MagnaFlow BMW 545I Stainless Cat-Back System PERFORMANCE EXHAUST - Manual

Step 1: (Carefully read all instructions before
installation) Begin removal of the OEM exhaust by
removing the crossmember and chassis stiffeners.
Next unbolt the flanges and hanger brackets behind
the Catalytic Converters. Working front to rear
disengage the welded hangers from the rubber
isolators and extract the exhaust system from the
vehicle.Do not discard the OEM fasteners or damage
the rubber isolators, as they will be used to mount
the new system.
Step 2: Install the Inlet Pipe Assemblies by
re-using the OEM fasteners at the front flanges and
the supplied fasteners for the hanger brackets. Next
install the Resonator Assembly using the supplied
2.5" clamps, leave all clamps loose for final
adjustments of the complete system. Install the
remaining assemblies in a similar fashion using the
OEM rubber isolators and the supplied 3.0" clamps.
Step 3: With all components mounted loosely,
adjust the system for overall aesthetics and
clearance of frame & bodywork. (MAGNAFLOW
recommends at least 1/2" of clearance between the
exhaust system and any body panels to prevent
heat-related body damage or fire.)
Step 4:
Once a final position has been chosen for
the new system, evenly tighten all fasteners from
front to rear. The supplied band clamps must be
VERY tight to properly align the pipes and prevent
leaks (Approximately 40ft-lbs). Inspect all fasteners
after 25-50 miles of operation and retighten if
necessary
Mufflers, Converters,
Systems and Tips
INSTALLATION INSTRUCTIONS
16558
2004-2005 BMW 545i 4.4L
Warning : When working on, under, or around
any vehicle exercise caution. Please allow the
vehicle's exhaust system to cool before removal,
as exhaust system temperatures may cause
severe burns. If working without a lift, always
consult vehicle manual for correct lifting
specifications. Always wear safety glasses and
ensure a safe work area. Serious injury or death
could occur if safety measures are not followed.
** Magnaflow Performance Exhaust recommends professional
installation on all their products
Magnaflow Performance Exhaust - 22961 Arroyo Vista Rancho Santa Margarita, CA 92688
Main #: 1-800-990-0905 Technical Support: 1-800-959-9226 ext 4500 06/30/12
D/S INLET PIPE
ASSY P/S INLET PIPE
ASSY
RESONATOR
ASSY
MUFFLER
ASSY
[2] 2.50"
CLAMP
[2] 3.00"
CLAMP
MID-PIPE
ASSY