Exhaust System: Testing and Inspection

Leak Test For Exhaust System

CAUTION: The maximum pressure permitted for performing the leak test is 1 bar.

NOTE: The leak test may not be carried out on a hot exhaust system, as the rubber seals are only functional at temperatures below 200 degree C.

Tools

Item 1: Plug for exhaust system leak test







Clamping position: rubber gasket constricted

Item 1:

Leak Test
1. Remove tailpipe on the rear muffler. Unscrew an M8 pan-head screw (hexagon socket a/f 6) on the 2.7 l tailpipe -arrow- or an M8 hexagon-head bold on a 3.2 l tailpipe -arrow in lower Figure- and remove the tailpipe.

Boxster 2.7 l tailpipe







Boxster 3.2 l tailpipe







2. Fit plug in exhaust pipe on the rear muffler. Insert the plug in the exhaust openings and twist the relevant lever clockwise or anti-clockwise to fit the diameter (rubber seals) until the exhaust openings are sealed airtight by repositioning the tensioning lever by 90 degrees.







NOTE: Do not exceed the permitted pressure of 1 bar.







3. Connect pressure gauge to a valve and subject exhaust system to 1 bar of excess pressure.







4. Coat individual connectors on the exhaust system (e.g. manifold flanges, clamping sleeves) with test spray in order to show up any leaks -see Figure-. Repeat test procedure if necessary.
5. Fit tailpipe again. Align tailpipe to the contour of the rear spoiler (gap dimensions).

Tightening torque: 23 Nm (17 ftlb.)