2010 Porsche Boxster (987) F62.9L
Copyright ? 2013, ALLDATA
10.52SS
Page 1
Vehicle: All Technical Service Bulletins
Exhaust System Sport Exhaust System Retrofitting
2
Boxster (987)
12/09 ENU 2601
Sep 22, 2009
Sport Exhaust System (Ino.XLF)
Information:
Retrofitting
Model Year:
As of 2009
Restriction:
ONLY in conjunction with sports tailpipe (Ino. XLS).
Engine Types:
MA120 = 2.9liter and MA121 = 3.4liter
INFORMATION:
In the sports exhaust system, the signal for activating the flaps in the main mufflers comes from the respective current map in the DME
control unit. This depends on the driving status and the accelerator pedal position among other things.
The sports exhaust system can be activated using a new switch console with the additional "Twin tailpipe" button (close to the center
console).
The regulating time after pressing the button, determined by the response time of the pneumatics, is approx. 2 3 seconds. The sports
exhaust system is active if the diode in the "Twin tailpipe" button lights up.
Engine power and exhaust behaviour of the vehicle are not affected. The sports exhaust system is also available as a factory installed
option for new vehicles by requesting optional equipment "XLF".
Parts Info:
987.044.200.02 > Sports exhaust system, complete WITH tailpipe
987.044.200.03 > Sports exhaust system, complete WITHOUT tailpipe2010 Porsche Boxster (987) F62.9L
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Page 2
Order at the same time in accordance with vehicle equipment:
987.612.905.25 > Electric wire harness, for vehicles with MA121 = 3.4liter engine; incl. tiewraps (12 x)
987.612.905.02 > Electric wire harness, for vehicles with MA120 = 2.9liter engine; incl. tiewraps (12 x)
997.613.549.00.A05 (1) > Sports exhaust system button, for vehicles with standard chassis (Ino. 029) and Porsche Stability
Management PSM (Ino. 476)
997.613.551.00.A05 (1) > Sports exhaust system button, for vehicles with I029 and I476 and manual transmission (Ino. 480) and Sport
Chrono Package (Ino. 639) or Sport Chrono Plus Package (Ino. 640)
997.613.553.00.A05 (1) > Sports exhaust system button, for vehicles with I475 and I476
997.613.555.00.A05 (1) > Sports exhaust system button, for vehicles with I475 and I476 and I480 and I639 or I640
997.613.561.00.A05 (1) > Sports exhaust system button, for vehicles with I029 and PDK transmission (Ino. 250) and I476 and I639 or
I640
997.613.563.00.A05 (1) > Sports exhaust system button, for vehicles with I250 and I475 and I476 and I639 or I640
(1) See also Porsche Electronic Parts Catalog (PET)2010 Porsche Boxster (987) F62.9L
Copyright ? 2013, ALLDATA
10.52SS
Parts List:
Spare Parts:
Materials:
Tools:
Socketwrench insert a/f
4/5/6/7/10/13/17
Slotted and Phillips screwdrivers
Internal polygon wrench, a/f 8
Shop light
Torx wrench insert T20/T30
Plastic wedge
PIWIS Tester 9718
Hotair gun
Pressout and unlocking tools for flat and round plug connections of every size Nr.155
Repair kit for wire harnesses Nr.1551
NOTES:
Page 32010 Porsche Boxster (987) F62.9L
Copyright ? 2013, ALLDATA
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Page 4
Identifying features when installed
The underside of the main mufflers is marked as follows:
Left main muffler (for cylinder bank 46): Porsche logo; code 987/37 and Part No.: 987.113.511.30.
Right main muffler (for cylinder bank 13): Porsche logo; code 987/36 and Part No.: 987.113.512.30 > Figure 3.
Both identification codes can be read using a mirror, for example.
Work Procedure:
1. Preparatory work
1.1 Remove trim panel for cabrio top compartment/engine compartment lid > Workshop Manual '700819 Removing and installing
trim panel for hood compartment/engine compartment lid section on "Removing" .
1.2 Drive the vehicle onto a lifting platform and raise it. > Workshop Manual '400000 Lifting the vehicle.
1.3 Remove both wheels on the rear axle. > Workshop Manual '44051900 Removing and installing wheel section on
"Removing" .
CAUTION:
Hot components
Risk of burns
Let hot components cool down.
Wear personal protective gear.
1.4 Remove both main mufflers > Workshop Manual '263319 Removing and installing rear silencer section on "Removing".
1.5 ONLY for vehicles with sports tailpipe (Ino. XLS):
1. 5. 1 Remove tailpipe > Workshop Manual '263419 Removing and installing tailpipe section on "Removing"
1. 5. 2 Cover the nanocoated, polished trim on the sports tailpipe with a cloth or similar cover ( > Figure 4 ).
1. 5. 3 Carefully remove spot weld on the clamp (2 ea.> Figure 4 1 & 2) on the sports tailpipe using a chisel or parting
grinder.
1. 5. 4 Remove clamps from sports tailpipe.
1. 5. 5 Deburr surface on sports tailpipe close to the spot welds.
1. 5. 6 Position a new clamp (2 ea.) on the sports tailpipe at the left and right.
2. Install main mufflers for sports exhaust system. > Workshop Manual '263319 Removing and installing rear silencer section on2010 Porsche Boxster (987) F62.9L
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Page 5
"Installing"
2.1 Position two new seals on the studs on the flange of the two catalytic converters.
2.2 Loosely prefit the new right main muffler on the right catalytic converter using three new M8 hexagon nuts.
2.3 Fit the clamping sleeve (> Figure 5 1), new sports tailpipe (> Figure 5 2) with prefitted clips (> Figure 5 3) or old sports
tailpipe with new clips (> Figure 5 3) loosely on the right main silencer.
2.4 Loosely prefit the new left main muffler (> Figure 5 4) on the left catalytic converter using three new M8 hexagon nuts.
2.5 Slide clamping sleeve and sports tailpipe onto the left main muffler and align them roughly symmetrically on both main
mufflers > Figure 5 arrows.
Tighten M8 hexagon nuts on the flange between the two main mufflers and the catalytic converter.
Tightening torque 23 Nm(17 ftlb.)
2.6 Secure the two main mufflers on the main silencer holder with four new M8 x 16 hexagonhead bolts (> Figure 6 A) and four
new M8 hexagon nuts (> Figure 6 B).
Tightening torque 23 Nm(17 ftlb.)2010 Porsche Boxster (987) F62.9L
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2.7 Secure the two main mufflers on the main silencer holder using a corrugated clip, a new M8 hexagonhead bolt and a new M6
hexagon nut on each one > Figure 7.
Tightening torque 23 Nm(17 ftlb.)
2.8 Align the clamping sleeve symmetrically between the two main mufflers and tighten it.
Tightening torque 23 Nm(17 ftlb.)
2.9 Align the sports tailpipe symmetrically with respect to the rear apron and tighten it. > Workshop Manual '263419 Removing
and installing tailpipe.
Tightening torque 55 Nm(41 ftlb.)
3. Install changeover valve.
3.1 Install changeover valve holder.
3. 1. 1 Loosen Torx screw (> Figure 8 1) on the intake bridge.
3. 1. 2 Slide the changeover valve holder (> Figure 8 2) under the Torx screw and tighten the Torx screw.
Tightening torque 13 Nm (9.5 ftlb.)2010 Porsche Boxster (987) F62.9L
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Page 7
3.2 Fit bent protective hoses on the electric changeover valve ( > Figure 9 1) and slide electric changeover valve onto the
holder > Figure 9 arrow.
3.3 Remove 2pin connector ( > Figure 10 1) from the left holder for the distributor pipe ( > Figure 10 2). Pull off dummy
connector and connect plug connection ( > Figure 10 arrow).
CAUTION
Risk of damage to lines and/or hoses (vacuum)
due to incorrect routing.
Maintain a sufficient distance from components exposed to high temperatures while driving.
Avoid making tight bends.2010 Porsche Boxster (987) F62.9L
Copyright ? 2013, ALLDATA
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Page 8
4. Route and connect vacuum lines for exhaust flap activation.
4.1 Connection diagram for vacuum lines
INFORMATION:
ONLY for vehicles with PDK transmission (Ino. 250):
Vacuum must NOT be removed from the changeover valve, which is installed as standard, close to the "engine locking hook"(Figure
12 1).
BACKGROUND:
Impairs the sensitive switching operations of the PDK transmission.2010 Porsche Boxster (987) F62.9L
Copyright ? 2013, ALLDATA
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Page 9
4.2 Route vacuum line to the electric changeover valve
4. 2. 1 Depending on engine and transmission type, unclip vacuum line (Tekalan 4 x 1 x X; black > Figure 13 1) close to
the vacuum unit ahead of the intake distributor ( > Figure 13 2) in direction of travel out of the line clip ( > Figure
13 3) if necessary.
4. 2. 2 Disconnect vacuum line (Tekalan 4 x 1 x X; black > Figure 13 1) in the middle and fit Ypiece ( > Figure 15).
4. 2. 3 Cut a 500mm length off the supplied Tekalan hose (5 x 1 x 1600; transparent).
4. 2. 4
Route the Tekalan hose (5 x 1 x 500; transparent) as follows: Electric changeover valve > under intake distributor,
in direction of travel going forward > to free Ypiece connection2010 Porsche Boxster (987) F62.9L
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Page 10
4. 2. 5 Fit the Tekalan hose (5 x 1 x 500; transparent) at least 10 mm into the free Ypiece connection (> Figure 15 arrow)
and
on the vacuum intake connection (> Figure 16 arrow) for the electric changeover valve.
4.3 Route vacuum line from the electric changeover valve to the transmission For more information, see also Connection
diagram for vacuum lines ( > Figure 11 ).
4. 3. 1 Fit the Tekalan hose (5 x 1 x 1100; transparent) at least 10 mm into the bent hose on the output vacuum connection (
> Figure 9 ) for the electric changeover valve.
4. 3. 2 ONLY for vehicles with manual transmission:
Clip hose clip ( > Figure 2 12 or > Figure 17 1 onto a cooling fin ( > Figure 17 2) on the transmission.
Fit Tekalan hose (5 x 1 x 1100, transparent) into the hose clip ( > Figure 17 1).2010 Porsche Boxster (987) F62.9L
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Page 11
4. 3. 3 Secure the Tekalan hose (5 x 1 x 1100; transparent) > Figure 18 1 in the middle with at least one hose clip (left: dia.
45 mm/right: dia. 1924 mm; > Figure 18 2) on the transmission shift cable ( > Figure 18 3).
INFORMATION: The description provided here is only for the right side. The installation procedure is the same for the left side.
4.4 Route and connect steelencased main muffler line.
4. 4. 1 Clip in hose clip (1 ea. > Figure 2, item 12) on the main muffler holder, with the opening for the steelencased line
facing backwards (> Figure 19 1).
Clip in hose clip (2 ea. > Figure 2, item 11) on the main muffler strut, with the opening for the steelencased line
facing backwards (> Figure 19 2).
4. 4. 2
Clip steelencased line into the clip on the main muffler holder (1 ea.) and main muffler strut (2 ea., > Figure 19).2010 Porsche Boxster (987) F62.9L
4. 4. 3
4. 4. 4
4. 4. 5
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Repeat the steps on the left side (> Figure 20 A).
Fit the Tekalan hose (5 x 1 x 1100; transparent > Figure 20 1) at least 10 mm into the Ypiece (> Figure 20 2).
Fit the Tekalan hoses (4 x 1 x X; black > Figure 20 3) for the steelencased lines at least 10 mm into the free
Ypiece connections (> Figure 20 2).
5. Installing sports exhaust system button and routing and connecting electric wire harness
5.1 Preparatory work
5. 1. 1 Move hood to service position > Workshop Manual '6101IN Hood service position'.
5. 1. 2 Disconnect the battery > Workshop Manual '2X00IN02 Work instructions after disconnecting the battery'.
5. 1. 3 Remove carpet lining at the sides of the luggage compartment and rear wall > Workshop Manual '700619 Removing
and installing rear luggage compartment trim (carpet lining)' section on "Removing".
5. 1. 4 Remove left side trim panel > Workshop Manual '707519 Removing and installing side trim panel' section on
"Removing".
5. 1. 5 Remove inner door sill trim at the left > Workshop Manual '680519 Removing and installing inner door sill trim'
section on "Removing".
5. 1. 6 Remove switch console in center console area > Workshop Manual '962719 Removing and installing switch console'
section on "Removing".
5.2 ONLY for Boxster
(engine type: MA120 = 2.9litre):
Connect wire harness (987.612.905.02) to the DME control unit
5. 2. 1 Expose DME control unit >Workshop Manual '247019 Removing and installing DME control unit' section on
"Removing" .
5. 2. 2
Pull off connector D on DME control unit ( > Figure 21 D).2010 Porsche Boxster (987) F62.9L
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Page 13
5. 2. 3 Connect electric wire harness for the sports exhaust system button to the DME control unit
5. 2. 4 Release secondary lock on connector housing D > Figure 23 A, arrows and pull both connectors out of the housing
( > Figure 23 B, arrow).
Insert line 2386; GY/GN; 0.5(2) into connector D; chamber 39 ( > Figure 22).
Insert line 2385; BU; 0.5(2) into connector D; chamber 6 ( > Figure 22).
Fit connector in connector housing D and connect all plug connections to the DME control unit.
5. 2. 5
5. 2. 6
5. 2. 72010 Porsche Boxster (987) F62.9L
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5.3 ONLY for Boxster S
(engine type: MA121 = 3.4liter):
Connect wire harness (987.612.905.25) to connection point 3_3.
5. 3. 1
5. 3. 2 Expose connection point 3_3 in rear luggage compartment at the left ( > Figure 24 A).
Remove 30pin black connector at the side of the vehicle ( > Figure 24 arrow) from the connection point.
5. 3. 3
5. 3. 4 Insert line 9711; GY/GN; 0.5(2) into chamber 7 ( > Figure 24 7 and > Figure 25).
Insert line 9710; BU; 0.5(2) into chamber 13 ( > Figure 24 13 and > Figure 25).2010 Porsche Boxster (987) F62.9L
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Page 15
5.4 Guide Tekalan hose or wire spindle on the left side wall, out of the rear luggage compartment (> Figure 26 A), under the
water drip pan in the wiring duct to the left Bpillar (> Figure 26 B).
Connect electric wire harness to the end facing the rear luggage compartment.
5.5 Route electric wire harness for sports exhaust system button.
5. 5. 1 DME control unit or connection point 3_3 > along wire harness at side of vehicle > left side panel > underneath
water drip pan > cable duct > Bpillar (between insulating mat and body)
5. 5. 2 Bpillar > left vehicle side member > along wiring duct to Apillar (> Figure 27).
5. 5. 3 Apillar > underneath the dashboard > installation position of button trim (> Figure 28).2010 Porsche Boxster (987) F62.9L
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Page 16
5.6 Connect electric wire harness to sports exhaust system button
5. 6. 1 Open secondary lock on 16pin connector.
5. 6. 2
ONLY for Boxster
(engine type: MA120 = 2.9liter):
Connect line 5625; RD/GY; 0.5(2) from the wire harness (987.612.905.02) to the 16pin plug socket for the sports
exhaust system button
Line 5625; RD/GY; 0.5(2) > Double crimp on line 6207; RD/GY; 0.5(2) to chamber A3 (terminal 15, > Figure 29 and
>Figure 22)
5. 6. 3
Line 2386 ( > Figure 22) and line 9711 ( > Figure 25); GY/GN; 0.5(2) > chamber A11 (button LED).
Line 2385 ( > Figure 22) and line 9710 ( > Figure 25); BU; 0.5(2) > chamber A10 (button signal).
5. 6. 4
Close secondary lock on 16pin connector.
5.7 Use tiewraps or wrapping tape to secure electric wire harness to existing lines or components without tension and so that no
chafing occurs.
5.8 Concluding work for installing button for sports exhaust system
5. 8. 1 Install switch console in center console area > Workshop Manual '962719 Removing and installing switch console'
section on "Installing" .
5. 8. 2 Install inner door sill trim at the left > Workshop Manual '680519 Removing and installing inner door sill trim'
section on "Installing".
5. 8. 3 Install left side trim panel > Workshop Manual '707519 Removing and installing side trim panel' section on
"Installing".
5. 8. 4 Install DME control unit > Workshop Manual '247019 Removing and installing DME control unit' section on
"Installing".
5. 8. 5 Install carpet lining at the sides of the luggage compartment and rear wall > Workshop Manual '700619 Removing
and installing rear luggage compartment trim (carpet lining)' section on "Installing".
5. 8. 6 Install engine compartment lid > Workshop Manual '700819 Removing and installing trim panel for hood
compartment/engine compartment lid' section on "Installing".
5. 8. 7 Connect the battery > Workshop Manual '2X00IN02 Work instructions after disconnecting the battery and then
connect the battery charger'. > Workshop Manual '2X00IN03 Battery trickle charging'.
5. 8. 8 Move hood out of service position and close it > Workshop Manual '6101IN Hood service position'.
6. Concluding work and function test
6.1 Read out the fault memory of all control units, correct any existing faults, and erase the fault memory.
6.2 Configure Required/Actual installed components list for gateway.
6. 2. 1 Select "GATEWAY coding" in the menu and continue with [>>].
6. 2. 2 Select "Required installed components lists" and continue with [>>].
6. 2. 3 Select "Sound exhaust system" and continue with [>>].
6. 2. 4 The menu item "Sound exhaust system not installed" is highlighted.
Select "Sound exhaust system installed" and press [F8] to write coding.
6. 2. 5 Press [<<] to return to the higherlevel menu items and check that the coding was completed successfully.
6.3 Disconnect PIWIS Tester P 9718 and the battery charger if necessary.
6.4 Carry out a function test on the "sports exhaust system."2010 Porsche Boxster (987) F62.9L
6. 4. 1
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Start the vehicle.
Depending on the vehicle status, the "sports exhaust system" is activated for 2 to 3 seconds because there is no
vacuum at the main silencers. The exhaust flaps are open and the exhaust motor noise can be heard clearly.
As the vacuum at the main mufflers increases, the exhaust flaps close and the sound of the exhaust motor eases off.
The "sports exhaust system" is not active.
The diode in the "Sport" or "Twin tailpipe" button does not light up when you start the vehicle.
6. 4. 2
Working Times:
Disclaimer
Copyright ? 2013, ALLDATA
Press the "Sport" or "Twin" tailpipe button.
After a regulating phase of around 2 to 3 seconds, the exhaust flaps open and the sound of the exhaust motor can be
heard clearly. The "sports exhaust system" is active.
The diode in both buttons ("Sport" and "Twin tailpipe") lights up.
The correct function of the sports exhaust system can also be checked at any time by getting a second person to
perform a visual inspection of the regulating movement (linkage at the exhaust flaps).
Copyright ? 2013, ALLDATA
10.52SS
Page 1
Vehicle: All Technical Service Bulletins
Exhaust System Sport Exhaust System Retrofitting
2
Boxster (987)
12/09 ENU 2601
Sep 22, 2009
Sport Exhaust System (Ino.XLF)
Information:
Retrofitting
Model Year:
As of 2009
Restriction:
ONLY in conjunction with sports tailpipe (Ino. XLS).
Engine Types:
MA120 = 2.9liter and MA121 = 3.4liter
INFORMATION:
In the sports exhaust system, the signal for activating the flaps in the main mufflers comes from the respective current map in the DME
control unit. This depends on the driving status and the accelerator pedal position among other things.
The sports exhaust system can be activated using a new switch console with the additional "Twin tailpipe" button (close to the center
console).
The regulating time after pressing the button, determined by the response time of the pneumatics, is approx. 2 3 seconds. The sports
exhaust system is active if the diode in the "Twin tailpipe" button lights up.
Engine power and exhaust behaviour of the vehicle are not affected. The sports exhaust system is also available as a factory installed
option for new vehicles by requesting optional equipment "XLF".
Parts Info:
987.044.200.02 > Sports exhaust system, complete WITH tailpipe
987.044.200.03 > Sports exhaust system, complete WITHOUT tailpipe2010 Porsche Boxster (987) F62.9L
Copyright ? 2013, ALLDATA
10.52SS
Page 2
Order at the same time in accordance with vehicle equipment:
987.612.905.25 > Electric wire harness, for vehicles with MA121 = 3.4liter engine; incl. tiewraps (12 x)
987.612.905.02 > Electric wire harness, for vehicles with MA120 = 2.9liter engine; incl. tiewraps (12 x)
997.613.549.00.A05 (1) > Sports exhaust system button, for vehicles with standard chassis (Ino. 029) and Porsche Stability
Management PSM (Ino. 476)
997.613.551.00.A05 (1) > Sports exhaust system button, for vehicles with I029 and I476 and manual transmission (Ino. 480) and Sport
Chrono Package (Ino. 639) or Sport Chrono Plus Package (Ino. 640)
997.613.553.00.A05 (1) > Sports exhaust system button, for vehicles with I475 and I476
997.613.555.00.A05 (1) > Sports exhaust system button, for vehicles with I475 and I476 and I480 and I639 or I640
997.613.561.00.A05 (1) > Sports exhaust system button, for vehicles with I029 and PDK transmission (Ino. 250) and I476 and I639 or
I640
997.613.563.00.A05 (1) > Sports exhaust system button, for vehicles with I250 and I475 and I476 and I639 or I640
(1) See also Porsche Electronic Parts Catalog (PET)2010 Porsche Boxster (987) F62.9L
Copyright ? 2013, ALLDATA
10.52SS
Parts List:
Spare Parts:
Materials:
Tools:
Socketwrench insert a/f
4/5/6/7/10/13/17
Slotted and Phillips screwdrivers
Internal polygon wrench, a/f 8
Shop light
Torx wrench insert T20/T30
Plastic wedge
PIWIS Tester 9718
Hotair gun
Pressout and unlocking tools for flat and round plug connections of every size Nr.155
Repair kit for wire harnesses Nr.1551
NOTES:
Page 32010 Porsche Boxster (987) F62.9L
Copyright ? 2013, ALLDATA
10.52SS
Page 4
Identifying features when installed
The underside of the main mufflers is marked as follows:
Left main muffler (for cylinder bank 46): Porsche logo; code 987/37 and Part No.: 987.113.511.30.
Right main muffler (for cylinder bank 13): Porsche logo; code 987/36 and Part No.: 987.113.512.30 > Figure 3.
Both identification codes can be read using a mirror, for example.
Work Procedure:
1. Preparatory work
1.1 Remove trim panel for cabrio top compartment/engine compartment lid > Workshop Manual '700819 Removing and installing
trim panel for hood compartment/engine compartment lid section on "Removing" .
1.2 Drive the vehicle onto a lifting platform and raise it. > Workshop Manual '400000 Lifting the vehicle.
1.3 Remove both wheels on the rear axle. > Workshop Manual '44051900 Removing and installing wheel section on
"Removing" .
CAUTION:
Hot components
Risk of burns
Let hot components cool down.
Wear personal protective gear.
1.4 Remove both main mufflers > Workshop Manual '263319 Removing and installing rear silencer section on "Removing".
1.5 ONLY for vehicles with sports tailpipe (Ino. XLS):
1. 5. 1 Remove tailpipe > Workshop Manual '263419 Removing and installing tailpipe section on "Removing"
1. 5. 2 Cover the nanocoated, polished trim on the sports tailpipe with a cloth or similar cover ( > Figure 4 ).
1. 5. 3 Carefully remove spot weld on the clamp (2 ea.> Figure 4 1 & 2) on the sports tailpipe using a chisel or parting
grinder.
1. 5. 4 Remove clamps from sports tailpipe.
1. 5. 5 Deburr surface on sports tailpipe close to the spot welds.
1. 5. 6 Position a new clamp (2 ea.) on the sports tailpipe at the left and right.
2. Install main mufflers for sports exhaust system. > Workshop Manual '263319 Removing and installing rear silencer section on2010 Porsche Boxster (987) F62.9L
Copyright ? 2013, ALLDATA
10.52SS
Page 5
"Installing"
2.1 Position two new seals on the studs on the flange of the two catalytic converters.
2.2 Loosely prefit the new right main muffler on the right catalytic converter using three new M8 hexagon nuts.
2.3 Fit the clamping sleeve (> Figure 5 1), new sports tailpipe (> Figure 5 2) with prefitted clips (> Figure 5 3) or old sports
tailpipe with new clips (> Figure 5 3) loosely on the right main silencer.
2.4 Loosely prefit the new left main muffler (> Figure 5 4) on the left catalytic converter using three new M8 hexagon nuts.
2.5 Slide clamping sleeve and sports tailpipe onto the left main muffler and align them roughly symmetrically on both main
mufflers > Figure 5 arrows.
Tighten M8 hexagon nuts on the flange between the two main mufflers and the catalytic converter.
Tightening torque 23 Nm(17 ftlb.)
2.6 Secure the two main mufflers on the main silencer holder with four new M8 x 16 hexagonhead bolts (> Figure 6 A) and four
new M8 hexagon nuts (> Figure 6 B).
Tightening torque 23 Nm(17 ftlb.)2010 Porsche Boxster (987) F62.9L
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10.52SS
Page 6
2.7 Secure the two main mufflers on the main silencer holder using a corrugated clip, a new M8 hexagonhead bolt and a new M6
hexagon nut on each one > Figure 7.
Tightening torque 23 Nm(17 ftlb.)
2.8 Align the clamping sleeve symmetrically between the two main mufflers and tighten it.
Tightening torque 23 Nm(17 ftlb.)
2.9 Align the sports tailpipe symmetrically with respect to the rear apron and tighten it. > Workshop Manual '263419 Removing
and installing tailpipe.
Tightening torque 55 Nm(41 ftlb.)
3. Install changeover valve.
3.1 Install changeover valve holder.
3. 1. 1 Loosen Torx screw (> Figure 8 1) on the intake bridge.
3. 1. 2 Slide the changeover valve holder (> Figure 8 2) under the Torx screw and tighten the Torx screw.
Tightening torque 13 Nm (9.5 ftlb.)2010 Porsche Boxster (987) F62.9L
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10.52SS
Page 7
3.2 Fit bent protective hoses on the electric changeover valve ( > Figure 9 1) and slide electric changeover valve onto the
holder > Figure 9 arrow.
3.3 Remove 2pin connector ( > Figure 10 1) from the left holder for the distributor pipe ( > Figure 10 2). Pull off dummy
connector and connect plug connection ( > Figure 10 arrow).
CAUTION
Risk of damage to lines and/or hoses (vacuum)
due to incorrect routing.
Maintain a sufficient distance from components exposed to high temperatures while driving.
Avoid making tight bends.2010 Porsche Boxster (987) F62.9L
Copyright ? 2013, ALLDATA
10.52SS
Page 8
4. Route and connect vacuum lines for exhaust flap activation.
4.1 Connection diagram for vacuum lines
INFORMATION:
ONLY for vehicles with PDK transmission (Ino. 250):
Vacuum must NOT be removed from the changeover valve, which is installed as standard, close to the "engine locking hook"(Figure
12 1).
BACKGROUND:
Impairs the sensitive switching operations of the PDK transmission.2010 Porsche Boxster (987) F62.9L
Copyright ? 2013, ALLDATA
10.52SS
Page 9
4.2 Route vacuum line to the electric changeover valve
4. 2. 1 Depending on engine and transmission type, unclip vacuum line (Tekalan 4 x 1 x X; black > Figure 13 1) close to
the vacuum unit ahead of the intake distributor ( > Figure 13 2) in direction of travel out of the line clip ( > Figure
13 3) if necessary.
4. 2. 2 Disconnect vacuum line (Tekalan 4 x 1 x X; black > Figure 13 1) in the middle and fit Ypiece ( > Figure 15).
4. 2. 3 Cut a 500mm length off the supplied Tekalan hose (5 x 1 x 1600; transparent).
4. 2. 4
Route the Tekalan hose (5 x 1 x 500; transparent) as follows: Electric changeover valve > under intake distributor,
in direction of travel going forward > to free Ypiece connection2010 Porsche Boxster (987) F62.9L
Copyright ? 2013, ALLDATA
10.52SS
Page 10
4. 2. 5 Fit the Tekalan hose (5 x 1 x 500; transparent) at least 10 mm into the free Ypiece connection (> Figure 15 arrow)
and
on the vacuum intake connection (> Figure 16 arrow) for the electric changeover valve.
4.3 Route vacuum line from the electric changeover valve to the transmission For more information, see also Connection
diagram for vacuum lines ( > Figure 11 ).
4. 3. 1 Fit the Tekalan hose (5 x 1 x 1100; transparent) at least 10 mm into the bent hose on the output vacuum connection (
> Figure 9 ) for the electric changeover valve.
4. 3. 2 ONLY for vehicles with manual transmission:
Clip hose clip ( > Figure 2 12 or > Figure 17 1 onto a cooling fin ( > Figure 17 2) on the transmission.
Fit Tekalan hose (5 x 1 x 1100, transparent) into the hose clip ( > Figure 17 1).2010 Porsche Boxster (987) F62.9L
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4. 3. 3 Secure the Tekalan hose (5 x 1 x 1100; transparent) > Figure 18 1 in the middle with at least one hose clip (left: dia.
45 mm/right: dia. 1924 mm; > Figure 18 2) on the transmission shift cable ( > Figure 18 3).
INFORMATION: The description provided here is only for the right side. The installation procedure is the same for the left side.
4.4 Route and connect steelencased main muffler line.
4. 4. 1 Clip in hose clip (1 ea. > Figure 2, item 12) on the main muffler holder, with the opening for the steelencased line
facing backwards (> Figure 19 1).
Clip in hose clip (2 ea. > Figure 2, item 11) on the main muffler strut, with the opening for the steelencased line
facing backwards (> Figure 19 2).
4. 4. 2
Clip steelencased line into the clip on the main muffler holder (1 ea.) and main muffler strut (2 ea., > Figure 19).2010 Porsche Boxster (987) F62.9L
4. 4. 3
4. 4. 4
4. 4. 5
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Repeat the steps on the left side (> Figure 20 A).
Fit the Tekalan hose (5 x 1 x 1100; transparent > Figure 20 1) at least 10 mm into the Ypiece (> Figure 20 2).
Fit the Tekalan hoses (4 x 1 x X; black > Figure 20 3) for the steelencased lines at least 10 mm into the free
Ypiece connections (> Figure 20 2).
5. Installing sports exhaust system button and routing and connecting electric wire harness
5.1 Preparatory work
5. 1. 1 Move hood to service position > Workshop Manual '6101IN Hood service position'.
5. 1. 2 Disconnect the battery > Workshop Manual '2X00IN02 Work instructions after disconnecting the battery'.
5. 1. 3 Remove carpet lining at the sides of the luggage compartment and rear wall > Workshop Manual '700619 Removing
and installing rear luggage compartment trim (carpet lining)' section on "Removing".
5. 1. 4 Remove left side trim panel > Workshop Manual '707519 Removing and installing side trim panel' section on
"Removing".
5. 1. 5 Remove inner door sill trim at the left > Workshop Manual '680519 Removing and installing inner door sill trim'
section on "Removing".
5. 1. 6 Remove switch console in center console area > Workshop Manual '962719 Removing and installing switch console'
section on "Removing".
5.2 ONLY for Boxster
(engine type: MA120 = 2.9litre):
Connect wire harness (987.612.905.02) to the DME control unit
5. 2. 1 Expose DME control unit >Workshop Manual '247019 Removing and installing DME control unit' section on
"Removing" .
5. 2. 2
Pull off connector D on DME control unit ( > Figure 21 D).2010 Porsche Boxster (987) F62.9L
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5. 2. 3 Connect electric wire harness for the sports exhaust system button to the DME control unit
5. 2. 4 Release secondary lock on connector housing D > Figure 23 A, arrows and pull both connectors out of the housing
( > Figure 23 B, arrow).
Insert line 2386; GY/GN; 0.5(2) into connector D; chamber 39 ( > Figure 22).
Insert line 2385; BU; 0.5(2) into connector D; chamber 6 ( > Figure 22).
Fit connector in connector housing D and connect all plug connections to the DME control unit.
5. 2. 5
5. 2. 6
5. 2. 72010 Porsche Boxster (987) F62.9L
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5.3 ONLY for Boxster S
(engine type: MA121 = 3.4liter):
Connect wire harness (987.612.905.25) to connection point 3_3.
5. 3. 1
5. 3. 2 Expose connection point 3_3 in rear luggage compartment at the left ( > Figure 24 A).
Remove 30pin black connector at the side of the vehicle ( > Figure 24 arrow) from the connection point.
5. 3. 3
5. 3. 4 Insert line 9711; GY/GN; 0.5(2) into chamber 7 ( > Figure 24 7 and > Figure 25).
Insert line 9710; BU; 0.5(2) into chamber 13 ( > Figure 24 13 and > Figure 25).2010 Porsche Boxster (987) F62.9L
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5.4 Guide Tekalan hose or wire spindle on the left side wall, out of the rear luggage compartment (> Figure 26 A), under the
water drip pan in the wiring duct to the left Bpillar (> Figure 26 B).
Connect electric wire harness to the end facing the rear luggage compartment.
5.5 Route electric wire harness for sports exhaust system button.
5. 5. 1 DME control unit or connection point 3_3 > along wire harness at side of vehicle > left side panel > underneath
water drip pan > cable duct > Bpillar (between insulating mat and body)
5. 5. 2 Bpillar > left vehicle side member > along wiring duct to Apillar (> Figure 27).
5. 5. 3 Apillar > underneath the dashboard > installation position of button trim (> Figure 28).2010 Porsche Boxster (987) F62.9L
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5.6 Connect electric wire harness to sports exhaust system button
5. 6. 1 Open secondary lock on 16pin connector.
5. 6. 2
ONLY for Boxster
(engine type: MA120 = 2.9liter):
Connect line 5625; RD/GY; 0.5(2) from the wire harness (987.612.905.02) to the 16pin plug socket for the sports
exhaust system button
Line 5625; RD/GY; 0.5(2) > Double crimp on line 6207; RD/GY; 0.5(2) to chamber A3 (terminal 15, > Figure 29 and
>Figure 22)
5. 6. 3
Line 2386 ( > Figure 22) and line 9711 ( > Figure 25); GY/GN; 0.5(2) > chamber A11 (button LED).
Line 2385 ( > Figure 22) and line 9710 ( > Figure 25); BU; 0.5(2) > chamber A10 (button signal).
5. 6. 4
Close secondary lock on 16pin connector.
5.7 Use tiewraps or wrapping tape to secure electric wire harness to existing lines or components without tension and so that no
chafing occurs.
5.8 Concluding work for installing button for sports exhaust system
5. 8. 1 Install switch console in center console area > Workshop Manual '962719 Removing and installing switch console'
section on "Installing" .
5. 8. 2 Install inner door sill trim at the left > Workshop Manual '680519 Removing and installing inner door sill trim'
section on "Installing".
5. 8. 3 Install left side trim panel > Workshop Manual '707519 Removing and installing side trim panel' section on
"Installing".
5. 8. 4 Install DME control unit > Workshop Manual '247019 Removing and installing DME control unit' section on
"Installing".
5. 8. 5 Install carpet lining at the sides of the luggage compartment and rear wall > Workshop Manual '700619 Removing
and installing rear luggage compartment trim (carpet lining)' section on "Installing".
5. 8. 6 Install engine compartment lid > Workshop Manual '700819 Removing and installing trim panel for hood
compartment/engine compartment lid' section on "Installing".
5. 8. 7 Connect the battery > Workshop Manual '2X00IN02 Work instructions after disconnecting the battery and then
connect the battery charger'. > Workshop Manual '2X00IN03 Battery trickle charging'.
5. 8. 8 Move hood out of service position and close it > Workshop Manual '6101IN Hood service position'.
6. Concluding work and function test
6.1 Read out the fault memory of all control units, correct any existing faults, and erase the fault memory.
6.2 Configure Required/Actual installed components list for gateway.
6. 2. 1 Select "GATEWAY coding" in the menu and continue with [>>].
6. 2. 2 Select "Required installed components lists" and continue with [>>].
6. 2. 3 Select "Sound exhaust system" and continue with [>>].
6. 2. 4 The menu item "Sound exhaust system not installed" is highlighted.
Select "Sound exhaust system installed" and press [F8] to write coding.
6. 2. 5 Press [<<] to return to the higherlevel menu items and check that the coding was completed successfully.
6.3 Disconnect PIWIS Tester P 9718 and the battery charger if necessary.
6.4 Carry out a function test on the "sports exhaust system."2010 Porsche Boxster (987) F62.9L
6. 4. 1
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Start the vehicle.
Depending on the vehicle status, the "sports exhaust system" is activated for 2 to 3 seconds because there is no
vacuum at the main silencers. The exhaust flaps are open and the exhaust motor noise can be heard clearly.
As the vacuum at the main mufflers increases, the exhaust flaps close and the sound of the exhaust motor eases off.
The "sports exhaust system" is not active.
The diode in the "Sport" or "Twin tailpipe" button does not light up when you start the vehicle.
6. 4. 2
Working Times:
Disclaimer
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Press the "Sport" or "Twin" tailpipe button.
After a regulating phase of around 2 to 3 seconds, the exhaust flaps open and the sound of the exhaust motor can be
heard clearly. The "sports exhaust system" is active.
The diode in both buttons ("Sport" and "Twin tailpipe") lights up.
The correct function of the sports exhaust system can also be checked at any time by getting a second person to
perform a visual inspection of the regulating movement (linkage at the exhaust flaps).