2005-2008 Porsche Cayman Service Repair Manual

BRAKES Anti-Lock Brake System (ABS) 45 01 01 PSM/ABS CHECK USING THE PIWIS TESTER - AS OF MY 2005 (ALL MODELS) TOOLS TEST OVERVIEW Test overview The ABS/PSM test includes:  Reading out fault memory.  Static test.  Swap testing hydraulics in the Checks/Tests menu. The swap test is menu-driven. Once you start the test, follow the instructions on the PIWIS Tester.  Checking function and correct allocation of speed sensor in the Actual values menu. Turn all four wheels individually during the test. The speed assigned to the wheel in question must be displayed when you turn the wheel. The non-tested wheel must be held (by a second person) when the test is performed on the driven axle. Fig. 1: Hydraulic unit Courtesy of PORSCHE OF NORTH AMERICA, INC. Procedure: If work has been done on the hydraulic unit -D- , the speed sensors and the wire harness or if the hydraulic unit -D- is replaced, an ABS/PSM test (system check) must be performed using the PIWIS Tester! This is the case, for example, after accident repairs! This prevents any confusion of electrical or hydraulic lines and ensures faultless operation of the system! See Fig. 1 . Designation Type Number Explanation PIWIS Tester special tool P 9718 NOTE:  PSM is installed as standard.  PSM comprises the functions ABS (anti-lock braking system), ABD (automatic brake differential), ASR (anti-slip regulation), EDTC (engine drag torque control), EBD (electronic brake-force distribution) and vehicle dynamic control. 2007 Porsche Cayman S BRAKES Anti-Lock Brake System (ABS) 2007 Porsche Cayman S BRAKES Anti-Lock Brake System (ABS)

If certain brake lines are replaced, e. g. at the intermediate piece in the front left wheel housing -E- , a swap test must also be performed (in the Checks/Tests menu)! Unintentional bending of the brake lines could lead to incorrect hydraulic allocation despite the markings (FL = front left, FR = front right, RL = rear left, RR = rear right)! See Fig. 1 . If a fault is displayed during operation (when no assembly work was carried out beforehand), diagnosis and fault finding are also carried out using the PIWIS Tester! To do this, select the PSM system and read out the fault memory there! The fault can then be located using the appropriate menus (Drive links, Actual values, Checks/Tests)! PSM check using the PIWIS Tester 1. PIWIS Tester P 9718 must be connected to the vehicle, then start it. Switch on ignition and press >> to continue. Fig. 2: Diagnostic socket Courtesy of PORSCHE OF NORTH AMERICA, INC. The PIWIS Tester 9718 is connected to the vehicle via a diagnostic socket. The diagnosis socket is located inside the vehicle in the vicinity of the driver's A-pillar below the instrument panel. 2. Select the vehicle type and call up the PSM system. 3. Carry out ABS/PSM test (see Test overview). 45 30 19 REMOVING AND INSTALLING HYDRAULIC UNIT - AS OF MY 2005 (ALL MODELS) INFORMATION Information Fig. 3: Luggage compartment cover Courtesy of PORSCHE OF NORTH AMERICA, INC. The brake components (brake booster, brake master cylinder, hydraulic unit) are installed under the luggage compartment cover -2- . See Fig. 3 . Fig. 4: Brake components Courtesy of PORSCHE OF NORTH AMERICA, INC. Remove hydraulic unit -D- together with the support and the four brake lines, which are fitted on the intermediate piece -E- . See Fig. 4 . A - Brake fluid reservoir B - Brake master cylinder 2007 Porsche Cayman S BRAKES Anti-Lock Brake System (ABS)

C - Brake booster D - Hydraulic unit E - Intermediate piece PRELIMINARY WORK Preliminary work 1. Remove cover over hydraulic unit (front luggage compartment cover) Refer to 70 30 19 Removing and installing front luggage compartment cover - as of MY 2005 (All Models) . Refer to 70 30 19 Removing and installing rear luggage compartment cover - as of MY 2006 (Cayman S, Cayman S RHD) . Fig. 5: Removing luggage compartment cover Courtesy of PORSCHE OF NORTH AMERICA, INC. There are two types of luggage compartment covers -1- (drawings below). See Fig. 5 . Fig. 6: Removing luggage compartment cover Courtesy of PORSCHE OF NORTH AMERICA, INC. REMOVING HYDRAULIC UNIT Removing hydraulic unit Fig. 7: Hydraulic unit Courtesy of PORSCHE OF NORTH AMERICA, INC. 1. Remove hydraulic unit -D- . See Fig. 7 . 1.1. Hold down brake pedal with pedal holder so that the brake fluid (in the reservoir) does not drain completely. 1.2. Loosen the brake lines -1- on the brake master cylinder. See Fig. 7 . 1.3. Loosen the brake lines -2- from the hydraulic unit -D- on the intermediate piece -E- . See Fig. 7 . 1.4. Close the brake lines and connections with suitable plugs. 1.5. Release control unit connector on the hydraulic unit and pull it off. Cover the plug connection and connector (to shield them from brake fluid or water). 1.6. Loosen support on hydraulic unit -Arrows- (3-point mount). See Fig. 7 . 1.7. Remove support/hydraulic unit assembly. 2007 Porsche Cayman S BRAKES Anti-Lock Brake System (ABS)

INSTALLING HYDRAULIC UNIT Installing hydraulic unit Fig. 8: Hydraulic unit Courtesy of PORSCHE OF NORTH AMERICA, INC. 1. Install hydraulic unit -D- . Observe tightening torques Refer to 47 Tightening torques for brake hydraulics - as of MY 2005 (All Models) . See Fig. 8 . 1.1. Insert hydraulic unit with support and tighten fastening nuts -Arrows- (3-point mount). See Fig. 8 . 1.2. Connect control unit connector to hydraulic unit and lock it. 1.3. Fit the brake lines -1- in the correct position on the brake master cylinder. HZ 1 = Brake master cylinder push-rod circuit (close to fastening flange). HZ 2 = Intermediate piston circuit. See Fig. 8 . 1.4. Fit brake lines -2- in correct position. Observe marking on the hydraulic unit -D- and intermediate piece -E- . RL = rear left/RR = rear right/FR = front right/FL = front left. See Fig. 8 . 2. Bleed the brake system and adjust the brake-fluid level. Refer to 47 01 07 Bleeding the brake system - as of MY 2005 (All Models) . NOTE: First connect the electric plug connections on the hydraulic unit. This will protect the plug connections from brake fluid or water. After bleeding, check the assignment of the brake lines to the correct brake callipers. Carry out a swap test using the PIWIS Tester. NOTE: First bleed the brake system in the normal way - with the bleeding device at the reservoir and approx. 2.0 bar pressure (primary circuit). Then, use the PIWIS Tester to bleed the brakes as well (secondary circuit). Only necessary if the hydraulic unit was replaced and if brake pedal travel is excessive after bleeding in the normal way (primary circuit). The process is menu-driven. Always observe the specified sequence rear left, front left, front right, rear right. To bleed the secondary circuit, the bleeding device remains connected to the brake fluid reservoir. Bleeding pressure is approx. 2.0 bar. Throughout the entire bleeding process, the brake pedal must be operated cyclically (keep depressed for 2 to 3 seconds, then release slowly). After operating the pedal for the last time, hold the brake pedal down and close the bleeder valve. 2007 Porsche Cayman S BRAKES Anti-Lock Brake System (ABS)

3. When replacing the hydraulic unit, code the control unit (manual transmission/Tiptronic). 4. Carry out the following tests:  Check the system for leaks.  Read out and erase the fault memory of the ABS/PSM control unit using the PIWIS Tester. Carry out a static test as well.  Check electric and hydraulic lines for incorrect assignment using the PIWIS Tester. This test checks that the brake lines/solenoid valves are assigned to the corresponding brake callipers.  Then start the engine. The ABS/PSM-related lights in the instrument cluster must go out when the engine is running.  Carry out a function check on the brakes. Then take a short test drive and perform at least one ABS control operation, taking the road conditions into consideration. Read out the ABS/PSM fault memory again. There must not be any stored faults. SUBSEQUENT WORK Subsequent work Fig. 9: Installing luggage compartment cover Courtesy of PORSCHE OF NORTH AMERICA, INC. Install cover over hydraulic unit (luggage compartment cover) -1- , Refer to 70 30 19 Removing and installing front luggage compartment cover - as of MY 2005 (All Models) . Refer to 70 30 19 Removing and installing rear luggage compartment cover - as of MY 2006 (Cayman S, Cayman S RHD) . See Fig. 9 . Fig. 10: Installing luggage compartment cover Courtesy of PORSCHE OF NORTH AMERICA, INC. 45 59 19 REMOVING AND INSTALLING ROTATION-RATE SENSOR FOR PSM - AS OF MY 2005 (ALL MODELS) INFORMATION Information The lateral-acceleration sensor is integrated in the rotation-rate sensor. Fig. 11: Rotation - rate sensor Courtesy of PORSCHE OF NORTH AMERICA, INC. REMOVING ROTATION-RATE SENSOR Removing 1. Move the left seat back and adjust the steering wheel upwards. 2007 Porsche Cayman S BRAKES Anti-Lock Brake System (ABS)

Fig. 12: Cover in left footwell Courtesy of PORSCHE OF NORTH AMERICA, INC. 2. Remove left cover on the center console. Unscrew screw -2- and take off cover -1- . See Fig. 12 . Fig. 13: Rotation - rate sensor Courtesy of PORSCHE OF NORTH AMERICA, INC. 3. Remove rotation-rate sensor. Unscrew screws -1- (the screws -1- can only be accessed using a 1/4-inch tool). Pull off plug connection and take out rotation-rate sensor. See Fig. 13 . INSTALLING ROTATION-RATE SENSOR Installing Fig. 14: Rotation - rate sensor Courtesy of PORSCHE OF NORTH AMERICA, INC. 1. Install in reverse order. Subsequent work Fig. 15: Diagnostic tester Courtesy of PORSCHE OF NORTH AMERICA, INC. 1. After installing the rotation-rate sensor, read out the PSM fault memory with the PIWIS Tester (diagnostic tester) and erase it. Carry out a static test. Then start the engine. The PSM-related lights in the instrument cluster must go out when the engine is running. Read out the PSM fault memory again. There must not be any stored faults. 45 60 INITIALIZING AND CALIBRATING STEERING-ANGLE SENSOR - AS OF MY 2005 (ALL MODELS) GENERAL WARNING NOTES --> The steering-angle sensor must be initialized (taught) whenever the battery is disconnected. CAUTION: Increased risk of accident whenever power supply is interrupted. PSM does not function. NOTE:  The steering-angle sensor is integrated into the steering column switch 2007 Porsche Cayman S BRAKES Anti-Lock Brake System (ABS)

CHECKING STEERING-ANGLE SENSOR Initialize steering-angle sensor 1. Turn wheels to straight-ahead position. 2. Start engine. 3. From the straight-ahead position, turn steering wheel approx. 20° to the left and 20° to the right (past straight- ahead position). 4. Drive the vehicle straight ahead for at least three seconds at a speed above 6 km/h (3.7 mph). After successful initialization, the stored fault code is erased from the fault memory. The PSM indicator light in the instrument cluster goes out. After initialization has been completed, the battery must not be disconnected, the relevant fuse must not be removed and there must not be undervoltage. Otherwise, initialization will have to be carried out again. ADJUSTING STEERING-ANGLE SENSOR Calibrating steering-angle sensor and records the movements of the steering wheel (steering wheel angle) using light switches. The data is transmitted to the PSM control unit via the CAN bus.  During initialization, the steering-angle sensor learns its current position (straight-ahead position).  The steering-angle sensor must always be initialized if terminal 30 was interrupted (for example, battery replacement, undervoltage, steering column switch disconnected, relevant fuse removed)!  Calibration must be performed when working on or carrying out subsequent work on the chassis. This is described in detail in the next chapter -- > 456000 Initializing and calibrating steering - angle sensor - section on "Calibrating" .  The calibration results in zero point balancing (exactly straight ahead).  The steering angle sensor is calibrated when first fitted and when any work has been carried out on steering and chassis. Examples of this would be opening the steering wiring and alterations to toe and camber.  Calibration includes initialization. NOTE:  The steering-angle sensor must be recalibrated on the measuring platform following repairs to or work on the chassis/steering or if the steering-angle sensor/steering column switch/hydraulic unit is replaced. 2007 Porsche Cayman S BRAKES Anti-Lock Brake System (ABS)

The steering angle sensor must be calibrated using the menu with PIWIS tester under the specified test conditions: 1. Switch on ignition. 2. Turn wheels or steering wheel to straight-ahead position. In the straight-ahead position, the steering wheel must deviate by no more than ± 2.0° from the horizontal position (steering center position). 3. Before calibrating, first turn the steering wheel from the straight-ahead position approx. 20° to the left and 20° to the right (past straight-ahead position). 4. Turn wheels or steering wheel to straight-ahead position and calibrate the steering-angle sensor. To calibrate, you must enter the security code in the actual values menu. 45 60 19 REMOVING AND INSTALLING STEERING-ANGLE SENSOR FOR PSM - AS OF MY 2005 (ALL MODELS) INFORMATION Information The steering-angle sensor is integrated into the steering-column switch. The steering angle is recorded in the airbag contact unit (spring). Only replace the steering-angle sensor together with the airbag contact unit (spring) and electronic unit. Fig. 16: Steering - angle sensor Courtesy of PORSCHE OF NORTH AMERICA, INC. Fig. 17: Diagram of steering - column switch Courtesy of PORSCHE OF NORTH AMERICA, INC. A - Direction indicator switch B - On-board computer switch C - Wiper switch D - Cruise control switch  In order to be able to calibrate the steering angle sensor correctly, the vehicle must be on the measuring platform, the wheel alignment values correct and the steering in the straight-ahead position.  The security code is displayed in the PIWIS tester under Menu >> PSM >> Actual values. 2007 Porsche Cayman S BRAKES Anti-Lock Brake System (ABS)

E - Airbag contact unit (spring)/steering-angle sensor F - Electronic unit PRELIMINARY WORK Preliminary work 1. Remove airbag unit --> 69 58 19 REMOVING AND INSTALLING DRIVER'S AIRBAG UNIT - AS OF MY 2005 (ALL MODELS) . 2. Remove steering wheel --> 48 10 19 REMOVING AND INSTALLING STEERING WHEEL - AS OF MY 2005 (ALL MODELS) . Removing --> Airbag contact unit (spring) must not be twisted. 1. Remove steering-column panels. Fig. 18: Steering - column panels Courtesy of PORSCHE OF NORTH AMERICA, INC. 1.1. Remove lower steering-column panel -3- . See Fig. 18 . Unscrew screws -1- and unclip cable clamp -2- . See Fig. 18 . Move steering-wheel adjustment lever to a vertical position and remove lower steering-column panel -3- . See Fig. 18 . Fig. 19: Steering - column switch Courtesy of PORSCHE OF NORTH AMERICA, INC. 1.2. Remove upper steering-column panel -4- . See Fig. 18 . Unclip upper steering-column panel -4- , see -Arrows- , and disconnect electric plug connection. See Fig. 18 , Fig. 19 . Fig. 20: Steering - column switch, bottom Courtesy of PORSCHE OF NORTH AMERICA, INC. 2. Remove steering-column switch. CAUTION: Malfunction  Fault in airbag contact unit (spring)! 2007 Porsche Cayman S BRAKES Anti-Lock Brake System (ABS)

Unscrew screw -1- , unclip cable guide -2- , pull out electric plug connections and remove steering-column switch. See Fig. 20 . 3. Remove airbag contact unit (spring) from steering-column switch. Fig. 21: Airbag contact unit marking Courtesy of PORSCHE OF NORTH AMERICA, INC. Fig. 22: Airbag contact unit Courtesy of PORSCHE OF NORTH AMERICA, INC. Unclip airbag contact unit (spring) -Arrows- and carefully remove it. See Fig. 22 . REPLACING STEERING-ANGLE SENSOR FOR PSM Replacing The steering-angle sensor can only be replaced together with the airbag contact unit -E- and electronic unit -F-. See Fig. 23 . Fig. 23: Diagram of steering - column switch Courtesy of PORSCHE OF NORTH AMERICA, INC. A - Direction indicator switch B - On-board computer switch C - Wiper switch D - Cruise control switch E - Airbag contact unit (spring)/steering-angle sensor F - Electronic unit 1. Replace the steering-angle sensor. Replace the airbag contact unit (spring)/steering-angle sensor -E- and electronic unit -F- . See Fig. 23 . INSTALLING STEERING-ANGLE SENSOR FOR PSM Installing NOTE: Ensure that arrow -A- on the rotor is positioned between the markings -B- of the arrows -C- on the airbag contact unit and that the locking element -D- is engaged. 2007 Porsche Cayman S BRAKES Anti-Lock Brake System (ABS)

2005-2008 Porsche Cayman Service Repair Manual

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