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Porsche Cayman 2005-2007 Factory Service Repair Workshop Manual

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🏷️ Basic Information Identification Make: Porsche Model: Cayman Generation Generation Code: 987 Production Years: 2005-2007 Codes Chassis Code: 987 👋 Introduction Market Position Positioning: The Porsche Cayman (987) occupies the mid-engine sports car segment, known for its exceptional handling, driver engagement, and premium build quality. Competitive Analysis Competitors: Competes with vehicles like the Chevrolet Corvette, BMW M2/M3 variants, Audi TT RS, and Mercedes-AMG GT. Key Features Handling: Renowned for its balanced chassis and communicative steering, making it a favorite among driving enthusiasts. Mid Engine Layout: Contributes to optimal weight distribution and a low center of gravity, enhancing dynamic performance. Design: Distinctive Porsche design language, blending aggressive sports car styling with everyday usability. 📋 Manual Details Coverage Areas Covered Years: 2005, 2006, 2007 Covered Models: All Porsche Cayman models, including all engine variants Page Count Estimated Page Count: Extensive (Specific page count not provided, but described as comprehensive A-Z) Manual Type Manual Type: Factory Service Repair Workshop Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine: Complete engine mechanicals, diagnostics, troubleshooting, and repair procedures for all variants. Transmission: Coverage of manual and Tiptronic transmissions, including removal, installation, fluid service, and internal repairs. Drivetrain: Detailed information on rear-wheel drive system, differential, axles, and CV joints. Suspension: Comprehensive coverage of front and rear suspension systems, including component identification, testing, alignment, and replacement. Brakes: In-depth coverage of ABS, brake system hydraulics, caliper overhaul, rotor replacement, parking brake, and bleeding procedures. Steering: Information on power steering system, steering rack, tie rods, and related components. Electrical System: Extensive coverage of the entire electrical system, including battery, charging system, ignition, lighting, power windows, seats, and comfort features. HVAC: Detailed procedures for air conditioning system service, repair, and refrigerant handling. Bodywork: Procedures for body panel removal, installation, collision repair, and interior trim. Wiring Diagrams: Included, providing detailed circuit schematics for all vehicle systems. Procedures Included Routine Maintenance: Covers all routine maintenance tasks, from oil changes to spark plug replacement. Troubleshooting: Step-by-step troubleshooting guides for common and complex issues. Repair: All repair procedures are covered, from minor adjustments to major component overhauls. Diagnostics: Diagnostic procedures utilizing Porsche's diagnostic tools and common OBD-II protocols. Disassembly Reassembly: Detailed instructions for the complete disassembly and reassembly of major vehicle components. Technical Depth Depth: Comprehensive, ranging from basic owner maintenance to advanced technical repair and diagnostics. 📊 Manual Specifications File Format File Format: PDF Searchable: Yes (typical for well-produced PDF manuals) Print Quality Image Quality: High (includes pictures and diagrams) Binding Type Binding Type: Digital Download (Not physically bound) Paper Type Paper Type: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Code Base: MA1.01 Engine Type: Flat-Six (Boxer) Displacement Base: 2.7 Liters (for base Cayman) Displacement S Model: 3.4 Liters (for Cayman S) Performance Horsepower Base: 245 hp @ 6500 rpm (approx.) Torque Base: 201 lb-ft @ 4600 rpm (approx.) Horsepower S Model: 295 hp @ 6200 rpm (approx.) Torque S Model: 251 lb-ft @ 4400 rpm (approx.) Fuel System Fuel Delivery: Sequential multi-point fuel injection (MPI) Fuel Type: Premium Unleaded Gasoline (91 Octane or higher) 🔧 Transmission Standard Transmission Type Standard: 6-Speed Manual Transaxle Optional Transmission Type Optional: 5-Speed Tiptronic Automatic Transaxle Features Clutch Type: Dry single-plate clutch (Manual) 📐 Dimensions Exterior Length: 4427 mm (174.3 in) Width: 1801 mm (70.9 in) Height: 1301 mm (51.2 in) Wheelbase: 2415 mm (95.1 in) Weights Curb Weight Base: 1340 kg (2954 lbs) Curb Weight S: 1360 kg (2998 lbs) Cargo Front Trunk Volume: 150 liters (5.3 cu ft) Rear Trunk Volume: 260 liters (9.2 cu ft) 🛡️ Safety Features Ratings NHTSA Rating: Not explicitly rated by NHTSA for this generation, but generally expected to meet high safety standards. Active Features ABS: Standard Anti-lock Braking System (ABS) Psm: Standard Porsche Stability Management (PSM) Traction Control: Standard Traction Control System (TCS) Passive Features Airbags: Driver and front passenger airbags, side airbags (Porsche Side Impact Protection - POSIP), head airbags. Seat Belts: 3-point inertia-reel seat belts with pretensioners and load limiters. Rollover Protection: Integrated rollover protection system behind the seats. 💡 Technology Features Infotainment Audio System: Standard CD player, optional Bose high-end sound system, optional CDR-24 or PCM (Porsche Communication Management) infotainment units. Navigation: Optional GPS navigation integrated into the PCM system. Driver Assistance Cruise Control: Standard cruise control. Parking Sensors: Optional ParkAssist (parking sensors). Connectivity Bluetooth: Optional Bluetooth connectivity for hands-free calling, typically part of the PCM system. 🔧 Maintenance Service Intervals Oil Change Interval: Typically every 10,000-15,000 miles or 12-24 months, depending on driving conditions (check manual for exact specification). Major Service: Major services often include spark plug replacement, brake fluid flush, coolant flush, and belt inspection at intervals like 30,000-60,000 miles. Fluid Specifications Engine Oil: Mobil 1 0W-40 synthetic or equivalent (refer to manual for exact Porsche A40 approval). Engine Oil Capacity: Approx. 8.5 liters (8.9 US quarts) Coolant:...
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Porsche Cayman 2005-2007 Factory Service Repair Workshop Manual
🏷️ Basic Information
Identification
Make:
Porsche
Model:
Cayman
Generation
Generation Code:
987
Production Years:
2005-2007
Codes
Chassis Code:
987
👋 Introduction
Market Position
Positioning:
The Porsche Cayman (987) occupies the mid-engine sports car segment, known for its exceptional handling, driver engagement, and premium build quality.
Competitive Analysis
Competitors:
Competes with vehicles like the Chevrolet Corvette, BMW M2/M3 variants, Audi TT RS, and Mercedes-AMG GT.
Key Features
Handling:
Renowned for its balanced chassis and communicative steering, making it a favorite among driving enthusiasts.
Mid Engine Layout:
Contributes to optimal weight distribution and a low center of gravity, enhancing dynamic performance.
Design:
Distinctive Porsche design language, blending aggressive sports car styling with everyday usability.
📋 Manual Details
Coverage Areas
Covered Years:
2005, 2006, 2007
Covered Models:
All Porsche Cayman models, including all engine variants
Page Count
Estimated Page Count:
Extensive (Specific page count not provided, but described as comprehensive A-Z)
Manual Type
Manual Type:
Factory Service Repair Workshop Manual
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Engine:
Complete engine mechanicals, diagnostics, troubleshooting, and repair procedures for all variants.
Transmission:
Coverage of manual and Tiptronic transmissions, including removal, installation, fluid service, and internal repairs.
Drivetrain:
Detailed information on rear-wheel drive system, differential, axles, and CV joints.
Suspension:
Comprehensive coverage of front and rear suspension systems, including component identification, testing, alignment, and replacement.
Brakes:
In-depth coverage of ABS, brake system hydraulics, caliper overhaul, rotor replacement, parking brake, and bleeding procedures.
Steering:
Information on power steering system, steering rack, tie rods, and related components.
Electrical System:
Extensive coverage of the entire electrical system, including battery, charging system, ignition, lighting, power windows, seats, and comfort features.
HVAC:
Detailed procedures for air conditioning system service, repair, and refrigerant handling.
Bodywork:
Procedures for body panel removal, installation, collision repair, and interior trim.
Wiring Diagrams:
Included, providing detailed circuit schematics for all vehicle systems.
Procedures Included
Routine Maintenance:
Covers all routine maintenance tasks, from oil changes to spark plug replacement.
Troubleshooting:
Step-by-step troubleshooting guides for common and complex issues.
Repair:
All repair procedures are covered, from minor adjustments to major component overhauls.
Diagnostics:
Diagnostic procedures utilizing Porsche's diagnostic tools and common OBD-II protocols.
Disassembly Reassembly:
Detailed instructions for the complete disassembly and reassembly of major vehicle components.
Technical Depth
Depth:
Comprehensive, ranging from basic owner maintenance to advanced technical repair and diagnostics.
📊 Manual Specifications
File Format
File Format:
PDF
Searchable:
Yes (typical for well-produced PDF manuals)
Print Quality
Image Quality:
High (includes pictures and diagrams)
Binding Type
Binding Type:
Digital Download (Not physically bound)
Paper Type
Paper Type:
N/A (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine Code Base:
MA1.01
Engine Type:
Flat-Six (Boxer)
Displacement Base:
2.7 Liters (for base Cayman)
Displacement S Model:
3.4 Liters (for Cayman S)
Performance
Horsepower Base:
245 hp @ 6500 rpm (approx.)
Torque Base:
201 lb-ft @ 4600 rpm (approx.)
Horsepower S Model:
295 hp @ 6200 rpm (approx.)
Torque S Model:
251 lb-ft @ 4400 rpm (approx.)
Fuel System
Fuel Delivery:
Sequential multi-point fuel injection (MPI)
Fuel Type:
Premium Unleaded Gasoline (91 Octane or higher)
🔧 Transmission
Standard
Transmission Type Standard:
6-Speed Manual Transaxle
Optional
Transmission Type Optional:
5-Speed Tiptronic Automatic Transaxle
Features
Clutch Type:
Dry single-plate clutch (Manual)
📐 Dimensions
Exterior
Length:
4427 mm (174.3 in)
Width:
1801 mm (70.9 in)
Height:
1301 mm (51.2 in)
Wheelbase:
2415 mm (95.1 in)
Weights
Curb Weight Base:
1340 kg (2954 lbs)
Curb Weight S:
1360 kg (2998 lbs)
Cargo
Front Trunk Volume:
150 liters (5.3 cu ft)
Rear Trunk Volume:
260 liters (9.2 cu ft)
🛡️ Safety Features
Ratings
NHTSA Rating:
Not explicitly rated by NHTSA for this generation, but generally expected to meet high safety standards.
Active Features
ABS:
Standard Anti-lock Braking System (ABS)
Psm:
Standard Porsche Stability Management (PSM)
Traction Control:
Standard Traction Control System (TCS)
Passive Features
Airbags:
Driver and front passenger airbags, side airbags (Porsche Side Impact Protection - POSIP), head airbags.
Seat Belts:
3-point inertia-reel seat belts with pretensioners and load limiters.
Rollover Protection:
Integrated rollover protection system behind the seats.
💡 Technology Features
Infotainment
Audio System:
Standard CD player, optional Bose high-end sound system, optional CDR-24 or PCM (Porsche Communication Management) infotainment units.
Navigation:
Optional GPS navigation integrated into the PCM system.
Driver Assistance
Cruise Control:
Standard cruise control.
Parking Sensors:
Optional ParkAssist (parking sensors).
Connectivity
Bluetooth:
Optional Bluetooth connectivity for hands-free calling, typically part of the PCM system.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 10,000-15,000 miles or 12-24 months, depending on driving conditions (check manual for exact specification).
Major Service:
Major services often include spark plug replacement, brake fluid flush, coolant flush, and belt inspection at intervals like 30,000-60,000 miles.
Fluid Specifications
Engine Oil:
Mobil 1 0W-40 synthetic or equivalent (refer to manual for exact Porsche A40 approval).
Engine Oil Capacity:
Approx. 8.5 liters (8.9 US quarts)
Coolant:
Glysantin G48 or Porsche approved equivalent (blue/green silicate-based).
Brake Fluid:
DOT 4 (high-performance) or DOT 5.1 (refer to manual for specific Porsche approval).
Transmission Fluid Manual:
Pentosin MTF 2 or equivalent, check manual for specific gear oil specification.
Transmission Fluid Tiptronic:
Porsche ATF AW-1 or equivalent.
Known Issues
Intermediate Shaft Bearing (Ims):
While less prone than earlier models, some 987 Boxster/Cayman models with certain engine variants can still experience IMS bearing failure. The manual would cover diagnostic and repair procedures.
Pdk Clutch Actuation:
Not applicable to this generation as it uses Tiptronic or manual transmissions, not PDK.
Rear Main Seal:
Potential for oil leaks from the rear main seal, often requiring transmission removal for replacement. The manual details this procedure.
Suspension Components:
Wear on suspension bushings and ball joints due to the sports-oriented nature and driving style. Covered in detail.
📚 Vehicle History
Brand Heritage
Heritage:
Porsche has a long and illustrious history in motorsport and sports car manufacturing, renowned for engineering excellence and performance.
Model Evolution
Predecessor:
The Cayman concept evolved from Porsche's mid-engine road car experiments and the success of the Boxster.
Introduction Year:
2005
Production
Manufacturing Location:
Stuttgart, Germany (as part of the 987 generation, sharing production facilities with the Boxster).
🏆 Awards & Recognition
Recognitions
Car And Driver:
The Cayman and its sibling, the Boxster, have consistently been recognized by publications like Car and Driver on their '10Best' lists for their exceptional driving dynamics.
Auto Express:
Often praised in reviews from automotive media for handling and performance.
Ratings
Handling Dynamics:
Universally acclaimed for superior handling, agility, and driver feedback, often setting benchmarks in its class.
Certifications
Porsche Engineering:
Represents Porsche's commitment to sports car engineering and performance, built to rigorous German engineering standards.
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