brake PORSCHE BOXSTER 2007 2.G Service Manual

Headlights,lights,interiorandexterior
plasticparts,adhesivelms
Useonlycleanwaterandalittledishwashingdetergenttocleanlightlenses,plasticheadlightlenses,plasticpartsandsurfaces.Donotcleanwhendry.Useasoftspongeorasoft,lint-freecloth.Gentlywipethesurfacewithoutapplyingtoomuchpressure.ThePorscheinsidewindowcleanerisalsosuitableforcleaningplasticsurfaces.Followthecleaninginstructionsonthecontainer.Neveruseotherchemicalcleanersorsolvents.
Rinsecleanedsurfaceswithclearwater.
Lightalloywheels
Pleaseobservethechapter”WASHING”onpage233.
Warning!
Dangerofaccidentresultinginseriouspersonalinjuryordeathifcleaningagents(e.g.wheelcleaningagents)comeintocontactwiththebrakediscs.Theresultinglmonthebrakediscscanimpairbrakingperformance.
Makesurethatnocleaningagentcomesintocontactwiththebrakediscs.
Ifcleaningagenthascomeintocontactwiththebrakediscs,thoroughlycleanthebrakediscswithastrongjetofwater.
Payingattentiontoanyroadusersbehindyou,drythebrakediscsbyapplyingthebrakesatshortintervals.
Pittingmayoccurifmetallicparticleswhichcausecontactcorrosion(e.g.brassorcopperinbrakedust)areallowedtoremainonthealuminumfortoolong.
Ifpossible,washthewheelswithaspongeorwashbrushabouteverytwoweeks.Inareaswheresaltisspreadonwinterroadsorthereisalotofairborneindustrialdust,itisbesttocleanthewheelsweekly.ThePorscheLightAlloyWheelCleaner(ph-value9.5)canbeusedforthispurpose.Iftheph-valueofthedetergentisincorrect,theprotectivecoatingonthewheelswillbedestroyed.
Polisheswhichdissolveoxides,suchasthosefrequentlyusedforothermetals,orabrasivetoolsoragentsareunsuitablebecausetheybreakdowntheoxidelmoftheprotectivecoatingandwillcausediscolorationofthewheel.
Everythreemonths,aftercleaning,coatthewheelswithacarwaxornon-corrosivegrease(vaseline).Usingacleancloththoroughlyrubthegreaseintothesurface.
Leather
Characteristicsandspecialfeatures
Thenaturalsurfacemarkingsofleather,e.g.creases,healedscars,insectstingmarks,structuraldifferencesandslightvariationsinshadeandgrainaddtotheattractivenessofthenaturalleatherproduct.
Aspecialmentionmustbemadehereofnaturalleather.Fornaturalleather,carefullyselectedhidesofthehighestqualityareused.Itisnotcoveredcompletelywithdyeonproduction.“Nature’ssignature”isthereforeeasilyrecognizable.Thisfinematerialisdistinguishedbyanoutstandingseatingcomfort,specialsupplenessandatypicalpatina.
Leathercareandtreatment
Cleanalltypesofleatherregularlytoremovefinedustusingasoft,damp,whitewoolenclothoracommerciallyavailablemicrofibercloth.
RemoveheavycontaminationwithPorscheleathercleaner.Pleasealwaysfollowtheinstructionsforusegivenonthecontainers.
Causticcleanersandhardcleaningobjectsmustnotbeused.
Perforatedleathermustundernocircum-stancesgetwetonitsreverseside.
238Maintenance,CarCare

PracticalTips,EmergencyService
ExerciseExtremeCautionwhenWorkingonyourVehicle.......................................................242Tires/Wheels..............................................243LoadingInformation.....................................254FlatTire......................................................256LiftingtheVehicle........................................258WheelBolts................................................260Changingawheel........................................261Spacers.....................................................263ElectricalSystem........................................265Battery.......................................................268EmergencyStartingwithJumperCables........273Replacingbulbs...........................................275Headlights..................................................277Turnsignallight...........................................281Sidemarkerlight.........................................283Taillight......................................................284Additionalbrakelight...................................284Licenseplatelights......................................285Luggagecompartment/footwelllights...........286Interiorlight................................................287Doorguard/curblight..................................288AdjustingHeadlights....................................289Towing.......................................................292
PracticalTips,EmergencyService241

ExerciseExtremeCautionwhen
WorkingonyourVehicle
Danger!
Ignoringthefollowinginstructionsmaycauseseriouspersonalinjuryordeath.
Theenginecompartmentofanymotorvehicleisapotentiallyhazardousarea.Ifyouarenotfullyfamiliarwithproperrepairprocedures,donotattempttheadjustmentsdescribedonthefollowingpages.Thiscautionappliestotheentirevehicle.
Onlyworkonyourvehicleoutdoorsorinawellventilatedarea.
Ensurethattherearenoopenflamesintheareaofyourvehicleatanytimewhenfuelfumesmightbepresent.Beespeciallycautiousofsuchdevicessuchashotwaterheaterswhichigniteaflameintermittently.
Beforeworkingonanypartintheenginecom-partment,turntheengineoffandletitcooldownsufficiently.Hotenginecompartmentcomponentscanburnskinoncontact.
Bealertandcautiousaroundengineatalltimeswhiletheengineisrunning.Ifworkhastobeperformedwiththeenginerunning,alwayssettheparkingbrake,andmakesuretheshiftleverisinneutralortheselectorleverisinpositionPorN.
Inparticular,beverycarefultoensurethatitemsofclothing(ties,shirt,sleevesetc.),jewelry,longhair,handorfingerscannotgetcaughtintheengine-compartmentblower,fan,beltsorothermovingparts.Theradiatorandradiatorfansareinthefrontofthecar.Thefanscanstartorcontinuerunningasafunctionoftemperature,evenwiththeengineswitchedoff.Carryoutworkintheseareasonlywiththeengineoffandexerciseextremecaution.
YourPorscheisequippedwithanelectronicignitionsystem.Whentheignitionison,highvoltageispresentinallwiresconnectedwiththeignitionsystem;therefore,exerciseextremecautionwhenworkingonanypartoftheenginewhiletheignitionisonortheengineisrunning.
Alwayssupportyourcarwithsafetystandsifitisnecessarytoworkunderthecar.Jacksarenotsuitableforthiskindofwork.
Whenworkingunderthecarwithoutsafetystandsbutwiththewheelsontheground,makesurethecarisonlevelground,thewheelsareblocked,andthattheenginecannotbestarted.Removetheignitionkey.
Donotsmokeorallowanopenflamearoundthebatteryorfuel.Keepafireextinguisherinclosereach.
Incompleteorimproperservicingmaycauseproblemsintheoperationofthecar.Ifindoubtaboutanyservicing,haveitdonebyyourauthorizedPorschedealer.ImpropermaintenanceduringthewarrantyperiodmayaffectyourPorschewarrantycoverage.
Suppliesoffluids,e.g.engineoil,brakefluidorcoolant,arehazardoustoyourhealth.Keepthesefluidsoutofchildren’sreachanddisposeoftheminaccordancewiththeappropriateregulations.
Somecountriesrequireadditionaltoolsandspecialsparepartstobecarried.Pleasemakeenquiriesbeforedrivingabroad.
Workingintheenginecompartment
Havethenecessaryworkintheenginecompart-mentdonebyyourauthorizedPorschedealer.
242PracticalTips,EmergencyService

Tires/Wheels
TheoriginalequipmenttiresandwheelrimsonyourPorschecomplywithallapplicableFederalMotorVehicleSafetyStandards.
Foryoursafetyrememberthefollowing:
–WheelrimsandwheelboltsarematchedtofityourPorsche.
–Ifyouintendtouseotherthanoriginalequip-mentwheels,besurethattheyconformtoPorschespecificationsforyourmodel.Onlytireswiththesamemakeandwiththesamespecificationcode(e.g.“N0”,“N1”...)canbemounted.
–Theuseofwheelrimsandwheelboltsthatdonotmeetspecificationsoftheoriginalfactoryinstalledequipmentwillaffectthesafeoperationofyourvehicle.
–Beforeyouplanonexchangingwheels,orsnowtiresalreadymountedonthewheelrims,consultyourauthorizedPorschedealer.Yourdealerhasthetechnicalinformationnecessarytoadviseyouwhichwheelrimsandwheelboltsarecompatiblewiththeoriginalfactoryinstallations.
Danger!
Riskoflossofcontrolandseriouspersonalinjuryordeath.
Ifwhiledriving,yourvehicleexperiencesasuddenvibrationorridedisturbance,and/oryoususpectthatpossibledamagetoyourtiresorvehiclehasoccurred,youshouldimmediatelyreduceyourspeedwithoutexcessiveuseofthebrakes.
Stopthevehicleassoonaspossible,andinspectthetires.Ifyoucannotdeterminethecauseforthedisturbance,haveyourvehicletowedtothenearestPorscheortiredealertohaveyourvehicleortire(s)inspected.
Continuingtooperatethevehiclewithoutcorrectioncouldresultinalossofcontrolandseriouspersonalinjury.
Example
UniformTireQualityGrading
Qualitygradescanbefoundwhereapplicableonthetiresidewallbetweentreadshoulderandmaximumsectionwidth.
AllpassengercartiresmustconformtoFederalSafetyRequirementsinadditiontothesegrades.
Treadwear
Thetreadweargradeisacomparativeratingbasedonthewearrateofthetirewhentestedundercontrolledconditionsonaspecificgovernmenttestcourse.Forexample,atiregraded150would
PracticalTips,EmergencyService243

Tirewear
TheoriginalequipmenttiresonyourPorschehavebuilt-intirewearindicators.Theyaremoldedintothebottomofthetreadgroovesandwillappearasapproximately1/2in.(12mm)bandswhenthetiretreaddepthisdownto1/16ofanin.(1.6mm).
Whentheindicatorsappearintwoormoreadjacentgrooves,itistimetoreplacethetires.Werecommend,however,thatyoudonotletthetiresweardowntothisextent.Worntirescannotgriptheroadsurfaceproperlyandareevenlesseffectiveonwetroads.
IntheUnitedStates,statelawsmaygoverntheminimumtreaddepthpermissible.Followallsuchlaws.
Danger!
Drivingonworntirescanresultinlossofcontrolofthevehicleandcouldcauseseriouspersonalinjuriesordeath.
Donotdrivewithworntiresortiresshowingcutsorbruisesastheymayleadtosuddendeflationandlossofcontrolwhichcouldcauseseverepersonalinjury.
Specializedhighperformancetiresonhighperformancesportscarsexhibitmorewearthanthoseonafamilysedan,orevenahighperformancesedan.Therefore,itisimportanttocheckyourtirepressureandconditionatleasteverytwoweeks.
Ifyounoticethattiresarewearingunevenly,consultyourPorschedealer.Unevenwearmaynotalwaysbeduetoimproperwheelalignment.Itcanbetheresultofindividualdrivinghabitssuchascorneringathighspeeds.Ifthetirepressureisnotcheckedandadjustedregularly,abnormaltirewearcanalsooccur.
Tirecare
Avoiddamagingtiresandwheelrims.
Ifyoumustdriveoveracurborotherobstacle,driveslowlyandatanobtuseangle.
Checktiresforunevenwearanddamagebeforedrivingoff.
Removeimbeddedmaterial.
Replacewornordamagedtiresimmediately.
Keepoil,fuel,brakefluid,etc.awayfromtires.
Replacemissingvalvestemcaps.
Keeptiresinflatedcorrectly.
Washtireswhenwashingthevehicle.Alsocleaninnersideofwheels.
Donotuseabrasivecleanerswhenwashingthewheels.
Checkwheelrimsforcorrosion.
Removeroadsalt,ifdrivinginwinter.
Tiredamage,puncture
Checktiresforimbeddedmaterial,cuts,punctures,cracksandbulges(sidewall)beforedrivingoff.
Incaseoftiredamage,whereitisuncertainwhetherthereisabreakintheplywithallitsconsequencesortiredamagecausedbythermalormechanicaloverloadingduetolossofpressureoranyotherpriordamage,werecommendthatthetirebereplacedforsafetyreasons.
Ifonefaultytireisreplaceditshouldbenotedthatthedifferenceintreaddepthononeaxlemustnotexceed30%.Handlinginconsistenciesmayresult.
Performavisualinspectionifnecessary.
Danger!
Riskofseriouspersonalinjuryordeath.Drivingthevehiclewithlowtirepressureincreasesriskofatirefailureandresultinglossofcontrol.Furthermore,lowtirepressureincreasesrateofwearoftheaffectedtires.
Checktires-includingsidewalls-regularlyforforeignbodies,nicks,cuts,cracksandbulges.
PracticalTips,EmergencyService247

Snowchains
Caution!
Riskofdamagetobody,axleorbrakecompo-nents.
Fitsnowchainsonlytotherearwheels,andonlywiththetire/rimcombinationlistedintheTechnicalData.Toensureadequateclearancebetweenchainandbody,Porscherecommendsonlytheuseoffine-linkchainssuchasthoseapprovedbyPorsche.
Followinstructionsissuedbythesupplierofthechains.
Differentstatesandcountrieshavevaryingstatutoryrequirementsregardingmaximumspeed.Checkwithlocalauthoritiesforpossiblerestrictions.
Removechainsassoonastheroadsarefreeoficeandsnow.
Fittingsnowchains
Theuseofsnowchainsisnotpermittedwhen5mmspacersaremounted.
Caution!
Riskofdamagetothewheelhousingsifthe5mmspacersarenotremovedbeforettingsnowchains.
Topermitthefittingofsnowchains,havethe5mmspacersremovedonall4wheels.
Tofit/removethespacers:PleaseconsultanauthorizedPorschedealer.
Pleaseobservethechapter”SPACERS”onpage263.
Tiredesignations
Duetonewspeedandloadratingsforradialtires,newdesignationshavecomeintoforceforsnowtiresforyourPorsche.
ThedesignationtobeusedforZRtiresise.g.,265/40ZR18(Z=codeletterforradialtiresforspeedsabove150mph/240km/h).
PracticalTips,EmergencyService251

FlatTire
Generalinformation
Warning!
Failuretofollowtheseinstructionsmayresultinseriouspersonalinjuryordeathtoyouortobystanders.
Ifyouhaveaflattire,moveasafedistanceofftheroad.Turntheemergencyflasheronanduseotherwarningdevicestoalertothermotorists.Settheparkingbrake.
Donotparkyourvehiclewhereitmaycontactdrygrass,brushorotherflammablematerials.Thehotpartsoftheexhaustsystemcouldsetsuchmaterialsonfire,therebycausingbothpropertydamageandseriouspersonalinjuryordeath.
Atiresealantandcompressorwithpressuretesterarelocatedinthetoolboxintheluggagecompartment.
PleaseobservethesafetyandoperatinginstructionsonthespecialsealantbottlewithaspecialPorschepartnumberandonthecompressor-theseareessential.
Caution!
Sealingthetirewiththetirerepairkitisonlyanemergencyrepair.Evenwiththetireair-tight,itmaybeusedonlyforshorttripsinanemergency.Themaximumpermittedspeedis50mph(80km/h).
Donotusecommerciallyavailablesealantortireinflatingbottles.Useonlythetiresealantlocatedintheluggagecompartment.
Warning!
Riskofaccidentresultinginseriouspersonalinjuryordeath.
Havetiresreplacedbyaspecialistworkshopassoonaspossible.
Avoidhardaccelerationandhighcorneringspeeds.
A-FillerbottleB-Fillerhose
Tiresealant
Usage
Thetiresealantcanbeusedtosealsmallcuts,especiallyinthetiretread.
Sealingthetirewiththetiresealantisonlyanemergencyrepair,soyoucandrivetothenextworkshop.Evenwiththetireair-tight,itmaybeusedonlyforshorttripsinanemergency.
256PracticalTips,EmergencyService

Changingawheel
Danger!
Riskofseriouspersonalinjuryordeath.Thecarmayslipoffthejack.
Makesurethatnooneisinthevehiclewhenjackingupandchangingawheel.
Alwaysplacethecaronstablesupportsifworkhastobecarriedoutunderthecar.
Warning!
RiskofdamagetothebrakediscsofthePorscheCeramicCompositeBrake(PCCB).
Alwaysscrewinbothassemblyaidswhenchangingawheel.
Note
Thetoolsrequiredforchangingawheel(e.g.jack,wheelboltwrench,assemblyaids)arenotsuppliedwiththecar.TheyareavailableatyourauthorizedPorschedealer.
1.Fullyapplythehandbrake,engage1stgearorselectpositionPandwithdrawtheignitionkey.
2.Securethecaragainstrollingaway,e.g.bymeansofwedgesunderthewheelsontheoppositeside.Thisisparticularlyimportantonslopes.
ScrewinassemblyaidforvehicleswithoutPorscheCeramicCompositeBrake
3.Slightlyslackenthewheelboltsofthewheeltobechanged.
4.Raisethecaruntilthewheelliftsofftheground.
Pleaseobservethechapter”LIFTINGTHEVEHICLEWITHALIFTINGPLATFORMORGARAGELIFT”onpage258.
ScrewintwoassemblyaidsforvehicleswithPorscheCeramicCompositeBrake
Noteonoperation
Toremoveormountthespacers:
Pleaseobservethechapter”SPACERS”onpage263.
5.Remove1or2wheelbolts(seerespectiveillustration).Screwinassemblyaidsinsteadofthewheelbolts.Removetheremainingwheelbolts.
6.Takethewheeloffandputanewwheelon.
PracticalTips,EmergencyService261

Removingthespacers
Pleaseobservethechapter”CHANGINGAWHEEL”onpage261.
1.Unscrewbothcountersunkscrews(M6x16)onthewheelhub.
2.Removethespacer.
3.FastenthebrakediscwiththeshortM6x12countersunkscrews,partNo.900.269.047.09.Tighteningtorque10Nm(7.5ftlb.).
4.Forwheelmountingwithoutaspacer,5mmshorterwheelbolts(partNo:996.361.203.02)mustbeused.Tighten-ingtorque130Nm(96ftlb.).
Mountingthespacers
Pleaseobservethechapter”CHANGINGAWHEEL”onpage261.
1.Removewheel
2.Unscrewbothcountersunkscrews(M6x12)onthebreakdisc.
3.FastenthespacerwiththelongM6x16countersunkscrews.Tighteningtorque10Nm(7.5ftlb.).
4.Fitwheel.Todothisusethelongerwheelboltsforfasteningthewheels.Tighteningtorque130Nm(96ftlb.).
Longwheelbolt,X-boltlengthapprox.50mm,Arrows-marks
Wheelboltidentifyingfeatures
ThelongwheelboltsareidentifiedonthefacesurfaceoftheboltheadwithGTorinred,orthemoveablesphericalcapringisgalvanisedinred.Thelongwheelboltsmustonlybeusedtogetherwith5mmspacersfitted.
Theshortwheelboltsarenotmarkedincolor.Theshortwheelboltsmustonlybeusedwithout5mmspacersfitted.
Tighteningtorqueforbothwheelbolts:130Nm(96ftlb.).
264PracticalTips,EmergencyService

Bulbchart
Type,rating
HalogenlowbeamH7,55W
LowbeamwithBi-XenonheadlighPhilips,D2S35W
HalogenhighbeamH9,65W
AdditionalhighbeamwithBi-XenonheadlightH11,55W
FoglightH8,35W
Taillight,rearfoglight,brakelight,taillightP21,4W
Taillight,reflectorP21,5W
ReversinglightP21W
Turnsignallight,frontandrearLLPY21W(long-life)
Doorguard-/curblight/footwelllight/luggagecom-partmentlightW5W
ParkinglightW5WBlue-Vision
LicenseplatelightC5W
SidemarkerLightW3W
276PracticalTips,EmergencyService