18 12 061 Replacing center muffler

WARNING: This page does not describe the selected car, but rather 7 other vehicles, including the 2003 BMW 540i, 2002 BMW 540i, 2001 BMW 540i, 2000 BMW 540i, and 1999 BMW 540i. However, it is still accessible from the selected car via links, so may be relevant.

Remove complete exhaust system.

Refer to 18 00 020 REMOVING AND INSTALLING COMPLETE EXHAUST SYSTEM (M62) .

WARNING: Scalding hazard!
These tasks should only be carried out on an exhaust system that has cooled down!

Measure length (B) of pipe sections on new center muffler.

Fig 1: Measuring Length (B) Of Pipe Sections On Center Muffler

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Courtesy of BMW OF NORTH AMERICA, INC.

Carry over calculated measurement (B) to removed exhaust system and mark cutting points.

Fig 2: Identifying Dimension B

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Courtesy of BMW OF NORTH AMERICA, INC.

Cut through exhaust pipes between catalytic converter and center muffler and between catalytic converter and rear muffler at marked points with a parting-off grinder and deburr.

Fig 3: Cutting Exhaust Pipes Between Catalytic Converter And Center Muffler

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Courtesy of BMW OF NORTH AMERICA, INC.

Grind off remaining welding beads from center muffler.

Remove pipe necks from catalytic converter pipes.

Fig 4: Removing Pipe Necks From Catalytic Converter Pipes

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Courtesy of BMW OF NORTH AMERICA, INC.

NOTE: If the pipe necks cannot be removed from the catalytic converter pipes, cut off the corresponding pipe length on the new center muffler.

Fig 5: Cutting Pipe Necks

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Courtesy of BMW OF NORTH AMERICA, INC.

CAUTION: If the openings on the new center muffler are sealed with adhesive film, remove the adhesive film completely from the new center muffler.

Fig 6: Removing Adhesive Film From Center Muffler

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Courtesy of BMW OF NORTH AMERICA, INC.

Connect new center muffler and catalytic converters by means of clamping sleeves.

Installation:

Nuts point downwards.

Fig 7: Connecting Center Muffler And Catalytic Converters By Means Of Clamping Sleeves

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Courtesy of BMW OF NORTH AMERICA, INC.

Install both rear mufflers.

Fig 8: Installing Rear Mufflers

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Courtesy of BMW OF NORTH AMERICA, INC.

Installation:

Align exhaust system and all clamping sleeves in such a way that there is sufficient spacing to adjoining components.

Fig 9: Aligning Exhaust System

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Courtesy of BMW OF NORTH AMERICA, INC.