key PORSCHE BOXSTER 2007 2.G Service Manual

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.
Alwaysplacethevehicleonstablesupportsifworkhastobecarriedoutunderthevehicle.Jacksarenotsuitableforthiskindofwork.
Whenworkingunderthecarwithoutsafetystandsbutwiththewheelsontheground,makesurethecarisonlevelground,thewheelsareblocked,andthattheenginecannotbestarted.Removetheignitionkey.
Donotsmokeorallowanopenflamearoundthebatteryorfuel.Keepafireextinguisherinclosereach.
Incompleteorimproperservicingmaycauseproblemsintheoperationofthecar.Ifindoubtaboutanyservicing,haveitdonebyyourauthorizedPorschedealer.ImpropermaintenanceduringthewarrantyperiodmayaffectyourPorschewarrantycoverage.
Suppliesoffluids,e.g.engineoil,brakefluidorcoolant,arehazardoustoyourhealth.Keepthesefluidsoutofchildren’sreachanddisposeoftheminaccordancewiththeappropriateregulations.
Somecountriesrequireadditionaltoolsandspecialsparepartstobecarried.Pleasemakeenquiriesbeforedrivingabroad.
Powermeasurements
PowermeasurementsondynamometersarenotapprovedbyPorsche.
Workingintheenginecompartment
Havethenecessaryworkintheenginecompart-mentdonebyyourauthorizedPorschedealer.
208Maintenance,CarCare

WiperBlades
Generalinformationtothewiperblades
Whenwiperperformancedeteriorates,replacethewipers.
Pleaseobservethechapter”CARCAREINSTRUCTIONS”onpage233.
Caution!
Riskofdamageifthewiperarmaccidentallyfallsbackontothewindow.
Alwaysholdthewiperarmsecurelywhenreplacingthewiperblade.
Caution!
Riskofdamageifwiperbladesthatarefrozeninplaceareloosenedimproperly.
Thawthewiperbladesbeforelooseningthem.
Maintenancenote
PeriodicallycleanthewiperbladeswithPorschewindowcleaner,especiallyafterthevehiclehasbeenwashedinacarwash.Iftheyareverydirty(e.g.withinsectremains),theycanbecleanedwithaspongeorcloth.
Ifthewiperbladesruborsqueak,thiscanbeasaresultofthefollowing:
Ifthevehicleiswashedinanautomaticcarwash,waxresiduesmayadheretothewindshield.Thesewaxresiduescanberemovedbyusingwindowcleanerconcentrate.
Pleaseobservethechapter”WASHERFLUID”onpage228.
PleasecontactyourauthorizedPorschedealerforfurtherinformation.
Thewiperbladesmaybedamaged.
Replacedamagedwiperbladesassoonaspossible.
Changingwindshieldwiperblades
Caution!
Riskofdamage.Ifawiperbladeisnotchangedproperly,itcancomeloosewhenthecarismoving.
Checkwhetherthewiperbladeisseatedsecurely.Thewiperblademustengagethewiperarmproperly.
1.Applythehandbrake.
2.Switchthewipersoff(position0)andremovetheignitionkey.
3.Foldwindshieldwiperarmawayfromthewindshield.
A-Passenger’sside,curvedwiperbladeB-Driver’sside,wiperbladewithspoiler
4.Presstogethertheplasticspringofthewiperblade(rightarrow).Pullwiperbladeoutofwiperarm.
5.Insertnewwiperbladeuntilyoufeelitengage.Ensurethatthenewwiperbladeisinsertedintothewiperarminthesameposition:
–directionofthespoileronthedriverside,
–curvatureonthepassengerside.
6.Carefullyfoldwiperarmbackontothewind-shield.
Maintenance,CarCare209

OperatingyourPorscheinother
Countries
GovernmentregulationsintheUnitedStatesandCanadarequirethatautomobilesmeetspecificemissionregulationsandsafetystandards.Therefore,carsbuiltfortheU.S.andCanadadifferfromvehiclessoldinothercountries.
IfyouplantotakeyourPorscheoutsidethecontinentallimitsoftheUnitedStatesorCanada,thereisthepossibilitythat
–unleadedfuelmaynotbeavailable;
–unleadedfuelmayhaveaconsiderablyloweroctanerating.Excessiveengineknockandseriousdamagetobothengineandcatalyticconverterscouldresult;
–servicemaybeinadequateduetolackofproperservicefacilities,toolsordiagnosticequipment;
–replacementpartsmaynotbeavailableorverydifficulttoget.
Porschecannotberesponsibleforthemechanicaldamagethatcouldresultbecauseofinadequatefuel,serviceorpartsavailability.
IfyoupurchasedyourPorscheabroadandwanttobringitbackhome,besuretofindoutaboutshippingandforwardingrequirements,aswellascurrentimportandcustomsregulations.
220Maintenance,CarCare

FuelRecommendations
YourPorscheisequippedwithcatalyticconvertersandmustuseUNLEADEDFUELONLY.
Yourengineisdesignedtoprovideoptimumperformanceandfueleconomyusingunleadedpremiumfuelwithanoctaneratingof98RON(93CLCorAKI).Porschethereforerecommendstheuseofthesefuelsinyourvehicle.
Porschealsorecognizesthatthesefuelsmaynotalwaysbeavailable.Beassuredthatyourvehiclewilloperateproperlyonunleadedpremiumfuelswithoctanenumbersofatleast95RON(90CLCorAKI),sincetheengine’s”ElectronicOctane™knockcontrol“willadapttheignitiontiming,ifnecessary.
TheuseofUNLEADEDFUELONLYiscriticallyimportanttothelifeofthecatalyticconvert-ers.Depositsfromleadedfuelswillruintheconvertersandmakeitineffectiveasanemis-sioncontroldevice.
Carswithcatalyticconvertershaveasmallerfueltankopening,andgasstationpumpshavesmallernozzles.Thiswillpreventaccidentalpumpingofleadedfuelintocarswithcatalyticconverters.
UnleadedfuelsmaynotbeavailableoutsidethecontinentalU.S.andCanada.Therefore,werecommendyoudonottakeyourcartoareasorcountrieswhereunleadedfuelmaynotbeavailable.
Octaneratings
Octaneratingindicatesafuel’sabilitytoresistdetonation.Therefore,buyingthecorrectoctanegasisimportanttopreventengine”damage“.
TheRONoctaneratingisbasedontheresearchmethod.TheCLC(U.S.CostofLivingCounciloctanerating)orAKI(antiknockindex)octaneratingusuallydisplayedonU.S.fuelpumpsiscalculatedasresearchoctanenumberplusmotoroctanenumber,dividedby2,thatiswrittenas:
RON+MONR+M
2or2
TheCLCorAKIoctaneratingisusuallylowerthantheRONrating:
Forexample:95RONequals90CLCorAKI.
Fuelscontainingalcoholandether
SomeareasoftheU.S.requireoxygenatedfuelsduringcertainportionsoftheyear.Oxygenatedfuelsarefuelswhichcontainalcohols(suchasmethanolorethanol)orether(suchasMTBE).
Undernormalconditions,theamountofthesecompoundsinthefuelwillnotaffectdriveability.
YoumayuseoxygenatedfuelsinyourPorsche,providedtheoctanerequirementsforyourvehiclearemet.Werecommend,however,tochangetoadifferentfuelorstationifanyofthefollowingproblemsoccurwithyourvehicle:
–Deteriorationofdriveabilityandperformance.
–Substantiallyreducedfueleconomy.
–Vaporlockandnon-startproblems,especiallyathighaltitudeorathightemperature.
–Enginemalfunctionorstalling.
FuelscontainingMMT
SomeNorthAmericanfuelscontainanoctaneenhancingadditivecalledmethylcyclopentadienylmanganesetricarbonyl(MMT).
Ifsuchfuelsareused,youremissioncontrolsystemperformancemaybenegativelyaffected.
Thecheckenginewarninglightonyourinstrumentpanelmayturnon.Ifthisoccurs,Porscherecom-mendsyoustopusingfuelscontainingMMT.
224Maintenance,CarCare

damagedbydesignfeatures(e.g.brushes)ofautomaticcarwashes.
Thefollowingpartsareparticularlysuscepti-bletodamage:
–Convertibletop(hotwaxtreatmentcannotbeused,asthewaxattackstheconvertibletopmaterial),
–Windshieldwipers(alwaysswitchthemofftopreventthemwipingunintentionallyinintermittentorsensoroperation)
–Externaltelephoneantenna(alwaysunscrew)
–Fixedrearspoilerorextendedrearspoiler
–Wheels(thewidertherimandthelowerthetireheight,thegreatertheriskofdamage)
–High-glosswheels(topreventthesefromgettingscratched,donotcleanwiththewheel-cleaningbrushesofthecarwash).
Pleaseconsulttheoperatorbeforeusingautomaticcarwashes.
Washanddrybyhandallpointsnotreachedbyacarwash,suchasdoorandlidseamsordoorsills.
Note
Automaticcarwashesspraywateratoddanglesandhighpressures,whicharenotseeninnormaldriving.Therefore,watercansometimesfinditswayintothepassengerscompartmentduringorshortlyafterthecarwash.
Doorlocks
Topreventthedoorlocksfromfreezingduringthecoldseason,thelockcylindersshouldbecoveredduringawash.
Shouldthelocksfreeze,useanordinaryde-icer.Inmanycases,awellwarmedkeycanhelp.Neveruseexcessiveforce.
Paint
Neverrubadustycarwithadryclothsincedustparticlesareabrasiveandcoulddullanddamagethesurfacefinish.
Thepaintworkofyourcarisexposedtoalltypesofmechanicalandchemicalconditions,particularlyclimaticonessuchasbrightsunlight,rain,frostandsnow.Ultravioletlight,rapidchangesintemperature,rain,snow,industrialdustandchemicaldepositsconstantlyattackthepaintwhichisonlyabletowithstandsuchexposureinthelongtermifitisgivenregularcareandattention.
Donotapplysiliconepolishestothewind-shield,windowsorconvertibletop.
Donottreatmatt-paintedcomponentswithpreservativesorpolishesasthiswillspoilthematteeffect.
Preservation
Thepaintsurfacebecomesdullovertimeduetoweathering.Itisthereforenecessarytopreservethepaintregularly.
Thiskeepsthepaintshinyandelastic.Dirtispreventedfromadheringtothepaintsurfaceandindustrialdustispreventedfrompenetratingthepaint.
Provideditiswashedandtreatedwithpreservativeregularly,thebrandnewfinishofyourvehiclewillberetainedforyearstocome.
Maintenance,CarCare235

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

WheelBolts
Danger!
Riskofwheelboltbreakageandwheelseparation,resultinginseriouspersonalinjuryordeath.
Followallinstructionsconcerningwheelbolts.
Alwayscleanthewheelboltsbeforefitting.
ApplyathincoatofOptimolyTA(aluminumpaste)onthethreadandbetweentheboltheadandmovablesphericalcapring(arrows).Thebearingsurfaceofthesphericalcapfacingthewheelmustnotbegreased.
Replacedamagedwheelbolts.OnlyusetheOriginalPorschewheelboltsspeciallydesignedforthisvehicletype.
Tighteningtorque
Tighteningtorqueofwheelbolts:130Nm/96ftlb.
WheelSecuringBolts
Ifthewheelshavetoberemovedattheworkshop,pleasedonotforgettohandoverthewrenchsocketforthewheelsecuringboltsalongwiththecarkey.
Thewrenchsocketforthewheelsecuringboltsisinthetoolbox.
Toloosenortightenthewheelboltwithanti-theftprotection,awrenchsocketwiththeappropriatecodingmustbeusedbetweenthewheelboltandthewheel-boltspanner.
Whenpositioningthewrenchsocket,ensurethatitengagesfullyintheteethofthewheelbolt.
260PracticalTips,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

ElectricalSystem
Generalinformation
Warning!
Riskofshortcircuitandre,resultinginseriouspersonalinjuryordeath.Replacingfusesorrelayswiththeenginerunningortheignitiononcouldcauseelectricalshock.
Disconnectedthebatteryduringallworkontheelectricalsystem.
Pleaseobservethechapter”BATTERY”onpage268.
Inordertoavoiddamageandfaultsinelectricalorelectronicsystems,electricalaccessoriesshouldbeinstalledatyourauthorizedPorschedealer.
OnlyuseaccessoriesauthorizedbyPorsche.
Relays
Defectiverelaysshouldbechangedonlybyanauthorizedworkshop.
Alarmsystem,centrallocking
Thestatusofthecentrallockingandalarmsystemisnotchangedbydisconnectingthebattery.Whenthebatteryisdisconnected,thealarmsystemceasestofunction.
Overloadprotection
Ifthecentrallockingsystemisoperatedmorethantentimeswithinaminute,furtheroperationisblockedfor30seconds.
Loadswitch-offafter2hoursor7days
Iftheignitionkeyisremoved,loadswhichareswitchedonorareinstandbymode(suchastheluggagecompartmentlight,interiorlightandradio)areautomaticallyswitchedoffafterapprox.2hours.
Ifthevehicleisnotstartedorunlockedwiththeremotecontrolwithin7days,theremotecontrolstandbyfunctionisswitchedoff(tosavethevehiclebattery).
1.Inthiscase,unlockthedriver’sdoorwiththekeyatthedoorlock.Leavethedoorclosedinordertopreventthealarmsystemfrombeingtriggered.
2.Pressbutton1ontheremotecontrol.
Theremotecontrolisnowactivatedagain.
A-Diagnosticsocket
Replacingfuses
Inordertopreventdamagetotheelectricalsystemduetoshortcircuitsandoverloads,theindividualcircuitsareprotectedbyfuses.Thefuseboxislocatedinthedriver’sfootwell.
PracticalTips,EmergencyService265

A-PlasticgripperB-Sparefuses
1.Switchofftheloadwiththedefectivefuse.
2.Pulloffplasticcoveratthefingerhole(arrow).Thefuseplanandinstructionsforemer-gencyunlockingoftheluggagecompart-mentlidcanbefoundontheinnersideofthecover.
3.RemovethecorrespondingfusefromitsslotusingtheplasticgripperAinordertocheckit.Ablownfusecanbeidentifiedbythemeltedmetalstrip.
4.Replaceonlywithfusesofthesamerating.
Note
Ifafuseblowsrepeatedlyconsultanauthor-izedPorschedealer.
Nevertryto“repair”fuses:youmaycauseseriousdamagetootherpartsoftheelectricalsystem.
Emergencyunlockingofthefrontluggage
compartmentlid
Ifthebatteryisdischarged,thelidcanbeopenedonlywiththeaidofadonorbattery.
Unlockinglid
1.Usethekeytounlockthevehicleatthedoorlock.
2.Removeplasticcoveroverthefusebox.
3.PulloutpositiveterminalAinthefusebox.
4.UseajumpercabletoconnectthepositiveterminalofthedonorbatterywithpositiveterminalAinthefusebox.
Note
Ifthevehiclewaslocked,thealarmhornwillsoundwhenthenegativecableisconnected.
5.UsethesecondjumpercabletoconnectthenegativeterminalofthedonorbatterywithlatchstrikerB.
6.Unlockthefrontluggagecompartmentlidwiththeremotecontrol.Thealarmsystemisswitchedoff.
266PracticalTips,EmergencyService