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Muffler Replacement
 
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Pelican Technical Article:

Muffler Replacement

Nick Czerula

Time:

2 hours2 hrs

Tab:

$200

Talent:

**

Tools:

13mm socket and wrench

Applicable Models:

BMW Z4 Convertible (2003-06)
BMW Z4 Coupe (2006)

Parts Required:

Rear muffler, muffler mounts and exhaust clamps

Hot Tip:

Work with a cool exhaust

Performance Gain:

Replace worn muffler system

Complementary Modification:

Use performance muffler

The exhaust system wears out or rusts and becomes leaky with age. A leaky exhaust can be a severe health hazard to passengers if odorless CO or other exhaust gases find their way into the cabin. A leaky exhaust system is usually far noisier than an intact one. Finally, bear in mind that the catalytic converters and oxygen sensors, an integral part of any modern automobile exhaust system, are critical to the emissions control system of the vehicle. Generally speaking, a vehicle with defective exhaust system fails most annual state safety and emissions tests because of the safety hazard, excess noise and emission control failure.

On the BMW Z4, you can replace the rear muffler without removing the entire exhaust system. It simply unbolts and is removed.

This article will illustrate how to replace the rear muffler. You can replace your muffler with a stock style muffler or a performance muffler.

Keep in mind that when your car was serviced before, parts may have been replaced with different size fasteners used in the replacement. The sizes of the nuts and bolts we give may be different from what you have, so be prepared with different size sockets and wrenches.

Protect your eyes, hands and body from fluids, dust and debris while working on your vehicle. If working with the electrical system, disconnect the battery before beginning. Always catch fluids in appropriate containers and properly dispose of any fluid waste. Recycle parts, packaging and fluids when possible. Do not work on your vehicle if you feel the task is beyond your ability.

Vehicle models change and evolve as they grow older, so the vehicle shown in our illustrations may vary slightly from yours. If something seems different, let us know and share your info to help other users. Questions or want to add to the article? Leave a comment below. When leaving a comment, please leave your vehicle information.

Raise and support rear of the vehicle on jack stands. See our Pelican Parts Technical Article on Jacking Up Your BMW.

On the BMW Z4, you can replace the rear mufflers (red arrows) without removing the entire exhaust system.
Figure 1

On the BMW Z4, you can replace the rear mufflers (red arrows) without removing the entire exhaust system. It simply unbolts and is removed.

Working at the muffler to center pipe connection, counterhold the 13mm bolt (red arrow) while removing the 13mm nuts (purple arrows).
Figure 2

Working at the muffler to center pipe connection, counterhold the 13mm bolt (red arrow) while removing the 13mm nuts (purple arrows).

Working above the muffler near the rear shock, remove the two 13mm muffler mounting fasteners.
Figure 3

Working above the muffler near the rear shock, remove the two 13mm muffler mounting fasteners. Support the muffler from below when removing. There is a single bolt (purple arrow) to detach the muffler from the hanger, however these are always rusty and easier to remove once the muffler is out of the vehicle.

Working above the muffler near the center of the rear bumper, remove the two 13mm muffler mounting fasteners.
Figure 4

Working above the muffler near the center of the rear bumper, remove the two 13mm muffler mounting fasteners. Support the muffler from below when removing.

Slide the muffler toward the rear of the vehicle to detach the center pipe connection (purple arrow), then, remove the muffler from the vehicle (red arrow).
Figure 5

Slide the muffler toward the rear of the vehicle to detach the center pipe connection (purple arrow), then, remove the muffler from the vehicle (red arrow).

With the muffler removed, remove the 13mm fasteners (red arrows) for the hangers and transfer them over to the new muffler.
Figure 6

With the muffler removed, remove the 13mm fasteners (red arrows) for the hangers and transfer them over to the new muffler. Then the raise muffler and install the muffler mount fasteners, do not tighten them yet. Install the muffler donut seal, then center pipe fasteners and tighten. Check the muffler alignment to the body and adjust as needed. Tighten hanger fasteners.

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Page last updated: Sat 12/3/2016 03:05:30 AM