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Fabspeed Cat Bypass Pipe Installation
 
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Pelican Technical Article:

Fabspeed Cat Bypass Pipe Installation

Steve Vernon

Time:

4 hours4 hrs

Tab:

$800

Talent:

***

Tools:

15mm (2), 13mm (2), 10mm (2) socket, extensions, floor jack, jack stands, wheel chocks, safety glasses, torque wrench

Applicable Models:

Porsche 944 Turbo (1986-89)

Parts Required:

Fabspeed cat bypass pipe

Hot Tip:

Get a fiend to help

Performance Gain:

Better performance and sounds

Installation of the Fabspeed Cat bypass pipe is a great way to add some performance and reliability to your Porsche 951. The Fabspeed Cat by pass pipe and downtube for the Porsche 944 Turbo 951 increases exhaust flow from the headers to the mufflers and improves power and sound by replacing the catalytic converters with straight-through pipes. The pipe fits all turbo 951's and increases horsepower by 26 whp and adds 29 ft-lbs of torque. The components are made from CNC mandrel-bent T304L stainless steel.

The Fabspeed Cat bypass will eliminate the catalytic convertor on your vehicle so please check with the regulations in your area for legality. In some areas the system is only legal for track purposes and is not SMOG compliant.

While the replacement of the pipe itself is not that large of a job. Certainly once it is installed you will not need to worry about it. There are as always a few concerns when work on old exhaust and turbo components. Make sure to soak everything in penetrating oil before you begin. If you can do it for a few days in advance the better. Use heat where possible to help break nuts loose.

Begin by safely supporting and jacking up your vehicle. 

The stock Porsche 951 down pipe has two catalytic convertors: one for the exhaust gases (red arrow) and a small one for the gases from the wastegate (yellow arrow).
Figure 1

The stock Porsche 951 down pipe has two catalytic convertors: one for the exhaust gases (red arrow) and a small one for the gases from the wastegate (yellow arrow).

The Fabspeed Cat bypass pipe eliminates both catalytic convertors and greatly increases air flow and reduces back pressure (red arrow).
Figure 2

The Fabspeed Cat bypass pipe eliminates both catalytic convertors and greatly increases air flow and reduces back pressure (red arrow). This system will increase horsepower by 26 whp and adds 29 ft-lbs of torque.

You will need to access the connection between the turbo outlet pipe and down pipe.
Figure 3

You will need to access the connection between the turbo outlet pipe and down pipe. The connection is located under the intake manifold, and there are several other components that will need to come off as well.

You will need to remove the fuel injectors and fuel rail; please see our article on fuel injector and rail removal for additional assistance.
Figure 4

You will need to remove the fuel injectors and fuel rail; please see our article on fuel injector and rail removal for additional assistance.

Next you will need to remove the intake manifold (red arrow) to give you access to the turbo and outlet pipe below (yellow arrow).
Figure 5

Next you will need to remove the intake manifold (red arrow) to give you access to the turbo and outlet pipe below (yellow arrow). Please see our article on intake manifold removal for further instruction.

Begin by removing the mounting 15mm hardware where the down pipe connects to the factory outlet pipe (red arrows).
Figure 6

Begin by removing the mounting 15mm hardware where the down pipe connects to the factory outlet pipe (red arrows). Some of the fasteners are accessed from the top and some from the bottom.

You will also need to access some of the fasteners from below so please see our article on safely lifting and supporting your Porsche 951.
Figure 7

You will also need to access some of the fasteners from below so please see our article on safely lifting and supporting your Porsche 951. Be very careful working around the O-2 sensor. If you are worried about damaging it use a 22mm crowfoot socket and remove it until you have completed the installation.

Once the down pipe fasteners are removed the front of the pipe will be free but will probably be held in place between the engine and heatshield.
Figure 8

Once the down pipe fasteners are removed the front of the pipe will be free but will probably be held in place between the engine and heatshield. Check and make sure it will not drop before you move on to the next fasteners.

Remove the hardware connecting the waste gate pipe (red arrow).
Figure 9

Remove the hardware connecting the waste gate pipe (red arrow). Check the placement of the heat shield, as these can get pretty beat up over time and may need to be massaged to get the down pipe out.

Next, remove the fasteners that join the Cat pipe to the exhaust pipe (red arrow).
Figure 10

Next, remove the fasteners that join the Cat pipe to the exhaust pipe (red arrow). Check the condition of the hanger and rubber on the exhaust pipe (yellow arrow) before separating these, as once the hardware is removed if the hanger is not in good shape and working correctly the exhaust can fall and damage both you and the vehicle.

Tilt the pipe down towards the rear and slip the pipe off the hanger on the front of the torque tube (red arrow).
Figure 11

Tilt the pipe down towards the rear and slip the pipe off the hanger on the front of the torque tube (red arrow).

With the stock system removed check the condition of the heat shield.
Figure 12

With the stock system removed check the condition of the heat shield. You may need to gently bend it back into shape so you can properly fit the Fabspeed.

Test fit the Fabspeed system without any hardware.
Figure 13

Test fit the Fabspeed system without any hardware. Next, install the new gasket between the outlet pipe (red arrows) and the down pipe. Using the new hardware loosely place the appropriate hardware in place.

Place the new mounting hardware on the waste gate pipe (green arrow).
Figure 14

Place the new mounting hardware on the waste gate pipe (green arrow). Slip the extension pipe (yellow arrow) on making sure you already have the clamp on. Line everything up, and using a new rubber hanger mount the down pipe. You may have to remove the hardware from the outlet pipe if you have problems getting things in place and then reinstall it.

Line up the Cat bypass pipe with the exhaust pipe.
Figure 15

Line up the Cat bypass pipe with the exhaust pipe. Install the new gasket and hardware; loosely tighten the hardware (red arrow).

Line up and loosely tighten the waste gate pipe connectors and hardware (red arrows).
Figure 16

Line up and loosely tighten the waste gate pipe connectors and hardware (red arrows).

With everything lined up and fitting correctly start by tightening the three-inch clamp on the extension pipe (red arrow).
Figure 17

With everything lined up and fitting correctly start by tightening the three-inch clamp on the extension pipe (red arrow). Place the bolt up high so as not to interfere with the ground clearance.

Slowly and evenly tighten up all the hardware until the system is firmly in place.
Figure 18

Slowly and evenly tighten up all the hardware until the system is firmly in place. Congratulations! You just got yourself some more horsepower and torque.

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