Sports Exhaust System - Installation And Conversion
2911 (997)
2/09 ENU 2601
Sep 22, 2009
Sport Exhaust System (I-no. 176)
Filing:
This bulletin replaces bulletin Group 2, # 2/09, dated June 30, 2009.
Model Year:
As of 2009
INFORMATION:
Retrofitting
Restriction:
Not approved for vehicles with power kit (I-no. X51).
NOTES:
In the sports exhaust system, the signal for activating the flaps in the rear mufflers comes from the respective current map in the DME control unit. This depends on the driving status and the accelerator pedal position among other things.
The sports exhaust system is activated and deactivated using the new switch console with additional "Double tailpipe" button.
If the diodes in the "Double tailpipe" button light up, the sports exhaust system is active (exhaust motor can be heard).
The regulating time after pressing the button, determined by the response time of the pneumatics, is approx. 1 - 2 seconds.
Engine power and exhaust behaviour of the vehicle are not affected.
Parts Info:
997.044.200.06 -> Sports exhaust system without front muffler, set Sports exhaust system button
997.613.5xx.xx(1)
(1) Order separately according to vehicle equipment (see Porsche Electronic Parts Catalog).
Parts List:
Materials:
NOTES:
Identifying features when installed:
The rear mufflers are marked on the outside as follows:
Left rear muffler (for cylinder bank 4-6): Porsche logo; code 997/35 and Part No.: 997.111.511.31;
Right rear muffler (for cylinder bank 1-3): Porsche logo; code 997/34 and Part No.: 997.111.512.32.
The identification codes can be read using a mirror.
Tools:
PIWIS Tester 9718
Press-out and unlocking tools for flat and round plug connections of every size Nr.155
Repair kit for wiring harnesses Nr.155-1
Overview:
INFORMATION:
For a better understanding of the system layout, see system diagram, Figure 3.
Routing of vacuum lines on 3.6-liter engine with manual transmission:
Routing of vacuum lines on 3.6-liter engine with Porsche Doppelkupplung (PDK):
Routing of vacuum lines on 3.8-liter engine:
Work Procedure:
1. Preparatory work.
1.1 Remove air cleaner housing -> Workshop Manual '242519 Removing and installing air cleaner housing'.
1.2 Only for vehicles with 3.6-liter engine:
Remove cover for rear underbody -> Workshop Manual '519419 Removing and installing cover for rear underbody'
1.3 Unscrew two side fastening screws at the left and right of the rear apron.
1.4 Remove both rear mufflers and tailpipe covers. -> Workshop Manual '263319 Removing and installing rear silencer'
1.5 Remove front muffler. -> Workshop Manual '262519 Removing and installing front silencer.
2. Fit holders for guiding steel flexi-pipes.
INFORMATION: Illustration shows the position of the holder with engine removed.
2.1 Fit holder -> Figure 6 -10- for guiding the steel flexi-pipe into the valve cover -> Figure 6 -G- at the right.
INFORMATION: Illustration shows the position of the holder with engine removed.
2.2 Fit holder -> Figure 7 -12- for guiding the left steel flexi-pipe on the positive crankcase ventilation cover -> Figure 7 -H-.
3. Install change-over valve.
3.1 Fit the change-over valve -> Figure 8 -16- to the change-over valve holder -> Figure 8 -15-.
3.2 Unscrew external Torx screw -> Figure 9 -arrow- on the intake bridge at the front right.
Secure change-over valve holder to the intake-air distributor using an external Torx screw.
Tightening torque 13 Nm(9.5ftlb.)
CAUTION:
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 making tight bends.
INFORMATION: Insert vacuum lines at least 10 mm into the free ends of the Y-piece.
4. Only for vehicles with 3.6-liter engine: Route and connect vacuum line (supply line).
4.1 Cut 1,200 mm vacuum line from the pipe (4 x 1 x 1,650 mm).
4.2 Only for vehicles with 3.6-liter engine and PDK:
4. 2. 1 Pull vacuum line with standard bent protective tube -> Figure 10 -arrow- off the vacuum supply adapter -> Figure 10 -B-.
4. 2. 2 Pull standard bent protective tube off the vacuum line.
4. 2. 3 Slide the vacuum line (1,200 mm) and standard vacuum line -> Figure 11 -arrow- into the distributing piece and then connect the distributing piece to the vacuum supply line adapter -> Figure 11 -B-.
4.3 Only for vehicles with 3.6-liter engine and manual transmission:
4. 3. 1 Pull dummy plug off the vacuum supply line adapter.
4. 3. 2 Insert vacuum line (1,200 mm) into the straight protective tube (item 18 in list of materials).
4. 3. 3 Connect straight protective tube to the vacuum supply line adapter.
4.4 Route the vacuum line (1,200 mm) -> Figure 12 -22- through the holder -> Figure 12 -A- on the right side of the transmission (near the speed sensor) to the engine compartment
Secure the vacuum line (1,200 mm) to the transmission oil pan with three holders -> Figure 12 -23-.
4.5 Only for vehicles with 3.6-liter engine:
Fit straight protective tube -> Figure 14 -18- on the vacuum line -> Figure 14 -22- and then fit the protective tube on the straight connection on the change-over valve.
Secure the vacuum line to the sheath with two tie-wraps -> Figure 14 -arrow-.
5. Only for vehicles with 3.8-liter engine: Route and connect vacuum line (supply line).
5.1 Shorten standard vacuum line for change-over valve for air cleaner housing. Length of vacuum line -> Figure 15 -E- from air cleaner housing connection X = 410 mm
5.2 Fit shortened standard vacuum lines -> Figure 16 -E, F- into the distributing piece -> Figure 16 -17-.
5.3 Cut vacuum line (280 mm) from the pipe provided (4 x 1 x 1,650 mm).
5.4 Route the vacuum line under the cable duct to the change-over valve and then slide the other end of the vacuum line (280 mm) into the distributing piece -> Figure 16 -17-.
5.5 Fit the bent protective tube -> Figure 16 -13- on the vacuum line (280 mm) Figure 16 -26-.
5.6 Fit the bent protective tube -> Figure 16 -13- on the straight connection on the change-over valve -> Figure 16 -16-.
5.7 Clip the vacuum lines -> Figure 17 -arrows- into the cable duct.
6. Route vacuum lines (control lines).
6.1 Fit hose clips on the engine carrier -> Figure 18 -arrow-.
6.2 Cut three vacuum lines - measuring 60, 230 and 860 mm long - from the pipe provided (4 x 1 x 1,650 mm).
6.3 Assemble vacuum line set.
6. 3. 1 Fit vacuum line (60 mm) -> Figure 19 -21- and vacuum line (860 mm) -> Figure 19 -20- into the steel flexi-pipes -> Figure 19 -19- and secure with a clamping sleeve -> Figure 20 -inset A-.
6. 3. 1 Push the vacuum lines (60 mm, 230 mm, 860 mm) Figure 19 -21, 25, 20- into the distributing piece -> Figure 19 -17-.
6. 3. 1 Slide hose clamps -> Figure 20 -inset B- onto the steel flexi-pipes.
6.4 Route vacuum line set.
INFORMATION: Illustration shows the installation position of the holder with engine removed.
6. 4. 1 Route the vacuum line set under the heater pipe and behind the cable duct to the change-over valve.
6. 4. 2 Secure the distributing piece -> Figure 20 -17- to the heater pipe with a holder -> Figure 20 -23-.
6. 4. 3 Slide the vacuum line (230 mm) -> Figure 21 -25- into the bent protective tube -> Figure 21 -13- and connect the protective tube to the side connection on the change-over valve -> Figure 21 -16-.
6. 4. 4 Position the steel flexi-pipes -> Figure 21 -19- in the holder -> Figure 21 -10, 12- and close the holder.
6. 4. 5 Fit the vacuum line into the holder -> Figure 22 -arrows-.
7. Install sports exhaust system.
7.1 Install front muffler.
7. 1. 1 Only for USA set without front muffler:
Install original front muffler with new clamps. -> Workshop Manual '262519 Removing and installing front silencer'
7.2 Remove support strut from the original rear muffler and use new nuts -> Figure 23 -arrows- to secure it to the new -> Figure 23 -I- rear silencer.
Tightening torque 23 Nm(17ftlb.)
7.3 Install new rear mufflers.
7. 3. 1 Install the rear mufflers with the help of another technician.
INFORMATION: Available space restricted at the left rear muffler.
7. 3. 2 Secure the steel flexi-pipe -> Figure 24 -19- to the vacuum unit with a hose clamp -> Figure 24 -arrow-.
7. 3. 3 Secure rear muffler. -> Workshop Manual '263319 Removing and installing rear silencer
7. 3. 4 Screw in side fastening screws on the rear apron.
INFORMATION: Do not loosen hexagon socket screw arrow B. This was fitted at the factory using screw locking compound and tightened to the specified tightening torque.
7.4 Install tailpipe covers -> Figure 25 -A-.
INFORMATION: The funnel -29- must not be touching the tailpipe -28-.
7. 4. 1 Push tailpipe cover onto the tailpipe.
7. 4. 2 Tighten clamp -> Figure 26 -arrow A- on the tailpipe cover hand-tight and align the tailpipe cover with the cut-out in the rear apron.
7. 4. 3 Tighten clamp on tailpipe cover.
Tightening torque 30 Nm (22 ftlb.)
7.5 Only for vehicles with 3.6-liter engine:
Install cover for rear underbody -> Workshop Manual '519419 Removing and installing cover for rear underbody'
8. Route and connect electric wiring harness.
8.1 Preparatory work.
8. 1. 1 Disconnect the battery. -> Workshop Manual '2X00IN02 Work instructions after disconnecting the battery'
8. 1. 2 Remove strip for switches. -> Workshop Manual '962719 Removing and installing switch console'
8. 1. 3 Remove oddments tray. -> Workshop Manual '681619 Removing and installing oddments tray'
8. 1. 4 Loosen center console completely, but do not remove it. -> Workshop Manual '681719 Removing and installing centre console'
8. 1. 5 Remove trim panel on the front left side panel. -> Workshop Manual '702419 Removing and installing trim panel for front side panel'
8. 1. 6 Remove trim panel under the steering wheel. -> Workshop Manual '701919 Removing and installing trim panel under dashboard'
8. 1. 7 Remove left door entry guard. -> Workshop Manual '680519 Removing and installing inner door sill trim'
8. 1. 8 ONLY for vehicles with Bose Surround Sound System (I-no. 680): Remove subwoofer. -> Workshop Manual '91361900 Removing and installing subwoofer'
8. 1. 9 Remove headliner. -> Workshop Manual '708519 Removing and installing rear headliner'
8. 1. 10 Remove trim panel for seat well. -> Workshop Manual '702919 Removing and installing trim panel for seat well'
8. 1. 11 Loosen retaining brackets for the DME control unit. -> Workshop Manual '247019 Removing and installing DME (DFI) control unit'
8. 1. 12 Loosen retaining brackets for the relay carrier. -> Workshop Manual '979009 Removing and installing relay carrier'.
INFORMATION: For a better understanding of the system layout, see system diagram , Figure 3.
8.2 Block diagram.
8.3 Route electric wiring harness from change-over valve to the DME control unit.
8. 3. 1 Make a hole in the grommet -> Figure 29 -K- in the end plate between the passenger compartment and engine compartment at the right.
8. 3. 2 Secure electric wiring harness (2-pin connector for change-over valve) to an auxiliary line.
8. 3. 3 Route electric wiring harness as follows:
Engine compartment -> through the grommet -> Figure 31 -K- -> along the standard wiring harness -> DME control unit
8. 3. 4 Connect 2-pin plug connection to the electric change-over valve -> Figure 31 -arrow B- and fit the holder on the refrigerant line flange -> Figure 31 -arrow A-.
8. 3. 5 Seal the grommet in the end plate between the passenger compartment and engine compartment with adhesive compound.
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 change occurs and secure to existing wires/components with tie-wraps/electrical tape.
8.4 Connect GY/GN line (wiring harness for change-over valve) to the 58-pin connector on the DME control unit.
8. 4. 1 Remove tie-wrap -> Figure 32 -L-. Carefully open the locks -> Figure 32 -arrows- and remove cover -> Figure 32 -M- on connector.
8. 4. 2 Remove secondary lock.
8. 4. 3 Carefully release locking lugs -> Figure 34 -arrows- and press plug socket (chamber 1 - 32) out of the connector housing.
8. 4. 4 Insert socket contact of GY/GN line into chamber 31 -> Figure 35 -arrow- of the plug socket.
8.5 Connect RD/BU line (wiring harness for change-over valve) to the splice 090 (terminal 87 DME).
8. 5. 1 Expose splice 090 (terminal 87 DME) -> Figure 36 -N- on fuse carrier 2.
8. 5. 2 Choose a standard RD/BU line with the same cross-section as the splice and cut it.
Slide shrink-fit hose over the standard RD/BU line.
Crimp RD/BU line from the change-over valve and both ends of the line from the standard RD/BU line together using an insulated cable connection -> Figure 37 -32-.
Slide shrink-fit hose -> Figure 37 -33- over the splice and shrink the hose with a hot-air gun.
Secure splice 090 (terminal 87 DME) to the standard wiring harness with wrapping tape.
8.6 Connect GY/GN line (wiring harness for sports exhaust system button) to the 58-pin connector on the DME control unit.
8. 6. 1 Insert socket contact of GY/GN line into chamber 18 of the plug socket.
8. 6. 2 Push plug socket into connector housing until the locking lugs lock with an audible click.
8. 6. 3 Insert secondary lock -> Figure 40 -arrow- and close it.
8. 6. 4 Fit cover -> Figure 41 -M- and secure with a tie-wrap -> Figure 41 -L-.
8.7 Connect BU/BU line (wiring harness for sports exhaust system button) to the 96-pin connector on the DME control unit.
8. 7. 1 Remove tie-wrap, insert a screwdriver between the cover and connector housing and turn it sideways to open it.
8. 7. 2 Remove cover on connector in direction of arrow.
8. 7. 3 Remove secondary lock.
8. 7. 4 Carefully release locking lugs and press plug socket (chamber 1 - 48) out of the connector housing.
8. 7. 5 Insert socket contact of BU/BU line into chamber 33 of the plug socket.
8. 7. 6 Push plug socket into connector housing until the locking lugs lock with an audible click.
8. 7. 7 Insert secondary lock and lock it.
8. 7. 8 Push cover onto the connector. Fasten tie-wrap.
8.8 Secure lines close to the DME control unit to the standard wiring harness with wrapping tape and without tension so that no chafing occurs.
8.9 Route electric wiring harness for sports exhaust system button to the center console and connect it.
8. 9. 1 Route both lines along the electric wiring harness as follows: Coupe: DME control unit->along cable duct -> left side panel -> left B-pillar.
8. 9. 2 Insert pin contacts of lines -> Figure 46 -34- into the 2-pin connector socket -> Figure 46 -35- as follows:
GY/GN line in chamber 1
BU/BU line in chamber 2
8. 9. 3 Route wiring harness for sports exhaust system button -> Figure 47 -9- from connection point X2_1 (left B-pillar, cable duct) to the drawer slot for the strip for switches as follows:
Connection point X2_1 (left B-pillar) -> through cable duct ->
A-pillar->
above steering column -> installation slot in strip for switches
INFORMATION: Make sure the line colors match in the plug socket and pin connector socket.
8. 9. 4 Connect 2-pin plug connection for connection point X2_1 (left B-pillar, cable duct).
8. 9. 5 Remove tie-wrap, open lock -> Figure 51 -arrow- on 16-pin connector for the switch console and disconnect plug socket and plug carrier.
8. 9. 6 Insert pin contacts of lines into the 16-pin connector socket as follows:
Insert GY/GN line -> Figure 52 -arrow- into chamber A11.
Insert BU/BU line into chamber A10.
8. 9. 7 Push plug socket into connector housing until it locks with an audible click. Fasten tie-wrap.
8. 9. 8 Use tie-wraps or wrapping tape to secure electric line to existing lines or components without tension and so that no chafing occurs.
9. Concluding work and function test.
9.1 Secure retaining brackets for the relay carrier. -> Workshop Manual '979009 Removing and installing relay carrier'
9.2 Secure retaining bracket for the DME control unit. -> Workshop Manual '247019 Removing and installing DME control unit' - section on "Removing"
9.3 Install trim panel for seat well. -> Workshop Manual '702919 Removing and installing trim panel for seat well'
9.4 Install headliner. -> Workshop Manual '708519 Removing and installing rear headliner'
9.5 ONLY for vehicles with Bose Surround Sound System (I-no. 680):
Install subwoofer. -> Workshop Manual '91361900 Removing and installing subwoofer'
9.6 Install left door entry guard. -> Workshop Manual '680519 Removing and installing inner door sill trim'
9.7 Install trim panel under the steering wheel. -> Workshop Manual '701919 Removing and installing trim panel under dashboard'
9.8 Install trim panel on the front left side panel. -> Workshop Manual '702419 Removing and installing trim panel for front side panel'
9.9 Secure center console. -> Workshop Manual '681719 Removing and installing centre console'
9.10 Install oddments tray. -> Workshop Manual '681619 Removing and installing oddments tray'
9.11 Install strip for switches. -> Workshop Manual '962719 Removing and installing switch console'
9.12 Connect the battery. -> Workshop Manual '2X00IN02 Work instructions after disconnecting the battery'
9.13 Connect a battery charger. -> Workshop Manual '2X00IN03 Battery trickle charging'
NOTE:
Voltage drop
- Risk of irreparable damage to control unit
- Risk of damage to control unit
- Fault entries in the control unit
- Coding in the control unit is aborted
- Malfunctions in control unit, even during programming
- Switch off the ignition and remove the ignition key before disconnecting the control unit.
- Ensure that the power supply is not interrupted during programming.
- Connect a battery charger with a current rating of at least Nominal value 40 A to the vehicle battery.
INFORMATION:
The PIWIS Tester 9718 instructions take precedence and in the event of a discrepancy these are the instructions that must be followed. Deviations may occur with later software versions.
The procedure described here has been structured in general terms; different text or additions may appear in the PIWIS Tester 9718.
9.14 Code the sports exhaust system (Sound exhaust system).
9. 14. 1 PIWIS Tester 9718 must be connected and ignition switched on.
9. 14. 2 Select vehicle and run control unit search.
9. 14. 3 Select Gateway control unit.
9. 14. 4 Select Coding in the Gateway function selection menu. Press [F12] to continue.
9. 14. 5 Select Required installed components lists in the Gateway/Coding menu. Press [F12] to continue.
9. 14. 6 Select Sound exhaust system in the Gateway/Coding menu. Press [F12] to continue.
9. 14. 7 Select the option installed in the Gateway/Change coding menu and press [F8] to change the coding to installed . Press [F11] to return to the control unit selection screen.
9. 14. 8 Once coding is complete, read out the fault memories of all systems, correct any existing faults and erase the fault memories.
9. 14. 9 Switch off ignition and disconnect PIWIS Tester 9718.
9.15 Carry out a function test on the "sports exhaust system".
The exhaust flaps are open and the exhaust motor noise can be heard clearly after you press the "Double tailpipe" button.
9.16 Disconnect battery charger. -> Workshop Manual '2X00IN03 Battery trickle charging'.
Working Time:
Disclaimer