Leak test

1. Remove tailpipe on the rear muffler. Unscrew an M8 pan-head screw (hexagon socket a/f 6) on the 2.7 I tailpipe -arrow-  in Fig 1 or an M8 hexagon-head bold on a 3.2 I tailpipe -arrow-  in Fig 2 and remove the tailpipe.

   Boxster 2.7L tailpipe 

   Fig 1: Removing Tailpipe On Rear Muffler (2.7L Tailpipe)

   Courtesy of PORSCHE OF NORTH AMERICA, INC.

   Boxster 3.2L tailpipe 

   Fig 2: Removing Tailpipe On Rear Muffler (3.2L Tailpipe)

   Courtesy of PORSCHE OF NORTH AMERICA, INC.
2. 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 3: Inserting Plug In Exhaust Pipe On Rear Muffler

   Courtesy of PORSCHE OF NORTH AMERICA, INC.
   NOTE:

   • Do not exceed the permitted pressure of 1 bar.
3. Connect pressure gauge to a valve and subject exhaust system to 1 bar of excess pressure.
   Fig 4: Connecting Pressure Gauge To Valve

   Courtesy of PORSCHE OF NORTH AMERICA, INC.
4. Coat individual connectors on the exhaust system (e.g. manifold flanges, clamping sleeves) with test spray in order to show up any leaks. See Fig 5 . Repeat test procedure if necessary.
   Fig 5: Coating Connector With Test Spray

   Courtesy of PORSCHE OF NORTH AMERICA, INC.
5. Fit tailpipe again. Align tailpipe to the contour of the rear spoiler (gap dimensions).

Tightening torque: 23 Nm (17 ftlb.)