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Porsche Cayman 2006 Full Service Repair Manual

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🏷️ Basic Information Identification Make: Porsche Model: Cayman Year: 2006 Codes Chassis Code: 987 Generation Generation Name: 987 👋 Introduction Market Position Vehicle Segment: Mid-engine, two-seater sports car Competitive Analysis Key Competitors: Lotus Elise, Chevrolet Corvette (C6), Nissan 350Z, BMW Z4 Key Features Distinctive Attributes: Mid-engine layout for optimal weight distribution and handling, Porsche engineering and build quality, accessible sports car experience 📋 Manual Details Coverage Areas Coverage Scope: Comprehensive repair, maintenance, rebuild, refurbishment, and restoration Page Count Estimated Page Count: Not specified, but described as 'very detailed' Manual Type Manual Classification: Full Service Repair Manual Language Language: English Format Digital Format: PDF 📖 Manual Coverage Systems Covered Powertrain: Engine, Fuel System, Cooling System, Lubrication System, Exhaust System, Transmission (Manual & PDK) Chassis: Suspension (Front & Rear), Steering System, Brakes (Front & Rear, ABS, PSM) Electrical: Complete Electrical System, Lighting, Instrumentation, Diagnostics, Wiring Diagrams Body: Body Structure, Exterior Panels, Interior Trim, Doors, Hood, Trunk, Convertible Top (if applicable) Procedures Included Maintenance: Scheduled maintenance, fluid changes, filter replacements, tune-ups Repair: Component-level diagnostics and repair for all major systems Diagnostics: Troubleshooting guides, diagnostic trouble codes (DTCs), electrical system diagnostics Rebuild Refurbishment: Detailed instructions for engine, transmission, and other major component rebuilds Engine Mechanical: Engine removal/installation, cylinder head service, piston and connecting rod installation, crankshaft service, camshaft timing, oil pump servicing. Transmission Repair: Transmission removal/installation, internal component inspection and replacement, clutch assembly replacement, differential service. Suspension Steering: Strut replacement, shock absorber replacement, control arm bushings, ball joint service, steering rack and pinion repair, power steering system. Brake System Repair: Brake pad and rotor replacement, caliper servicing, brake line replacement, ABS and PSM system diagnostics, parking brake adjustment. Electrical Diagnostics: Detailed troubleshooting guides for common electrical faults, fuse and relay identification, power distribution, lighting system repair, diagnostic connector (OBD-II) functions, battery and charging system. Body And Trim: Front bumper removal, rear bumper removal, door panel removal, mirror replacement, seat removal, headliner inspection and repair. Technical Depth Depth Of Information: Professional technician level, suitable for advanced DIY mechanics Diagnostic Capabilities: Extensive diagnostic procedures and wiring schematics Torque Specifications: Includes critical torque specifications for all fasteners to ensure proper assembly and safety. Illustrations: Features detailed illustrations, drawings, and photos for step-by-step guidance. Troubleshooting Approach: Logical flowcharts and symptom-based troubleshooting for efficient problem resolution. 📊 Manual Specifications File Format Digital Format Details: PDF, compatible with Adobe PDF Reader Print Quality Printability: Fully printable, allowing for paper copy creation Binding Type Digital Binding: N/A (Digital Download) Paper Type Digital Paper Type: N/A (Digital Download) Compatibility Operating Systems: All versions of Windows and Mac OS Requirements Software Requirements: Adobe PDF Reader, WinRAR (for extraction) Delivery Delivery Method: Instant Download ⚙️ Engine Specifications Primary Engine Engine Code: M97.20 Engine Type: Naturally Aspirated Flat-Six (Boxer) Displacement: 3.4 liters (3387 cc) Performance Horsepower Peak: 295 hp @ 6200 rpm Torque Peak: 251 lb-ft @ 4600 rpm Fuel System Fuel Delivery: Sequential multi-point fuel injection Fuel Type: Premium Unleaded Gasoline (91 octane or higher recommended) 🔧 Transmission Standard Standard Transmission Type: 6-speed Manual Transmission Optional Optional Transmission Type: Tiptronic (5-speed Automatic with manual mode) Features Clutch Type: Dry single-plate clutch (for manual) 📐 Dimensions Exterior Length: 4427 mm (174.3 in) Width: 1801 mm (70.9 in) Height: 1295 mm (51.0 in) Wheelbase: 2415 mm (95.1 in) Cargo Front Trunk Capacity: 150 liters (5.3 cu ft) Rear Trunk Capacity: 260 liters (9.2 cu ft) Weights Curb Weight: 1330 kg (2932 lbs) for manual transmission 🛡️ Safety Features Ratings Crash Test Ratings: Not independently rated by NHTSA/IIHS for this specific year, but Porsche vehicles generally offer high safety standards. Active Features Stability Control: Porsche Stability Management (PSM) Traction Control: ASR (Anti-Slip Regulation) Braking System: ABS (Anti-lock Braking System), Electronic Brake-force Distribution (EBD) Passive Features Airbags: Driver and passenger airbags, side airbags (thorax), head airbags (curtain) Seatbelts: Three-point inertia-reel seat belts with pretensioners and belt force limiters 💡 Technology Features Infotainment Audio System: Standard Porsche CDR 24 CD-player with AM/FM radio. Optional Bose surround sound system available. Navigation: Optional GPS navigation system. Driver Assistance Cruise Control: Standard cruise control. Parking Assistance: Optional parking sensors (rear). Connectivity Auxiliary Input: Optional auxiliary audio input. 🔧 Maintenance Service Intervals Oil Change Interval: Typically every 10,000 miles or annually, whichever comes first. Check manual for specific interval. (e.g., 1 year/15,000 km for oil service) Major Service Interval: Refer to manual for comprehensive service schedule, often around 30,000 miles for spark plugs and other major items. Fluid Specifications Engine Oil: SAE 0W-40 or 5W-40 Synthetic Oil meeting Porsche A40 approval. Capacity: approx. 8.5 liters. Coolant: Porsche-approved coolant (G48 or similar) with a 50/50 mix of antifreeze and distilled water. Brake Fluid: DOT 4 or DOT 5.1 brake fluid. Transmission Fluid Manual: GL-4 or GL-5 SAE 75W-90 gear oil. Known Issues Common Wear Items: Clutch wear (especially with aggressive driving), RMS (Rear Main...
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Porsche Cayman 2006 Full Service Repair Manual
🏷️ Basic Information
Identification
Make:
Porsche
Model:
Cayman
Year:
2006
Codes
Chassis Code:
987
Generation
Generation Name:
987
👋 Introduction
Market Position
Vehicle Segment:
Mid-engine, two-seater sports car
Competitive Analysis
Key Competitors:
Lotus Elise, Chevrolet Corvette (C6), Nissan 350Z, BMW Z4
Key Features
Distinctive Attributes:
Mid-engine layout for optimal weight distribution and handling, Porsche engineering and build quality, accessible sports car experience
📋 Manual Details
Coverage Areas
Coverage Scope:
Comprehensive repair, maintenance, rebuild, refurbishment, and restoration
Page Count
Estimated Page Count:
Not specified, but described as 'very detailed'
Manual Type
Manual Classification:
Full Service Repair Manual
Language
Language:
English
Format
Digital Format:
PDF
📖 Manual Coverage
Systems Covered
Powertrain:
Engine, Fuel System, Cooling System, Lubrication System, Exhaust System, Transmission (Manual & PDK)
Chassis:
Suspension (Front & Rear), Steering System, Brakes (Front & Rear, ABS, PSM)
Electrical:
Complete Electrical System, Lighting, Instrumentation, Diagnostics, Wiring Diagrams
Body:
Body Structure, Exterior Panels, Interior Trim, Doors, Hood, Trunk, Convertible Top (if applicable)
Procedures Included
Maintenance:
Scheduled maintenance, fluid changes, filter replacements, tune-ups
Repair:
Component-level diagnostics and repair for all major systems
Diagnostics:
Troubleshooting guides, diagnostic trouble codes (DTCs), electrical system diagnostics
Rebuild Refurbishment:
Detailed instructions for engine, transmission, and other major component rebuilds
Engine Mechanical:
Engine removal/installation, cylinder head service, piston and connecting rod installation, crankshaft service, camshaft timing, oil pump servicing.
Transmission Repair:
Transmission removal/installation, internal component inspection and replacement, clutch assembly replacement, differential service.
Suspension Steering:
Strut replacement, shock absorber replacement, control arm bushings, ball joint service, steering rack and pinion repair, power steering system.
Brake System Repair:
Brake pad and rotor replacement, caliper servicing, brake line replacement, ABS and PSM system diagnostics, parking brake adjustment.
Electrical Diagnostics:
Detailed troubleshooting guides for common electrical faults, fuse and relay identification, power distribution, lighting system repair, diagnostic connector (OBD-II) functions, battery and charging system.
Body And Trim:
Front bumper removal, rear bumper removal, door panel removal, mirror replacement, seat removal, headliner inspection and repair.
Technical Depth
Depth Of Information:
Professional technician level, suitable for advanced DIY mechanics
Diagnostic Capabilities:
Extensive diagnostic procedures and wiring schematics
Torque Specifications:
Includes critical torque specifications for all fasteners to ensure proper assembly and safety.
Illustrations:
Features detailed illustrations, drawings, and photos for step-by-step guidance.
Troubleshooting Approach:
Logical flowcharts and symptom-based troubleshooting for efficient problem resolution.
📊 Manual Specifications
File Format
Digital Format Details:
PDF, compatible with Adobe PDF Reader
Print Quality
Printability:
Fully printable, allowing for paper copy creation
Binding Type
Digital Binding:
N/A (Digital Download)
Paper Type
Digital Paper Type:
N/A (Digital Download)
Compatibility
Operating Systems:
All versions of Windows and Mac OS
Requirements
Software Requirements:
Adobe PDF Reader, WinRAR (for extraction)
Delivery
Delivery Method:
Instant Download
⚙️ Engine Specifications
Primary Engine
Engine Code:
M97.20
Engine Type:
Naturally Aspirated Flat-Six (Boxer)
Displacement:
3.4 liters (3387 cc)
Performance
Horsepower Peak:
295 hp @ 6200 rpm
Torque Peak:
251 lb-ft @ 4600 rpm
Fuel System
Fuel Delivery:
Sequential multi-point fuel injection
Fuel Type:
Premium Unleaded Gasoline (91 octane or higher recommended)
🔧 Transmission
Standard
Standard Transmission Type:
6-speed Manual Transmission
Optional
Optional Transmission Type:
Tiptronic (5-speed Automatic with manual mode)
Features
Clutch Type:
Dry single-plate clutch (for manual)
📐 Dimensions
Exterior
Length:
4427 mm (174.3 in)
Width:
1801 mm (70.9 in)
Height:
1295 mm (51.0 in)
Wheelbase:
2415 mm (95.1 in)
Cargo
Front Trunk Capacity:
150 liters (5.3 cu ft)
Rear Trunk Capacity:
260 liters (9.2 cu ft)
Weights
Curb Weight:
1330 kg (2932 lbs) for manual transmission
🛡️ Safety Features
Ratings
Crash Test Ratings:
Not independently rated by NHTSA/IIHS for this specific year, but Porsche vehicles generally offer high safety standards.
Active Features
Stability Control:
Porsche Stability Management (PSM)
Traction Control:
ASR (Anti-Slip Regulation)
Braking System:
ABS (Anti-lock Braking System), Electronic Brake-force Distribution (EBD)
Passive Features
Airbags:
Driver and passenger airbags, side airbags (thorax), head airbags (curtain)
Seatbelts:
Three-point inertia-reel seat belts with pretensioners and belt force limiters
💡 Technology Features
Infotainment
Audio System:
Standard Porsche CDR 24 CD-player with AM/FM radio. Optional Bose surround sound system available.
Navigation:
Optional GPS navigation system.
Driver Assistance
Cruise Control:
Standard cruise control.
Parking Assistance:
Optional parking sensors (rear).
Connectivity
Auxiliary Input:
Optional auxiliary audio input.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 10,000 miles or annually, whichever comes first. Check manual for specific interval. (e.g., 1 year/15,000 km for oil service)
Major Service Interval:
Refer to manual for comprehensive service schedule, often around 30,000 miles for spark plugs and other major items.
Fluid Specifications
Engine Oil:
SAE 0W-40 or 5W-40 Synthetic Oil meeting Porsche A40 approval. Capacity: approx. 8.5 liters.
Coolant:
Porsche-approved coolant (G48 or similar) with a 50/50 mix of antifreeze and distilled water.
Brake Fluid:
DOT 4 or DOT 5.1 brake fluid.
Transmission Fluid Manual:
GL-4 or GL-5 SAE 75W-90 gear oil.
Known Issues
Common Wear Items:
Clutch wear (especially with aggressive driving), RMS (Rear Main Seal) leaks (less common than on earlier models but possible), IMS (Intermediate Shaft) bearing issues (though less prone than early 996/997 models, still a point of attention), exhaust system components, suspension bushings.
📚 Vehicle History
Brand Heritage
Porsche Legacy:
Porsche has a long-standing reputation for performance, engineering, and motorsport success dating back to the 1930s.
Model Evolution
Cayman Introduction:
The Cayman was introduced by Porsche in 2005 as a coupe variant of the Boxster, marking the first time Porsche offered a closed-top, mid-engine sports car in its lineup.
Production
Manufacturing Location:
Zuffenhausen, Germany and Finland (Valmet Automotive)
🏆 Awards & Recognition
Recognitions
Automotive Press Accolades:
Consistently praised by automotive journalists for its sharp handling, balanced chassis, and driver engagement. Often cited as a benchmark for affordable mid-engine sports cars.
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