Porsche 911 Turbo

Porsche 930 Exhaust Install

Step 1 - Separate Bellows from Bumper

Remove These Bolts Bellows from Outside

Remove 8mm nuts from behind bumper where black rubber bellows attaches to bumper. Also remove 8mm nut from rubber trim on bumper. Do this on both sides of car.

Step 2 - Remove Bumper Rubber Trim

Remove Plugs First Bare Bumper

Remove black rubber trim using 2pt Philips screwdriver. Notice separation of bellows from bumper on right picture. You may need to remove two screws holding fender lower section to give a little flex (refer to picture in step 5 - be careful). Also notice two nuts holding bumper to body actually to hydraulic dampers. These will be removed during step 4.

Step 3 - Remove License Plate Lamp

Lamp Location Lamp Removed

Remove two Philips screws holding license plate lamp and detach lamp housing. Pull wires out from behind bumper.

Step 4 - Remove Bumper

Bumper Removed

Remove the four (two on each side) nuts holding bumper to the body (picture in step 2). With the help of another person (highly recommended), gently work the bellows off the bumper and remove the bumper.

Step 5 - Remove Check Valve Pipe

Check Valve Pipe

Remove pipe connecting check valve to catalytic converter. The two small circles show the bolts holding the lower fender section referred to in step 2. Leave check valve on car.

Step 6 - Remove Muffler

Cut Cat Bolts Before Bolts Cut After Bolt Cut

Soak four nuts that connect catalytic converter to turbo with penetrating oil. Since I was replacing the exhaust, I cut two bolts that connected the catalytic converter to the muffler. This allows more room to get to the nuts on the turbo. Remove the muffler straps and allow the muffler to hang off the catalytic converter. You can remove the third bolt, if you can get to it, to completely remove the muffler.

Step 7 - Remove Catalytic Converter

Rmove 4 Bolts Cat Removed

Remove four bolts holding catalytic converter to turbo. If you should remove a stud from the turbo, replace it with a new one. Be sure to clean all remaining studs with penetrating oil and a thread cleaning kit (tap and die set will do - you will need M10X1.5). Replace 4 nuts with new nuts.

Step 8 - Install New Muffler

Modified Bracket

I had to modify my bracket to fit the new stainless steel exhaust. This took a big vise, a 4 LB hammer, and a couple of pipe wrenches (also a little blood, sweat, and tears). I also cut off the inner strap flange and only used the outer flange with the provided stainless strap. When you are satisfied with the modified bracket, attach the stainless steel exhaust using the four new nuts to the turbo (don't forget new flange gasket) and attach the exhaust to bracket using the stainless steel strap. Since I installed a GHL (and I think B&B are the same), I had room to get to the turbo nuts to tighten them down because the tail pipes are removable (and adjustable). Attach tail pipe using supplied stainless steel strap (do not fully tighten).

Step 9 - Re-attach Bumper

Installed Muffler Adjust Exhaust Pipe

Re-attach the bumper using steps 1-4 in reverse order. Adjust tail pipe and tighten stainless steel strap.