Exhaust system and emission control
| Exhaust system | 987 | 987 S | Cayman S |
|---|---|---|---|
| Exhaust system structure | Two-pipe, three-way catalytic converter exhaust system, two parallel rear mufflers with cross talk pipe and integrated catalytic converter Merging in front of the center tailpipe | ||
| Emission control system | |||
| Euro 2 | Oxygen sensor closed-loop control and 3-way catalytic converter system, each with a primary and main catalytic converter on left + right (RoW) | ||
| Euro 4 | Three-way catalytic converter system, each with a primary and main catalytic converter on left + right, oxygen sensor closed-loop control and post-catalytic converter trim control (four probes), secondary air system and EOBD | ||
| USA LEV / LEV II / CAL / Tier 2 / FEP | As Euro 4 except with OBD II + ORVR | ||
Tools
Designation Type Number Explanation socket wrench insert special tool P 300
Preliminary work
| WARNING | Incorrect raising of the vehicle Damage to person or property caused by the car falling down |
> Raise the vehicle at the prescribed jacking points.
| WARNING | Parts of the exhaust system become extremely hot! Danger of burns Permanent scarring of the skin |
> Do not begin work until the exhaust system has cooled down completely.
> If it is imperative that you work on the hot exhaust system, ensure that you wear fire-resistant and heat-resistant protective gear.
1. Remove rear underbody cover. Refer to 51 94 19 Removing and installing cover for rear underbody - as of MY 2005 (All Models) .
2. Remove rear wheel. Use the specified special tool socket wrench insert P 300 to avoid damaging the wheel rims Refer to 44 05 19 Removing and installing wheel - as of MY 2005 (All Models) .
3. Remove heat protection for brake hose. Unscrew two plastic nuts and one tapping screw and remove component.
4. Remove oxygen sensors Refer to 24 69 20 Removing and installing oxygen sensor in front of catalytic converter - as of MY 2005 (All Models) . Refer to 24 73 20 Removing and installing oxygen sensor behind catalytic converter - as of MY 2005 (All Models) .
Scheme 1
5. Unscrew three M8 lock nuts on the triangular flange of the exhaust manifold and remove metal seal.
Scheme 2
1. Remove the exhaust manifold. Unscrew six hexagon-head bolts (M8 x 26) -Arrows- on the cylinder head. Get another person to hold the component if necessary. (Scheme 2)
2. Remove exhaust manifold (with primary catalytic converter) -3- and flange gasket -2-. (Scheme 3)
Scheme 3
Installing exhaust manifold
Note. Always replace exhaust manifold screws during installation. Replace lock nuts. Replace gaskets.
1. Clean sealing surfaces on manifold flange and cylinder head using a brass wire brush for example.
2. Replace manifold seal -2-. Check that it is installed correctly - locating studs and beads must point to the cylinder head. see scheme 4
3. Fit exhaust manifold (with primary catalytic converter) -3- on the cylinder head and triangular flange with new metal seals. Get another person to help if necessary. see scheme 4
- 1 - Screw, M8 x 26
- 2 - Metal seal
- 3 - Exhaust manifold with primary catalytic converter
4. Position six new hexagon-head bolts (M8 x 26) -Arrows- by hand and tighten them from the inside outwards. --> Tightening torque: 23 (17 ftlb.) Nm see scheme 5
Subsequent work
1. Secure triangular flange for exhaust manifold using three new M8 lock nuts. Tighten nuts evenly. --> Tightening torque: 23 (17 ftlb.) Nm
2. Install oxygen sensors. Refer to 24 69 20 Removing and installing oxygen sensor in front of catalytic converter - as of MY 2005 (All Models) . Refer to 24 73 20 Removing and installing oxygen sensor behind catalytic converter - as of MY 2005 (All Models) .
3. Fit heat protection for brake hose using two plastic nuts and one tapping screw. Tighten nuts and screw carefully.
4. Fit rear wheel. Use the specified special tool socket wrench insert P 300 to avoid damaging the wheel rims. Refer to 44 05 19 Removing and installing wheel - as of MY 2005 (All Models) .
5. Install rear underbody cover. Refer to 51 94 19 Removing and installing cover for rear underbody - as of MY 2005 (All Models) .
Designation Type Number Explanation socket wrench insert special tool P 300
| WARNING | Incorrect raising of the vehicle Damage to person or property caused by the car falling down |
> Raise the vehicle at the prescribed jacking points.
1. Remove both rear wheels. Use the prescribed special tool socket wrench insert P 300 to avoid damaging the rims. Refer to 44 05 19 Removing and installing wheel - as of MY 2005 (All Models) .
2. Remove rear underbody cover. Refer to 51 94 19 Removing and installing cover for rear underbody - as of MY 2005 (All Models) .
3. Remove heat protection for brake hose. Unscrew two plastic nuts and one tapping screw and remove component.
Components of the Cayman exhaust system
Overview
Scheme 4
| Item | Designation | Explanation |
|---|---|---|
| 1 | Exhaust system support | Vehicle-specific version (Tiptronic, 5-speed/6-speed manual transmission) |
| 2 | Hexagon-head bolt, M8 x 40 | |
| 3 | Fastening screws for transmission bracket | Vehicle-specific version (Tiptronic, 5-speed/6-speed manual transmission) |
| 4 | Right rear silencer with integrated catalytic converter | |
| 5 | Left rear silencer with integrated catalytic converter | |
| 6 | Clamp | Replace following removal |
| 7 | Tailpipe | |
| 8 | Cayman S tailpipe cover | |
| 9 | Cayman tailpipe cover |
Removing rear silencer
| WARNING | Parts of the exhaust system become extremely hot! Danger of burns Permanent scarring of the skin |
> Do not begin work until the exhaust system has cooled down completely.
> If it is imperative that you work on the hot exhaust system, ensure that you wear fire-resistant and heat-resistant protective gear.
Note. The main catalytic converters are integrated in the rear silencer. The rear silencers can be replaced individually by disconnecting the system.
1. Unscrew three lock nuts (M8) -Arrows- on the right flange. see scheme 8
Scheme 5
2. Unscrew three lock nuts (M8) -Arrows- on the left flange. (Scheme 5)
3. Get another person to hold the rear silencer.
4. Remove two screws (M8) on the rear silencer holder -Arrows-. (Scheme 6)
Scheme 6
5. Remove the rear silencer with the help of another person.
Installing rear silencer
1. Replace flange gaskets on the triangular flange and on the cylinder head.
2. Position rear silencer with the help of an assistant.
3. Fit and tighten two screws (M8) on the rear silencer holder -Arrows-. --> Tightening torque: 23 (17 ftlb.) Nm. see scheme 11
4. Fit and tighten three new lock nuts (M8) -Arrows- on the left flange. --> Tightening torque: 23 (17 ftlb.) Nm. see scheme 12
5. Fit and tighten three new lock nuts (M8) -Arrows- on the right flange. --> Tightening torque: 23 (17 ftlb.) Nm. see scheme 13
1. Install rear underbody cover. Refer to 51 94 19 Removing and installing cover for rear underbody - as of MY 2005 (All Models) .
2. Fit both rear wheels. Use the prescribed special tool socket wrench insert P 300 to avoid damaging the rims. Refer to 44 05 19 Removing and installing wheel - as of MY 2005 (All Models) .
Designation Type Number Explanation socket wrench insert special tool P 300
| WARNING | Incorrect raising of the vehicle Damage to person or property caused by the car falling down |
> Raise the vehicle at the prescribed jacking points.
1. Remove both rear wheels. Use the prescribed special tool socket wrench insert P 300 to avoid damaging the rims. Refer to 44 05 19 Removing and installing wheel - as of MY 2005 (All Models) .
2. Remove rear underbody cover. Refer to 51 94 19 Removing and installing cover for rear underbody - as of MY 2005 (All Models) .
3. Remove heat protection for brake hose. Unscrew two plastic nuts and one tapping screw and remove component.
Components of the Boxster exhaust system
Overview
Scheme 7
| Item | Designation | Explanation |
|---|---|---|
| 1 | Exhaust system support | Vehicle-specific version (Tiptronic, 5-speed/6-speed manual transmission) |
| 2 | Hexagon-head bolt, M8 x 40 | |
| 3 | Fastening screws for transmission bracket | Vehicle-specific version (Tiptronic, 5-speed/6-speed manual transmission) |
| 4 | Right rear silencer with integrated catalytic converter | |
| 5 | Left rear silencer with integrated catalytic converter | |
| 6 | Clamp | Replace following removal |
| 7 | Tailpipe | |
| 8 | Boxster S tailpipe cover | |
| 9 | Boxster tailpipe cover |
| WARNING | Parts of the exhaust system become extremely hot! Danger of burns Permanent scarring of the skin |
> Do not begin work until the exhaust system has cooled down completely.
> If it is imperative that you work on the hot exhaust system, ensure that you wear fire-resistant and heat-resistant protective gear.
Note. The main catalytic converters are integrated in the rear silencer. The rear silencers can be replaced individually by disconnecting the system.
1. Unscrew three lock nuts (M8) -Arrows- on the right flange. see scheme 15
2. Unscrew three lock nuts (M8) -Arrows- on the left flange. see scheme 16
3. Get another person to hold the rear silencer.
4. Remove two screws (M8) on the rear silencer holder -Arrows-. see scheme 17
5. Remove the rear silencer with the help of another person.
1. Replace flange gaskets on the triangular flange and on the cylinder head.
2. Position rear silencer with the help of an assistant.
3. Fit and tighten two screws (M8) on the rear silencer holder -Arrows-. --> Tightening torque: 23 (17 ftlb.) Nm. see scheme 18
4. Fit and tighten three new lock nuts (M8) -Arrows- on the left flange. --> Tightening torque: 23 (17 ftlb.) Nm. see scheme 19
5. Fit and tighten three new lock nuts (M8) -Arrows- on the right flange. --> Tightening torque: 23 (17 ftlb.) Nm. see scheme 20
1. Install rear underbody cover. Refer to 51 94 19 Removing and installing cover for rear underbody - as of MY 2005 (All Models) .
2. Fit both rear wheels. Use the prescribed special tool socket wrench insert P 300 to avoid damaging the rims. Refer to 44 05 19 Removing and installing wheel - as of MY 2005 (All Models) .
Removing tailpipe
| WARNING | Incorrect raising of the vehicle Damage to person or property caused by the car falling down |
> Raise the vehicle at the prescribed jacking points.
Scheme 8
1. Loosen hexagon nut (M10) at the clamp on the tailpipe cover.
Scheme 9
2. Open up clamp.
3. Pull off tailpipe cover.
Note. The help of another person is required for removing and installing the rear silencer.
4. Remove one rear silencer. To do so, loosen clamps on the tailpipe and clamping sleeve on the connecting tube. Remove triangular flange for exhaust manifold and screws on silencer holder > 263319 Removing and installing rear silencer - section on "Removing" .
Scheme 10
The clamps on the tailpipe and tailpipe cover can be replaced if necessary. These can be obtained as a spare part from the Porsche parts service.
Scheme 11
1. Cut spotweld on the defective clamp.
2. Slide on new clamp and secure it between the rear silencers after adjusting the tailpipe or connecting tube (cross-coupling point). --> Tightening torque: 65 (48 ftlb.) Nm
| WARNING | Incorrect raising of the vehicle Damage to person or property caused by the car falling down |
> Raise the vehicle at the prescribed jacking points.
1. Loosen hexagon nut (M10) at the clamp on the tailpipe cover.
2. Open up clamp.
3. Pull off tailpipe cover.
Note. The help of another person is required for removing and installing the rear silencer.
4. Remove one rear silencer. To do so, loosen clamps on the tailpipe and clamping sleeve on the connecting tube. Remove triangular flange for exhaust manifold and screws on silencer holder > 263319 Removing and installing rear silencer - section on "Removing" .
Replacing the clamp
The clamps on the tailpipe and tailpipe cover can be replaced if necessary. These can be obtained as a spare part from the Porsche parts service.
1. Cut spotweld on the defective clamp.
2. Slide on new clamp and secure it between the rear silencers after adjusting the tailpipe or connecting tube (cross-coupling point). --> Tightening torque: 65 (48 ftlb.) Nm
Installing tailpipe
1. Clean tailpipe and flange on rear silencer with a wire brush for example. The connecting areas can be sprayed with high-temperature grease for easier assembly.
2. Position clamping sleeve on connecting tube.
3. Position tailpipe.
4. Install rear silencer > 263319 Removing and installing rear silencer - section on "Installing" .
5. Secure clamps loosely to tailpipe with hexagon nuts. Also secure clamping sleeve to connecting tube.
6. Fit and adjust tailpipe cover > 263519 Removing and installing decorative cover - section on "Installing" .
7. Tighten clamping sleeve on connecting tube. --> Tightening torque: 23 (17 ftlb.) Nm
8. Tighten hexagon nuts (M10) -Arrow- on tailpipe clamps. --> Tightening torque: 65 (48 ftlb.) Nm see scheme 29
Removing tailpipe cover
| WARNING | Incorrect raising of the vehicle Damage to person or property caused by the car falling down |
> Raise the vehicle at the prescribed jacking points.
1. Loosen hexagon nut (M10) at the clamp on the tailpipe cover.
2. Open up clamp.
3. Pull off tailpipe cover.
4. Clean tailpipe support with a wire brush. The connecting areas can be sprayed with high-temperature grease for easier assembly.
Installing tailpipe cover - Cayman
1. Push on tailpipe with clamp.
Note. When fitting the tailpipe cover for the first time, the dimension -a- must be reduced by 1.5 mm.
2. Adjust tailpipe position as shown below.
Scheme 12
a = Cayman, Cayman S - 20 mm
b = Cayman S - 22 mm
c = Cayman - 24 mm
3. Slide the tailpipe cover onto the tailpipe until the edge is flush with the rear end.
4. Tighten hexagon nut (M10) -1- on clamp. --> Tightening torque: 65 (48 ftlb.) Nm see scheme 33
| WARNING | Incorrect raising of the vehicle Damage to person or property caused by the car falling down |
> Raise the vehicle at the prescribed jacking points.
1. Loosen hexagon nut (M10) at the clamp on the tailpipe cover.
2. Open up clamp.
3. Pull off tailpipe cover.
4. Clean tailpipe support with a wire brush. The connecting areas can be sprayed with high-temperature grease for easier assembly.
Installing tailpipe cover - Boxster
1. Push tailpipe cover with clamp onto the tailpipe.
Note. When fitting the tailpipe cover for the first time, set the dimension -a- and -b- to 26.5 mm .
2. Adjust tailpipe position as shown below.
Scheme 13
a = Boxster S - 28 mm
b = Boxster - 28 mm
c = Boxster S - 34 mm
d = Boxster - 29 mm
3. Tighten hexagon nut (M10) -Arrow- on clamp. --> Tightening torque: 65 (48 ftlb.) Nm see scheme 37
Preliminary work for removing secondary air pump
1. Place protective covers on the vehicle to avoid damaging the body.
2. Remove intake-air distributor 4-6 Refer to 24 46 20 Removing and installing intake-air distributor - as of MY 2005 (All Models) .
Scheme 14
1. Loosen cable duct by unscrewing the Torx screw (M6 x 16) -arrow-. (Scheme 14)
Scheme 15
2. Carefully press cable duct down by hand and unscrew the three Torx screws (M6 x 50) -arrows-. (Scheme 15)
Scheme 16
3. Unclip cable plug -1- with retaining clip and disconnect plug connection. (Scheme 16)
Scheme 17
4. Carefully lever off air hose -1- using a wooden or plastic spatula. (Scheme 17)
5. Lift secondary air pump from the bracket.
Installing secondary air pump
1. Position secondary air pump in installation position.
2. Push on coolant hose -1-. see scheme 42
3. Connect cable plug and clip it in -1-. see scheme 43
4. Carefully press cable duct down by hand and screw in and tighten the three Torx screws (M6 x 50) -arrows-. --> Tightening torque: 7.5 ftlb.. see scheme 44
5. Fasten cable duct by screwing in and tightening the Torx screw (M6 x 16) -arrow-. --> Tightening torque: 7.5 ftlb. see scheme 45
Subsequent work for installing secondary air pump
1. Install intake-air distributor 4-6. Refer to 24 46 20 Removing and installing intake-air distributor - as of MY 2005 (All Models) .
Poses Online
See also:
• 51 94 19 Removing and installing cover for rear underbody - as of MY 2005 (All Models)
• 44 05 19 Removing and installing wheel - as of MY 2005 (All Models)
• 24 69 20 Removing and installing oxygen sensor in front of catalytic converter - as of MY 2005 (All Models)
• socket wrench insert P 300