Exhaust System - Repair BMW M5 E60/E61

18 00 020 Removing and Installing Complete Exhaust System (S85)

Special tools required

1. 312 220

Risk of injury!

Removal of the exhaust system must be carried out with the assistance of a second person.

Support exhaust system with special tool 31 2 220.

Scheme 1

Unscrew nuts (1).

Tightening torque: 27 Nm

Scheme 2

Unscrew nuts.

Scheme 3

Unscrew nuts.

Scheme 4

Picture shows E63

Release nuts on rear mufflers (1 and 2).

Scheme 5

Picture shows E61

Release screws.

Tightening torque: 24 N.m

Carefully lower exhaust system (1).

Scheme 6

18 10 032 Replacing both rear mufflers (S85)

Support final muffler with special tool 31 2 220.

Note. Illustrations show E63.

Scheme 7

Note. Illustrations show E63

While installed, mark cutting line with aid of replacement muffler on faulty rear muffler (1 and 2).

Scheme 8

Cut exhaust pipes with special tool 00 2 210 at marked points and deburr.

Scheme 9

Note. The same procedure applies to the opposite side.

Unscrew nuts. Modify grounding strap (1).

Scheme 10

Unscrew nuts. Remove rear mufflers (1 and 2).

Scheme 11

Connect rear muffler to center muffler. Align clamp and tighten down.

Scheme 12

18 12 045 Replacing center muffler (S85)

Necessary preliminary tasks

1. Remove «complete exhaust system»(/bmw/m5/e60e61-2004-2010/remont/exhaust/#exhaust-system-repair__18-00-020-removing-and-installing)

Using replacement muffler, mark length on faulty center muffler (1). Cut exhaust pipes with special tool 00 2 210 at marked points and deburr.

Scheme 13

Installation: Connect center muffler to left and right exhaust pipes by means of clamping sleeves.

Connect center muffler to rear muffler by means of clamping sleeve. Install and align exhaust system, tighten down clamping sleeves.

Scheme 14

Note. See 18 10 032 Replacing both rear mufflers (S85) .

Special tools required

1. 00 2 210

Necessary preliminary tasks

1. Remove «complete exhaust system»(/bmw/m5/e60e61-2004-2010/remont/exhaust/#exhaust-system-repair__18-00-020-removing-and-installing) .

Using replacement muffler, mark length on faulty center muffler (1).

Cut exhaust pipes with special tool 00 2 210 at marked points and deburr.

Scheme 15

Installation

Connect center muffler to left and right exhaust pipes by means of clamping sleeves.

Connect center muffler to rear muffler by means of clamping sleeve.

Install and align exhaust system, tighten down clamping sleeves.

Scheme 16

18 40 010 Removing and installing/replacing left exhaust manifold (S85)

Necessary preliminary tasks

1. Secure engine in installation position with special tool.
2. Remove complete «exhaust system»(/bmw/m5/e60e61-2004-2010/remont/exhaust/#exhaust-system-repair__18-00-020-removing-and-installing) .
3. Remove left control sensor. See «11 78 530 REPLACING LEFT OXYGEN CONTROL SENSOR (S85)»(/bmw/m5/e60e61-2004-2010/remont/mechanical/#engine-repair__11-78-530-replacing-left-oxygen) .
4. Remove left monitor sensor. See «11 78 540 REPLACING LEFT OXYGEN MONITOR SENSOR (S85)»(/bmw/m5/e60e61-2004-2010/remont/mechanical/#engine-repair__11-78-540-replacing-left-oxygen) .
5. Drain off engine oil.
6. Lower front axle support. «31 10 000 REMOVING AND INSTALLING COMPLETE FRONT AXLE (WITH SPRING STRUT SHOCK ABSORBER) (M5)»(/bmw/m5/e60e61-2004-2010/remont/axle-shafts/#front-axle-repair__31-10-000-removing-and-installing) or «31 10 000 REMOVING AND INSTALLING COMPLETE FRONT AXLE (WITH SPRING STRUT SHOCK ABSORBER) (M6)»(ref-263479-S39168294572007090700000)
7. Remove «LEFT ENGINE SUPPORT ARM (S85)»(/bmw/m5/e60e61-2004-2010/remont/mechanical/#engine-and-transmission-suspension-repair__22-11-110-replacing-left-engine) .
8. Remove left electric oil pump.

Note. For purposes of clarity, the following work steps are shown on the engine after it has been removed.

Unfasten screws. Remove heat shield (1).

Scheme 17

Unfasten screws.

Scheme 18

Unscrew nuts. Remove exhaust manifold downwards.

Scheme 19

Installation: Replace nuts. Replace seals.

18 40 020 Removing and Installing/Replacing Right Exhaust Manifold (S85)

Necessary preliminary tasks

1. Secure engine in «INSTALLATION POSITION»(/bmw/m5/e60e61-2004-2010/remont/mechanical/#engine-repair__11-00-670-securing-engine-in) .
2. Remove «complete exhaust system»(/bmw/m5/e60e61-2004-2010/remont/exhaust/#exhaust-system-repair__18-00-020-removing-and-installing) .
3. Remove left control sensor. See «11 78 530 REPLACING LEFT OXYGEN CONTROL SENSOR (S85)»(/bmw/m5/e60e61-2004-2010/remont/mechanical/#engine-repair__11-78-530-replacing-left-oxygen) .
4. Remove left monitor sensor. See «11 78 530 REPLACING LEFT OXYGEN CONTROL SENSOR (S85)»(/bmw/m5/e60e61-2004-2010/remont/mechanical/#engine-repair__11-78-540-replacing-left-oxygen) .
5. Drain off «ENGINE OIL»(/bmw/m5/e60e61-2004-2010/remont/oem-general-information/#maintenance-and-general-information-repair-instructions__00-00-610-service-engine) .
6. Lower front axle support.
7. Remove «RIGHT ENGINE SUPPORT ARM (S85)»(/bmw/m5/e60e61-2004-2010/remont/mechanical/#engine-and-transmission-suspension-repair__22-11-100-replacing-right-engine) .
8. Remove right electric oil pump.

Note. For purposes of clarity, the following work steps are shown on the engine after it has been removed.

Unfasten screws.

Remove heat shield (1).

Scheme 20

Unfasten screws.

Scheme 21

Unscrew nuts.

Remove exhaust manifold (1) downwards.

Installation

Tightening torque: 25 N.m

Replace nuts.

Replace seals.

Scheme 22

See also:
• 11 78 530 REPLACING LEFT OXYGEN CONTROL SENSOR (S85)
• 11 78 540 REPLACING LEFT OXYGEN MONITOR SENSOR (S85)
• 31 10 000 REMOVING AND INSTALLING COMPLETE FRONT AXLE (WITH SPRING STRUT SHOCK ABSORBER) (M5)
• LEFT ENGINE SUPPORT ARM (S85)
• INSTALLATION POSITION
• ENGINE OIL
• RIGHT ENGINE SUPPORT ARM (S85)
• complete exhaust system
• 18 10 032 Replacing both rear mufflers (S85)