2005-2008 Porsche Cayman Service Repair Manual

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🏷️ Basic Information Identification Make: Porsche Model: Cayman Model Variant: Cayman / Cayman S Production Years Covered: 2005, 2006, 2007, 2008 Chassis Code: 987 Generation Generation Code: 987 👋 Introduction Market Position Market Position: The Porsche Cayman (987) is a mid-engined sports car positioned as a more accessible entry into Porsche's sports car lineage, offering a balance of performance, handling, and luxury. It competed with cars like the Audi TT, BMW Z4, and Chevrolet Corvette. Competitive Analysis Competitive Analysis: The Cayman distinguished itself with its exceptional chassis balance derived from its mid-engine layout, superior steering feel, and the high-quality engineering expected from Porsche. While rivals might offer more outright power or different driving dynamics, the Cayman was lauded for its purity of driving experience. Key Features Key Features: Mid-engine platform, flat-six boxer engines, rear-wheel drive, precise handling, premium interior appointments, distinctive styling, robust build quality. Chassis Platform: Mid-engine, rear-wheel-drive layout on the Porsche 987 platform, shared significantly with the 987 Boxster, providing ideal weight distribution for handling. 📋 Manual Details Coverage Areas Systems Covered: ABS, Airbags, Automatic Transmission, Body (Front & Rear), Brakes (Hydraulics & Mechanical), Bumpers, Clutch Control, Communication Systems, Convertible Top/Hardtop, Cooling System, Crankshaft & Pistons, Crankshaft Suspension, Cylinder Head, Differential, Door Locking, Exterior Equipment, Front Wheel Suspension & Drive Shafts, Fuel Actuation & System, Heating, Ignition System, Instruments & Alarm System, Interior Equipment, Level Control, Lights, Lamps & Switches, Linings & Insulation, Lubrication, Maintenance, Manual Transmission, Rear Wheel Suspension & Drive Shafts, Seats, Spark Plugs, Starter, Power Supply, Cruise Control, Steering, Torque Converter, Ventilation, Wheels & Tires, Window Control, Wiper & Washer, Wiring Diagrams Specific Components Covered: Details on engine internal components (crankshaft, pistons, cylinder head assembly), transmission internals, brake caliper, rotor, and ABS modulator specifics, suspension arms and components, steering rack and pump, AC compressor and condenser. Page Count Page Count: 5500+ Manual Type Manual Type: Official Maintenance & Service Workshop Manual Purpose: Authoritative guide for all maintenance, diagnostics, repair, and overhaul procedures for professional Porsche technicians and advanced DIY mechanics. Language Language: English Format Format: Likely Digital (PDF), though not explicitly stated. Given the page count and typical industry practice, a searchable digital format is most probable. 📖 Manual Coverage Systems Covered Engine Systems: Crankshaft, Pistons, Cylinder Head, Cooling, Fuel System (Actuation & Components), Ignition System, Lubrication, Spark Plugs Drivetrain Systems: Clutch Control, Automatic Transmission (Actuation & Gears Control), Manual Transmission (Actuation, Gears & Shafts), Differential, Torque Converter, Front Wheel Suspension & Drive Shafts, Rear Wheel Suspension & Drive Shafts Chassis Systems: Brakes (Hydraulics & Mechanical), ABS, Steering, Wheels & Tires, Level Control Body Electronics: Covers power windows, central locking, seat adjustment mechanisms, convertible top operation (if applicable to certain Boxster variants which share the platform, though Cayman is a coupe), and interior trim removal. Suspension Components: Detailed instructions for servicing and replacing control arms, ball joints, shock absorbers, springs, sway bars, and wheel bearings for both front and rear axles. Body And Interior Body And Interior Systems: Body (Front & Rear), Bumpers, Convertible Top/Hardtop, Door Locking, Exterior Equipment, Interior Equipment, Linings & Insulation, Seats, Window Control, Wiper & Washer Electrical And Electronics Electrical And Electronics Systems: Airbags, Communication Systems, Heating, Ignition System, Instruments & Alarm System, Lights, Lamps & Switches, Starter, Power Supply, Cruise Control, Ventilation, Wiring Diagrams, Wiring Procedures Included Maintenance Procedures: Scheduled maintenance, fluid changes, filter replacements, lubrication, component inspection and servicing Repair Procedures: Detailed step-by-step instructions for component removal, installation, adjustment, and repair across all covered systems Diagnostic Procedures: Troubleshooting guides, fault code interpretation, diagnostic steps for various systems Wiring Diagrams: Comprehensive and detailed wiring schematics for all electrical systems, crucial for diagnosing and repairing electrical issues. Torque Specifications: Includes precise torque values for all critical fasteners, essential for proper reassembly and component longevity. Technical Depth Technical Depth: Comprehensive. Designed for professional technicians, implying detailed specifications, diagrams, diagnostic procedures, and complete rebuild information. Troubleshooting Coverage: The manual provides detailed diagnostic flowcharts and symptom-based troubleshooting for electrical and mechanical faults, enabling technicians to accurately pinpoint issues. Diagnostic Tools And Procedures: Likely references specific Porsche diagnostic tools (e.g., PIWIS) and procedures for reading fault codes and performing system tests. 📊 Manual Specifications File Format File Format: Assumed PDF for ease of distribution and searchability, given the volume of content. Searchability: If digital (PDF), the manual should be text-searchable, allowing quick access to specific topics and keywords. Print Quality Print Quality: Professional technical documentation quality, with clear schematics, diagrams, and text. If digital, expects high-resolution images. Diagram Clarity: Diagrams and illustrations are expected to be high-resolution, clear, and accurately labeled, with exploded views for complex assemblies. Binding Type Binding Type: Not Applicable (assuming digital format). If printed, would likely be a sturdy comb or spiral binding for lay-flat use in a workshop. Paper Type Paper Type: Not Applicable (assuming digital format). If printed, would...

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Tags: 2005 2006 2007 2008 Car Cars Cayman Porsche

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Description

🏷️ Basic Information

Identification

Make:

Porsche

Model:

Cayman

Model Variant:

Cayman / Cayman S

Production Years Covered:

2005, 2006, 2007, 2008

Chassis Code:

Generation

Generation Code:

👋 Introduction

Market Position

Market Position:

The Porsche Cayman (987) is a mid-engined sports car positioned as a more accessible entry into Porsche's sports car lineage, offering a balance of performance, handling, and luxury. It competed with cars like the Audi TT, BMW Z4, and Chevrolet Corvette.

Competitive Analysis

Competitive Analysis:

The Cayman distinguished itself with its exceptional chassis balance derived from its mid-engine layout, superior steering feel, and the high-quality engineering expected from Porsche. While rivals might offer more outright power or different driving dynamics, the Cayman was lauded for its purity of driving experience.

Key Features

Key Features:

Mid-engine platform, flat-six boxer engines, rear-wheel drive, precise handling, premium interior appointments, distinctive styling, robust build quality.

Chassis Platform:

Mid-engine, rear-wheel-drive layout on the Porsche 987 platform, shared significantly with the 987 Boxster, providing ideal weight distribution for handling.

📋 Manual Details

Coverage Areas

Systems Covered:

ABS, Airbags, Automatic Transmission, Body (Front & Rear), Brakes (Hydraulics & Mechanical), Bumpers, Clutch Control, Communication Systems, Convertible Top/Hardtop, Cooling System, Crankshaft & Pistons, Crankshaft Suspension, Cylinder Head, Differential, Door Locking, Exterior Equipment, Front Wheel Suspension & Drive Shafts, Fuel Actuation & System, Heating, Ignition System, Instruments & Alarm System, Interior Equipment, Level Control, Lights, Lamps & Switches, Linings & Insulation, Lubrication, Maintenance, Manual Transmission, Rear Wheel Suspension & Drive Shafts, Seats, Spark Plugs, Starter, Power Supply, Cruise Control, Steering, Torque Converter, Ventilation, Wheels & Tires, Window Control, Wiper & Washer, Wiring Diagrams

Specific Components Covered:

Details on engine internal components (crankshaft, pistons, cylinder head assembly), transmission internals, brake caliper, rotor, and ABS modulator specifics, suspension arms and components, steering rack and pump, AC compressor and condenser.

Page Count

Page Count:

5500+

Manual Type

Manual Type:

Official Maintenance & Service Workshop Manual

Purpose:

Authoritative guide for all maintenance, diagnostics, repair, and overhaul procedures for professional Porsche technicians and advanced DIY mechanics.

Language

Language:

English

Format

Format:

Likely Digital (PDF), though not explicitly stated. Given the page count and typical industry practice, a searchable digital format is most probable.

📖 Manual Coverage

Systems Covered

Engine Systems:

Crankshaft, Pistons, Cylinder Head, Cooling, Fuel System (Actuation & Components), Ignition System, Lubrication, Spark Plugs

Drivetrain Systems:

Clutch Control, Automatic Transmission (Actuation & Gears Control), Manual Transmission (Actuation, Gears & Shafts), Differential, Torque Converter, Front Wheel Suspension & Drive Shafts, Rear Wheel Suspension & Drive Shafts

Chassis Systems:

Brakes (Hydraulics & Mechanical), ABS, Steering, Wheels & Tires, Level Control

Body Electronics:

Covers power windows, central locking, seat adjustment mechanisms, convertible top operation (if applicable to certain Boxster variants which share the platform, though Cayman is a coupe), and interior trim removal.

Suspension Components:

Detailed instructions for servicing and replacing control arms, ball joints, shock absorbers, springs, sway bars, and wheel bearings for both front and rear axles.

Body And Interior

Body And Interior Systems:

Body (Front & Rear), Bumpers, Convertible Top/Hardtop, Door Locking, Exterior Equipment, Interior Equipment, Linings & Insulation, Seats, Window Control, Wiper & Washer

Electrical And Electronics

Electrical And Electronics Systems:

Airbags, Communication Systems, Heating, Ignition System, Instruments & Alarm System, Lights, Lamps & Switches, Starter, Power Supply, Cruise Control, Ventilation, Wiring Diagrams, Wiring

Procedures Included

Maintenance Procedures:

Scheduled maintenance, fluid changes, filter replacements, lubrication, component inspection and servicing

Repair Procedures:

Detailed step-by-step instructions for component removal, installation, adjustment, and repair across all covered systems

Diagnostic Procedures:

Troubleshooting guides, fault code interpretation, diagnostic steps for various systems

Wiring Diagrams:

Comprehensive and detailed wiring schematics for all electrical systems, crucial for diagnosing and repairing electrical issues.

Torque Specifications:

Includes precise torque values for all critical fasteners, essential for proper reassembly and component longevity.

Technical Depth

Technical Depth:

Comprehensive. Designed for professional technicians, implying detailed specifications, diagrams, diagnostic procedures, and complete rebuild information.

Troubleshooting Coverage:

The manual provides detailed diagnostic flowcharts and symptom-based troubleshooting for electrical and mechanical faults, enabling technicians to accurately pinpoint issues.

Diagnostic Tools And Procedures:

Likely references specific Porsche diagnostic tools (e.g., PIWIS) and procedures for reading fault codes and performing system tests.

📊 Manual Specifications

File Format

File Format:

Assumed PDF for ease of distribution and searchability, given the volume of content.

Searchability:

If digital (PDF), the manual should be text-searchable, allowing quick access to specific topics and keywords.

Print Quality

Print Quality:

Professional technical documentation quality, with clear schematics, diagrams, and text. If digital, expects high-resolution images.

Diagram Clarity:

Diagrams and illustrations are expected to be high-resolution, clear, and accurately labeled, with exploded views for complex assemblies.

Binding Type

Binding Type:

Not Applicable (assuming digital format). If printed, would likely be a sturdy comb or spiral binding for lay-flat use in a workshop.

Paper Type

Paper Type:

Not Applicable (assuming digital format). If printed, would typically be heavy-duty, glossy paper to withstand workshop environments and allow clear reproduction of diagrams.

⚙️ Engine Specifications

Primary Engine

Engine Type:

Naturally Aspirated Flat-Six Boxer

Displacement Cayman:

2.7 Liters (2687 cc)

Displacement Cayman S:

3.4 Liters (3387 cc)

Engine Codes:

Known engine codes for this generation include M97.20 (2.7L) and M97.21 (3.4L).

Performance Cayman

Horsepower Cayman:

245 hp @ 6500 rpm

Torque Cayman:

270 Nm (199 lb-ft) @ 4600-6000 rpm

Performance Cayman S

Horsepower Cayman S:

295 hp @ 6200 rpm

Torque Cayman S:

340 Nm (251 lb-ft) @ 4400-6000 rpm

Fuel System

Fuel System Type:

Fuel Injection (Multi-point Sequential)

Fuel Type:

Premium Unleaded Gasoline (91+ Octane)

🔧 Transmission

Standard

Standard Transmission Type:

6-Speed Manual

Optional

Optional Transmission Type:

5-Speed Tiptronic (Automatic with Manual Override)

Features

Transmission Features:

Rear-wheel drive, limited-slip differential (often optional or standard on 'S' models), close-ratio gearing for sporty performance.

📐 Dimensions

Exterior

Wheelbase:

Approx. 2,280 mm (89.8 in)

Length:

Approx. 4,435 mm (174.6 in)

Width:

Approx. 1,770 mm (69.7 in)

Height:

Approx. 1,300 mm (51.2 in)

Weights

Curb Weight Cayman:

Approx. 1,300 kg (2,866 lbs)

Curb Weight Cayman S:

Approx. 1,340 kg (2,954 lbs)

Cargo

Cargo Capacity:

Dual trunks (front and rear) providing a combined capacity of approximately 260 liters (9.2 cu ft).

🛡️ Safety Features

Ratings

Safety Ratings:

Generally high safety ratings from independent agencies of the era, reflecting Porsche's commitment to occupant protection.

Active Features

Active Safety Features:

Anti-lock Braking System (ABS), Electronic Stability Control (PSM - Porsche Stability Management), Traction Control System (TCS), Optional Porsche Active Suspension Management (PASM).

Passive Features

Passive Safety Features:

Front airbags, side airbags (thorax), optional head airbags, reinforced chassis structure, three-point seat belts with pre-tensioners.

💡 Technology Features

Infotainment

Infotainment System:

PCM (Porsche Communication Management) system, typically featuring a navigation system, radio, CD player, and optional enhanced audio systems (e.g., Bose).

Driver Assistance

Driver Assistance Features:

Cruise control, parking assistance (optional rear parking sensors), and the aforementioned PSM (stability control).

Adaptive Suspension:

Coverage of optional PASM (Porsche Active Suspension Management), including sensor locations, control module operation, and diagnostic procedures for damping control.

Connectivity

Connectivity Options:

Optional Bluetooth phone preparation, CD changer integration.

🔧 Maintenance

Service Intervals

Minor Service Interval:

Typically 1 year or 10,000 - 15,000 miles (16,000 - 24,000 km), whichever comes first. Includes oil and filter change, inspection of various components.

Major Service Interval:

Every 2 years or 20,000 - 30,000 miles (32,000 - 48,000 km). Includes additional checks like spark plugs, brake fluid flush, coolant, and drive belts.

Spark Plug Replacement:

Typically every 30,000 to 60,000 miles, depending on engine type and usage. The manual will specify the exact interval and correct spark plug part number.

Fluid Specifications

Engine Oil Specification:

Typically Mobil 1 0W-40 or equivalent synthetic oil meeting Porsche A40 approval. Specific viscosity may vary by region and climate.

Coolant Specification:

Porsche specified G48 (blue) coolant or equivalent. Mixture of 50% coolant and 50% distilled water.

Brake Fluid Specification:

DOT 4 (or DOT 5.1 if specified for certain systems) brake fluid, with a recommendation for flush every 2 years.

Transmission Fluid Manual:

Manual transmission fluid meeting Porsche specifications (e.g., Pentosin MTF-LT2). Refer to manual for specific part numbers and change intervals, often considered 'lifetime' but fluid service is recommended.

Transmission Fluid Automatic:

Tiptronic transmission fluid meeting Porsche specifications (e.g., ATF LT 71141). Change intervals vary, often around 60,000 miles.

Power Steering Fluid:

Hydrolic fluid for power steering system. Specific Porsche specification required. Often Dexron III/VI type for older models, but verification is critical. Manual will specify.

Known Issues

Common Issues:

IMS Bearing (Intermediate Shaft Bearing) failure in early models, potential bore scoring in some engines (especially early 3.4L), water pump leaks, clutch release bearing noise, HVAC blower motor issues, and headlight condensation.

Common Repair Tasks Covered:

The manual would detail procedures for replacing spark plugs, coils, serpentine belts, coolant hoses, various engine and transmission seals, brake pads and rotors, suspension bushings, and exhaust systems.

📚 Vehicle History

Brand Heritage

Brand Heritage:

Porsche has a rich history dating back to 1931, renowned for its engineering prowess, racing success, and iconic sports cars like the 911. The brand is synonymous with performance, precision, and luxury.

Model Evolution

Model Evolution:

The Cayman (987) was introduced in 2005 as a coupe version of the Boxster roadster. It represented Porsche's first foray into the mid-engined coupe market segment outside of its limited-production GT models. It shared a significant platform with the 987 Boxster.

Engine Updates:

The 2005-2008 models cover the initial introduction of the 987 Cayman with the M97 series engines. Later iterations within this range might see minor updates, but the core architecture remains consistent.

Production

Production Location:

Assembled in Stuttgart, Germany, or at the Finnish contract manufacturer Valmet Automotive.

🏆 Awards & Recognition

Recognitions

Industry Awards:

The Cayman platform received numerous accolades from automotive publications for its exceptional handling, driving dynamics, and value proposition within the Porsche brand, often being lauded as a driver's car.