Friday, March 25, 2011

2000-2004 Porsche Boxster S Exhaust System Installation

This Borla Performance Cat-Back™ Exhaust System (Part number 140115) has been designed for 2000-2004 Porsche Boxster S equipped with a 3.5L opposed 6 cylinder engine, rear-wheel drive and a manual transmission.
Original Exhaust System Removal
Note: With a used vehicle, we suggest a penetrating spray lubricant to be applied liberally to all exhaust fasteners and allowing a significant period of time for the chemical to lubricate the threads before attempting to disassemble.
1. Unbolt the clamps shown in figure 1 located just after each catalytic converter.
2. Unbolt all the brackets shown in figure 2 including the top bracket not shown. Place the hardware to the side for use during the installation of your new exhaust.
3. Using a muffler stand or an additional person to hold the rear muffler assembly up in place, remove the muffler inlet pipes from the catalytic converters and carefully remove the rear muffler assembly as shown in figure 3 from the vehicle.
4. Unbolt and remove the bracket shown in figure 4 located on the differential. Place the hardware to the side for use during the instal- lation of your new exhaust.
Borla Performance Cat-Back™ Exhaust System Installation
1. Using the original clamps, place your new exhaust system into position as shown in figure 5.
2. Using the original hardware install the hangers into the factory brackets as the one shown in figure 6, and secure the large bracket to the differential. Hand tighten all the hardware for now.
3. Check your exhaust system for proper clearance under the vehicle and also for tip alignment.

source pdf: http://www.borla.com/media/installations/140115.pdf

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