The Air Oil Separator (AOS) operates to return oil that was mixed with air from the cam covers and return it to the crankcase. It has two inlet pipes, one from each cam cover and a bottom hose where the oil returns to the crankcase. This articles shows the photos taken to remove the AOS from a 2007 Base Cayman. Remove the engine cover. Jack up the car and remove the right rear wheel. Remove the tie wrap on the wiring harness near the right hand hose connection. Squeeze the upper...
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Most of these photos were created and annotated by adsalmon as he trouble shoots a delayed cold start problem on his 2006 Cayman S. Very handy reference.
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Shown on 5 speed 987.1. I cut a 1 3/4 inch access hole in the plate under the trans axle to easily get to the drain plug. The other thing to note is the 6 speed trans axle gets filled to the bottom of the fill port while the 5 speed transmission requires the level to be diabolically set lower than the fill port by 11 mm. The five speed drain plug requires a special 16 mm triple square anti tamper socket I got from Pelican Parts. The six speed drain plugs are more rational, using 10 mm hex...
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This article describes the installation of the Tarett Engineering rear strut mounts ( no affiliation ) shown below. Because this install was part of a suspension upgrade I had the struts already out of the car. There are many articles out there describing the strut removal process in a Cayman or Boxster if your struts are in place. Access to the top of the rear struts require a fair amount of interior trim removal. You will need an impact driver with 13/16 socket and a spring compressor for...
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This article describes the installation of a set of Hella B133 horns into my 2007 Cayman. My car is on its third set of stock horns so I wanted try something better(?) now that the warranty has expired. This horn installation requires the bumper cover to be removed. I synced this project up with my CSF radiator install. The Hella kit comes with two horns and a horn relay. I used the relay not knowing the capacity of the Porsche horn relay. These new horns draw 11 Amps.... Here is the...
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This article describes the installation of three all aluminum radiators made by CSF ( no affiliation ) on my 2007 Cayman 2.7L. The radiators are welded things of beauty which promise to be more rugged than stock radiators and increase cooling capacity by 8 - 10% due to their design. There are three part numbers involved: CSF7047 Left Side Radiator CSF7048 Right Side Radiator CSF7049 Center Radiator Four fresh O rings on the radiator hoses: Two pieces P/N 99610680107 and two pieces...
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This article briefly describes the installation of a brake caliper stud kit supplied by Tarret Engineering ( no affiliation ) on the rear of my 2007 Cayman. The stud kit prevents stripping of the caliper mounting holes in the wheel bearing carrier. The studs are available in various lengths for different vehicles as shown here: http://www.tarett.com/items/986-987-products/986-987-engine~transmission~brakes~electrical/brake-caliper-stud-kit-bcsk-detail.htm The kit is shown here. The...
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UPDATE 2 from Vision Motorsports: Dwain replied to my question about trans axle temperature ranges to worry about: his response was, “220 is ok. 250 is getting hot. 275, I would start to be concerned.” UPDATE: I have some trans axle temp data from my recent visit to Sebring. On the drive over, 140 miles at 55 - 65 MPH, ambient air 90 F, the trans axle oil reached 150 F. The first day of the DE air temp was 80 F and I was re-learning the track the trans axle oil reached 190 F. On the...

This article describes the installation of the Vision Motorsports big brake kit for Cayman. Diver Dog had this kit installed previously. The advantages of this kit are ease of pad change, wide selection of pad choices and improved braking. Installation was straight forward, removing the stock calipers and rotors and replacing them with the new 350 mm AP rotors and 2004 GT3 6 piston calipers followed by a brake bleed. The kit consists of two new AP rotors, two new 2004 GT3 front calipers, two...
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This article describes the installation of an electric power steering pump kit into my 2007 Cayman 2.7L. The GSR Autosport Electric Power Steering pump kit I chose ( no affiliation ) allows replacement of the engine mounted power steering pump and lines with a Porsche Motorsport electric pump and new hose set. GSR Autosport is now Trinity and no longer stocks this kit. Reports are the pump can be purchased from Achilles and RS1. BILT Racing ( no affiliation ) also sells an electric PS pump...
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