Removing and installing complete exhaust system (B36, B38) (Cooper)

This repair work may only be carried out on an exhaust system which has cooled down.

Removal of the exhaust system must be carried out with the assistance of a second technician.

Preliminary work needed: 

• Remove both rear TENSION STRUTS .
• Remove both front TENSION STRUTS .
• Use a suitable jack to support and secure the exhaust system against falling.

Removal: 

Loosen screws.

Remove cover (1).

Courtesy of BMW OF NORTH AMERICA, INC.

Version 1 (ribbon clamp): 

Release clamp (1).

Replace clamp (1).

Parts:  Clamp.

Courtesy of BMW OF NORTH AMERICA, INC.

Version 2 (V-ribbon clamp): 

Release clamp (1).

Replace clamp (1).

Parts:  Clamp.

Courtesy of BMW OF NORTH AMERICA, INC.

Loosen screws (1).

Remove connection carrier.

Courtesy of BMW OF NORTH AMERICA, INC.

Spray rubber mount (1) with lubricant and detach from exhaust system.

Replaced damaged rubber mounts.

Parts:  rubber mount

Courtesy of BMW OF NORTH AMERICA, INC.

Loosen screws (1).

Remove cross strut (2) on rear axle support.

Courtesy of BMW OF NORTH AMERICA, INC.

Spray rubber mount (1) with lubricant and detach from rear silencer.

Replaced damaged rubber mounts.

Parts:  rubber mount

Lower and remove exhaust system with assistance of a second technician.

Courtesy of BMW OF NORTH AMERICA, INC.

Preparation for installation: 

Check rubber mount for damage, replace if necessary.

Installation: 

Version 1 (ribbon clamp): 

Install new snap ring (1).

Install exhaust system and connect to the catalytic converter with the assistance of a second technician.

Tighten clamp (1).

Tightening torque 18 20 1AZ .

Courtesy of BMW OF NORTH AMERICA, INC.

Courtesy of BMW OF NORTH AMERICA, INC.

Version 2 (V-ribbon clamp): 

Release nut (1) and remove sealing ring (2).

Courtesy of BMW OF NORTH AMERICA, INC.

Mount sealing ring (1) on exhaust system.

Make sure that the sealing ring (1) is positioned correctly for the V-ribbon clamp (2).

Courtesy of BMW OF NORTH AMERICA, INC.

Bend all metal sheets round, apart from those in the marked areas, with a suitable tool.

Mount the V-ribbon clamp (1) on the sealing ring (2).

Make sure that the V-ribbon clamp (1) is positioned correctly on the sealing ring (2).

Courtesy of BMW OF NORTH AMERICA, INC.

Make sure that, after mounting, the V-ribbon clamp is on the metal sheets (markings).

Courtesy of BMW OF NORTH AMERICA, INC.

Connect exhaust system (1) to catalytic converter (2) and position correctly.

Courtesy of BMW OF NORTH AMERICA, INC.

Ensure correct fit of the V-ribbon clamp (1).

Tighten screw (2).

Tightening torque 18 20 1AZ .

Courtesy of BMW OF NORTH AMERICA, INC.

Connect rubber mount (1) to rear silencer.

Courtesy of BMW OF NORTH AMERICA, INC.

Connect rubber mount (1) to exhaust system.

Courtesy of BMW OF NORTH AMERICA, INC.

Install connection carrier.

Tighten down screws (1).

Tightening torque 18 30 4AZ .

Courtesy of BMW OF NORTH AMERICA, INC.

Install cross strut (2) on rear axle support.

Tighten down screws (1).

Tightening torque 33 31 2AZ .

Courtesy of BMW OF NORTH AMERICA, INC.

Position cover (1).

Tighten the screws.

Courtesy of BMW OF NORTH AMERICA, INC.

Required follow-up work: 

• Install both rear TENSION STRUTS .
• Install both front TENSION STRUTS .
• Check exhaust system for leak tightness.