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Muffler Replacement - Porsche 911 Carrera
 
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Pelican Technical Article:

Muffler Replacement - Porsche 911 Carrera

Time:

4 hours4 hrs

Tab:

$250 to $600

Talent:

***

Tools:

10mm/13mm/17mm sockets and wrenches, screwdrivers, penetrant spray, channel locks

Applicable Models:

Porsche 996 Carrera (1999-05)
Porsche 997 Carrera (2005-12)

Parts Required:

New mufflers

Hot Tip:

Soak any rusty nuts or bolts overnight with penetrant oil

Performance Gain:

More power, better sound

Complementary Modification:

Replace headers and catalytic converters for even more power gains.

An easy way to add a small increase in power to almost any car is to add a set of aftermarket mufflers. The reduced backpressure can result in an engine that flows air easier, resulting in an increase in horsepower. However, the amount of power that you can expect to gain depends on a variety of factors. Exhaust design in itself is somewhat of a black art. I recommend that you research the set of mufflers you wish to buy very closely and see if the manufacturer has dyno-proven results.

On a Carrera engine, the exhaust system is already limited due to the space requirements of the rear engine design. However, it is fair to say that gains of up to 15 or more horsepower are attainable by changing out the stock mufflers for a set of aftermarket ones.

Keep in mind that this article is also written to illustrate the replacement of the stock muffler. If your muffler has rusted out at the bottom, simply follow the steps to replace your muffler and end any annoying exhaust leaks. While the 997s have a different style of fasteners for the exhaust, and use Torx screws in place of Philips, the basic geometry of the exhaust is the same as well as the procedures for removal and replacement.

To replace the mufflers, you'll need to remove the rear bumper to gain access. Begin by removing the four screws along the bumper threshold strip. Remove the strip and set it aside. You'll also want to remove the screws along the lower edge of the bumper cover both in the center and on each side of the bumper. On the 997s there is an addition body support piece attached to the leading edge screw, you will need to remove this as well.

Now look underneath each bumperette next to the license plate carrier. You'll see a small access hole. Up inside each bumperette is a 6mm hex bolt that clamps it in place. Loosen each bolt until you can swing each bumperette up and off the bumper cover from the bottom. At this point, you can give the bumper cover a good tug back from both sides and it will slide off. Disconnect the harness going to the license plate lights behind the cover. Be careful not to scratch the paint on the cover as it is flexible and a bit unwieldy.

You'll now see the large aluminum bumper itself underneath. Loosen and remove the two 19mm bolts that hold the bumper to the carriers on either side. Remove the bumper along with the lower heat shield. Each muffler is covered by a heat shield held in place by seven 10mm nuts. Remove the nuts and pull the shields off. You now have access to each muffler.

Before you start removing the fasteners that hold the muffler to the engine, it's a good idea to inspect them for rust and/or corrosion. Many times, I've had exhaust bolts simply snap the second any torque is applied to them. Spray each fastener with a high quality penetrant oil such as Kroil or Liquid Wrench but not WD-40. WD-40 is not actually a lubricant and it won't work to free up rusted or corroded exhaust fasteners as effectively as dedicated penetrant oil. The oil will soak into each joint and make things much easier. It's even a good idea to let the oil soak in for a day or two beforehand.

Additionally, if you have access to a propane or acetylene torch, freeing up stuck exhaust bolts becomes incredibly easy. Simply heat each fastener until it glows cherry red and pop it loose with a wrench. Obviously, if you choose to use this method, use EXTREME caution as you can very easy burn though many things that do not react well to fire.

Ok, so now that we have that out of the way, begin by removing the exhaust tips on each muffler if you plan on transferring them to the new mufflers. They are held on with a compression clamp that uses a mm nut to tighten it. Loosen the bolt and remove the clamp along with the tip.

Now loosen the large exhaust clamps going from each catalytic converter to each muffler. These are held tight with 17mm bolts on each end of the clamp. Loosen the bolts and slide each exhaust clamp towards the center of the car to release them from the muffler.

Now comes the trickiest part of the job, removing the three 13mm nuts that hold the mufflers to the mounting brackets on either side of the engine. There's not very much room to work with here, but it is possible to reach up in-between the muffler bracket and valve cover with a 13mm ratcheting wrench to remove them. It's also advisable to have a helper hold the muffler as you remove the nuts. These mufflers are heavy. You don't want it dropping in your lap just as you remove the last nut.

Once removed, you'll need to remove the mounting bracket on the back of each muffler and transfer it to the new muffler. These are held on with two long 13mm nuts and bolts. Remove the bolts and pry the bracket out of the mounting tabs on the back of the muffler. Don't forget the small mesh gaskets in the ears of each bracket. Now just transfer these over to the new mufflers. Installation of the new mufflers is the opposite of removal.

1: Loosen and remove the four screws that hold the bumper threshold strip in place.
Figure 1

1: Loosen and remove the four screws that hold the bumper threshold strip in place. Remove the strip and set it aside.

2: Also remove the screws along the bottom edge of the bumper cover as shown here (green arrows) and also on each side of the bumper cover.
Figure 2

2: Also remove the screws along the bottom edge of the bumper cover as shown here (green arrows) and also on each side of the bumper cover.

3: Look underneath each black plastic bumperette.
Figure 3

3: Look underneath each black plastic bumperette. You'll see a small access hole with a 6mm hex bolt inside. Loosen the 6mm bolt and you will be able to swing the bumperette up and off the bumper from the bottom.

4: Also remove the two Phillips head screws along the bottom edge on either side of the bumper cover (green arrows).
Figure 4

4: Also remove the two Phillips head screws along the bottom edge on either side of the bumper cover (green arrows). On the 997s there is an addition body support piece attached to the leading edge screw (insert lower right), you will need to remove this as well. At this point, you can give the bumper cover a good tug towards the back of the car and it will come off.

5: Once the bumper cover is removed, you'll need to remove the bumper itself.
Figure 5

5: Once the bumper cover is removed, you'll need to remove the bumper itself. Loosen and remove the two 19mm bolts shown here (green arrows). Then remove the bumper with the heat shield attached.

6: Remove the 10mm nuts holding each exhaust shield over the mufflers on each side of the car and take the exhaust shields off.
Figure 6

6: Remove the 10mm nuts holding each exhaust shield over the mufflers on each side of the car and take the exhaust shields off.

7: Shown here is the muffler attached to the car with the heat shields removed.
Figure 7

7: Shown here is the muffler attached to the car with the heat shields removed. Loosen the clamp shown here to allow the exhaust tip to be removed from the muffler (green arrow).

8: Loosen the 17mm nuts on each exhaust clamp holding the muffler to the catalytic converter.
Figure 8

8: Loosen the 17mm nuts on each exhaust clamp holding the muffler to the catalytic converter. Once loose, pull the clamp inboard enough to allow the pipe from the muffler to pull out easily once the muffler is unbolted.

9: Here is the bracket that attaches the muffler to the side of the car.
Figure 9

9: Here is the bracket that attaches the muffler to the side of the car. Note the three holes (green arrows). There are three studs on the back of the other muffler bracket that pass through the holes and are secured with three 13mm nuts. It is possible to remove these three nuts with a ratcheting wrench, although getting aPicture of them in place is nearly impossible.

10: Here is the side of the car with the muffler completely removed.
Figure 10

10: Here is the side of the car with the muffler completely removed.

11: Shown here is the bracket that attaches directly to the muffler.
Figure 11

11: Shown here is the bracket that attaches directly to the muffler. You'll need to remove this from the old muffler and transfer it to the new muffler. Loosen the 13mm nuts while counter-holding the long 13mm bolts (green arrows) to remove it. Also note the three studs that attach the muffler assembly to the side of the car (red arrows).

12: Don't forget the small mesh gaskets that sit in the cups of the muffler brackets when transferring them to the new mufflers.
Figure 12

12: Don't forget the small mesh gaskets that sit in the cups of the muffler brackets when transferring them to the new mufflers.

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Comments and Suggestions:
Jboy Comments: Will 2007 997 c2 mufflers fit on a 2000 996 c2 .
November 4, 2016
  Followup from the Pelican Staff: No. - Nick at Pelican Parts  
danielB Comments: Would 996 GT3 mufflers direct fit on 996 Carrera?

Thanks for the tutorial!
July 2, 2016
  Followup from the Pelican Staff: I don't believe so. The exhaust is different. - Nick at Pelican Parts  
Garry Comments: The 3 nuts holding the exhaust box to the bracket are more than likely to be rusted preventing you easily removing them. I think it's less time consuming to cut the exhaust away from this bracket using an angle grinder and cut through the vertical bolts in fig 11 so they drop out. The exhaust wil come off then. Put the new exhaust on with the bolts angled upwards nuts on top and you'll save the next owner the pain too.
June 5, 2016
  Followup from the Pelican Staff: Thanks for the additional info and feedback. We appreciate it.
- Nick at Pelican Parts
 

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