How to install a performance free-flow exhaust on a BMW or MINI
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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
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
• MechanicAll penetrant and lubricant spray
• Exhaust tubing cutter
• SafeGrip Gloves
• 10mm through 15mm 3/8" drive socket and ratchet set with various
• 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
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
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
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