Removing Exhaust System

→ Let hot components cool down.

→ Wear personal protective gear.

Information 

Specifications for wrench sizes (a/f specifications) for screw heads are described as follows:

• Torx screws  : (E..) for external Torx, (T..) for internal Torx. 
• Hexagon-head bolts (internal and external hexagon): Wrench size (a/f) 

1. Unclip and pull off plug connection for the oxygen sensors -1 and 2-  in the engine compartment.
   1. 1.1. Connectors on cylinder bank 1-3:
      Fig 1: Identifying Oxygen Sensor Connectors (Cylinder Bank 1-3)

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   2. 1.2. Connectors on cylinder bank 4-6:
      Fig 2: Identifying Oxygen Sensor Connectors (Cylinder Bank 4-6)

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2. Guide the oxygen sensor connectors through at the side of the engine as far as the catalytic converters and unclip the oxygen sensor cables from the holders -arrows-  .
   Fig 3: Locating Catalytic Converter Oxygen Sensors

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.
3. Remove flange bolts securing catalytic converter to the turbocharger.
   1. 3.1. Loosen and screw off four M8 hexagon nuts (a/f 13) -1-  on both cylinder banks.
      Fig 4: Identifying Turbocharger Flange Bolts

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      Flange bolts at the bottom:

      Fig 5: Identifying Turbocharger Flange Bottom Bolts

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4. Loosen rear silencer mounting.
   1. 4.1. Loosen two M8 x 50 cheese head bolts (hexagon socket head, a/f 6) -2-  for the restraining straps.
      Fig 6: Identifying Rear Silencer Mounting

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   2. 4.2. Slide the restraining straps outwards off the holders -arrow-  .
      Fig 7: Sliding Straps On Rear Silencer Holder

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      CAUTION: Heavy components

      • Risk of squashing

      → Wear personal protective gear.

      → Get someone to help if necessary.

5. Pull the exhaust system to the rear and off the studs on the turbochargers.

   Only remove the exhaust system with the help of another person. 

6. Replace all metal seals.