Leak test

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Remove tailpipes. To do this, unscrew the hexagon nuts of the fastening clamps, spread the clamps and completely remove tailpipe -tailpipe on the left in Fig 1 - .

Fig 1: Locating Tailpipe Fastening Clamps
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Fit plug in exhaust pipe on the rear muffler. Insert the plug in the exhaust openings and twist the relevant lever clockwise or anti-clockwise to fit the diameter (rubber seals) until the exhaust openings are sealed airtight by repositioning the tensioning lever by 90°.

Fig 2: Fitting Plug In Exhaust Pipe On Rear Muffler
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NOTE: Do not exceed the permitted pressure of 1 bar.
Connect a pressure gauge to a valve and subject exhaust system to 1 bar of excess pressure.

Fig 3: Connecting Pressure Gauge To Valve And Subjecting Exhaust System To 1 Bar Of Excess Pressure
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Coat individual connectors on the exhaust system (e.g. manifold flanges, -see Fig 4 - , clamping sleeves) with test spray in order to show up any leaks. Repeat test procedure if necessary.

Fig 4: Coating Individual Connectors On Exhaust System With Test Spray
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Pull off pressure gauge, remove both plugs.
NOTE: Replace fastening clamps for tailpipes.
Fit tailpipes again. To do this, put the new fastening clamps (in the new installation position) - Fig 5 shows right-hand side- with tailpipe onto the connecting pipe to the muffler. Slightly tighten the M8 hexagon nut with a commercially available long 3/8-inch socket wrench insert (a/f 16).
Installation position and tool for tailpipe fastening clamp (right-hand side)

Fig 5: Fastening Tailpipe Clamp (Right-Hand Side)
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Align tailpipes. To do this, position the tailpipes with respect to the rear spoiler; see ADJUSTING TAILPIPE or Adjusting tailpipe (as of MY '02) .
Tighten hexagon nuts of the fastening clamps for the tailpipes to the specified torque.

Fig 6: Tightening Hexagon Nuts Of Fastening Clamps For Tailpipes

Courtesy of PORSCHE OF NORTH AMERICA, INC.

Tightening torque for fastening nut (a/f 16): 30 Nm (22 ftlb.)