Exhaust System - Tailpipe Rattles

911 (996)

9/02 2634

Binder - 2, Fuel, Exhaust, Engine EI.

Exhaust Tailpipe Rattle

Vehicle Type:
911 Carrera (996) / 911 Carrera 4 (996)

Model Year:
As of '02 (2)

Concerns:
Exhaust system rattling noise in exhaust tailpipe cover.

Information:

Rattling noise in the exhaust system while driving is caused by a gap between the exhaust tailpipe and cover. The solution is to add an additional washer.

Parts Information:

Part Number Description

900 025 008 09 Washer, 2 ea.

900 910 129 02 Hexagon nut, 2 ea.

Tools:

Box wrench a/f 13/16/17
Sockets a/f 13/16/17
Torque wrench up to 30 Nm
Snap ring pliers
Shop light
Plastic hammer
Tape Measure

Warning!
Danger of burns when working on hot exhaust components!

> Do not carry out the following work procedure until the exhaust system has cooled down or wear suitable protective gloves.

Work Procedure:

Retrofitting an additional washer.

1. Remove both exhaust tailpipes.

1.1 Raise vehicle on lifting platform.





1.2 Remove hexagon nut (Figure 1) on V-band clamp of exhaust tailpipe according to Technical Manual, Group 2, Chapter 26 34 15.

1.3 Spread the V-band clamp, e.g. with a pair of snap ring pliers.

1.4 Separate exhaust tailpipe and clamp from the main muffler.

2. Affixing additional washer.





2.1 Unscrew hexagon nut on exhaust tailpipe cover (Figure 1, arrow C) and remove washer (Figure 2, arrow B).

2.2 Remove the screw for fastening exhaust tailpipe cover.

2.a Insert the removed washer (Figure 2, arrow B) between the exhaust tailpipe cover and the exhaust tailpipe (Figure 2, arrow A).

2.4 Insert the screw for exhaust tailpipe cover through the exhaust tailpipe, washer (Figure 2, arrow A) and exhaust tailpipe cover again.

2.5 Secure exhaust tailpipe cover using a new, additional washer (Figure 2, arrow B), part number,

900 025 008 09 and a new hexagon nut (Figure 2, arrow C), with part number, 900.910 129 02.

Do not tighten yet!

3. Installing both exhaust tailpipes.

3.1 Push V-band clamp and exhaust tailpipe onto the tapered flange of main muffler.

3.2 Align the exhaust tailpipe with the cut-out in the rear spoiler and position the V-band clamp so that it is accessible to be tightened.

4. Adjust exhaust tailpipe cover according to the Technical Manual, Group 2, Chapter 26 34 15.

5. Tighten the hexagon nut (Figure 1) of the V-band clamp to 30 Nm (22 ftlb.).

6. Tighten hexagon nut of exhaust tailpipe cover to 23 Nm (17 ftlb.).

7. Remove vehicle from the lifting platform.





Working Time:

Literature:
911 Carrera (996) Technical Manual, Group 2:
> Repairs: 26 34 15 - Adjusting tailpipe (as of MY '02)