2005–2008 Porsche Cayman S & Boxster S Service and Repair Manual

This workshop service and repair manual covers the 2005–2008 Porsche Cayman S and Boxster S, with shared Boxster procedures and right-hand-drive variants identified throughout. It also includes the Cayman/Cayman S Owner's Manual, publication WKD 987 621 07.

• Engine and cooling: Engine removal and disassembly, crankshaft and piston work, cylinder-head service, cooling-system testing, and lubrication specifications.

• Transmissions and clutch: Manual gearbox and Tiptronic service, clutch wear inspection, shift-cable adjustment, torque-converter replacement, and differential work.

• Brakes and chassis: PSM/ABS diagnosis, secondary-circuit bleeding, steering-angle calibration, suspension alignment, wheel bearings, steering gear, and hydraulic-pump replacement.

• Fuel and electrical systems: Fuel-pressure and pump-delivery tests, DME programming, ignition service, wiring diagrams, connector identification, and harness replacement.

• Air conditioning: Refrigerant recovery, evacuation and filling, compressor service, sun-sensor replacement, and temperature-mixing and central-distribution flap servo motors.

• Body and roof: Structural body repair, panel-gap references, convertible-top frame and mechanism adjustment, hardtop installation, and interior-trim removal.

• Restraints and convenience equipment: Airbag diagnosis, AWS calibration, central locking, power windows, seat memory, radio, and navigation-system service.

The workshop procedures suit technicians familiar with Porsche systems and equipped for PIWIS diagnostics, drivetrain handling, and the specialized work described.

Engine and Transmission Variants

Engine data identifies the Boxster M96/25, Boxster S M96/26, and Cayman S M97/21. Cylinder-head coverage extends to camshaft timing, valve-guide inspection, disassembly, and machining criteria, with torque tables and component-specific adjustment data.

The intermediate-shaft bearing-cover instructions separate Boxster M96/25 and Boxster S M96/26 engines by engine-number break. These distinctions help match the cover design and service procedure before parts are selected. The accompanying cautions explain how disturbing the timing chain during this work can cause engine damage.

Gearbox coverage: Specifications distinguish the Boxster G87/01 five-speed, Boxster/Boxster S G87/20 six-speed, and Cayman S G87/21 six-speed units. The detailed gearbox housing, gear-shaft, and differential disassembly sections identify Boxster/Boxster RHD applicability; S-model procedures include transmission removal, shift-cable work, and input-shaft seal replacement.

PIWIS Diagnosis and Calibration

The PSM/ABS material covers fault-memory checks, wheel-speed actual values, rotation-rate sensor service, and hydraulic assignment tests using PIWIS Tester P 9718. The assignment tests help identify crossed electrical or brake-line connections after repair.

Passenger-seat recognition: AWS calibration and system testing use test weight P 9742. The calibration section applies to USA, Canada, and Mexico equipment from model year 2006.

DME replacement instructions cover vehicle-data transfer, programming, and throttle adaptation. Fuel-system testing is accompanied by injector work and exhaust-system oxygen-sensor replacement before and after the catalytic converters.

HVAC, Roof, and Body Repairs

HVAC procedures distinguish compressor access for the coupe and roadster, with separate work on the air-conditioning regulator, desiccator, expansion valve, and blower regulator.

Boxster roof coverage includes tension-cable replacement, convertible-top frame alignment, drive-motor and microswitch service, and hardtop adjustment. Body sections add welding and bonding references, panel replacement, corrosion protection, and model-specific trim access.

The seat sections include air-cushion hose-connection views alongside memory-seat component work.

Wiring Diagrams and Component Views

The Cayman wiring section separates the 2.7L and 3.4L Engine Performance circuits. Other examples include Automatic A/C, Anti-lock Brakes, and Computer Data Lines circuits, alongside mechanical references such as the front spring-strut exploded view and cylinder-head flatness illustrations.

MOST optical wiring: The manual documents optical-waveguide handling and replacement. It explains how fluid contamination at the optical connections can impair or disable the MOST system; damaged optical waveguides require replacement.

Safety: A/C refrigerant, braking hydraulics, and airbag work require the precautions and equipment specified in the manual. These procedures assume appropriate training for the system being serviced.

A Preview of Cylinder-Head Inspection Limits

These are two examples from the cylinder-head machining data. The manual specifies permissible sealing-face unevenness of 0.05 mm for a used cylinder head and 0.03 mm after machining, distinguishing the inspection limit from the finished-surface requirement.

Searchable Text, Section Bookmarks, and PDF Contents

Finding procedures and reading diagrams: Service text supports PDF search, and section bookmarks link to the major workshop groups, wiring diagrams, and owner's manual. Wiring labels within the diagrams are not searchable; small pin numbers and wire-color codes require magnification.

The download is one printable, English-language, 5,568-page PDF: 5,250 pages of workshop information and wiring diagrams, a 314-page owner's manual, three pages of TSB summaries, and one compilation cover. The owner's manual includes its own cover and blank page; all of these pages are already included in the total.