2005 Porsche Cayman Service Repair Manual

2006 Porsche Cayman S ACCESSORIES & EQUIPMENT Front

ACCESSORIES & EQUIPMENT Front

50 IN DIAGRAM OF BODY BONDING POINTS AND SEALING ELEMENTS AS OF MY 2005 (CAYMAN S, CAYMAN S RHD) DIAGRAM OF BODY BONDING POINTS AND SEALING ELEMENTS Installation Location:

Fig. 1: Diagram of body bonding points and sealing elements Courtesy of PORSCHE OF NORTH AMERICA, INC. Microsoft Monday, September 21, 2009 12:13:23 12:13:12 PM

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A - Bonding area for cowl panel frame, roof frame. Refer to 51 03 55 Replacing roof - as of MY 2006 (Cayman S, Cayman S RHD) .

B - Spot welding/bonding procedure in area of wheel housing, inner side section and outer side section. Refer to 53 55 55 Replacing side section - as of MY 2006 (Cayman S, Cayman S RHD) .

C - Seal (moulded part) in area of inner side section and outer side section. Refer to 53 55 55 Replacing side section - as of MY 2006 (Cayman S, Cayman S RHD) .

D - Bonding procedure in light housing area. Refer to 53 55 55 Replacing side section - as of MY 2006 (Cayman S, Cayman S RHD) .

E - Rivet-bonding procedure in roof frame reinforcement area. Refer to 51 08 55 Replacing roof reinforcement - as of MY 2006 (Cayman S, Cayman S RHD) .

F - Resistance spot-welding/bonding procedure in cowl panel frame area. Manufacturer does not provide specific Instructions.

G - Resistance spot-welding/bonding procedure in hinge pillar reinforcement area. Refer to 51 62 55 Replacing hinge pillar reinforcement - as of MY 2006 (Cayman S, Cayman S RHD) .

H - Resistance spot-welding/bonding procedure in inner side member area. Manufacturer does not provide specific Instructions.

I - Bonding procedure in the area. Refer to 51 03 55 Replacing roof - as of MY 2006 (Cayman S, Cayman S RHD) .

J - Bonding procedure in the bulkhead panel area. Refer to 51 08 55 Replacing roof reinforcement - as of MY 2006 (Cayman S, Cayman S RHD) .

K - Bonding procedure in the bulkhead panel area. Refer to 51 08 55 Replacing roof reinforcement - as of MY 2006 (Cayman S, Cayman S RHD) .

L - Expanded sealant in the roof reinforcement is sealed using 2K acoustic filler foam when replacing the roof reinforcement. Refer to 51 08 55 Replacing roof reinforcement - as of MY 2006 (Cayman S, Cayman S RHD) .

The bonding and sealing elements must be replaced during repairs. The procedure is described in the relevant chapter on body repairs.

50 IN DIAGRAM OF BODY BONDING POINTS AND SEALING ELEMENTS AS OF MY 2005 (BOXSTER, BOXSTER RHD, BOXSTER S, BOXSTER S RHD) DIAGRAM OF BODY BONDING POINTS AND SEALING ELEMENTS Microsoft Monday, September 21, 2009 12:13:12 PM

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Installation Location:

Fig. 2: Diagram of body bonding points and sealing elements Courtesy of PORSCHE OF NORTH AMERICA, INC. B - Spot welding/bonding method in area of wheel housing, inner side section and outer side section. Refer to 53 55 55 Replacing side section - as of MY 2005 (Boxster, Boxster RHD, Boxster S, Boxster S RHD) .

C - Seal (moulded part) in area of inner side section and outer side section. Refer to 53 55 55 Replacing side section - as of MY 2005 (Boxster, Boxster RHD, Boxster S, Boxster S RHD) .

E - Spot welding/bonding method in area of inner lower side member and inside of A-pillar.

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The bonding and sealing elements must be replaced during repairs. The procedure is described in the relevant chapter on body repairs.

50 IN GENERAL INFORMATION AND NOTES ON QUALITY - AS OF MY 2005 (ALL MODELS) MEASURES FOR MAINTAINING LONG-TERM BODY PROTECTION NOTE:

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After repair work, the standard corrosion-inhibiting coating should only be restored with the corrosion-inhibiting agents approved by the manufacturer. The following points must be observed for body repairs.

Always apply welding primer to both sides of the welding flange when resistance spot welding.

Prime repair areas from outside. Prime on both sides in the accessible areas.

Seal all sheetmetal overlaps, sheetmetal edges, butt joints, weld seams etc. with body sealant.

When replacing structurally bonded body parts, proceed according to the information in the respective repair instructions.

Only apply body sealant to primed sheetmetal parts.

Apply top coat paint to the inside of the outer sheetmetal shell before welding. See "Paint build-up": --> "Paint Manual" Build up paint on bare sheetmetal panels according to the painting methods described in the --> "Paint Manual".

Repair or create standard undersealing by applying long-life undersealing material.

Preserve cavities in the repair area with cavity preservative after applying a top coat paint.

Check that the standard water drains (plugs) function correctly or clean them after the cavity preservation material has dried.

Prerequisite for maintaining the long-life guarantee

All body repair work must be carried out correctly and according to the specific Porsche instructions for sheetmetal, paint and corrosion protection/preservation work. To avoid jeopardising the long-life guarantee, a Paint Condition Report is prepared two years after delivery of the vehicle. This condition report must be updated annually by every Official Porsche center.

ELECTRONIC CONTROL MODULES NOTE:

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If electronic components, e. g. ABS control module, have been removed for repair work and are then reused, they must undergo a functional check after fitting in accordance with existing specifications.

Battery trickle charge

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To prevent the vehicle battery from discharging while at the workshop, a battery charging unit with a rated current of at least 40 A must be connected as soon as the vehicle is unlocked.

Refer to 27 06 01 BATTERY TRICKLE CHARGE - AS OF MY 2005 (ALL MODELS) for instructions about connecting the battery charging unit.

Protection against overvoltage when performing welding work

To protect electronic control units from overvoltage during electric arc welding, the following work regulations must be observed: 

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When welding work is extensive, the electronic control units must be removed. Ensure that there are no electrically insulated parts between the ground connection and the welding point.

Remove clamp from negative terminal of battery and cover negative terminal of battery.

Connect the ground connection of the electric arc welding equipment as near as possible to the welding point on the part to be welded.

Do not touch electronic control units or electric cables with the ground connection or the welding electrode.

Replacing control modules

The replacement of electronic control modules after an accident is necessary if at least one of the following conditions is met: The housing is noticeably deformed or damaged.

The supporting surface or bracket is deformed (the unit shows no external damage).

The plug connection is damaged or corroded by moisture.

Functional checks or self-diagnosis of the unit reveals the fault "Control module faulty".

50 IN BODY PARTS OF VARIOUS SHEETMETAL STRENGTHS - AS OF MY 2005 (ALL MODELS) HIGH-STRENGTH STEEL PLATES NOTE:

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Only "Original Porsche parts" must be used for repair work!

Body parts of high-strength steel contribute to better protection of the passenger compartment and thus increase protection of the passengers. In addition to improved crash safety, these parts also have a positive influence on fatigue strength. In terms of crash behavior, body parts made from high-strength sheet steel are characterised by their higher energy absorption. But this also means that higher reshaping force must be applied in reshaping work.

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Fig. 3: High-strength steel plates Courtesy of PORSCHE OF NORTH AMERICA, INC. HIGHEST-STRENGTH STEEL PLATES WARNING: This affects torsion resistance, resistance to bending and crash safety 

Danger of injury and material damage

--> Body parts made of highest-strength steel plate cannot be reshaped. Highest-strength body parts cannot be straightened or reshaped!

Fig. 4: Highest-strength steel plates Microsoft Monday, September 21, 2009 12:13:12 PM

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Courtesy of PORSCHE OF NORTH AMERICA, INC. TAILORED BLANKS The indicated body parts are made by welding together plates of different thicknesses and characteristics and then deep-drawing these parts. In their crash behavior, these body parts are characterised by their high energy absorption.

Fig. 5: Tailored blanks Courtesy of PORSCHE OF NORTH AMERICA, INC. BAKED HARDENING WARNING: This affects torsion resistance, resistance to bending and crash safety 

Danger of injury and material damage

--> The spare parts are heat-treated. "Original Porsche parts" attain their final strength only after the production stage of cathodic immersion painting and drying.

--> Only "Original Porsche parts" or sections of "Original Porsche parts" may be used for repair work!

ALUMINUM PARTS The marked body parts are made of aluminum

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Fig. 6: aluminum parts Courtesy of PORSCHE OF NORTH AMERICA, INC. HIGH-STRENGTH STAINLESS STEEL The marked body parts are made of high-strength stainless steel

Fig. 7: High-strength stainless steel Courtesy of PORSCHE OF NORTH AMERICA, INC. STRAIGHTENING BODY PARTS NOTE:

Only "Original Porsche parts" or sections of "Original Porsche parts" may be

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used!

The body and floor assembly are produced in series from deep-drawn panels. For this reason, accident damage must be reshaped in the same way. Body repairs by reshaping are not possible if these body parts are correspondingly deformed. Here, the repair must be carried out using new parts or by means of sectional repairs. The separation of damaged body parts after reshaping against the accident direction should not take place until after connection pieces have been straightened.

WELDING WORK NOTE:

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The use of the oxyacetylene welding process is not permissible for body parts made of high-strength steel!

Test welding must be carried out in the case of resistance spotwelding (RP) of different panel strengths!

The body parts made from high-strength steel can be welded using the RP resistance spot-welding and MIG welding processes that are customary in workshops.

RESHAPING NOTE:

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Only "Original Porsche parts" or sections of "Original Porsche parts" may be used for repair work!

The separation of damaged body parts should not take place until after reshaping against the accident direction has taken place and connection pieces have been straightened!

Body repairs by reshaping are not possible if these body parts are correspondingly deformed. Here, the repair must be carried out using new parts or by means of sectional repairs.

SEPARATION POINTS NOTE:

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Separation points which influence the strength of the body, and thus also the operating and traffic safety of the vehicle, must be carried out according to the specifications of the relevant Technical Manual covering body repair!

Body reinforcements can be separated or joined together only if this is specified in the method descriptions. Otherwise, a damaged reinforcement must always be replaced with a new one!

50 IN WORK SEQUENCE FOR DETERMINING EXTENT OF DAMAGE TO VEHICLES INVOLVED IN AN ACCIDENT - AS OF MY 2005 (ALL MODELS) WORK SEQUENCE FOR DETERMINING EXTENT OF DAMAGE TO VEHICLES INVOLVED IN Microsoft Monday, September 21, 2009 12:13:13 PM

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AN ACCIDENT Notes

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A body is constructed so that it has deformable zones in the front and rear areas. These deformable zones enable absorption of impact energy through their special design. The bearing structure in these areas is adapted by a specific cross section reduction to provide optimum energy reduction in the event of an impact.

Due to the vehicle dimensions in the side area of the body, deformable zones cannot be provided for absorbing energy. The impact energy can only be absorbed to a lesser extent here through the deformation of doors and pillars. This is also the case for the roof area where only the roof skin can absorb impact energy to a very small extent. In these areas, passenger protection is guaranteed by a rigid design of the passenger cell.

The aim of this design is to absorb the impact energy in defined areas to keep the passenger cell as free of damage as possible in the event of an accident. If the passenger cell has been deformed in the event of an accident, extremely large reshaping forces can be expected. Repair work is often only possible in this case by replacing body parts.

In general, an impact occurs diagonally or offset to the vehicle axle so that mixed forms are usually the result of a front and side impact or a rear and side impact. The deformation is not always restricted to the impact area.

Due to inertia forces of masses, such as running gear, drive line, occupants of the vehicle and load or the body itself, deformation can also occur in the opposite areas.

The following work sequence should provide assistance to correctly determine the scope of damage of vehicles damaged in an accident.

Work sequence for determining scope of damage to vehicles involved in an accident

1. Identify impact points on the outer shell or the wheels 2. Remove accessories which limit view of the impact area 3. Check unit mounts, running gear parts and steering parts for deformation and cracks 4. Determine scope of damage on the body See Identifiable deformations on the body structure See No identifiable deformations on the body structure 5. Repair vehicle, if necessary.

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1. Visual inspection of the structural parts for creasing and bending, starting from the point of impact toward the center of the vehicle 2. Visual inspection of the structural parts at the joints for gaping panel joints (e. g. entry area at the side member under the rubber seal of the door) 3. Drive vehicle onto a lifting platform and raise it. Measure the measuring points or reference points specified in the repair check dimensions table diagonally, horizontally and vertically using a beam compass or an electronic measuring system and compare with the specified values. 50 IN Diagram - body gap dimensions as of MY 2005 (Cayman S, Cayman S RHD) or 50 IN Diagram - body gap dimensions - as of MY 2005 (Boxster, Boxster RHD, Boxster S, Boxster S RHD).

4. Decide whether vehicle is technically repairable 5. Decide whether vehicle is economically repairable Repair vehicle, if necessary.

No identifiable deformations on the body structure

1. Check seam joining line on the accessories . 50 IN Diagram - body gap dimensions - as of MY 2005 (Cayman S, Cayman S RHD) or 50 IN Diagram - body gap dimensions - as of MY 2005 (Boxster, Boxster RHD, Boxster S, Boxster S RHD).

2. Check accessories for paint abrasion (accessories that were hit during impact) 3. Drive vehicle onto a lifting platform and raise it. Measure the measuring points or reference points specified in the repair check dimensions table diagonally, horizontally and vertically using a beam compass or an electronic measuring system and compare with the specified values. . 50 IN Diagram - body gap dimensions as of MY 2005 (Cayman S, Cayman S RHD) or 50 IN Diagram - body gap dimensions - as of MY 2005 (Boxster, Boxster RHD, Boxster S, Boxster S RHD).

4. Determine extent of any apparent damage to vehicle partsMeasure running gear electronically if necessary.

Refer to 44 95 03 Suspension alignment, complete - as of MY 2005 (All Models) .

5. Decide whether vehicle has to be repaired Repair vehicle, if necessary.

50 IN WORK SEQUENCE FOR ACCIDENT REPAIR - AS OF MY 2005 (ALL MODELS) WORK SEQUENCE FOR ACCIDENT REPAIR Procedure for accident repairs.

1. Determine scope of damage Microsoft Monday, September 21, 2009 12:13:13 PM

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2. Expose the area to be repaired 3. Make an economic or technical decision: Should parts be repaired or replaced?

4. Determine the scope of replacement parts and order the partsSee Repair See Replacement 5. If necessary, prime and seal the seam areas 6. If necessary, renew the stone impact protection 7. Paint the repaired area 8. If necessary, touch up the undersealing 9. Seal cavities 10. Fit accessories Repair

1. Cover undamaged areas of the vehicle 2. Reshape damaged areas 3. Fill or soak reshaped areas 4. Apply fine filler on repair areas Replacement

1. Cover undamaged areas of the vehicle so that they are protected against fire 2. Disconnect battery 3. Pre-paint new parts from the inside 4. Reshape damaged area by straightening so that adjacent contours or gap dimensions correspond to the standard condition 5. Roughly cut out damaged areas 6. Cut out remaining pieces 7. Fit new parts in, then check the gap dimensions with the accessories fitted 8. Protect spot-welded flanges against corrosion Microsoft Monday, September 21, 2009 12:13:13 PM

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9. Observe safety and quality instructions for welding. Manufacturer does not provide specific Safety Instructions.

10. Weld in new parts 11. Grind visible weld seams flat; if necessary apply body solder or filler

50 IN TOOLS AND METALWORKING TOOLS FOR BODY REPAIRS - AS OF MY 2005 (ALL MODELS) TOOLS Designation Celette type straightening system

Type commercially available tool

Car Bench

commercially available tool

Number

Explanation we1121

we1122

STRAIGHTENING SYSTEMS Straightening systems

NOTE:

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Detailed and additional information about tools and equipment can be found in the "Workshop Equipment" manual.

Shown on Celette type

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Fig. 8: Straightening systems Courtesy of PORSCHE OF NORTH AMERICA, INC. Celette type straightening system we1121 Car Bench we1122 METALWORKING TOOLS Electrical equipment

NOTE:

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Detailed and additional information about tools and equipment can be found in the "Workshop Equipment" manual.

Fig. 9: Electrical equipment Courtesy of PORSCHE OF NORTH AMERICA, INC. 1 - Drill 2 - Angle grinder, large 3 - Angle grinder, small 4 - Sander 5 - Hot-air gun Mechanical equipment

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NOTE:

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Detailed and additional information about tools and equipment can be found in the "Workshop Equipment" manual.

Fig. 10: Mechanical equipment Courtesy of PORSCHE OF NORTH AMERICA, INC. 6 - Hole punch 7 - Edge setter Compressed-air equipment

NOTE:

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Detailed and additional information about tools and equipment can be

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found in the "Workshop Equipment" manual.

Fig. 11: Compressed-air equipment Courtesy of PORSCHE OF NORTH AMERICA, INC. 8 - Air chisel 9 - Body saw 10 - Spot-weld remover Welding equipment

NOTE:

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Detailed and additional information about tools and equipment can be found in the "Workshop Equipment" manual.

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Fig. 12: Welding equipment Courtesy of PORSCHE OF NORTH AMERICA, INC. 11 - Spotweld device and Multispot metalworking tool 12 - MIG welder

50 IN DIAGRAM - KEYS TO SYMBOLS FOR WELDING WORK - AS OF MY 2005 (ALL MODELS) DIAGRAM - KEYS TO SYMBOLS FOR WELDING WORK Resistance spot welding

A - Spot seam, single row B - Spot seam, double row

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Fig. 13: Resistance spot welding Courtesy of PORSCHE OF NORTH AMERICA, INC. C - Spot seam, double row offset Inert-gas arc welding (MAG procedure)

A - Plug weld B - Stitch weld C - Full weld

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Fig. 14: Inert-gas arc welding (MAG procedure) Courtesy of PORSCHE OF NORTH AMERICA, INC. D - Intermittent full weld Gas welding

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Fig. 15: Gas welding Courtesy of PORSCHE OF NORTH AMERICA, INC. A - Brazing

50 IN CORROSION PROTECTION MEASURES DURING REPAIRS - AS OF MY 2005 (ALL MODELS) MEASURES FOR MAINTAINING LONG-TERM BODY PROTECTION Measures for maintaining long-term body protection

NOTE:

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After repair work, the standard corrosion-inhibiting coating should only be restored with the corrosion-inhibiting agents approved by the manufacturer. The following points must be observed for body repairs.

Always apply welding primer to both sides of the welding flange when resistance spot welding.

Prime repair areas from outside. Prime on both sides in the accessible areas.

Seal all sheetmetal overlaps, sheetmetal edges, butt joints, weld seams etc. with body sealant.

Only apply body sealant to primed sheetmetal parts.

Apply top coat paint to the inside of the outer sheetmetal shell before welding. See "Paint build-up": --> "Paint Manual" Build up paint on bright sheetmetal panels according to the painting methods described in the --> "Paint

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  

manual".

Repair or create standard undersealing by applying long-life undersealing material.

Preserve cavities in the repair area with cavity preservative after applying a top coat paint.

Check that the standard water drains (plugs) function correctly or clean them after the cavity preservation material has dried.

PREREQUISITE FOR ENSURING VALIDITY OF THE LONG-LIFE GUARANTEE Prerequisite for ensuring validity of the long-life guarantee

Porsche long-life guarantee conditions 

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All body repair work must be carried out correctly and according to the specific Porsche instructions for sheetmetal, paint and corrosion protection/preservation work.

To prevent jeopardising the long-life guarantee, a Paint Condition Report is made out 2 years after delivery of the vehicle. This condition report must be drafted annually be every Official Porsche center.

50 IN VEHICLE IDENTIFICATION NUMBER - AS OF MY 2005 (ALL MODELS) TOOLS Designation Handschlagstempel

Type special tool

8 mm letter/digit embossing special tool tool with DIN 1451 closely spaced lettering, letter set

Number

Explanation 96930

NR.128-1

RE-IMPRINTING NEW VEHICLE IDENTIFICATION NUMBER Vehicle identification number

After replacing the body or the sheetmetal parts in the area of the vehicle identification number (firewall), the original vehicle identification number must be reimprinted onto the new body or the new sheet metal part.

The documentation of the imprinted vehicle identification number in the vehicle supplementary document or legally permissible treatment can be obtained from the importer of the respective country.

An incorrectly imprinted (stamped) vehicle identification number should be permanently crossed through with a X so that it remains legible. The vehicle identification number to be newly imprinted should be imprinted above the crossed through identification number.

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Spacer for replacing the vehicle identification number

The spacer for applying the vehicle identification number is in the front, right firewall. Two sections are intended for use.

- Section 1 -A- is the standard spacer. See Fig. 16.

Fig. 16: Vehicle identification number Courtesy of PORSCHE OF NORTH AMERICA, INC. - Section 2 -B- is the spare spacer for a corrected vehicle identification number. See Fig. 16.

Re-imprinting new vehicle identification number

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NOTE:

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Only imprint vehicle identification number in a cathodic-dip coated sheetmetal part.

The area should be countered when imprinting the vehicle identification number.

1. Stamp the vehicle identificaiton number to be replaced with 8 mm letter/digit embossing tool with DIN 1451 closely spaced lettering, letter set NR.128-1 and the Porsche star Handschlagstempel 96930 in den Platzhalter einschlagen.

2. Mask imprinted vehicle identification number.

3. Apply exterior paintwork.

4. Remove the vehicle identification number mark.

5. Paint repair area with clear lacquer.

Cathodic-dip coating is the primer applied to the sheetmetal parts at the factory

50 IN CHANGE IDENTIFICATION DATA PLATE - AS OF MY 2005 (ALL MODELS) CHANGE IDENTIFICATION DATA PLATE Installation location of identification data plate on the vehicle

A new type data plate must be affixed after replacing the side section or door sheetmetal parts.

The identification data plate must be ordered from the importer of the respective country.

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Fig. 17: Installation location of identification data plate on the vehicle Courtesy of PORSCHE OF NORTH AMERICA, INC. When ordering the identification data plate, the item number and vehicle identification number must be specified.

A - Right side section RoW B - Left doors USA/Canada Identification data plate RoW

1 - Item number

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Fig. 18: Identification data plate RoW Courtesy of PORSCHE OF NORTH AMERICA, INC. 2 - Vehicle identification number Identification data plate USA

1 - Item number

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Fig. 19: Identification data plate USA Courtesy of PORSCHE OF NORTH AMERICA, INC. 2 - Vehicle identification number Identification data plate Canada

1 - Item number

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Fig. 20: Identification data plate Canada Courtesy of PORSCHE OF NORTH AMERICA, INC. 2 - Vehicle identification number

50 IN DIAGRAM: PLUG PLAN - AS OF MY 2005 (CAYMAN S, CAYMAN S RHD) DIAGRAM: PLUG PLAN Top of front of vehicle

Illustrated on the body of an all-wheel drive vehicle

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Fig. 21: Top of front of vehicle Courtesy of PORSCHE OF NORTH AMERICA, INC. A - Rubber grommet hole Ø 20 mm B - Rubber grommet hole Ø 30 mm C - Plug hole Ø 35 mm Bottom of front of vehicle

Fig. 22: Bottom of front of vehicle Courtesy of PORSCHE OF NORTH AMERICA, INC. Microsoft Monday, September 21, 2009 12:13:13 PM

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A - Rubber grommet hole Ø 20 mm B - Rubber grommet hole Ø 30 mm C - Plug hole Ø 20 mm Side of front of vehicle

Fig. 23: Side of front of vehicle Courtesy of PORSCHE OF NORTH AMERICA, INC. A - Rubber grommet hole Ø 20 mm A1 - Rubber grommet hole (only when no sliding roof) Ø 20 mm B - Plug hole Ø 10 mm C - Plug hole Ø 15 mm D - Rubber grommet hole Ø 30 mm Bottom of lower side member and floor

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