Exhaust problems...

[Rom]

Hi all,

My '99 Boxster sounds like a Harley Davidson Edition right now, and I just wanted some opinions of common Boxster-specific exhaust faults before I get under and start removing parts. The car went from sounding normal to sounding like there is no exhaust at all within about 5-10 miles. It's coming from the rear left side of the car, and does not appear to be from the main exhaust assembly. I'm guessing an exhaust gasket either between the head and the header, or between the header and the first cat has reached its end of life...

Are there any caveats with removing the Boxster exhaust system I should know about? I can reach the 3-to-1 header pretty easily, and should be able to remove it with no trouble, but if the problem turns out to be some where else, is there a description of the process somewhere? I don't want to go re-inventing the wheel!

Thanks in advance for any comments!

Shash

[boggtown]

Isolate it, get it on a lift or jack it up and feel your hand around until you feel the "wind". If its as loud as you make it out to be you shouldnt have a problem seeing/hearing/feeling the leak.

[Rom]

I found the issue - I took off the manifold, and where it connects to the flange (the end that bolts to the cat), the pipe has completely sheered off! Since there have been no modifications, and I didn't hit anything under the car, that seems like a design flaw (i.e. it looked like circular stresses as the manifold, which is rigidly bolted to the engine, moves in a slight circular motion with acceleration against the cat, which is bolted to the chassis - of course, it could also indicate worn engine mounts though...). I saw one other person report this issue on the forums - although I don't know how common it is overall...

Anyway, I could try welding it back, but I think I'll just try to find another manifold...

Thanks!

S.

PS - boggtown - thanks for the feedback, but I was aware how to find the leak - I just wanted to know if there were any Boxster-specific issues before I went in!

[Rom]

I spoke with the Porsche dealer here and they said they've "never seen this issue"... Although I've seen a few posts now with people having this issue on the internet - although they all seem to be older Boxsters, so it wouldn't surprise me if the dealers never see it (since people are unlikely to go to a dealer to have this fixed!).

Anyway, anyone happen to have a stock manifold for a 99 Boxster (or equivalent) that they don't want (preferably in the California Bay Area)? :)

Thanks!

Shash

[Tool Pants]

Some of use Boxster owners went to Laguna Seca last month and we got to see the Boxster spec cars race. 1997-1999 2.5s is the spec race car. They take everything out of the car to reduce weight and then make modifications to what is left.

I thought this was great, a great source of parts for us 2.5 owners. :rolleyes:

But I asked one of the guys if they were permitted to use headers. He said no, they are required to use the stock manifolds. But you might ask if someone has an extra manifold. There is at least one local owner, Bill Pickering in Campbell.

http://www.boxsterspecracing.whsites.net/phpBB2/

[Rom]

Some of use Boxster owners went to Laguna Seca last month and we got to see the Boxster spec cars race. 1997-1999 2.5s is the spec race car. They take everything out of the car to reduce weight and then make modifications to what is left.

I thought this was great, a great source of parts for us 2.5 owners. :rolleyes:

But I asked one of the guys if they were permitted to use headers. He said no, they are required to use the stock manifolds. But you might ask if someone has an extra manifold. There is at least one local owner, Bill Pickering in Campbell.

http://www.boxsterspecracing.whsites.net/phpBB2/

Thanks - I'll try them out!

Shash

[Tool Pants]

Or, try Todd. http://www.renntech.org/forums/index.php?showtopic=15988