2012-2015 Porsche Cayman (981) Service & Repair Manual

Contents ACCESSORIES AND BODY CAB 2 ........................................... ACCESSORIES AND BODY, CAB 50 - Body Front - (981) Boxster_Cayman 2 .............. ACCESSORIES AND BODY, CAB 51 - Body Center, Roof, Frame - (981) Boxster_Cayman 84 ... ACCESSORIES AND BODY, CAB 53 - Body Rear - (981) Boxster_Cayman 170 ............. ACCESSORIES AND BODY, CAB 55 - Lids, Flaps - (981) Boxster_Cayman 262 ............. ACCESSORIES AND BODY, CAB 57 - Door Front, Central Locking System - (981) Boxster_Cayman 342 ACCESSORIES AND BODY, CAB 63 - Bumpers - (981) Boxster_Cayman 402 .............. ACCESSORIES AND BODY, CAB 64 - Glazing, Window Control - (981) Boxster_Cayman 449 ... ACCESSORIES AND BODY, CAB 66 - Exterior Equipment - (981) Boxster_Cayman 558 ....... ACCESSORIES AND BODY, CAB 68 - Interior Equipment - (981) Boxster_Cayman 627 ........ ACCESSORIES AND BODY, CAB 70 - Linings, Insulation - (981) Boxster_Cayman 680 ........ ACCESSORIES AND BODY, CAB 72 - Seat Frames - (981) Boxster_Cayman 781 ........... ACCESSORIES AND BODY, CAB 74 - Seat Upholsteries, Cover - (981) Boxster_Cayman 897 ... ACCESSORIES AND BODY, CAB 7X - Body-Equipment Inside - General - (981) Boxster_Cayman 999 ACCESSORIES AND BODY, CAB 90 - Instruments - (981) Boxster_Cayman 1008 ........... ACCESSORIES AND BODY, CAB 91 - Radio, Stereo, Telephone, On-Board Computer - (981) Boxster_Ca 1043 ACCESSORIES AND BODY, CAB 92 - Windshield Wiper And Washer System - (981) Boxster_Cayman 1121 ACCESSORIES AND BODY, CAB 94 - Lights, Lamps, Switches, Exterior - (981) Boxster_Cayman 1155 ACCESSORIES AND BODY, CAB 96 - Lights, Lamps, Switches, Interior - (981) Boxster_Cayman 1223 ACCESSORIES AND BODY, CAB 97 - Cables - (981) Boxster_Cayman 1254 .............. BRAKES 1344 ......................................................... BRAKES 45 - Anti Locking Brake System (ABS) - (981) Boxster_Cayman 1344 ............. BRAKES 46 - Brakes - Brake Mechanics - (981) Boxster_Cayman 1363 .................. BRAKES 47 - Brakes - Hydraulic Brake System, Regulator - (981) Boxster_Cayman 1439 ...... ELECTRICAL 1482 ...................................................... ELECTRICAL 2X - Petrol, Exhaust, Engine-Electric - General - (981) Boxster_Cayman 1482 ..... ELECTRICAL 9X - Electrical System - General - (981) Boxster_Cayman 1507 .............. ENGINE 27 - Starter, Power Supply, Cruise Control - (981) Boxster_Cayman 1553 ........... SYSTEM WIRING DIAGRAMS Porsche - Cayman 1592 ............................. Using Wiring Diagrams 1708 ............................................... ENGINE 1717 .......................................................... ENGINE 10 - Engine - Crankcase, Suspension - (981) Boxster_Cayman 1717 .............. ENGINE 13 - Engine - Crankgear, Pistons - (981) Boxster_Cayman 1805 ................. ENGINE 15 - Engine - Cylinder Head, Valve Control - (981) Boxster_Cayman 1884 ........... ENGINE 17 - Engine - Lubrication - (981) Boxster_Cayman 1951 ....................... ENGINE 19 - Engine - Cooling - (981) Boxster_Cayman 2022 ......................... ENGINE 20 - Fuel Supply, Control - (981) Boxster_Cayman 2149 ....................... ENGINE 24 - Fuel System - Electronic Ignition - (981) Boxster_Cayman 2201 ............... ENGINE 26 - Exhaust System - (981) Boxster_Cayman 2312 ......................... ENGINE 27 - Starter, Power Supply, Cruise Control - (981) Boxster_Cayman 2344 ........... ENGINE 28 - Ignition System - (981) Boxster_Cayman 2390 .......................... GENERAL INFORMATION 1X - Engine - General - (981) Boxster_Cayman 2418 ............ HVAC 2445 ........................................................... HVAC 80 - Heating - (981) Boxster_Cayman 2445 ................................. HVAC 85 - Ventilation - (981) Boxster_Cayman 2450 ............................... HVAC 87 - Air Conditioning - (981) Boxster_Cayman 2498 ........................... HVAC 8X - Air Conditioning - General - (981) Boxster_Cayman 2554 .................... RESTRAINTS 2577 ...................................................... RESTRAINTS 69 - Passenger Protection - (981) Boxster_Cayman 2577 .................. STEERING 2693 ........................................................ STEERING 48 - Steering - (981) Boxster_Cayman 2693 ............................. SUSPENSION 2748 ..................................................... SUSPENSION 40 - Front Wheel Suspension, Drive Shafts - (981) Boxster_Cayman 2748 ....... SUSPENSION 42 - Rear Wheel Suspension, Drive Shafts - (981) Boxster_Cayman 2788 ....... SUSPENSION 43 - Level Control, Air Suspension - (981) Boxster_Cayman 2843 ............ SUSPENSION 44 - Wheels, Tires, Suspension Alignment - (981) Boxster_Cayman 2851 ....... SUSPENSION PORSCHE WHEEL ALIGNMENT SPECIFICATIONS 2921 ................. TRANSMISSION 2960 .................................................... TRANSMISSION 30 - Clutch, Control - (981) Boxster_Cayman 2960 ..................... TRANSMISSION 34 - Mechanical Gear-Shift System - Actuation, Housing - (981) Boxster_Cayman 2995 TRANSMISSION 35 - Mechanical Gear-Shift System - Gears & Shafts - (981) Boxster_Cayman 3031 TRANSMISSION 37 - Automatic Transmission - Actuation, Ass 3035 .................... TRANSMISSION 38 - Automatic Transmission - Gears, Control - (981) Boxster_Cayman 3086 ... TRANSMISSION 39 - Final Drive - Differential, Differential Lock - (981) Boxster_Cayman 3112 ... TRANSMISSION 3X - Power Transmission - General - (981) Boxster_Cayman 3165 .......... REMINDER INDICATOR (RESET PROCEDURES) Porsche - 1977-16 3172 ................ 2013-15 MAINTENANCE 03 - Maintenance, Diagnostics - (981) Boxster_Cayman 3180 .........

Back To Article 201315 ACCESSORIES AND BODY, CAB 50  Body Front  (981) Boxster/Cayman WM 501055 REPLACING FRONT CLOSING PANEL (ALL MODELS) TOOLS Designation Type Number Description Â twist drill Commercially available tool Nr.201 Â Countersink Commercially available tool Nr.202 Â TECHNICAL VALUES Location Description Type Basic value Tolerance 1 Tolerance 2 twist drill, Â diameter 6.5 mm Â Â Twist drill, Â diameter 6.6 mm Â Â PRELIMINARY WORK Preliminary Work For Body Repairs (Without Straightening System) 1. Remove accessories in the repair area. 1.1. Remove accessories in the repair area according to the extent of damage on the vehicle. 2. Cover accessories adjacent to the repair area on the vehicle. 2.1. Cover all accessories remaining on the vehicle and adjacent areas with fireproof protective covers. 3. Reshape connection area of the sheetmetal parts to be replaced. See Information on aluminum repairs → WM 5X00IN INFORMATION ON ALUMINUM REPAIRS (EXCEPT BOXSTER GTS, BOXSTER SPYDER) 4. Expose joint areas. 4.1. Remove underbody protection, paint, etc. from the joint areas of the body using a hotair gun or rotary brush. SAFETY INSTRUCTIONS AND INFORMATION ON QUALITY CAUTION: Nonobservance of safety instructions for body repairs Risk of damage to the vehicle Danger of injury → Read the relevant safety instructions as well as general information and quality instructions → 5X00IN01 SAFETY INSTRUCTIONS . Protection of electrical components during body repairs → 5X00IN02 PROTECTION OF ELECTRICAL COMPONENTS DURING BODY REPAIRS Corrosion protection measures during repairs → 5X00IN03 CORROSION PROTECTION MEASURES DURING REPAIRS 2 of 3206

Information on aluminum repairs → WM 5X00IN INFORMATION ON ALUMINUM REPAIRS (EXCEPT BOXSTER GTS, BOXSTER SPYDER) Body parts of various sheetsteel strengths → 5X00IN04 BODY PARTS OF VARIOUS SHEETSTEEL STRENGTHS Replacing punch rivets and penetrated joints → 5X00IN23 REPLACING PUNCH RIVETS AND PENETRATED JOINTS Setting selftapping screws → 5X00IN24 SETTING SELFTAPPING SCREWS Working with body structural adhesive → 5X00IN21 WORKING WITH BODY STRUCTURAL ADHESIVE REMOVING FRONT CLOSING PANEL Fig. 1: Identifying Front Closing Panel Courtesy of PORSCHE CARS NORTH AMERICA, INC. 1. Drill through clinch points using a → diameter: 6.5 mm . 3 of 3206

Fig. 2: Identifying Closing Panel Courtesy of PORSCHE CARS NORTH AMERICA, INC. 2. Drill through punch rivets using a twist drill Nr.201 . 4 of 3206

Fig. 3: Identifying Closing Panel Courtesy of PORSCHE CARS NORTH AMERICA, INC. 3. Remove closing panel. PREPARING FRONT CLOSING PANEL FOR INSTALLATION 1. Fit closing panel and secure it to the body. 1.1. Drill bores for the rivets through the existing holes. → diameter: 6.6 mm 2. Remove closing panel. 3. Countersink bores for installing countersunk rivets. Countersink Nr.202 4. Prepare connection areas for bonding. 5 of 3206

Fig. 4: Identifying Closing Panel Position Courtesy of PORSCHE CARS NORTH AMERICA, INC. PREPARING CONNECTION AREAS OF BODY FOR INSTALLING CLOSING PANEL 1. Prepare connection areas for bonding. 6 of 3206

Fig. 5: Identifying Bonding Connection Areas Courtesy of PORSCHE CARS NORTH AMERICA, INC. INSTALLING FRONT CLOSING PANEL 1. Apply adhesive. 7 of 3206

Fig. 6: Identifying Bonding Connection Areas Courtesy of PORSCHE CARS NORTH AMERICA, INC. 2. Fit closing panel. 3. Rivet in closing panel. → BLIND RIVET 000.043.207.59 SUBSEQUENT WORK Subsequent Work For Body Repairs (Without Straightening System) 1. Clean joint areas and sheetmetal flanges with a wire brush. 2. Prime joint areas and sheetmetal flanges with 2K primer. 3. Restore standard seal with body sealant → 5X00IN42 SEAM SEALING . Also seal the repair area carefully. 4. Paint repair area and adjacent surfaces, if necessary. 5. Restore standard underbody protection with underbody sealant → 5X00IN43 UNDERBODY PROTECTION . 6. Apply standard cavity preservation → 5X00IN44 CAVITY PRESERVATION . Also apply cavity preservation to the repair area. 7. Install removed accessories in the repair area. WM 501455 REPLACING FRONT PANEL (EXCEPT BOXSTER GTS) TOOLS Designation Type Number Description Â Hotair blower, Leister Workshop equipment WE 1119 Â 8 of 3206

Electron/V.A.G. 1416 twist drill Commercially available tool Nr.201 Â Countersink Commercially available tool Nr.202 Â TECHNICAL VALUES Location Description Type Basic value Tolerance 1 Tolerance 2 Drill bit Â Diameter 6.5 mm Â Â Drill bit Â Diameter 6.5 mm Â Â Applying adhesive Spread out evenly Application depth 0.5 mm Â Â Bead of adhesive Â Application depth 5 mm Â Â Drill bit Â Diameter 8.2 mm Â Â Threaded joint for ground connection Â Tightening torque 15 Nm (11 ftlb.) Â Â PRELIMINARY WORK Preliminary Work For Body Repairs (With Straightening System) 1. Remove accessories in the repair area. 1.1. Remove accessories in the repair area according to the extent of damage to the vehicle. 2. Set vehicle on the straightening system. 3. Cover the accessories adjacent to the repair area on the vehicle. 3.1. Cover all accessories remaining on the vehicle and the adjacent areas with fireproof protective covers. 4. Reshape connection area of the sheetmetal parts to be replaced. See Information on aluminum repairs → 5X00IN04 INFORMATION ON ALUMINUM REPAIRS 5. Expose joint areas. 5.1. Remove undersealing, paint, etc. from the joint areas of the body with a hotair gun or rotary brush. SAFETY INSTRUCTIONS AND INFORMATION ON QUALITY CAUTION: Nonobservance of safety instructions for body repairs Risk of damage to the vehicle Danger of injury → Read the relevant safety instructions as well as general information and quality instructions → 5X00IN01 SAFETY INSTRUCTIONS . 9 of 3206

Protection of electrical components during body repairs → 5X00IN02 PROTECTION OF ELECTRICAL COMPONENTS DURING BODY REPAIRS Corrosion protection measures during repairs → 5X00IN03 CORROSION PROTECTION MEASURES DURING REPAIRS Information on aluminum repairs → WM 5X00IN INFORMATION ON ALUMINUM REPAIRS (EXCEPT BOXSTER GTS, BOXSTER SPYDER) Body parts of various sheetsteel strengths → 5X00IN04 BODY PARTS OF VARIOUS SHEETSTEEL STRENGTHS Replacing punch rivets and penetrated joints → 5X00IN23 REPLACING PUNCH RIVETS AND PENETRATED JOINTS Setting selftapping screws → 5X00IN24 SETTING SELFTAPPING SCREWS Working with body structural adhesive → 5X00IN21 WORKING WITH BODY STRUCTURAL ADHESIVE REMOVING FRONT PANEL Information Some of the repair illustrations show only one side of the vehicle . Naturally, some steps also have to be performed on the opposite side of the vehicle as well . Fig. 7: Identifying Front Panel Courtesy of PORSCHE CARS NORTH AMERICA, INC. 1. Remove wing joining plate. → 505355 REPLACING WING JOINING PLATE 2. Drill through punch rivets using a twist drill Nr.201 . Grind down welded seams. 10 of 3206

2012-2015 Porsche Cayman (981) Service & Repair Manual

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