Saturday, September 14, 2013

How to Install Porsche 996 Turbo Exhaust

How to Install Porsche 996 Turbo Exhaust

In 1931, Ferdinand Porsche founded the Porsche Engineering Office in Stuttgart, Germany. Prior years as an automotive engineer gave Ferdinand a large knowledge base for creating quality vehicles. Volkswagen was a great inspiration to the first Porsches as Ferdinand designed the original Volkswagen Beetle. By the 60s, the first Porsche 911 went into production. Through the decades Porsche cars won acclaim on racetracks around the world. Porsche enthusiasts enjoy the craftsmanship, brand history and performance of the many models now available. The Porsche 996 Turbo is one example of the many turbocharged sports cars the company produces. Those interested in further performance gains may install an aftermarket exhaust.

Instructions

Removing Stock Exhaust

    1

    Lift the Porsche 996 Turbo off the ground using a hydraulic lift or a floor jack and jack stands. Place the vehicle in gear with the handbrake on as well. Verify the lifted vehicle is stable before you slide underneath.

    2

    Remove the rear taillights. Start by opening the rear hood. Locate the bolts holding each taillight in place from within the rear compartment. Use your socket set to unbolt each taillight. Before removing, disconnect the power connector relay attached to each light by pinching and pulling the plastic relay apart where the connectors mate.

    3

    Unbolt the four screws securing the rear bumpers retaining strip, located on the top of the bumper. Now remove the metal retaining strip. Then remove the two top corner screws underneath the quarter panel, located near the end of the bumper. Finally, remove the six screws running along the underside of the bumper. The bumper is now completely unscrewed and almost ready for removal.

    4

    Unplug the license plate connector by pinching the plastic relay where the two sections mate, and pull apart firmly. This connector is located behind the license plate portion of the rear bumper. Once disconnected, remove the rear bumper, which exposes the bumper beam.

    5

    Remove the bumper beam after unbolting its two 16 mm bolts holding it in place along with the two heat shield screws holding the adjacent heat shields in place.

    6

    Open the engine bay and remove the air box by removing the securing bolts along the perimeter of the box. Refer to the installation instructions manual provided by the new exhaust for more detail. Also, unplug the four oxygen sensors located underneath the taillights by pinching the mating point of the relay connector.

    7

    Unbolt the 13 mm nuts holding the turbos to the headers, located in the top side of the engine bay. Then unbolt the nine bolts connecting the headers to the engines head ports before removing the exhaust headers.

    8

    Remove the catalytic converter from the turbo exhaust outlets by removing the four nuts that hold it in place. Then unscrew the 6 mm Allen bolts securing the muffler clamps in place.

    9

    Slide the loosened muffler clamps off to one side of the exhaust piping and remove the muffler assembly.

Installing New Exhaust

    10

    Install the new headers in the reverse order used when uninstalling the stock headers. Hand tighten each bolt before sequentially tightening each as specified in the new exhaust installation instructions.

    11

    Reconnect the headers to the turbochargers.

    12

    Install the oxygen sensors on the new exhausts catalytic converters in the same way they were installed on the stock catalytic converters.

    13

    Use the factory vent bolts and hardware when installing the new muffler assembly when required. Then reclamp the muffler clamps in place. Shape the muffler clamps to the new muffler assembly with a hammer.

    14

    Install the new muffler tips as specified by the exhaust instructions.

    15

    Reinstall the air box, factory oxygen sensors, bumper beam, rear bumper and rear taillights in reverse order used during removal.

    16

    Start the engine and listen for exhaust leaks.


No comments:

Post a Comment