This Article provides a guide on how to rebuild the brake calipers of a Cayman S (987.1S). The instructions in this article can apply to other Porsche models that use Brembo alloy monoblock painted brake calipers as well. The only variations will be in the size and number of pistons, seals, and dustboots. Otherwise the instructions presented here should be very similar. This guide should not be used for Ceramic Brakes.
Brakes are a critical system on any vehicle. On a performance... 9 Comments
This document describes replacing the Air Oil Separator(AOS) for a 987.2
The design of the part that attaches to the motor casing is slightly different that other Porsche AOS.
There are two round stubs that have o-rings on them, so no more hose clamps.
Otherwise, it seems very similar to previous AOS designs.
Two bolts on the AOS, E10 torque 13Nm(9.5 ftlb.)
Here are the steps to replace the AOS:
1) Remove the top access hatch.
My new-to-me 2009 987.2 has 40,000 miles and it is time to change the spark plugs. Although there is no problem, IMO it is wise to change plugs to prevent them from galling to the cylinder head. I offer this little guide as there doesn't seem to be any 987.2 plug change instructions on the site. Mine is a base 2.9 liter but the S models will be very much the same.
Tools you will need include a 10mm socket, a 10mm ET socket (external torx), an assortment of torx wrenches, and a spark plug... 2 Comments
These are photos of the attachment between the outer door handle and lock assembly.
To disconnect the ouster door handle from the lock:
The black plastic piece is a slider. Press it and slide it back. This will expose the threaded shaft which can then be separated from the white plastic connection. To reinstall, snap the threaded shaft into the white plastic connector and slide the black plastic slider forward to lock the two pieces together.
Following the instructions for removing the Gauge Cluster:
1. Remove the trim under the gauges.
2. Remove the two screws that hold the gauge cluster to the dash.
3.Pull the gauge cluster out of the dash.
I spent a week pulling & pulling, but could never get enough force on the slippery plastic housing to disengage it from the clips.
Finally, after a lot of frustration, I taped a loop of strapping tape to the plastic housing and pulled like hell. It Popped out without causing any damage. ... 2 Comments
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... 13 Comments
The greenfrog (Cayman R) is hitting 222F (coolant) and 252F (oil) at VIR on a 90F+ day, so it's time to add some more cooling. The center radiator installation is well documented and straight forward. Flushing the whole cooling system is much messy and requires special tool (UView Airlift 550000) to refill. In addition there are some differences between 987.1 and 987.2 water pumps.
Here are some of the articles and forum threads I researched:
... 17 Comments
P0455 error, leak inevaporative system
2006 Cayman S
There is a lot of informationfor this error code for earlier Boxsters and other models that focus on ventline valve near the fuel filler neck and/or vent lines at the charcoalcanister (carbon canister), but, unfortunately, most of this information didnot apply to my car.Since I could notfind this information when I searched here before, I thought I would do a shortwrite-up for other Porsche novices.
I am new to Porsches in general... 6 Comments
If you ever have to run a wire to the back of a Cayman, you'll need to remove the Driver Side Sill Plate. I had to do so to run a wire for my Oil Pressure Gauge and I learned that unlike most cars where that plate is held down with just plastic friction pins, the sill plate on a Cayman is rock solid. It's held in with two rather substantial bolts. If you need to remove yours, you'll want to read on.
1). There are two plastic plugs in the side of the sill plate between... 5 Comments
A clutch slave cylinder should last a long time. But there have been incidents of slave cylinders leaking in Caymans, which can leave your clutch pedal on the floor. There was a Workshop Campaign (W802) back in 2008 to replace more than 1,200 bad slave cylinders that made their ways into cars (987s and 997s).
Should you find yourself in need of a new slave cylinder, this article should be of great help to you.
Fastener LocationDescriptionTool SizeTorque ValueClutch... 3 Comments