

1. Remove flanged shaft. To do this, place a chisel or spacer -A- under the flanged shaft and pull out the flanged
shaft by turning the screw -B- . See Fig. 24.
2. Unscrew Torx screws -3- between cover and housing and tap cover off using a rubber hammer if necessary.
See Fig. 23.
3. Remove differential.
INSTALLING DIFFERENTIAL
Installing differential
NOTE: The flanged shafts are installed with polygonal bearings. The rough running of
these bearings when the flanged shafts are not installed does not indicate that
the bearings are faulty. The polygonal bearings can be replaced only with the
flanged shaft.
Microsoft
Fig. 25: Overview

No. Designation Qty. Fitting

Grease circlip and drive in using a
1 Flanged shaft 2
rubber hammer
2 Circlip 2 Always replace
--> Tightening torque: 25 (19 ftlb.)
3 Torx screw 10
Nm
4 Cover for final drive 1 Seal with Loctite 574
5 Differential 1
6 Speedometer-drive gear 1
7 Tachometer sensor 1
8 O-ring 1 Always replace, lightly oil
9 Transmission housing 1
1. Insert differential in transmission housing.
2. Position cover for differential on transmission housing and screw in screws.
Microsoft
Fig. 26: Replacing circlip

3. Replace circlip for the halfshaft flange. To do this, clamp the flange in the vice with a hexagon-head bolt -B-
and press out the circlip with the new circlip -A- . See Fig. 26.
4. Grease circlip for easier fitting.
5. Drive halfshaft flange into transmission using a rubber hammer.
SUBSEQUENT WORK
Subsequent work
RHD) .

Models) .
39 09 37 DISASSEMBLING AND ASSEMBLING DIFFERENTIAL - AS OF MY

2005 (BOXSTER, BOXSTER RHD)
Microsoft
TOOLS

pressure piece VW-tool 2050
pressure piece commercially p 263

available tool
drive-in mandrel commercially vw 295

available tool
pressure piece commercially vw 472/1

available tool
thrust washer commercially vw 511

available tool
PRELIMINARY WORK
Preliminary work
DISASSEMBLING DIFFERENTIAL
Microsoft
Fig. 27: Overview of differential

No. Designation Qty. Removal

-1- Speedometer-drive gear 1
Pull off using a commercially
-2- Taper roller bearing inner ring () 1 available two-arm puller and the
pressure piece p 263.
Pull off using a commercially
-3- Taper roller bearing inner ring () available two-arm puller and the
pressure piece p 263.
-4- Crown wheel screw 10
Force off with a mandrel through the
-5- Crown wheel () 1
threaded bores.
-6- Roll pin 1
-7- Axle 1
-8- Differential bevel gear (small) 2
-9- Differential bevel gear (large) 2
-10- Thrust washer assembly 1
-11- Differential housing () 1
Drive out using a suitable aluminum
-12- Taper roller bearing outer ring 1 or copper mandrel (diameter of 6...8
mm).
-13- Adjusting shim S1 X Note the thickness for re-installation.
-14- Cover for final drive () 1
-15- Taper roller bearing outer ring 1 Drive out using a suitable aluminum
or copper mandrel (diameter of 6...8
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mm).
-16- Adjusting shim X Note the thickness for re-installation.
-17- Transmission housing () 1
() If these parts
are replaced,
re-adjustment
is necessary.
Removal instructions for differential
Fig. 28: Removing crown wheel

1. Force crown wheel off differential housing with a punch.
ASSEMBLING DIFFERENTIAL
Fitting differential
Microsoft
Fig. 29: Overview of differential


-1- Speedometer-drive gear 1
Heat to approx. 100 °C, put into
-2- Taper roller bearing inner ring () 1 position and press again after heat
exchange.
Heat to approx. 100 °C, put into
-3- Taper roller bearing inner ring () position and press again after heat
exchange.
Always replace. The thread must be
dry and free of grease. Tighten -->
-4- Crown wheel screw 10 Tightening torque: 60 (44 ftlb.)
Nm cross-wise. Then, turn -->
Torque angle: 45 ° further.
If required, heat up to approx. 100 °
-5- Crown wheel () 1
C
-6- Roll pin 1 Drive in at the correct position
-7- Axle 1
-8- Differential bevel gear (small) 2
-9- Differential bevel gear (large) 2
-10- Thrust washer assembly 1 Insert with transmission oil.
-11- Differential housing () 1
Press in using thrust washer vw
-12- Taper roller bearing outer ring 1 511 or pressure piece 2050 and
drive-in mandrel vw 295.
Calculate the thickness again if
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-13- Adjusting shim S1 X necessary.

-14- Cover for final drive () 1 Seal with Loctite 574.
Drive in using pressure piece vw
-15- Taper roller bearing outer ring 1
472/1.
-16- Adjusting shim X
necessary.
-17- Transmission housing () 1
() If these parts
are replaced,
re-adjustment
is necessary.
Installation instructions for differential
1. Install differential pinions.
 Insert the thrust washer assembly with hypoid transmission oil (Burmah-Oil TAF 21).
 Oil the differential pinions thoroughly.
 Insert large differential pinions and fix them with the flanged shafts (without circlip).
 Insert the small differential pinions offset by 180° and swivel them in by turning the flanged shafts.
 Align the thrust washer assembly and small differential pinions.
 Insert the axle and secure with a roll pin.
Microsoft
Fig. 30: Bevel gears

Fig. 31: Crown wheel

2. Heat up the crown wheel to approx. 100 °C and position with centering pin -A- (shop-made). See Fig. 31.
SUBSEQUENT WORK
Subsequent work
1. Install differential. --> 390919 Removing and installing differential - section on "Installing"
39 22 19 REMOVING AND INSTALLING SEALING RING FOR RIGHT-HAND

HALFSHAFT FLANGE - AS OF MY 2005 (ALL MODELS)
TOOLS

pressure piece special tool P 9738
Microsoft
PRELIMINARY WORK
Preliminary work
1. Raise the vehicle at the prescribed jacking points. Refer to 40 Tightening torques for front axle - as of MY
2005 (All Models) .
Models) .
3. Remove right halfshaft flange. --> 392519 Removing and installing right halfshaft flange - section on
"Removing" [987310 987311] --> 392519 Removing and installing right halfshaft flange - section on
"Removing" [987120 987121 987320 987321]
REMOVING SEALING RING FOR HALFSHAFT FLANGE
Removing sealing ring for halfshaft flange

1. Lever the sealing ring out of the transmission.
INSTALLING SEALING RING FOR HALFSHAFT FLANGE

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Installing sealing ring for halfshaft flange
1. Thinly coat sealing lip and outer circumference of sealing ring with Vaseline and place the sealing ring on
pressure piece P 9738.
Fig. 33: Tapping in sealing ring

2. Drive sealing ring into the transmission using pressure piece P 9738.
SUBSEQUENT WORK
Subsequent work
1. Install the right halfshaft flange. --> 392519 Removing and installing right halfshaft flange - "Installing"
chapter [987310 987311] --> 392519 Removing and installing right halfshaft flange - "Installing" chapter
[987120 987121 987320 987321]
2. Check transmission oil and, if necessary, top up. Refer to 34 01 35 Checking and topping up transmission
oil - as of MY 2005 (Boxster, Boxster RHD) . Refer to 34 01 35 Checking and topping up transmission oil -
as of MY 2005 (Boxster S, Boxster S RHD, Cayman S, Cayman S RHD) .
3. Fit support plate. Refer to 42 14 19 Removing and installing support plate - as of MY 2005 (All Models) .
Microsoft
39 22 19 REMOVING AND INSTALLING SEALING RING FOR LEFT

TOOLS

PRELIMINARY WORK
Preliminary work
2005 (All Models) .
Models) .
3. Remove left halfshaft flange. --> 392519 Removing and installing left halfshaft flange - section on
"Removing" [987310 987311] --> 392519 Removing and installing left halfshaft flange - section on
"Removing" [987120 987121 987320 987321]
REMOVING SEALING RING FOR HALFSHAFT FLANGE
Removing sealing ring for halfshaft flange
Microsoft

1. Lever the sealing ring out of the transmission.
INSTALLING SEALING RING FOR HALFSHAFT FLANGE
Installing sealing ring for halfshaft flange
pressure piece P 9738.
Microsoft

2. Drive sealing ring into the transmission using pressure piece P 9738.
SUBSEQUENT WORK
Subsequent work
1. Install left halfshaft flange. --> 392519 Removing and installing left halfshaft flange - "Installing"
chapter [987310 987311] --> 392519 Removing and installing left halfshaft flange - "Installing" chapter
[987120 987121 987320 987321]
39 15 19 REMOVING AND INSTALLING DOUBLE SEALING RING - AS OF

Microsoft
TOOLS

Hook VW-tool VW 681
PRELIMINARY WORK
Preliminary work
2005 (All Models) .
Models) .
Microsoft

5. Retaining device P 9624/1 must then be screwed to cross member, then turn spindle upwards and support
engine.
6. Drain oil for final drive. --> 399055 Changing oil for final drive
7. Remove the differential. --> 390919 Removing and installing differential - section on
"Removing" [987310 987311] --> 390919 Removing and installing differential - section on
"Removing" [987120 987121 987320 987321]
REMOVING DOUBLE SEALING RING
Removing double sealing ring
Microsoft
Fig. 37: Outer bearing ring and adjusting shim

NOTE: The adjusting shim is calibrated and cannot be exchanged for a different shim.
1. Remove outer bearing ring -1- and adjusting shim -2- from the transmission housing by hand. See Fig. 37.
Microsoft
Fig. 38: Removing sealing ring

NOTE: Hook VW 681 must be fitted behind both sealing lips of the sealing ring because
fitting it on the outer circumference of the sealing ring can damage the contact
surface in the transmission housing. Guide the tool carefully while pulling out.
2. Carefully pull out sealing ring with hook VW 681.
INSTALLING DOUBLE SEALING RING
Installing double sealing ring
1. Check seat of sealing ring in transmission housing for damage.
2. Thinly coat outer circumference and sealing lips of sealing ring with Vaseline.
Microsoft
Fig. 39: Pushing on the sealing ring

3. Push double sealing ring on so that the projecting sealing lip is pointing towards the pressure piece 3383.
Microsoft

4. Drive double sealing ring into the transmission housing up to the stop with pressure piece 3383.
SUBSEQUENT WORK
Subsequent work
1. Install differential. --> 390919 Removing and installing differential - section on "Installing" [987310
987311] --> 390919 Removing and installing differential - section on "Installing" [987120 987121 987320
987321]
2. Top up oil for final drive and perform all assembly work described. --> 399055 Changing oil for final drive

3. Retaining device P 9624/1 must then be removed from cross member.

1 2

Microsoft
Models) .
39 22 19 REMOVING AND INSTALLING SEALING RING FOR SHORT

TOOLS

hook VW-tool VW 681
PRELIMINARY WORK
Preliminary work
2005 (All Models) .
Models) .
3. Remove short halfshaft flange. --> 392519 Removing and installing halfshaft flange - section on
"Removing" [987310 987311] --> 392519 Removing and installing halfshaft flange - section on
"Removing" [987120 987121 987320 987321]
REMOVING SEALING RING
Removing sealing ring
Microsoft

1. Remove sealing ring with hook VW 681.
INSTALLING SEALING RING
Installing sealing ring
pressure piece 3382.
Microsoft

2. Drive in sealing ring with pressure piece 3382.
SUBSEQUENT WORK
Subsequent work
1. Install short halfshaft flange. --> 392519 Removing and installing halfshaft flange - chapter on
"Installing" [987310 987311] --> 392519 Removing and installing halfshaft flange - chapter on
"Installing" [987120 987121 987320 987321]
2. Check oil for final drive and top up if necessary. --> 399035 Checking and topping up oil for final drive
39 22 19 REMOVING AND INSTALLING SEALING RING FOR LONG

TOOLS

Microsoft
pull-in tool and extractor special tool P 254
assembly sleeve special tool P 9263
thrust washer VW-tool VW 511
PRELIMINARY WORK
Preliminary work
2005 (All Models) .
2. Drain oil for final drive. --> 399055 Replacing oil for final drive - section on "Draining"
Models) .
4. Remove long halfshaft flange. --> 392519 Removing and installing long halfshaft flange - section on
"Removing" [987310 987311] --> 392519 Removing and installing long halfshaft flange - section on
"Removing" [987120 987121 987320 987321]
REMOVING SEALING RING
Removing sealing ring
Microsoft
Fig. 44: Circlip

1. Remove circlip for ball bearing.
Microsoft
Fig. 45: Pressing out halfshaft flange

2. Press halfshaft flange out of mounting saddle.
3. Press sealing ring out of mounting saddle using a suitable tool.
INSTALLING SEALING RING
Installing sealing ring

1. Drive in new sealing ring as far as it will go using pressure piece P 9615 and pull-in tool and extractor P
254.
Microsoft
Fig. 47: Pressing in halfshaft flange

2. Press mounting saddle with assembly sleeve P 9263 and thrust washer VW 511 onto the halfshaft flange.
Fig. 48: Circlip

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3. Fit circlip.
SUBSEQUENT WORK
Subsequent work
1. Install long halfshaft flange. --> 392519 Removing and installing long halfshaft flange - "Installing"
chapter [987310 987311] --> 392519 Removing and installing long halfshaft flange - "Installing" chapter
[987120 987121 987320 987321]
2. Top up oil for final drive. --> 399055 Replacing oil for final drive - "Topping up" chapter
39 25 19 REMOVING AND INSTALLING RIGHT HALFSHAFT FLANGE - AS

PRELIMINARY WORK
Preliminary work
2005 (All Models) .
Models) .
3. Place oil collection pan under the transmission.
REMOVING HALFSHAFT FLANGE
Removing halfshaft flange
Microsoft

has been cut open).
1. Remove right drive shaft on transmission side. To do this, screw in the six Allen screws joining each drive
shaft and transmission flange and tighten screws. Counter at the wheel or activate the parking brake to avoid
simultaneous turning.
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2. Remove halfshaft flange. To do this, place a suitable support -B- under the halfshaft flange and press the
halfshaft flange out of the transmission by screwing in a screw -A- .
INSTALLING HALFSHAFT FLANGE
Installing halfshaft flange
Microsoft

1. Replace the circlip for the halfshaft flange. To do this, clamp the halfshaft flange in a vice using a screw -B-
2. Grease circlip and drive in halfshaft flange using a rubber hammer.
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3. Fit right drive shaft on transmission side. To do this, screw in the six Allen screws joining each drive shaft
and transmission flange and tighten screws. Counter at the wheel or activate the parking brake to avoid

1 2
Drive Fastening screws between drive shaft and Tightening 81 (60 ftlb.)
shafts halfshaft flange torque Nm
SUBSEQUENT WORK
Subsequent work
39 25 19 REMOVING AND INSTALLING LEFT HALFSHAFT FLANGE - AS OF

Microsoft

PRELIMINARY WORK
Preliminary work
2005 (All Models) .
Models) .

has been cut open).
1. Remove left drive shaft on transmission side. To do this, unscrew the six Allen screws joining each drive
Microsoft
shaft and transmission flange. Counter at the wheel or activate the parking brake to avoid simultaneous turning.

2. Remove halfshaft flange. To do this, place a suitable support -B- under the halfshaft flange and press the
halfshaft flange out of the transmission by screwing in a screw -A- . See Fig. 54.
Microsoft

1. Replace the circlip for the halfshaft flange. To do this, clamp the halfshaft flange in a vice using a screw -B-
2. Grease circlip and drive in halfshaft flange using a rubber hammer.
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3. Fit left drive shaft on transmission side. To do this, screw in the six Allen screws joining each drive shaft and
transmission flange and tighten screws. Counter at the wheel or activate the parking brake to avoid

1 2
shafts halfshaft flange torque Nm
SUBSEQUENT WORK
Subsequent work
39 25 19 REMOVING AND INSTALLING SHORT HALFSHAFT FLANGE - AS

Microsoft
OF MY 2005 (BOXSTER, BOXSTER RHD)

PRELIMINARY WORK
Preliminary work
2005 (All Models) .
Models) .

has been cut open).
1. Remove right drive shaft on transmission side. To do this, unscrew the six Allen screws joining each drive
Microsoft
Fig. 58: Loosening screw for halfshaft flange

2. Unscrew fastening screw for halfshaft flange. To do this, screw two drive shaft screws into the halfshaft
flange for countering purposes and loosen fastening screw.
3. Remove the halfshaft flange.
1. Insert halfshaft flange.
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Fig. 59: Tighten screw for halfshaft flange

2. Screw in fastening screw for halfshaft flange. For this purpose, screw in two drive shaft screws to counter and
tighten fastening screw.

1 2
Tightening screw for halfshaft Tightening 25 (18.5 ftlb.)
flange torque Nm
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1 2
shafts transmission flange torque Nm
SUBSEQUENT WORK
Subsequent work
1. Check and, if necessary, top up oil for final drive. --> 399035 Checking and topping up oil for final drive
39 25 19 REMOVING AND INSTALLING SHORT HALFSHAFT FLANGE - AS

OF MY 2005 (BOXSTER S, BOXSTER S RHD, CAYMAN S, CAYMAN S RHD)
Microsoft
PRELIMINARY WORK
Preliminary work
2005 (All Models) .
Models) .

has been cut open).
1. Remove right drive shaft on transmission side. To do this, unscrew the six Allen screws joining each drive
Microsoft

Microsoft


1 2
Tightening screw for halfshaft Tightening 25 (18.5 ftlb.)
flange torque Nm
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1 2
SUBSEQUENT WORK
Subsequent work
1. Check and, if necessary, top up oil for final drive. --> 399035 Checking and topping up oil for final drive
39 25 19 REMOVING AND INSTALLING LONG HALFSHAFT FLANGE - AS

OF MY 2005 (BOXSTER S, BOXSTER S RHD, CAYMAN S, CAYMAN S RHD)
Microsoft
PRELIMINARY WORK
Preliminary work
2005 (All Models) .
Models) .

has been cut open).
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Fig. 66: Mounting saddle screws

2. Unscrew fastening screws for mounting saddle.
3. Carefully pull halfshaft flange out of transmission.
1. Replace square sealing ring in mounting saddle.
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Fig. 67: Checking halfshaft flange

2. Check halfshaft flange for burrs and sharp edges on the transmission end of the shaft and deburr if necessary.
NOTE: To avoid damaging the sealing ring in the transmission, the halfshaft flange
must be guided carefully into position by hand.
3. Carefully insert halfshaft flange into the transmission.
4. Screw in fastening screws for mounting saddle.

Mounting saddle Tightening torque 23 (17 ftlb.) Nm
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1 2
SUBSEQUENT WORK
Subsequent work
39 25 19 REMOVING AND INSTALLING LONG HALFSHAFT FLANGE - AS

Microsoft
PRELIMINARY WORK
Preliminary work
2005 (All Models) .
Models) .

has been cut open).
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Fig. 70: Mounting saddle screws

2. Unscrew fastening screws for mounting saddle.
3. Carefully pull halfshaft flange out of transmission.
1. Replace square sealing ring in mounting saddle.
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Fig. 71: Checking halfshaft flange

2. Check halfshaft flange for burrs and sharp edges on the transmission end of the shaft and deburr if necessary.
NOTE: To avoid damaging the sealing ring in the transmission, the halfshaft flange
must be guided carefully into position by hand.
3. Carefully insert halfshaft flange into the transmission.
4. Screw in fastening screws for mounting saddle.

Mounting saddle Tightening torque 23 (17 ftlb.) Nm
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1 2
SUBSEQUENT WORK
Subsequent work
39 90 35 CHECKING AND TOPPING UP OIL FOR FINAL DRIVE - AS OF MY

2005 (ALL MODELS)
Microsoft
INFORMATION
Notes
NOTE: Fill only with oil approved by Porsche. See Spare Parts Catalogue.
PRELIMINARY WORK
Preliminary work
2005 (All Models) .
Models) .
CHECKING AND TOPPING UP OIL FOR FINAL DRIVE
Checking and topping up oil for final drive
WARNING: Risk of scalding from hot oil
--> Let the oil cool down
--> Wear personal protective gear (goggles, gloves)
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1. Unscrew oil filler plug.
The oil level is correct if transmission oil emerges. Continue with step 3.
If transmission oil does not flow out, the oil level in the final drive is too low. Continue with step 2.
NOTE: Filling must be carried out very slowly because there is a dust plate in the cover
of the final drive.
2. Fill in transmission oil up to the bottom edge of the filler opening.
3. Clean oil filler screw and screw in with a new O-ring.

Oil filler screw on final drive Tightening torque 22 ftlb.
SUBSEQUENT WORK
Subsequent work
Models) .
Microsoft
39 90 55 CHANGING OIL FOR FINAL DRIVE - AS OF MY 2005 (ALL

MODELS)
TOOLS

INFORMATION
Notes
PRELIMINARY WORK
Preliminary work
2005 (All Models) .
Models) .
Microsoft

5. Retaining device P 9624/1 must then be screwed to cross member, then turn spindle upwards and support
engine.
DRAINING OIL FOR FINAL DRIVE
Dismantling
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Fig. 75: Anti-roll bar

1. Loosen fastening screws between anti-roll bar and rear axle carrier side panel and fold anti-roll bar forward.
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has been cut open).
2. Remove right drive shaft on transmission side. For this purpose, unscrew six hexagon socket screws between
the drive shaft and the transmission flange, respectively. Counter on the brake disc or activate the parking brake
to avoid simultaneous turning.
Fig. 77: Transmission support

3. Unscrew fastening screws between the transmission support and the transmission.
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NOTE: The front transmission support cannot be removed. It can only be moved for
better access.
4. Unscrew fastening screws between the body and the hydraulic mount -arrow- . See Fig. 78.
B - Hydraulic mount
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5. Unscrew fastening screws for coolant pipes.
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Fig. 80: Retaining screw

6. Unscrew retaining screw between the transmission and the coolant pipe.
Draining oil for final drive

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NOTE:  The coolant line holder and coolant line can be pulled down slightly for
easier access to screw no. 3.
 Use a Torx socket wrench insert with a minimum length of 120 mm to
loosen or tighten screw no. 5.
4. Screw out lid screws in the sequence -12 to 1- . See Fig. 82.
5. Loosen lid by tapping lightly on the final drive housing and drain the oil.
REPLENISHING OIL FOR FINAL DRIVE
Topping up oil for final drive
1. Coat new toroidal sealing ring on lid with oil and place onto lid.
2. Place lid on transmission.
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3. Screw in lid screws -1, 2 and 3- and tighten by hand. See Fig. 83.
4. Screw in lid screws in the following order -1 to 12- and tighten. See Fig. 83.

Lid screws Tightening torque 17 ftlb.
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Tightening screw for halfshaft flange Tightening torque 18.5 ftlb.
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7. Unscrew oil filler screw.
NOTE: Filling must be carried out very slowly because there is a dust plate in the cover
of the final drive.
8. Fill in transmission oil up to the bottom edge of the filler opening.

Final drive filling capacity approx. 0.8 liter
9. Clean oil filler screw and screw in.

Oil filler screw on final drive Tightening torque 22 ftlb.
Assembly work
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1. Screw in retaining screw between the transmission and the coolant pipe.

value 1 2
Retaining Retaining screws between coolant pipe Tightening
17 ftlb.
screw and transmission torque
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2. Screw in fastening screws for coolant pipes.

Fastening screws for coolant pipes Tightening torque 7.4 ftlb.
3. Screw tight right transmission support with hydraulic mount.

value 1 2
Transmission Fastening screws between transmission Tightening
48 ftlb.
support support and transmission torque
Fastening screws between hydraulic Tightening
Hydraulic mount 24 ftlb.
mount and body torque
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4. Fit drive shaft on transmission side. For this purpose, tighten six hexagon socket screws between the drive
shaft and the transmission flange, respectively. Counter on the brake disc or activate the parking brake to avoid

value 1 2
Drive Fastening screws between drive shaft and Tightening
60 ftlb.
shafts transmission flange torque
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5. Screw in fastening screws between anti-roll bar and rear axle carrier side member.

value 1 2
Anti-roll Fastening screws between anti-roll bar and Tightening
17 ftlb.
bar rear axle carrier side member torque
SUBSEQUENT WORK
Subsequent work
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1. Remove holding device P 9624/1 from the cross member.

1 2
Restraining Fastening nut between restraining cable tightening 23 (17 ftlb.)
cable and cross member torque Nm
3. Install sheetmetal brace. Refer to 42 14 19 Removing and installing support plate - as of MY 2005 (All
Models) .
Microsoft
TRANSMISSION Torque converter
TRANSMISSION
Torque converter
32 47 19 REMOVING AND INSTALLING TORQUE CONVERTER SEALING

RING - AS OF MY 2005 (ALL MODELS)
TOOLS

assembly sleeve VW-tool 3295
hook VW-tool VW 681
PRELIMINARY WORK
Preliminary work

automatic transmission - as of MY 2005 (Boxster, Boxster RHD) .
2. Remove torque converter. --> 325019 Removing and installing torque converter
REMOVING THE TORQUE CONVERTER SEALING RING
Removing the torque-converter sealing ring
Microsoft

NOTE: Screw in hook VW 681 directly behind the sealing lip, otherwise the mounting-
face ring will be damaged.
1. Remove sealing ring for torque converter with hook VW 681.
INSTALLING THE TORQUE CONVERTER SEALING RING
Installing the torque-converter sealing ring
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Fig. 2: Sealing ring and mounting-face ring

1. Check mounting-face ring -2- for damage and replace if necessary.
1 - Sealing ring
2 - Mounting-face ring
2. Thinly grease outer circumference and sealing lip of sealing ring with Vaseline.
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Fig. 3: Installing sealing ring

3. Drive in sealing ring up to the stop with assembly sleeve 3295.
SUBSEQUENT WORK
Subsequent work
1. Install torque converter. --> 325019 Removing and installing torque converter

32 50 19 REMOVING AND INSTALLING TORQUE CONVERTER - AS OF MY

2005 (ALL MODELS)
TOOLS

locating pin special tool 95951
Microsoft
PRELIMINARY WORK
Preliminary work

2. Put transmission in horizontal position.
REMOVING TORQUE CONVERTER
Removing the torque converter
Fig. 4: Locating pin

1. Pull out Locating Pins 95951(long), see Tools from transmission housing.
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NOTE: When pulling out, the torque converter must be kept horizontal, otherwise ATF
can emerge.
2. Pull off torque converter from transmission input shaft.
INSTALLING TORQUE CONVERTER
Installing the torque converter
Fig. 5: Hub
1. Grease the hub of the torque converter lightly, e. g. with Olista Longtime 3EP.
NOTE: Before installing the torque converter, check the hub for scoring. If damaged,
the converter must be replaced.
2. Move torque converter up to stop on the transmission input shaft.
CAUTION: The ATF pump can be damaged if the torque converter is incorrectly
positioned during refitting.
--> Note the installation position of the torque converter.
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--> Check installation position of torque converter.
3. Press torque converter by hand into the converter bell housing and turn until the cutout of the converter hub
clicks into place in the driver of the impeller. The converter must slip inwards until it makes a noise.
Fig. 6: Locating pin

NOTE: If the Locating Pins 95951(long), see Tools cannot be inserted as shown, check
the torque converter again to ensure that the installation position is correct.
4. Fix torque converter with Locating Pin 95951(long), see Tools into installation position.
SUBSEQUENT WORK
Subsequent work

2. After re-installing the transmission, the ATF level is to be checked and, if necessary, replenished. Refer to 37
02 35 Checking and topping up ATF - as of MY 2005 (All Models) .
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TRANSMISSION Automatic - Actuation, assembly housing
TRANSMISSION
Automatic - Actuation, assembly housing
37 02 35 CHECKING AND TOPPING UP ATF - AS OF MY 2005 (ALL

MODELS)
TOOLS

ATF filling device V. A. G. special tool 00000
1924
INFORMATION
Notes
NOTE: Fill only with ATF approved by Porsche. See Spare Parts Catalogue.
Hot vehicles should cool down before beginning the activity.
Vehicle must be horizontal in order to be filled and checked.
PRELIMINARY WORK
Preliminary work
2005 (All Models) .
Models) .
3. Attach the filled ATF filling device V. A. G. 1924 00000 as high up on the vehicle as possible.
CHECKING AND TOPPING UP ATF
Checking and topping up the ATF
The transmission must not be in the reduced driving program. The ATF temperature must be between --> ATF
temperature: 30 (C and --> ATF temperature: 45 (C . An ATF inspection when the temperature is too high
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causes insufficient filling, while an inspection when the temperature is too low causes over-filling. The selector
lever must be in position "P" and the engine must be idling. The air conditioning must be switched off. The
vehicle must stand horizontally.
NOTE: The ATF temperature at the start of testing must not be higher than --> ATF
temperature: 40 gradCelsius .
1. Connect the PIWIS Tester 97180 and call up the ATF temperature.
2. Put selector lever in position "P", start vehicle, and allow engine to idle.
Fig. 1: ATF filler plug and ATF guard cap

WARNING: Danger of scalding and chemical burns from hot ATF
--> Allow ATF to cool down
3. Unscrew ATF filler plug -1- . See Fig. 1.
If ATF escapes the ATF level is OK. Continue with Item 5.
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If no ATF escapes the ATF level is too low. Continue with Item 4.
Fig. 2: ATF filler plug and ATF guard cap

NOTE: The filler hook of the ATF filling device V. A. G. 1924 00000 must be carefully
inserted into one of the openings of the ATF guard cap. Never push the filler
hook upwards as the oil guard cap -2- can spring off upwards. See Fig. 2.
4. Fill up with ATF using ATF filling device V. A. G. 1924 00000 until surplus ATF escapes at the hole of the
ATF filler plug.
NOTE: On reaching a maximum ATF temperature of --> ATF temperature: 45 (C the ATF
filler plug must be closed.
5. Fit ATF filler plug with a new sealing ring.

value 1 2
ATF filler plug on automatic Tightening
59 ftlb.
transmission torque
SUBSEQUENT WORK
Subsequent work
Microsoft
Models) .
37 02 55 CHANGING ATF - AS OF MY 2005 (ALL MODELS)

TOOLS

1924
INFORMATION
Notes
Filling capacities

1 2
Automatic Filling capacity for dry Filling
9 liters
transmission transmission capacity
Automatic Change quantity for ATF Filling
3.5 liters
transmission change capacity
Filling approx. 0.8
Final drive
capacity liters
PRELIMINARY WORK
Preliminary work
2005 (All Models) .
Models) .
CHANGING ATF
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Draining ATF
CAUTION: Transmission cannot be filled, or only insufficiently with ATF.
--> Do not start engine
--> Do not tow vehicle
Fig. 3: Automatic transmission drain and filler plugs

1. Unscrew ATF drain plug -1- and drain ATF. See Fig. 3.
2. Replace sealing ring for drain plug and tighten screw. --> Tightening torque: 30 ftlb. .
Topping up ATF
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1. Unscrew the ATF filler plug -2- and fill up with ATF using ATF filling device V. A. G. 1924 00000 until
surplus ATF escapes at the hole of the ATF filler plug. See Fig. 4.
2. Move selector lever to position P and allow engine to idle.
3. With engine running, add more ATF again until excess ATF emerges from the bore of the ATF filler plug.
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4. Inspect and if necessary add ATF. --> 370235 Inspecting and adding ATF
5. Replace sealing ring for ATF filler plug and tighten screw.

Filler plug Tightening torque 59 ftlb.
SUBSEQUENT WORK
Subsequent work
Models) .
37 04 19 REMOVING AND INSTALLING SELECTOR KNOB - AS OF MY 2005

(ALL MODELS)
REMOVING SELECTOR KNOB
Removing selector knob
NOTE: The ignition key must be in position 1 before the locking button can be pressed.
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Fig. 5: Levering locking button off

1. Press locking button and release lug under the locking button in direction of travel using an Allen key, for
example.
Fig. 6: Pulling off locking button

2. Pull off locking button against the direction of travel.
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Fig. 7: Detaching spring clip

3. Use a screwdriver to lever the spring clip out of the lock.
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Fig. 8: Removing selector knob

4. Pull selector knob up and off the selector lever.
INSTALLING SELECTOR KNOB
Installing selector knob
1. Push spring clip all the way back.
2. Fit locking button.
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Fig. 9: Pushing on selector knob

3. Push complete selector knob over the lock and all the way onto the selector lever.
37 08 19 REMOVING AND INSTALLING SELECTOR SUPPORT - AS OF MY

2005 (ALL MODELS)
PRELIMINARY WORK
Preliminary work
1. Remove selector knob. --> 370419 Removing and installing selector knob - chapter on "removing"
Microsoft
Models) .
REMOVING SELECTOR SUPPORT
Removing selector frame
1. Move selector lever to position P.
Fig. 10: Opening bayonet lock

2. Open bayonet lock.
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Fig. 11: Disengaging the selector cable

3. Detach adjustment pins.
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Fig. 12: Unclipping support bracket

4. Unclip support bracket at selector frame.
Fig. 13: Removing electric plug

5. Disconnect electric plug on selector frame.
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Fig. 14: Removing selector frame

6. Undo the nuts and lift selector frame up and out.
INSTALLING SELECTOR SUPPORT
Installing selector frame
NOTE: Before starting to install the selector frame, ensure that the transmission and
selector frame are in parking position.
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Fig. 15: Installing selector frame

1. Fit selector frame and screw in nuts.

Selector frame Tightening torque 10 (7.5) Nm (ftlb.)
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Fig. 16: Fitting electric plug

2. Insert electric plug on selector frame.
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Fig. 17: Clipping in support bracket

3. Clip in support bracket at selector frame.
Fig. 18: Engaging selector cable

4. Engage adjustment pins.
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Fig. 19: Closing bayonet lock

5. Close bayonet lock.
SUBSEQUENT WORK
Reworking
Models) .
2. Install selector knob. --> 370419 Removing and installing selector knob - chapter on "Installing"
37 15 19 REMOVING AND INSTALLING SELECTOR LEVER CABLE - AS OF

PRELIMINARY WORK
Preliminary work
2005 (All Models) .
Microsoft
Models) .
Models) .
5. Remove selector knob. --> 370419 Removing and installing selector knob - section on "Removing"
Models) .
REMOVING SELECTOR LEVER CABLE
Loosening selector lever cable on automatic transmission
Fig. 20: Selector cable

1. Lever selector cable off the ball pin and disengage from support bracket.
Detaching selector lever cable inside vehicle
1. Move selector lever to position P.

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2. Open bayonet lock.
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Fig. 22: Disengaging the selector cable

3. Detach adjustment pins.
Fig. 23: Unclipping support bracket

4. Unclip support bracket at selector frame.
Removing selector lever cable
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Fig. 24: Selector lever cable support

1. Unclip selector lever cable.
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Fig. 25: Pulling out selector lever cable

2. Pull end of selector lever cable - at transmission side - out through the opening in the engine compartment lid.
Fig. 26: Support

3. Remove support for selector lever cable.
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Fig. 27: Support

4. Disengage selector lever cable from support.
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Fig. 28: Bulkhead panel threaded joint

5. Remove fastening nuts and pull selector lever cable into the interior of the vehicle.
INSTALLING SELECTOR LEVER CABLE
Installing selector lever cable
Fig. 29: Bulkhead threaded joint

1. Push selector lever cable through the bulkhead panel from the interior of the vehicle and fit fastening nuts.

value 1 2
Shift and selector Fastening nuts between shift and Tightening
7.5 ftlb.
cables to bulkhead selector cables and bulkhead torque
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Fig. 30: Support

2. Engage selector lever cable in support.
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Fig. 31: Support

3. Fit support for selector lever cable.

value 1 2
Support for shift and Fastening screw between shift and Tightening
7.5 ftlb.
selector cables selector cables and body torque
Fig. 32: Pushing in selector lever cable

4. Push end of selector lever cable - at transmission side - into the opening in the engine compartment lid.
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Fig. 33: Selector lever cable support

5. Clip in selector lever cable.
Securing selector lever cable inside vehicle
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Fig. 34: Clipping in support bracket

1. Clip in support bracket at selector frame.
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Fig. 35: Engaging selector cable

2. Engage adjustment pins.
Fig. 36: Closing bayonet lock

3. Close bayonet lock.
Securing selector lever cable on automatic transmission
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1. Engage selector lever cable into support on transmission and press end piece onto ball head.
SUBSEQUENT WORK
Subsequent work
Models) .
2. Install selector knob. --> 370419 Removing and installing selector knob - section on "Installing"
3. Install the engine-compartment lid. Refer to 55 78 19 Removing and installing engine compartment lid -
Models) .
37 18 20 REMOVING AND INSTALLING TIPTRONIC ROCKER SWITCH - AS

Microsoft
PRELIMINARY WORK
Preliminary work
1. Remove driver's airbag unit. Refer to 69 58 19 Removing and installing driver's airbag unit - as of MY
2005 (All Models) .
REMOVING TIPTRONIC ROCKER SWITCH
Removing Tiptronic rocker switch
The graphics below show how to remove the left rocker switch. The description also applies for the right rocker
switch.
Fig. 38: Rocker switch fastening screw

1. Unscrew fastening screw for rocker switch.
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Fig. 39: Rocker switch

2. Carefully lever out rocker switch using a screwdriver. Watch out for the washer -A- when levering out the
rocker switch. See Fig. 39.
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Fig. 40: Pull out electric plug

3. Unlock and disconnect the electric plug connection.
INSTALLING TIPTRONIC ROCKER SWITCH
Installing Tiptronic rocker switch
The graphics below show how to install the left rocker switch. The description also applies for the right rocker
switch.
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Fig. 41: Inserting electric plug

1. Insert electric plug connection into rocker switch until the plug engages firmly.
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Fig. 42: Fitting rocker switch

2. Insert rocker switch and washer into steering wheel and screw in fastening screw.

value 1 2
Fastening Fastening screw between rocker switch Tightening 3 (2 ftlb.)
screw and steering wheel torque Nm
SUBSEQUENT WORK
Subsequent work
1. Install driver's airbag unit. Refer to 69 58 19 Removing and installing driver's airbag unit - as of MY 2005
(All Models) .
37 30 19 REMOVING AND INSTALLING THE TIPTRONIC CONTROL

MODULE - AS OF MY 2005 (BOXSTER, BOXSTER RHD, BOXSTER S,
BOXSTER S RHD)
TOOLS

Disassembly tool, universal commercially NR.21
available tool
PRELIMINARY WORK
Preliminary work for Tiptronic control module (also referred to generally as control unit below)- - erase
Microsoft
Fig. 43: Rear luggage compartment trim panel

Open rear luggage compartment lid and lever out the clips for the carpet lining using the disassembly tool.
Disassembly tool, universal NR.21
TOOLS AND MATERIALS
Tools
Removal tool, universal NR.21
Microsoft
REMOVING TIPTRONIC CONTROL MODULE
Removing Tiptronic control module (also referred to generally as control unit below)
Fig. 44: Installation location

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Fig. 45: Unscrew fastening nuts

1. Fold over the carpet lining and unscrew the three fastening nuts for the Tiptronic control module.
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2. Remove control unit then release and pull off the electric connector -Arrow- .
INSTALLING TIPTRONIC CONTROL MODULE
Installing Tiptronic control unit (also referred to generally as control unit below)
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1. Connect the connector to the control unit and insert the closing clip until it engages.
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Fig. 48: Screw down control unit with fastening nuts.

2. Position control unit and secure with the fastening nuts. --> Tightening torque: 7.5 ftlb.
3. Fold back the carpet lining into position and fasten with the clips.
SUBSEQUENT WORK
Subsequent work for Tiptronic control unit
Fold back the carpet lining and fasten with the clips.
If a new or different Tiptronic control unit has been installed then code it using the PIWIS Tester P 9718.
PROGRAMMING TIPTRONIC CONTROL MODULE
Reading out from and writing in to the Tiptronic control unit (also referred to generally as control unit below)
Microsoft
Continue.
4. Select Tiptronic with the cursor keys and press the >> key.
8. Switch off ignition and replace control module. --> 373019 Removing and installing transmission control
module - chapter on "Removing"
key.
In the menu Write in data >> the data read-out are installed.
12. If the control module has been installed in another vehicle it will be necessary, as of tester software 8.0, to
Reset adaption values :
12.1. In the menu Tiptronic , select the menu Reset adaption values and continue with >>.
12.2. Confirm with F7 for Yes, F8 for No and continue with >>.
12.3. Follow the instructions on the tester.
13. Exit the menu, carry out a test drive and afterwards read out the fault memory.
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CODING TIPTRONIC CONTROL MODULE
Coding Tiptronic control unit
NOTE:  When the transmission is renewed/replaced, the adaptation values must

be reset using the
 Resetting adaptation values:
 In the Tiptronic control module, select menu item Reset adaptation values
and continue with >>.
 Confirm with F7 for Yes, F8 for No and continue with >>.
 Follow the instructions on the Tester.
 If a new control unit is installed, it must adapt first. Poor shifting quality
can therefore be expected in the adaptation phase.
 After the test drive, let the engine run for 10 minutes at idle speed. This
ensures that all adaptation values are stored in the control unit.
 The instructions of the Porsche System Tester have highest priority.
 The procedure listed has been structured generally; changes or additions
may occur.
PIWIS tester P 9718. It is expected that this function will not be

implemented until tester software V8.0 is available:
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8. Select Vehicle version and code with the F8 key.
South East Asia

Japan
RoW/USA
9. Tester confirms: "Coding has been changed".
11. Quit menu, perform test drive and check fault memory with the system tester.
37 30 19 REMOVING AND INSTALLING THE TIPTRONIC CONTROL

MODULE (ALSO REFERRED TO GENERALLY AS CONTROL UNIT BELOW)
- AS OF MY 2006 (CAYMAN S, CAYMAN S RHD)
TOOLS

PRELIMINARY WORK
Preliminary work for Tiptronic control module (also referred to generally as control unit below)
Remove trim panel for rear luggage compartment at the right. Refer to 70 06 19 Removing and installing rear
If the control unit must be replaced, first read out the values from the control unit before removal. --> 373019
Removing and installing Tiptronic control unit - section on "Programming"
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REMOVING TIPTRONIC CONTROL UNIT
Removing Tiptronic control unit

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Fig. 50: Releasing control unit at support

1. Use a screwdriver to release the latch at the left and right and remove the control unit.
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2. Remove control unit, then release and pull off the electric connector -Arrow- .
INSTALLING TIPTRONIC CONTROL UNIT
Installing Tiptronic control unit
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1. Connect the connector to the control unit and insert the closing clip until it engages.
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Fig. 53: Engaging control unit in support

2. Push control unit into the support and engage it at the left and right.
SUBSEQUENT WORK
Subsequent work for Tiptronic control module (also referred to generally as control unit below)
Install trim panel for rear luggage compartment at the right. Refer to 70 06 19 Removing and installing rear
If a new or different Tiptronic control unit has been installed, then code it using the PIWIS tester P 9718.
PROGRAMMING TIPTRONIC CONTROL UNIT
Reading out from and writing in to the Tiptronic control unit (also referred to generally as control unit below)
Microsoft
Continue.
8. Switch off ignition and replace control module. --> 373019 Removing and installing transmission control
module - chapter on "Removing"
key.
In the menu Write in data >> the data read-out are installed.
13. Exit the menu, carry out a test drive and afterwards read out the fault memory.
Microsoft
CODING TIPTRONIC CONTROL UNIT
Coding Tiptronic control unit
NOTE:  When the transmission is renewed/replaced, the adaptation values must

be reset using the
 Resetting adaptation values:
 In the Tiptronic control module, select menu item Reset adaptation values
and continue with >>.
 Confirm with F7 for Yes, F8 for No and continue with >>.
 Follow the instructions on the Tester.
 If a new control unit is installed, it must adapt first. Poor shifting quality
can therefore be expected in the adaptation phase.
 After the test drive, let the engine run for 10 minutes at idle speed. This
ensures that all adaptation values are stored in the control unit.
 The instructions of the Porsche System Tester have highest priority.
 The procedure listed has been structured generally; changes or additions
may occur.
PIWIS tester P 9718. It is expected that this function will not be

implemented until tester software V8.0 is available:
Microsoft
8. Select Vehicle version and code with the F8 key.
South East Asia

Japan
RoW/USA
9. Tester confirms: "Coding has been changed".
11. Quit menu, perform test drive and check fault memory with the system tester.
37 31 19 REMOVING AND INSTALLING MULTI-FUNCTIONAL SWITCH - AS

TOOLS

safety device VW-tool 10-222 A
PRELIMINARY WORK
Preliminary work
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Fig. 54: Safety device

2. Fix the engine in the installation position using safety device 10-222 A at the engine lifting bracket.
2005 (All Models) .
Models) .
REMOVING MULTI-FUNCTIONAL SWITCH
Removing multi-functional switch
WARNING: If the supports are folded down, the vehicle will roll off the platform lift
when it is lowered.
--> Ensure that the platform is prevented from lowering.
--> Remove supports before lowering.
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2. Place transmission jack under the transmission.
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Fig. 56: Transmission jack screws

3. Unscrew fastening screws between the transmission and the transmission support.
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NOTE: The fastening nuts of the transmission support must never be loosened at the
hydraulic mount because otherwise the transmission brackets will be damaged.
4. Unscrew fastening screws between the body and the hydraulic mount -arrows- . See Fig. 57.
B - Hydraulic mount
Fig. 58: Connector

5. Disconnect the plug connection for the multi-function switch.
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Fig. 59: Fastening screws of multi-functional switch

6. Unscrew fastening screws between multi-functional switch and transmission and pull off multi-functional
switch from selector lever.
INSTALLING MULTI-FUNCTIONAL SWITCH
Installing multi-functional switch
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Fig. 60: Connecting multi-functional switch

NOTE:  When connecting the multi-functional switch to the selector lever, the
multi-functional switch must not be tilted or pushed with force onto the
selector lever. Otherwise there is a risk of damaging the switch contact.
1. Connect multi-functional switch to the selector shaft. The flattened area of the switch splines -1- must be
covered with the flattened side of the selector shaft splines. -2- . See Fig. 60.
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Fig. 61: Aligning multi-functional switch

2. Connect multi-functional switch to transmission housing. To do this, turn the multi-functional switch until the
dowel pin -3- on the transmission housing is covered by the fitted bore -4- on the housing of the multi-
functional switch. See Fig. 61.
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Fig. 62: Fastening screws of multi-functional switch

3. Screw in fastening screws between multi-functional switch and transmission.

value 1 2
Fastening Fastening screws between multi- Tightening 8 (6 ftlb.)
screws functional switch and transmission torque Nm
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Fig. 63: Connector

4. Connect the plug connection for the multi-function switch.
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5. Screw in fastening screws between the body and the hydraulic mount -arrows- . See Fig. 64.
B - Hydraulic mount

1 2
Hydraulic Fastening screws between hydraulic Tightening 33 (24 ftlb.)
mount mount and body torque Nm
Fig. 65: Transmission jack screws

6. Screw in fastening screws between the transmission and the transmission support.

value 1 2
Transmission Fastening screws between Tightening 65 (48
support transmission support and transmission torque ftlb.) Nm
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7. Remove transmission jack.

8. Engage selector cable in support bracket and push onto ball journals.
SUBSEQUENT WORK
Subsequent work
Models) .
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3. Remove safety device 10-222 A.
37 33 19 REMOVING AND INSTALLING SEALING RING FOR SELECTOR

SHAFT - AS OF MY 2005 (ALL MODELS)
TOOLS

safety device VW-tool 10-222 A
mandrel VW-tool 3385
Microsoft
PRELIMINARY WORK
Preliminary work

2. Fix the engine in the installation position using safety device 10-222 A at the engine lifting bracket.
2005 (All Models) .
Models) .
5. Remove multi-functional switch. --> 373119 Removing and installing multi-functional switch - section on
"Removing"
REMOVING SEALING RING FOR SELECTOR SHAFT
Removing sealing ring for selector shaft
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Fig. 69: Push rod

1. Disengage push rod from ball head on selector lever.
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Fig. 70: Driving out roll pin

2. Drive out roll pin and pull selector lever off selector shaft.
Fig. 71: Levering out sealing ring

3. Pierce sealing ring with a small screwdriver and lever it out.
INSTALLING SEALING RING FOR SELECTOR SHAFT
Installing sealing ring for selector shaft
1. Thinly coat sealing lip and outer circumference of sealing ring with Vaseline.
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With open side of sealing ring facing transmission, tap sealing ring as far as it will go into the transmission
using a mandrel 3385.
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Fig. 73: Tapping in roll pin

2. Attach selector lever to selector shaft and tap in roll pin.
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Fig. 74: Push rod

3. Engage push rod in ball head on selector lever.
SUBSEQUENT WORK
Subsequent work
1. Install multi-functional switch. --> 373119 Removing and installing multi-functional switch - section on
"Installing"
Models) .

4. Remove safety device 10-222 A.
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37 35 TW TECHNICAL DATA, AUTOMATIC TRANSMISSION - AS OF MY

TECHNICAL VALUES
Technical data
Transmission type: A87/01
Equipment: 5-gear
Installed in: Boxster (987)
Model Year: 2005
Transmission ratios
1st gear: 3.66
2nd gear: 2.00
3rd gear: 1.41
4th gear: 1.00
5th gear: 0.74
Reverse gear: 4.10
Final-drive ratio: 4.379
Filling capacities

1 2
9 liters
3.5 liters
Filling approx. 0.8
Final drive
capacity liters

Microsoft
TECHNICAL VALUES
Technical data
Equipment: 6-gear
Installed in: Cayman S
Model Year: 2005
Transmission ratios
1st gear: 3.66
2nd gear: 2.00
3rd gear: 1.41
4th gear: 1.00
5th gear: 0.74
Reverse gear: 4.10
Final drive ratio: 4.161
Filling capacities

1 2
9 liters
3.5 liters
Filling approx. 0.8
Final drive
capacity liters

2005 (BOXSTER S, BOXSTER S RHD)
TECHNICAL VALUES
Technical data
Microsoft
Equipment: 5-gear
Installed in: Boxster S (987)
Model Year: 2005
Transmission ratios
1st gear: 3.66
2nd gear: 2.00
3rd gear: 1.41
4th gear: 1.00
5th gear: 0.74
Reverse gear: 4.10
Filling capacities

1 2
9 liters
3.5 liters
Filling approx. 0.8
Final drive
capacity liters
37 35 19 REMOVING AND INSTALLING AUTOMATIC TRANSMISSION - AS

OF MY 2005 (BOXSTER S, BOXSTER S RHD)
TOOLS

hose clamp VW-tool 3094
Microsoft
locating pins (short) special tool P 9595/1

PRELIMINARY WORK
Preliminary work
WARNING: Burns and scalding through hot components and fluids
--> Allow vehicle to cool down before beginning work
1. Disconnect battery. Refer to 27 06 19 Removing and installing battery - as of MY 2005 (All Models) .
Models) .
3. Remove the engine-compartment lid. Refer to 55 78 19 Removing and installing engine compartment lid -
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5. Retaining device P 9624/1 must be screwed to cross member. Then turn spindle upwards and support
engine.
6. Remove the starter. Refer to 27 60 19 Removing and installing starter - as of MY 2005 (All Models) .
2005 (All Models) .
8. Remove wheels. Refer to 44 05 19 Removing and installing wheel - as of MY 2005 (All Models) .
Models) .
REMOVING AUTOMATIC TRANSMISSION
Removing converter bolts
1. Turn crankshaft to the extent that one of the U4, U5 or U6 bores in the belt pulley is aligned with the
centering bore in the crankcase.
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Fig. 77: Fix crankshaft

NOTE:  The crankshaft is fixed in a defined position by inserting the fixing pin.
 If the fixing pin can not be inserted, check the correct positioning of the
belt pulley in relation to the crankcase.
2. Insert locating pins (short) P 9595/1 through the belt pulley in the crankcase housing bore.
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Fig. 78: Special tool 9596 in starter opening

3. Insert assembly aid P 9596 into starter opening.
4. Unscrew converter fastening screws with 6mm hexagon socket through the openings -arrows- in the
assembly aid P 9596. See Fig. 78.
5. Pull locating pins (short) P 9595/1 out of the belt pulley.
6. Turn crankshaft by 120° so that one of the U4, U5 or U6 bores in the belt pulley is aligned with the centering
bore in the crankcase.
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10. Turn crankshaft by 120° so that one of the U4, U5 or U6 bores in the belt pulley is aligned with the
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13. Unscrew support for positive crankcase ventilation line on engine transport eyebolt.
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Fig. 82: Fasten converter

14. Push locating pins (long) P 9595/1 through the opening in the transmission housing to prevent the
transformer from falling out.
Dismantling
Fig. 83: Vacuum line

1. Pull vacuum line off the switch-over valve.
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Fig. 84: Vent line

2. Unscrew vent line on engine transport eyebolt.
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4. Remove the cross member
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has been cut open).
5. Remove drive shafts on transmission side. To do this, unscrew the six Allen screws joining each drive shaft
and transmission flange. Counter at the brake disc or activate the parking brake to avoid simultaneous turning.
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7. Turn connector of transmission socket anticlockwise and pull off.
Fig. 90: Plug

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Fig. 92: Clamping shut coolant hoses

10. Clamp shut coolant hoses (flow and return sides) with hose clamp 3094.

11. Unscrew fastening screws between transmission and mount for exhaust system and remove mount for
exhaust system.
12. Place collection pan for coolant under the transmission.
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Fig. 94: Coolant line

13. Unscrew fastening screw between ATF cooler and coolant line and pull coolant line out of ATF cooler.
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Removing automatic transmission
when it is lowered.
NOTE: When pulling out the automatic transmission, ensure that the transmission
support has already been loosened.
1. Place transmission jack under transmission and fasten fixing strap.

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B - Hydraulic mount
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Fig. 98: Fastening transmission engine

4. Unscrew fastening screws -1 to 7- and pull out transmission to the rear and downward. See Fig. 98.
INSTALLING AUTOMATIC TRANSMISSION
Installing automatic transmission
when it is lowered.
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1. Run in transmission and screw in fastening screws -1 to 7- . See Fig. 99.

value 1 2
Transmission/engine Hexagon-head bolt no. 1 in Tightening
63 ftlb.
connection figure, M12 x 70 torque
63 ftlb.
connection figure M12 x 100; with washer torque
Transmission-engine Hexagon bolt No. 3 M12 x 90 in Tightening
63 ftlb.
connection graphic torque
Transmission/engine Internal-serration screw no. 4 in
Tightening
33 ftlb.
connection figure M10 x 50 torque
Transmission-engine Tightening 33.3
Nut No. 5 M10 in graphic
connection torque ftlb.
63 ftlb.
63 ftlb.
NOTE: In order to install the right-hand transmission support with hydraulic mount, the
automatic transmission must be pushed towards the left.
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2. Install right transmission support with hydraulic mount.

value 1 2
48 ftlb.
3. Install left transmission support with hydraulic mount.

value 1 2
48 ftlb.
Assembly work

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1. Insert coolant pipe with new O-ring in ATF cooler and screw in fastening screw.

value 1 2
Fastening Fastening screws between coolant pipes Tightening
17 ftlb.
screw and ATF cooler torque


value 1 2
17 ftlb.
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3. Install engine mount for exhaust system and tighten fastening screws between transmission and engine mount
for exhaust system.

value 1 2
Exhaust system Fastening screws between Tightening
33.3 ftlb.
holder transmission housing holder torque
4. Remove hose clamp 3094 from coolant pipes (flow and return sides).
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value 1 2
17 ftlb.
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Fig. 104: Plug

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Fig. 105: Lock plug

7. Plug in transmission socket plug and turn clockwise up to the stop.

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9. Fit drive shafts on the transmission side. For this purpose, tighten six hexagon socket screws between the
drive shaft and the transmission flange, respectively. Counter on the brake disc or activate the parking brake to
avoid simultaneous turning.

value 1 2
60 ftlb.
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10. Install cross member.

value 1 2
Cross Fastening screws between cross member Tightening
48 ftlb.
member and body torque
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value 1 2
17 ftlb.
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Fig. 110: Vent line

12. Screw vent line onto the engine transport eyebolt.

value 1 2
Line Fastening screws between line holder and Tightening
7.4 ftlb.
holder engine transport eyebolt torque
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13. Push vacuum pipe onto switch-over valve.
Install converter screw connection
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1. Pull fixing pins (long) P 9595/1 out of the opening in the transmission housing.
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2. Screw on support for positive crankcase ventilation line to the engine transport eyebolt.

value 1 2
7.4 ftlb.
3. Screw in converter fastening screws with 6mm hexagon socket through the openings in the assembly aid P
9596.

value 1 2
Converter screw Fastening screws between torque Tightening 28.8
connection converter and driver plate torque ftlb.
4. Pull fixing pins (short) P 9595/1 out of the belt pulley.

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6. Insert fixing pins (short) P 9595/1 through the belt pulley in the crankcase housing bore.
9596.

value 1 2

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9596.

value 1 2

13. Remove assembly aid P 9596 from the starter opening.
SUBSEQUENT WORK
Subsequent work
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1. Remove retaining device P 9624/1 from cross member.

1 2
Models) .
4. Install rear silencers. Refer to 26 33 19 Removing and installing rear silencer - as of MY 2005 (Boxster,
5. Mount wheels. Refer to 44 05 19 Removing and installing wheel - as of MY 2005 (All Models) .
7. Install the starter. Refer to 27 60 19 Removing and installing starter - as of MY 2005 (All Models) .
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Models) .
10. Connect the battery. Refer to 27 06 19 Removing and installing battery - as of MY 2005 (All Models) .
11. Bleed the cooling system. Refer to 19 38 17 Draining and filling in coolant - as of MY 2005 (All
Models) .
12. Check and top up the ATF. --> 370235 Checking and topping up ATF

TOOLS


PRELIMINARY WORK
Preliminary work
Models) .
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engine.
2005 (All Models) .
Models) .
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Dismantling

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Fig. 126: Vent line

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has been cut open).
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Fig. 132: Plug

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exhaust system.
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when it is lowered.

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B - Hydraulic mount
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when it is lowered.
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value 1 2
63 ftlb.
63 ftlb.
63 ftlb.
Tightening
33 ftlb.
63 ftlb.
63 ftlb.
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value 1 2
48 ftlb.

value 1 2
48 ftlb.
Assembly work

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value 1 2
17 ftlb.


value 1 2
17 ftlb.
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for exhaust system.

value 1 2
33.3 ftlb.
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value 1 2
17 ftlb.
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Fig. 146: Plug

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Fig. 147: Lock plug


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value 1 2
28.8 ftlb.
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value 1 2
48 ftlb.
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value 1 2
17 ftlb.
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Fig. 152: Vent line


value 1 2
7.4 ftlb.
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Microsoft

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value 1 2
7.4 ftlb.
9596.

value 1 2

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9596.

value 1 2

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9596.

value 1 2

SUBSEQUENT WORK
Subsequent work
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1 2
Models) .
4. Install rear silencers. Refer to 26 33 19 Removing and installing rear silencer - as of MY 2005 (Boxster,
Microsoft
Models) .
Models) .

TOOLS


PRELIMINARY WORK
Preliminary work
Models) .
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engine.
2005 (All Models) .
9. Remove rear silencer. Refer to 26 33 19 Removing and installing rear silencer - as of MY 2005 (Cayman
S, Cayman S RHD) .
Models) .
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Dismantling

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Fig. 168: Vent line

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has been cut open).
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Fig. 174: Plug

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exhaust system.
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when it is lowered.

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B - Hydraulic mount
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when it is lowered.
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value 1 2
63 ftlb.
63 ftlb.
63 ftlb.
Tightening
33 ftlb.
63 ftlb.
63 ftlb.
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value 1 2
48 ftlb.

value 1 2
48 ftlb.
Assembly work

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value 1 2
17 ftlb.


value 1 2
17 ftlb.
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for exhaust system.

value 1 2
33.3 ftlb.
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value 1 2
17 ftlb.
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Fig. 188: Plug

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Fig. 189: Lock plug


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value 1 2
60 ftlb.
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value 1 2
48 ftlb.
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value 1 2
17 ftlb.
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Fig. 194: Vent line


value 1 2
7.4 ftlb.
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Assembly work
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value 1 2
17 ftlb.
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value 1 2
17 ftlb.
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for exhaust system.

value 1 2
33.3 ftlb.
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value 1 2
17 ftlb.
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Fig. 200: Plug

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Fig. 201: Lock plug


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value 1 2
28.8 ftlb.
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value 1 2
48 ftlb.
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value 1 2
17 ftlb.
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Fig. 206: Vent line


value 1 2
7.4 ftlb.
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value 1 2
7.4 ftlb.
9596.

value 1 2

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9596.

value 1 2

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9596.

value 1 2

SUBSEQUENT WORK
Subsequent work
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1 2
Models) .
4. Install rear silencers. Refer to 26 33 19 Removing and installing rear silencer - as of MY 2005 (Cayman
S, Cayman S RHD) .
Microsoft
Models) .
Models) .
37 35 27 REMOVING AND REFITTING THE AUTOMATIC TRANSMISSION -

TOOLS

PRELIMINARY WORK
Preliminary work
Remove engine-transmission unit. Refer to 10 01 19 Removing and installing engine - as of MY 2005

(Boxster, Boxster RHD, Boxster S, Boxster S RHD) . Refer to 10 01 19 Removing and installing engine - as
Remove the starter. Refer to 27 60 19 Removing and installing starter - as of MY 2005 (All Models) .
REMOVING THE AUTOMATIC TRANSMISSION
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Removing the automatic transmission

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Fig. 221: Vent line

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7. Attach transmission to workshop crane.
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8. Unscrew fastening screws -1 to 7- and pull out transmission to the rear, separating it from the engine. See
Fig. 225.
REFITTING THE AUTOMATIC TRANSMISSION
Refitting the automatic transmission
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value 1 2
Transmission/engine Hexagon-head bolt no. 1 in Tightening 85 (63
connection figure, M12 x 70 torque ftlb.) Nm
connection figure M12 x 100; with washer torque ftlb.) Nm
Transmission-engine Hexagon bolt No. 3 M12 x 90 Tightening 85 (63
connection in illustration torque ftlb.) Nm
Transmission/engine Internal-serration screw no. 4 in Tightening 45 (33
connection figure M10 x 50 torque ftlb.) Nm
Transmission-engine Tightening 45 (33
Nut No. 5 M10 in illustration
connection torque ftlb) Nm
connection in graphic torque ftlb.) Nm
2. Loosen transmission from workshop crane.
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1 2
Fastening Fastening screws between coolant Tightening 23 (17 ftlb.)
screw pipes and ATF cooler torque Nm
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1 2
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1 2
Retaining Retaining screws between coolant pipe Tightening 23 (17 ftlb.)
screw and transmission torque Nm
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Fig. 230: Vent line


1 2
Line Fastening screws between line holder and Tightening 10 (7.5
holder engine transport eyebolt torque ftlb.) Nm
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value 1 2
7.4 ftlb.
9596.

value 1 2

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9596.

value 1 2

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9596.

value 1 2

SUBSEQUENT WORK
Reworking
Install the starter. Refer to 27 60 19 Removing and installing starter - as of MY 2005 (All Models) .
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Install engine-transmission unit. Refer to 10 01 19 Removing and installing engine - as of MY 2005 (Boxster,
Boxster RHD, Boxster S, Boxster S RHD) . Refer to 10 01 19 Removing and installing engine - as of MY
37 50 19 REMOVING AND INSTALLING SEAL FOR SPUR-GEAR COVER -

TOOLS

centering pin special tool P 9321
PRELIMINARY WORK
Preliminary work
(ALL MODELS) .
2. Remove rear muffler. Refer to 26 33 19 Removing and installing rear silencer - as of MY 2005 (Boxster,
Boxster RHD, Boxster S, Boxster S RHD) . Refer to 26 33 19 Removing and installing rear silencer - as of
REMOVING SEAL FOR SPUR-GEAR COVER
Removing seal for spur-gear cover
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exhaust system.
NOTE: The spur gears are prevented from falling out. Remove spur-gear cover to
prevent wheels from falling out. Wheels that fall out must not be reinstalled. If
this happens, the transmission must be replaced.
2. Unscrew fastening screws for spur-gear cover and remove spur-gear cover.
3. Prevent spur gearing from falling out.
INSTALLING SEAL FOR SPUR-GEAR COVER
Installing seal for spur-gear cover
1. Screw in centering pin P 9321 in transmission housing.
2. Position new seal on transmission housing.
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Fig. 238: Spur-gear cover

3. Position spur-gear cover on transmission housing, screw in screws -1,2 and 3- and tighten evenly by hand.
See Fig. 238.
4. Screw in remaining screws and tighten in sequence -1...14- . See Fig. 238.

value 1 2
Spur-gear Fastening screws between transmission Tightening 23 (17
cover housing and spur-gear cover torque ftlb.) Nm
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for exhaust system.

1 2
Exhaust system Fastening screws between Tightening 45 (33
mount transmission housing and mount torque ftlb.) Nm
SUBSEQUENT WORK
Subsequent work
1. Install rear mufflers. Refer to 26 33 19 Removing and installing rear silencer - as of MY 2005 (Boxster,
2. Check and if necessary, top up the ATF. --> 370235 Checking and topping up the ATF
37 55 19 REMOVING AND INSTALLING ATF PAN - AS OF MY 2005 (ALL

MODELS)
TOOLS
Microsoft

1924
INFORMATION
Notes
TECHNICAL VALUES
Filling capacities

1 2
9 liters
3.5 liters
Filling approx. 0.8
Final drive
capacity liters
PRELIMINARY WORK
Preliminary work
2005 (All Models) .
Models) .
Draining ATF

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REMOVING ATF PAN
Removing ATF pan
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Fig. 241: ATF pan

1. Remove screws -1- . See Fig. 241.
2. Remove ATF- pan -2- with seal -3- . Pay attention to the magnet -4- . See Fig. 241.
INSTALLING ATF PAN
Installing ATF pan
1. Clean sealing surfaces of ATF pan and transmission.
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Fig. 242: ATF pan

2. Clean magnet -4- and place it in the bead of the ATF pan. Ensure contact over full area. See Fig. 242.
3. Fit ATF pan -2- with new seal -3- and screw in screws -1- . See Fig. 242.
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Fig. 243: Tightening sequence:

4. Tighten screws to specified tightening torque --> Tightening sequence: . --> Tightening torque: 8 ftlb. . See
Fig. 243.
SUBSEQUENT WORK
Topping up ATF
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Microsoft
Subsequent work
37 58 55 REPLACING ATF FILTER - AS OF MY 2005 (ALL MODELS)

TOOLS

1924
INFORMATION
Notes
TECHNICAL VALUES
Filling capacities

1 2
9 liters
3.5 liters
Filling approx. 0.8
Final drive
capacity liters
PRELIMINARY WORK
Preliminary work
2005 (All Models) .
Models) .
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Draining ATF

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Removing ATF pan
Fig. 246: ATF pan

1. Remove screws -1- . See Fig. 246.
2. Remove ATF- pan -2- with seal -3- . Pay attention to the magnet -4- . See Fig. 246.
REMOVING ATF FILTER
Removing ATF filter
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Fig. 247: ATF filter

1. Undo the screws -arrow- and pull ATF filter downwards from the electrohydraulic control mechanism. See
Fig. 247.
INSTALLING ATF FILTER
Installing ATF filter
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Fig. 248: ATF filter

1. Insert ATF Filter from below into the die electrohydraulic control mechanism and screw in the screws -

value 1 2
ATF ATF filter to electrohydraulic control Tightening
4.5 ftlb.
filter mechanism torque
SUBSEQUENT WORK
Installing ATF pan
1. Clean sealing surfaces of ATF pan and transmission.
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Fig. 249: ATF pan

2. Clean magnet -4- and place it in the bead of the ATF pan. Ensure contact over full area. See Fig. 249.
3. Fit ATF pan -2- with new seal -3- and screw in screws -1- . See Fig. 249.
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Fig. 250: Tightening sequence:

4. Tighten screws to specified tightening torque --> Tightening sequence: . --> Tightening torque: 8 ftlb. . See
Fig. 250.
Topping up ATF
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Subsequent work
37 60 19 REMOVING AND INSTALLING DEFLECTION LEVER - AS OF MY

2005 (ALL MODELS)
REMOVING DEFLECTION LEVER
Removing deflection lever
Fig. 252: Levering off selector cable

1. Lever selector cable off ball pin.
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Fig. 253: Push rod

2. Unclip push rod on transmission lever.
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Fig. 254: Circlip

3. Remove circlip for deflection lever and remove deflection lever with push rod.
INSTALLING DEFLECTION LEVER
Installing deflection lever
1. Grease deflection lever axle and bushings with Optimol TA.
Fig. 255: Circlip

2. Install deflection level and fit circlip.
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Fig. 256: Push rod

3. Clip in push rod on transmission lever.
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Fig. 257: Levering off selector cable

4. Press off selector cable on ball pin.
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TRANSMISSION Automatic - Gears, control
TRANSMISSION
Automatic - Gears, control
38 60 19 REMOVING AND INSTALLING ATF COOLER - AS OF MY 2005 (ALL

MODELS)
TOOLS

PRELIMINARY WORK
Preliminary work
2005 (All Models) .
2. Remove rear underside panel. Refer to 51 94 19 Removing and installing cover for rear underbody - as of
REMOVING ATF COOLER
Removing ATF cooler
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1. Clamp shut coolant hoses (flow and return sides) with Hose clamp 3094 (Tools).
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Fig. 2: ATF cooler

NOTE: If necessary, use a mirror when screwing in and unscrewing the top screws.
3. Unscrew fastening screws between ATF cooler and port plate and remove ATF cooler.
INSTALLING ATF COOLER
Installing ATF cooler
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Fig. 3: Sealing rings in port plate

1. Insert new sealing rings in port plate.
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Fig. 4: Sealing ring for ATF cooler

2. Insert new sealing rings for ATF cooler.
Fig. 5: ATF cooler

3. Position ATF cooler on port plate and screw in screws.

1 2
ATF cooler to Fastening screws between ATF- Tightening 10 (7.5
port plate cooler and port plate torque ftlb.) Nm
4. Remove Hose clamp 3094 (Tools) from coolant pipes (flow and return sides).
SUBSEQUENT WORK
Subsequent work
1. Fill in coolant and bleed cooling system. Refer to 19 38 17 Draining and filling in coolant - as of MY 2005
(All Models) .
Microsoft
2. Check and if necessary, top up the ATF. Refer to 37 02 35 Checking and topping up ATF - as of MY 2005
(All Models) .
3. Install rear underside panel. Refer to 51 94 19 Removing and installing cover for rear underbody - as of
38 63 19 REMOVING AND INSTALLING PORT PLATE FOR ATF COOLER -

TOOLS

PRELIMINARY WORK
Preliminary work
2005 (All Models) .
2. Remove rear underside panel. Refer to 51 94 19 Removing and installing cover for rear underbody - as of
REMOVING PORT PLATE FOR ATF COOLER
Removing port plate for ATF cooler
Microsoft

Microsoft

exhaust system.

Microsoft

Microsoft
Fig. 10: ATF cooler

6. Unscrew fastening screws between ATF cooler and port plate and remove ATF cooler.
Fig. 11: Port plate

7. Unscrew fastening screws between port plate and transmission housing and remove port plate.
INSTALLING PORT PLATE FOR ATF COOLER
Installing port plate for ATF cooler
Microsoft
Fig. 12: Port plate

1. Position port plate with new sealing rings on transmission housing and screw in fastening screws.

value 1 2
Port plate to Fastening screws between port Tightening 10 (7.5
transmission housing plate and transmission housing torque ftlb.) Nm
Microsoft
Fig. 13: ATF cooler

2. Position ATF cooler on port plate and screw in screws.

1 2
ATF cooler to Fastening screws between ATF- Tightening 10 (7.5
port plate cooler and port plate torque ftlb.) Nm
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1 2
Microsoft


1 2
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for exhaust system.

1 2
mount transmission housing mount torque ftlb.) Nm
SUBSEQUENT WORK
Subsequent work
1. Install rear mufflers. Refer to 26 33 19 Removing and installing rear silencer - as of MY 2005 (Boxster,
2. Fill in coolant and bleed cooling system. Refer to 19 38 17 Draining and filling in coolant - as of MY 2005
(All Models) .
3. Check and if necessary, top up the ATF. Refer to 37 02 35 Checking and topping up ATF - as of MY 2005
Microsoft
(All Models) .
4. Install rear underside panel. Refer to 51 94 19 Removing and installing cover for rear underbody - as of
38 77 19 REMOVING AND INSTALLING CONTROL MECHANISM FOR

TRANSMISSION - AS OF MY 2005 (ALL MODELS)
INFORMATION
Notes
Filling capacities

1 2
9 liters
3.5 liters
Filling approx. 0.8
Final drive
capacity liters
PRELIMINARY WORK
Preliminary work
2005 (All Models) .
Models) .
3. Drain ATF. Refer to 37 02 55 Changing ATF - as of MY 2005 (All Models) .
4. Remove ATF pan. Refer to 37 55 19 Removing and installing ATF pan - as of MY 2005 (All Models) .
5. Remove ATF filter. Refer to 37 58 55 Replacing ATF filter - as of MY 2005 (All Models) .
REMOVING CONTROL MECHANISM FOR TRANSMISSION
Removing control mechanism for transmission

Microsoft
Fig. 17: Securing clasp

1. Pull off securing clasp for wiring harness plug.
Microsoft
Fig. 18: Transmission speed connector

2. Pull off transmission speed connector.

3. Unscrew designated fastening screws for hydraulic control unit.
NOTE: Do not set down removed control mechanism for transmission on transmission
input speed sender (rear of control mechanism). This can damage the sender.
4. Removed control mechanism from transmission and follow up wiring harness plug.
Microsoft
INSTALLING CONTROL MECHANISM FOR TRANSMISSION
Installing control mechanism for transmission
1. Thinly coat Toroidal sealing ring for wiring harness plug with Vaseline and insert plug into transmission
housing.
Fig. 20: Inserting control mechanism

2. Carefully position control mechanism and insert pin -1- of detent disc into groove of selector valve -2- .
Microsoft

3. Screw in fastening screws for control mechanism until hand-tight.
4. Tighten fastening screws from inside outwards.

value 1 2
Control mechanism for Fastening screws for control Tightening 8 (6 ftlb.)
transmission mechanism to transmission torque Nm
Microsoft
Fig. 22: Securing clasp

5. Attach securing clasp for wiring harness plug and engage holding tongue.
SUBSEQUENT WORK
Subsequent work
1. Install ATF filter. Refer to 37 58 55 Replacing ATF filter - as of MY 2005 (All Models) .
2. Install ATF pan. Refer to 37 55 19 Removing and installing ATF pan - as of MY 2005 (All Models) .
3. Fill in ATF. Refer to 37 02 55 Changing ATF - as of MY 2005 (All Models) .
Models) .
38 77 37 DISASSEMBLING AND ASSEMBLING CONTROL MECHANISM FOR

TRANSMISSION - AS OF MY 2005 (ALL MODELS)
TOOLS
Microsoft

an insertion aid VW-tool 3381
PRELIMINARY WORK
Preliminary work
2005 (All Models) .
Models) .
3. Drain ATF. Refer to 37 02 55 Changing ATF - as of MY 2005 (All Models) .
4. Remove ATF pan. Refer to 37 55 19 Removing and installing ATF pan - as of MY 2005 (All Models) .
5. Remove ATF filter. Refer to 37 58 55 Replacing ATF filter - as of MY 2005 (All Models) .
6. Remove control mechanism for transmission. --> 387719 Control mechanism for transmission.
DISASSEMBLING CONTROL MECHANISM FOR TRANSMISSION
Disassembling control mechanism for transmission
Microsoft
Fig. 23: Overview


-1- See See --> 387719 Control mechanism
Control mechanism for transmission 1
Fig. 23. for transmission
Remove plug connections from
solenoid valves and from transmission
-2- Wire harness 1
input speed sender and disengage wire
harness on brackets.
-3- O-ring 2
-4- Screw 1
Unscrew fastening screw and remove
-5- Transmission input speed sender 1
sender and sleeve.
-6- Spacer sleeve (20 mm) 1
-7- Screw 1
-8- Holder 1
Microsoft
-9- Pressure regulator and O-ring 1

-10- Screw 4
-11- Holder 2
Unscrew guide plate for parking-lock
-12- Solenoid valve 1 1
mechanism
-13- Pressure regulator 2 and O-ring 1
-18- Screw 1
Unscrew fastening screw and remove
-19- Transmission speed sender 1
sender and sleeve.
-21- Oil pipe 1 Lever out oil pipe with a screwdriver.
-22- O-ring 2
ASSEMBLING CONTROL MECHANISM FOR TRANSMISSION
Assembling control mechanism for transmission
Microsoft
Fig. 24: Overview

No. Designation Qty. Installation

-1- See See --> 387719 Control mechanism
Control mechanism for transmission 1
Fig. 24. for transmission
Engage wire harness in brackets and
connect plug connections to solenoid
-2- Wire harness 1
valves and transmission input speed
sender.
-3- O-ring 2 Always replace and coat with Vaseline
-4- Screw 1 Tightening torque : 6 Nm (4.5 ftlb.)
-5- Transmission input speed sender 1
-8- Holder 1
Microsoft

-11- Holder 2
Do not tighten screws for guide plate in
-12- Solenoid valve 1 1 selector lever position "P". Tightening
torque : 6 Nm (4.5 ftlb.)
-13- Pressure regulator 2 and O-ring 1 Thinly coat O-ring with Vaseline
-19- Transmission speed sender 1
-21- Oil pipe 1
-22- O-ring 2 Always replace and coat with Vaseline
Instructions for assembling control mechanism
NOTE: The ATF temperature sender is integrated in the wire harness. Therefore, in the
case of damage, the entire wire harness must be replaced.
In the event of mechanical stress (e. g. if it falls) the transmission input speed
sender or the transmission speed sender must not be reinstalled as the
permanent magnet will have been destroyed.
Always replace an oil pipe that has been removed.
Always insert an oil pipe using an insertion aid 3381 as otherwise the oil pipe
can be bent.
Microsoft
Fig. 25: Overview

1. Coat new oil pipe -21- and new O-rings -22- lightly with Vaseline. See Fig. 25.
Microsoft
Fig. 26: Insertion aid

2. Insert oil pipe into insertion aid 3381 and drive evenly into transmission housing as far as the stop on the
tool. The open side of the tool should face the outer wall of the transmission.
Microsoft
Fig. 27: Transmission speed sender

3. Screw in transmission speed sender -19- and spacer (8 mm) -20- and tighten screw -18- . See Fig. 25.

1 2
Fastening screw for transmission input Tightening 6 (4.5 ftlb.)
speed sender torque Nm
Microsoft
Fig. 28: Transmission input speed sender

4. Screw in transmission input speed sender -5- and spacers (20 mm) -6- and tighten screws -4- . See Fig. 25.

1 2
Fastening screw for transmission input Tightening 6 (4.5 ftlb.)
speed sender torque Nm
Microsoft
Fig. 29: Wire harness

5. Insert wiring harness -2- with the flat point facing the ATF pan. See Fig. 25.
SUBSEQUENT WORK
Subsequent work
1. Install control mechanism for transmission. --> 387719 Control mechanism for transmission
2. Install ATF filter. Refer to 37 58 55 Replacing ATF filter - as of MY 2005 (All Models) .
3. Install ATF pan. Refer to 37 55 19 Removing and installing ATF pan - as of MY 2005 (All Models) .
4. Fill in ATF. Refer to 37 02 55 Changing ATF - as of MY 2005 (All Models) .
Models) .
Microsoft
TRANSMISSION Manual - Actuation, assembly housing
TRANSMISSION
Manual - Actuation, assembly housing
34 01 35 CHECKING AND TOPPING UP TRANSMISSION OIL - AS OF MY

TOOLS

angled wire hook (shop special tool 00000
made)
INFORMATION
Notes
PRELIMINARY WORK
Preliminary work
2005 (All Models) .
Models) .
CHECKING AND TOPPING UP TRANSMISSION OIL
Checking and topping up transmission oil
Microsoft
Fig. 1: Filler plug

Microsoft
Fig. 2: Oil level in the transmission

2. Insert angled wire hook (shop made) 00000 through the filler opening and check oil level. The oil level
must be 2 to 3 mm below the filler opening, otherwise oil must be added.
3. Clean oil filler plug and screw in with a new sealing ring.

Oil filler plug on manual transmission Tightening torque 30 ftlb.

Microsoft
Fig. 3: Filler plug

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Fig. 4: Oil level in transmission

2. Push angled wire hook (shop-made) 00000 through oil opening and check oil level. The oil level must be 11
mm below the filler opening. If it is lower add more oil.

SUBSEQUENT WORK
Subsequent work
Microsoft
Models) .
34 01 35 CHECKING AND TOPPING UP TRANSMISSION OIL - AS OF MY

2005 (BOXSTER S, BOXSTER S RHD, CAYMAN S, CAYMAN S RHD)
TOOLS

angled wire hook (shop special tool 00000
made)
INFORMATION
Notes
PRELIMINARY WORK
Preliminary work
2005 (All Models) .
Models) .
CHECKING AND TOPPING UP TRANSMISSION OIL
Microsoft
Fig. 5: Filler plug

Microsoft
Fig. 6: Oil level in the transmission

2. Insert angled wire hook (shop made) 00000 through the filler opening and check oil level. The oil level
must be 2 to 3 mm below the filler opening, otherwise oil must be added.

SUBSEQUENT WORK
Subsequent work
Microsoft
Models) .
34 01 55 CHANGING TRANSMISSION OIL - AS OF MY 2005 (BOXSTER S,

BOXSTER S RHD, CAYMAN S, CAYMAN S RHD)
INFORMATION
Notes
TECHNICAL VALUES
Filling capacities

Manual transmission Filling capacity 2.8 liters
PRELIMINARY WORK
Preliminary work
2005 (All Models) .
Models) .
DRAINING TRANSMISSION OIL
Draining transmission oil

Microsoft
Fig. 7: Filler plug

Microsoft

2. Unscrew oil drain plug and drain transmission oil.
REFILLING TRANSMISSION OIL
Filling in transmission oil
1. Clean oil drain plug and screw in with new sealing ring.

value 1 2
Oil drain plug on manual Tightening
30 ftlb.
transmission torque
2. Filling capacity 2.8 litersFill with transmission oil.
Microsoft
3. Clean oil filler plug and screw in with a new seal.

XX
SUBSEQUENT WORK
Subsequent work
34 01 55 CHANGING TRANSMISSION OIL - AS OF MY 2005 (BOXSTER,

BOXSTER RHD)
INFORMATION
Notes
TECHNICAL VALUES
Filling capacities

Filling capacities

PRELIMINARY WORK
Preliminary work
2005 (All Models) .
Models) .
Microsoft
DRAINING TRANSMISSION OIL
Fig. 9: Filler plug


Microsoft

Microsoft
Fig. 11: Filler plug

Microsoft

REFILLING TRANSMISSION OIL

value 1 2
Oil drain plug on manual Tightening
19 ftlb.
transmission torque


value 1 2
Oil drain plug on manual Tightening 30 ftlb.
Microsoft
transmission torque

XX
SUBSEQUENT WORK
Subsequent work
34 04 19 REMOVING AND INSTALLING SHIFT LEVER KNOB - AS OF MY

2005 (ALL MODELS)
REMOVING SHIFT LEVER KNOB
Removing shift-lever knob
Microsoft
Fig. 13: Unclipping leather sleeve

1. Unclip retaining frame of the leather sleeve in upward direction by pulling on the leather.
Microsoft
Fig. 14: Turning leather sleeve clockwise

2. Turn leather sleeve clockwise by 90° as far as it will go.
Fig. 15: Pulling off shift-lever knob

3. Pull shift-lever knob up and off the shift lever.
INSTALLING SHIFT LEVER KNOB
Installing shift-lever knob
Microsoft
Fig. 16: Pushing on shift-lever knob

1. Push shift-lever knob fully onto the shift lever.
Microsoft
Fig. 17: Turning leather sleeve anti-clockwise

2. Turn leather sleeve anti-clockwise by 90° as far as it will go.
Fig. 18: Clipping in leather sleeve

Microsoft
3. Clip retaining frame of the leather sleeve into the center console
34 08 19 REMOVING AND INSTALLING GEARSHIFT BRACKET - AS OF MY

2005 (ALL MODELS)
TOOLS

Locking bridge special tool P 9619
Locking bridge special tool P 9619/1
PRELIMINARY WORK
Preliminary work
1. Remove shift lever knob. --> 340419 Removing and installing shift lever knob - section on "Removing"
Models) .
REMOVING GEARSHIFT BRACKET
Removing gearshift bracket
Microsoft
Fig. 19: Fitting locking bridge

1. Locking bridge P 9619/1 must be fitted on the gearshift bracket.
Microsoft

2. Open bayonet locks on the pre-selector and shifting connections.
Fig. 21: Disengaging shift cables

3. Disengage adjustment pin on pre-selector and shifting connections.
Microsoft
Fig. 22: Unclipping supports

4. Unclip supports on the gearshift bracket.
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Fig. 23: Removing gearshift bracket

5. Unscrew nut and lift gearshift bracket up and off.
Microsoft
Fig. 24: Removing locking bridge

6. Remove locking bridge.
INSTALLING GEARSHIFT BRACKET
Installing gearshift bracket
Microsoft
Fig. 25: Installing gearshift bracket

1. Fit gearshift bracket and screw in nuts.

Gearshift bracket Tightening torque 10 (7.5 ftlb.) Nm
Microsoft

Microsoft
Fig. 27: Clipping in supports

3. Clip in supports on the gearshift bracket. The support with the blue hinged tube must be fitted on the left and
the support with the black hinged tube must be fitted on the right.
Fig. 28: Engaging shift cables

NOTE: Before starting to install the gearshift bracket, ensure that the transmission is in
neutral.
4. Engage adjustment pin on pre-selector and shift connections.
Microsoft
Fig. 29: Closing bayonet locks

5. Close bayonet locks on the pre-selector and shift connections.
Microsoft

6. Locking bridge P 9619 must be removed.
SUBSEQUENT WORK
Subsequent work
Models) .
2. Install shift lever knob. --> 340419 Removing and installing shift lever knob - section on "Installing"
34 12 19 REMOVING AND INSTALLING SHIFT AND SELECTOR CABLES -

TOOLS

PRELIMINARY WORK
Preliminary work
2005 (All Models) .
Models) .
Models) .
Models) .

2005 (All Models) .
Microsoft
REMOVING SHIFT AND SELECTOR CABLES
Detaching shift and selector cables at transmission
Fig. 31: Shift and selector cables

1. Lever off shift cable (with grey sealing cap) -1- and selector cable (with blue sealing cap) -2- from ball pin
and detach from supports.
Microsoft

Detaching shift and selector cables inside vehicle
Microsoft

Microsoft

2. Open bayonet locks at preselector and shift connections.
Fig. 35: Detaching shift cables

3. Detach adjustment pins at preselector and shift connections.
Microsoft

Removing shift and selector cables
Microsoft
Fig. 37: Pulling out shift and selector cable

1. Pull end of shift and selector cable - at transmission side - out through the opening in the engine compartment
lid.
Microsoft
Fig. 38: Support

2. Remove support for shift and selector cables.
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Fig. 39: Support

3. Disengage shift and selector cables from support.

4. Remove fastening nuts and pull shift and selector cables into the interior of the vehicle.
Microsoft
Fig. 41: Shift cable at distributor pipe

1. Unclip shift cable at the distributor pipe.
Microsoft
Fig. 42: Pulling out shift and selector cables

lid.
Fig. 43: Support

Microsoft
Fig. 44: Support

4. Disengage shift and selector cable from support.
Microsoft

INSTALLING SHIFT AND SELECTOR CABLES
Installing shift and selector cables

1. Push the shift and selector cables through the bulkhead panel from the interior of the vehicle and fit fastening
nuts.

value 1 2
Microsoft
cables to bulkhead selector cables and bulkhead torque 7.5 ftlb.
Fig. 47: Support

2. Engage shift and selector cables in support.
Microsoft
Fig. 48: Support

3. Fit support for shift and selector cables.

value 1 2
7.5 ftlb.
Microsoft
Fig. 49: Pushing in shift and selector cables

4. Push end of shift and selector cable - at transmission side - into the opening in the engine compartment lid.
Microsoft
Fig. 50: Clipping in shift cable

5. Clip in shift cable at the distributor pipe.

nuts.

value 1 2
7.5 ftlb.
cables to bulkhead selector cables and bulkhead torque
Microsoft
Fig. 52: Support

Microsoft
Fig. 53: Support


value 1 2
7.5 ftlb.

Securing shift and selector cables inside vehicle
Microsoft

Microsoft


3. Engage adjustment pins at preselector and shift connections.
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4. Close bayonet locks at preselector and shift connections.
Securing shift and selector cables at transmission
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1. Engage shift -1- (grey end piece) and selector cable -2- (blue end piece) into support bracket for transmission
and press end pieces onto ball heads.
Microsoft

SUBSEQUENT WORK
Subsequent work
Microsoft

1. Locking bridge P 9619/1 must be removed.

2005 (All Models) .
Models) .
Models) .
34 12 19 REMOVING AND INSTALLING SHIFT AND SELECTOR CABLES -

Microsoft
RHD)
TOOLS

PRELIMINARY WORK
Preliminary work
2005 (All Models) .
Models) .
Models) .
Models) .

2005 (All Models) .
REMOVING SHIFT AND SELECTOR CABLES
Microsoft

Detaching shift and selector cables inside vehicle
Microsoft

Microsoft

2. Open bayonet locks at preselector and shift connections.
Fig. 65: Detaching shift cables

3. Detach adjustment pins at preselector and shift connections.
Microsoft

Microsoft
Fig. 67: Shift cable at distributor pipe

1. Unclip shift cable at the distributor pipe.
Microsoft
Fig. 68: Pulling out shift and selector cables

lid.
Fig. 69: Support

Microsoft
Fig. 70: Support

4. Disengage shift and selector cable from support.
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INSTALLING SHIFT AND SELECTOR CABLES

nuts.

value 1 2
Microsoft
cables to bulkhead selector cables and bulkhead torque 7.5 ftlb.
Fig. 73: Support

Microsoft
Fig. 74: Support


value 1 2
7.5 ftlb.
Microsoft

Microsoft
Fig. 76: Clipping in shift cable

5. Clip in shift cable at the distributor pipe.
Securing shift and selector cables inside vehicle

Microsoft

Microsoft

3. Engage adjustment pins at preselector and shift connections.
Microsoft

4. Close bayonet locks at preselector and shift connections.

SUBSEQUENT WORK
Subsequent work
Microsoft

1. Locking bridge P 9619/1 must be removed.

2005 (All Models) .
Models) .
Models) .
34 35 TW TECHNICAL DATA, TRANSMISSION - AS OF MY 2005 (BOXSTER

Microsoft
S, BOXSTER S RHD)
TECHNICAL VALUES
Technical data
Transmission type: G87/20
Equipment: 6-gear
Installed in: Boxster S (987)
Model Year: 2005
Transmission ratios
1st gear: 3.67
2nd gear: 2.05
3rd gear: 1.41
4th gear: 1.13
5th gear: 0.97
6th gear: 0.82
Reverse gear: 3.33
Filling capacities

34 35 TW TECHNICAL DATA, TRANSMISSION - AS OF MY 2005 (BOXSTER,

BOXSTER RHD)
TECHNICAL VALUES
Technical data
Microsoft
Equipment: 5-gear
Model Year: 2005
Technical data
Equipment: 6-gear
Model Year: 2005
Transmission ratios
1st gear: 3.50
2nd gear: 2.12
3rd gear: 1.43
4th gear: 1.09
5th gear: 0.84
Reverse gear: 3.44
Transmission ratios
1st gear: 3.67
2nd gear: 2.05
3rd gear: 1.41
4th gear: 1.13
5th gear: 0.97
6th gear: 0.82
Reverse gear: 3.33

Microsoft
Filling capacities

Filling capacities

34 35 TW TECHNICAL DATA, TRANSMISSION - AS OF MY 2005 (CAYMAN

S, CAYMAN S RHD)
TECHNICAL VALUES
Technical data
Equipment: 6-gear
Installed in: Cayman S
Model year: 2006
Transmission ratios
1st gear: 3.308
2nd gear: 1.95
3rd gear: 1.41
4th gear: 1.13
5th gear: 0.97
6th gear: 0.82
Reverse gear: 3.00
Filling capacities
Microsoft

34 35 19 REMOVING AND INSTALLING TRANSMISSION - AS OF MY 2005

TOOLS

retaining device special tool P 9624/1
PRELIMINARY WORK
Preliminary work
(ALL MODELS) .
Models) .
Microsoft

6. Screw retaining device P 9624/1 to cross member, turn spindle upwards and support engine.
REMOVING TRANSMISSION
Dismantling
Microsoft

Microsoft

has been cut open).
Fig. 86: Reversing-light switch

3. Pull off electric connector for back-up light switch.
Microsoft

and disengage from supports. See Fig. 87.
Removing transmission
when it is lowered.
Microsoft

2. Remove cross member.
Microsoft


4. Unscrew fastening screws between body and hydraulic mount -arrow- and remove transmission support with
hydraulic mount. See Fig. 90.
B - Hydraulic mount
NOTE:  The clutch pedal must not be pressed if the clutch slave cylinder has been
removed. Danger of injury from the push rod which can be pressed out of
the slave cylinder hydraulically. Affix a warning note in the vehicle!
5. Remove the clutch slave cylinder but while doing so, do not disconnect the clutch line. Refer to 30 30 19
Microsoft
Removing and installing clutch slave cylinder - 6-speed transmission - as of MY 2005 (All Models) .
Fig. 91: Engine/transmission mount

6. Unscrew fastening screws -1 to 7- and pull out transmission to the rear and downwards. See Fig. 91.
INSTALLING TRANSMISSION
Installing transmission
Microsoft

NOTE: Before installing the transmission, clean splines of transmission input shaft and
grease lightly, e. g. with Olista Longtime 3 EP.
1. Move in transmission and screw in fastening screws -1 to 7- . See Fig. 92.

value 1 2
connection illustration, M12 x 70 torque ftlb.) Nm
Hexagon-head bolt no. 2 in
Transmission/engine Tightening 85 (63
illustration, M12 x 100; with
connection torque ftlb.) Nm
washer
Transmission-engine Hexagon bolt No. 3 M12 x 90 in Tightening 85 (63
connection illustration torque ftlb.) Nm
Transmission-engine Internal serration screw No. 4 Tightening 45 (33
connection M10 x 35 in illustration torque ftlb.) Nm
Nut No. 5 M10 in illustration
Transmission-engine Hexagon bolt No. 7 M12 x 90 in Tightening 85 (63
Microsoft
connection illustration torque ftlb.) Nm
2. Insert clutch slave cylinder in transmission opening and screw in fastening screw. Refer to 30 30 19

value 1 2
Clutch slave Fastening screw between transmission Tightening 23 (17
cylinder housing and clutch slave cylinder torque ftlb.) Nm
3. Fit left and right transmission supports with hydraulic mount.

value 1 2
Fastening screws between hydraulic Tightening 33 (24
Hydraulic mount
mount and body torque ftlb.) Nm

Microsoft

1 2
Cross Fastening screws between cross Tightening 65 (48 ftlb.)
member member and body torque Nm
Assembly work

1. Engage shift cable (with grey sealing cap) -1- and selector cable (with blue sealing cap) -2- in the support and
press on the ball pin. See Fig. 94.
Microsoft
Fig. 95: Back-up light switch

2. Push on electric connector for back-up light switch.
Microsoft


1 2


value 1 2
Anti-roll Fastening screws between anti-roll bar and Tightening 23 (17
bar rear axle carrier side member torque ftlb.) Nm
SUBSEQUENT WORK
Subsequent work
Microsoft


1 2
Models) .
6. Check transmission oil level and top it up, if necessary. --> 340135 Checking and topping up transmission
oil
Microsoft
34 35 19 REMOVING AND INSTALLING TRANSMISSION - AS OF MY 2005

(ALL MODELS)
TOOLS

Schremm 48-2 puller special tool 00000
retaining device special tool P 9624/1
PRELIMINARY WORK
Preliminary work
(ALL MODELS) .
Models) .
Microsoft

6. Screw retaining device P 9624/1 to cross member, turn spindle upwards and support engine.
Dismantling
Microsoft

Microsoft

has been cut open).
2. Remove drive shafts on transmission side. To do this, unscrew the six hexagon socket head bolts joining each
drive shaft and transmission flange. Counter at the brake disc or activate the parking brake to avoid

3. Pull off electric connector for reversing-light switch.
Microsoft

and detach from supports. See Fig. 115.
when it is lowered.
Microsoft

2. Remove cross member.
Microsoft


4. Unscrew fastening screws between body and hydraulic mount -arrow- and remove transmission support with
hydraulic mount. See Fig. 106.
B - Hydraulic mount
5. Lower the transmission for better access when removing the clutch slave cylinder.
Microsoft

6. Unscrew fastening nut of exterior shift.
Microsoft
Fig. 108: Pulling off the exterior shift

7. Pull off exterior shift using Schremm 48-2 puller 00000 from shifting shaft.

NOTE:  The clutch pedal must not be pressed if the clutch slave cylinder has been
removed. Danger of injury from the push rod which can be pressed out of
the slave cylinder hydraulically. Affix a warning note in the vehicle!
8. Unscrew fastening screw between clutch slave cylinder and transmission and remove clutch slave cylinder.
While doing so, do not separate clutch line. Refer to 30 30 19 Removing and installing clutch slave cylinder -
6-speed transmission - as of MY 2005 (All Models) .
Microsoft

INSTALLING TRANSMISSION
Installing transmission
Microsoft
Fig. 111: Fastening transmission to engine

1. Move in transmission and screw in fastening screws -1 to 8- . See Fig. 111.

value 1 2
Nut no. 6 in figure M10
Microsoft


2. Insert clutch slave cylinder in transmission opening and screw in fastening screw.

value 1 2
Clutch slave Fastening screws between transmission Tightening 23 (17
Microsoft

3. Fit the external shift mechanism and tighten nut.

value 1 2
External shift Fastening nut between shifting shaft Tightening 23 (17
mechanism and external shifting mechanism torque ftlb.) Nm
4. Fit left and right transmission supports with hydraulic mount.

value 1 2
Fastening screws between hydraulic Tightening 33 (24
Hydraulic mount
mount and body torque ftlb.) Nm
Microsoft


1 2
Cross Fastening screws between cross Tightening 65 (48 ftlb.)
member member and body torque Nm
Assembly work
Microsoft

1. Engage shift cable (with grey sealing cap) -1- and selector cable (with blue sealing cap) -2- in the support and
press on the ball pin. See Fig. 115.
Microsoft

2. Push on electric connector for reverse gear switch.
Microsoft

drive shaft and the transmission flange, respectively. Counter at the brake disc or activate the parking brake to

value 1 2
60 ftlb.


value 1 2
17 ftlb.
SUBSEQUENT WORK
Subsequent work
Microsoft


1 2
Models) .
6. Check transmission oil level and top it up, if necessary. --> 340135 Checking and topping up transmission
oil [987310 987311] --> 340135 Checking and topping up transmission oil [987120 987121 987320 987321]

Microsoft
34 35 27 REMOVING AND REFITTING TRANSMISSION - AS OF MY 2005

(BOXSTER S, BOXSTER S RHD, CAYMAN S, CAYMAN S RHD)
TOOLS

PRELIMINARY WORK
Preliminary work
1. Remove engine-transmission unit. Refer to 10 01 19 Removing and installing engine - as of MY 2005

Removing accessories

Microsoft

Microsoft

Fig. 123: Reversing light switch

4. Pull off electric connector for reversing light switch.
Microsoft
Fig. 124: Mount for exhaust system

5. Remove mount for exhaust system from transmission.
Microsoft

1. Unscrew fastening screws -1 to 8- and pull out transmission to the rear. See Fig. 125.
REFITTING TRANSMISSION
Refitting transmission
Microsoft

1. Move transmission into position and screw in fastening screws -1 to 8- . See Fig. 126.

value 1 2
Microsoft

Fitting accessories

1. Fit mount for exhaust system on transmission.

1 2
Microsoft

Microsoft


value 1 2


value 1 2
mechanism and external shift mechanism torque ftlb.) Nm
SUBSEQUENT WORK
Microsoft
Subsequent work
1. Install engine-transmission unit. Refer to 10 01 19 Removing and installing engine - as of MY 2005

34 35 27 REMOVING AND REFITTING TRANSMISSION - AS OF MY 2005

TOOLS

PRELIMINARY WORK
Preliminary work
1. Remove engine-transmission unit. Refer to 10 01 19 Removing and installing engine - as of MY 2005

Microsoft

2. Remove clutch slave cylinder. Refer to 30 30 19 Removing and installing clutch slave cylinder - 6-speed

Microsoft

Microsoft


Microsoft

Microsoft


Microsoft

REFITTING TRANSMISSION
Microsoft


value 1 2
Hexagon-head bolt no. 2 in
figure (M12 x 100); with
washer
Transmission-engine Hexagon bolt No. 3 (M12 x 90) Tightening 85 (63
Transmission-engine Internal serration screw No. 4 Tightening 45 (33
connection (M10 x 35) in illustration torque ftlb.) Nm
Nut No. 5 (M10) in illustration
Transmission-engine Hexagon bolt No. 7 (M12 x 90) Tightening 85 (63
Microsoft


value 1 2
Microsoft

Fitting accessories


1 2
holder transmission housing holder torque ftlb.) Nm
2. Insert clutch slave cylinder into transmission opening and screw in fastening screw. Refer to 30 30 19
Microsoft

value 1 2

3. Push on electric connector for reversing light switch.
Fitting accessories
Microsoft


1 2
Microsoft

Microsoft


value 1 2


value 1 2
mechanism and external shift mechanism torque ftlb.) Nm
SUBSEQUENT WORK
Microsoft
Subsequent work
1. Install engine-transmission unit. Refer to 10 01 19 Removing and installing engine - as of MY 2005

34 35 37 DISASSEMBLING AND ASSEMBLING TRANSMISSION - AS OF MY

TOOLS

press-in device VW-tool 3235
taper roller bearing puller, commercially NR.119

Boxster manual available tool
transmission
puller commercially v. a. g. 1582
available tool
grip piece commercially v. a. g.1582/2
available tool
PRELIMINARY WORK
Preliminary work
1. Remove transmission. --> 343519 Removing and installing transmission - section on "Removing"
Microsoft

support.
3. Drain transmission oil. --> 340155 Changing transmission oil - section on "Draining"
4. Remove sealing ring for drive shaft. Refer to 35 50 19 Removing and installing sealing ring for input shaft
DISASSEMBLING TRANSMISSION
Removing transmission housing
Microsoft
Fig. 149: Overview of transmission housing


Already removed during preliminary
1 Torx screw 3
work.
2 Guide sleeve 1
work.
3 O-ring 1
work.
4 Shaft seal 1
work.
5 Cup spring 1
Note the thickness for re-installation
6 Circlip 1
(must not be interchanged).
Pull out with puller v. a. g. 1582 and
7 Ball bearing 1
grip piece v. a. g.1582/2.
Note the thickness for re-installation
8 Circlip 1
(must not be interchanged).
9 Hexagon-head bolt 1
10 Tab washer 1
11 Reversing-light switch 1
12 O-ring 1
13 Torx screw 1
Removal instructions for transmission housing
Microsoft

Fig. 151: Driving out bearing

1. Drive ball bearing -7- out of the housing with taper roller bearing puller, Boxster manual transmission
NR.119. See Fig. 150.
Microsoft
Removing transmission cover
Fig. 152: Removing transmission cover


14 Torx screw 14
15 Transmission cover 1
16 Torx screw 1
17 Spacer 1
18 Torx screw 1
19 Spacer 1
20 Torx screw with collar 1
21 Switch interlock 1
22 Drive shaft 1
23 Output shaft 1
24 Relay shaft 1
Shift rod and shift fork for 3rd and
25 1
4th gear
26 Interior shift rod 1
Shift rod with shift fork for 1st, 2nd,
27 1
5th, and reverse gear
Removal instructions for transmission cover
Microsoft
Fig. 153: Gear set with gearshift

1. Pull out drive shaft -A- , output shaft -B- , deflection rod -C- , shift rods -D- and shift fork -E- together.
ASSEMBLING TRANSMISSION
Fitting transmission cover
Microsoft
Fig. 154: Removing transmission cover


14 Torx screw 14
Nm
Apply sealing material Loctite 574 to
15 Transmission cover 1 the contact surfaces and tighten Torx
screws -14- .
16 Torx screw 1
Nm
17 Spacer 1
18 Torx screw 1
Nm
19 Spacer 1
20 Torx screw with collar 1
Nm
21 Switch interlock 1
22 Drive shaft 1
23 Output shaft 1
24 Relay shaft 1
Shift rod and shift fork for 3rd and
25 1
4th gear
26 Interior shift rod 1
Only replace shift rod for 5th and
Shift rod with shift fork for 1st, 2nd,
27 1 reverse gear complete with shift fork
5th, and reverse gear
and driver.
Installation instructions for transmission cover
Microsoft
Fig. 155: Inserting shafts

1. Place drive shaft and output shaft together and insert into the transmission housing.
Microsoft
Fig. 156: Inserting interior shift rod

2. Insert relay shaft and interior shift rod.
- Shift into 3rd gear.
- Insert relay shaft.
- Place interior shift rod next to the guide bore of the bearing cover.
- Slide the shift finger into the driver of the relay shaft and swivel this carefully into the guide bore by turning
the interior shift rod.
3. Install switch interlock.
- Put the interlock slide into the center position.
- Shift into neutral.
- Insert switch interlock.
- Latch relay shaft into switch interlock.
- Secure switch interlock with Torx screw with collar.

Torx screw Tightening torque 25 (19 ftlb.) Nm
4. Insert and tighten screws for relay shaft.

5. Seal transmission cover with Loctite 574 and fit it. Ensure correct position of dowel sleeves in transmission
housing. See --> 34 37 37 Disassembling and assembling transmission housing - as of MY 2005 (Boxster,
Boxster RHD).
Fitting transmission housing
Microsoft


1 Torx screw 3 Fitted during subsequent work.
2 Guide sleeve 1 Fitted during subsequent work.
3 O-ring 1 Fitted during subsequent work.
4 Shaft seal 2 Fitted during subsequent work.
Insert with the smaller diameter
5 Cup spring 1
(curved side) towards the guide sleeve.
If ball bearing No. 7, the drive shaft or
the transmission housing is replaced,
calculate the thickness again. Refer to
6 Circlip 1
35 40 15 Adjusting the drive shaft -
as of MY 2005 (Boxster, Boxster
RHD) .
With the open side of the plastic cage
7 Ball bearing 1 pointing towards the guide sleeve,
press in with the press-in device 3235.
If ball bearing No. 7, the drive shaft or
the transmission housing is replaced,
calculate the thickness again. Refer to
8 Circlip 1
35 40 15 Adjusting the drive shaft -
RHD) .
9 Hexagon-head bolt 1
Nm
10 Tab washer 1
Microsoft
11 Reversing-light switch 1 Insert in the correct position.

12 O-ring 1 Always replace, and lightly oil.
--> Tightening torque: 10 (7.5 ftlb.)
13 Torx screw 1
Nm
Installation instructions for transmission housing
Fig. 158: Pressing in ball bearing

1. Press in ball bearing for the drive shaft.
- Place thrust washer -A- of the press-in device 3235 onto the ball bearing. See Fig. 158.
- Position press-in device 3235 behind the toothing for the clutch plate on the drive shaft and pretension with
both screws -B- . The screws are supported in the two lowered areas of the thrust washer. See Fig. 158.
- Press in the ball bearing as far as it will go by alternately tightening the screws -B- (tighten only in 1/2 turns to
avoid tilting and thus damaging the ball bearing). See Fig. 158.
SUBSEQUENT WORK
Subsequent work
1. Install sealing ring for drive shaft. Refer to 35 50 19 Removing and installing sealing ring for input shaft -
Microsoft
as of MY 2005 (Boxster, Boxster RHD) .
2. Fill with transmission oil. --> 340155 Changing transmission oil - section on "Filling"
4. Install transmission. --> 343519 Removing and installing transmission - section on "Installing"
34 37 37 DISASSEMBLING AND ASSEMBLING TRANSMISSION HOUSING -

TOOLS

pressure piece VW-tool 30-205
pressure piece VW-tool 40-202
threaded piece commercially 771/15

available tool
pressure piece commercially 9247/1
available tool
pull-in tool and puller commercially p 254
available tool

available tool

available tool
Microsoft
hook commercially vw 681

available tool
striker commercially vw 771

available tool
threaded piece commercially vw 771/15
available tool
bridge commercially vw 771/29

available tool
PRELIMINARY WORK
Preliminary work
Microsoft

support.
4. Disassemble the transmission. --> 343537 Disassembling and assembling transmission - section on
"Disassembling"
DISASSEMBLING TRANSMISSION HOUSING
Disassembling transmission housing
Microsoft

If the parts marked are replaced, re-adjustment is necessary (see Refer to 39 08 15 Adjusting the drive set - as
of MY 2005 (Boxster, Boxster RHD) ).

-1- Oil drain plug 1
-2- Torx screw 2
-3- Torx screw 1
-4- Tab washer 1
-5- Reversing-light switch 1
-6- O-ring 1
-7- Cap 1
Pull out using pressure piece 3128
-8- Taper roller bearing outer ring 1
and bridge vw 771/29.
-9- Adjusting shim S3 X Note the thickness for re-installation.
Press out using drive-in mandrel vw
-10- Needle-roller bearing 1
295 and pressure piece 40-202.
Remove with striker vw 771,
threaded piece 771/15 and a suitable
-11- Bushing 1
internal puller (e. g. Kukko 21/4,
23.5...30 mm).
-12- Torx screw 2
threaded piece vw 771/15 and a
-13- Lid 1
suitable internal puller (e. g. Kukko
21/3, 18.5...23.5 mm).
Microsoft
-14- Torx screw 1

-15- Lock (5th gear and reverse) 1
-16- O-ring 1
-17- Shaft seal 1 Pull out using hook vw 681.
Taper roller bearing outer ring
-18- 1 or copper mandrel (diameter of 6...8
(small)*
mm).
-19- Adjusting shim S2 X Note the thickness for re-installation
-20- Adapter 1
-21- Ball pin 1
-22- Sleeve 2
-23- Transmission housing 1
-24- Oil filler plug 1
-25- Shaft seal 1 Pull out using hook VW681.
Taper roller bearing outer ring
-26- 1 or copper mandrel (diameter of 6...8
(large)
mm).
-27- Adjusting shim S1 X Note the thickness for re-installation
-28- Cover for final drive 1
Instructions for disassembling transmission housing

Microsoft
Fig. 162: Pulling out bearing

1. Pull out taper roller bearing outer ring -8- using pressure piece 3128 and bridge vw 771/29. See Fig. 161.
Microsoft
Fig. 163: Needle-roller bearing for drive shaft

2. Press out needle-roller bearing for drive shaft -10- using drive-in mandrel vw 295 and pressure piece 40-
202. -A = Schraube M10x135- . See Fig. 161, Fig. 162.
ASSEMBLING TRANSMISSION HOUSING
Assembling transmission housing

If the parts marked are replaced, re-adjustment is necessary (Refer to 39 08 15 Adjusting the drive set - as of
MY 2005 (Boxster, Boxster RHD) ).

-1- Oil drain plug 1
Nm
-2- Torx screw 2
Nm
-3- Torx screw 1
Nm
-4- Tab washer 1
-5- Reversing-light switch 1
-6- O-ring 1 Always replace, lightly oil.
-7- Cap 1
-8- Taper roller bearing outer ring 1 Press in using a suitable pressure piece.
Microsoft
Calculate thickness again if necessary;

Adjusting shim S3 see Refer to 39 08 15 Adjusting the
-9- X
drive set - as of MY 2005 (Boxster,
Boxster RHD) .
Press into correct position (labelled
side facing the pressure piece) using
pressure piece 40-202 and drive-in
mandrel vw 295; do not drive in!
Press in using pressure piece 9247/1
-11- Bushing 1
and pull-in tool and puller p 254.
-12- Torx screw 2
Nm
-13- Lid 1
-14- Torx screw 1
Nm
-15- Lock (5th gear and reverse) 1
-16- O-ring 1 Always replace.
Fill space between dust and sealing lips
with multipurpose grease. Drive into
-17- Shaft seal 1 correct position with drive-in mandrel
vw 195 (5.5 mm below top edge of
lid).
Taper roller bearing outer ring Press in using pressure piece 30-205
-18- 1
(small) and drive-in mandrel vw 295.
Adjusting shim S2 Calculate the thickness again if
-19- X
necessary.
-20- Adapter 1
-21- Ball pin 1
Nm
-22- Sleeve 2 Press into correct position.
-24- Oil filler plug 1
Nm
Fill space between dust and sealing lips
with multipurpose grease. Drive into
-25- Shaft seal 1 correct position with drive-in mandrel
vw 195 (5.5 mm below top edge of
lid).
Taper roller bearing outer ring Press in using pressure piece 30-205
-26- 1
(large) and drive-in mandrel vw 295.
Adjusting shim S1 Calculate the thickness again if
-27- X
necessary.
-28- Cover for final drive 1 Seal with Loctite 574.
Microsoft
Instructions for assembling transmission housing

Fig. 166: Measuring needle-roller bearing

1. Press in needle-roller bearing for drive shaft -10- using drive-in mandrel vw 295 and pressure piece 40-202
Microsoft
(do not drive in!). Measurement from top edge of rule to top edge of needle-roller bearing -a = 39.5 ± 0.3 mm- .
See Fig. 165, Fig. 166.
Fig. 167: Transmission vent rim offset

2. Rim offset of sleeve for transmission vent. -a = 27 ± 0.5 mm- . See Fig. 167.
3. Installation instructions for lock for 5th gear and reverse
- Insert spring -4- into plastic bushing -1- and press lightly to turn it anti-clockwise until the spring engages at
the base of the plastic part. See Fig. 168.
- Position the bushing -3- on the spring in such a way that the bent end of the spring is located in the groove
provided. See Fig. 168.
- Press the spring together with the bushing -3- , twist it on by turning it once anti-clockwise (to the left) until
the lug of the bushing -3- is located above the groove in the plastic bushing.
- Press the lug of the bushing -3- as far as it will go into the groove of the plastic bushing -1- .
- Turn the bushing -3- clockwise (to the right) and let it go.
Microsoft
Fig. 168: Lock assembly

- Bushing -3- pops into assembly end position.
1 - Plastic bushing
2 - O-ring
3 - Bushing with lock for 5th gear and reverse
4 - Spring
Microsoft
Fig. 169: Lock assembly

- The lug -A- of the bushing for 5th gear and reverse must always be positioned as far as it will go opposite the
groove -B- of the plastic bushing. See Fig. 169.
SUBSEQUENT WORK
Subsequent work
1. Assemble transmission. --> 343537 Disassembling and assembling transmission - section on

"Assembling"
34 55 37 DISASSEMBLING AND ASSEMBLING TRANSMISSION COVER - AS

TOOLS

Microsoft
pressure pieces (4) commercially 9247/1

available tool
pull-in tool and puller commercially p 254
available tool

auxiliary piece commercially vw 295 a
available tool
commercially vw 407
available tool
commercially vw 420
available tool
commercially vw 423
available tool
striker commercially vw 771

available tool
threaded piece commercially vw 771/15
available tool
PRELIMINARY WORK
Microsoft
Preliminary work

support.
DISASSEMBLING TRANSMISSION COVER
Disassembling transmission cover
Microsoft
Fig. 171: Overview of transmission cover


1 Oil collection pan 1
2 Circlip 1
3 Washer 1
4 Reverse idler gear 1
5 Needle-roller bearing 2
6 Thrust washer 1
Drive out with a suitable internal puller
7 Retaining sleeve 1
and striker vw 771.
threaded piece vw 771/15,
8 Taper roller bearing outer ring 1
commercially available thread adapter
and a suitable internal puller.
9 Adjusting shim S4 X Note the thickness for re-installation.
10 Pressure plate 1
Drill a hole and remove washer with a
11 Rubber plate 1
sheetmetal screw.
Needle-roller bearing with plastic threaded piece vw 771/15 and a
12 1
sleeve suitable internal puller. Destroy the
plastic sleeve before fitting the puller.
13 Bushing 1 threaded piece vw 771/15 and a
suitable internal puller.
14 Shaft seal 1 Lever out.
Only remove if reversing gear axle is
15 Torx screw 1
replaced.
Microsoft
Undo Torx screws and remove

16 Transmission cover 1
transmission cover
Instructions for disassembling transmission cover

Fig. 173: Knocking out outer bearing ring

Microsoft
1. Remove retaining sleeve -7- . The retaining sleeve may be destroyed when it is removed as it does not need
to be refitted (it is only required during manufacture of the transmission). See Fig. 172.
2. Remove outer bearing ring -8- with a suitable internal puller and striker vw 771. See Fig. 172.
3. To remove the rubber plate -11- , turn sheetmetal screw in rubber plate if necessary and remove rubber plate
on sheetmetal screw. See Fig. 172.
4. Remove needle-roller bearing with plastic sleeve -12- using a suitable internal puller and striker vw 771. The
plastic sleeve must be destroyed in order to position the puller. See Fig. 172.
5. Remove bushing -13- with a suitable internal puller and striker vw 771. See Fig. 172.
ASSEMBLING TRANSMISSION COVER
Assembling transmission cover


Insert until the catch engages in the
1 Oil collection pan 1 bore of the transmission cover. The
collection pan must be facing upwards.
2 Circlip 1
3 Washer 1
4 Reverse idler gear 1
5 Needle-roller bearing 2
6 Thrust washer 1
Do not re-install! This part is only
7 Retaining sleeve 1
required during production.
Microsoft
Press in using a pressure piece 3005

8 Taper roller bearing outer ring 1
and a suitable plunger (e. g. vw 407 ).
Adjusting shim S4 necessary Refer to 39 08 15 Adjusting
9 X
the drive set - as of MY 2005
10 Pressure plate 1
11 Rubber plate 1 Replace.
Always replace. Press into correct
position using auxiliary piece vw 295
Needle-roller bearing with plastic a and a suitable tubular piece (e. g. vw
12 1
sleeve 420 ). The large collar of the auxiliary
piece vw 295 a is facing the needle-
roller bearing.
Press in with pressure pieces (4)
13 Bushing 1 9247/1 and pull-in tool and puller p
254.
Fill the space between the dust and
sealing lips with multipurpose grease
14 Shaft seal 1
and drive in with a suitable tubular
piece (e. g. vw 423 ).
15 Torx screw 1 Tightening torque: 35 Nm (26 ftlb.)
If the transmission cover is replaced,
calculate the thickness of the adjusting
16 Transmission cover 1 shim S4 again --> Seal with Loctite
574.
Instructions for assembling transmission cover

Microsoft

1. Fill the shaft seal -14- between the dust and sealing lips with multipurpose grease and drive in with a suitable
tubular piece (e. g. vw 423 ). Observe the correct drive-in depth -a = 1 mm- . See Fig. 176.
NOTE:  The needle-roller bearing and plastic sleeve must always be replaced.
2. Press in bushing -13- as far as the stop with pressure pieces (4) 9247/1 and pull-in tool and puller p 254.
Microsoft
Fig. 177: Drive-in depth for needle-roller bearing

3. Press needle-roller bearing and plastic sleeve -12- into correct position using auxiliary piece vw 295 a and a
suitable tubular piece (e. g. vw 420 ). The large collar of the auxiliary piece vw 295 a is facing the needle-roller
bearing. Observe the correct drive-in depth -a = 216- . See Fig. 177.
Microsoft
Fig. 178: Pressing in outer bearing ring

4. Press in outer bearing ring -8- with a pressure piece 3005 and a suitable extension. See Fig. 175.
5. Fit transmission cover -16- . To do this, coat cover sealing surfaces lightly with Loctite 574 and screw in
Torx screws. See Fig. 175.

SUBSEQUENT WORK
Subsequent work
Microsoft
TRANSMISSION Manual - Gears, shafts, internal gears
TRANSMISSION
Manual - Gears, shafts, internal gears
35 31 19 REMOVING AND INSTALLING SHIFT CONTROL LOCK DEVICE -

RHD)
TOOLS

press-in tool special tool P 9225/1
puller VW-tool T40054
striker VW-tool VW 771/1
PRELIMINARY WORK
Preliminary work

Models) .
REMOVING SHIFT CONTROL LOCK DEVICE
Removing shift control lock device
Microsoft

1. Unscrew fastening screw between transmission bracket and transmission housing and remove transmission
bracket.
Microsoft
Fig. 2: Removing lock device

2. Remove gearshift lock device from the transmission housing using a Striker VW 771/1 and Puller T40054 ,
see Tools.
Microsoft

3. Remove selector lock device from the transmission housing using a Striker VW 771/1 and Puller T40054 .
Microsoft

4. Remove shift rod lock device for 5th/6th gear from the transmission housing using a Striker VW 771/1 and
Puller T40054 , see Tools.

5. Remove shift rod lock device for 3rd/4th gear from the transmission housing using a Striker VW 771/1 and
Puller T40054 .
Microsoft

6. Remove shift rod lock device for 1st/2nd gear from the transmission housing using a Striker VW 771/1 and
Puller T40054 , see Tools.
Microsoft

7. Remove shift rod lock device for reverse gear from the transmission housing using a Striker VW 771/1 and
Puller T40054 .
INSTALLING SHIFT CONTROL LOCK DEVICE
Installing shift control lock device
Microsoft
Fig. 8: Driving in lock device

1. Drive shift rod lock device for reverse gear into the transmission housing, as far as it will go, using a Press-in
tool P 9225/1 . See Tools.
Microsoft

2. Drive shift rod lock device for 1st/2nd gear into the transmission housing, as far as it will go, using a Press-in
tool P 9225/1 .
Microsoft

3. Drive shift rod lock device for 3rd/4th gear into the transmission housing, as far as it will go, using a Press-in
tool P 9225/1 . See Tools.
Microsoft

4. Drive shift rod lock device for 5th/6th gear into the transmission housing, as far as it will go, using a Press-in
tool P 9225/1 .
Microsoft

5. Drive selector lock device into the transmission housing, as far as it will go, using a Press-in tool P 9225/1 .
See Tools.
Microsoft

6. Drive gearshift lock device into the transmission housing, as far as it will go, using a Ppress-in tool P
9225/1 .
Microsoft

7. Screw in fastening screw between transmission bracket and transmission housing.

value 1 2
Transmission Fastening screws between transmission Tightening 45 (33
bracket bracket and transmission housing torque ftlb.) Nm
SUBSEQUENT WORK
Subsequent work

Models) .
35 40 15 ADJUSTING THE DRIVE SHAFT - AS OF MY 2005 (BOXSTER,

BOXSTER RHD)
TOOLS

driver sleeve VW-tool 30-100
Microsoft
measuring bridge VW-tool 3167

PRELIMINARY WORK
Preliminary work

Models) .

Microsoft
2. Tighten the transmission using Engine support P 9589 or Engine and gear support VW 540 at the
assembly support. See Tools.
RHD) .

ADJUSTING THE DRIVE SHAFT
Adjusting the drive shaft
1. Clamp the drive shaft in the vice with protective jaws.
Fig. 16: Measuring bridge

2. Put the Measuring bridge 3167 onto the 3rd gear and position the transmission housing on the special tool
via the drive shaft. See Tools.
A - Measuring bridge 3167
Microsoft
Fig. 17: Dimension a

3. With a depth gauge, measure the dimension -a- from the housing to the lower drive shaft groove (e. g.
dimension a =28.5 mm). See Fig. 17.
Microsoft
Fig. 18: Dimension b

4. With a depth gauge, measure the dimension -b- from the housing to the contact surface of the ball bearing (e.
g. dimension b =26.8 mm). See Fig. 18.
5. Determine dimension x for the thickness of the lower circlip (see No. 8 in Refer to 34 35 37 Disassembling
and assembling transmission - as of MY 2005 (Boxster, Boxster RHD) .).
Sample calculation of dimension x
x = a - b = 28.5 mm - 26.8 mm = 1.7 mm
6. Determine the thickness of the circlip in accordance with the table.
Dimension x (in mm) Thickness of circlip (in mm)

1.48 ... 1.56 1.54
1.57 ... 1.65 1.63
1.66 ... 1.74 1.72
1.75 ... 1.83 1.81
1.84 ... 1.92 1.80
1.93 ... 2.01 1.99
2.02 ... 2.10 2.08
2.11 ... 2.20 2.17
Microsoft
2.21 ... 2.27 2.25

2.28 ... 2.35 2.33
7. Force circlip and ball bearing onto the drive shaft with the Driver sleeve 30-100 . See Tools.
Fig. 19: Circlip

8. Determine and use the thickest circlip that can still be used.
SUBSEQUENT WORK
Subsequent work

RHD) .

Models) .
Microsoft
35 40 37 DISASSEMBLING AND ASSEMBLING THE DRIVE SHAFT - AS OF

MY 2005 (BOXSTER, BOXSTER RHD)
TOOLS

PRELIMINARY WORK
Preliminary work

Models) .

Microsoft
RHD) .

DISASSEMBLING THE DRIVE SHAFT
Removing drive shaft
Fig. 21: Overview of drive shaft


-1- Circlip 1 Mark for re-installation.
Press off above loose gear wheel for 4th
-2- Fixed gear wheel, 5th gear 1
gear.
-3- Needle-roller bearing 1 Mark for re-installation.
-4- Loose gear wheel, 4th gear 1
-5- Synchronizer ring, 4th gear 1 Mark for re-installation.
-6- Operating sleeve 1
-7- Blue circlip 1 Mark for re-installation.
-8- Synchronizing hub 1 Press off.
-9- Synchronizer ring, 3rd gear 1 Mark for re-installation.
-10- Loose gear wheel, 3rd gear 1
-11- Brown circlip 1 Mark for re-installation.
-13- Drive shaft 1
Microsoft

Refer to 34 35 37 Disassembling and
-15- Ball bearing 1 assembling transmission - as of MY
-17- Needle-roller bearing 1 assembling transmission housing - as
of MY 2005 (Boxster, Boxster RHD) .
-19- Needle-roller bearing 1 assembling transmission cover - as of
-20- Plastic sleeve 1 assembling transmission cover - as of
-21- Transmission cover 1
Removal instructions for drive shaft
NOTE: Circlips of different sizes and thicknesses are used. For this reason, the
individual circlips must be marked (e. g. with numbers). The thickness of the
circlip must be determined again if a directly affected component is replaced.
Fig. 22: Pressing off gear wheel

Microsoft
1. Press off fixed gear wheel for 5th gear -as shown in illustration- . See Fig. 22.
Fig. 23: Pressing off synchronizing hub

2. Press synchronizer ring for 3rd gear -Arrow- to the loose gear wheel for 3rd gear. See Fig. 23.
3. Press off synchronizing hub for 3rd and 4th gear -as shown in illustration- . See Fig. 23.
ASSEMBLING THE DRIVE SHAFT
Fitting drive shaft
Microsoft
Fig. 24: Overview of drive shaft


Calculate thickness of circlip again if
-1- Circlip 1 the drive shaft and fixed gear wheel for
5th gear are replaced.
Heat to approx. 100 °C and press on in
-2- Fixed gear wheel, 5th gear 1
the correct position.
Fit with loose gear wheel for 4th gear -
4- .
-4- Loose gear wheel, 4th gear 1 Insert spring before assembly.
Check for wear and fit with loose gear
-5- Synchronizer ring, 4th gear 1
wheel for 4th gear -4- .
Observe installation position; fit
operating sleeve so that the slant is
facing 4th gear and the offset side is
facing 3rd gear.
Calculate thickness of circlip again if
-7- Blue circlip 1 the drive shaft and synchronizing hub -
8- are replaced.
Heat to approx. 100 °C and press on
-8- Synchronizing hub 1 (high collar facing loose gear wheel for
3rd gear).
Check for wear and fit with loose gear
-9- Synchronizer ring, 3rd gear 1
wheel for 3rd gear -10- .
-10- Loose gear wheel, 3rd gear 1 Insert spring before assembly.
-11- Brown circlip 1 Always use the same thickness!
Microsoft
-12- Needle-roller bearing 1 Fit with loose gear wheel for 3rd gear.
If the drive shaft and ball bearing -15-
are replaced, the circlips -14- and -16-
-13- Drive shaft 1
must be measured again. --> 354015
Adjusting the drive shaft
-14- Circlip 1 necessary. --> 354015 Adjusting the
drive shaft
-15- Ball bearing 1 assembling transmission - as of MY
-16- Circlip 1 necessary. --> 354015 Adjusting the
drive shaft
-17- Needle-roller bearing 1 assembling transmission - as of MY
-19- Needle-roller bearing 1 assembling transmission cover - as of
-20- Plastic sleeve 1
-21- Transmission cover 1 assembling transmission cover - as of
Assembly instructions for drive shaft
All transmission parts, particularly synchronization parts, must always be
coated with transmission oil before assembly. Avoid assembling dry parts.
1. Check the synchronizer rings for wear.
 Push ring into shift sleeve.

 Measure gap dimension -a- with a feeler gauge in positions -A, B and C- . See Fig. 25.
 Add up the measured values and divide by three. The value obtained must not be less than 0.5 mm.
Microsoft
Fig. 25: Checking synchronization

Fig. 26: Inserting spring
Microsoft
2. Insert the spring into the loose gear wheel so that the angled end engages in the bore.
Fig. 27: Operating sleeve

3. Fit operating sleeve so that the slant -1- is facing 4th gear and the offset side -2- is facing 3rd gear. See Fig.
27.
Microsoft
Fig. 28: Determining circlip

4. Determine the circlip for 4th gear. To do this, determine the thickest ring that can still be used.
5. Determine the circlip for 5th gear in the same way as for 4th gear.
Microsoft
Fig. 29: Pressing on synchronizing hub

6. Heat the synchronizing hubs for 3rd and 4th gear to approx. 100 °C and press onto the drive shaft. The high
collar is facing the loose gear wheel for 3rd gear.
Microsoft
Fig. 30: Pressing on fixed gear wheel

7. Heat the fixed gear wheel for 5th gear to approx. 100 °C and press onto the drive shaft. The high collar is
facing reverse gear and the oil pockets are facing 4th gear.
SUBSEQUENT WORK
Subsequent work

RHD) .

Models) .
35 50 19 REMOVING AND INSTALLING SEALING RING FOR INPUT SHAFT -

RHD)
Microsoft
TOOLS

PRELIMINARY WORK
Preliminary work
1. Remove transmission. --> 21 Removing and installing transmission - removing
2. Remove guide sleeve. Refer to 30 47 19 Removing and installing guide sleeve - as of MY 2005 (Boxster S,
REMOVING SEALING RING FOR INPUT SHAFT
Removing sealing ring for drive shaft

1. Press guide sleeve on sufficiently and drive sealing ring out of the guide sleeve using a punch.
INSTALLING SEALING RING FOR INPUT SHAFT
Microsoft
Installing sealing ring for drive shaft
Fig. 32: Positioning sealing ring

1. Place new sealing ring on side of Pressure piece P 9743 with a cut-out. See Tools.
Microsoft

2. Tap sealing ring into the guide sleeve using a rubber hammer.
SUBSEQUENT WORK
Subsequent work
1. Install guide sleeve. Refer to 30 47 19 Removing and installing guide sleeve - as of MY 2005 (Boxster S,
2. Install transmission. --> 23 Removing and installing transmission - installing
35 50 19 REMOVING AND INSTALLING SEALING RING FOR INPUT SHAFT -

TOOLS

PRELIMINARY WORK
Preliminary work
Microsoft
1. Remove transmission. --> 21 Removing and installing transmission - removing
2. Remove guide sleeve. Refer to 30 47 19 Removing and installing guide sleeve - as of MY 2005 (Boxster,
Boxster RHD) .
REMOVING SEALING RING FOR INPUT SHAFT
Removing sealing ring for drive shaft

1. Press guide sleeve on sufficiently and drive sealing ring out of the guide sleeve using a punch.
INSTALLING SEALING RING FOR INPUT SHAFT
Microsoft

1. Place new sealing ring on side of Pressure piece P 9743 with no cut-out. See Tools.
Microsoft


1. Place new sealing ring on side of Pressure piece P 9743 with a cut-out. See Tools.
Microsoft

SUBSEQUENT WORK
Subsequent work
1. Install guide sleeve. Refer to 30 47 19 Removing and installing guide sleeve - as of MY 2005 (Boxster,
Boxster RHD) .
2. Install transmission. --> 23 Removing and installing transmission - installing
35 59 37 DISASSEMBLING AND ASSEMBLING THE OUTPUT SHAFT - AS

TOOLS

special tool VW-tool 30-100
Microsoft

pressure plate commercially VW 401
available tool
pressure plate commercially VW 402

available tool
special tool commercially VW 415a

available tool
PRELIMINARY WORK
Preliminary work

Models) .
Microsoft

RHD) .

DISASSEMBLING THE OUTPUT SHAFT
Removing output shaft
Microsoft
Fig. 40: Overview of output shaft


Press off via the reverse gear wheel
-1- Taper roller bearing 1 using a suitable separating device (e. g.
Kukko 17/2).
-2- Loose gear wheel, reverse gear 1
-3- Synchronizer ring 1 Mark for re-installation.
Press off together with loose gear wheel
-7- Synchronizing hub 1 for 5th gear using a suitable separating
device (e. g. Kukko 17/2).
-8- Synchronizing ring, 5th gear 1 Mark for re-installation.
-9- Loose gear wheel, 5th gear 1
-10- Brown circlip 1 Mark for re-installation.
-13- Fixed gear wheel, 4th gear 1 Press off with pressure plate VW 402.
-15- Fixed gear wheel, 3rd gear 1 Press off with pressure plate VW 402.
-16- Loose gear wheel, 2nd gear 1
-17- Friction ring, 2nd gear 1 Mark for re-installation.
-18- Synchronizer ring, 2nd gear 1 Mark for re-installation.
Microsoft

Press off together with loose gear wheel
-23- Synchronizing hub 1 for 1st gear using a suitable separating
device (e. g. Kukko 17/2).
-24- Synchronizer ring, 1st gear 1 Mark for re-installation.
-25- Cone ring, 1st gear 1 Mark for re-installation.
-26- Friction ring, 1st gear 1 Mark for re-installation.
-27- Loose gear wheel, 1st gear 1
Press off with taper roller bearing outer
-30- Taper roller bearing 1 ring and pressure plate VW 401 and
pressure plate VW 402.
-31- Output shaft 1
-32- Taper roller bearing outer ring 1 assembling transmission housing - as
-33- Adjusting shim S3 X assembling transmission housing - as
-34- Retaining sleeve 1 assembling transmission cover - as of
-35- Taper roller bearing outer ring 1 assembling transmission cover - as of
-36- Adjusting shim S4 X assembling transmission cover - as of
-37- Pressure plate 1 assembling transmission cover - as of
-38- See
Rubber washer 1 assembling transmission cover - as of
Fig. 40.
-39- See
Transmission cover 1 assembling transmission cover - as of
Fig. 40.
-40- See
Transmission housing 1 assembling transmission housing - as
Fig. 40.
Microsoft
Removal instructions for output shaft
When replacing the taper roller bearings, determine the installation position
before removing the output shaft (actual measurement Refer to 39 08 15
Adjusting the drive set - as of MY 2005 (Boxster, Boxster RHD) .).
Fig. 41: Taper roller bearing

1. Use the outer bearing ring -A- to press off the taper roller bearing. See Fig. 41.
ASSEMBLING THE OUTPUT SHAFT
Assembling the output shaft
Microsoft
Fig. 42: Overview of output shaft


using a suitable tubular piece (e. g.
-1- Taper roller bearing 1
special tool 30-100). Press again after
heat exchange.
-2- Loose gear wheel, reverse gear 1 Insert spring before assembly.
Check for wear. Fit with the same gear
-3- Synchronizer ring 1 wheel (press off taper roller bearing -
use the outer ring to do this).
Install operating sleeves in correct
position. The slanted side is facing the
loose gear wheel for reverse gear in the
case of the operating sleeve for 5th and
reverse gear. The slanted side is facing
the loose gear wheel for 2nd gear in the
case of the operating sleeve for 1st and
2nd gear.
Always fit with loose gear wheel for
reverse gear.
-6- Blue circlip 1 Calculate again if necessary.
Heat to approx. 100 °C and press on.
-7- Synchronizing hub 1 The high collar is facing the loose gear
wheel for 5th gear.
Check for wear. Fit with the same gear
-8- Synchronizer ring, 5th gear 1 wheel (press off taper roller bearing -
use the outer ring to do this).
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-9- Loose gear wheel, 5th gear 1 Insert spring before assembly.
-10- Brown circlip 1 Must always be 2.00 mm thick.
5th gear.
-12- Circlip 1 Calculate again if necessary.
-13- Fixed gear wheel, 4th gear 1 the correct position so that the groove
and high collar are facing 3rd gear.
-14- Circlip 1 Calculate again if necessary.
-15- Fixed gear wheel, 3rd gear 1 the correct position so that the groove is
facing 4th gear.
-16- Loose gear wheel, 2nd gear 1 Insert spring before assembly.
Check for wear with synchronizer ring
-17- Friction ring, 2nd gear 1
fitted.
Check for wear with friction ring fitted.
-18- Synchronizer ring, 2nd gear 1
Fit with gear wheel for 2nd gear.
-19- Operating sleeve 1 Slant is facing 2nd gear.
2nd gear.
-21- Blue circlip 1 Must always be 2.5 mm thick.
-22- Blue circlip 1 Calculate again if necessary.
Heat to approx. 100 °C and press on.
-23- Synchronizing hub 1 The high collar is facing the loose gear
wheel for 2nd gear.
Check for wear with friction ring and
-24- Synchronizer ring, 1st gear 1
cone ring fitted.
Check for wear with friction ring and
-25- Cone ring, 1st gear 1
cone ring fitted.
Check for wear with cone ring and
-26- Friction ring, 1st gear 1
synchronizer ring fitted.
-27- Loose gear wheel, 1st gear 1 Insert spring before assembly.
Always fit with loose gear wheel for 1st
gear.
Always fit with loose gear wheel for 1st
-29- Circlip 1
gear.
using a suitable tubular piece (e. g.
-30- Taper roller bearing 1
special tool VW 415a). Press again
after heat exchange.
This is paired with the crown wheel
-31- Output shaft 1 (drive set). Re-adjust if replaced. Refer
to 39 08 15 Adjusting the drive set -
Microsoft
RHD) .
-32- Taper roller bearing outer ring 1 assembling transmission housing - as
-33- Adjusting shim S3 X assembling transmission housing - as
-34- Retaining sleeve 1 assembling transmission cover - as of
-35- Taper roller bearing outer ring 1 assembling transmission cover - as of
-36- Adjusting shim S4 X assembling transmission cover - as of
-37- Pressure plate 1 assembling transmission cover - as of
-38- See
Rubber washer 1 assembling transmission cover - as of
Fig. 42.
-39- See
Transmission cover 1 assembling transmission cover - as of
Fig. 42.
-40- See
Transmission housing 1 assembling transmission housing - as
Fig. 42.
Assembly instructions for output shaft
NOTE: All transmission parts, particularly synchronization parts, must always be

coated with transmission oil before assembly. Avoid assembling dry parts.
Microsoft
Fig. 43: Check synchronization.

1. Check triple-cone synchronization (1st gear) for wear. To do this, press the friction ring, cone ring and
synchronizer ring onto the gear wheel and measure the gap dimension with a feeler gauge.
Installation dimension (new): 1.4 to 2.0 mm

Wear dimension: 0.6 mm
Microsoft
Fig. 44: Check synchronization.

2. Check double-cone synchronization (2nd gear) for wear. To do this, press the friction ring and synchronizer
ring firmly onto the gear wheel by hand and measure the gap dimension with a feeler gauge.
Installation dimension (new): 1.4 to 2.0 mm

Wear dimension: 0.6 mm
3. Check single-cone synchronization for wear.
 Push ring into shift sleeve.

 Measure gap dimension -a- with a feeler gauge in positions -A, B and C- . See Fig. 45.
 Add up the measured values and divide by three. The value obtained must not be less than 0.5 mm.
Microsoft
Fig. 45: Checking synchronization

Fig. 46: Inserting spring
Microsoft
4. Insert the spring into the loose gear wheel so that the angled end engages in the bore.
Fig. 47: Operating sleeve

5. Install operating sleeves in correct position. The slanted side -1- is facing the loose gear wheel for reverse
gear in the case of the operating sleeve for 5th and reverse gear. The slanted side is facing the loose gear wheel
for 2nd gear in the case of the operating sleeve for 1st and 2nd gear. See Fig. 47.
Microsoft
Fig. 48: Inserting circlip

6. Determine the circlip for the taper roller bearing. To do this, determine the thickest ring that can still be used.
7. Determine the other circlips in the same way.
Microsoft
Fig. 49: Circlips for output shaft

NOTE: The thickness of circlips 1, 2, 4, 5 and 7 must be calculated again. Circlips 3 and
6 always have the same thickness. Circlip 3 is 2.5 mm and circlip 6 is 2.0 mm
thick.
Arrangement of the circlips:
SUBSEQUENT WORK
Subsequent work

Microsoft
RHD) .

Models) .
Microsoft
2007 SYSTEM WIRING DIAGRAMS Porsche - Boxster
2007 SYSTEM WIRING DIAGRAMS
Porsche - Boxster
USING MITCHELL1'S WIRING DIAGRAMS

For information on using these wiring diagrams, see USING MITCHELL1'S SYSTEM WIRING
DIAGRAMS article.
ACTIVE BODYWORKS
Microsoft
Microsoft
Fig. 1: Active Bodyworks Circuit
AIR CONDITIONING
Microsoft
Microsoft
Fig. 2: Automatic A/C Circuit (1 of 2)
Microsoft
Microsoft
Fig. 3: Automatic A/C Circuit (2 of 2)
ANTI-LOCK BRAKES
Microsoft
Microsoft
Fig. 4: Anti-lock Brakes Circuit
ANTI-THEFT
Microsoft
Microsoft
Fig. 5: Anti-theft Circuit
BODY CONTROL MODULES
Microsoft
Microsoft
Fig. 6: Front Controller Circuit
Microsoft
Microsoft
Fig. 7: On-Board Computer Circuit
Microsoft
Microsoft
Fig. 8: Rear Control Unit Circuit
COMPUTER DATA LINES
Microsoft
Microsoft
Fig. 9: Computer Data Lines Circuit
COOLING FAN
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Microsoft
Fig. 10: Cooling Fan Circuit
CRUISE CONTROL
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Microsoft
Fig. 11: Cruise Control Circuit
DEFOGGERS
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Microsoft
Fig. 12: Defogger Circuit
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Microsoft
Fig. 13: Heated Mirrors Circuit
ELECTRONIC SUSPENSION
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Microsoft
Fig. 14: Electronic Suspension Circuit
ENGINE PERFORMANCE
2.7L
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Microsoft
Fig. 15: 2.7L, Engine Performance Circuit (1 of 3)
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Microsoft
Microsoft
Microsoft
3.2L
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Microsoft
Microsoft
Microsoft
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Microsoft
EXTERIOR LIGHTS
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Microsoft
Fig. 21: Back-up Lamps Circuit
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Microsoft
Fig. 22: Exterior Lamps Circuit (1 of 2)
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Microsoft
Fig. 23: Exterior Lamps Circuit (2 of 2)
GROUND DISTRIBUTION
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Microsoft
Fig. 24: Ground Distribution Circuit (1 of 4)
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Microsoft
Microsoft
Microsoft
Microsoft
Microsoft
HEADLIGHTS
Microsoft
Microsoft
Fig. 28: Headlights Circuit, W/ Halogen Lamps
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Microsoft
Fig. 29: Headlights Circuit, W/ Xenon Lamps
HORN
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Microsoft
Fig. 30: Horn Circuit
INSTRUMENT CLUSTER
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Microsoft
Fig. 31: Instrument Cluster Circuit
INTERIOR LIGHTS
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Microsoft
Fig. 32: Interior Lights Circuit (1 of 2)
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Microsoft
Fig. 33: Interior Lights Circuit (2 of 2)
MEMORY SYSTEMS
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Fig. 34: Memory Mirrors Circuit
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Microsoft
Fig. 35: Memory Seat Circuit (1 of 2)
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Microsoft
Fig. 36: Memory Seat Circuit (2 of 2)
NAVIGATION
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Microsoft
Fig. 37: Navigation Circuit, W/ Bose (1 of 2)
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Microsoft
Fig. 38: Navigation Circuit, W/ Bose (2 of 2)
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Microsoft
Fig. 39: Navigation Circuit, W/O Bose (1 of 2)
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Microsoft
Fig. 40: Navigation Circuit, W/O Bose (2 of 2)
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Fig. 41: Parking Assistant Circuit
POWER DISTRIBUTION
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Fig. 42: Power Distribution Circuit (1 of 4)
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Microsoft
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POWER DOOR LOCKS
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Microsoft
Fig. 46: Power Door Locks Circuit (1 of 2)
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Microsoft
Fig. 47: Power Door Locks Circuit (2 of 2)
POWER MIRRORS
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Microsoft
Fig. 48: Auto Anti-dazzling Mirror Circuit
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Microsoft
Fig. 49: Power Mirror Circuit
POWER SEATS
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Microsoft
Fig. 50: Driver Power Seat Circuit
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Microsoft
Fig. 51: Heated Seats Circuit
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Microsoft
Fig. 52: Passenger Power Seat Circuit
POWER TOP/SUNROOF
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Fig. 53: Convertible Top Circuit
POWER WINDOWS
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Fig. 54: Power Windows Circuit
RADIO
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Microsoft
Fig. 55: Radio Circuit, W/ Bose W/O Navigation (1 of 2)
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Microsoft
Fig. 56: Radio Circuit, W/ Bose W/O Navigation (2 of 2)
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Microsoft
Fig. 57: Radio Circuit, W/ Navigation, W/ Bose (1 of 2)
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Fig. 58: Radio Circuit, W/ Navigation, W/ Bose (2 of 2)
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Fig. 59: Radio Circuit, W/ Navigation, W/O Bose (1 of 2)
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Fig. 60: Radio Circuit, W/ Navigation, W/O Bose (2 of 2)
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Microsoft
Fig. 61: Radio Circuit, W/O Bose W/O Navigation
SHIFT INTERLOCK
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Microsoft
Fig. 62: Shift Interlock Circuit
STARTING/CHARGING
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Fig. 63: Charging Circuit
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Microsoft
Fig. 64: Starting Circuit
SUPPLEMENTAL RESTRAINTS
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Fig. 65: Supplemental Restraints Circuit (1 of 2)
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Fig. 66: Supplemental Restraints Circuit (2 of 2)
TRANSMISSION
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Fig. 67: A/T Circuit (1 of 2)
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Microsoft
Fig. 68: A/T Circuit (2 of 2)
TRUNK, TAILGATE, FUEL DOOR
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Microsoft
Fig. 69: Trunk, Tailgate, Fuel Door Circuit
WARNING SYSTEMS
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Microsoft
Fig. 70: Tire Pressure Monitoring Circuit
WIPER/WASHER
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Microsoft
Fig. 71: Wiper/Washer Circuit, W/ Rain Sensor
Microsoft
Microsoft
Fig. 72: Wiper/Washer Circuit, W/O Rain Sensor
Microsoft

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Porsche Boxster 987

Maintenance, Self Diagnostics

03 TEST DRIVE - AS OF MY 2005 (ALL MODELS)

The following test items are included in the test drive.

- Actuate remote control of central locking and check operation.

- Seats: check operation of adjustments.

- Check footbrake operation and actuation travel.

- Start engine, check operation.

- Actuate clutch, check operation.

- Actuate steering, check operation.

- Shift transmission, check operation.

- ParkAssist: select reverse gear and check operation.

- Check operation of heating adjustment when engine is warm.

- Check operation of air-conditioning system when engine is running.

- Check operation of instruments.

03 IN RUNNING GEAR MAINTENANCE: VISUAL INSPECTION OF BRAKE

Brake hoses and lines

 Injury and material damage due to impaired braking effect.

--> Brake discs must be replaced on reaching the wear limits.

Fig. 1: Checking brake pads

Designation Type Note, dimensions Wear limit

Boxster/Boxster S approx. 12 mm approx. 2 mm

03 IN RUNNING GEAR MAINTENANCE: AXLE JOINTS/DRIVE SHAFTS - AS

Axle joints: checking play and dust boots

2. Visually inspect the dust boots for damage.

The procedure for the front axle is as follows:

 Turn the front wheels as far as they will go

Drive shafts: visual inspection of boots

- Perform a visual inspection of the boots for leaks and damage.

03 IN RUNNING GEAR MAINTENANCE: STEERING GEAR - VISUAL

- Visually inspect bellows for damage.

Tie rod ends: check play and dust bellows

2. Check play and dust bellows.

03 IN ADDITIONAL MAINTENANCE - AS OF MY 2005 (ALL MODELS)

Maintenance every 2 years

Maintenance every 2 years OK

Maintenance every 4 years

Maintenance every 4 years OK

Maintenance after 4 then every 2 years

Maintenance after 4 then every 2 years OK

Maintenance after 4, 8, 10 then every 2 years

Maintenance after 4, 8, 10 then every 2 years OK

03 24 00 MINOR MAINTENANCE - AS OF MY 2005 (ALL MODELS)

Minor maintenance at:

03 26 00 MAJOR MAINTENANCE - AS OF MY 2005 (ALL MODELS)

maintenance must be carried out after 4, 8, 12...... years.

03 35 00 ON-BOARD DIAGNOSIS (OBD) - AS OF MY 2005 (ALL MODELS)

Designation Type Number Explanation

READING OUT AND ERASING FAULT MEMORY

Reading out and erasing fault memory

 Damage to control units.

Fig. 2: Diagnostic socket

03 60 00 ADDITIONAL MAINTENANCE OF DRIVE BELT - AS OF MY 2005

Additional maintenance - checking drive belt OK

03 81 00 ADDITIONAL MAINTENANCE OF SPARK PLUGS - AS OF MY 2005

Additional maintenance for spark plugs

Additional maintenance, replacing spark plugs OK

03 83 00 ADDITIONAL MAINTENANCE EVERY 90,000 KM/60.000 MLS OR

Additional maintenance every 90,000 km/60,000 mls or every 6 years OK

03 88 00 ADDITIONAL MAINTENANCE EVERY 180,000 KM/120.000 MLS OR

Additional maintenance every 180,000 km/120,000 mls or every 12 years

Additional maintenance every 180,000 km/120,000 mls or every 12 years OK

Additional maintenance every 180,000 km/120,000 mls or every 12 years