Muffler: Service and Repair

Removing And Installing Rear Muffler - Manual Transmission

WARNING:
- Danger of burns. Parts of the exhaust system can be extremely hot.
- Do not carry out the work until the exhaust system has cooled down or wear suitable protective gloves.







The figure shows the rear muffler for the Boxster 2.7 l

Removing Rear Muffler

Lower fastening points for the removal and installation of the rear muffler







- 1 = Double clamps
- 2 = Clamps on rear muffler connection
- 3 = Retaining plates on catalytic converters
- 4 = Retainer on transmission bracket at the bottom
- 5 = Fastening point for holder on rear muffler (hexagon nuts)







1. Remove exhaust pipes at the sides. To do this, open the double clamping sleeves by undoing the hexagon nuts M8 (a/f 13) -arrows- and moving them towards the catalytic converter. If necessary, prise the clamps apart and then move them. If there is corrosion, removing the exhaust pipes and clamps is made easier by heating.







2. Open the clamp on the rear muffler connection by undoing the hexagon nut (a/f 15) -arrow- and push it onto the exhaust pipe. Pull the exhaust pipe with twisting movements out of the connection and remove it.







3. Detach the two retaining plates on the catalytic converters left and right -3- and the bottom holder on the transmission bracket -4-. To do this, unscrew the four hexagon-head bolts M8 and two hexagon nuts M8 and remove the retaining plates and threaded plate respectively. For better access to the top collar nuts, the holder can be removed by undoing the hexagon nuts M8 -5-.
4. Remove the two top hexagon collar nuts M8 (a/f 13) on the transmission bracket -arrows-.







NOTE: When lifting out the rear muffler the assistance of a second person is recommended to avoid damage to the rear apron and injury due to the muffler being dropped. Place the muffler on a transmission jack.







5. Push rear muffler towards bumper and press the retaining plate to the the rear between the studs -arrow- to guide the studs out of the transmission bracket. Carefully tilt the rear muffler downwards and with the help of a second person remove it past the rear apron.

Installing Rear Muffler
1. Raise rear muffler with the transmission jack and with the help of a second person bring it into the installation position. Insert the two mounting bolts M8 on the rear muffler retaining plate into the transmission bracket, screw on the hexagon nuts M8 (a/f 13) and tighten -arrows-.

Tightening torque of M8 collar nut 23 Nm (17 ftlb.)







NOTE: The damps and double clamping sleeves must be renewed and fitted before assembling the exhaust pipes. Pay attention to the installation position.

2. Push the exhaust pipes into the rear muffler connections with gentle left and right twisting movements and align.
3. Position the new clamps on the connection with the threaded part upwards. Screw on the M8 nut (a/f 15) and tighten -arrow-.







Tightening torque 45 Nm (33 ftlb.).

4. Renew the double clamping sleeve and place in the installation position (screwed points upwards). The double clamp must adequately cover both the exhaust pipe and the connection to the catalytic converter to avoid leaks. Screw on the M8 nuts (a/f 13) and tighten -arrows-.







Tightening torque: 23 Nm (17 ftlb.)







5. Fit the two retaining plates on the catalytic converters left and right -3- and the bottom holder on the transmission bracket -4-. To do this, fit the retaining plates and and threaded plate and tighten the four hexagon-head bolts M8 and two hexagon nuts M8 respectively. If necessary, refit the holder with two hexagon nuts M8 to the rear muffler -5-.







Tightening torque for M8 hexagon-head bolts and hexagon nuts 23 Nm (17ftlb.)