Replacing mufflers (BMW 7 Series E38)

Petrol models

1. Measure the length (A) of the end of the pipe on the new additional muffler.



2. Transfer the obtained value to the additional muffler to be replaced and cut off the exhaust pipe at this point using a pipe cutter.

3. On models with engines M60, M62 and M73 remove the extra (for the main) muffler (see section Removal and installation of the exhaust system) and install a rubber-metal hinge on the new muffler to hang it on the rear axle beam.

4. On models with an engine M52 remove the extra (for the main) muffler (see section Removal and installation of the exhaust system).



5. Place the coupling onto the new additional muffler so that the cut of the muffler pipe is in the middle of the coupling.



6. Connect the muffler to the exhaust system using a coupling.

Diesel models

1. Measure the length (B) of the pipe ends on the new intermediate muffler.



2. Transfer the obtained value to the intermediate muffler to be replaced and cut off the exhaust pipes at this point using a pipe cutter.



3. Cut both pipes between the catalytic converter and the intermediate muffler with a cutting machine along the weld seam and clean the cut area. Grind off the remains of the weld seam on the intermediate muffler, remove the remains of the pipes from the catalytic converter pipes.

If the pipe remnants cannot be removed from the catalytic converter pipes, cut the new intermediate muffler pipes to the appropriate length.

4. The holes on the new catalytic converter are covered with self-adhesive film – remove it completely.



5. Connect the new intermediate muffler to the catalytic converter using connecting couplings.

The clamp nuts must face down.

6. Connect both additional mufflers.