PORSCHE BOXSTER S 2010 2.G Information Manual

· 26 ·· 27 ·
Boxster3.4-litre six-cylinder Boxer engine in the Boxster S
Six-cylinder Boxer engines.
Both Boxster models are pow-
ered by water- cooled six- cylinder
Boxer engines, mounted cen -
trally – just a few centimetres
behind the driver – to ensure an
authentic roadster experience. The power unit is free rev ving,
and boasts excellent load-change
characteristics and out
standing
smooth running performance.
With a perfectly matched inter -
play of all engine
components,
the Boxster develops 188 kW
(255 hp).

Many experiences have to be rationalised first.
Others speak directly to your heart.
Engine.
VarioCam Plus (see p. 36) in
conjunction with the resonance
intake manifold ensures high
torque even at low speeds, and
excellent power development
in the upper rev range. Maximum
torque is available over a wide
rev range, reaching 290 Nm
bet ween 4,400 and 6,000 rpm.
The engine in the Boxster S fea -
tures direct fuel injection (DFI)
and delivers a power output of
228 kW (310 hp). The 3.4 - litre
power plant develops a maxi-
mum torque of 360 Nm bet ween
4,400 and 5,500 rpm.

For incredible driving perform -
ance and higher torque, espe-
cially in the lower rev range, with
Boxster | Drive
a reduction in fuel consumption of
up to 15 %* and in CO
2 emissions
of up to 16 % (compared with the
previous model),
achieved by DFI
and VarioCam Plus technology.
* Depending on t ype of transmission

· 28 ·· 29 ·
Boxster S
Direct fuel injection (DFI).
The Boxster S engine has direct
fuel injection (DFI). With milli-
second precision, fuel is injected
directly into the combustion
chamber at up to 120 bar pres -
sure via electromagnetically
actuated injection valves.
The spray and cone angles have
been optimised for torque,
power output, fuel consumption
and emissions by enabling a
homogeneous distribution of the
air/fuel mixture and, therefore,
effective combustion.

Depending on throt tle input, mul
-
tiple fuel injection takes place.
DFI improves the internal cooling
of the combustion chamber by
preparing the mixture directly in
the cylinder. The resulting higher
compression ratio (12.5:1) helps
to deliver more power along with enhanced engine ef ficiency.
Translated into figures, this
means, when compared with the
previous model, a reduction in
fuel consumption of up to 15
%,
depending on the t ype of trans -
mission, and up to 16 % fewer
CO
2 emissions. Injection is regu -
lated by the electronic engine
management system.

The exhaust gas cleaning system
ensures that emissions remain
well below the strict limits of the
Euro 5 European emission stand -
ard, thus helping to protect the
environment.
Boxster | Drive

· 30 ·· 31 ·
1
2
3
4
56
78
9
1011
12
13
14
15
1617
19
20
21
18
20
Boxster | Drive
3.4-litre six-cylinder Boxer engine in the Boxster S
1. High pressure pump
2. High pressure injector
3. Ignition rod module
4. Camshaft controller
5. Tappets with integral valve
play compensation
6. Inlet camshaft
7. Inlet valve
8. Valve spring
9. Combustion chamber with
Alusil running surface 1 0 .
Forged aluminium pistons
11. Forged connecting rod
12. Crankshaft
13. Water pump

14. Vibration damper
15. Resonance valve
16.
Twin flow valve

17.
Intake distributor with
integral acoustic volume

18. Vacuum pump
19. Cooling jacket
20. Crankshaft breather
21. Timing chain
200
180
280 300
320
340
360 380 400
420 40
20
60 80
100 120 140 160 180 200 220 240
260
1500
7500
2000 25003000 3500400045005000 5500600065007000 220 240 260 1000
360 Nm
280
440

Power (kW)
Engine speed (rpm)
Torque (Nm)
228 kW (310 hp)
200
180
280 300
320 340 360 380 400 420
220 240
260
44040
20
60 80
100 120 140 160 180 200 220 240 260
1500
7500
2000 25003000 3500400045005000 55006000650070001000
290 Nm
280

Power (kW)
Engine speed (rpm)
Torque (Nm)
188 kW (255 hp)
Boxster: 290 Nm between 4,400 and 6,000 rpm, 188 kW (255 hp) at 6,400 rpm
Boxster S: 360 Nm between 4,400 and 5,500 rpm, 228 kW (310 hp) at 6,400 rpm

· 32 ·· 33 ·
Boxster and Boxster S
Lightweight construction.
Both Boxster models are equipped
with alloy engines. Ingenious
design down to the finest detail
has enabled weight – and conse-
quently fuel consumption – to be
reduced. Integrating the camshaf t
bearings fully into the cylinder
heads is just one example of the
ef fective light weight construction
measures that have been imple -
mented.
Integrated dry-sump lubrication.
Integrated dry-sump lubrication
guarantees a reliable oil supply
while reducing engine tempera -
tures, even in sportily driven cars.

The oil reservoir is located inside
the engine. Four oil pumps trans -
port the oil from the cylinder heads

directly into the oil sump. A fif th
pump in the oil sump directly sup -plies the lubricating points in the
engine. To reduce power losses
and increase efficiency, an elec
-
tronically controlled oil pump
supplies the engine lubrication
points as and when required.

This means that the oil pump does
not work so hard when there is
less demand for lubrication. The
benefits of an on-demand oil
supply system are optimum effi -
ciency combined with a reduction in both fuel consumption and

CO
2 em issio ns.

For the engine, these detailed
solutions mean a consistent

oil supply, regardless of gravita -
tional loads, even in the most
demanding track conditions.
Engine cooling system.
Our cross-flow cooling system,
as used in motorsport, supplies
each cylinder uniformly with cool -
ant. Valves are thus protected
against overload and premature
wear, which minimises the
engine’s tendency to knock and
reduces emissions, fuel con -
sumption and engine noise.
Boxster | Drive

· 34 ·· 35 ·
Boxster
Boxster
Boxster
Engine management system
with electronic throttle.
The electronic engine manage -
ment system ensures optimum
engine performance under all
operating conditions. It regulates
all engine-related functions and
assemblies (see diagram). The
results: optimum performance
and torque with reduced fuel con -
sumption and emissions.
Another important function of the
system is cylinder-specific knock
control. Since the six cylinders
never all work under precisely
the same conditions, they are
monitored individually by the
knock control. If necessary, the
ignition point is shifted individu -
ally to protect the cylinders and
pistons at high engine speeds
and loads. The on-board diagnos -
tics, which are compliant with
European standards, ensure
timely detection of any faults and
defects that may occur in the
exhaust and fuel system in good
time and notify the driver
immediately. This also prevents
increased pollutant emissions
and
unnecessary fuel consumption.
Two-stage resonance intake
manifold.
The intake manifold with dual-flow
distributor pipe has an adjustment
valve which closes and opens at
set engine speeds. A t wo -stage
tuning effect creates oscillation
of the air mass in the intake

system, which in turn generates
a turbocharging effect and opti -
mises induction.
These t wo effects combine to
produce higher torque at low
engine speeds, a flat ter torque
curve, and increased power
output at high engine speeds.
The acoustic properties of the
system are second to none,
producing the characteristic
Boxster sound.
Boxster | Drive
Input data Used to regulate/control
Engine management system
ME 7.8/Boxster – SDI 3.1/Boxster S
Engine load
Lambda sensor signals
Engine speed (from crankshaft)
Inlet camshaft phase angle
Knock sensor signals
Vehicle speed
Pressures
– Engine oil
– Fuel
– Ambient air
Air-conditioning settings
Accelerator pedal
Temperatures
– Coolant
– Intake air
– Air in engine compartment
– Engine oil
– Ambient air
Ignition
Heating of lambda sensors
Fuel pump (Boxster)/fuel pumps
controlled on - demand (Boxster S)
Camshaft position
Fuel-tank venting
Engine fan
Starter
Continuously variable oil pump
Fuel pressure (Boxster S)
Throttle valve
Throt tle -valve angle
Idling via throttle valve
and ignition
Manifold injection (Boxster)/
direct fuel injection (Boxster S)
Valve lift switchover
(VarioCam Plus)
Secondary-air injection (Boxster)
CAN inter face with driving dynamics control, transmission control, immobiliser, instrument cluster, climate control,
SPORT button, SPORT PLUS button, sports exhaust system button, diagnostics, etc.

· 36 ·· 37 ·
VarioCam Plus.
VarioCam Plus combines variable
valve timing with t wo -stage lift
on the inlet side. This results in
smoother running, bet ter fuel
economy and lower exhaust emis-
sions. As well as greater top - end
power and low-end torque.
This two-in-one engine concept
seamlessly adapts in response to
driver input. The result: instant
acceleration and extremely smooth
running.

The variation in intake timing is
steplessly controlled by means of
an electro -hydraulic rotary vane adjuster at the head of the corre
-
sponding camshaft.To improve throt tle response
during the warm-up phase, Vario -
Cam Plus selects high valve lifts
with retarded valve timing. In the
middle and low load ranges, low
valve lifts with advanced timing
Boxster | Drive
reduce fuel consumption and
exhaust emissions. High valve
lifts generate high torques and
maximum output.
VarioCam Plus Boxster S and Boxster
Ignition system.
The ignition system in the Boxster
models is designed for high-
voltage static distribution. The
individual ignition coils, located
on the spark plugs for optimum
ignition reliabilit y, are controlled
directly by the engine electronics.

· 38 ·· 39 ·
Exhaust system.
The exhaust system – with t win
tailpipes on the Boxster S – is
made of stainless steel. Until it
converges in the connecting tube,
the exhaust gas is channelled
through t wo separate tracts and,
thanks to separate exhaust gas cleaning systems, the exhaust
gas can flow more freely – for
increased power and torque.
The stereo lambda control

circuitry controls and monitors
each cylinder bank separately.
For each exhaust tract, four
corresponding oxygen sensors regulate the composition of the
exhaust gas and monitor the con
-
version of pollutants in the cata -
ly tic converters.
A sports exhaust system – for a
more resonant sound – is avail -
able as an option for each of the
Boxster models.
Boxster | Drive
Servicing.
Every Porsche is designed with
durabilit y in mind. On the Boxster
models, this is reflected in the
lengthy service intervals. The alternator, power steering
pump and the air- conditioning
compressor are all driven by a
single self-adjusting belt. The
drive chains on the camshafts
and intermediate shaf ts do not
normally require servicing. With the sole exception of the
spark plugs, the ignition system
is also maintenance-free.
So your Boxster remains where
it belongs for as long as possible:
on the road.
Boxster S exhaust system
Boxster S twin tailpipe
Boxster tailpipe

· 40 ·· 41 ·
1
4
2
3
7
6
12
8
9
4
13
5
10
11
6. Resonance intake system
7. Coolant expansion tank
8. Electronic throttle valve
9. Connecting pipe

10. Rear silencer
11. Attenuation pipe 12. Oil filler pipe
13. Air filter pipe

1. Radiator module
2. Brake force amplifier
3. Selector/gear lever
4. PASM damper
5. 6-speed manual or
7-speed PDK
Boxster S
Boxster | Drive

· 42 ·· 43 ·
The optional Porsche Doppel-
kupplung (PDK), with both man -
ual gearshift and an automatic
mode, enables smooth gear
changes with no interruption in
the flow of power. This results

in significantly faster acceleration
and lower fuel consumption, without having to sacrifice the
ease of automatic transmission.
In total, PDK has seven gears at
its disposal. Gears 1 to 6 have a
sports ratio and top speed is
reached in 6th gear. The 7th gear
has a long ratio and helps to

For people who have no time to spare.
Even when changing gear.
Porsche Doppelkupplung (PDK).
reduce fuel consumption even
f u rt h e r.
PDK is essentially t wo half gear-
boxes in one and thus requires
t wo clutches – designed as a
double wet clutch transmission.
This double clutch provides an
alternating, non-positive connec -
tion bet ween the t wo half gear -
boxes and the engine by means
of t wo separate input shafts
(input shaft 1 is nested inside the
hollowed-out input shaft 2).
The flow of power from the
engine is only ever transmit ted
through one half gearbox and
one clutch at a time, while the
next gear is preselected in the second half gearbox. During a
gear change, therefore, a con
-
ventional shif t no longer takes
place. Instead, one clutch simply
opens and the other closes at
the same time. Gear changes
can therefore take place within
milliseconds.
Clutch 1 controls the first half
gearbox, which contains the odd
gears (1, 3, 5, 7) and reverse.
Clutch 2 controls the second,
Boxster | Drive
which contains the even gears
(2, 4, 6).
Porsche Doppelkupplung (PDK)
in detail.
The crankshaf t transmits engine
torque to the dual-mass fly wheel
which is then channelled through
the clutch housing and onto the
multi-plate clutches, or to be more
precise, the outer disc carrier.
4
6
2
1
R
7 3
5
Porsche Doppelkupplung (PDK)
Boxster S

· 44 ·· 45 ·
Under oil pressure, clutch 1
closes and forms a frictional
connection with input shaf t 1.
The torque is now transmit ted
through the first half gearbox
– and then the dif ferential – to
the rear axle. At this stage,
PDK has already preselected
the next gear in the second
half gearbox. Engine torque
is already acting on the other
outer disc carrier and, in
response to a gear change
signal, the overlap shift is initi -
ated, i.e. as clutch 1 opens,

clutch 2 closes. The non-positive
connection with input shaft 2
is
established, and power is
trans
mit ted to the wheels.
The gear which is engaged is
displayed on the instrument
cluster.
Depending on the gearshift
programme, the gear change
is optimised for comfort or for
sport y handling and takes place
in a mat ter of milliseconds.

The advantage over a fully manual
transmission is the considerably
faster rate of acceleration for the
same rate of fuel consumption.
Boxster | Drive
The advantage over a fully auto -
matic transmission
is the per -
ceptible increase in driving
dynamics – with a similar level of
comfort, and a distinct reduction
in fuel consumption.
The com -
pact dimensions of the gearbox
reduce rotational
masses which
means a more direct engine
response, and the system is
more lightweight.
PDK function diagram
This, along with the long-ratio
7th gear, helps to achieve
reduced fuel consumption and
emission figures comparable with
those of a manual gearbox.
With the optional Sport Chrono
Package, PDK is enhanced by
the
‘Launch Control’ and ‘motor-
sport- derived gearshif t strategy’
functions (p. 57). In essence, PDK combines sport
i
-
ness with efficiency and comfort.

What does all this mean for you?
Uninterrupted driving pleasure.
Multi-plate clutch 1
Multi-plate clutch 2
Semi -gearbox 2
(2nd, 4th, 6th gear)
Rear semi-gearbox 1
(1st, 3rd, 5th, 7th, R gear)
Differential
Motor
Rear wheel
Rear wheel
Boxster