The header, muffler, and the catalytic converter can all be removed as a unit. Remove the clamps around the muffler, the oxygen sensor, and heater connections, then unbolt the system from the cylinder heads. Be sure to have the system supported as it comes loose so you do not damage any studs. Consult your factory service manual when necessary.
After you check all the exhaust studs, clean the gasket surface on the cylinder heads. Remove the muffler bracket. At this time, if you have purchased a twin outlet muffler, go ahead and remove the valance panel now. It will have to be cut in order to clear your second (optional) outlet.
The factory rubber oil cooler hose and thermostat line will have to be replaced in order to install your new Billy Boat Performance Exhaust system. Remove these in the following order:
First, drain oil from oil tank. Be sure to use a clean pan and/or change oil filter at this time. Be sure to re-install the drain plug! Next, remove the factory rubber S hose that runs from the oil tank to the engine oil cooler. Factory oil line runs from the bottom of the engine case, around the back of the car, and up in the right rear fender well to the thermostat housing. At the thermostat, the fitting for this line is on the inside of the housing. In order to remove this line, you must first take the outside fitting off in order to be able to get a wrench on the inside fitting. It may be helpful to soak these fittings in WD40 to help loosen them up.
Remove both fittings from the thermostat, and then remove factory line from the bottom of the engine case. Leave these lines off until after the headers are installed.
Using the supplied gaskets, copper nuts, and stainless washers, bolt the B&B headers to the cylinder heads. It is suggested that you use a ¼ drive 12mm wobble socket with a 12” extension to reach the nuts. Use the supplied B&B wrench to reach any nuts that are difficult to get at. Be sure to tighten all nuts sufficiently and evenly. Check to be sure that the flanges on the headers have clearance against the side of the cylinder head. Any interference may cause an exhaust leak.
It is easy to install the muffler straps and bracket to the muffler before you put the muffler on to the car. Position the straps and bracket on the muffler and tighten the straps to form them to the muffler, then loosen them in order to position the bracket on the engine. The muffler bracket is adjustable and should lie flat against the muffler. Bolt the muffler to headers using the supplied 3-bolt gaskets, 8mm bolts and 8mm lock nuts. Bolt the muffler bracket to the two bolts on the engine cover. Tighten the bracket and straps.
The Billy Boat Performance Exhaust Muffler supplied with the kit will bolt to the 3-bolt flanges on the headers. The slip joint in the muffler is for expansion/contraction. It will not leak and does not need a clamp. Check for clearance around the header/muffler 3-bolt flanges. On some model years you may have to clearance them slightly near the frame.
The tips on the Billy Boat Performance Exhaust Muffler have been made adjustable so that you may fine-tune their location to your car. Position the tip(s) in the center of the cutout 1/2" to 3/4" from bumper. Tighten the flat band clamps in order to secure the tips.
If you have a dual outlet muffler, trim your valance to match the driver side after your muffler is installed. It is best to rough cut it with tin snips, then finish with a small grinder. You may want to have the valance refinished in order to avoid any rust.
On the 911 Carrera, all factory heater connections will hook-up as before. On the 911SC or earlier, you will want to use the 90 degree steel connector off your old heat exchangers, and some flexible heater ducting in order to effectively hook up the heater.
The oxygen sensor wire will have to be extended in order to reach the port on your new headers. If you have a 3-wire oxygen sensor use the supplied extension, which will plug into the factory connectors. If you have a single or two-wire oxygen sensor, you will need some wire to extend this.
The supplied oil scavenge line with your Billy Boat Performance Exhaust headers is a steel unit with two short rubber hoses on each end. Double-check the tightness of the clamps prior to installation. After checking this, install the oil line with a short 1” section of hose to the tank and the other hose to the engine. Tighten the clamps securely.
Important! You must make sure you have at least a 1/2" minimum clearance between the oil line and the headers. If this is not the case, try to reposition this line in order to obtain clearance Do not run the car without sufficient clearance on this line.
This oil line consists of the following components: One 57" stainless oil line with a 30-mm 90 degree female fitting on one end and a straight aluminum fitting at the other
Start by screwing the 30mm 90-degree hose end to the bottom of the engine case. You may want to use some oil or anti-seize on the threads. This line will point to the front of the car. This oil line will be routed under the flywheel area of the transmission, into the fender well, and to the thermostat. Connect the line to the thermostat block in order to secure the line. The factory clamp may be used in the wheel well, and you may want to use cable ties to secure it in a couple of other locations.
After installing the oil lines and securing them tightly, refill the car with oil. Start the car and let the oil get up to temperature, then recheck the oil level.
After starting your car, check for any exhaust leaks or oil leaks, or for any clearance problems. It is also a good idea to recheck the exhaust nuts on the cylinder heads after getting the engine up to temperature, then letting it cool off.
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