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Porsche Cayman 2005-2008 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Porsche Model: Cayman Generation: 987 Codes Chassis Code: 987c 👋 Introduction Market Position Segment: Premium Sports Car / Mid-Engine Coupe Target Audience: Enthusiasts and owners seeking in-depth knowledge for maintenance and repair. Competitive Analysis Competitors: Lotus Evora, BMW M2, Chevrolet Corvette (C6) Key Features Design Philosophy: Mid-engine layout for optimal weight distribution and handling characteristics, driver-focused cockpit. Performance Focus: Emphasis on agile handling, braking, and acceleration. Manual Utility: Empowers owners to perform complex maintenance and repairs, saving on labor costs and ensuring optimal vehicle performance. 📋 Manual Details Coverage Areas Applicable Years: 2005, 2006, 2007, 2008 Page Count Estimated Page Count: Comprehensive (exact count not provided, typical for factory manuals exceeding 1000 pages) Manual Type Type: Factory Service Repair Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine: Detailed diagnostics, repair, overhaul, and maintenance for all engine variants Transmission: Manual and Tiptronic transmission diagnostics, repair, and fluid service Drivetrain: Rear-wheel drive system, including clutch, differentials, and axle shafts Brakes: Brake system components, ABS, PSM (Porsche Stability Management), and brake fluid service Suspension: Front and rear suspension systems, shock absorbers, springs, control arms, and alignment procedures Steering: Power steering system, steering column, and wheel alignment Electrical: Comprehensive electrical system coverage, including battery, charging system, lighting, and power distribution Body: Exterior body panels, doors, hood, trunk, bumpers, and interior trim HVAC: Heating, ventilation, and air conditioning system diagnosis and repair Fuel: Fuel system components, fuel pump, injectors, and EVAP system Cooling: Cooling system, radiator, water pump, and coolant specifications Exhaust: Exhaust system components, catalytic converters, and muffler service Safety Systems: Airbag system, seat belts, and active safety system components Infotainment: PCM (Porsche Communication Management) system troubleshooting and basic functions Wiring Diagrams: Detailed color wiring diagrams for all vehicle systems Procedures Included Maintenance: Scheduled maintenance procedures, fluid changes, filter replacements, and inspections Troubleshooting: Systematic troubleshooting guides for common and complex issues Repair: Step-by-step repair instructions for all major vehicle components Diagnostics: Diagnostic procedures, including OBD-II fault code interpretation and component testing Overhaul: Complete overhaul procedures for engines and transmissions Assembly Disassembly: Detailed instructions for component disassembly and reassembly Special Tools: Identification and usage instructions for required special tools Technical Depth Depth: Comprehensive, covering from routine maintenance to complete engine and transmission rebuilds, including advanced diagnostics. 📊 Manual Specifications File Format File Type: PDF Searchability: Searchable text content within PDF (assuming OCR or native text) Compatibility: Compatible with all Windows and Mac operating systems via Adobe PDF Reader. Print Quality Printability: Printable pages for easy workshop use. Binding Type Binding: N/A (Digital PDF format) Paper Type Paper: N/A (Digital PDF format) ⚙️ Engine Specifications Primary Engine Engine Code Base: M97.20 (Boxster derived flat-six) Engine Details Displacement 2 7: 2.7 Liters (2687 cc) Displacement 3 4: 3.4 Liters (3387 cc) (Cayman S) Performance 2 7 Horsepower 2 7: 245 PS (242 hp) @ 6500 rpm Torque 2 7: 270 Nm (199 lb-ft) @ 4600 rpm Performance 3 4 Horsepower 3 4: 295 PS (291 hp) @ 7400 rpm (Cayman S) Torque 3 4: 340 Nm (251 lb-ft) @ 4750 rpm (Cayman S) Fuel System Injection Type: Sequential Multi-Point Fuel Injection (MPI) Fuel Type: Premium Unleaded Gasoline (91 Octane or higher recommended) Engine Management ECU: Bosch Motronic (Specific variant may vary) Cooling Cooling System Type: Water-cooled, closed-loop system with electric fan and coolant reservoir. Lubrication Oil System: Dry-sump lubrication system with external oil tank. 🔧 Transmission Standard Type Standard: 6-Speed Manual Transaxle Optional Type Optional: 5-Speed Tiptronic Automatic Transaxle Features Clutch Type: Hydraulically actuated single-plate dry clutch. Gear Ratios: Specific ratios vary by model and transmission type, detailed in manual. Differential: Limited-slip differential (LSD) often optional or standard on S models. Maintenance Manual Fluid Spec: Porsche Part No. 000.043.205.28 (G50/30, G97/00, G97/01, G97/02 Gear Oil) - typically a GL-4 or GL-5 synthetic gear oil Tiptronic Fluid Spec: Porsche ATF JWS 3309 (or equivalent) - typically a Dexron III/VI compatible fluid 📐 Dimensions Exterior Length: Approx. 4435 mm (174.6 in) Width: Approx. 1801 mm (70.9 in) Height: Approx. 1301 mm (51.2 in) Wheelbase: Approx. 2415 mm (95.1 in) Weights Curb Weight Base: Approx. 1330 kg (2932 lbs) Curb Weight S: Approx. 1370 kg (3020 lbs) (Cayman S) Gvw: Gross Vehicle Weight (specified by model, consult manual) Cargo Trunk Volume Front: Approx. 150 Liters (5.3 cu ft) Trunk Volume Rear: Approx. 260 Liters (9.2 cu ft) 🛡️ Safety Features Ratings NHTSA Ratings: Specific NHTSA ratings not readily available for this model year/variant, refer to official reports if required. IIHS Ratings: Specific IIHS ratings not readily available for this model year/variant, refer to official reports if required. Active Features Psm: Porsche Stability Management (PSM) system, including ABS, ASR, ABD, MSR. Brakes Front: Ventilated discs, typically 318 mm diameter (Cayman) / 340 mm diameter (Cayman S). Brakes Rear: Ventilated discs, typically...
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Porsche Cayman 2005-2008 Factory Service Repair Manual
🏷️ Basic Information
Identification
Make:
Porsche
Model:
Cayman
Generation:
987
Codes
Chassis Code:
987c
👋 Introduction
Market Position
Segment:
Premium Sports Car / Mid-Engine Coupe
Target Audience:
Enthusiasts and owners seeking in-depth knowledge for maintenance and repair.
Competitive Analysis
Competitors:
Lotus Evora, BMW M2, Chevrolet Corvette (C6)
Key Features
Design Philosophy:
Mid-engine layout for optimal weight distribution and handling characteristics, driver-focused cockpit.
Performance Focus:
Emphasis on agile handling, braking, and acceleration.
Manual Utility:
Empowers owners to perform complex maintenance and repairs, saving on labor costs and ensuring optimal vehicle performance.
📋 Manual Details
Coverage Areas
Applicable Years:
2005, 2006, 2007, 2008
Page Count
Estimated Page Count:
Comprehensive (exact count not provided, typical for factory manuals exceeding 1000 pages)
Manual Type
Type:
Factory Service Repair Manual
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Engine:
Detailed diagnostics, repair, overhaul, and maintenance for all engine variants
Transmission:
Manual and Tiptronic transmission diagnostics, repair, and fluid service
Drivetrain:
Rear-wheel drive system, including clutch, differentials, and axle shafts
Brakes:
Brake system components, ABS, PSM (Porsche Stability Management), and brake fluid service
Suspension:
Front and rear suspension systems, shock absorbers, springs, control arms, and alignment procedures
Steering:
Power steering system, steering column, and wheel alignment
Electrical:
Comprehensive electrical system coverage, including battery, charging system, lighting, and power distribution
Body:
Exterior body panels, doors, hood, trunk, bumpers, and interior trim
HVAC:
Heating, ventilation, and air conditioning system diagnosis and repair
Fuel:
Fuel system components, fuel pump, injectors, and EVAP system
Cooling:
Cooling system, radiator, water pump, and coolant specifications
Exhaust:
Exhaust system components, catalytic converters, and muffler service
Safety Systems:
Airbag system, seat belts, and active safety system components
Infotainment:
PCM (Porsche Communication Management) system troubleshooting and basic functions
Wiring Diagrams:
Detailed color wiring diagrams for all vehicle systems
Procedures Included
Maintenance:
Scheduled maintenance procedures, fluid changes, filter replacements, and inspections
Troubleshooting:
Systematic troubleshooting guides for common and complex issues
Repair:
Step-by-step repair instructions for all major vehicle components
Diagnostics:
Diagnostic procedures, including OBD-II fault code interpretation and component testing
Overhaul:
Complete overhaul procedures for engines and transmissions
Assembly Disassembly:
Detailed instructions for component disassembly and reassembly
Special Tools:
Identification and usage instructions for required special tools
Technical Depth
Depth:
Comprehensive, covering from routine maintenance to complete engine and transmission rebuilds, including advanced diagnostics.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Searchable text content within PDF (assuming OCR or native text)
Compatibility:
Compatible with all Windows and Mac operating systems via Adobe PDF Reader.
Print Quality
Printability:
Printable pages for easy workshop use.
Binding Type
Binding:
N/A (Digital PDF format)
Paper Type
Paper:
N/A (Digital PDF format)
⚙️ Engine Specifications
Primary Engine
Engine Code Base:
M97.20 (Boxster derived flat-six)
Engine Details
Displacement 2 7:
2.7 Liters (2687 cc)
Displacement 3 4:
3.4 Liters (3387 cc) (Cayman S)
Performance 2 7
Horsepower 2 7:
245 PS (242 hp) @ 6500 rpm
Torque 2 7:
270 Nm (199 lb-ft) @ 4600 rpm
Performance 3 4
Horsepower 3 4:
295 PS (291 hp) @ 7400 rpm (Cayman S)
Torque 3 4:
340 Nm (251 lb-ft) @ 4750 rpm (Cayman S)
Fuel System
Injection Type:
Sequential Multi-Point Fuel Injection (MPI)
Fuel Type:
Premium Unleaded Gasoline (91 Octane or higher recommended)
Engine Management
ECU:
Bosch Motronic (Specific variant may vary)
Cooling
Cooling System Type:
Water-cooled, closed-loop system with electric fan and coolant reservoir.
Lubrication
Oil System:
Dry-sump lubrication system with external oil tank.
🔧 Transmission
Standard
Type Standard:
6-Speed Manual Transaxle
Optional
Type Optional:
5-Speed Tiptronic Automatic Transaxle
Features
Clutch Type:
Hydraulically actuated single-plate dry clutch.
Gear Ratios:
Specific ratios vary by model and transmission type, detailed in manual.
Differential:
Limited-slip differential (LSD) often optional or standard on S models.
Maintenance
Manual Fluid Spec:
Porsche Part No. 000.043.205.28 (G50/30, G97/00, G97/01, G97/02 Gear Oil) - typically a GL-4 or GL-5 synthetic gear oil
Tiptronic Fluid Spec:
Porsche ATF JWS 3309 (or equivalent) - typically a Dexron III/VI compatible fluid
📐 Dimensions
Exterior
Length:
Approx. 4435 mm (174.6 in)
Width:
Approx. 1801 mm (70.9 in)
Height:
Approx. 1301 mm (51.2 in)
Wheelbase:
Approx. 2415 mm (95.1 in)
Weights
Curb Weight Base:
Approx. 1330 kg (2932 lbs)
Curb Weight S:
Approx. 1370 kg (3020 lbs) (Cayman S)
Gvw:
Gross Vehicle Weight (specified by model, consult manual)
Cargo
Trunk Volume Front:
Approx. 150 Liters (5.3 cu ft)
Trunk Volume Rear:
Approx. 260 Liters (9.2 cu ft)
🛡️ Safety Features
Ratings
NHTSA Ratings:
Specific NHTSA ratings not readily available for this model year/variant, refer to official reports if required.
IIHS Ratings:
Specific IIHS ratings not readily available for this model year/variant, refer to official reports if required.
Active Features
Psm:
Porsche Stability Management (PSM) system, including ABS, ASR, ABD, MSR.
Brakes Front:
Ventilated discs, typically 318 mm diameter (Cayman) / 340 mm diameter (Cayman S).
Brakes Rear:
Ventilated discs, typically 299 mm diameter (Cayman) / 330 mm diameter (Cayman S).
Traction Control:
ASR (Anti-Slip Regulation)
Passive Features
Airbags:
Driver and passenger front airbags, side airbags, and head airbags (curtain).
Seatbelts:
Three-point inertia-reel seatbelts with pre-tensioners and belt force limiters.
Rollover Protection:
Integrated rollover protection bars behind the headrests.
💡 Technology Features
Infotainment
PCM Version:
PCM 2.1 or optional PCM 3.0 depending on configuration.
Audio Options:
Standard CDR-24 CD radio, optional Bose or Burmester surround sound systems.
Navigation:
Optional GPS navigation module integrated into PCM.
Driver Assistance
Cruise Control:
Standard cruise control system.
Parking Sensors:
Optional ParkAssist system.
Connectivity
Bluetooth:
Optional Bluetooth hands-free connectivity module.
Aux Input:
Standard AUX input for audio devices.
🔧 Maintenance
Service Intervals General
Oil Change Interval:
Typically 10,000 miles or 1 year, whichever comes first (refer to manual for specific model year recommendations).
Major Service Interval:
Major services with spark plug replacement and other checks typically at 30,000 or 40,000 miles.
Fluid Specifications
Engine Oil Spec:
Porsche A40, or API SN/SP with ACEA C3. Viscosity typically 0W-40 or 5W-40 depending on climate and specific engine variant.
Coolant Spec:
Porsche Coolant (Antifreeze) G48 (or equivalent approved silicate-free coolant with ethylene glycol base).
Brake Fluid Spec:
Porsche Brake Fluid DOT 4 (or DOT 5.1 if approved).
Power Steering Fluid Spec:
Pentosin CHF 11S or equivalent.
Known Issues
Intermediate Shaft Bearing:
While less common than in earlier models, IMS bearing failures can occur; manual provides inspection and replacement procedures.
Rear Main Seal:
Potential for oil leaks from the rear main seal, often addressed during clutch replacement.
Clutch Wear:
Normal wear item, replacement intervals depend heavily on driving style. Manual details clutch inspection and replacement.
Coolant Leaks:
Potential for leaks from hoses, water pump, or radiators; manual covers diagnosis and replacement.
Oil Pressure Sender:
Can sometimes fail, leading to inaccurate oil pressure readings.
📚 Vehicle History
Brand Heritage
Manufacturer:
Dr. Ing. h.c. F. Porsche AG, Stuttgart, Germany.
Legacy:
Renowned for sports car engineering, performance, and racing heritage.
Model Evolution
Introduction Year:
2005
Platform:
Based on the Boxster (987) platform, but with a unique chassis and body.
Positioning:
Positioned as a more performance-oriented and track-focused alternative to the Boxster.
Production
Production Years:
2005-2008 (for this generation/manual coverage)
Manufacturing Location:
Finland (Valmet Automotive under contract for Porsche).
🏆 Awards & Recognition
Recognitions
Car And Driver Otr:
Often praised by automotive publications for its exceptional handling and driver engagement, frequently appearing on '10Best' lists or similar awards for its class.
Ratings
Handling Reputation:
Consistently high ratings for steering feel, balance, and chassis feedback, widely regarded as one of the best handling cars in its segment.
Certifications
Euro Ncap:
Specific Euro NCAP results for this generation are not as prominently documented as for newer models, but Porsche vehicles generally meet high safety standards.
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