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Removing Your BMW Exhaust System
 
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Pelican Technical Article:

Removing Your BMW Exhaust System

Nick Czerula

Time:

2 hours2 hrs

Tab:

$200

Talent:

***

Tools:

Set of sockets (13mm, 18mm, E10, T45 Torx) pipe cutter, flathead screwdriver, pry bar

Applicable Models:

BMW E90 3-Series (2006-11)
BMW E91 3-Series (2006-12)
BMW E92 3-Series (2007-13)
BMW E93 3-Series (2007-13)

Parts Required:

Exhaust system, Exhaust gaskets, Exhaust fasteners, Rubber exhaust insulators

Hot Tip:

Work with a cool exhaust

Performance Gain:

Replace worn exhaust system

Complementary Modification:

Use performance exhaust, replace oxygen sensors

When replacing your exhaust system remove the entire unit as one piece. Once exhaust has been removed, repairs or modifications can be made. You can replace the rear muffler with exhaust installed, but not the center mufflers. See our tech article on rear muffler replacing. When removing the exhaust system, have new fasteners, gaskets and rubber insulators on hand. These parts wear out just like the exhaust system and help to complete the repair.

Raise and support vehicle on jack stands. If you raise just the rear, you should have enough space to work at the front of exhaust. If not, raise front of vehicle to work on front, then raise rear of vehicle when removing exhaust system. See our tech article on jacking up your vehicle.

Working at front of exhaust system, remove four 13mm nuts that connect exhaust system to exhaust manifold.
Figure 1

Working at front of exhaust system, remove four 13mm nuts that connect exhaust system to exhaust manifold. (green arrows) Be careful when loosening these nuts. I like to spray studs with penetrating oil and clean end of stud with wire brush before removing. Depending on your region, these can seize up. If they break, don't worry. You can remove the studs by hammering them out and replacing with new studs. Once the nuts are removed, remove the header reinforcement place. (yellow arrow) If the exhaust has been repaired on your vehicle, you may have clamps at the mid-point of exhaust, loosen these now.

Support exhaust system from below using a hydraulic floor jack or jack stand.
Figure 2

Support exhaust system from below using a hydraulic floor jack or jack stand. I like to put the jack under the muffler. If your vehicle has a tailpipe flap, disconnect vacuum hose to tailpipe flap. The flap vacuum hose is located right above the left rear of muffler.

Next, working at center of vehicle, remove eight T45 fasteners.
Figure 3

Next, working at center of vehicle, remove eight T45 fasteners. (green arrows) Then remove reinforcement plate from vehicle. (yellow arrow) Working below transmission, remove transmission splash shield. See our tech article on lower splash shield replacing.

After you remove the splash shield and have the jack supporting your exhaust system, it's time to start unbolting it.
Figure 4

After you remove the splash shield and have the jack supporting your exhaust system, it's time to start unbolting it. The first support to remove is located at the transmission. There are two ways to remove it. There is a clamp that is held in place by an E10 bolt. (green arrow) You can unbolt it here, however I find in my area it is usually rusted solid. The other option is to remove the entire support bracket with the exhaust, which means unbolting it from the transmission. To do this, remove two E10 bolts (yellow arrows), you will have to counter hold the 13mm nuts on the back side of bracket when removing.

Working at rear differential, remove exhaust mount 18mm fastener.
Figure 5

Working at rear differential, remove exhaust mount 18mm fastener. (green arrow) An alternate way to disconnect the exhaust from the rear differential hanger would be to lever the rubber insulator off hanger. (yellow)

Working at muffler, remove E10 mount fastener.
Figure 6

Working at muffler, remove E10 mount fastener. (yellow arrow) Then remove 13mm mount fastener. (green arrow) Lower exhaust and remove from vehicle. You may have to wiggle exhaust out of exhaust manifold studs. If stuck, raise exhaust slightly, then pull exhaust off toward rear of vehicle. Once exhaust has been removed, you can replace the front mufflers or repair system as needed. Line up new parts with old, and mark where you will cut. Use a pipe cutter to cut pipes, then remove any sharp edges from pipes. Install new parts using exhaust clamps then reinstall exhaust system.

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Comments and Suggestions:
mauvais Comments: thank you!!
April 20, 2016
  Followup from the Pelican Staff: Thanks for the feedback. Glad we could help.
- Nick at Pelican Parts
 
Miki Comments: Thanks for the info, the part I need looks very similar the one above in figure no. 4 but needs to fit 2006 BMW 325i. I have the old pieces that I can probably weld back together, but it would be preferable to have a replacement part if possible. Thanks again in advance for any new info you can provide. Cheers, Miki
September 7, 2015
  Followup from the Pelican Staff: I’m not the best with part numbers.

Give our parts specialists a call at 1-888-280-7799. They can figure out what part or repair kit you need.
- Nick at Pelican Parts
 
Miki Comments: I need a new exhaust bracket that connects from transmission to tail pipes on a 2006 BMW 325i. The one on the car has sheared in the middle and the exhaust system rattles now. Do you have this part or do I need to weld it back together myself?
September 7, 2015
  Followup from the Pelican Staff: Not sure if that is available. There may be an aftermarket solution.

I’m not the best with part numbers.

Give our parts specialists a call at 1-888-280-7799. They can figure out what part or repair kit you need.
- Nick at Pelican Parts
 

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Page last updated: Sat 12/3/2016 02:22:22 AM