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Porsche C2 Turbo Header without Heat Exchangers 1 5/8″ 3.6L (Requires install kit) #FPOR-0145


Product Details

Porsche C2 Turbo Header without Heat Exchangers 1 5/8″ 3.6L (Requires install kit, FPOR-1220) #FPOR-0145
  • Mandrel bent from the highest-grade 16G 321 stainless steel.
  • Designed, tested, and manufactured to the finest hand-made integrity found in any exhaust system.
  • Limited Lifetime Warranty

Lifetime Warranty

Have more questions? Contact us!

The Magnuson-Moss Warranty Act makes it illegal for companies to void your warranty or deny coverage under the warranty simply because you used an aftermarket part. READ MORE…

product image WARNING: This product in the physical form it is sold does not present a hazard. However, operations including, but not limited to welding, brazing, or thermal cutting can expose you to chemicals including Chromium, Nickel, Cobalt, Arsenic, Cadmium and Lead which are known to the State Of California to cause cancer, birth defects and other reproductive harm. For more information go to www.P65Warnings.ca.gov

Download PDF here… FPOR0145


  1. Remove Factory Exhaust System. The factory header system can all be removed as a unit.  Unbolt the turbo from the factory header, then unbolt the header from the cylinder head.  Be sure to unhook any heater connection and the oxygen sensor.  You will need to take off the factory turbo oil accumulator, but the turbo oil inlet, the wastegate connections, and the air intake can remain intact.  After the factory header is off remove the factory side muffler and cat. – (If a replacement muffler is to be used.)
  2. Check Exhaust Studs and Clean Gasket Surfaces. At this point check all your exhaust studs for damage and clean the gasket surfaces at the cylinder head and at the turbo.  The factory muffler mount may also be removed at this time.  If you have a twin outlet muffler, you may want to remove your rear valance panel now.
  3. Remove Oil Line. The factory oil line runs from the bottom of the engine case, around the back of the car, and up to a connection near the oil tank. Remove this line at that connection and leave it off until after the headers are installed.
  4. Install Billy Boat Performance Exhaust Headers – Clean First. It is recommended that the headers be thoroughly cleaned on the inside to avoid getting any contamination inside the turbo.  After cleaning, install the header to the cylinder head using the supplied gaskets, copper nuts, and stainless washers.  It is suggested that you use a ¼” drive 12mm wobble socket with a 12” extension to reach the nuts.  Use the supplied Billy Boat Exhaust wrench to reach any nuts that are difficult to get to.  Be sure to tighten all nuts sufficiently and evenly.  Use stainless bolts at the turbo with 10m copper nuts.
  5. Install Wastegate. Your wastegate and the small catalytic converter / wastegate pipe will install just as before.
  6. Install Oil Accumulator and Line. Install the black oil accumulator to the bottom of the turbo using the supplied gasket.  The accumulator line runs up to the factory hard line next to the valve cover.  Connect this line using the supplied metric 10 – 8 adapter.
  7. Install Muffler and Bracket.
    1. Bolt the Billy Boat Exhaust muffler bracket in the same location as the factory.  (cat bracket.)
    2. Install the Billy Boat Exhaust muffler to the turbo using the supplied gasket, nuts, and bolts.  Tighten the bracket and straps.  It is recommended the factory turbo support bracket be maintained.
    3. Install the stainless steel strap around the bracket and muffler can.  The bracket should lie flat against the muffler.  Tighten the strap.
  8.  Install Heater Connections.
    1. Driver’s Side: The factory stainless heater pipe that you took off is used on this side.  It will slip into the heater pipe on the Billy Boat Exhaust Header.  Position the pipe and use the factory clamp to hold it.
    2. Passenger’s Side: Your Billy Boat Exhaust Header was supplied with a stainless pipe that connects with rubber at the header.  Use the factory clamp to connect the hose.
  9. Install Oxygen Sensor.  (If needed) 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 that will plug into the factory connectors.
  10. Install Oil Line. The oil line supplied with your Billy Boat Exhaust Header consists of the following components:
  1. Steel 90-degree adapter 30mm female to –12 male.
  2. 40” stainless oil line with a 90 degree fitting on one end and a straight fitting on the other.
  3. 12 male Aeroquip to 30mm male adapter

*Start by screwing the steel 90-degree adapter to the aluminum fitting located at bottom of the engine case.  You may want to use some anti-seize on the threads.  This adapter will point to the front of the car.  Next, install the 90-degree –12 hose end that is on the end of the stainless braided hose on the steel 90-degree adapter.  Route this hose under the flywheel area.  The stainless hose connects at the factory line near the oil tank. Be sure to wash the hose out before the final installation.

11. Fill and Check Oil Level. 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.

12. Check for Leaks or Problems. After starting your car, check for any exhaust 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.

13. Enjoy the quality and performance of your new Billy Boat Exhaust system. With proper installation, your Billy Boat Exhaust Headers will provide unmatched performance, durability, and beauty.

Billy Boat Exhaust Safety, Installation and Liability Statements

SAFETY: Appropriate disassembly, assembly methods and procedures are essential to ensure the personal safety of the individual performing the kit installation. Improper installation due to the failure to correctly follow these instructions could cause personal injury or death. Read each step of the installation manual carefully before starting the installation.

  • Always wear safety glasses for eye protection.
  • Place the ignition switch in the OFF position.
  • Always apply the parking brake when working on the vehicle.
  • Block the front and rear tire surfaces to prevent unexpected vehicle movement.
  • Operate the engine only in well-ventilated areas to avoid exposure to carbon monoxide.
  • Do not smoke or use flammable items near or around the fuel system.
  • Use chemicals and cleaners only in well-ventilated areas.
  • Batteries can produce explosive hydrogen gas which can cause personal injury. Do not allow flames, sparks or flammable sources to come near the battery.
  • Keep hands and any other objects away from the radiator fan blades.
  • Keep yourself and your clothing away from moving parts when the engine is running.
  • Do not wear loose clothing or jewelry that can be caught in rotating or moving parts.

VEHICLE SUPPORT WARNING: Should the purchaser decide to install this exhaust product at home, be warned that car or light duty truck/van “bumper” jacks are intended for emergency use only. The use of frame contact jack stands in conjunction with a floor jack as main support is highly recommended to minimize accidental dropping of a vehicle while the installation proceeds. We recommend the use of a shop hoist if possible. Please use caution!

GENERAL STATEMENT OF LIABILITY: While we provide information for do-it-yourself installation of exhaust systems and related items, these operations are not without risk. Injury may occur during an installation or exhaust systems and their components may be damaged in the process. We are not responsible or liable for damages that may be sustained to persons or property during an installation. For this reason, we recommend professional installation as the best option when at all possible. While care has been taken in the preparation of the information contained in this web site, Billy Boat Exhaust and BillyBoatExhaust.com does not and cannot guarantee its accuracy. Anyone accessing this information does so at their own risk. It will be assumed that access indemnifies Billy Boat Exhaust and BillyBoatExhaust.com from any and all injury or damage arising from such use.

LOCAL LAWS & LIMITATION OF LIABILITY/DISCLAIMERS: Local Laws & Limitation of Liability/Disclaimers: The regulation of emissions production, noise levels and safety standards is undertaken by the federal government, each of the fifty state legislatures, and by many local municipalities, towns and counties. The manufacturer makes no warranties of merchantability, of fitness for a particular purpose, or that its products are approved for general use, or that its products comply with laws, regulations or ordinances in the states where they may be sold to the ultimate purchaser, the consumer. The entire risk as to the conformity of this product in any such state and as to repair, should the product prove to be defective or non-conforming, is on the retail purchaser, the buyer, the ultimate consumer of such product and it is not upon the seller, distributor, or manufacturer. In this connection, retail purchaser, the buyer, the ultimate consumer assumes the burden of the entire cost of any and all necessary service, alterations, and or repair. The foregoing statement limits the liability of the manufacturer.

If you have any questions please feel free to give us a call. Our direct line to the sales departments is 1-888-228-7435, ext 18. We are in Phoenix, AZ and can be reached 8am-5pm. Should you have questions that images would help explain, please email Mike at mike@bbexhaust.com.

*Please note, we do not follow daylight savings time if you are contacting us outside of Arizona.

We try to put as much information as possible within our product pages to help with application choice and the installation process. The business you purchased our product from can be a wealth of information, but should you need additional help and information, please feel free to call or our sales department.

Monday-Friday 8:30am-5:00pm Arizona time.
888-228-7435 x18 or 623-581-7600 x18

*Note that Arizona does not follow Daylight Savings Time.

More information in additional browser tab.

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