Installation of the B&B Performance Exhaust on your E39 540 requires that the original equipment muffler system be cut off, as there is no natural break. It is recommended that a professional do the installation. These installation instructions will guide one through the original equipment removal and B&B installation procedure.
First, disconnect the battery negative terminal for safety to allow the computer to reset.
Next, the original muffler pipes need to be cut through to remove the mufflers. Measuring 2.25” back from the front of the differential sump, mark each pipe and cut straight through. Remove all burrs and clean surface of remaining pipes.
There are three hangers per muffler on the M5. It is easiest to unbolt the hangers from the vehicle, rather than the muffler, and remove as an assembly. The hangers also support heat shields which will drop out with the assembly. HINT: The mufflers weight 30-pounds each – watch your head!
With the muffler assemblies removed, remove the hangers and heat shields from them, then install on the car as original. HINT: When installing the hangers, install with the bolts that support the muffler. Once the hangers are installed there is little room to get the muffler bolts in/out of the hangers.
Slip the B&B muffler inlet pipe and supplied clamp over the remaining original pipe. Do not tighten the clamps yet. Position the muffler in the hanger mounts and thread the muffler bolts (the ones you put up with the hangers) into the B&B muffler mounts. Center and level the exhaust tips and tighten all hardware, starting with the hangers and finishing with the clamp.
Ensure that the mufflers are positioned correctly and do not make contact with heat sensitive objects (CV boots, bodywork, hoses, etc.). Start the car and drive around the block. Check that the mufflers and tips are still centered when hot. It may be necessary to readjust at operating temperature. Enjoy this fine B&B Performance Exhaust!
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