The factory stock 545i features the powerful 4.4L V-8 and produces 325 HP and 330 lb-ft. of torque. Developing an exhaust system worthy of this outstanding automobile was a tall order. Billy Boat Exhaust was up to the task and delivered the ultimate performance exhaust for this beautiful BMW.
Featuring mandrel bent, T-304 stainless steel and precision hand-craftsmanship, the system for the 545i provides custom-tuned performance with a harmonious, subdued exhaust note and no interior resonance. The proprietary design of each Billy Boat Exhaust provides increases in horsepower and torque throughout the entire RPM band.
Aesthetics were another important factor in the development and design of this muffler system. Simply providing performance gains and a balanced exhaust note were not enough to declare this the ultimate system for the expertly engineered BMW 545i. With twin 3.5″ fully-polished double-wall tips the Billy Boat system delivers well beyond expectations.
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The Magnuson-Moss Warranty Act makes it illegal for companies to void your warranty or deny coverage under the warranty simply because you used an aftermarket part. READ MORE…
Download PDF here… FBMW3110
Installation of the Billy Boat Exhaust on your E60 545 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 Billy Boat Exhaust installation procedure.
1) Disconnect the battery negative terminal for safety to allow the computer to reset.
2) The original muffler pipe needs to be cut through to remove the muffler. First remove the vacuum line from existing muffler and plug. See photo A. Cut approximately 2” from bend in existing pipe. See photo B.
3) Slip the Billy Boat Exhaust muffler inlet pipe and supplied clamp over the remaining original pipe. Do not tighten the clamps yet.
4) Position the muffler in the hanger mount. Center and level the muffler can, tighten clamp.
5) Ensure that the muffler is positioned correctly and do not make contact with heat sensitive objects (CV boots, bodywork, hoses, etc.).
6) Enjoy your Billy Boat Exhaust!
SAFETY: Appropriate disassembly, assembly methods and procedures are essential to ensure the personal safety of the individual performing the kit installation. Improper installation due to the failure to correctly follow these instructions could cause personal injury or death. Read each step of the installation manual carefully before starting the installation.
VEHICLE SUPPORT WARNING: Should the purchaser decide to install this exhaust product at home, be warned that car or light duty truck/van “bumper” jacks are intended for emergency use only. The use of frame contact jack stands in conjunction with a floor jack as main support is highly recommended to minimize accidental dropping of a vehicle while the installation proceeds. We recommend the use of a shop hoist if possible. Please use caution!
GENERAL STATEMENT OF LIABILITY: While we provide information for do-it-yourself installation of exhaust systems and related items, these operations are not without risk. Injury may occur during an installation or exhaust systems and their components may be damaged in the process. We are not responsible or liable for damages that may be sustained to persons or property during an installation. For this reason, we recommend professional installation as the best option when at all possible. While care has been taken in the preparation of the information contained in this web site, Billy Boat Exhaust and BillyBoatExhaust.com does not and cannot guarantee its accuracy. Anyone accessing this information does so at their own risk. It will be assumed that access indemnifies Billy Boat Exhaust and BillyBoatExhaust.com from any and all injury or damage arising from such use.
LOCAL LAWS & LIMITATION OF LIABILITY/DISCLAIMERS: Local Laws & Limitation of Liability/Disclaimers: The regulation of emissions production, noise levels and safety standards is undertaken by the federal government, each of the fifty state legislatures, and by many local municipalities, towns and counties. The manufacturer makes no warranties of merchantability, of fitness for a particular purpose, or that its products are approved for general use, or that its products comply with laws, regulations or ordinances in the states where they may be sold to the ultimate purchaser, the consumer. The entire risk as to the conformity of this product in any such state and as to repair, should the product prove to be defective or non-conforming, is on the retail purchaser, the buyer, the ultimate consumer of such product and it is not upon the seller, distributor, or manufacturer. In this connection, retail purchaser, the buyer, the ultimate consumer assumes the burden of the entire cost of any and all necessary service, alterations, and or repair. The foregoing statement limits the liability of the manufacturer.
If you have any questions please feel free to give us a call. Our direct line to the sales departments is 1-888-228-7435, ext 18. We are in Phoenix, AZ and can be reached 8am-5pm. Should you have questions that images would help explain, please email Mike at firstname.lastname@example.org.
*Please note, we do not follow daylight savings time if you are contacting us outside of Arizona.
We try to put as much information as possible within our product pages to help with application choice and the installation process. The business you purchased our product from can be a wealth of information, but should you need additional help and information, please feel free to call or our sales department.
Monday-Friday 8:30am-5:00pm Arizona time.
888-228-7435 x18 or 623-581-7600 x18
*Note that Arizona does not follow Daylight Savings Time.
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