fuel PORSCHE CAYMAN 2006 1.G Information Manual

· 33 · · 32 ·The new Cayman and the Cayman S |
Drive
The variable valve system
generates additional torque at
lower engine speeds. Other
benefits include greater top-end
power, better fuel economy
and lower exhaust emissions.
Fuel injection and ignition
are centrally controlled by
the Motronic ME7.8 engine
management system. Power
is applied with control and
precision by means of an
electronically operated throttle.
The engine sound, so rich and
distinctive, is also instantly
Porsche.
Cayman

· 37 · · 36 ·The new Cayman and the Cayman S |
Drive
Integrated dry-sump
lubrication.
This proprietary Porsche
technology ensures consistent
lubrication in even the most
extreme high-speed corners.
Oil is extracted from each of the
cylinder heads by a dedicated
scavenge pump. The oil return
system features narrow-section
lines which de-foam the oil before
it is collected in the integral sump.
A third pump then feeds the oil
back to the lubrication points and
the cycle begins once more. A
stable oil pressure is maintained
throughout the engine, even
during racetrack use.
Oil-level indicator.
Both Cayman models have an
electronic oil-level indicator as
part of the on-board computer
system. The reading is so precise
that a conventional dipstick is not
required.
Engine cooling.
Both flat-six engines have a
cross-flow cooling system with
all coolant channels cast in the
block. With no external hoses
or pipework involved, the system
is much more secure than
conventional designs.
Coolant is supplied separately
to each individual cylinder, so
it never arrives pre-warmed. As
well as maintaining a consistent
engine temperature, this means
the valves are much less
susceptible to wear. Important
benefits include greater engine
reliability, less risk of knocking,
better fuel economy, lower
emissions and reduced mechanical
noise.
Engine management system
with electronic throttle.
The Motronic ME7.8 engine
management system is the
primary source of control for
all engine-related systems and
processes, e.g., ignition and
fuel supply. It is an essential
prerequisite for enhanced
performance in all operating
conditions. The electronic throttle
is not only more precise, it can
modulate the volume of incoming
air to compensate for sudden load
transfer (e.g., when lifting off the
throttle before braking). Electronic
engine management ensures
better power delivery from a
standing start and a smoother rev-
limiter action. It also coordinates
the various sub-systems within the
Used to regulate /control
Engine management system
(Motronic ME7.8)
Engine load
Throttle-pedal position
Oxygen sensor signals
Engine speed (from crankshaft)
Inlet camshaft phase angle
Knock sensor signals
Vehicle speed
Air-conditioning settings
Engine immobiliser status
Ambient pressure
Sport Chrono button
Temperatures
– coolant
– intake air
– engine oil
– air in engine compartment
Ignition
Fuel injection
Idling via throttle
and ignition
Heating elements in oxygen sensors
Fuel-tank venting
CAN interface to instrument cluster,
transmission control unit, stability control system, etc.Moment interface to
Porsche Stability Management (PSM)
Input data
Twin-flow valve in intake manifold
Resonance valve in intake manifold
Inlet camshaft phase angle
Inlet valve lift
Secondary air injection
Engine fan
Starter
Diagnostics
Air-conditioning compressor
standard Porsche Stability
Management (PSM), e.g., anti-slip
regulation (ASR) and the automatic
brake differential (ABD). Other
important functions include
coordination and control of the
optional Tiptronic S transmission,
the oxygen sensors in the exhaust,
variable valve timing (VarioCam
Plus) and cylinder-specific knock
control.
Cayman S

· 39 · · 38 ·VarioCam Plus The new Cayman and the Cayman S |
Drive
higher torque at low rpm, a flatter
torque curve, and greater top-end
power. It also brings an additional
dimension to the unique engine
sound.VarioCam Plus.
VarioCam Plus combines variable
valve timing with two-stage lift
on the inlet side. The resulting
benefits include greater power and
torque at all engine speeds, as
well as smoother running, better
fuel economy and fewer exhaust
emissions.
Essentially, the system creates
two engines out of one, switching
seamlessly between them as
driver inputs change. All operations
are centrally controlled by
the Motronic ME7.8 engine
management system. The result:
rapid acceleration and balanced
running characteristics.
The two-stage valve lift mechanism
on the inlet side incorporates
a series of electro-hydraulically
switchable tappets. Each of
the 12 tappets consists of two
concentric lifters which can be
locked together by means of a
pin when required by the engine
management system. When the
tappets are locked, the outermost
ring – which is driven by two large-
profile cams – is in direct contact
Two-stage resonance intake
manifold.
The intake manifold has a twin-flow
pipe with two-stage valve which
opens and closes at predefined
engine speeds. An additional
‘resonance’ pipe connecting the
twin plenum chambers is used
to alter the geometry within the
manifold. The resulting vibration in
the incoming air helps to maximise
cylinder charging and create the
optimum air/fuel mix. The results:
with the valve. When the pin is
removed, the innermost lifter –
operated by a smaller cam lobe –
has sole influence over the
amount of valve lift. The timing of
each valve is steplessly controlled
by means of an electro-hydraulic
rotary vane adjuster at the head
of each inlet camshaft.
To improve responsiveness when
starting from cold, VarioCam Plus
will raise the amount of lift and
retard the timing of the valves.
At medium revs and minimal load,
the valve lift is lowered and timing
advanced to help minimise fuel
consumption and emissions.
To achieve maximum power and
torque, the lift is raised and the
timing advanced.
Cayman

· 41 · · 40 ·The new Cayman and the Cayman S |
Drive
Ignition system.
The ignition system in the Cayman
and Cayman S features static
high-voltage technology. Separate
coils on each of the plugs ensure
perfect ignition every time. With
no central coil, there is no need
for leads, which are a frequent
source of faults. All six coils are
directly controlled by the engine
management system. This
Cylinder-specific knock control.
Since temperatures tend to
vary across the engine, each
cylinder is monitored separately
for unwanted pre-ignition of the
air/fuel mix. If a risk is detected
in one or more cylinders, the
timing is adjusted on the
corresponding spark plug.
The system is effective under
all engine conditions, including
extremely heavy loads at low
rpm.
Exhaust system.
Both Cayman models have a
specially designed stainless steel
exhaust system. Gas is passed
from each bank of cylinders
through twin cross-linked silencer
units and exits the car through
a central tailpipe. A system of
four oxygen sensors – one before
and one after each of the two
pre-catalytic converters – provides
separate monitoring of the gas
composition and catalyst
performance for each cylinder
bank.
arrangement means they can
also be integrated with other
electronic-based systems. If the
optional Tiptronic S, for example,
requests smoother downshifts,
the system responds within a
fraction of a second and adjusts
the ignition timing.
Since a twin-tract layout allows a
higher rate of throughput than a
conventional exhaust, the system
also has a positive impact on
overall power and torque. It also
contributes to the distinctive
engine sound – on starting, at
idle and across the entire engine
speed range.
For even more powerful acoustics,
both cars can be equipped with
an optional sports exhaust system.
Servicing.
Regular servicing is extremely
important on any high-precision
machine. In the case of a
Porsche, it is equally important
to give you maximum enjoyment
from your car. We therefore aim
to reduce servicing requirements
and extend all service intervals.
The generator, power-steering
pump and air-conditioning
compressor are all driven by a
single, self-adjusting belt. Under
normal usage, the drive chains
for the cam and auxiliary shafts
are entirely maintenance-free.
The ignition system is also
maintenance-free, with the sole
exception of the spark plugs
(60,000 miles). The engine oil
interval is 20,000 miles, while
hydraulic tappets provide
automatic clearance adjustment
on each of the 24 valves.
In short: when we design a car
for the road, that’s where we
intend it to stay.Exhaust system
Dual-tube tailpipe (Cayman S) Single-tube tailpipe (Cayman)Cayman

· 45 · · 44 ·
Tiptronic S.
Both Cayman models are available
with five-speed Tiptronic S as
optional equipment. This versatile
system combines an automatic
transmission with the option of
manual gearshifts.
For manual control, simply slot
the gear selector into the manual
gate and use the gearshift controls
on the steering wheel. Press up
to change up, and down to change
down. Gearshifts are performed
in around 0.2 seconds with
virtually no interruption in drive.
The action is comparable with
that of a manual gearbox.
Switch to automatic, and you can
still change gear by hand using
the rocker controls on the steering
wheel. This race-derived function
is particularly useful during
overtaking manoeuvres. If there
is no manual input for a period
of eight seconds, the system will
revert to automatic mode. The
drive position and gear selection
are displayed at all times on a
dedicated cockpit display.
In automatic mode, Tiptronic S
can choose from a range of
gearshift points for each individual
gear. The standard gearshift
pattern, designed for maximum
fuel economy, can be steplessly
varied up to a dedicated ‘Sport’
configuration for optimum high-
performance driving. Each
gearshift point is automatically
selected based on current road
conditions and driving style. Within
a short space of time, you’ll
develop a feel for the system and
begin to influence gearshifts using
the throttle alone. The benefits
of Tiptronic S are particularly
apparent when exploring the car’s
performance. Even in automatic,
the rapid gearshift action
enhances the agility of the car.
The new Cayman and the Cayman S |Drive
Manual gearbox with
dual-mass flywheel.
Both the Cayman and Cayman S
are specifically designed for a more
immediate driving experience. A
crucial element within that concept
is the standard manual gearbox.
The new Cayman has a five-speed
unit as standard equipm
ent. The
optional Sport package combines a
How do we make the most of engine performance?
By knowing how to apply it.
Transmission.
mechanical noise and thus greater
focus on the natural sound of the
engine. The flywheel is mated to
a hydraulically operated clutch,
while the final drive ratio has been
carefully selected for optimum
sports performance. The gearshift
mechanism is cable operated
so as to insulate the lever against
vibration from the engine and
gearbox.
Other useful functions include a
warm-up programme, automatic
selection of the ‘Sport’ gearshift
pattern by means of rapid throttle
inputs, gearshift suppression
during cornering manoeuvres,
automatic downshifts under heavy
braking, an incline sensor
(improves uphill acceleration and
downhill engine braking), a nd
automatic upshifts when traction
is threatened under braking in
the wet.
If the optional Sport Chrono
Package is enabled, the gearshift
action is even more direct and
responsive. If you happen to be
driving in manual mode, automatic
upshifts are restricted.
six-speed manual gearbox with
Porsche Active Suspension
Management (PASM – see page
52). The Cayman S has a six-speed
unit as standard. Both gearbox
types have a short-throw action
and a balanced spread of ratios
which are specially adapted to
the individual character of each car.
A dual-mass flywheel ensures
smoother delivery with reduced
Tiptronic S gear selector Tiptronic S control on steering wheel
Cayman S

· 63 · · 62 ·
lighter than metal, but also
harder and more resistant to
high temperatures.
Within each disc is a system of
internal channels which provide
highly efficient heat dispersal,
particularly during heavy use. An
area of ongoing development,
we’ve now doubled the number
of channels and optimised the
airflow characteristics. With twice
the number of internal walls, thenew PCCB disc has even greater
structural stability. The ring of
vent openings around the outer
rim is one of the key distinguishing
features of this technology.
Matched to the disc is a special
brake-pad compoun d offering
rapid deceleration and consistent
friction properties. The front pads
are mounted in six-piston monobloc
aluminium calipers, while those at
the rear come in four-piston units.
Porsche Ceramic Composite
Brake (PCCB).
The Cayman S is also available
with a carbon fibre-reinforced
ceramic brake system: the
Porsche Ceramic Composite
Brake (PCCB). The PCCB disc is
made from a specially treated
carbon-fibre compound that is
silicated in a high-vacuum process
at 1,700 ºC. The result is a
product that is not only much
The overall response is fast and
precise, with only moderate pedal
force required. The front disc
diameter – 350 mm – is larger
than that of the standard metal
disc. The longer radius brings
increased leverage and therefore
additional performance.
Even at high temperatures, the
thermal resistance of the ceramic
disc ensures excellent dimensional
stability. The ceramic material istotally resistant to corrosion and
offers excellent acoustic damping
properties. Braking distances
are significantly reduced in even
the toughest road and track
conditions. Inherent fade resistance
ensures optimum balance when
slowing the car from high speed.
Porsche Ceramic Composite Brake (PCCB) The new Cayman and the Cayman S |
Safety
Cayman S
The key advantage of PCCB is
its ultra-lightweight construction.
Compared with conventional metal
discs, it offers a remarkable
weight saving of approximately
50 %.
As well as enhancing performance
and fuel economy, this represents
an enormous reduction in both
unsprung and rotating mass –
important factors when it comes
to handling, agility and comfort.
To find out more, see the latest
PCCB brochure.

· 73 · · 72 ·The new Cayman and the Cayman S |
Comfort
consumption, average speed,
range till empty and audio
information.
Steering wheel.
Both Cayman models have a three-
spoke leather steering
wheel with full-size airbag as
Instruments.
A single glance is all it takes –
particularly when it comes to the
instruments. The familiar Porsche
grouping of symmetrical round
instruments forms an integral
part of the cockpit design.Above the instruments is a
specially designed shroud with
semi-transparent grille. The dials
on the new Cayman have a black
background, while those on the
Cayman S have an aluminium-
coloured finish. Both sets of
instruments feature crisp white
backlight illumination. An integral
light sensor automatically adjuststhe degree of illumination to match
the ambient light conditions.
The dials provide a continuous
overview of all key information,
including external temperature,
time, trip odometer, total odometer
and vehicle speed. You can also
view a range of additional data
from the standard on-board
computer, e.g., average fuel
access to audio, navigation and
– if fitted – telephone functions
(only in conjunction with PCM).
For a detailed overview of the
available steering wheel options,
see pages 109-113. standard. Special features include
40 mm of height and reach
adjustment. A smooth leather
finish is available as an optional
extra on the steering wheel rim
and airbag module. Alternatively,
you can specify a three-spoke
sports or three-spoke multifunction
wheel. The latter is equipped with
six integral keys offering direct
Cayman dashboard with optional equipment, e.g., leather interior package with two-tone combination, PCM

· 87 · · 86 ·The new Cayman and the Cayman S |
Comfort
zoom layers available on the map
enable a finer gradation of scale.
The time displayed in both the
instrument cluster and the PCM
terminal is synchronised with the
standard GPS time.
Extended navigation module.
Available in conjunction with PCM,
this optional expansion module
enables automatic navigation
along a previously recorded route
(reverse route navigation). It also
facilitates compass and GPS-
based navigation in regions not
covered by your navigation DVD.
Porsche Communication
Management (PCM).
PCM is an optional multimedia
control and display system
featuring radio, CD player, audio
controls, on-board computer and
GPS navigation. It can also be
combined with an optional tri-band
telephone module. Key features
include a high-resolution 5.8-inch
colour display with 16 : 9 aspect
ratio. The menu structure is easy
to navigate using a multifunction
rotary push-button control. A 12-
digit keypad is also included for
dialling outgoing calls. The system
also provides easy access to the
performance display and memory
function included with the optional
Sport Chrono Package Plus.The DVD drive used for satellite
navigation is housed in the front
luggage compartment. One of the
benefits of this arrangement is
that the MP3-compatible CD drive
in PCM can be used exclusively
for audio CDs.
On-board computer.
The standard on-board computer
provides a wide range of
information, including average
fuel consumption, average speed,
range till empty and audio data.
It can also be used to view data
from the optional Tyre Pressure
Monitoring (TPM). Information is
accessed using a control stalk on
the steering column and viewed in the central instrument display.
If combined with the optional
PCM, you can access additional
data and functions such as
average values and driver-defined
speed-limit warnings. The control
stalk for the computer is also
used to select the analogue and
digital timing functions in the
optional Sport Chrono Package
(see pages 54/55).Navigation system.
The PCM navigation system
includes an intuitive menu
structure and dedicated DVD
drive. One of the main benefits
of DVD navigation is rapid route
calculation. The wide range of
Porsche Communication Management (PCM)
Electronic logbook.
This optional addition to PCM
enables you to automatically
record on every journey the
mileage, route distance, date and
time as well as starting location
and destination. Data can be
downloaded from PCM via the
infrared port and processed on
a PC using software included
with the package. This easy-to-
use option fulfils the statutory
requirements for automatic
logbooks as specified by the
German revenue authorities.
Telephone module.
Available in conjunction with PCM,
this optional GSM telephone
module has an integral hands-free
facility. The microphone is
concealed beneath the steering
column casing and is directed
towards the driver’s position.
Functions can be accessed using
dedicated keys on the PCM
terminal, a control stalk on the
steering column, or the optional
three-spoke multifunction steering
wheel.Special features include SMS
(text) messaging as well as card-
free calls to emergency services.
The antenna is located neatly
out of sight beneath the scuttle
at the base of the windscreen.
A passive (keyless) handset
offering greater call privacy is
available as an optional extra.
CDC-4 CD autochanger.
This optional CD autochanger
has a total capacity of six CDs.
Compatible with both the
standard audio system and PCM,
it installs neatly away in a
compact niche within the front
luggage compartment. Both
standard cars include a CD
autochanger preparation.

· 89 · · 88 ·
EnvironmentThere are two possibilities when
it comes to protecting the
environment: react to regulations
or establish your own and
incorporate them within the
development process. For us,
there has only ever been one
way. With the Cayman and
Cayman S, we have followed that
path as on every Porsche before.
So while their powerful capability
is second to none, it doesn’t
come at any price. At Porsche,
the principle of high performanceextends to every area of the
car. Including its relationship
with the environment. That is our
commitment with the Cayman
and Cayman S. Why settle for
anything less?

4 catalytic converters with
4 Lambda sensors

EU4 /ULEV II-compliant

Lengthy service intervals

Modest fuel consumption

85 % recyclable (approx.)

· 90 ·
Exhaust emission control.
Four-valve cylinder heads and
VarioCam Plus ensure minimal
emissions at source. After leaving
the engine, the gases are cleaned
by a system of four catalytic
converters and four ‘Lambda’ or
oxygen sensors. Controlling it
all with optimum efficiency is
the Motronic ME7.8 engine
management system. Each bank
of cylinders has its own Lambda
circuit, enabling precision
adjustment of the air/fuel mix.
Each exhaust tract has two
Lambda sensors, one upstream
and one downstream of the
primary catalyst.* The resulting
benefits include full compliance
with both the EU4 emissions
standard and ULEV II regulations
in the United States, as well as
excellent fuel economy.
Noise.
The Cayman and Cayman S comply
with all current noise regulations
without any form of engine
encapsulation. To do that, we’ve
eliminated noise at source in
every area of each car. Engine
components are rigid, moving
parts are light, and tolerances
have been reduced to a minimum.
The result is a pure and distinctive
sound – with all the character
you’d expect from a Porsche.
Fuel system.
All fuel lines are made from robust
aluminium, while those carrying
vapours are multi-layer plastic. The
result is a significant reduction in
the evaporation of hydrocarbons.
Materials and recycling.
All structural components,
switchgear and trim are made
from fully recyclable materials.
Better still, it is highly unlikely
that they will ever need recycling
at all. Long-term durability is,
after all, one of the defining
qualities of every Porsche car.
A key objective during the
development process was all-
round weight reduction. This was
achieved using cast aluminium
alloys, synthetic materials and
high-tensile metals. Used correctly,
this blend of materials is both
stronger and lighter than
conventional
steel. As well as
reducing fuel consumption, it
offers positive environmental
benefits.
Approximately 85 % of all com-
ponents can already be recycled
using today’s technology. This
proportion is set to increase as
* Not featured in markets with leaded fuel.The new Cayman and the Cayman S |
Environment
new thermal methods are
introduced. To simplify recycling,
all synthetic components are
clearly labelled in accordance
with the relevant standards.
Both Cayman models are entirely
free of CFCs and components
manufactured with the aid of
these chemicals. Water-based
paints are used throughout each
car, thereby reducing the need
for chemical solvents during the
production process.
Servicing.
Longer service intervals are not
only more convenient for you, they
are also better for the environment.
With the new Cayman and
Cayman S, we have achieved
very modest servicing
requirements: engine oil every
20,000 miles (or two years),
oil filter every 20,000 miles, air
filter every 40,000 miles, spark
plugs every 60,000 miles (or
four years), and brake fluid every
two years.
In addition to the obvious
environmental benefits, the
advantage for you is two-fold: a
lower cost of ownership throughout
the life of the car, and more time
spent on the road. Based on
mileage alone, the new Cayman
models require just three stops
for servicing every 60,000 miles,
or one service every two years.
· 91 ·
There’s a world of driving pleasure to explore.
It needn’t cost the earth.
Cayman