Disclaimer2020 Porsche Boxster S (986) F6-3.2L Technical Service Bulletin # 2/00 Date: 000626
Sport Exhaust System - Installation Procedures
Boxster
2/00
2601
Binder - 2, Fuel, Exhaust & Eng. EI.
Sport Exhaust System
Vehicle Type:
Boxster / Boxster S
Model Year:
As of 1997 (V)
Concern:
Service installation of the Sport Exhaust System
Information:
The Sports Exhaust System is available for 2.5 I M96/20, 2.7I M96/22, and 3.2I M96/21 engines. The sound behavior of the system is controlled as
a function of the vehicle speed. The sports exhaust system has two extra exhaust passage ways which are opened and closed by control flaps. The
flaps are activated by means of a control unit, which receives a speed signal from the speedometer. This exhaust system produces a sporty, powerful
sound when both flaps are open. Visible differences between the sports exhaust system and the standard exhaust system are:
^ Visible merging of the exhaust pipes below the rear bumper cover.
^ Eccentric double tailpipe with extra ports (Figure 1).
The exhaust pipe is made from polished, stainless steel. The engine power and exhaust behavior of the vehicle is not affected. The Porsche logo is
(T) visible from below when the system is installed.
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Parts Information
Tools:
Work Procedure:
Prepping the vehicle.
1.0. Remove the driver side seat.
1.1 Move the convertible top to the service position and disengage both tension cables.
1.2 Remove the storage compartment, carpet., and engine compartment cover.
1.3 Disconnect and cover the negative battery terminal.
1.4 Remove the fuse board 1 and relay carrier.
1.5 Remove the driver-side doorsill by detaching the sill cover and disengaging the carpet.
1.6 Remove the left rear side panel lining.
1.7 Partially detach the water collection tray below the convertible top compartment lid on the driver's side.
1.8 Remove the rear spoiler.
1.9 Remove the rear bumper cover and bumper bar.
1.10 Remove the exhaust muffler.
1.11 Remove the throttle body distribution pipe and tuning pipe. Follow procedure below.
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A. On Engine types M96/22 and /21 only (Egas)7 Loosen the throttle body/distribution pipe with both rubber sleeves and remove (See
figure 2). Remove right-hand rubber sleeve (Item A) from the tuning pipe.
B. For engine type M96/20 (non E-gas), remove the right-hand sleeve from the throttle body distribution pipe.
Note:
Non-E-gas engines do not a have tuning pipe.
C. Close all openings on the intake system with cloths.
D. Check whether there is a connection nipple on the removed right-hand rubber sleeve. If it doesn't have one, replace that rubber sleeve
with the rubber sleeve with connection nipple included with the parts.
E. If there is already a connection nipple with a vacuum line attached to that sleeve, you must drill a 3.5 mm hole to provide a vacuum
source for the actuating solenoids.
Note:
The position of the hole is facing the passenger compartment. Mark the hole to be drilled with a tire crayon before removing the sleeve.
Installing the wiring harness.
2.0 Plug the relay socket into any free slot in the relay carrier 1. Insert the branches of the electrical wiring harness into the associated jumper
plug of the relay carrier according to the table 1. Make sure the connector is inserted in the bridge connector that has a jumper connection.
2.1 Run the new wiring harness along with the vehicle wiring harness via the sill, up the left side into the rear luggage compartment. Attach it to
the vehicle harness with cable ties.
Note:
Make sure you leave enough wire up by the fuse board so you can reinstall it.
2.2 Crimp the terminals which were taped to that harness on the wire ends and insert them into the corresponding housing. See table 2.
Installing the wiring harness.
WARNING
Risk of damage to components in the luggage compartment or engine compartment during drilling due to drill chuck or drill.
> Remove existing components in the drilling area (luggage compartment or engine compartment).
> Mask drilling area and use a power drill with a bit stop.
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2.3 Using a 4.5 mm drill bit, drill a hole through the grommet (Figure 3, item A) in the rear luggage compartment. The hold is drilled in the 12
o-clock position.
2.4 From the engine compartment side, guide the plug pins of the second short wiring harness threw the drilled hole into the rear luggage
compartment.
2.5 Crimp the terminals, which were taped to that harness to the wire ends then insert the terminals into the connector housing.
2.6 Loop the extra wire and tie it to the main harness.
Installing the exhaust system.
3.0 On vehicles with 2.5 I engines, remove the old bracket (support) of the main muffler from the transmission.
3.1 Attach the blade (figure 4 item B) with the provided bolts to support A.
3.2 Install support A to the transmission.
Note:
If fitting brackets to a Tiptronic transmission, use the M8 X 35 bolts inserting them in the right mounting holes. If fitting bracket to a
manual transmission, use the M8 X 75 bolts, inserting them in the left holes.
3.3 Open the lateral clamps and install the cylindrical mounts on the top of the muffler.
3.4 Install the new main muffler on the mounts.
3.5 On vehicles with 2.7 or 3.2 engines, transfer over the cylindrical mounts before mounting the muffler.
Installing the components for pneumatic actuation of the exhaust flaps.
4.0 Position the rubber sleeve (described in step 1.11) with the connection nipple on the bottom, pointing to the passenger compartment. Fasten it
with its hose clamps.
4.1 If drilling a hole was necessary, install the sleeve with the hole pointing towards the passenger compartment. When the sleeve 5 reinstalled,
the nipple will be facing downward in the opposite direction.
4.2 Insert the hose (Tekalan) at least 25 mm deep into the connection nipple or the additional hole.
Installing the components for pneumatic actuation1 of the exhaust flaps.
4.3 Install the tuning pipe (2.7I and 3.2I engines) and the throttle body with the distribution piece on the intake manifold.
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Note:
Make sure the rubber sleeves are completely on the tuning and distribution pipe before tightening the hose clamps.
4.4 Using the supplied bracket, attach the vacuum tank to it and install the assembly on the engine removal hook. The hook is located where the
transmission bolts onto the engine. The correct installed position of the vacuum tank is between the clutch Dell housing and the vehicle body.
4.5 Route the vacuum hose under the intake manifold from the rubber sleeve up to the vacuum an Cut the vacuum hose at the vacuum tank. See
figure 5 for vacuum system lay out.
4.6 Push the Y-piece (Figure 6, Item B) as far as it will go onto the connection nipple of the vacuum tank (Figure 6, Item C). Insert white side of
the check valve (Figure 6, Item D) as far as it will go into an output of the Y-piece (Figure 6, Item B).
4.7 Trim the hose (Tekalan) from the intake distributor to the check valve (Item D) and insert it 10 mm deep into the bent protective sheath (Item
E). Push Y-piece (Figure 7, Item A) as far as it will go onto the switchover valve (Item B).
Note:
Figure 6 is shown for vehicles with out secondary air.
4.8 Clip the switchover valve into the fitted long retaining bracket for the vacuum tank.
4.9 Route the hose (Tekalan) from the free connection of the Y-piece (Figure 6, Item B) to the switchover valve (Figure 7, Item B) and connect it
with the bent protective sheath.
4.10 Push 2-pin plug connection on the switchover valve and fix the electrical wiring harness to existing components (e.g. vacuum line).
4.11 Cut hose (Tekalan) in the middle and insert at least 10 mm deep into both free connections of the Y-piece on the switchover valve (Figure 7,
Item A).
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4.12 Route hose (Tekalan) between the heat shield and body panel toward the two vacuum modulators on the muffler. In the area of the two
vacuum modulators, guide the vacuum lines past the neat shield and vertically up to the connections.
4.13 Trim the hose (Tekalan) and connect to the vacuum modulator with one bent protective sheath each.
Reassembling the vehicle.
5.0 Fit the fuse board and relay carrier 1. Insert the relay into the relay socket of the electrical wiring harness.
5.1 Install the remaining interior parts including the seat.
5.2 Uncover and connect the batter!.
5.3 Hook up the PST2.
Perform a function test of the system.
6.0 form a control unit search.
6.1 Select menu item "instrument cluster" and then page down and select "Speedometer A signal".
6.2 Have a second person visually check the operation of the exhaust flaps. Using the F5 button, increase the speedometer A-signal. The
movement of the linkage from the vacuum modulator to the exhaust flap indicates the flap function. If the flap function is correct, vacuum
will be present at the vacuum modulators at a speed of approx. 27 to approx. 42 mph. The exhaust flaps are closed in this case (closing
process: linkage moves up).
Note:
The flaps are normally open, and are closed by the actuators.
6.3 Use the F6 button to reset the signal back to zero.
Completing the reassembly.
7.0 Fit the engine compartment cover, carpet, and storage compartment.
7.1 Install the top tension cables and close top. Calibrate if necessary.
7.2 Install the rear spoiler, bumper bar, and bumper cover.
7.3 Input the radio code and set the time in the instrument cluster.
7.4 Road test the vehicle and then read out the fault memory of the control units. If necessary, repair faults then clear fault memory.
Troubleshooting:
Fault symptoms and remedies.
8.0 Exhaust flaps perform only one control process:
- Connection reversed on switchover valve (Figure 5, Item C).
- Connect vacuum hoses as shown in the diagram in Figure 5.
8.1 Check engine light on:
- Read out fault memory of the DME control unit. Most likely the fault set will be due to an intake leak. Leak test the intake system with
the special pressure tester tool (# 9264/6).
- Check the insertion depth of vacuum hoses.
8.2 Exhaust flaps do not react completely or do not react at high acceleration.
- This results from the response characteristics of the exhaust flaps.
Working Time:
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