911 (996)

Technical Information
6/02 2601 2
Binder - 2, Fuel, exhaust, Engine Elec.
Exhaust System/Sports Exhaust System This bulletin replaces bulletin Group 2,
#6/02, dated 8-30-02.

Vehicle Type: 911 Carrera (996) / 911 Carrera 4 (996)

Model Year: As of MY 1999 (X) (see also notes on Page 2)

Concerns: Retrofitting

Information: As was the case with the old sports exhaust system, sound behaviour in the new sports exhaust
system is controlled by muffler flaps. Changes over the old sports exhaust system include:

.. Modified exhaust gas routing in the muffler and the new engine sound produced by it.
Installation of a switch in the center console area which can be used to switch off the sound typi-
cal of the sports exhaust system. The vehicle reverts to the sound behaviour of a vehicle with the
standard exhaust system. The deactivated state is indicated by the light-emitting diode lighting
up in the switch.

Engine performance and vehicle emissions are not changed.

The new sports exhaust system is also available for new vehicles under Exclusive option No. XLF.

Figure 1

Engine Types Affected:

M96/01 /02/04 = 3.4 I and M96/03 = 3.6 I.
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2 2601 6/02
Technical Information

Notes: The new switch with the tailpipe symbol (sports exhaust system switched off) is ordered separately
and, in contrast to the (gloss) switches installed in MY 99 (X) up to and including 01 (1), has a matt
surface. A gloss-look switch is not available.

A hybrid installation, i. e. the installation of only one new sports exhaust system muffler (Part Number
996 III 984 03/985 03) in a vehicle already fitted with an old sports exhaust system (Index .00 on
the mufflers) is not permissible and not approved. Warranty will not apply in the event of repair or dam-
age.

Important:
Observe the respective valid legal regulations as they apply in your location.

Identifying features:
When installed, the sports exhaust system can only be distinguished by the Porsche trademark Wand
the designation ~
030923 on the side of the mufflers (see inset in Figure 1). Use a mirror to read
the designation.

Please inform your sales department of this information. Give your customer a copy of the first two
pages of this Technical Information bulletin.

Parts Information: 000 044 200 19 1 x Sports exhaust system

996613 987 10 A05* 1 x Switch, sports exhaust system; installation location> right of radio
996613 988 10 A05 * 1 x Switch, sports exhaust system; installation location> left of radio
. 00'
order according to the vehicle equipment

Parts List: 996 III 984 03 1 x Left main muffler with flap and hose
996 111 985 03 1 x Right main muffler with flap and hose
964 110 950 01 1 x Check valve
996 11068552 1 x Rubber sleeve; internal 96.5 mm
928574 717 03 4 x Protective sheath, bent
90091804840 3 m Hose; 4.0 x 1.0 mm;material: Tekalan
99951206902 4 x Hose clamp; clamping range 8.0 mm; width 7.0 mm
993 110 14003 1 x Vacuum tank
477 971 881 A 1 x Holder for vacuum tank 22 x 16 x 1.5
1 x Hexagon-head bolt M6x 80; DINISO4762
1 x Spacer sleeve
1 x Retaining bracket for switch-over valve
III 971 911 A 2 x Rubber grommet; 25 x 22 mm
99661297800 1 x Electrical wiring harness incl. 1 x Relay, 1 x switch-over valve,
1 x Socket housing, 2 x Socket contact und 2 x single seal
Replacement Parts: 996 618 980 03 1 x Relay
996605 12301 1 x Switch-over valve
917355021 00 2 x Teflon hose with stainless steel mesh; external 6.35 mm; internal
3.1 mm; at the ends: internal 4.0 mm; length approx. 380 mm

Materials: 996610 11200 1 x Tie-wrap (relay carrier strain relief)

1 x Commercially available rust solvent, e.g. WD40
Adhesive tape
Tie-wraps
Technicallnformation
911 (996)
6/02 2601 2
Tools: Socket wrench for hexagon sockets a/f 4/5/6 Porsche System Tester 2 (PST 2)
Plastic spatula Handheld power drill
Flash light Release lever
Slotted and crosshead screw driver Hexagon socket wrench a/f 7/10/13/17
Teflon hose or flexible wire Drill for steel; 4.5 and 6.5 mm
Torx T27 socket wrench Large snap ring pliers external

Work Procedure: 1. Preparation.

Cabriolet only:
Take hardtop off the vehicle (Technical Manual, Group 6, Servo No. 6102), move convertible top
to service position (61 0279, Page 61-69 Removing the hardtop), and disengage both tension cables.
Remove battery cover. Disconnect and cover the battery.
1.1 Position vehicle on lifting platform, taking care not to damage any side member panels from the
Exclusive/Tequipment product range.

1.2 Rear of vehicle:

12.1 Remove rear spoiler (Technical Manual, Group 6, 63 55 19, Page 63-7).

12.2 Remove both exhaust tailpipes and V-band clamps.

12.3 Remove both side heat shields and main mufflers.

13 Engine:

13.1 Remove air cleaner housing.

1.32 Remove throttle with intermediate part and both rubber sleeves (Technical Manual, Group 2,
244637, Page 24-5). Cover or seal all line openings with a cleaning cloth or similar.
1.3.3 For the installation of an additional vacuum connection, check whether a connection nipple is
already present on the left rubber sleeve of the tuning pipe on the intake distributor; to do so,
remove the throttle, incl. the rubber sleeves.
No: Remove rubber sleeve and replace with the rubber sleeve with connection nipple (scope of
parts).
If the hose clamps interfere with installation, support the engine with a car jack and
unscrew both the hexagon nuts on the rear engine mounts as far as the next-to-the-Iast turn
( Technical Manual, Group 1, 10 01 19, Page 10-1).
Yes: Check the remaining rubber sleeves (3 pieces, 2 already removed) for an available
connection nipple. Replace one rubber sleeve without connection nipple with the rubber
sleeve with connection nipple (scope of parts).

lA Vehicle interior:

lA.1 Remove radio or PCM (Technical Manual, Group 9, 91 10 19, 91-7 Page 1).
Note:
If there is no longer a slot free in the upper section of the center console (switch cover) for the
sports exhaust system switch, installed it in the center console area.
In this case: remove center console (Technical Manual, Group 6, 68 17 19, Page 68-9).
 911 (996)
2 2601 6/02
Technicallnformation

Work Procedure: lA2 Remove driver-side front seat ( Technical Manual, Group 7, 72 01 19, 72-1 Page 1).
(cant'd)
lA.3 Remove fuse and relay carrier 1, carpet lining and the center console trim panel on the drivers side.

lA.4 Uncover the driver-side door sill by detaching the sill cover (Technical Manual, Group 5,
55 10 37, 55-29 Page 1) and removing the carpet.

lA.5 Remove driver-side side-panel lining (Technical Manual, Group 7, 70 75 19, 70-39, Page 1).

lA.6 Only for vehicles with Bose sound system, M-Option 680, remove passenger-side side panel
lining and bass box from the rear luggage rack.

lA.7 Remove the rear seat backs and the rear seat panel

lA.8 Coupe only:

Left-hand drive: Remove passenger-side side-panel lining
(Technical Manual, Group 7, 707519,70-39, Page 1).

All: Remove the trim under the rear window and the moulded foam on the right
C-pillar. Remove clips from the trim and reclip to the member
(under the rear window).

Cabriolet only:
Remove the moulded carpet under the convertible-top compartment lid.

2. Install and connect the two electrical wiring

harnesses.

2.1 Lay wiring harness for the switch.

Note:
The switch should preferably be installed in
the bottom right position in the switch cover
(see Figure 2) or just to the left of the
radio/PCM.
Alternatively, if there is no space left in the
switch cover, the switch may also be installed
in the lower section of the center console
(area of the handbrake lever). Figure 2

2.1.1 If necessary, wrap adhesive tape around the wiring harness before laying.

2.12 Run the five leads (1 x RE/GR; 2 x GRjBUjBN,1 x GR/GN and 1 x REjBU) with the three flat con-
nectors from the chosen installation location of the switch to the holder of the lower section of
the center console.

2.1.3 Detach the adhesive tape fixing the left and right footwell trim to the center tunnel and lay the
leads under the steering column and over the pedals to the relay or fuse carrier, ensuring there
is no chafing or tension.

2.1.4 Fasten wiring harness to existing wiring/components with adhesive tape or a tie-wrap.
Technical Information
911 (996)
6/02 2601 2
Work Procedure: 2.1.5 Mount switch socket into the chosen slot.
(cant'd)
2.1.6 Fit switch cover and switch.

2.2 Install relay socket for the second wiring harness.

22.1 Run the three leads (1 x GR/RE; 1 x BR and Ix GR/PK) of the relay socket through any free slot
in relay carrier 1, noting the direction of installation of the relay socket.

22.2 Release the relay socket at the sides and assign the openings in the relay socket according to
the following table.

Pin # Function Wires Work to be done

1 Unassigned
2 Terminal 15
3 Terminal 31
4 Switch indicator light
5 Activation of
switch-over valve
6 Speedometer A Signall GRjPK; 0.52 approx. 700 mm long
7 On signal
8 Unassigned
9 Unassigned
2 x RE/BU, different lengths from switch
BR; 0.52 approx. 950 mm long
GR/GN; 0.352 approx. 2700 mm long from switch
I
GR/RE; 0.52 approx. 6600 mm long
RE/GR; 0.352 approx. 2000 mm long from switch
Route together with wire from
position 5 (GRIRE wire), connect
RE/BU wire to PIN 1 of switch-over
valve.
Insert in free position on jumper plug
11 (slot 28)
Insert
Route together with RE/BU wire from
position 2 (RE/BU wire; 0.52 approx.
7000 mm long from switch), connect
GRIRE wire to PIN 2 of switch-Dver
valve.
Insert in free position on jumper plug
1/1 (slot 23).
Insert

223 Lock the relay socket and insert in the chosen slot in relay carrier 1.

23 Wrap both wires, approx. 7000 mm long (1 x GR/RE; 0.52 from relay and 1 x RE/BU; 0.52 from
switch) together with adhesive tape.

2A Connect the wires from the switch socket according to the following table.

Pin # FUlllction Wires Work to be done

1 Onsignal RE/GR; 0.352 approx. 2000 mm long from switch Insert in opening 7 of relay socket
2 Unassigned
3 Dim signal GR/BL/BR; 0.352 approx. 2100 mm long To jumper plug 5/2 (slot 28)
4 Terminal 15 RE/BU 0.352 approx. 1800 mm long Crimp to wire BK/RE; 1.52 for fuse
BI0 (instrument cluster/ diagnosis/
headlight beam adjustment)
5 Switch indicator light GRjGN; 0.352 approx. 2700 mm Ion Insert in opening 4 of relav socket

2.5 Lay wrapped wires (GR/RE; 0.52 from relay and 1 x REjBU; 0.52) along side member to B-pillar.
 911 (996)
2 2601 6/02
Technical Information

Work Procedure: 2.6 Lay wrapped wires to the rear of the vehicle.
(cont'd)
2.6.1 Cabriolet: Lay the wiring from the B-pillar along the Bowden cable for the rear lid as far as the
convertible-top compartment lid. Lay the wiring harness underneath the convertible-top compart-
ment lid alongside existing wiring to the grommet (Figure 3, Item A) located on the right in the
firewall of the rear end.

2.62 Coupe:
Detach panel in the engine compartment beneath
grommet (Figure 3, Item B).

Left-hand drive:
Lay wiring harness from the B-pillar along
the cover panels for the control modules to
the grommet (Item B).

Figure 3

& Caution!
Risk of damage to components in the engine compartment during drilling due to drill chuck
or drill.
> Remove existing components from the drilling area (engine compartment).
> Mask drilling area and use a power drill with bit stop.

2.7 Cabriolet:
Drill or pierce a hole 4.5 mm in the collar of the grommet (Figure 3, Item A) at the desired
breaking point in the 11 o'clock position.

Coupe:
Drill or pierce a hole 4.5 mm in the plug 19.6 mm (Figure 3, Item B).

2.8 Feed the wiring harness through the bore into the engine compartment and fasten to the existing
wiring/components with adhesive tape or a tie-wrap.

3. Functional diagram (Figure 4) of pneumatic control of

the exhaust flaps.

Vacuum direction:
From the rubber sleeve on the tuning pipe
via the check valve (Figure 4, Item A),
if necessary via the vacuum tank (Item B);
via the switch-over valve, with the
support (Item C) clipped on the underside,
and the V-piece to the vacuum modulator
on the mufflers. Figure 4
Technical Information
911 (996)
6/02 2601 2
Work Procedure: 4. Install new exhaust system.
(cont'd)
4.1 Loosely pre-fit both exhaust tailpipes and install the
two new main mufflers.
Note:
For vehicles from MY 99 (X) up to and including
MY 01 (1) the new mufflers can only be fitted using
the existing muffler holder on the engine.
4.2 Installing pneumatic control components.
42.1 Install the rubber sleeve with connection
nipple on the left side of the tuning pipe or where the Figure 5
rubber sleeve without connection nipple was removed
(see Item 1.3.3). The connection nipple should pointtowards the rear on the underside (Figure 5).

42.2 Insert hose (Tekalan) at least 25 mm deep into the connection nipple (Figure 5, Arrow) and lay to
the plastic housing of the positive terminal in the engine compartment.
42.3 Remove cleaning cloth and install throttle including rubber sleeves.
42.4 Push V-piece (Figure 6, Item B) onto the connection nipple on the vacuum tank (Item A) as far as
the stop.
425 Insert white side of the check valve (Item C) as far as
it will go into an output of the V-piece (Item B). Push
the bent protective sheath (Item 0) onto the black side
of the check valve as far as it will go.
42.6 Remove the rearmost fastening screw of the fuel
collection pipe (Item E). Install the fuel collection pipe
and the vacuum tank with spacer sleeve and new
hexagon-head bolt M6 x 80 in the same position
(Figure 6). Figure 6
42.7 Lay the hose (Tekalan) from the rubber sleeve on the tuning pipe (Figure 5, Arrow) to the protec
tive sheath (Figure 6, Item 0), cut to the correct length and insert the hose 10 mm deep into the
protective sheath.
42.8 Insert switch-over valve (Figure 7, item A) into the
holder supplied (Item B). Insert the bent protective
sheath (Item C) and V-piece (Item 0) into the connec-
tions on the switch-over valve as shown in Figure 7.
42.9 Mount switch-over valve above the positive terminal in
the engine compartment.
42JO Insert the hose (Tekalan) 10 mm deep into the free
connection of the V-piece of the vacuum container
(Figure 6, Item B) and lay to the bent protective
sheath (Figure 7, Item C). Figure 7
42.11 Trim the hose (Tekalan) and insert 10 mm deep into
the bent protective sheath (Item C).
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2 2601 6/02
Technical Information

Work Procedure: 4.3 Connect the switch-over valve electrically.

(cont'd)
43.1 Guide a single blue seal (scope of delivery) onto each electrical wire to the switch-over valve and
crimp jacks onto both wires.

432 Release socket housing and insert wires according to the following table.

Pin # Function Wires Work to be done

1 Terminal 15 REjBU; 0.52 approx. 7000 mm long Insert in pin 1 of socket housing.
2 Activation of GRjRE; 0.52 approx. 6600 mm long Insert in pin 2 of socket housing.
switch-over valve

433 Lock socket housing and make plug connection to switch-over valve (Figure 7).

5. Connect vacuum modulators of both mufflers.

5.1 Left side.

5.1.1 Lay the remaining hose (Tekalan) from the connection of the switch-over valve pointing to the left
to the bore in the left wheel housing (corner of the rear closing panel/left side wall).

5.12 Make a hole approx. 4 mm in the rubber sleeve 25 x 22 mm (scope of delivery) and push the
rubber sleeve onto the hose, observing the direction of installation.

5.13 Route hose (Tekalan) through the bore in the wheel housing to the steel-armoured hose of the
vacuum modulator and trim.

5.1.4 Push the hose at least 10 mm into the steel-armoured hose and fasten with a hose clamp (8 mm).
Note:
Due to the high temperatures, the steel-
armoured hose must cover at least the area
under the heat shield as far as the vacuum
modulator on the muffler (Figure 8).

5.2 Right side.

52.1 Insert the remaining hose (Tekalan) 10 mm

deep into the right connection of the V-piece
on the switch-over valve and, for the right
vacuum modulator, work through steps
similar to those in 5.1.1 to 5.1.4.

6. Concluding work. Figure 8

6.1 Fit fuse carrier and relay carrier 1, and insert the relay into the relay socket of the electrical
wiring harness.

6.2 Install trims, rear seat assembly and front seat.

Technical Information
911 (996)
6/02 2601 2
Work Procedure: 6.3 Tighten both rear engine mounts (Technical Manual, Group 1,100119, Page 10-1).
(cant'd) Tightening torque: 85 Nm (63 ftlb.).
Install components in the engine compartment (air cleaner housing, oil filler neck, etc.).

6.4 Lower the vehicle until the wheels touch the ground.

6.5 Connect battery and PST2

Cabriolet only:
Close convertible top and calibrate if necessary
(Technical Manual, Group 6,61 01 19,61-1 Page 13, Test Step #11).

6.6 Carry out function test on the sports exhaust system.

6.6.1 Switch ignition on and select the vehicle type in the PST2.

6.62 Select menu item Instrument cluster and then menu item Speedometer A-signal.

6.63 Start the engine and increase the speedometer A-signal in steps of 10 up to 70 kmh / 45 mph
by pressing the F5 key.

6.6.4 Have a second person visually check the operation
indicated by the movement of the linkage from the
If the flaps function as intended, vacuum is present
approx. 45 kmh / 28 mph to approx. 68 kmh / 42
case (closing process: linkage moves up).
of the exhaust flaps. The flap function is
vacuum modulator to the exhaust flap.
at the vacuum modulators at a speed of
mph. The exhaust flaps are closed in this

6.65 Use the F6 key to reset the speedometer A-signal in the digital display of the instrument
cluster to 0 kmh/ 0 mph.

6.6.6 Switch off the engine sound of the sports exhaust system in the loud speed ranges by pressing
the tailpipe symbol on the switch (center console). If operation is correct, the light-emitting diode
in the switch starts to light up.

6.6.7 Press the tailpipe symbol once more to switch on the engine sound of the sports exhaust system
again. The light-emitting diode must go out in this case.
Note:
Switching operations with the switch must only be triggered by pressing the tailpipe symbol. If
only one switching operation is triggered by pressing the light-emitting diode, check the
assignment of the openings in the switch socket and change if necessary.

6.7 Install both side heat shields and bumper mount with rear spoiler (Technical Manual, Group 6,
6355 19, Page 63-7).

6.8 Align the exhaust tailpipes in the cut-outs of the rear spoiler and screw the V-band clamps tight.

6.9 Input radio code and set the time in the instrument cluster.

6.10 Remove the vehicle from the lifting platform, perform a test drive and then read out control units
with the PST2. Erase fault memory if necessary.
 911 (996)
2 2601 6/02
Technical Information

Work Procedure: 7. Fault symptoms, possible faults and remedy.

(cont'd)
7.1 Exhaust system flaps perform only one control operation: Connection on switch-over valve
interchanged (Fig. 4, Item C).
Connect vacuum hoses as shown in the diagram in Figure 5.

7.2 CHECK ENGINE emission control warning light flashes or is continuously lit intake system leaks:
Read out fault memory of DME control unit with the PST2 and, if necessary, carry out a short
test. Leak-test the components and the intake air distributor with the pressure tester (special tool
9264/6 - see Workshop Equipment Manual, Chapter 2.2b), and check the insertion depth of the
hoses (Tekalan).

7.3 Exhaust flaps do not react fully or do not react under fast acceleration: The reason for this is the
slower response of the mechanics (exhaust flaps) in relation to the pneumatics (vacuum).

Working Time: labor Operation Description Time Units

26 01 31 06 Retrofitting sports exhaust system (1 x) 750 TU
Includes: Removing both standard mufflers; installing muffler with
exhaust flaps;routing electro-pneumatic actuation system of the
exhaust flaps; installing switch for switching on/off the engine
sound; carrying out function test and test drive.
Without: Removing and installing hardtop (separate LO No. !)
Checking intake air distributor (separate LO No.!).

Literature: 911 Carrera Technical Manual, Groups 1/2/5/6/7/9:

> Technical Information:
Group 2, No. 2/00 Exhaust system/Sports exhaust system
Group 7, No. 2/99 Sports bucket seat

>Repair:
10 01 19 - Removing and installing engine - Page 10-1
24 42 19 - Removing and installing throttle body - Page 24-5
24 46 37 - Disassembling and assembling intake distributor - Page 24-5
55 10 37 - Disassembling and assembling release for front lid - 55-29, Page 1
61 01 19 - Removing and installing convertible top - 61-1, Page 1
61 02 19 - Removing and installing hardtop - Page 61-69
63 55 19 - Removing and installing rear spoiler - Page 63-7
68 56 37 - Removing and installing center console - Page 68-9
70 75 19 - Removing and installing side-panel lining - 70-39, Page 1
72 01 19 - Removing and installing front seat - 72-1, Page 1
91 10 19 - Removing and installing display and operator control unit (PCM) - 91-7, Page 1

OBD Manual
 911 (996)
Technicallnformatiol1 6/02 2601 2