Porsche 911 997.1 Turbo Exhaust Install

Written By: DriveDIY (and one other contributor)
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Difficulty

Difficult

Steps

18

Time Required

04:00:00 - 05:00:00

Sections

3

Flags

0

Introduction

Discover Porsche 911 997.1 Turbo AWE exhaust installation.

Summary & Impressions

1)at idle, much deeper and a slight growl. Very reminscent of a 993 with motorsound

2)throttle response is sharpened tremendously, especially in non-sport mode. The motor responsiveness now is closer to the sport level

3)MORE BOOST!!!! I saw at least a couple more # of boost in non-sport, perhaps another # peak in sport mode. Difference is also that the boost hits earlier (2-300 rpm) and the peak is wider than before. Imagine it as "Sport II"

4)very little to no resonance at cruising speeds

If I had to summarize the nature of the AWE exhaust, I would say it is the way the car should have come. It is not a whole lot louder than stock, and it has more of a menacing tone than the "Dyson". You would not be embarrassed at all driving this into a church parking lot. It truly adds some much needed character to the powertrain. It still won't enthrall the way a Gallardo does but the disappointment is surely gone. It takes the tt from a 3/10 to about a 7.5/10 in terms of exhaust.

Problem Areas

I did have one stud at the turbine housing break and had to:

1)attempt drilling it for an easy-out

2)broke easy out off inside the broken stud

3)broke 3 drill bits trying to drill out the easy out

4)removed the turbo - 5 oil and water lines to remove, 1 vacuum line, 1 bracket, 3 more troublesome nuts at the header flange, 1 air inlet hose

5)took turbocharger to specialty welder, who built up a nub using a TIG welder to the broken stud, then torqued it out with a vice grip and then chased the threads. Took him all of 2 minutes. This guy is my new "favorite person"!!

6)re-installed the turbo

7)re-installed the exhaust

  1. Using one of the REAR factory jack points. Jack up vehicle and place a jack stand under the front jack points. Carefully position the jack stand to correctly contact that jack point of the vehicle

    • Using one of the REAR factory jack points. Jack up vehicle and place a jack stand under the front jack points.

    • Carefully position the jack stand to correctly contact that jack point of the vehicle

    • Repeat this procedure on opposite side of vehicle.

    • The Porsche Factory jack points are designed for pin top style jack pads. While a normal jack will work, the pin top ones are the safest to use and safest for the vehicle.

    Edit

  2. Using a low profile jack, center the jack directly in front of the engine and using chassis cross member, lift vehicle and place jack stands on rear jack points. Photo #1 is 991 Cross Member Photo #2 is 997.2 Cross Member

    • Using a low profile jack, center the jack directly in front of the engine and using chassis cross member, lift vehicle and place jack stands on rear jack points.

    • Photo #1 is 991 Cross Member

    • Photo #2 is 997.2 Cross Member

    • Photo 3 Shows a Cayman/Boxster rear jack point with optional jacking block.

    Edit

  3. Place a solid jack stand under the 4 jack points located near each respective wheel.

    • Place a solid jack stand under the 4 jack points located near each respective wheel.

    Edit

  4. Open Trunk

    • Open Trunk

    • Loosen Torx Screws

    Edit

  5. Remove Tail Light and disconnect electrical connections

    • Remove Tail Light and disconnect electrical connections

    Edit

  6. In the far corner is a small fastener securing a tab on the bumper to the quarter panel, remove.

    • In the far corner is a small fastener securing a tab on the bumper to the quarter panel, remove.

    Edit

  7. From underneath remove the screw that secures the tip of the bumper to the quarter panel.

    • From underneath remove the screw that secures the tip of the bumper to the quarter panel.

    Edit

  8. You can now pull the sides of the bumper away from the quarter panel.

    • You can now pull the sides of the bumper away from the quarter panel.

    Edit

  9. From underneath remove the 2 screws holding the very bottom edge of the bumper.

    • From underneath remove the 2 screws holding the very bottom edge of the bumper.

    Edit

  10. From underneath, by the muffler, remove the 2 bolts holding the bottom center in place.

    • From underneath, by the muffler, remove the 2 bolts holding the bottom center in place.

    Edit

  11. Carefully slide the rear bumper cover off of the car.

    • Carefully slide the rear bumper cover off of the car.

    Edit

  12. Remove Both Exhaust Tips

    • Remove Both Exhaust Tips

    Edit

  13. Insert wisdom here.

    • Insert wisdom here.

    Edit

  14. Removal of the Intercoolers will help access the O2 Sensors

    • Removal of the Intercoolers will help access the O2 Sensors

    Edit

  15. Insert wisdom here.

    • Insert wisdom here.

    • loosen rear muffler clamps and disengage from brackets

    Edit

  16. Coat all the exhaust bolts in a penetrating oil such as PB Blaster. Give the penetrating oil time to break up the rust. These bolts are very easy to snap off. I would advise letting it soak for at least an hour. The use of 90 degree open ended wrenches will really help get access to the difficult bolts.

    • Coat all the exhaust bolts in a penetrating oil such as PB Blaster.

    • Give the penetrating oil time to break up the rust. These bolts are very easy to snap off. I would advise letting it soak for at least an hour.

    • The use of 90 degree open ended wrenches will really help get access to the difficult bolts.

    Edit

  17. Installation is sort of reverse, but with some tricks. Pre-tighten muffler clamps onto the AWE exhaust (bolts barely are long enough and clamps need to be "shaped" thru tensioning to fit correctly). Then remove clamps and engage them on the exhaust brackets without the exhaust.

    • Installation is sort of reverse, but with some tricks.

    • Pre-tighten muffler clamps onto the AWE exhaust (bolts barely are long enough and clamps need to be "shaped" thru tensioning to fit correctly).

    • Then remove clamps and engage them on the exhaust brackets without the exhaust.

    • Install 1 cat (I chose drivers) and then loosely fit the (drivers) muffler to that.

    • Loosely fit the other cat and muffler into place - since everything is a slip-fit, you have to leave some wiggle room to get the next cat and muffler to engage both the turbo studs and the opposite muffer at the same time.

    Edit

  18. Installation is sort of reverse, but with some tricks.

    • Installation is sort of reverse, but with some tricks.

    • 1) Pre-tighten muffler clamps onto the AWE exhaust (bolts barely are long enough and clamps need to be "shaped" thru tensioning to fit correctly).

    • 2) Then remove clamps and engage them on the exhaust brackets without the exhaust.

    • 3) Install 1 cat (I chose drivers) and then loosely fit the (drivers) muffler to that.

    • 4) Loosely fit the other cat and muffler into place - since everything is a slip-fit, you have to leave some wiggle room to get the next cat and muffler to engage both the turbo studs and the opposite muffer at the same time.

    Edit
Finish Line

Author

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DriveDIY

Member since: 12/12/2015

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