PSE retro fit and manual overide to MY2005 Boxster 987S

[berty987]

I've recently finished installing a full factory PSE (Porsche Sports Exhaust) on my MY 2005 boxster 987 S. Along with the install I've also added an additional switch to allow manual control of the PSE to prevent the ECU control reverting the system to quiet mode between 20 and 40 mph. The addition of the switch also allows the PSE to remain in the "loud " state when the ignition is switched off , so you no longer need to reselect the PSE or sport button on restarting the car (The mod will also apply to the Cayman and 997). The PSE rear silencers are a direct replacement for the 3.2 units and bolt straight on , no mods to the rear bumper, support hangars or tailpipe outlet are required. As my car was already equipped with sport chrono , the activation of the PSE is taken from this input (as per OEM installation) though the overide button also does the same job. Fitting and piping up the control solenoid in the engine compartment was also pretty straight forward as all the fixing points and vacuum lines are present. Only the piping to the vacuum control valves needed to be added , no drilling into vacuum manifolds is required. The only additional wiring required was between the rear ECU (DME) and the solenoid itself , just two wires. The overide switch I installed is a plug in adapter between the solenoid and the plug that supplies it , so its also applicable as a retro fit to standard factory fit PSE systems too (Boxster, Cayaman and 997).
Here are some pics.
PSE exhaust:

Standard Exhaust

Removing the standard exhaust : Note the top rear bolt is the most difficult to access. Wire brushing the threads and using plenty of penetrating / disassembly spray over a period of hours beforehand does help.

PSE solenoid installed and piped up. Takes vacuum from the change over valve solenoid between cylinders 3 and 4 by fitting a T piece.

Removing rear carpet from rear boot/ trunk allows access to unused rubber grommet. Wiring passed through here and then through to passenger compartment.

Wiring into the rear DME - plug locations C14 used for the PSE activation on early 2005 and 2006 cars.

I used a repair pin to add the connector for C14 in the plug

Here is the Kit I made up and installed for the manual overide switch of the PSE. It would also apply to vehicles already ftted with a PSE from the factory. There is no need to cut any of the existing wiring to install.

Manual overide switch for PSE. This is the easiest location to fit , requires the least work to run cables to.

Results : PSE switched "OFF" - quiet mode.



PSE switched "ON" - loud mode

 

[MHAK]

An excellent and helpful post, thanks. I have a 2006 Boxster S and was informed by two main dealers that Porsche does not produce a sports exhaust for the 3.2 987. The catalogue which one of the dealers showed me lists only a PSE for the 3.4 model 987. For this reason I bought an aftermarket system. I decided on the tubi system which I am very pleased with. It has settled in nicely and is not intrusive at motorway speeds. I hope that you are also enjoying yours.

 

[Rodney Naghar]

Excellent post.

ORIGINAL: berty987

I've recently finished installing a full factory PSE (Porsche Sports Exhaust) on my MY 2005 boxster 987 S. Along with the install I've also added an additional switch to allow manual control of the PSE to prevent the ECU control reverting the system to quiet mode between 20 and 40 mph. The addition of the switch also allows the PSE to remain in the "loud " state when the ignition is switched off , so you no longer need to reselect the PSE or sport button on restarting the car (The mod will also apply to the Cayman and 997). The PSE rear silencers are a direct replacement for the 3.2 units and bolt straight on , no mods to the rear bumper, support hangars or tailpipe outlet are required. As my car was already equipped with sport chrono , the activation of the PSE is taken from this input (as per OEM installation) though the overide button also does the same job. Fitting and piping up the control solenoid in the engine compartment was also pretty straight forward as all the fixing points and vacuum lines are present. Only the piping to the vacuum control valves needed to be added , no drilling into vacuum manifolds is required. The only additional wiring required was between the rear ECU (DME) and the solenoid itself , just two wires. The overide switch I installed is a plug in adapter between the solenoid and the plug that supplies it , so its also applicable as a retro fit to standard factory fit PSE systems too (Boxster, Cayaman and 997).
Here are some pics.
PSE exhaust:

Standard Exhaust



Removing the standard exhaust : Note the top rear bolt is the most difficult to access. Wire brushing the threads and using plenty of penetrating / disassembly spray over a period of hours beforehand does help.

PSE solenoid installed and piped up. Takes vacuum from the change over valve solenoid between cylinders 3 and 4 by fitting a T piece.

Removing rear carpet from rear boot/ trunk allows access to unused rubber grommet. Wiring passed through here and then through to passenger compartment.

Wiring into the rear DME - plug locations C14 used for the PSE activation on early 2005 and 2006 cars.


I used a repair pin to add the connector for C14 in the plug



Here is the Kit I made up and installed for the manual overide switch of the PSE. It would also apply to vehicles already ftted with a PSE from the factory. There is no need to cut any of the existing wiring to install.

Manual overide switch for PSE. This is the easiest location to fit , requires the least work to run cables to.



Results : PSE switched "OFF" - quiet mode.

http://s260.photobucket.com/albums/ii20/berty987/PSE/?action=view&current=MOV00088.flv


PSE switched "ON" - loud mode

http://s260.photobucket.com/albums/ii20/berty987/PSE/?action=view&current=MOV00089.flv

 

[berty987]

ORIGINAL: MHAK

An excellent and helpful post, thanks. I have a 2006 Boxster S and was informed by two main dealers that Porsche does not produce a sports exhaust for the 3.2 987. The catalogue which one of the dealers showed me lists only a PSE for the 3.4 model 987. For this reason I bought an aftermarket system. I decided on the tubi system which I am very pleased with. It has settled in nicely and is not intrusive at motorway speeds. I hope that you are also enjoying yours.

Thanks for the support. Yes I was also told the pre 2007 models (3.2 and 2.7) were not able to have the sport exhaust fitted, but I realised that the rear silencers are identical in terms of fitting between the cayman and boxster 987 models over all years. My original plan was to fit the rear silencers and then install my own control system. After fitting i researched some more and found that a complete integration was possible , so went the extra step , but retained the switch as a manual overide.