Notes On Removal And Installation: Installation

WARNING: This page does not describe the selected car, but rather 8 other vehicles, including the 2004 Porsche Boxster, 2003 Porsche Boxster, 2002 Porsche Boxster, 2001 Porsche Boxster, and 2000 Porsche Boxster. However, it is still accessible from the selected car via links, so may be relevant.

Inspect all bearing bushings X for clutch pedal lever and brake pedal and replace them if necessary. Lubricate sliding surfaces of the bearing bushings X and the pedal bearing axle with Optimol, Optitemp LG 2, part No. 000.043.203.37.

Fig 1: Identifying Pedal Bearing Axle Components
Courtesy of PORSCHE OF NORTH AMERICA, INC.

(1...4) Removal sequence
Fit brake pedal and stop light switch. Tightening sequence of the pedal bearing axle See Fig 1 .
No. 4 = Pedal bearing axle (8...10 Nm (6.0...7.5 ft.lb)

No. 3 = Hexagon nut (10 Nm (7.5 ft.lb)

No. 2 = Lock nut for steering outer tube (20 Nm (15 ft.lb)/before Mod. '98 = 30 Nm (22 ft.lb)
NOTE:
- Stop light switch installation and stop light switch adjustment: refer to ADJUSTING BRAKE PUSH ROD (ADJUSTING STOP LIGHT SWITCH) .
Assemble boost spring, bracket and clutch pedal lever.
1. 3.1 Boxster Mod. '98/partly Mod. '99
2. 3.2 Boxster from current Mod. '99
NOTE: Different types of boost springs can be fitted in the Boxster. Observe proper allocation when replacing the boost spring and/or the bracket.

In some cases, a modified (optimised) clutch pedal must also be used when replacing the boost spring.

Lubricating the boost spring bearing surfaces is sometimes necessary and sometimes prohibited (according to boost spring version).

Information can be found in CLUTCH BOOST SPRING: ALLOCATION AND GREASE SPECIFICATIONS .
1. 3.1 Boxster Mod. '98/partly Mod. '99
  Identification/distinction: Boost-spring push rod open on one side, boost spring components not coated.
  
  Grease pin for boost spring (arrow) (see Fig 2 ) with mating bearing on the boost spring push rod, the boost spring bearing (arrows) (see Fig 2 ) and the bearing pins on the boost spring with Optimol, Optitemp LG 2, part No. 000.043.203.37. First remove old grease with solvent naphtha.
  
  Lubrication necessary (arrows) see Fig 2 .
  
  Fig 2: Identifying Greasing Points For Boost Spring
  Courtesy of PORSCHE OF NORTH AMERICA, INC.
2. 3.2 Boxster from current Mod. '99
Identification/distinction: Push rod closed/boost spring components coated. The date of introduction for this boost spring is contained in the Parts Catalogue.

Engage the hexagon-socket bolts of the boost spring into the hexagon on the clutch pedal (arrow). See Fig 3 .

Fig 3: Engaging Hexagon-Socket Bolts Of Boost Spring Into Hexagon On Clutch Pedal
Courtesy of PORSCHE OF NORTH AMERICA, INC.

IMPORTANT: Do not lubricate since the sliding surfaces of this boost spring version are coated. 'Do not lubricate' applies to all sliding surfaces (boost spring pins, boost spring bearing in the bracket, bearing pins on the boost spring, and the boost spring in the boost spring pot). Do not lubricate (prohibited)

NOTE: Silver bracket (986.423.571.00) and boost spring with white marking (986.423.081.08 Mod. '98/partly Mod. 99 or 986.423.081.11 from current Mod. '99) must be used only in this combination and installed only in the Boxster.
Installation and adjustment specification for boost spring bracket. Install preassembled boost spring bracket with clutch pedal lever. Valid only for Boxster vehicles before Mod. '98 (bracket cannot be unscrewed or adjusted).
To do this:

Step 1: Tighten the three fastening nuts (arrows) only slightly (the bracket must still be movable). See Fig 4 .

Step 2: Tighten the clutch master cylinder to 10 Nm (7.5 ft.lb) (if the clutch master cylinder was detached).

Step 3: Press the clutch pedal against the direction of travel until the pull stop in the clutch master cylinder is reached.

Step 4: Remove cotter pin (retaining pin) on the spring cup so that the clutch pedal is pressed against the rubber stop in the boost spring bracket.

Step 5: The bracket is screwed down with the clutch pedal pressed back (to make full use of the slots). Tighten hexagon nuts (arrows) in the prescribed sequence. See Fig 4 . Tightening torque: 7.5 Nm (5.5 ft.lb). Sequence: 5a / 5b /5c

Fig 4: Installing And Adjusting Boost Spring Bracket
Courtesy of PORSCHE OF NORTH AMERICA, INC.

NOTE: The push rod of the clutch save cylinder should not be lubricated in general (for all versions).
Fit new retainer on the pedal bearing axle. On vehicles as of Mod. '98, subsequently secure the retainer by wedging it with a mandrel.
Install clutch pedal switch. First pull operating plunger out of the switch as far as it will go. By means of its self-adjustment function, the switch then compensates for tolerances in the pedals.
Check the interlock switch adjustment on vehicles with interlock.
Adjustment specification for interlock switch:

The switch must be aligned so that, with the clutch pedal depressed, it is operated a pprox. 1 to max. 2 mm before the limit stop of the clutch slave cylinder is reached.

Fig 5: Adjusting Interlock Switch
Courtesy of PORSCHE OF NORTH AMERICA, INC.
Install relay carrier, diagnostic socket and air duct.
Perform a function test on clutch and brake operation.