slicky rick

For 997.1 owners is it exactly the same procedure? Heard that there was a headache plug in the 997.1. Apparently from our op, there is none in the 997.2

Bruce In Philly

Thank you very much. I just did mine today using your instructions...fantastic! .... some finer points from a rookie perspective:

1) Ignition packs screws - to keep them from dropping between the heat shield and engine, I jammed a shop towel in there first.... worked perfectly.
2) I used a few extenders for my ratchet wrenches and a swivel joint for a screw or two
3) That top nut on the exhaust/cat joint.... sheeeeesh!!! I almost gave up trying to get it off. They were the only nuts that were rusted up. Make sure you soak them with a penetrating oil for at least a few hours. I purchased some simple S wrenches from Harbor Freight and the teeth in the wrench socket are rounded... the wrench immediately rounded the nut. I then used a socket set I had from ACE that allows a bolt to pass through the head and had a full hex socket, and accessed the nut by putting the entire wrench above the pipes. I could only move the wrench 1 or 2 clicks of the ratchet.... just horrible... I think I spent about 1/2 hour on one nut.
4) I didn't need to remove the exhaust tips (2009 C2S). I took the strap bolts off of one and had trouble getting the tip off so I went ahead and just tried to pull the muffler out.... no problem at all.
5) You have to remove the wheel to get the muffler out and for easy access to the plugs. I had a grease pit and figured I could do it all from below, but you can't... although access from below makes taking out muffler bolts very easy.

Thanx again! Great job.

Bruce in Philly

cool flash

I am about to embark on this DYI and prepared the corresponding nuts with penetrating oil.

The top nut on the cat/exhaust joint does have me worried some! I dont see how I can get any leverage up in there to get that first crucial turn. Any ideas?

Thanks.

Regards,
CF

DGrayling

For me this was the most frustrating part of the entire job . . . that is why I ended up buying a set of Craftsman elbow ratcheting wrenches from the local True Value hardware store. It was easy with this wrench. Thus some of the money I saved by doing this DIY was thus spent on a few new tools.

cool flash

Thanks for your quick reply.

Looking at the explosion drawing in the electronic parts catalog I am now considering removing the 2 long vertical bolts that hold the brackets to the muffler. That way I would be able to avoid the 3 bolts at the cat alltogether.

What is your take on that approach?

DGrayling

That might do it although I have never tried it. Please let us know if this works.

cool flash

Okay, I am progressing: got the top nut off with a half moon wrench. Slowly but surely.

Loosened the exhaust tips bolt all the way (e12) but for some unknown reason can't manage to pull tips off. It swivels around freely but wont come off. Is there a trick to this? The easiest of all steps and I am actually stuck. Arghhh!!!! It's the Carrera base model tip with single oval shape.

Thanks guys.

Regards,
CF

stefang

Pull harder - and use some lube. There's an inner sleeve, so you can adjust the angle of the tips.

cool flash

Thanks. I will try that.

The top nut on the other side (passenger) is not coming off. It doesnt look rounded off but it seems smaller. Wrench is not getting any grip....neither is a socket.

I was really hoping to get the two top nuts done before I go to sleep but no such luck.

Bruce In Philly

You don't need to take the muffler tips off. I could not get them off, so I stopped trying. The muffler comes nicely out of the wheel well.

If the nut you are talking about is that evil nut (the triad), I had to put a socket set above the pipes and manipulate it with my finger tips. The socket I used was a full hex and not a toothed job. The toothed S wrench I put on it only made things worse by rounding the nut.

Peace
Bruce in Philly

cool flash

Thanks Bruce.

I will leave muffler tips as they are for now.

The evil nut will have to go. I will get a wrench with a head that can be rotated so that I can use a full hex socket as you advised.

cool flash

As always in life having the right tools and a little perseverance goes a long way. That ratchet is quite a gem and cost a mere 26 Euros.

I soaked that nut maybe 5 times in the last 2 weeks as well.

So now I am ready to finally proceed...

Regards,
CF

turbozv

Good job! Very useful information, I followed your instructions and finished the job in 2.5 hours

Thanks again!

bob hoern

How long did it take you to do the complete job including removing and reinstalling the exhaust?

cgfen

Thanks for posting this.
I'm on board for doing this next weekend.