Hi guys, just wondering if their is anyone who has a fitting guide for 996tt exhaust? Also any warnings as to what issues i may run into or be aware of, like chances of siezed nuts/bolts. Thanks in advance

 

Soak the all the nuts and bolts to be removed in penatrating oil the night before you begin. If you're unsure of your mechnical ablities or don't have the right bend wrentches, take off the rear bumper cover and heat sheilds so you have a easy access to the muffler/cat assembly. Unbolt the stock exhaust at the cat flanges from the turbo's first and remove the heat sheilds. Then unbolt the band brackets holding the stock muffler assembly. After the bands are loose they will slide to the outside of the car. Carefully lower the stock exhaust as not to stretch the OBD2 sensor wiress and carefully remove them. (0r you can uplug the sensor wires in the engine comparment and remove the sensors when the exhaust is out. When putting everything back use an antiseize compound but be careful not to get any on the tips of the OBD2 sensors. There are metal o-rings between the turbos and the cat flanges. PCNA tech manuals indicate these should also be replaced, but most board members have not had to do so.

 

Very good advice. The last thing you want to deal with is a broken turbo stud and pre-soaking the nuts works wonders for avoiding that type of problem.

 

P.S. I learned all this from John in the first place.

 

Thankyou for the advice, when it stops raining ill get onto it

 

Hi Mpsuk

What exhaust are you putting on your car?

(I'm in Kenilworth)

 

:-) Duane, take care!

I learned this the hard way, but got lucky, as there was enough of the stud left to grab it with vice grips. After soaking overnight in WD40, it came right out. I later saw a tech snap one flush and have to drill the turbo out...so it happens somewhat regularly.

 

Hi, b&b race exhaust with 100 cell cats from dan at vivid, im in wolverhampton

 

Good man
Are there any meets near you?
There doesn't seem to be much going on in my area


Regarding the exhaust - it's a relatively straight forward job
just make sure you soak the nuts beforehand, mine were really corroded
you might need some heat if they're really bad

let me know if you need a hand at all - happy to help

 

Dont know of any meets that arnt full of corsas, also thanks for the kind offer, did you remove your bumper?

 

Definately remove rear lights and bumper, as well as the large "foil" exhaust silencer heatshield

Whilst they don't actually need to be removed it just makes the whole job easier as you can see more of what you're doing

Besides, it doesn't take very long to take the bumper of anyway

 

Ok, i dont mean to appear stupid bit i havnt worked on the car before, how do you remove the lights and bumper, thanks for all the help, Adam

 

Lights and bumper are pretty easy.

Lights:

Pop the engine lid, and remove two torx screws on the inner side of each light, then gently slide them out - will hinge on the outside front - then pull straight out. Disconnect wires.

Bumper: remove bumperettes by licenseplate - gently pry open cover on bottom and use a hex wrench to loosen the bolts - no need to take them all the way out - just enough to slide the bottom out and then the top will come out.

Remove I think 3-4 screws at the top of the bumper between the lights. Then remove two torx screws each side under the intercooler exit vents. Then remove 3-4 torx screws under the center of the bumper between the exhaust tips.

Then remove one phillips screw from each side from the front tip of the bumper in the wheel well - can do it without taking the wheels off if yo have a short enough driver.

Bumper should then come off - two people would be best, but one will do - just be careful not to scratch it.

Have fun!

 

Oh, when removing the bumper - disconnect the licence plate light. Don't forget to hook it back up when you re-install - ask my why! :-)

 

Yep that's pretty much it....
Ignore the bumperettes part though

From memory the fixings are as follows....

2 screws hold each light in
4 screws on top of the bumper (by the air filter)
1 screw by each tail pipe (just in from tailpipe)
1 torx screw by each tail pipe (just out from tailpipe)
1 torx screw just behind each rear tyre at the bottom of the bumper
1 torx screw inside each wheel arch holding the top of the bumper to the rear wing

The large 'foil' heatshield is held in by 3 bolts (one in the centre and one at each end)
and one torx screw each side holding it to the bottom of the intercooler bracket

Job done
Let me know if you need anything