Work Procedure
1 Preparatory work1.1 Drive vehicle onto the lifting platform.
1.2 Disconnect the battery Workshop Manual 2706/N Work instructions after disconnecting the battery" and raise the vehicle --> Workshop Manual "400000 Lifting the vehicle".
Danger of burns
^ from extremely hot parts of the exhaust system
--> Do not work on the exhaust system until it has cooled down and wear suitable protective gear.
1.3 Remove both rear mufflers and exhaust tailpipes. --> Workshop Manual "263319 Removing and installing rear silencer - section on "Removing""
1.4 Get the two new rear mufflers for the sports exhaust system ready for installation. The description here relates only to the right rear muffler!
1.4.1 Remove stop-chock holder (--> Figure 4-A-) from the old rear muffler and fit it on the new rear muffler using new MB nuts (2 x 900.380.005.09).
Tightening torque: 23 Nm (17 ftlb.)
1.4.2 Clip in hose clip (1 x 999.591.746.02; --> Figure 4 -B-) on the web plate bearing (small) of the stop-chock holder (see Inset, --> Figure 4).
1.4.3 Connect hose (1 x 999.181.295.40; --> Figure 4-C-) to the connection nipple on the vacuum unit and secure with a hose clamp (1 x 999.512.361.02; --> Figure 4-D-).
1.4.4 Clip hose (999.181.295.40; --> Figure 4-C-) into the hose clip (999.591.746.02; Figure 4-B-) on the web plate bearing (small).
1.4.5 ONLY for right rear muffler (997.111.611.02):
Insert line (1 x 999.181.374.40; --> Figure 4-E-) at least 15 mm into the hose (999.181.295.40).
1.4.6 ONLY for left rear muffler (997.111.612.02):
Insert line (999.181.424.40) at least 15 mm into the hose (999.181.295.40).
1.4.7 Secure hose (--> Figure 4-C-) and line (--> Figure 4 -E-) with a hose clamp (--> Figure 4-F-).
1.5 Clip hose clip (999.591.746.02) in at the top of both rear muffler holders at the engine side (right side of engine [cylinder bank 4-6] see --> Figure 5 -A-).
1.6 Lower the vehicle and open engine compartment lid.
1.7 Remove air cleaner housing completely --> Workshop Manual "242519 Removing and installing air cleaner housing - section on "Removing"."
2 Install electric switch-over valve.
2.1 Clip in holder (996.111.989.00; --> Figure 6-A-) at the switch-over valve (996.605.123.01; --> Figure 6-B-).
2.2 Connect Y-piece (1 x 928.573.727.03; --> Figure 6-C-) and bent protective tube (928.574.717.03; --> Figure 6-D-) to the switch-over valve as required.
2.3 Remove hexagon-head bolt for Pentosin reservoir support from intake distributor for cylinders 4-6.
Note
Observe installation position of electric switch-over valve! For vertical installation, the 2-pin connector for the switch-over valve can no longer be plugged in or becomes chafed at the body.
2.4 Position holder with switch-over valve at an angle of approx. 550 and fit it and the reservoir support on the intake distributor for cylinders 4-6 (--> Figure 6-Bottom-).
Tightening torque: 9.7 Nm (7.5 ftlb.)
3 Install the two new rear silencers for the sports exhaust system and the exhaust tailpipes.
3.1 Route auxiliary lines for installing rear mufflers.
Note
Auxiliary lines (Tekalan or Teflon) are used as an aid for routing the lines from the vacuum unit (rear muffler) to the electric switch-over valve. Route auxiliary lines as follows:
3.1.1 Auxiliary line (--> Figure 7-A-) for right rear silencer (997.111.611.00):
Underneath filler neck for hydraulic oil --> above air-conditioning compressor --> underneath fuel collection pipe (cylinders 4-6) --> between intake manifold supports for cylinders 4 and 5 --> right rear muffler holder.
3.1.2 Auxiliary line for left rear muffler
(997.111.612.00):
Underneath filler neck for hydraulic oil --> underneath throttle housing (electronic throttle adjuster) --> underneath intake distributor for cylinders 1-3 --> left rear muffler holder.
3.2 Lift the vehicle and position new clamping sleeves (2 x 997.111.520.00) on the catalytic converters.
3.3 Position the two new rear mufflers (997.111.611.02/997.111.612.02) under the vehicle at the right or left according to their installation position.
3.4 Secure auxiliary lines that are hanging down to the rear muffler vacuum lines with adhesive tape, for example.
3.5 Position rear muffler on the rear muffler holder at the engine side (--> Figure 8-A-) with the help of a second person, who must pull the auxiliary lines into the engine compartment at the same time, and pre-fit loosely using new M8 nuts (3 x 900.380.005.09).
Risk of damage to lines and/or hoses (vacuum)
^ due to incorrect routing.
--> Maintain a sufficient distance from components exposed to high temperatures while driving.
-->Avoid using tight bending radius.
3.6 Clip hose (999.181.295.40; --> Figure 8-B-) into the hose clip (999.591.746.02; --> Figure 8-C-) and secure it to the rear muffler holder at the engine side using a tie-wrap (--> Figure 8-D-).
3.7 Fully tighten rear muffler on the holder at the engine side.
Tightening torque: 23 Nm (17 ftlb.)
3.8 Tighten clamping sleeves for rear muffler/catalytic converter.
Tightening torque: 23 Nm (17 ftlb.)
3.9 Fit the two new exhaust tailpipes (997.111.981.20/997.111.982.20).
3.9.1 Loosen M8 hexagon-head bolt on the exhaust tailpipes.
3.9.2 Fit exhaust tailpipe onto the exhaust pipes of the relevant muffler.
3.9.3 Tighten clamp on exhaust tailpipe hand4ight and align the exhaust tailpipe with the cut-out in the rear apron.
3.9.4 Tighten clamp on the exhaust tailpipe fully.
Tightening torque: 30 Nm (22 ftlb.)
4 Route and connect remaining lines (Tekalan).
4.1 Guide lines of both rear mufflers to the Y-piece on the electric switch-over valve.
4.2 Mark the length you need plus 10-20 mm on the lines and shorten lines if necessary.
4.3 Insert lines at least 10 mm into the free connection nipples of the Y-piece.
Note
Figure 9 Item A shows the standard routing.
4.4 Pull line (Tekalan, --> Figure 9-A1-) for the electric switch-over valve (resonance tube) with the protective tube (--> Figure 9-A2-) until it emerges out of the T-piece (--> Figure 9-A3-; vacuum pump line for engine/brake booster).
4.5 Replace protective tube with Y-piece and insert it into the T-piece of the vacuum pump line for the engine/brake booster in such a way that one connection nipple is facing forwards (in direction of travel) and one connection nipple is facing backwards.
4.6 Push vacuum pump line for engine/brake booster at least 10 mm into the forward-facing connection nipple of the Y-piece.
4.7 Push line (999.181.401.40) at least 10 mm into the backward-facing connection nipple (--> Figure 9-B-) and route it to the electric switch-over valve as follows:
Intake distributor (cylinders 1-3) underneath throttle valve (electronic throttle adjuster) --> under Pentosin supply tank --> protective tube at electric switch-over valve (--> Figure 9-C-).
WARNING
Risk of short circuit and fire
^ due to work on the vehicle electrical system.
--> When working on the electrical system, the battery must always be disconnected and covered.
--> Always route the electrical wires without tension and so that no chafing occurs and secure to existing wires/components with tie-wraps/electrical tape.
5 Route electric wire for switch-over valve to DME control module and connect it.
5.1 Preparatory work.
5.1.1 ONLY for vehicles with BOSE Surround sound system (I No.680):
Remove subwoofer --> Workshop Manual "973619 Removing and installing subwoofer-section on Removing"".
5.1.2 Remove rear side trim panels --> Workshop Manual "707579 Removing and installing rear side trim panel - section on "Removing"".
5.1.3 Remove belt fittings for rear threepoint belts --> Workshop Manual "697219 Removing and installing rear three-point belt-section on "Removing " " and rear seat-belt buckles --> Workshop Manual "692519 Removing and installing rear seat-belt buckle - section on "Removing"".
5.1.4 Expose DME control module --> Workshop Manual "247019 Removing and installing DME control module - section on "Removing"".
5.2 Route electric wire harness from switch-over valve to the DME control module.
5.2.1 Connect 2-pin plug connection (-->Figure 10-A-) to electric switch-over valve and clip in cable clip (Figure 10-B-) on refrigerant line flange.
5.2.2 Make a hole in the grommet (--> Figure 10-Inset-) in the passenger compartment end plate (right engine compartment).
5.2.3 Secure end of electric wire harness (with 2-pin connector) to an auxiliary line (Teflon or Tekalan) using adhesive tape.
5.2.4 Route electric wire harness (--> Figure 10-C-) from the engine compartment through the grommet into the passenger compartment to the DME control module.
5.3 Connect electric wire harness.
5.3.1 Release connectors A and C for the DME control module.
5.3.2 Insert wire 5625 (MY '05) or 5631 (as of MY '06); GY/ON; 0.5sq. into connector C; chamber 14 (sports exhaust system valve).
5.3.3 Cut off existing wire 5359; RD/BU; 1.0sq. in connector A; chamber 8 (terminal 87) approx. 5 cm behind connector A.
Strip the ends of both wires 5359; RD/BU; 1.0sq. and 9132; RD/BU; 0.5sq. (retrofit kit) and slide shrink-fit hose over line 5359; RD/BU; 1.0sq. on the connector side.
Bundle the ends of wires 5359; RD/BU; 1.0sq. and 9132; RD/BU; 0.5sq. (retrofit kit) and crimp them together as a splice with wire 5359; RD/BU; 1.5sq. on the connector side and a cable connection.
Slide shrink-fit hose over the splice and shrink the hose to make it water-tight with a hot-air gun.
5.3.4 Use tie-wraps or wrapping tape to secure electric wire to existing wires or components without tension and so that no chafing occurs.
5.3.5 Seal grommet in passenger compartment end plate with adhesive compound (000.043.204.82).
6 ONLY for vehicles without Sport Chrono package (I Nos. 639/640):
Installing switch console with "Double tailpipe" button Button for vehicles without PASM (I No. 475):
997.613.129.00FMH; --> Figure 12-A-
Button for vehicles with PASM (I No.475):
997.613.130.00 FMH; --> Figure 12-B-
6.1 Preparatory work.
6.1.1 Remove center console cover at the left/right --> Workshop Manual "681419 "Removing and installing centre console cover - section on "Removing"" and remove air-conditioning system regulator --> Workshop Manual "870279 Removing and installing air-conditioning system regulator - section on "Removing"".
6.1.2 Remove shift-lever knob with shift-lever boot Workshop Manual "340419 Removing and installing shift-lever knob - section on "Removing"" and front center console cover.
6.1.3 Loosen center console completely Workshop Manual "687 719 Removing and installing centre console - section on "Removing"" but do not remove it!
6.1.4 Remove oddments tray --> Workshop Manual "687679 Removing and installing oddments tray - section on "Removing "" and switch console close to the center console --> Workshop Manual "962779 Removing and installing switch console-section on "Removing""
6.1.5 Loosen fuse box --> Workshop Manual "978409 Loosening and securing fuse box - section on "Loosening and remove left inner door sill trim --> Workshop Manual "680519 Removing and installing inner door sill trim - section on "Removing""
main light switch Workshop Manual "940519 Removing and installing main light switch - section on "Removing"
and trim panel under dashboard --> Workshop Manual "701979 Removing and installing trim panel under dashboard - section on "Removing"".
6.2 Connect electric wire harness to DME control module ONLY for vehicles in model year '05 (Figure 13 A = Connector to sports exhaust system button
X2_1 = B-pillar connection point
C DME control module, connector C
D = DME control module, connector D
6.2.1 Insert wire 9726; BU/BU; 0.5sq. in connector D;
chamber 6 (button for sports exhaust system).
6.2.2 Cut off existing wire 5625; GY/GN; 0.5sq. in
connector C; chamber 14 (sports exhaust system valve, see also Step 5.3.2) approx. 5 cm behind connector C.
Strip the ends of both wires 5625; GY/GN; 0.5sq. and 9727; GY/GN; 0.5sq. (retrofit kit) and slide shrink-fit hose over line 5625; GY/GN; 0.5sq. on the connector side.
Bundle the ends of wires 5625; GY/GN; 0.5sq. and 9727; CY/GN; 0.5sq. (retrofit kit) and crimp them together as a splice with wire 5625; GY/GN; 0.5sq. on the connector side and a cable connection.
Slide shrink-fit hose over the splice and shrink the hose to make it water-tight with a hot-air gun.
6.3 Connect electric wire harness to DME control module ONLY for vehicles as of model year '06 (--> Figure 14):
A = Connector to sports exhaust system button
X2_1 = B-pillar connection point
D = DME control module, connector D
6.3.1 Insert wire 9726; BU/BU; 0.5sq. in connector D; chamber 6 (button for sports exhaust system).
6.3.2 Insert wire 9727; GY/GN; 0.5sq. in connector D; chamber 17 (diode for sports exhaust system).
6.4 Route electric wire harness to the center console and connect it.
6.4.1 Wrap electrical tape around wire 9726; BU/BU; 0.5sq. and wire 9727; GY/GN; 0.5sq.
6.4.2 Route both wires along the electric wire harness as follows:
DME control module (on the Coupe: see --> Figure 15-A-) --> node point of floorpan assembly for rear seats --> left side panel --> left B-pillar (--> Figure 15-B-).
6.4.3 Plug pin contacts of both wires into 2-pin connector as follows:
Wire 9727; GY/GN; 0.5sq. in chamber 1 (button LED)
Wire 9726; BU/BU; 0.5sq. in chamber 2 (button signal)
6.4.4 Connect 2-pin plug connection for connection point X2_1 (left B-pillar).
Make sure the wire colors match in the plug socket and connector!
Chamber 1: GY/GN; 0.5sq; wires: 9727 (connector; --> Figure 16-A-) and 9740 (plug socket; --> Figure 16-B-)
Chamber 2: BU/BU; 0.5sq; wires: 9726 (connector) and 9741 (plug socket)
6.4.5 Route wires 9740; GY/GN; 0.52 and 9741; BU/BU; 0.5 from the B-pillar to the switch console, in the center console area, as follows:
Connection point X2_1 (left B-pillar) --> door sill --> A-pillar --> underneath dashboard, above retaining frame (along standard wire harness) --> lower slot in center console
6.4.6 Open secondary lock on 16-pin connector for the new switch module including "sports exhaust system" symbol and insert socket contacts of the wires (No. 9741 and No. 9740) into the 16-pin plug socket as follows:
Wire 9740; GY/GN; 0.5sq. in chamber A11 (button LED)
Wire 9741; BU/BU; 0.5sq. in chamber A10 (button signal)
Close secondary lock on 16-pin connector.
6.4.7 Use tie-wraps or wrapping tape to secure electric wire to existing wires or components without tension and so that no chafing occurs.
6.5 Concluding work for installing button for sports exhaust system
6.5.1 Install trim panels for both B-pillars Workshop Manual "706719 Removing and installing B-pillar trim - section on "Installing""
6.5.2 Install trim panel under dashboard --> Workshop Manual "701919 Removing and installing trim panel under dashboard - section on "installing"", main light switch --> Workshop Manual "940519 Removing and installing main light switch - section on Installing"",
left inner door sill trim --> Workshop Manual "680579 Removing and installing inner door sill trim - section on Installing ""and fuse box ~ Workshop Manual "978409 Loosening and securing fuse box - section on "Securing""
6.5.3 Install new button for sports exhaust system (997.613.129.00 FMH or 997.613.130.00 FMH; depending on vehicle equipment [with or without PASM - I No.475]) in the center console area --> Workshop Manual "962719 Removing and installing switch console - section on "Installing"" and install oddments tray --> Workshop Manual "681619 Removing and installing oddments tray --> section on "Installing"".
6.5.4 Completely install center console Workshop Manual "687779 Removing and installing centre console - section on "Installing"" front centre console cover and shift-lever knob with shift lever boot --> Workshop Manual "340479 Removing and installing shift-lever knob --> section on "Installing"".
6.5.5 Install air-conditioning system regulator --> Workshop Manual "870219 Removing and installing air conditioning system regulator - section on "Installing ""and centre console cover at the left/right --> Workshop Manual "681419 Removing and installing centre console cover- section on "Installing"".
7 Concluding work and function test.
7.1 Install trim panels in back seat area.
7.1.1 Connect plug connections to the DME control module, then install DME control module and secure trim panels --> Workshop Manual "247019 Removing and installing DME control module - section on "Installing"".
7.1.2 Install belt fittings for rear three-point belts --> Workshop Manual "691219 Removing and installing rear three-point belt - section on "installing ""and rear seat-belt buckles --> Workshop Manual "692519 Removing and installing rear seat-belt buckle - section on "Installing"". Tightening torque for both; 50 +/-5 Nm (37 +/- 3.5 ftlb.)
7.1.3 Install rear side trim panels --> Workshop Manual "707519 Removing and installing rear side trim panel - section on "Installing"".
7.1.4 ONLY for vehicles with BOSE Surround sound system (I No.680):
Install subwoofer --> Workshop Manual "913619 Removing and installing subwoofer-section on "Installing"".
7.2 Read out fault memory and erase it if necessary.
7.2.1 Connect a battery charger and PIWIS Tester P9718 to the vehicle.
7.2.2 Read out the fault memories of all control units and delete any faults that are present.
7.2.3 PIWIS Tester P9718 and battery charger must now be disconnected.
7.3 Carry out a function test on the "sports exhaust system".
7.3.1 Start the vehicle.
Depending on the vehicle status, the "sports exhaust system" is activated for 2 to 3 seconds because there is no vacuum at the rear mufflers. The exhaust flaps are open and the exhaust motor noise can be heard clearly.
As the vacuum at the rear mufflers increases, the exhaust flaps close and the exhaust motor noise eases off. The "sports exhaust system" is not active.
ONLY for vehicles in model year '05:
The diode in the "Sport" button (Sport Chrono package: I Nos. 639/640) does not light up when you start the vehicle! However, the diode in the "Double tailpipe" button (sports exhaust system: I No. XLF) lights up.
ONLY for vehicles as of model year '06:
The diode in both buttons ("Sport" and "Double tailpipe") does not light up when you start the vehicle!
7.3.2 Press "Sport" or "Double tailpipe" button.
After a regulating phase of around 2 to 3 seconds, the exhaust flaps open and the exhaust motor noise can be heard clearly. The "sports exhaust system" is active!
ONLY for vehicles in model year '05:
The diode in the "Sport" button lights up!
However ,the diode in the "Double tailpipe" button (sports exhaust system: I No. XLF) does not light up! Additionally, the diode flashes to indicate the regulating status of the flaps in the rear mufflers.
ONLY for vehicles as of model year '06:
The diode in both buttons ("Sport" and "Double tailpipe") lights up!
In any event, the correct function of the sports exhaust system can also be checked by getting a second person to perform a visual inspection of the regulating movement (linkage at the exhaust flaps).