ECU PORSCHE CAYMAN 2007 1.G Service Manual

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Denitions
TheCurbweight-actualweightofyourvehicle-vehicleweightincludingstandardandoptionalequipment,fluidsandemergencytools.Thisweightdoesnotincludepassengersandcargo.
TheGrossVehicleWeightissumofthecurbweightandtheweightofpassengersandcargocombined.
TheGrossVehicleWeightRatingisthemaxi-mumtotalweightofvehicle,passengers,luggageandoptionalequipment.
TheGrossAxleWeightRatingisthemaximumloadlimitforthefrontortherearaxle.Thisinformationislocatedonthesafetycompliancestickerlocatedinthedriver’ssidedoorjamb.
Fordeterminingthecompatibilityofthetireandvehicleloadcapabilities:
Pleaseobservethechapter”TIRES,RIMS,TRACKS”onpage298.
Theloadcapacitycoefficient(e.g.“101”)isaminimumrequirement.
TheGrossCombinedWeightRatingisthemaxi-mumtotalweightratingofvehicle,passengersandcargo.
TheVehicleCapacityWeight-LoadLimit-isthemaximumtotalweightlimitspecifiedoftheload(passengersandcargo)forthevehicle.Thisisthe
maximumweightofpassengersandcargothatcanbeloadedintothevehicle.Thisinformationcanbefoundonthetirepressureplate.
Themaximumloadedvehicleweightisthesumofcurbweight,accessoryweight,vehiclecapacityweightandproductionoptionsweight.
Theloadratingisthemaximumloadthatatireisratedtocarryforagiveninflationpressure.
Themaximumloadratingistheloadratingforatireatthemaximumpermissbleinflationpressure.
Thecargocapacityisthepermissibleweightofcargo,thesubtractedweightofpassengersfromtheloadlimit.
Neverexceedthepermissiblelimits.
Danger!
Riskoflossofcontrol,damagetovehicleandseriouspersonalinjuryordeath.
Neverexceedthespecifiedaxleloads.Overloadingcanshortentheservicelifeofthetiresandcar,aswellasleadtodangerousvehiclereactionsandlongbrakingdistances.Damageduetooverloadingisnotcoveredbythevehiclewarranty.
Examplefordeterminingthecombinedweightofoccupantsandcargo
VehicleLoadCapacity
Thecombinedweightofoccupantsandcargoshouldneverexceedtheweightshownonthetireplateinthevehicle.
Pleaseobservethechapter”TIREPRESSUREPLATE”onpage240.
Neverexceedthenumberofpassengersshownonthetirepressureplateinthevehicle.
248PracticalTips,EmergencyService

WheelBolts
Danger!
Riskofwheelboltbreakageandwheelseparation,resultinginseriouspersonalinjuryordeath.
Followallinstructionsconcerningwheelbolts.
Alwayscleanthewheelboltsbeforefitting.
ApplyathincoatofOptimolyTA(aluminumpaste)onthethreadandbetweentheboltheadandmovablesphericalcapring(arrows).Thebearingsurfaceofthesphericalcapfacingthewheelmustnotbegreased.
Replacedamagedwheelbolts.OnlyusetheOriginalPorschewheelboltsspeciallydesignedforthisvehicletype.
Tighteningtorque
Tighteningtorqueofwheelbolts:130Nm/96ftlb.
WheelSecuringBolts
Ifthewheelshavetoberemovedattheworkshop,pleasedonotforgettohandoverthewrenchsocketforthewheelsecuringboltsalongwiththecarkey.
Thewrenchsocketforthewheelsecuringboltsisinthetoolbox.
Toloosenortightenthewheelboltwithanti-theftprotection,awrenchsocketwiththeappropriatecodingmustbeusedbetweenthewheelboltandthewheel-boltspanner.
Whenpositioningthewrenchsocket,ensurethatitengagesfullyintheteethofthewheelbolt.
254PracticalTips,EmergencyService

Changingawheel
Danger!
Riskofseriouspersonalinjuryordeath.Thecarmayslipoffthejack.
Makesurethatnooneisinthevehiclewhenjackingupandchangingawheel.
Alwaysplacethecaronstablesupportsifworkhastobecarriedoutunderthecar.
Warning!
RiskofdamagetothebrakediscsofthePorscheCeramicCompositeBrake(PCCB).
Alwaysscrewinbothassemblyaidswhenchangingawheel.
Note
Thetoolsrequiredforchangingawheel(e.g.jack,wheelboltwrench,assemblyaids)arenotsuppliedwiththecar.TheyareavailableatyourauthorizedPorschedealer.
1.Fullyapplythehandbrake,engage1stgearorselectpositionPandwithdrawtheignitionkey.
2.Securethecaragainstrollingaway,e.g.bymeansofwedgesunderthewheelsontheoppositeside.Thisisparticularlyimportantonslopes.
ScrewinassemblyaidforvehicleswithoutPorscheCeramicCompositeBrake
3.Slightlyslackenthewheelboltsofthewheeltobechanged.
4.Raisethecaruntilthewheelliftsofftheground.
Pleaseobservethechapter”LIFTINGTHEVEHICLE”onpage252.
ScrewintwoassemblyaidsforvehicleswithPorscheCeramicCompositeBrake
Noteonoperation
Toremoveormountthespacers:
Pleaseobservethechapter”SPACERS”onpage257.
5.Remove1or2wheelbolts(seerespectiveillustration).Screwinassemblyaidsinsteadofthewheelbolts.Removetheremainingwheelbolts.
6.Takethewheeloffandputanewwheelon.
PracticalTips,EmergencyService255

Spacers
Generalinformationtotheuseofspacers
UsethespacersonlytogetherwithwheelsandfasteningpartsapprovedbyPorsche.Beforehavingspacersfitted,findoutaboutthecurrentauthorizationstatus.
Mountinganemergencysparewheel
If5mmspacersarefitted,thesemustnotberemovedtomountanemergencysparewheel.
Fittingsnowchains
Theuseofsnowchainsisnotpermittedwhen5mmspacersaremounted.
Caution!
Riskofdamagetowheelhousingsifthe5mmspacersarenotremovedbeforettingsnowchains.
Inordertoenablethefittingofsnowchains,havethe5mmspacersremovedonall4wheels.
Noteonoperation
Tofit/removethespacers:PleaseconsultanauthorizedPorschedealer.
Removing/mountingthespacers
Requiredscopeofpartsifthespacersare
removed
Shortcountersunkscrews(M6x12)PartNo:900.269.047.09
1setofshortwheelboltsPartNo:996.361.203.02
Shortanti-theftprotectiondevicesPartNo:996.361.057.01
PracticalTips,EmergencyService257

Chargestate
Awellchargedbatterywillnotonlypreventstartingproblemsbutwillalsolastlonger.
Inordertoavoidunintendedbatterydischarge
Switchoffunnecessaryelectricalloadsincitytraffic,onshorttripsorinalineortraffic.
Alwaysremovetheignitionkeyfromtheignitionswitchwhenleavingthecar.
AvoidfrequentoperationofthePorscheCommunicationManagementsystemwhentheengineisnotrunning.
Batterycare
Ensurethatbatteryissecurelymounted.
Keepterminalsandconnectionscleanandproperlytightened.Corrosioncanbepreventedbycoatingtheterminalsandconnectionswithpetroleumjellyorsiliconespray.
Ensurethatventcapsaresecurelytightenedtopreventspillage.
Checkingtheelectrolyteuidlevel
Generally,theelectrolytelevelmustbecheckedmoreofteninsummerthaninwinter,andmoreoftenwhendrivinglongdistances.
Whenaddingwater,useonlycleancontainers.Innocasemayalcohol(e.g.windowcleanerresidues)bepermittedtoenterthebattery.
Unscrewandopenthefillerventcapsofeachcell.
Withthecaronalevelsurface,thefluidlevelshouldmeettheindicatormarkineachcell.
Ifnecessary,topupwithdistilledwater.Donotuseacid.Onlyfilluptothemark,otherwisetheelectrolytewilloverflowwhenthebatteryisbeingchargedandcausedamage.
Batterycharging
Automotivebatteriesloosetheirefficiencywhennotinuse.Thechargeavailableinyourbatterycanbemeasuredwithabatteryhydrometer.WerecommendthatthebatteryvoltagebetestedbyyourPorschedealerwhohastheappropriateequipment.
Ifthecarisnotdrivenforprolongedperiods,thebatterymustbechargedatleastevery6weeks.Adischargedbatteryallowsrapidformationofsulfates,leadingtopermaturedeteriorationoftheplates.
Danger!
Hydrogengasgeneratedbythebatterycouldcauseanexplosion,resultinginseriouspersonalinjuryordeath.
Chargebatteryinawellventilatedarea.
Neverchargeafrozenbattery.Itmayexplodebecauseofgastrappedintheice.Allowafrozenbatterytothawoutfirst.
Ifyougetelectrolyte,whichisanacid,inyoureyesoronyourskin,immediatelyrinsewithcoldwaterforseveralminutesandcalladoctor.
PracticalTips,EmergencyService263

EmergencyStartingwithJumper
Cables
Generalinformation
Ifthebatteryisdischarged,e.g.inwinterorafterthecarhasbeenparkedforalongtime,thebatteryofanothercarcanbeusedforstartingwiththehelpofjumpercables.Makesurethevoltageofbothbatteriesisthesame.Bothbatteriesmustbe12volttypes.Thecapacity(Amperehours,Ah)oftheboosterbatterymustnotbesubstantiallylessthanthatofthedischargedbattery.Thedischargedbatterymustbecorrectlyconnectedtothevehicle’selectricalsystem.
Pleaseobservethechapter”BATTERY”onpage262.
Pleaseobservethechapter”EMERGENCYUNLOCKINGOFTHEFRONTLUGGAGECOMPARTMENTLID”onpage260.
Note
Donottrytostartthecarbypushingortowing.Damagetothecatalyticconvertersandothercomponentsofthecarmayresult.
Danger!
Riskofshortcircuit,damageandexplosion,resultinginseriouspersonalinjuryordeath.
Useonlyjumpercablesofadequatediametercross-sectionandfittedwithcompletelyinsulatedalligatorclips.
Followallwarningsandinstructionsofthejumpercablemanufacturer.
Whenconnectingjumpercables,makesurethattheycannotgetcaughtinanymovingpartsintheenginecompartment.Thejumpercablesmustbelongenoughsothatneithervehiclesnorcablestouchanother.
Thevehiclesmustnotbeincontact,otherwisecurrentmightflowassoonasthepositiveterminalsareconnected.
Thecableclampsmustnotbeallowedtocontacteachotherwhenoneendofthejumpercablesareconnectedtoabattery.
Ensurethattoolsorconductivejewelry(rings,chains,watchstraps)donotcomeintocontactwiththepositivejumpercableorthepositivebatterypost.
Improperhook-upofjumpercablescanruinthealternator.
Warning!
Dangerofcausticburns.
Donotleanoverthebattery.
Warning!
Dangerofgasexplosion.
Improperuseofboosterbatterytostartavehiclemaycauseanexplosion,resultinginseriouspersonalinjuryordeath.
Keepsourcesofignitionawayfromthebattery,e.g.openflame,burningcigarettesorsparkingduetocablecontactorweldingwork.
Adischargedbatterycanfreezeevenat23°F/-5°C.Beforeconnectingjumpercables,afrozenbatterymustbethawedout.
PracticalTips,EmergencyService267

Installing
1.Insertheadlightintotheguiderailsandpushitfullyintothefender.
2.PushheadlighttotherearandatthesametimeturnthesocketwrenchuntilitpointshorizontallytotherearC.Theheadlightlockingdevicemustperceptiblyandaudiblyengage.
3.Inserttherubberplugintotheunlockingopeningandsecurethecarpet.Checkthefunctionofalllights.
Lowbeam,highbeamandadditionalhigh
beam
Openingthelidoftheheadlighthousing
1.Unscrewthe4screwsA.
2.FirstliftreleasetabB,thenpushbothreleasetabsCupwardsandtakeofflid.
Halogenheadlights:Changingbulbforlow
beam
1.PulloffplugA.
2.DisengagefixingloopB.
3.Replacedefectivebulb.Whendoingso,ensurebulbisseatedproperly.
4.Reassembleinreverseorder.
272PracticalTips,EmergencyService

Changingfoglightbulb
3.Pressthereleasetab(arrow)oftheplugandpullplugoff.
4.Turnbulbholderclockwise(bayonetlock)andremoveholder.
5.Replacedefectivebulb.
6.Insertthebulbholderandturnitcounter-clockwise.
7.Pushonpluguntilitisfelttoengage.
Changingparkinglightbulb
8.Turnbulbholdercounter-clockwise(bayonetlock)andremoveholder.
9.Removedefectivebulbandreplace.
10.Insertthebulbholderandturnitclockwise.
11.Insertbulbhousingandtightenwithth3screwsB.
12.Firstinsertthelightcoverintothesidecut-out1andthenpressdownthecoveratpoints2-7oneaftertheother.Makesurethattheframeiscompletelyclippedin.
13.Checkoperationoflights.
PracticalTips,EmergencyService277

Sidemarkerlight
Changingbulb
1.Removethecapinthewheelhousinglinerwithascrewdriver.
2.Insertthescrewdriverintotheopeninginthewheelhousinglineratrightanglestotheturnsignalhousing.Bypressingwiththescrewdriver,disengagethesecuringspringBofthedirectionindicatorhousing.
3.Swivelouttheindicatorlightandundobulbholder(bayonetlock).
4.Removethebulbfromtheholderandreplaceit.Insertholder.Checkoperationofthelight.
5.Inserttheturnsignal’sretaininglugsAintothesidesectionatthefront.PushinturnsignaluntilthesecuringspringBisfelttoengage.
6.Pressthecapintothewheelhousingliner.
278PracticalTips,EmergencyService

Example:Frontluggagecompartmentlight
Frontluggage
compartment/footwelllights
Changingbulb
1.Withascrewdriver(arrow),carefullypushoutthelight.
2.Removedefectivebulbfrombetweenthecontactspringsandreplace.
3.Insertthelightintothecut-out,firstfromonesidethenfromtheother.Checkoperation.
282PracticalTips,EmergencyService