3.14

Install inner door sill trim at the left. 
Workshop Manual '680519 Removing and
installing inner door sill trim'

Install DME control unit and holder.  Workshop
Manual '247019 Removing and installing DME control unit'

Tequipment

Figure 23

Installation and Conversion Instructions

911 (991)
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2

CAUTION
Hot components
•

Risk of burns



Let hot components cool down.



Wear personal protective gear.
5

Remove exhaust system.
5.1

Remove heat shield for turbocharger at the
left  Figure 24 -2- and right.

Figure 24
WARNING
Danger of objects or loads falling down
•

Risk of squashing or crushing



Secure components to prevent them from falling down.

Information
The exhaust system must only be removed with the help of another person.
5.2

6

Remove exhaust system.  Workshop Manual '260119 Removing and installing exhaust
system'

Install vacuum line.
6.1

Assemble vacuum line.
6.1.1

Cut off 3 sections (length: 25 mm, 70 mm, 350 mm) of plastic tube
(9P1.251.838.A).

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Installation and Conversion Instructions

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Information
Insert plastic tubes at least 12 mm into the steel flexi-pipe/moulded hose or
connecting hose.
6.1.2

Connect components together as
shown in Figure 33.
1
2
3
4
5
6
7
8
9

–
–
–
–
–
–
–
–
–

190-mm steel flexi-pipe
One-ear hose clamp
Plastic tube (25 mm)
Moulded hose
Plastic tube (70 mm)
50-mm hose
T-piece
Plastic tube (350 mm)
Moulded hose

Press one-ear hose clamp  Figure
25 -2- together.
6.1.3

Figure 25

Insert metal vacuum line
(9P1.251.838.A)  Figure 26 -3as far as the marking (white) 
Figure 26 -arrow a- into the T-piece
 Figure 26 -4-.
Insert metal vacuum line as far as
the marking (white)  Figure 26
-arrow a- into the 93-mm steel
flexi-pipe  Figure 26 -1-.
Press one-ear hose clamp  Figure
26 -2- together.

6.2

Figure 26

Secure assembled vacuum line  Figure 27
-1- to the engine carrier with four clips 
Figure 27 -2-.

Figure 27

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Installation and Conversion Instructions
6.3

911 (991)
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2

Clip cable holder  Figure 28 -1- to the
engine carrier  Figure 28 -2-.
Clip steel flexi-pipe  Figure 28 -2- into cable
holder.

7

Install sports exhaust system.

Figure 28
7.1

Install right catalytic converter  Figure 29
-1- with a new seal on the turbocharger 
Figure 29 -3- and secure with a new hexagon
nut  Figure 29 -2- to prevent it from falling
down.
Information
•

When re-installing oxygen sensors, only
grease the thread with lubricant.

•

New oxygen sensors have already been
greased and the thread is installed with a
protection cap.

Figure 29
Information

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Installation and Conversion Instructions

The oxygen sensors can only be screwed by 4 – 5 turns without disconnecting the electric
plug connections.
7.2

Install oxygen sensors upstream of catalytic
converter  Figure 30 -1- and downstream
of catalytic converter  Figure 30 -2- on the
right catalytic converter.
Tightening torque 50 Nm (37 ftlb.)
+/-8 Nm (+/-6 ftlb.)

7.3

Install left catalytic converter with a new seal
on the turbocharger and secure with a new
hexagon nut to prevent it from falling down.
Information
The oxygen sensors can only be screwed by
4 – 5 turns without disconnecting the electric
plug connections.

7.4

Install oxygen sensors upstream and
downstream of catalytic converter on the left
catalytic converter.
Tightening torque 50 Nm (37 ftlb.) +/-8 Nm (+/-6 ftlb.)

7.5

Install clamping sleeve at the left  Figure 31
-1- and right on the catalytic converters.

Figure 30

Install clamps  Figure 31 -2- on the main
silencer.

Figure 31

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Information
•
7.6

Apply a light coating of high-temperature grease (e.g. Optimoly HT, Part No.
000.043.004.00) on the clamp or pipe adapter before installation.

Guide main silencer  Figure 32 -1- into the
catalytic converter at the left and right with
the help of another person  Figure 32 -a-.
Slide clamping sleeves  Figure 32 -2- over
the pipe adapters.

Figure 32
7.7

Install restraining straps  Figure 33 -1-.

Figure 33
7.8

Slide vacuum line at the left and right 
Figure 34 -1- onto the exhaust flap control
box and press one-ear hose clamp  Figure
34 -2- together.

Figure 34

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7.9

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Installation and Conversion Instructions

Position main silencer with lock  Figure 35
-1- on the main silencer holder  Figure 35
-2- ( Figure 36 -arrow-).
Tighten restraining straps.
Tightening torque 15 Nm (11 ftlb.) +/-10
%

Figure 35
7.10

Install and tighten the remaining hexagon
nuts  Figure 36 -1- securing the catalytic
converters to the turbocharger.
Tightening torque 25 Nm (19 ftlb.) +/-10
%

Figure 36

Figure 37

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Information
It is important to ensure that the clamps
and pipe joiners are tightened in horizontal
position.

Clamps must be horizontal when tightened
7.11

Tighten clamping sleeves  Figure 38 -4and clamps  Figure 38 -1-.
7.11.1

Tighten clamping sleeves.
Tightening torque 30 Nm
(22 ftlb.)

7.11.2

Tighten clamps.
Tightening torque 55 Nm
(41 ftlb.) +/-10 %

Figure 38
7.12

8

Install heat shield for turbocharger at the left

 Figure 39 -2- and right.

Convert heat shield on bumper.
8.1

Remove standard heat shield from rear
bumper.

Figure 39

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8.1.1

Installation and Conversion Instructions
Unscrew tapping screw  Figure
40 -1- and remove bracket 
Figure 40 -2-.

Figure 40

8.2

8.1.2

Unscrew hexagon nuts  Figure 41
-1- and remove rear supports 
Figure 41 -2-.

8.1.3

Disconnect heat shield and rear
bumper.

Assemble new heat shield and bumper.

Figure 41
8.2.1

Position rear support  Figure 42
-1- on the heat shield. Screw on
and tighten hexagon nuts  Figure
42 -2-.
Tightening torque 9.7 Nm
(7.5 ftlb.)

Figure 42

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911 (991)

Installation and Conversion Instructions
8.2.2

9

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Position fastening bracket  Figure
43 -1- and screw in and tighten
tapping screw  Figure 43 -2-.
Tightening torque 2.8 Nm
(2 ftlb.)

Convert rear apron.

Figure 43
9.1

Remove rear skirt.  Workshop Manual
'636819 Removing and installing rear skirt'

9.2

Make cut-out for new rear skirt.
9.2.1

Mark rear apron.

Figure 44

Figure 45
1
X
Y

– Bar
– Distance from bar: 5 mm
– Dimension = 16 mm

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911 (991)
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