How to change your Muffler on a 996TT - 6SpeedOnline - Porsche Forum and Luxury Car Resource

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07-10-2003, 10:11 PM

PorschePhd

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How to change your Muffler on a 996TT

OK gang here it is. A guide to changing the exhaust in your turbo....

These are the tools required:
Floor jack
Block of wood
Jack Stands
13mm wrench
6mm Allen or allen socket
13mm Socket (3/4 or 1/4 ratchet)
Extensions for both (optional)
02 Wrench (22mm) or Crescent wrench (I would rather you use the proper wrench)

Jack the car up from the center of the motor via a block of wood. this is safe, but very important NEVER to jack up the engine without the wood buffer.

Place the jackstands on either side of the car. You should be able to locate them via the markings as seen below on the rocker. Mine is on the lift, but you can see where the pads are underneath the car.

Next move to the engine compartment. To the left and right of the air box you will see two harnesses as indicated by my pointer. Disconnect the plugs. One simply pinches together the other you pull up out of the bracket and pull the lever back. The plug will separate. Do this to both sides. Now pull them out of the wire clips directly down stream of the wire. They simply pull out of a plastic clip. Remember there are 4 sensors total. Two per side.

Next carefully reach up through the bottom of the car and pull the 02 sensor wires out of the side and lower clips. You want to have the wires dangling as not to catch when removing the bumper.

Now remove the four 13mm nuts surrounding the cats. The cats attach directly to the turbo via four studs. You might want to soak these down with WD-40 or equivalent. The next

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#2

07-10-2003, 10:12 PM

PorschePhd

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With all 8 nuts removed, 4 on each side pull the shield around the turbo loose from the studs.

[IMG]http://Imagineauto.com/porschephd/996TT/turboIII.jpg{/IMG]

Working now at the muffler you will want to remove the the tips. Simply loosen the 13mm nut from the bottom and pull the tip straight off.

Looking directly under the muffler as indicated by my pointer remove the 6mm Allen head bolts. This is the main straps to the muffler. I doubt it will go any where, but you may want to have a helper as this thing is very heavy. Once the straps are loose you will need to feed them off of the rear support. Looking up behind the muffler on the engine side you will see how the strap passes over two ears on each side. You will have to work these off of their supports. Now push the muffler back as far as you can off of the studs. Slightly push the cats up over the turbo and pull the muffler out at an angle from the rear.

Remove the 02 Sensors from the old muffler. Notice that the 02 sensors are colored. Black wire goes closest to the cat inlet. The gray wire goes towards the rear or farthest away from the opening.

install on the Fabspeed set up is quiet simple. Place the cats back up there making sure to have the metal oring in the groove of the turbo and the metal shroud in place before to bolt the cat back on. Place the two pipes on either end of the muffler then place the muffler up on the original muffler support. The attachment system is very neat with the Fabspeed. There are two metal plates with studs. Place these behind the support and start the 13mm nuts. You will see what I mean when the muffler is in place. Now take the two clamps and clamp the pipes you placed on your muffler and the cats. Make sure you have both ridges inside of the clamp and tighten them down. Tighten the rest of the clamps, and the muffler down. Now put your tips on. They should slide right over. If not you may need to open the gap of the tip. The inner ring of the tip clamp will need to removed or opened up as well. Plug your o2 sensors back in and hit the key....That's it.