Replacing the Boxster's Porsche Sports Exhaust

[@mattbeattie981]

Great video. My GTS is from Harbour too. Had the same issue, same great service. Autotechnics replaced my full PSE last month. Looking to Ceramic coat the system before it gets dirty 👍

[@christianpratt]

Thanks Matt. Seems we’re in the same boat! I need to get some suitable grease or product on mine too.

[@Peter-Oxley-Modelling-Lab]

I recommend to lubricate both the pivot points on the valves twice a year to stop them seizing. 👍🏻

[@christianpratt]

@@Peter-Oxley-Modelling-Lab It’s good advice Peter - thank you. 👍

[@hughrobertson7242]

I’m in the same boat with mine. Got my 981 only 7 days ago and thought the offside valve was a bit sticky ( but still sounded fab while driving) so I coated mines with Molyslip high temp copper grease to try and make sure they were going to be ok. Gave the actuator piston a good bit of encouragement to move in and out and the little actuator arm snapped in my fingers!! So I’m away to call my local OPC to get it booked in for repair. ( Porsche approved warranty 👌🤞🤞)

[@christianpratt]

A not uncommon scenario, I believe. 🙄 Good news on the warranty; it’s not a part that really should be breaking, is it? Will be getting both sides of mine protected pronto, for that reason.

[@hughrobertson7242]

All too common from what I read on the forums. I can scarcely believe that given Porsche’s design engineering excellence and experience that some bright boffin in Zuffenhausen hasn’t come up with a better design. Could have saved the company a lot of money from replacing faulty actuators with cats-back replacements. The best solution would be to make the valve assembly a consumable part requiring replacement every 40,000 miles and design it accordingly so it can be unbolted from the pipes and swapped out. I’m no design engineer ,but it’s got me thinking of ways to try and protect that valve assembly and actuator piston/arm from the worst of the elements. Again, it doesn’t need to be as exposed as it is. Frustrating and unnecessary really.

[@christianpratt]

@@hughrobertson7242 A good summary. Either engineer the system to be ‘lifetime’ or acknowledge it will fail and make it far easier to replace. As you suggest.

[@harbourcars911]

Great report, very nice to watch thank you.

[@christianpratt]

Thanks folks - and thanks for all your help! 😀

[@Ollie_5]

The PSE valves on my 981 Cayman GTS started sticking at just over 30k miles. Porsche couldn’t guarantee that it wouldn’t happen again with a new exhaust. So rather than pay for a new exhaust for it only to happen again, Cameron Sports cars did a great job and stuck the valves open and sealed off the vacuum with a silicon plug so they remain open all the time. I can still control the volume inside the cabin by switching the sound imposer valve on/off through the PSE button.

[@christianpratt]

Sounds like a sensible option, if you’re happy with always-on option. Mine could yet fail again though I’m obviously hoping that won’t be for a while!

[@scotdoc]

Great video thanks. I am about to replace my PSE on my Cayman for the same reason. I'll be lubricating the spindles of the valves with Gleitmo spray grease (approved by Porsche for turbo linkage lubrication on the 997TT). Also some Gleitmo grease on the bolts and nuts. Stainless seems sensible way to go too. Enjoy the flat 6 symphony!

[@christianpratt]

Useful to know about Gleitmo - thank you. Sound great don’t they!

[@stephenmcnamara4393]

You are right about changing the exhaust bolts where they join the manifold for stainless as they deteriorate quite quickly & if not changed they will eventually rot and the exhaust will come away I have put double nuts on mine The factory fitted bolts are a real pain to get out I had mine done at an Indi

[@christianpratt]

Thanks Stephen. Yes, I’ve been caught out before (on another car) by Porsche’s poor choice of material for their fasteners. Knowing they’ve now been replaced is very reassuring.

[@NorthHoustonCityLimits]

Hi and thanks for the videos and your commentaries they are great! I have a 2016 Cayman base with the 2.7. My car has the Sport button which i assume is the sports exhaust.When i got the car it had the singe fat exhaust tip which I replaced with the Graphite Black dual tip by Fab Sport X Flow and it looks great. However I'm not happy with the sound and was wondering what you would suggest to get this car louder. I live in the USA. Thanks in advance and thanks for sharing your videos they rock!

[@christianpratt]

Hi Frank. Long reply coming up… Firstly, thanks so much for commenting - it’s appreciated. I really enjoy the chat with fellow Porsche fans. I’ve had a quick look at your channel and your earlier shorts of the Cayman (great-looking car!). From the looks of things you don’t have Sports Chrono - I can’t see the clock on the dash. So it’s just the standard Sport button. I’m sorry to have to tell you that the Sport button alone doesn’t mean you have a sports exhaust. The sports exhaust (PSE) is very definitely a separate cost-option, and it brings with it it’s own button on the console - the one that is often referred to as the sunglasses button. (You can see my own buttons, including the PSE, on my separate video about the Boxster’s buttons.) So your Sport button won’t have any effect on your exhaust. It’ll only tweak the throttle response and the PSM. (The forums suggest it also moderates thermostat settings.) The good news is that your car sounds pretty tasty already, from what I can hear (the 981 engines all sound good, irrespective of size and tune) - and that’s with the entirely standard exhaust muffler setup. You say you’re not happy with it - so either you’re after a different tone, or more volume - or both! Tone is subjective - but any modifications will change tone, so you need to be sure you listen to any possible set-ups. Adding volume/noise is achieved in two ways; reducing the gas flow restriction represented by the silencer, and reducing the restriction imposed by the catalytic convertor. There are no particulate filters on the 981. Cutting to the chase, you can straight-pipe the car, but that’s going to be crazy loud and might not be legal in Texas for road use. Swapping out the headers and adding high-gas flow cats. (eg. 200 cell cats) will get you more volume, but is expensive. Swapping out the standard silencer (muffler) is your best bet; I’m sure Fabspeed offer an alternative that will be a bit louder, and sound - different. There are plenty of other similar aftermarket options. Soul is popular in the States. FVD in Europe. If you want a switchable exhaust (quiet/loud - as per PSE) then those brands will also oblige. Given your car is light and lean, I’d favour a non-switchtable muffler replacement, while keeping your new X tips. Hope that all makes sense. Happy to answer any other questions.

[@NorthHoustonCityLimits]

@@christianpratt Hi Christian, thanks for the long comment and that was well received!! I appreciate the suggestions and that was just exactly what i needed. Sounds like you suggested to stay with the Fab product so that i can still use my exhaust tips. Thanks for the clarification also on what I have. Now I know! Sometimes it can be confusing. Definitely don't want it to be obnoxious I have a Harley for that! They say loud pipes saves lives and I believe that one. Thanks very much for your advice! you rock! Cheers mate!!

[@German-Whip-V8]

Been looking forward to this, don't currently have a boxster but giving it some serious consideration.

[@christianpratt]

Thanks for commenting. Do you need any more encouragement to get a Boxster? 😃

[@oddballbender]

Get one. They are wonderful

[@hughrobertson7242]

Drive one-drive it like you stole it and you will put a deposit down immediately 😜👍

[@hughrobertson7242]

Perfect walk-through of PSE and its operation-kind of an ‘idiots’ guide sir! 👍 Get the valve actuators coated with high temp copper grease to extend the life expectancy.

[@christianpratt]

Thanks Hugh - glad you found it useful. Grease - yup! 😀

[@FA-fq6co]

Excellent and informative video, thank you!

[@christianpratt]

Glad you found it useful. 👍

[@allynwithington]

Amazing timing - I just had mine replaced too. Got mine from Design 911, as one side seized and one actuator snapped. All good and back to normal now, with the right noises happening. Great video walk through - I was wondering if you'd have a go yourself at fitting it. (I didn't) Loving this series..

[@christianpratt]

Thanks Allan. Glad you’re enjoying the series; hearing that really does make my day. As I understand it, fitting the PSE isn’t difficult, but it’s best done on a ramp, which is where my home resources fall short. Some jobs are best done by the right people with the right tools! It’s good to get everything back to working order isn’t it? Happy PSE-ing!

[@s10lucky]

Great video. Mines from Harbour cars too 👍

[@christianpratt]

Thanks for the comment. Lots of love for Harbour Cars.

[@radiatorgrillestore]

Great info! Checked ours and the passenger side (US) same side as yours was sticky. Interesting that it was the same side.

[@christianpratt]

Interesting! Hope you’re able to resolve it without spending too many $$$ 😳

[@981_pdk3]

Nice video I like the pse sound and what you fixed. I fitted the FVD exhaust and it’s been great though like you mentioned it initially had some drone at around 2000 rpm but I got rid of it by fitting some sound deadening at the rear of the boot in my Cayman.I believe that the cats are same part number as GT4 at least on my Cayman 981,not sure about the Boxster. This is really good as you get quality track tested parts.

[@christianpratt]

FVD make decent kit don’t they? I have my eye on their 200-cell headers. Glad you solved the drone. I’m not sure about the GT part numbers, but the standard PSE is the same item for both Boxster and Cayman, which makes life a little easier.

[@981_pdk3]

@@christianpratt yes the kit through FVD is made by M&M in Germany who make the 911 Cup Car exhausts.

[@oddballbender]

Great video. Mines from Harbour cars also

[@christianpratt]

Thank you. Harbour have a few customers round these parts!

[@YosiSchiffer]

Hi Chris, great informative video… thank you. Can you please share were did you ordered the new sport exhaust system. I like to do the same job on my Boxster 981S and can’t fine a system in stock anywhere… Thanks in advance 👍

[@christianpratt]

Hello Yosi. Glad you enjoyed the video. The dealership I bought the car from - Harbour Cars - sourced the exhaust. I don’t know where from, however. I’ve bought various other parts from Design911 before; they’re well worth asking… www.design911.com/p/sports-exhaust-system-pse-porsche-981-boxster---981c-cayman-cars-with-sports-tail-pipes/

[@hardy5235]

Interesting, so what did the exhaust sound like when PSE was off with the sticky valve compared to how it sounds now ? My PSE, probably the original, is a bit boomy/droney in the 2/2500 rev range compared to some. Valves appear to be working OK. It's in a Cayman which I feel is a more resonant environment compared to the Boxster. I also noticed an image of the road on the Orwell Bridge looking west at sundown 🙂

[@christianpratt]

Thanks for your comments Hardy. When the sticky valve was sticking, it meant that PSE was effectively off on that side of the system. So running with the PSE switched off (on the centre panel) made no practical difference to the sound. With PSE switched on, but the valve still sticking, I'd get the full-fat sound but less intensity, compared with the now fully-working PSE. All-in, with PSE off - no change. With PSE on an full load - similar, only better! The greatest improvement is with PSE on but at light load and low engine and road speeds, when you can finally hear the engine burbling and rumbling nicely. And then there's the sound symposer too, which kicks in variously depending on mode and speed... (And yes, the Boxster is a little more tolerant of drone, I suspect.) Orwell Bridge - good spot!

[@WFORacer]

You read my mind. Mine doesn’t seem that loud when button is pushed. Many thanks sir.👏👏👏 I have a 981S so the plunger cannot simply be replaced?

[@christianpratt]

In my conversations with more knowledgeable folk, it turns out that it’s hard to diagnose what actually goes wrong with the PSE. Yes, the actuator itself can fail and they can indeed be replaced. But it’s also clear that the small lever and pivot point are vulnerable to corrosion, and that the valve inside the exhaust simply gets sticky and won’t easily open. It’s tempting to think the actuator is stuck when actually it’s the valve it’s attached to that is. In truth, all a bit frustrating. But that’s cars!

[@WFORacer]

@@christianpratt thank you for the cognizant reply. May I trouble you with another question, what is the part number for replacement?

[@christianpratt]

@@WFORacer My pleasure. The PSE >without< the exhaust tips is 981.044.200.03. You can buy the same with exhaust tips included too (there’s a different part number for that.) In both cases that number equates to the full cat-back system, ie. the left AND right silencers together. The PSE is still listed on the Tequipment part of the Porsche website, as an aftermarket accessory.

[@WFORacer]

@@christianpratt again thank you sir, the tips on mine are in good shape. Mine are currently chrome but having them black chromed.

[@christianpratt]

@@WFORacer Nice!

[@rogernorman2621]

I have a similar system by eisenamm which is a single box with control valves each side. I always thought that the valves needed to be pushed back against the spring for maximum sound but you say its the other way around ie. noisier in the natural resting position? I have wired mine up to hold them against the spring action so do I need to unwire them?

[@christianpratt]

Hi Roger. Thanks for commenting. Unless I’ve totally got the wrong end of the stick, the Porsche system is louder/sportier when the rod is fully extended out of the actuator body. (This the resting state when the engine is switched off.) The vacuum pulls the rod into the body (which you can hear, if you know what you’re listening for, just after you start the engine); which is then the default PSE ‘off’ position once the engine is running. However - your system may work differently. I’m not familiar with Eisenamm, and their valves and actuators may work the other way around. Best check with somebody who knows that specific system before you get the wire cutters out!

[@rogernorman2621]

@@christianpratt Thanks for your prompt reply Christian. My Boxster is a 986 . I can not find a switch anywhere so I assume the valves work purely on the vacuum produced. Silly question but might help answer the in or out argument. Is the most vacuum produced on tick over rather than flat out? In other words does the rod go in on tick over or the other way round?

[@christianpratt]

@@rogernorman2621 On the OEM 981 PSE exhaust, the application of vacuum appears to be binary, ie. there is only two positions for the rod - in and out - irrespective of engine speed (idle or higher rpm). So the rod is >in< at tickover (any engine speed - see above) if PSE is switched off. Switching PSE on - at any engine speed - will interrupt the vacuum, allowing the rod to extend. If you don’t seem to have a switch it does beg the question: what is mechanically activating the valving, and what triggers that activation?

[@DMR777-p5o]

excellent thks

[@christianpratt]

My pleasure!

[@justinmc722]

Hi Chris, great video and I have got a new one on my new car too. Get some lubricant on that straight away I have gone for a high temp ceramic lubricant and I see from another post Porsche do Thier own version. I plan on coating that area to keep it fully protected. Would like to have a personal chat with you how can I make contact?

[@christianpratt]

Thanks for the comments. Definitely need to protect my new actuators! Will get on that…

[@christianpratt]

Look me up on Twitter - @PrattStuff - or LinkedIn - and send me a message. We can go from there.

[@allynwithington]

@@christianpratt I was thinking of Lanoguard as an option here... but just not sure

[@christianpratt]

@@allynwithington I understand that, whatever the product, it needs to be tolerant of / designed to work at high temperatures.

[@Trophy_R]

You could have just taken the vacuum pipe off the valves and they will stay fully open.

[@christianpratt]

@@Trophy_R True! Though I wanted the original system to work properly, hence the replacement.

[@cayman9815]

Cayman & PSE gives “drone”

[@christianpratt]

I wonder whether that’s uniquely a Cayman thing? I’ve done some long steady speed drives in the Boxster and while there’s plenty of tyre and wind noise (the roof is good but not that good!) I’ve never noticed exhaust drone specifically.

[@ortontom]

They always go wrong, like the electronic engine mounts. At this age would suggest non chrono, no PSE...problem solved. On non GTS models.

[@christianpratt]

True enough. Complication doesn’t always mean improvement. 😕

[@Jay-xr3sb]

The mounts can be replaced with passive ones, mine is under warranty so I'm covered for now. I don't think I'll owner the 981 without an extended warranty, but if I do I'll go for an ecu tune, gt3 steering software, passive mounts, specialist service and save the warranty money towards a new pse of it ever fails. The only real worry is pdk, but they seem solid.

[@christianpratt]

@@Jay-xr3sb That sounds like a sensible forward plan. PDK needs a (twin) oil change at the scheduled intervals, as I understand it. Otherwise seems strong. If my active mounts fail, I will likely go passive, it's true. It's hard to discern their 'active' effect, which kinda seals the replacement deal.