E46 Header Installation Guide
Parts needed:
Aftermarket Headers (be sure you have the right one that fits your car)
OEM header gasket (Tischer BMW or local dealership)
Spark Plug Non-Foulers (found at local Auto store): http://forum.e46fanatics.com/showthread.php?t=486937&highlight=spark+plug+non-fouler
Threadlocker or Loctight (found at local Auto store)
WD-40 (for loosening rusted nuts/bolts)
Masking or Blue painter’s tape (for labeling 02 sensors)
Tools needed:
Allen wrenches
Phillips screw driver
Rachet
10, 11 (short & long drive), 13, 16mm socket
11 and 22 mm open/box wrench
Pliers or Adjustable wrench
OEM Jack and/or Hydraulic Jacks
Jack stands
(modified version of dubplaya’s install guide)
1. Place your front wheels on ramps or jack stands.
----- Jack stands (especially for lowered vehicles): Use your OEM jack (or Hydraulic jack) to jack up either side of your car using the front jack point underneath the side skirt.
----- Now locate the center jack point underneath (There should be a circle indentation located in the front of the car right in the middle).
----- Once you find it use your second jack to lift the front end high enough in order to place the jack stands securely underneath the front jack points (underneath the side skirt)
(courtesy of berserker)
<a href="http://www.rasmus.ca/bmw/jacking_front2.jpg">
<img src="http://www.rasmus.ca/bmw/jacking_front2.jpg" width="265x200" border="0">
</a>
2. Remove the engine covers (four 10mm bolts), cabin filter and housing (four allen wrench bolts)
(courtesy of Minnoe07)
<a href="http://i112.photobucket.com/albums/n161/Minnoe07/BMW%20Headers/2008_0217Image0045.jpg">
<img src="http://i112.photobucket.com/albums/n161/Minnoe07/BMW%20Headers/2008_0217Image0045.jpg" width="265x200" border="0">
</a> <a href="http://i112.photobucket.com/albums/n161/Minnoe07/BMW%20Headers/2008_0217Image0046.jpg">
<img src="http://i112.photobucket.com/albums/n161/Minnoe07/BMW%20Headers/2008_0217Image0046.jpg" width="265x200" border="0">
</a> <a href="http://i112.photobucket.com/albums/n161/Minnoe07/BMW%20Headers/2008_0217Image0055.jpg">
<img src="http://i112.photobucket.com/albums/n161/Minnoe07/BMW%20Headers/2008_0217Image0055.jpg" width="265x200" border="0">
</a>
3. Remove the secondary air pump (three 10mm bolts). There’s two on the top and one on the bottom. Remove the connected plug.
(courtesy of Minnoe07)
<a href="http://i112.photobucket.com/albums/n161/Minnoe07/BMW%20Headers/2008_0217Image0052.jpg">
<img src="http://i112.photobucket.com/albums/n161/Minnoe07/BMW%20Headers/2008_0217Image0052.jpg" width="265x200" border="0">
</a> <a href="http://i112.photobucket.com/albums/n161/Minnoe07/BMW%20Headers/2008_0217Image0053.jpg">
<img src="http://i112.photobucket.com/albums/n161/Minnoe07/BMW%20Headers/2008_0217Image0053.jpg" width="265x200" border="0">
</a>
**** At this point you can remove and label the top two 02 sensors (22mm) you see above with blue/masking tape (ex. L1, L2, R1, R2)
4. Remove the underbody tray cover (six screws with Phillips head). After you remove it, slide the cover towards the rear of the car.
(courtesy of Minnoe07)
<a href="http://i112.photobucket.com/albums/n161/Minnoe07/BMW%20Headers/2008_0217Image0051.jpg">
<img src="http://i112.photobucket.com/albums/n161/Minnoe07/BMW%20Headers/2008_0217Image0051.jpg" width="265x200" border="0">
</a>
5. Remove the metal subframe brace (eight 16mm bolts)
(courtesy of Minnoe07)
<a href="http://i112.photobucket.com/albums/n161/Minnoe07/BMW%20Headers/2008_0217Image0044.jpg">
<img src="http://i112.photobucket.com/albums/n161/Minnoe07/BMW%20Headers/2008_0217Image0044.jpg" width="265x200" border="0">
</a>
6. Support the bottom of the motor with a jack and 2x4
7. Unbolt the connecting ground wire from the car coming from the engine mount (13mm)
(courtesy of Minnoe07)
<a href="http://i112.photobucket.com/albums/n161/Minnoe07/BMW%20Headers/2008_0217Image0049.jpg">
<img src="http://i112.photobucket.com/albums/n161/Minnoe07/BMW%20Headers/2008_0217Image0049.jpg" width="265x200" border="0">
</a>
8. Unbolt the passenger side engine mount (four 13mm bolts)
9. Remove the bolt holding the passenger engine mount (16mm)
10. Remove Passenger Side engine mount.
**** At this point, you can label and remove the remaining two 02 sensors (22mm) you see below on the headers (ex. L1, L2, R1, R2)
11. Remove the OEM headers and gaskets(sixteen 11mm nuts, eight on each header)
----- You will be spending most of your time here at this point.
----- Start first on the header (longest one) closest to the front of the car.
**** At this point, you can take a break to soak the nuts and bolts w/ WD-40 removing the rust.
(courtesy of Minnoe07)
<a href="http://i112.photobucket.com/albums/n161/Minnoe07/BMW%20Headers/2008_0217Image0048.jpg">
<img src="http://i112.photobucket.com/albums/n161/Minnoe07/BMW%20Headers/2008_0217Image0048.jpg" width="265x200" width="265x200" border="0">
</a>
12. Install the new OEM gasket and aftermarket headers.
----- Start with the header closest to the front of the car because it will be easier to maneuver the second header in.
----- Make sure you apply Threadlocker or Loctight on the last couple of millimeters of thread before tightening.
----- Be sure to have a paper towel (or Q-tips) handy to wipe off any excess that forms around the hex nut because the product will harden. Do not get any of this stuff in your hair or eyes.
13. Re-install the 02 sensors and spark plug non-foulers in the correct locations
14. With the passenger engine mount, use a pair of pliers or adjustable wrench to remove the excess heat shield. This will help with header clearance.
15. Reverse steps 10 thru 1
----- If you’re having trouble getting the engine mount back in, start with one end (the side w/ four bolts) coming in towards the front of the car then turning it.
----- If you’re having trouble bolting the engine mount back on, start with two bolts in at first tightening them down one by one. Be sure not to strip any threads.
----- After you re-install the passenger side engine mount and ground wire. Start up the car to check and see if you have any leaks.
----- You will see some smoke rise off the headers at first from the Threadlock/Loctight, which will burn off after a few minutes.
Parts needed:
Aftermarket Headers (be sure you have the right one that fits your car)
OEM header gasket (Tischer BMW or local dealership)
Spark Plug Non-Foulers (found at local Auto store): http://forum.e46fanatics.com/showthread.php?t=486937&highlight=spark+plug+non-fouler
Threadlocker or Loctight (found at local Auto store)
WD-40 (for loosening rusted nuts/bolts)
Masking or Blue painter’s tape (for labeling 02 sensors)
Tools needed:
Allen wrenches
Phillips screw driver
Rachet
10, 11 (short & long drive), 13, 16mm socket
11 and 22 mm open/box wrench
Pliers or Adjustable wrench
OEM Jack and/or Hydraulic Jacks
Jack stands
(modified version of dubplaya’s install guide)
1. Place your front wheels on ramps or jack stands.
----- Jack stands (especially for lowered vehicles): Use your OEM jack (or Hydraulic jack) to jack up either side of your car using the front jack point underneath the side skirt.
----- Now locate the center jack point underneath (There should be a circle indentation located in the front of the car right in the middle).
----- Once you find it use your second jack to lift the front end high enough in order to place the jack stands securely underneath the front jack points (underneath the side skirt)
(courtesy of berserker)
<a href="http://www.rasmus.ca/bmw/jacking_front2.jpg">
<img src="http://www.rasmus.ca/bmw/jacking_front2.jpg" width="265x200" border="0">
</a>
2. Remove the engine covers (four 10mm bolts), cabin filter and housing (four allen wrench bolts)
(courtesy of Minnoe07)
<a href="http://i112.photobucket.com/albums/n161/Minnoe07/BMW%20Headers/2008_0217Image0045.jpg">
<img src="http://i112.photobucket.com/albums/n161/Minnoe07/BMW%20Headers/2008_0217Image0045.jpg" width="265x200" border="0">
</a> <a href="http://i112.photobucket.com/albums/n161/Minnoe07/BMW%20Headers/2008_0217Image0046.jpg">
<img src="http://i112.photobucket.com/albums/n161/Minnoe07/BMW%20Headers/2008_0217Image0046.jpg" width="265x200" border="0">
</a> <a href="http://i112.photobucket.com/albums/n161/Minnoe07/BMW%20Headers/2008_0217Image0055.jpg">
<img src="http://i112.photobucket.com/albums/n161/Minnoe07/BMW%20Headers/2008_0217Image0055.jpg" width="265x200" border="0">
</a>
3. Remove the secondary air pump (three 10mm bolts). There’s two on the top and one on the bottom. Remove the connected plug.
(courtesy of Minnoe07)
<a href="http://i112.photobucket.com/albums/n161/Minnoe07/BMW%20Headers/2008_0217Image0052.jpg">
<img src="http://i112.photobucket.com/albums/n161/Minnoe07/BMW%20Headers/2008_0217Image0052.jpg" width="265x200" border="0">
</a> <a href="http://i112.photobucket.com/albums/n161/Minnoe07/BMW%20Headers/2008_0217Image0053.jpg">
<img src="http://i112.photobucket.com/albums/n161/Minnoe07/BMW%20Headers/2008_0217Image0053.jpg" width="265x200" border="0">
</a>
**** At this point you can remove and label the top two 02 sensors (22mm) you see above with blue/masking tape (ex. L1, L2, R1, R2)
4. Remove the underbody tray cover (six screws with Phillips head). After you remove it, slide the cover towards the rear of the car.
(courtesy of Minnoe07)
<a href="http://i112.photobucket.com/albums/n161/Minnoe07/BMW%20Headers/2008_0217Image0051.jpg">
<img src="http://i112.photobucket.com/albums/n161/Minnoe07/BMW%20Headers/2008_0217Image0051.jpg" width="265x200" border="0">
</a>
5. Remove the metal subframe brace (eight 16mm bolts)
(courtesy of Minnoe07)
<a href="http://i112.photobucket.com/albums/n161/Minnoe07/BMW%20Headers/2008_0217Image0044.jpg">
<img src="http://i112.photobucket.com/albums/n161/Minnoe07/BMW%20Headers/2008_0217Image0044.jpg" width="265x200" border="0">
</a>
6. Support the bottom of the motor with a jack and 2x4
7. Unbolt the connecting ground wire from the car coming from the engine mount (13mm)
(courtesy of Minnoe07)
<a href="http://i112.photobucket.com/albums/n161/Minnoe07/BMW%20Headers/2008_0217Image0049.jpg">
<img src="http://i112.photobucket.com/albums/n161/Minnoe07/BMW%20Headers/2008_0217Image0049.jpg" width="265x200" border="0">
</a>
8. Unbolt the passenger side engine mount (four 13mm bolts)
9. Remove the bolt holding the passenger engine mount (16mm)
10. Remove Passenger Side engine mount.
**** At this point, you can label and remove the remaining two 02 sensors (22mm) you see below on the headers (ex. L1, L2, R1, R2)
11. Remove the OEM headers and gaskets(sixteen 11mm nuts, eight on each header)
----- You will be spending most of your time here at this point.
----- Start first on the header (longest one) closest to the front of the car.
**** At this point, you can take a break to soak the nuts and bolts w/ WD-40 removing the rust.
(courtesy of Minnoe07)
<a href="http://i112.photobucket.com/albums/n161/Minnoe07/BMW%20Headers/2008_0217Image0048.jpg">
<img src="http://i112.photobucket.com/albums/n161/Minnoe07/BMW%20Headers/2008_0217Image0048.jpg" width="265x200" width="265x200" border="0">
</a>
12. Install the new OEM gasket and aftermarket headers.
----- Start with the header closest to the front of the car because it will be easier to maneuver the second header in.
----- Make sure you apply Threadlocker or Loctight on the last couple of millimeters of thread before tightening.
----- Be sure to have a paper towel (or Q-tips) handy to wipe off any excess that forms around the hex nut because the product will harden. Do not get any of this stuff in your hair or eyes.
13. Re-install the 02 sensors and spark plug non-foulers in the correct locations
14. With the passenger engine mount, use a pair of pliers or adjustable wrench to remove the excess heat shield. This will help with header clearance.
15. Reverse steps 10 thru 1
----- If you’re having trouble getting the engine mount back in, start with one end (the side w/ four bolts) coming in towards the front of the car then turning it.
----- If you’re having trouble bolting the engine mount back on, start with two bolts in at first tightening them down one by one. Be sure not to strip any threads.
----- After you re-install the passenger side engine mount and ground wire. Start up the car to check and see if you have any leaks.
----- You will see some smoke rise off the headers at first from the Threadlock/Loctight, which will burn off after a few minutes.