Port PORSCHE CAYMAN 2007 1.G Repair Manual

FuelRecommendations
YourPorscheisequippedwithcatalyticconvertersandmustuseUNLEADEDFUELONLY.
Yourengineisdesignedtoprovideoptimumperformanceandfueleconomyusingunleadedpremiumfuelwithanoctaneratingof98RON(93CLCorAKI).Porschethereforerecommendstheuseofthesefuelsinyourvehicle.
Porschealsorecognizesthatthesefuelsmaynotalwaysbeavailable.Beassuredthatyourvehiclewilloperateproperlyonunleadedpremiumfuelswithoctanenumbersofatleast95RON(90CLCorAKI),sincetheengine’s”ElectronicOctane™knockcontrol“willadapttheignitiontiming,ifnecessary.
TheuseofUNLEADEDFUELONLYiscriticallyimportanttothelifeofthecatalyticconvert-ers.Depositsfromleadedfuelswillruintheconvertersandmakeitineffectiveasanemis-sioncontroldevice.
Carswithcatalyticconvertershaveasmallerfueltankopening,andgasstationpumpshavesmallernozzles.Thiswillpreventaccidentalpumpingofleadedfuelintocarswithcatalyticconverters.
UnleadedfuelsmaynotbeavailableoutsidethecontinentalU.S.andCanada.Therefore,werecommendyoudonottakeyourcartoareasorcountrieswhereunleadedfuelmaynotbeavailable.
Octaneratings
Octaneratingindicatesafuel’sabilitytoresistdetonation.Therefore,buyingthecorrectoctanegasisimportanttopreventengine”damage“.
TheRONoctaneratingisbasedontheresearchmethod.TheCLC(U.S.CostofLivingCounciloctanerating)orAKI(antiknockindex)octaneratingusuallydisplayedonU.S.fuelpumpsiscalculatedasresearchoctanenumberplusmotoroctanenumber,dividedby2,thatiswrittenas:
RON+MONR+M
2or2
TheCLCorAKIoctaneratingisusuallylowerthantheRONrating:
Forexample:95RONequals90CLCorAKI.
Fuelscontainingalcoholandether
SomeareasoftheU.S.requireoxygenatedfuelsduringcertainportionsoftheyear.Oxygenatedfuelsarefuelswhichcontainalcohols(suchasmethanolorethanol)orether(suchasMTBE).
Undernormalconditions,theamountofthesecompoundsinthefuelwillnotaffectdriveability.
YoumayuseoxygenatedfuelsinyourPorsche,providedtheoctanerequirementsforyourvehiclearemet.Werecommend,however,tochangetoadifferentfuelorstationifanyofthefollowingproblemsoccurwithyourvehicle:
–Deteriorationofdriveabilityandperformance.
–Substantiallyreducedfueleconomy.
–Vaporlockandnon-startproblems,especiallyathighaltitudeorathightemperature.
–Enginemalfunctionorstalling.
FuelscontainingMMT
SomeNorthAmericanfuelscontainanoctaneenhancingadditivecalledmethylcyclopentadienylmanganesetricarbonyl(MMT).
Ifsuchfuelsareused,youremissioncontrolsystemperformancemaybenegativelyaffected.
Thecheckenginewarninglightonyourinstrumentpanelmayturnon.Ifthisoccurs,Porscherecom-mendsyoustopusingfuelscontainingMMT.
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HowEmissionControlWorks
Whenanautomobileengineisrunning,itusesenergygeneratedthroughthecombustionofamixtureofairandfuel.Dependingonwhetheracarisdrivenfastorslowlyorwhethertheengineiscoldorhot,someofthefuel(hydrocarbons)maynotbeburnedcompletely,butmaybedischargedintotheenginecrankcaseorexhaustsystem.Additionalhydrocarbonsmayentertheatmospherethroughevaporationoffuelfromthefueltank.Thesehydrocarbons(HC),whenreleasedintotheair,contributetoundesirablepollution.
Inaddition,carbonmonoxide(CO)andoxidesofnitrogen(NOx)contributetoengineemissions.They,too,areformedduringthecombustionprocessanddischargedintotheexhaustsystem.
Toreducethesepollutants,yourPorscheisequippedwithapreciselycalibratedfuelinjectionsystemtoassureafinelybalancedair/fuelmixtureunderalloperatingconditions.
Oxygensensor
Theoxygensensor,installedintheexhaustpipecontinuouslysensestheoxygencontentoftheexhaustandsignalstheinformationtoanelectroniccontrolunit.Thecontrolunitcorrectstheair/fuelratio,sotheenginealwaysreceivesanaccuratelymeteredair/fuelmixture.
Crankcaseventilation
Throughcrankcaseventilation,undesirableemissionsfromtheenginecrankcasearenotpermittedtoreachtheoutsideatmosphere.Theseemissionsarerecirculatedfromthecrankcasetotheairintakesystem.Fromheretheemissionsmixwiththeintakeairandarelaterburnedintheengine.
Catalyticconverters
Thecatalyticconvertersareefficient”clean-up“devicesbuiltintotheexhaustsystemofthevehicle.Thecatalyticconvertersburntheundesirablepollutantsintheexhaustgasbeforeitisreleasedintotheatmosphere.
Theexclusiveuseofunleadedfueliscriticallyimportantforthelifeofthecatalyticconvert-ers.Therefore,onlyunleadedfuelmustbeused.
Thecatalyticconverterswillbedamagedby:
–pushortowstartingthevehicle,
–misfiringoftheengine,
–turningofftheignitionwhilethevehicleismovingor
–drivinguntilthefueltankiscompletelyempty,
–byotherunusualoperatingconditions.
Donotcontinuetooperateyourvehicleundertheseconditions,sincerawfuelmightreachthecatalyticconverters.Thiscouldresultinoverheatingoftheconverters.Federallawprohibitsuseofleadedfuelinthiscar.
Maintenance,CarCare221

Afterwashing,rinsethecarwithplentyofwaterandthendrywithachamoisleather.Donotusethesamechamoisleatherfordryingasyouuseforcleaningthewindshieldandwindows.
Warning!
Moisturewhichgetsontothebrakesduringacarwashcanreducebrakingefciencyormakethebrakespullunevenlywhichcouldincreasethedangerofanaccident,causingseriouspersonalinjuriesordeath.
Alwaysapplythebrakesafewtimesafterwashingthecartotestbrakingefficiencyanddrythebrakediscs.Whendoingthis,takecarenottohamperotherroadusersbehindyou(trafficconditionspermitting).
Automaticcarwashes
Optionaladd-onpartsorpartswhichprojectbeyondthecontoursofthevehiclemaybedamagedbydesignfeatures(e.g.brushes)ofautomaticcarwashes.
Washanddrybyhandallpointsnotreachedbyacarwash,suchasdoorandlidseamsordoorsills.
Pleaseconsulttheoperatorbeforeusingautomaticcarwashes.
Pleaseobservethechapter”WIPERBLADES”onpage203.
Thefollowingpartsareparticularlysuscepti-bletodamage:
–Windshieldwipers(alwaysswitchthemofftopreventthemwipingunintentionallyinintermittentorsensoroperation).
–Fixedrearspoilerorextendedrearspoiler.
–Wheels(thewidertherimandthelowerthetireheight,thegreatertheriskofdamage).
–High-glosswheels(topreventthesefromgettingscratched,donotcleanwiththewheel-cleaningbrushesofthecarwash).
–Externalantenna(alwaysunscrew).
–RoofTransportSystem(alwaysremovecompletely).
Note
Automaticcarwashesspraywateratoddanglesandhighpressures,whicharenotseeninnormaldriving.Therefore,watercansometimesfinditswayintothepassengerscompartmentduringorshortlyafterthecarwash.
Doorlocks
Topreventthedoorlocksfromfreezingduringthecoldseason,thelockcylindersshouldbecoveredduringawash.
Shouldthelocksfreeze,useanordinaryde-icer.Inmanycases,awellwarmedkeycanhelp.Neveruseexcessiveforce.
Maintenance,CarCare229

Windows
Theroaddustwhichsettlesonthewindshieldandwindowscontainsparticlesoftirerubberandoilresidue.Theinteriortrimandupholsteryreleaseparticles,particularlyinstrongsunlight,whichcollectontheinsidesofthewindows.Thesedepositsareaugmentedbyimpuritiesintheairwhichentersthecarthroughthefreshairvents.
Cleanallwindowsregularly,insideandoutside,withPorschewindowcleaner.
Ifyouuseachamoisleatherforthewindows,donotuseitforpaintworkasitwillotherwisepickupacertainamountofpreservativeorpolishandcouldsmearthewindowsandthusimpairvision.
RemovedeadinsectswiththePorscheinsectremover.
Note
Doorwindowsfeatureawater-repellent(hydropho-bic)coatingwhichpreventssoilingofthewindows.
Thiscoatingissubjecttonaturalwearandcanberenewed.
ConsultanauthorizedPorschedealer.
Wiperblades
Wiperbladesthatareinperfektconditionarevitalforaclearview.
Replacethewiperbladestwiceperyear(beforeandafterthecoldseason)orwheneverwiperperformancedeteriorates.
PeriodicallycleanthewiperbladeswithPorschewindowcleaner,especiallyafterthevehiclehasbeenwashedinacarwash.Iftheyareverydirty(e.g.withinsectremains),theycanbecleanedwithaspongeorcloth.
Undercoating
Theundersideofyourcarisdurablyprotectedagainstchemicalandmechanicalinfluences.
Asitisnotpossibletoexcludetheriskofdamagetothisprotectivecoatingindaytodaydriving,itisadvisabletohavetheundersideofthecarinspectedatcertainintervals-preferablybeforethestartofwinterandagaininspring-andtheundercoatingrestoredasnecessary.
YourauthorizedPorschedealerisfamiliarwiththebodysealtreatmentproceduresandhasthenecessaryequipmentforapplyingfactoryapprovedmaterials.Werecommendthatyouentrustthemwithsuchworkandinspections.
Unlikeconventionalsprayoils,undercoatingandrust-proofingcompoundsbasedonbitumenorwaxdonotattackthesound-proofingmaterialsappliedatthefactory.
Warning!
Dangerofreresultinginseriouspersonalinjuryordeath.
Donotapplyadditionalundercoatingorrust-proofingonorneartheexhaustmanifold,exhaustpipes,catalyticconvertersorheatshields.Duringdrivingthesubstanceusedforundercoatingcouldoverheatandignite.
Beforeapplyingfreshunderseal,carefullyremovedepositsordirtandgrease.Onceithasdried,thenewundercoatingcompoundformsatoughprotectivecoatingwhichprovidesefficientrust-proofingofthefloorpanelsandcomponents.
Alwaysapplyafreshcoatingofsuitablepreservativetounprotectedareasaftercleaningtheundersideofthebody,thetransmission,theengineorcarryingoutrepairstounder-body,engineortransmissioncomponents.
Effectiverust-proofingisparticularlyimportantdur-ingthecoldweatherseason.Ifyourcarisdrivenfrequentlyinareaswheresalthasbeenspreadontheroads,thewholeenginecompartmentshouldbecleanedthoroughlyafterthewintertopreventsaltfromcausinganylastingdamage.Afullunder-bodywashshouldalsobeperformedatthesametime.
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ExerciseExtremeCautionwhen
WorkingonyourVehicle
Danger!
Ignoringthefollowinginstructionsmaycauseseriouspersonalinjuryordeath.
Theenginecompartmentofanymotorvehicleisapotentiallyhazardousarea.Ifyouarenotfullyfamiliarwithproperrepairprocedures,donotattempttheadjustmentsdescribedonthefollowingpages.Thiscautionappliestotheentirevehicle.
Onlyworkonyourvehicleoutdoorsorinawellventilatedarea.
Ensurethattherearenoopenflamesintheareaofyourvehicleatanytimewhenfuelfumesmightbepresent.Beespeciallycautiousofsuchdevicessuchashotwaterheaterswhichigniteaflameintermittently.
Beforeworkingonanypartintheenginecom-partment,turntheengineoffandletitcooldownsufficiently.Hotenginecompartmentcomponentscanburnskinoncontact.
Bealertandcautiousaroundengineatalltimeswhiletheengineisrunning.Ifworkhastobeperformedwiththeenginerunning,alwayssettheparkingbrake,andmakesuretheshiftleverisinneutralortheselectorleverisinpositionPorN.
Inparticular,beverycarefultoensurethatitemsofclothing(ties,shirt,sleevesetc.),jewelry,longhair,handorfingerscannotgetcaughtintheengine-compartmentblower,fan,beltsorothermovingparts.Theradiatorandradiatorfansareinthefrontofthecar.Thefanscanstartorcontinuerunningasafunctionoftemperature,evenwiththeengineswitchedoff.Carryoutworkintheseareasonlywiththeengineoffandexerciseextremecaution.
YourPorscheisequippedwithanelectronicignitionsystem.Whentheignitionison,highvoltageispresentinallwiresconnectedwiththeignitionsystem;therefore,exerciseextremecautionwhenworkingonanypartoftheenginewhiletheignitionisonortheengineisrunning.
Alwayssupportyourcarwithsafetystandsifitisnecessarytoworkunderthecar.Jacksarenotsuitableforthiskindofwork.
Whenworkingunderthecarwithoutsafetystandsbutwiththewheelsontheground,makesurethecarisonlevelground,thewheelsareblocked,andthattheenginecannotbestarted.Removetheignitionkey.
Donotsmokeorallowanopenflamearoundthebatteryorfuel.Keepafireextinguishercloseathand.
Incompleteorimproperservicingmaycauseproblemsintheoperationofthecar.Ifindoubtaboutanyservicing,haveitdonebyyourauthorizedPorschedealer.ImpropermaintenanceduringthewarrantyperiodmayaffectyourPorschewarrantycover-age.
Suppliesoffluids,e.g.engineoil,brakefluidorcoolant,arehazardoustoyourhealth.Keepthesefluidsoutofchildren’sreachanddisposeoftheminaccordancewiththeappropriateregulations.
Somecountriesrequireadditionaltoolsandspecialsparepartstobecarriedinyourvehicle.Pleasemakeenquiriesbeforedrivingabroad.
Workingintheenginecompartment
Havethenecessaryworkintheenginecompart-mentdonebyaqualifiedspecialistworkshop.WerecommendthatyouuseyourauthorizedPorschedealerforcarryingoutthiswork.
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Tirewear
TheoriginalequipmenttiresonyourPorschehavebuilt-intirewearindicators.Theyaremoldedintothebottomofthetreadgroovesandwillappearasapproximately1/2in.(12mm)bandswhenthetiretreaddepthisdownto1/16ofanin.(1.6mm).
Whentheindicatorsappearintwoormoreadjacentgrooves,itistimetoreplacethetires.Werecommend,however,thatyoudonotletthetiresweardowntothisextent.Worntirescannotgriptheroadsurfaceproperlyandareevenlesseffectiveonwetroads.
IntheUnitedStates,statelawsmaygoverntheminimumtreaddepthpermissible.Followallsuchlaws.
Danger!
Drivingonworntirescanresultinlossofcontrolofthevehicleandcouldcauseseriouspersonalinjuriesordeath.
Donotdrivewithworntiresortiresshowingcutsorbruisesastheymayleadtosuddendeflationandlossofcontrolwhichcouldcauseseverepersonalinjury.
Specializedhighperformancetiresonhighperformancesportscarsexhibitmorewearthanthoseonafamilysedan,orevenahighperformancesedan.Therefore,itisimportanttocheckyourtirepressureandconditionatleasteverytwoweeks.
Ifyounoticethattiresarewearingunevenly,consultyourPorschedealer.Unevenwearmaynotalwaysbeduetoimproperwheelalignment.Itcanbetheresultofindividualdrivinghabitssuchascorneringathighspeeds.Ifthetirepressureisnotcheckedandadjustedregularly,abnormaltirewearcanalsooccur.
Tirecare
Avoiddamagingtiresandwheelrims.
Ifyoumustdriveoveracurborotherobstacle,driveslowlyandatanobtuseangle.
Checktiresforunevenwearanddamagebeforedrivingoff.
Removeimbeddedmaterial.
Replacewornordamagedtiresimmediately.
Keepoil,fuel,brakefluid,etc.awayfromtires.
Replacemissingvalvestemcaps.
Keeptiresinflatedcorrectly.
Washtireswhenwashingthevehicle.Alsocleaninnersideofwheels.
Donotuseabrasivecleanerswhenwashingthewheels.
Checkwheelrimsforcorrosion.
Removeroadsalt,ifdrivinginwinter.
Tiredamage,puncture
Checktiresforimbeddedmaterial,cuts,punctures,cracksandbulges(sidewall)beforedrivingoff.
Incaseoftiredamage,whereitisuncertainwhetherthereisabreakintheplywithallitsconsequencesortiredamagecausedbythermalormechanicaloverloadingduetolossofpressureoranyotherpriordamage,werecommendthatthetirebereplacedforsafetyreasons.
Ifonefaultytireisreplaceditshouldbenotedthatthedifferenceintreaddepthononeaxlemustnotexceed30%.Handlinginconsistenciesmayresult.
Performavisualinspectionifnecessary.
Danger!
Riskofseriouspersonalinjuryordeath.Drivingthevehiclewithlowtirepressureincreasesriskofatirefailureandresultinglossofcontrol.Furthermore,lowtirepressureincreasesrateofwearoftheaffectedtires.
Checktires-includingsidewalls-regularlyforforeignbodies,nicks,cuts,cracksandbulges.
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ExampleofInscription
Inscriptiononradialtire
ATiresize
Example:P265/40ZR18101Y
–P-ThetireisdesignedforPassengervehicle.Thisinformationisnotincludedonalltires.
–265-Indicationoftirewidthinmm
–40-Indicationoftireheighttotirewidthratioinpercent
–ZR-codeletterforradialtiresforspeedsabove150mph/240km/h.Therearecur-rentlynostandardsconcerningtirestrengthatspeedsabove150mph(240km/h).
–R-Belttypecodeletterforradial
–18-Indicationofrimdiameterininches
–101-Loadcapacitycoefficient
–Y-Speedcodeletter
–XL(ExtraLoad)-Tirewithincreasedloadrating
BTIN(TireIdenticationNumber)
Example:DOTxxxxxxxxxxxx
–DOTTheDOTsymbolindicatesthatthetirescomplywiththerequirementsoftheUSDepartmentofTransportationandprovidesinformationabout:
–firsttwo-digitcodemeansmanufacture’sidentificationmark.
–secondtwo-digitcodemeanstiresize.
–thirdfour-digitcodemeanstiretypecode.
246PracticalTips,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.
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Slowbatterycharging
1.Payattentiontoallwarningsandfollowinstructionsthatcomewithyourbatterycharger.
2.Whencharging,ensureadequateventilation.
3.Removebattery.
Pleaseobservethechapter”REMOVINGTHEBATTERY”onpage265.
4.Allventcapsshouldbeopen.Thefluidlevelshouldmeettheindicatormarkineachcell.
5.Ensurethatchargerisswitchedoff-dangerofshortcircuit!
6.Connectchargercables.ChargercablesmustbeconnectedPOSITIV(+)toPOSITIV(+)andNEGATIVE(-)toNEGATIVE(-).
7.Switchoncharger.Normallyabatteryshouldbechargedatnomorethan10percentofitsratedcapacity.Ratedcapacityofthebatteryinyourvehicleislistedonthebatteryhousing.
8.Aftercharging,turnoffchargeranddisconnectchargercables.
9.Tightentheventcapsandreinstallbattery.
Pleaseobservethechapter”INSTALLINGTHEBATTERY”onpage265.
Winteroperation
Thecapacityandabilityofthebatterytostorepowerdecreasesatlowoutsidetemperatures.
Additionally,morepowerisconsumedwhilestarting,andtheheadlights,heater,rearwindowdefogger,etc.,areusedmorefrequently.
LetyourPorschedealertestthebattery’scapacitybeforewintersetsin.
Thebatterywilldischargemorequicklyifyourvehicleisnotdrivenonadailybasisoveradistanceofseveralmiles.Themoreoftenyoudriveyourvehicle,andthelongerthedistancedriveneachtrip,themoreopportunitythevehicle’schargingsystemwillhavetorechargethebattery.
Replacingthebattery
Theservicelifeofthebatteryissubjecttonormalwear;itdependsgreatlyoncare,climaticcondi-tionsanddrivingconditions(distances,loads).
OnlyuseanoriginalPorschebatterywiththecorrectpartnumber,asareplacement.
Pleaseobservethedisposalinstructionsforbatteries.
Puttingvehicleintooperation
Afterthebatteryisconnectedorafteracom-pletelydischargedbatteryischarged,themul-tifunctionalPSMlightlightsupontheinstrumentpanelandamessageappearsontheon-boardcomputertoindicateafault.
Thisfaultcanberemediedwithafewsimplesteps:
1.Starttheengine.
2.Withthevehiclestationary,performafewsteeringmovementstotheleftandrightandthendriveashortdistanceinastraightlineuntilthemultifunctinalPSMlightgoesoutandthemessageontheon-boardcomputerdisappears.
3.Ifthewarningsdonotdisappear,then:DrivecarefullytothenearestauthorizedPorschedealer.Havethefaultremedied.
4.Afterthewarningsdisappear:Stopthevehicleinasuitableplace.
5.Performadaptionofthepowerwindows:
Pleaseobservethechapter”STORINGENDPOSITIONOFTHEWINDOWS”onpage35.
Ignitionkey/ignitionlock
Donotinserttheignitionkeyintotheignitionlockifthevehiclebatteryisdischarged.Theignitionkeycannolongerberemoved.
Thekeycannotberemoveduntilthevehicleelectricalsystemissuppliedwithpoweragain.
Pleaseobservethechapter”EMERGENCYUNLOCKINGOFTHEFRONTLUGGAGECOMPARTMENTLID”onpage260.
Pleaseobservethechapter”EMERGENCYSTARTINGWITHJUMPERCABLES”onpage267.
264PracticalTips,EmergencyService

Removingthebattery
Therequiredtoolisinthetoolkit.
Thebatteryislocatedinthefrontluggagecompart-mentunderablackplasticlid.
Warning!
Riskofdamagetoalternatorandelectroniccontrolunits.
Donotdisconnectbatterywhiletheengineisrunning.Thisalsoappliestocarsequippedwithabatterymainswitch.
Neverdrivethecarwithadisconnectedbattery.
Warning!
Riskofcausticburnsfromescapingacid.
Keepventcapsontoavoidspillage.
Donottiltthebatterywhenremovingandinstallingit.
1.Switchoffengineandallelectricalloads.
2.Openturn-locksA.Removeplasticlid.
3.PulloffventhoseC.
Danger!
Riskofshortcircuitandexplosion,resultinginseriouspersonalinjuryordeath.
Important:disconnectthenegative(-)groundwirefirst,andthenthepositive(+)cable.
4.Important:disconnectthenegative(-)groundwirefirst,andthenthepositive(+)cable-dangerofshortcircuit!
5.UnscrewfasteningscrewB.
6.Removebattery.
Installingthebattery
1.Putbatteryinandpushitallthewaytothestop.
2.ScrewinfasteningscrewB.
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