E53 X5 M54 3.0i Headers

[Canadian_E53]

Hi,

I purchased and installed some stainless steel headers to replace the stock catalytic converter exhaust manifold combo. I installed them today and realized the lower output flanges don't match up with the mid pipes at all. I believe they are intended for e46 cars and not an e53.

Anyways, I am where I am and I'm not going back! I bought some 2 inch 45s and 2 inch stainless straight it's on its way this week. Picked up some stainless wire for my mig I'll give it a shot to fab up from the header flange to somewhere in the mid pipe. Wish me luck!

Tyler

[BimmerBreaker]

Most ebay headers don't line up with any midpipes regardless of model. The longtubes *definitely* don't. It's trivial work to customize the section 1 to mate with the headers. I recommend using V bands to connect everything. They don't leak (commonly used on turbo applications) but make fabrication easier and make removal/reinstallation easier in the future.

[Happy]

These are the direct fit. Unfortunately they can no longer be purchased.

I wanted another pair for an E39.




E53 RiPPeR
XOuTPoST jUNkiE
ReVELaTiON 22:21

[Canadian_E53]

So I finished modifying the mid pipe to connect with the header flanges and got it all bolted up. Took it for a test drive today and it's AWESOME! I kept the stock exhaust system and I think it's the perfect level of noise. It's a bit deeper of a tone and not all that louder with normal driving. Under load right around the 3500rpm range it just sounds wicked.


I'm looking into tuning options right now. Has anyone done custom tunes on their m54s? I've got a obd-usb cable on the way and I'm going to tune out the SAP and turn off the post cat o2 sensors. Just wondering if someone has a good e53 tune with headers they can share.


Cheers,
Tyler

[Happy]

Originally Posted by Canadian_E53

So I finished modifying the mid pipe to connect with the header flanges and got it all bolted up. Took it for a test drive today and it's AWESOME! I kept the stock exhaust system and I think it's the perfect level of noise. It's a bit deeper of a tone and not all that louder with normal driving. Under load right around the 3500rpm range it just sounds wicked.

I'm looking into tuning options right now. Has anyone done custom tunes on their m54s? I've got a obd-usb cable on the way and I'm going to tune out the SAP and turn off the post cat o2 sensors. Just wondering if someone has a good e53 tune with headers they can share.

Cheers,
Tyler

That’s awesome you were able to get the fitment sorted out!

The only tuning I’m aware of is through Active.


E53 RiPPeR
XOuTPoST jUNkiE
ReVELaTiON 22:21

[Canadian_E53]

Not the prettiest welds but it's air tight and that's what is most important. I made a YouTube video I'll post the link here once it's finished uploading. It's got a few before and after clips of the exhaust sound.


There seems to be a pretty big community over on the e46 forums with guys tuning the m54. I've been reading through it a bit and doesn't seem to bad to get into and DIY.

[Canadian_E53]

Here's the YouTube vid of the install with some before and after sound clips. The check engine light just came on with E9 and EA catalytic-converter efficiency codes. I suspected this may happen but I'll just tune it out in addition to the secondary air pump once my obd-usb cable gets here.



https://www.youtube.com/watch?v=zYdhPB2Zs6U&t=3s

[Happy]

Nice vid!


E53 RiPPeR
XOuTPoST jUNkiE
ReVELaTiON 22:21

[Canadian_E53]

Alright so to nobody's surprise. I had fun with the headers and cat delete. I didn't think it would bother me so much but the smell of the deleted cats is getting to me. I don't like to smell it in the cabin occasionally or when I get out of the vehicle.


To maintain the flow, I'm keeping the headers and installing this magnaflow dual inlet/outlet cat (https://amzn.to/3Cgfs6R) right after the flanges at the exit of the headers. That should keep the smell down and still maintain the flow capabilities. I'll take some after clips to compare the sound and post it on YouTube/here.


Install this weekend, in addition to the EU2 flash since the check engine light ended up coming on with the new headers.


Tyler,

[Factory6speed]

I was wondering about the smell. I couldn't do it on my f30. Lasted a week. Tried again 2 years later, forgetting what it was like, lasted 3 days.

"It smells like a race track" were the comments from management. I also felt like I had a 3 star wanted level just putting around town.

I ended up learning some chemistry. Pretty cool how a piece of metal can change gas molecules.

High flow cat just to get the smell down should be great.