The header, muffler, and the catalytic converter can all be removed as a unit. Start by removing the engine under-tray and the shields around the valve covers. These will have to trimmed upon reinstallation in order to provide clearance around the headers. Remove the clamps around the muffler, 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.
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 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.
Using the supplied gaskets, copper nuts, and stainless washers, bolt the headers to the cylinder heads. It is suggested that you use a 1/4" drive 12mm wobble socket with a 12” extension to reach the nuts. Use the supplied 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.
The 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. Bolt the muffler to headers using the supplied 3-bolt baskets and 8mm Allen Head bolts and 3mm lock nuts. Remove the factory brackets and install the muffler brackets in the same location. After you install the muffler, the straps will go around the bracket and muffler. Tighten the bracket and straps.
The tips on the B & B 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 chipping.
On the 911 Carrera, all factory heater connections will hook-up as stock
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.
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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