030000 Test drive 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. Check operation of heating adjustment when engine is warm. Check operation of air-conditioning system when engine is running. Check operation of instruments. Test drive Page 36
0300IN Running gear maintenance: visual inspection of brake lines/brake pads/brake discs Information Brake hoses and lines 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. 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 440519 Removing and installing wheel. Running gear maintenance: visual inspection of brake lines/brake pads/brake discs Page 37
2. Visually inspect the brake pads for wear -Arrows- (wear limit 2 mm). 3. Carry out a visual inspection of the brake discs for wear Page 38 0300IN Technical values. Technical values Technical values Checking brake pads Designation Type, dimensions Wear limit Pad thickness, front Pad thickness, rear Brake disc thickness, new front Brake disc thickness, new rear Boxster/Boxster S Boxster/Boxster S approx. 12 mm approx. 10.5 mm approx. 2 mm approx. 2 mm Boxster 24 mm 22 mm Boxster S 28 mm 26 mm Boxster 20 mm 18 mm Boxster S 24 mm 22 mm Running gear maintenance: visual inspection of brake lines/brake pads/brake discs Page 38
0300IN Running gear maintenance: axle joints/drive shafts Information Axle joints: checking play and dust boots 1. Check play. 2. Visually inspect the dust boots for damage. 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. 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 Perform a visual inspection of the boots for leaks and damage. Running gear maintenance: axle joints/drive shafts Page 39
0300IN Running gear maintenance: steering gear - visual inspection of bellows and tie rod joints: Checking Checking bellows 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 400000 Lifting the vehicle. 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. Running gear maintenance: steering gear - visual inspection of bellows and tie rod joints: Page 40
0300IN Additional maintenance Additional maintenance s 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 Maintenance every 2 years Prepare Long-Life Guarantee Condition Report Change brake fluid 470855 Changing brake fluid Maintenance every 4 years Maintenance every 4 years Replace tyre sealant Maintenance after 4 then every 2 years Maintenance after 4 then every 2 years Check tyre pressure monitoring system battery Maintenance after 4, 8, 10 then every 2 years Maintenance after 4, 8, 10 then every 2 years Check the airbag system 690101 Airbag diagnosis. Ancillary unit mounts and running gear: visual inspection of all rubber mounts for damage Additional maintenance Page 41
032400 Minor maintenance Minor maintenance 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. 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. Maintenance item > Check drive belt< must always be performed 60,000 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./ 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 170155 Engine oil and oil filter change 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 190101 Checking cooling system Particle filter: replace filter element 851819 Removing and installing particle filter Brake system: visual inspection of the brake pads and brake discs for wear Page 37 0300IN Running gear maintenance: visual inspection of brake lines/brake pads/brake discs Brake hoses and lines: visual inspection for leaks, damage, routing and corrosion Page 37 0300IN Running gear maintenance: visual inspection of brake lines/brake pads/brake discs Minor maintenance Page 42
Minor maintenance at: 30,000, 90,000, 150,000, 210,000 km etc./ 20,000, 60,000, 100,000, 140,000 mls etc. Drive shafts: visual inspection of the boots for leaks and damage Page 39 0300IN Running gear maintenance: axle joints/drive shafts Tyres: check condition and tyre pressure 440000 Wheels and tyres/tyre pressure Check the door locks, lid locks and safety hooks of the front lid to ensure that they are secure and function properly Page 8 010101 Checking lid and doors Vehicle lighting: check operation All headlights: check adjustment Horn: check operation Page 11 0101IN Checking the function of the vehicle s lights Windscreen wiper/washer system, headlight washer system: check fluids and nozzle settings; pay attention to antifreeze protection in winter months; check wiper blades Page 9 0101IN Windscreen washer/headlight cleaning system: Check operation, nozzle settings Electrical equipment, warning and indicator lights: check function Page 33 0101IN 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 Page 36 030000 Test drive Oils, fluids: visual inspection for leaks Minor maintenance Page 43
032600 Major maintenance Major maintenance 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. If the mileage for scheduled maintenance is not reached, major 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. Maintenance item > Check drive belt< must always be performed 60,000 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./ 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 170155 Engine oil and oil filter change 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 190101 Checking cooling system Air cleaner: replace air cleaner element 242419 Removing and installing air cleaner element Particle filter: replace filter element 851819 Removing and installing particle filter Fuel system: visual inspection for damage, routing and secure fit of line connections Handbrake: check the free play of the parking-brake lever 468316 Adjusting parking brake shoes Brake system: visual inspection of the brake pads and brake discs for wear Page 37 0300IN Running gear maintenance: visual inspection of brake lines/brake pads/brake discs Brake hoses and lines: visual inspection for leaks, damage, routing and corrosion Page 37 0300IN Running gear maintenance: visual inspection of brake lines/brake pads/brake discs Clutch: check pedal end position Major maintenance Page 44
Major maintenance at 60,000, 120,000, 180,000, 240,000 km etc./ 40,000, 80,000, 120,000, 160,000 mls etc. Steering gear: visual inspection of bellows for damage Tierodends: checktheplayanddustbellows Page 40 0300IN 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 Page 39 0300IN 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 Page 39 0300IN Running gear maintenance: axle joints/drive shafts Exhaust system: visual inspection for leaks and damage, check mounts Tyres: check condition and tyre pressure 440000 Wheels and tyres/tyre pressure Check the door locks, lid locks and safety hooks of the front lid to ensure that they are secure and functioning properly Page 8 010101 Checking lid and doors Seat belts: check operation and condition 691301 Checking seat belts Vehicle lighting: check operation All headlights: check adjustment Horn: check operation Page 11 0101IN Checking the function of the vehicle s lights 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 Page 9 0101IN Windscreen washer/headlight cleaning system: Check operation, nozzle settings Electrical equipment, warning and indicator lights: check function Page 33 0101IN 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 Page 36 030000 Test drive Oils, fluids: visual inspection for leaks Major maintenance Page 45
033500 On-board diagnosis (OBD) Tools Designation Type Number Explanation PIWIS tester special tool 9718 Reading out and erasing fault memory Reading out and erasing fault memory The PIWIStester9718is 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. 1. Start the PIWIS tester 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. Diagnostic socket On-board diagnosis (OBD) Page 46
036000 Additional maintenance of drive belt Additional maintenance of drive belt 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. Additional maintenance - checking drive belt Check drive belt at 60,000 km/40,000 mls or every 4 years 137819 Removing and installing drive belt Check drive belt at 150,000 km/100,000 mls or every 10 years 137819 Removing and installing drive belt Check drive belt at 240,000 km/160,000 mls or every 16 years 137819 Removing and installing drive belt Additional maintenance of drive belt Page 47
038100 Additional maintenance of spark plugs Additional maintenance of spark plugs Additional maintenance for spark plugs 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. Additional maintenance, replacing spark plugs Replace spark plugs every 90,000 km/60,000 mls or every 4 years 287020 Removing and installing spark plugs Additional maintenance of spark plugs Page 48
038300 Additional maintenance every 90,000 km/60.000 mls or every 6years Additional maintenance every 90,000 km/60.000 mls or every 6 years 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. Additional maintenance every 90,000 km/60,000 mls or every 6 years Replace drive belt 137819 Removing and installing drive belt Additional maintenance every 90,000 km/60.000 mls or every 6 years Page 49
038800 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 s 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. 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 Manual transmission: change oil 340155 Changing transmission oil 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 Automatic transmission: change ATF and ATF filter 370255 Changing ATF 375855 Changing ATF filter Automatic transmission: change oil in final drive 399055 Changing oil for final drive Additional maintenance every 180,000 km/120.000 mls or every 12 years Page 50