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Installing a performance free-flow muffler or exhaust system on your BMW or MINI is a task that most DIYers should be able to complete in a couple hours to half a day. Most systems are a direct bolt-on to replace the original parts or a simple cut-in, where the pipe is cut and the new system slips over the cut end of the pipe. The new systems hang from the original mounting points and center into the rear valance opening in the same manner as the original systems.
Since the installation of a full bolt-on system is as straight forward as simply removing the old system and installing the new system in exactly the same manner, in this DIY we will show you a typical cut-in system installation. The only specialized tool that you will need is a pipe cutter, such as the one that we offer.
Follow along as we install a Scorpion Free-Flow muffler set on a 2007 335i. Then, listen to the before and after sound clips. Of the 100% stainless steel systems that we offer, the Scorpion system is our quietest Free-Flow system (on most models). For a bit more “European” sound, choose the Remus systems. For those who wish to have the most aggressive exhaust sounds (and performance), we suggest the MagnaFlow and the Billy-Boat systems. Remember, all of these systems are 100% stainless steel.
• Scorpion Free-Flow Mufflers for BMW 335i
• Wurth Exhaust Assembly Paste
• New rubber exhaust hangers, as needed.
• MechanicAll penetrant and lubricant spray
• Exhaust tubing cutter
• SafeGrip Gloves
• 10mm through 15mm 3/8″ drive socket and ratchet set with various extensions
• 10mm through 15mm combination wrench set
• Assorted flat-blade screwdrivers and pry-bars.
NOTE: We suggest that you work with a helper to support the muffler assemblies during set-up and installation.
1) Safely and properly raise the rear of the vehicle. Drive-on ramps can be used for this procedure, as well as a floor-jack and jack-stands.
NOTE: This DIY is performed on an E90 (06-12) 335i model. This model has two separate mufflers with two inlet pipes and a cross-over pipe between the mufflers. In order to lower these units, mark and cut both inlet pipes and lower as a complete unit. On this vehicle, we separated the two mufflers at the cross-over pipe due to our performing a live DIY for an audience and then a second DIY for our video. In separating the mufflers, we could perform these two full DIYs on one car.
2) Raise and support the new muffler assembly, below the original muffler. Align the hanging points with the original hanging points. Mark the exhaust pipe in a location that will allow the original piping to be inserted into the new muffler’s piping by about 2″. Remember, it is better to have to cut a second time to shorten the pipe, rather than be too short on the first cut.
3) Position the pipe cutter around the pipe, at the marked location. Tighten the tool and roll the tool as far clockwise and counter-clockwise as clearance allows. Keep working the tool until the pipe is cut (similar to cutting copper plumbing pipe with a tubing cutter).
4) Support the muffler and disconnect the forward and rear hangers. Unbolt the forward hanger bracket from the chassis. Unbolt the rear hanger from the muffler.
5) Lower the original muffler.
6) Note that the new Muffler has welded on hanger pins for both the front and the rear hangers.
7) We’re sorry, but the description can not be any longer (youtube requirement). Watch the video and see our tech blog for the full DIY steps at http://blog.bavauto.com/
NOTE: For this vehicle, and others with separate left and right mufflers, install and align both mufflers at the same time. Do not fully tighten the clamps until you are satisfied that both sides are hanging symmetrically.
All products noted in this video can be purchased in our online store, http://www.bavauto.com/, 24 hours a day, 7 days a week. You are also welcome to e-mail us at email@example.com or call into our headquarters and speak to our knowledgeable advisors at (800) 535-2002 (Mon.-Thurs. 8AM to 9PM EST, Fri. 8AM to 7PM EST, and Sat. 9AM to 4PM EST).