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Porsche Cayman 2005-2008 Service Repair Manual

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🏷️ Basic Information Identification Make: Porsche Model: Cayman Model Variant: 987 (First Generation) Model Years Covered: 2005, 2006, 2007, 2008 Codes Chassis Code: 987 👋 Introduction Market Position Vehicle Segment: Mid-engine, rear-wheel-drive sports car. Target Audience: Enthusiasts seeking a pure driving experience, often positioned as a more accessible alternative to the 911. Competitive Analysis Key Competitors: Chevrolet Corvette (C6), Nissan 350Z/370Z, BMW Z4, Mercedes-Benz SLK. Key Features Performance Orientation: Renowned for precise handling, balanced chassis, and driver-focused cockpit. Design Philosophy: Emphasizes lightweight construction, aerodynamic efficiency, and driver engagement. Manual Value Proposition Diy Repair Benefit: Empowers owners to perform maintenance and repairs, potentially saving significant costs compared to dealership labor. Diagnostic Advantage: Provides detailed diagnostic flowcharts and information crucial for identifying and rectifying complex issues often encountered in high-performance vehicles. 📋 Manual Details Coverage Areas Manual Type: Factory Service and Repair Manual Primary Coverage Focus: Maintenance, Repair, Troubleshooting, Diagnostics, Technical Specifications Page Count Estimated Page Count: Extensive (Specific count not provided, but described as 'a lot of information' and detailed step-by-step) Format File Format: PDF Language Language: English Compatibility Operating Systems: All Versions of Windows & Mac Requirements Software Requirements: Adobe PDF Reader 📖 Manual Coverage Systems Covered General Information: Vehicle identification, general safety precautions, diagnostic tools and procedures. Specifications: Detailed technical specifications for all major components, fluids, torque values, and clearances. Technical Features And Description: In-depth explanations of vehicle systems, design principles, and technologies specific to the Cayman 987. Rigging Information: Guidelines for lifting, towing, and securing the vehicle for maintenance and repair operations. Troubleshooting: Systematic diagnostic procedures and fault finding for common and complex issues across all vehicle systems. Electrical System: Comprehensive coverage of wiring diagrams, component testing, diagnostic trouble codes (DTCs), lighting, power distribution, ECUs, and sensor circuits. Fuel System: Fuel delivery, injectors, fuel pump, fuel tank, emissions control, and evaporative emission systems (EVAP). Power Unit: Engine mechanical (disassembly, assembly, component testing), lubrication system, cooling system, engine management, ignition system, and exhaust system. Lower Unit: Covers driveline components, including clutch, transmission (manual and Tiptronic), drive shafts, CV joints, and differential. Bracket Unit: Refers to chassis components, suspension (front and rear), steering system, brakes, wheels, and tires. Maintenance: Routine service schedules, fluid changes, filter replacements, inspections, and preventative maintenance procedures. Body And Frame: Body panel removal/installation, interior trim, doors, windows, locks, and structural components. Heating Ventilation And Air Conditioning HVAC: AC system diagnostics, refrigerant handling, climate control units, and component replacement. Procedures Included Major Repair Procedures: Engine rebuilds, transmission overhaul, suspension and brake component replacement, electrical system diagnosis and repair. Diagnostic Procedures: Systematic troubleshooting guides, fault code interpretation, component testing using multimeters and specialized tools. Maintenance Procedures: Oil changes, filter replacements, spark plug replacement, brake fluid flush, coolant replacement, belt inspection/replacement. Adjustment Procedures: Wheel alignment, parking brake adjustment, clutch free play adjustment (if applicable). Technical Depth Depth Of Information: Factory-level detail, suitable for professional technicians and experienced DIY enthusiasts. Includes component-level diagnostics and repair. 📊 Manual Specifications File Format PDF Quality: High-resolution, zoomable images and text for clarity. Searchability: Likely searchable text within the PDF, enhancing ease of use. Print Quality Digital Reproduction: Electronic format allows for high clarity zooming, superior to original paper limitations. Binding Type Binding Type: N/A (Digital PDF) Paper Type Paper Type: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Code Base: M97 Engine Type: Naturally Aspirated Flat-Six (Boxer) Displacement Cayman: 2.7 Liters (2687 cc) Displacement Cayman S: 3.4 Liters (3387 cc) Performance Horsepower Cayman: 245 PS (242 hp) @ 6500 RPM Torque Cayman: 270 Nm (199 lb-ft) @ 4600 RPM Horsepower Cayman S: 295 PS (291 hp) @ 7200 RPM Torque Cayman S: 340 Nm (251 lb-ft) @ 4700 RPM Fuel System Fuel Injection: Multi-point Fuel Injection (MPI), Sequential Electronic Ignition Fuel Type: Premium Unleaded Gasoline (91 Octane or higher recommended) Other Valve Train: DOHC, 4 valves per cylinder with VarioCam Plus (variable valve timing and lift) 🔧 Transmission Standard Standard Transmission: 6-speed Manual Transmission Optional Optional Transmission: 5-speed Tiptronic S Automatic Transmission Features Transmission Construction: Lightweight aluminum casing, rear-mounted transaxle design for optimal weight distribution. Fluid Specifications Manual Transmission Fluid: Pentosin MTF LT-2 (or equivalent API GL-4, SAE 75W-90 synthetic) Tiptronic Transmission Fluid: Dexron VI (or equivalent ATF fluid meeting Porsche specifications) 📐 Dimensions Exterior Length: 4435 mm (174.6 in) Width: 1801 mm (70.9 in) Height: 1300 mm (51.2 in) Wheelbase: 2415 mm (95.1 in) Weights Curb Weight Cayman: Approx. 1330 kg (2932 lbs) Curb Weight Cayman S: Approx. 1350 kg (2976 lbs) Gross Vehicle Weight Rating: Varies by model, typically around 1760-1780 kg. Towing Capacity: Not Recommended/Designed for Towing 🛡️ Safety Features Ratings NHTSA Crash Test Rating: Typically achieved 5-star ratings in frontal and side impact tests where applicable. Active Features Electronic Stability Control: Porsche Stability Management (PSM) - standard, includes ABS, ASR, ABD, MSR. Braking System: Four-piston aluminum monobloc fixed-piston...
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Porsche Cayman 2005-2008 Service Repair Manual
🏷️ Basic Information
Identification
Make:
Porsche
Model:
Cayman
Model Variant:
987 (First Generation)
Model Years Covered:
2005, 2006, 2007, 2008
Codes
Chassis Code:
987
👋 Introduction
Market Position
Vehicle Segment:
Mid-engine, rear-wheel-drive sports car.
Target Audience:
Enthusiasts seeking a pure driving experience, often positioned as a more accessible alternative to the 911.
Competitive Analysis
Key Competitors:
Chevrolet Corvette (C6), Nissan 350Z/370Z, BMW Z4, Mercedes-Benz SLK.
Key Features
Performance Orientation:
Renowned for precise handling, balanced chassis, and driver-focused cockpit.
Design Philosophy:
Emphasizes lightweight construction, aerodynamic efficiency, and driver engagement.
Manual Value Proposition
Diy Repair Benefit:
Empowers owners to perform maintenance and repairs, potentially saving significant costs compared to dealership labor.
Diagnostic Advantage:
Provides detailed diagnostic flowcharts and information crucial for identifying and rectifying complex issues often encountered in high-performance vehicles.
📋 Manual Details
Coverage Areas
Manual Type:
Factory Service and Repair Manual
Primary Coverage Focus:
Maintenance, Repair, Troubleshooting, Diagnostics, Technical Specifications
Page Count
Estimated Page Count:
Extensive (Specific count not provided, but described as 'a lot of information' and detailed step-by-step)
Format
File Format:
PDF
Language
Language:
English
Compatibility
Operating Systems:
All Versions of Windows & Mac
Requirements
Software Requirements:
Adobe PDF Reader
📖 Manual Coverage
Systems Covered
General Information:
Vehicle identification, general safety precautions, diagnostic tools and procedures.
Specifications:
Detailed technical specifications for all major components, fluids, torque values, and clearances.
Technical Features And Description:
In-depth explanations of vehicle systems, design principles, and technologies specific to the Cayman 987.
Rigging Information:
Guidelines for lifting, towing, and securing the vehicle for maintenance and repair operations.
Troubleshooting:
Systematic diagnostic procedures and fault finding for common and complex issues across all vehicle systems.
Electrical System:
Comprehensive coverage of wiring diagrams, component testing, diagnostic trouble codes (DTCs), lighting, power distribution, ECUs, and sensor circuits.
Fuel System:
Fuel delivery, injectors, fuel pump, fuel tank, emissions control, and evaporative emission systems (EVAP).
Power Unit:
Engine mechanical (disassembly, assembly, component testing), lubrication system, cooling system, engine management, ignition system, and exhaust system.
Lower Unit:
Covers driveline components, including clutch, transmission (manual and Tiptronic), drive shafts, CV joints, and differential.
Bracket Unit:
Refers to chassis components, suspension (front and rear), steering system, brakes, wheels, and tires.
Maintenance:
Routine service schedules, fluid changes, filter replacements, inspections, and preventative maintenance procedures.
Body And Frame:
Body panel removal/installation, interior trim, doors, windows, locks, and structural components.
Heating Ventilation And Air Conditioning HVAC:
AC system diagnostics, refrigerant handling, climate control units, and component replacement.
Procedures Included
Major Repair Procedures:
Engine rebuilds, transmission overhaul, suspension and brake component replacement, electrical system diagnosis and repair.
Diagnostic Procedures:
Systematic troubleshooting guides, fault code interpretation, component testing using multimeters and specialized tools.
Maintenance Procedures:
Oil changes, filter replacements, spark plug replacement, brake fluid flush, coolant replacement, belt inspection/replacement.
Adjustment Procedures:
Wheel alignment, parking brake adjustment, clutch free play adjustment (if applicable).
Technical Depth
Depth Of Information:
Factory-level detail, suitable for professional technicians and experienced DIY enthusiasts. Includes component-level diagnostics and repair.
📊 Manual Specifications
File Format
PDF Quality:
High-resolution, zoomable images and text for clarity.
Searchability:
Likely searchable text within the PDF, enhancing ease of use.
Print Quality
Digital Reproduction:
Electronic format allows for high clarity zooming, superior to original paper limitations.
Binding Type
Binding Type:
N/A (Digital PDF)
Paper Type
Paper Type:
N/A (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine Code Base:
M97
Engine Type:
Naturally Aspirated Flat-Six (Boxer)
Displacement Cayman:
2.7 Liters (2687 cc)
Displacement Cayman S:
3.4 Liters (3387 cc)
Performance
Horsepower Cayman:
245 PS (242 hp) @ 6500 RPM
Torque Cayman:
270 Nm (199 lb-ft) @ 4600 RPM
Horsepower Cayman S:
295 PS (291 hp) @ 7200 RPM
Torque Cayman S:
340 Nm (251 lb-ft) @ 4700 RPM
Fuel System
Fuel Injection:
Multi-point Fuel Injection (MPI), Sequential Electronic Ignition
Fuel Type:
Premium Unleaded Gasoline (91 Octane or higher recommended)
Other
Valve Train:
DOHC, 4 valves per cylinder with VarioCam Plus (variable valve timing and lift)
🔧 Transmission
Standard
Standard Transmission:
6-speed Manual Transmission
Optional
Optional Transmission:
5-speed Tiptronic S Automatic Transmission
Features
Transmission Construction:
Lightweight aluminum casing, rear-mounted transaxle design for optimal weight distribution.
Fluid Specifications
Manual Transmission Fluid:
Pentosin MTF LT-2 (or equivalent API GL-4, SAE 75W-90 synthetic)
Tiptronic Transmission Fluid:
Dexron VI (or equivalent ATF fluid meeting Porsche specifications)
📐 Dimensions
Exterior
Length:
4435 mm (174.6 in)
Width:
1801 mm (70.9 in)
Height:
1300 mm (51.2 in)
Wheelbase:
2415 mm (95.1 in)
Weights
Curb Weight Cayman:
Approx. 1330 kg (2932 lbs)
Curb Weight Cayman S:
Approx. 1350 kg (2976 lbs)
Gross Vehicle Weight Rating:
Varies by model, typically around 1760-1780 kg.
Towing Capacity:
Not Recommended/Designed for Towing
🛡️ Safety Features
Ratings
NHTSA Crash Test Rating:
Typically achieved 5-star ratings in frontal and side impact tests where applicable.
Active Features
Electronic Stability Control:
Porsche Stability Management (PSM) - standard, includes ABS, ASR, ABD, MSR.
Braking System:
Four-piston aluminum monobloc fixed-piston calipers, ventilated and cross-drilled discs (318mm front, 299mm rear for Cayman; 320mm front, 300mm rear for Cayman S).
Passive Features
Airbags:
Driver and passenger front airbags, side airbags, and head airbags (optional).
Roll Over Protection:
Integrated rollover protection bars behind the seats.
💡 Technology Features
Infotainment
Available Systems:
Porsche Communication Management (PCM) with navigation, CD player, and optional Bose premium sound system.
Driver Assistance
Traction Control:
PSM (Porsche Stability Management) provides advanced traction and stability control.
Cruise Control:
Standard cruise control system.
Connectivity
Bluetooth Handsfree:
Optional Bluetooth connectivity for hands-free calling.
Other Features
Xenon Headlights:
Optional Bi-Xenon headlights for improved nighttime visibility.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 10,000-15,000 miles or 1 year, whichever comes first. Check manual for specific conditions.
Major Service Interval:
Spark plugs typically at 60,000 miles. Drive belt inspection/replacement at similar intervals. Brake fluid flush every 2 years.
Fluid Specifications
Engine Oil Specification:
Mobil 1 0W-40 Synthetic (or Porsche A40 approved oil). Check oil capacity: ~8.7 liters for 2.7L, ~9.3 liters for 3.4L.
Coolant Specification:
Glysantin G48 (or equivalent ethylene glycol-based coolant with Porsche approval).
Brake Fluid Specification:
Porsche spec. DOT 4 (or DOT 5.1, check manual for specifics).
Known Issues
Intermediate Shaft Bearing Ims:
While less prone than earlier 996 models, the IMS is still a potential failure point. The manual will cover inspection and potential preventative measures.
Oil Seepage Leaks:
Potential for oil leaks from cylinder head gaskets, valve cover gaskets, and oil filter housing seals.
Clutch Release Bearing:
Wear on the clutch release bearing can lead to noise or difficulty shifting.
Suspension Components:
Wear in control arm bushings, ball joints, and shock absorbers can occur over time, affecting handling.
Water Pump And Thermostat:
Potential for failure of the water pump or thermostat, leading to cooling system issues.
📚 Vehicle History
Brand Heritage
Porsche Sports Car Legacy:
Porsche has a rich history in motorsport and sports car manufacturing, dating back to the Porsche 356 and the iconic 911.
Model Evolution
Cayman Introduction:
The Cayman was introduced in 2005 as a coupe counterpart to the Boxster roadster, sharing its mid-engine platform.
987 Generation Details:
The 987 generation (2005-2012) marked a significant step in refinement over the 986 Boxster, with improved aesthetics, interior quality, and performance.
Production
Manufacturing Location:
Zuffenhausen, Germany and Valmet Automotive in Uusikaupunki, Finland.
🏆 Awards & Recognition
Recognitions
Car And Driver 10Best:
The Cayman lineup often received accolades from automotive publications like Car and Driver for its performance and handling.
Ward S 10 Best Engines:
Porsche's flat-six engines have frequently been recognized on Ward's 10 Best Engines list.
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