Download PDF here… FPOR0665
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, and 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 a twin outlet muffler, go ahead and remove the valance panel now.
The factory rubber oil cooler hose and thermostat line will have to be replaced in order to install your new Billy Boat Exhaust system. Remove these in the following order:
Remove both fittings from the thermostat, and then remove factory line B 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 Billy Boat Exhaust 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 Billy Boat Exhaust 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, and 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 and 8mm Allen Head bolts lock nuts. Bolt the muffler bracket to the two bolts on the engine cover. Tighten the bracket and straps.
On the 911 Carrera, all factory heater connections will hook-up as before. On the 911 SC 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 most 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, extend this wire using the supplied wire, connectors, and heat shrink tubing.
Re-Install Oil Lines.
Important: You must make sure you have at least a ½” 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 no run the car without sufficient clearance on this line.
Oil Line B. This oil line consists of the following components:
Start by screwing the 90-degree end of the oil line to the bottom of the engine case. You may want to use some oil or anti-seize on the threads.
This adapter 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.
With proper installation, your Billy Boat Exhaust Headers will provide unmatched performance, durability, and beauty.
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.
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 firstname.lastname@example.org.
*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.
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