Installing the Akrapovic Evolution Line on your 718 Cayman transforms both the driving experience and the vehicle's visual presence. This weight-saving, high-performance exhaust system, crafted from titanium with carbon-fiber tips, delivers a noticeably deeper, more aggressive exhaust note while reducing overall weight by up to 40% compared to the factory system. The step-by-step instructions below will guide you through a safe, successful installation, ensuring you unlock the full potential of your mid-engine Porsche. Always refer to the official Akrapovic manual specific to your model year for torque values and component diagrams.

Tools and Materials Needed

Gathering the right equipment before you start prevents delays and ensures precision. The following list covers everything from standard hand tools to safety gear.

  • Akrapovic Evolution Line Exhaust Kit – Complete with downpipes, center muffler section, rear muffler cans, carbon-fiber tips, all hardware, and springs.
  • Metric socket set – 10 mm, 13 mm, 15 mm, 18 mm, and 21 mm sockets (deep and shallow).
  • Torque wrench – A quality torque wrench capable of 15 – 70 Nm (check Akrapovic specs).
  • Jack and jack stands – A low-profile floor jack and at least four jack stands rated for your Cayman’s weight.
  • Penetrating oil (optional) – Helps loosen rusted or stubborn bolts, especially on older vehicles.
  • Safety glasses and gloves – Protect hands and eyes from debris, sharp edges, and hot exhaust components.
  • Heat-resistant mat or exhaust hanger removal tool – For safely supporting the exhaust and releasing rubber hangers.
  • Trim removal tools – Plastic pry tools to remove the rear diffuser without scratching paint.
  • O₂ sensor socket – A 22 mm slotted socket for removing and reinstalling oxygen sensors.
  • Ratchet straps or exhaust jack – To safely lower and raise heavy exhaust sections.
  • Anti-seize compound – Apply sparingly to exhaust bolts and sensor threads during reassembly.

Preparation Steps

Proper preparation protects your 718 Cayman and ensures the installation proceeds smoothly. Follow these steps before touching any exhaust hardware.

Workspace and Vehicle Safety

  • Park on a level, well‑lit concrete or asphalt surface. Avoid gravel or uneven ground.
  • Engage the parking brake fully.
  • Place wheel chocks behind the rear tires (since you will be working mainly at the back, chocking the front wheels adds stability).
  • Disconnect the battery negative terminal. On the 718 Cayman, the battery is in the front trunk. Removing power prevents accidental short circuits and avoids triggering fault codes while sensors are unplugged.
  • If your vehicle has a manual transmission, leave it in gear (first or reverse) for extra security.

Vehicle Lift and Access

  • Raise the car using a jack. The 718 Cayman has designated lift points on the side sills. Consult your owner’s manual for exact locations.
  • Place jack stands under the reinforced jack‑point pads. For exhaust work, raising all four corners provides the safest and easiest access. If raising only the rear, ensure the front wheels are chocked.
  • Lower the car onto the stands and give it a gentle shake to confirm stability.
  • Allow the exhaust to cool completely if the car was driven recently – wait at least 90 minutes.

Interior and Electrical Prep

  • Remove the key from the ignition and keep it away from the vehicle.
  • If your 718 Cayman is equipped with a sound symposer or active exhaust valves, note their wiring location. Disconnect any electrical connectors to the stock exhaust valves before lifting the car.

Removing the Stock Exhaust System

Removing the factory exhaust requires patience, especially on vehicles with accumulated road grime. Work methodically to avoid damaging oxygen sensors, heat shields, or mounting hardware.

Removing the Rear Diffuser

  • Using a trim removal tool, carefully pry off the black plastic rear diffuser. The diffuser is secured by several push‑clips and a few Torx screws (T25 or T30).
  • Place the diffuser in a safe location to avoid scratching it.
  • With the diffuser removed, you will have clear access to the rear muffler hangers and the exhaust tips.

Disconnecting the Oxygen Sensors

  • Locate the oxygen sensors: there are four on the 718 Cayman (two in the downpipes before the catalytic converters, two after).
  • Unplug each sensor connector by pressing the release tab and pulling apart. Clean the connectors with electrical contact cleaner if dirty.
  • Use an O₂ sensor socket to unscrew each sensor from the exhaust. Turn counter‑clockwise. If stuck, apply penetrating oil and allow it to soak for 10 minutes.
  • Label each sensor (e.g., “bank 1 upstream”) to simplify reinstallation.

Removing the Stock Exhaust Sections

  • Start at the downpipes. Loosen the V‑band clamps securing the downpipes to the turbo outlet flanges. Use a 13 mm socket for the clamp bolts.
  • Support the downpipe assembly with a jack stand or strap, then unbolt the downpipe from the lower bracket (usually a 15 mm bolt).
  • Lower the downpipes and remove them from the vehicle.
  • Next, unbolt the center section (the large resonator/muffler). Remove the bolts connecting the center section to the rear muffler cans (two 13 mm bolts per side).
  • Release the rubber exhaust hangers using pliers and a lubricant. There are four hangers supporting the center section and rear cans.
  • Carefully slide the center section out toward the rear of the car.
  • Finally, remove the rear muffler cans. Each can is held by two hanger brackets and a single 13 mm bolt to the rear subframe. Lower the cans one at a time.

Important: The stock exhaust is heavy – use a second person or an exhaust jack to handle the rear muffler section. Avoid letting the exhaust hang by the O₂ sensor wires.

Inspecting and Cleaning

  • With the stock system removed, inspect the turbo outlet flanges for gasket residue. Clean the flange faces with a Scotch‑Brite pad or fine emery cloth.
  • Check the rubber hangers for cracks or deformation. Replace any worn hangers with the new ones supplied in the Akrapovic kit.
  • Apply anti‑seize to the threads of the oxygen sensor bungs on the new downpipes (if they are not pre‑threaded).

Installing the Akrapovic Evolution Line

The Akrapovic Evolution Line for the 718 Cayman is designed as a direct bolt‑on replacement. Follow the order below to avoid fitment issues.

Downpipe Installation

  • Position the Akrapovic downpipes (with integrated 200‑cell sport catalysts) onto the turbo outlet flanges. Use the provided springs and V‑band clamps.
  • Hand‑tighten the clamp bolts initially – do not fully torque them yet.
  • Install the lower mounting bracket bolts (supplied hardware). Torque to 20 Nm.
  • Reinstall the oxygen sensors into the bungs on the downpipes. Use the supplied spacer washers if required (some downpipes include them to prevent CEL from the low restriction). Torque sensors to 42 Nm.

Center Section and Connecting Pipes

  • Attach the center muffler section (the large X‑pipe or crossover) to the downpipes using the supplied slip‑joints and clamps. Do not tighten fully.
  • Slide the rear connecting pipes into the center section outlets.
  • Mount the rubber hangers onto the new exhaust studs. The Akrapovic system uses specific hanger positions – match them to the factory hanger locations.
  • Support the center section with a jack, then loosely install the hanger bolts (13 Nm).

Rear Muffler Cans and Tips

  • Slide each rear muffler can into the connecting pipes. The cans are handed – note the inlet and outlet orientation (the valve actuator cutout should face upward).
  • Attach the exhaust valves (if your kit includes active valve control) by connecting the rod to the valve lever. Akrapovic provides a new valve cable kit for the 718.
  • Bolt the cans to the factory hanger points. Torque to 20 Nm.
  • Fit the carbon‑fiber exhaust tips over the tailpipe outlets. Gently tighten the set screws to secure them but do not overtighten – carbon can crack if stressed.

Adjusting and Torquing All Connections

  • With all components loosely assembled, check clearances around the rear bumper, diffuser area, heat shields, and suspension components. Rotate the tips so they are centered in the cutouts.
  • Working from front to back, torque all V‑band clamps to the values in the Akrapovic manual (typically 25 Nm).
  • Tighten the slip‑joint clamps to 15 Nm.
  • Recheck all hanger bolts and brackets.
  • Reattach the oxygen sensor connectors and secure any loose wiring with zip ties (avoid contact with hot surfaces).

Final Checks and Post‑Installation Steps

Before lowering the car, perform a thorough inspection. After the car is back on the ground, you will need to run the engine and verify operation.

Reassembly of Rear Diffuser

  • Reinstall the rear diffuser. Align the clips and press firmly until they snap into place.
  • Ensure the diffuser does not touch the exhaust tips – there should be at least 5 mm of clearance. Adjust tip position if necessary.

Battery Reconnection and System Checks

  • Reconnect the battery negative terminal in the front trunk.
  • Insert the key and turn the ignition to “ON” (do not start yet). Wait 10 seconds for the fuel pump and sensors to initialize.
  • Start the engine. Listen for any obvious leaks: a hissing sound indicates an exhaust leak. If you hear it, shut off the engine and recheck the V‑band clamps and slip joints.
  • Allow the engine to reach operating temperature (about 5 minutes of idling). You may notice a strong smell from the new catalysts – this is normal for the first heat‑up.
  • Check for exhaust smoke under the car. If smoke is present, look for loose connections or a leaking gasket.

Leak Test and Torque Re‑check

  • With the engine off and exhaust cool, use a soapy water spray (1:1 dish soap to water) on all joints and flanges. Start the engine and rev gently – bubbles indicate a leak. Tighten accordingly.
  • After the first heat cycle, re‑torque all V‑band clamps and hanger bolts while the exhaust is still warm (but not hot). This compensates for gasket settling.

Sound Adaptation and Performance Notes

  • The Akrapovic Evolution Line will be louder and deeper than stock, especially under load. The sound moderates slightly after the carbon buildup on the catalysts (approximately 500 miles).
  • Performance gains: expect a modest increase of 10–15 hp and 8–10 lb‑ft of torque (depending on model year and other modifications). The weight savings (~10 kg total) improve handling dynamics.
  • Drive gently for the first 50 miles to allow the new gaskets to seal and the electronics to adapt.

Conclusion

Installing the Akrapovic Evolution Line on your 718 Cayman is a rewarding DIY project that delivers immediate auditory and performance gratification. By following this detailed guide and using the correct tools, you can complete the installation in a single weekend. The result is a lighter, more responsive exhaust system that accentuates the flat‑four’s character. For additional technical data, visit the official Akrapovic product page. For model‑specific tips and community feedback, check the 718 Cayman section on Rennlist. If you need to rent a torque wrench or buy lifting equipment, ECS Tuning offers a broad selection of tools and OE‑quality hardware. Always follow the manufacturer’s torque specifications and safety procedures to ensure a long‑lasting, trouble‑free installation.