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Thread: Another Exhaust Question

  1. #1
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    Another Exhaust Question

    So looking into upgrades and modification for my 98 540i. My entire exhaust system needs to be replaced minus the headers. So I would like either a smart answer or something from personal experience.

    For the catalytic converter should I stay with single dual like stock, or just go with one with either 2 in & 2 out or 2-1?

    Kissing the "Y" resonators goodbye and going Dual Exhaust.

    Any ideas would be nice. If you have a type or brand in mind, please share.

    Thanks. Full Exhaust System.jpeg

  2. #2
    JimLev's Avatar
    JimLev is offline Artifically Aspirated Moderator
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    Gonna be loud without the resonator.
    If you have to pass emissions you should keep the 2 OE CAT's. They are probably bigger and have less restriction that what you would use to replace them, unless you are going to use some pricey 100 cell CAT's.

  3. #3
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    Quote Originally Posted by JimLev View Post
    Gonna be loud without the resonator.
    If you have to pass emissions you should keep the 2 OE CAT's. They are probably bigger and have less restriction that what you would use to replace them, unless you are going to use some pricey 100 cell CAT's.
    My orginal CAT's are bad and have an exhaust leak i have to change them regardless. So I know there are 4 O2 sensors that have to be plugged in there and living in Texas.

  4. #4
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    I have dual on my car, big pain in the ass getting two mufflers in thanks to the battery.
    1997 540 / 6 Sport, 2001 540 staggered rims
    Suspension = Bilstein B8 Performance Plus Struts, Xeon headlights & fog lights, LED tail lights, Evo short shifter, Custom air engine intake, 3 inch dual exhaust hollow cats,NGK iridium spark plugs, removed -clutch delay valve

  5. #5
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    Quote Originally Posted by Franktea View Post
    I have dual on my car, big pain in the ass getting two mufflers in thanks to the battery.
    Did you keep the CAT's or change them out?

  6. #6
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    Removed them, i rewired my 02 to pass with 02 simulator. If you just go with stock muffler remove resonator car sounds awesome.
    Last edited by Franktea; 09-01-2017 at 12:26 PM.
    1997 540 / 6 Sport, 2001 540 staggered rims
    Suspension = Bilstein B8 Performance Plus Struts, Xeon headlights & fog lights, LED tail lights, Evo short shifter, Custom air engine intake, 3 inch dual exhaust hollow cats,NGK iridium spark plugs, removed -clutch delay valve

  7. #7
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    Quote Originally Posted by Franktea View Post
    Removed them, i rewired my 02 to pass with 02 simulator
    Notice power change? Thata why i might just go with a single system by 2 in 2 out with x pipe

  8. #8
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    Quote Originally Posted by TJ98E39 View Post
    Did you keep the CAT's or change them out?
    ill upload a video of my set up later today but my set up is catless headers true duel exhaust 2.5 inch stainless straight piping to the y now on the y section i dont have the factory resonator but have have a after market resonators on eon each pipe leading to the y section. Then from there i have it going to single muffler with akraprovic carbon tips
    540i 6spd DUDMD tuned-weekend brute, sounds like an M5 throaty V8 "Vtec-ish" cam noise.

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  9. #9
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    Your butt dyno will notice a great increase in power, due to the noise.

    Magnaflow makes good quality high-flow cats, model-specific.

    If you do go with duals, be sure to include an X-pipe.
    Last edited by edjack; 09-01-2017 at 01:37 PM.


    Ed in San Jose '97 540i 6 speed aspensilber over aubergine leather. Build date 3/97. Golden Gate Chapter BMW CCA Nr 62319.

  10. #10
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    Quote Originally Posted by edjack View Post
    Your butt dyno will notice a great increase in power, due to the noise.

    Magnaflow makes good quality high-flow cats.
    Yeah that's what I was looking at the high-flow, maybe an X pipe.

  11. #11
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    I edited my post to include "model-specific."


    Ed in San Jose '97 540i 6 speed aspensilber over aubergine leather. Build date 3/97. Golden Gate Chapter BMW CCA Nr 62319.

  12. #12
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    Cool guess I'll just get everything maganflow make it easy

  13. #13
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    One day i was in Manhattan and the cats were so clogged i could even run the motor, I pulled the 02 sensors out before the cats just to have enough exhaust flow to get home. Long story short i bet i have more HP than stock, all restrictions gone, A CAT is like trying to take a poop through a cheese grater.
    1997 540 / 6 Sport, 2001 540 staggered rims
    Suspension = Bilstein B8 Performance Plus Struts, Xeon headlights & fog lights, LED tail lights, Evo short shifter, Custom air engine intake, 3 inch dual exhaust hollow cats,NGK iridium spark plugs, removed -clutch delay valve

  14. #14
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    Yeah but I live in TX we still require emissions.

  15. #15
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    Thats why you get the 02 sims
    1997 540 / 6 Sport, 2001 540 staggered rims
    Suspension = Bilstein B8 Performance Plus Struts, Xeon headlights & fog lights, LED tail lights, Evo short shifter, Custom air engine intake, 3 inch dual exhaust hollow cats,NGK iridium spark plugs, removed -clutch delay valve

  16. #16
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    I'm already taking the resonators off and putting X-Pipe, going to try dual Mufflers, that's going to be extra loud. I might just keep the CAT's

  17. #17
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    The mufflers you choose will be very important, i would listen online at other on You Tube could sound really bad depending on setup.
    1997 540 / 6 Sport, 2001 540 staggered rims
    Suspension = Bilstein B8 Performance Plus Struts, Xeon headlights & fog lights, LED tail lights, Evo short shifter, Custom air engine intake, 3 inch dual exhaust hollow cats,NGK iridium spark plugs, removed -clutch delay valve

  18. #18
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    Well it's done, sounds beautiful. Not loud at all, even with the resonator delete.

  19. #19
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    Looks Good,

    Going to do mine in the near future. Just a Catback setup. Leaning towards a Billy Boat or the cheap route with a TopSpeed Pro-1 and possibly a Vibrant bottle resonator to replace the stock Y-res.
    1998 540A M62 Black/Black Style 37's Dynavin N6 (SOLD)

  20. #20
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    Quote Originally Posted by Texasdeere View Post
    Looks Good,

    Going to do mine in the near future. Just a Catback setup. Leaning towards a Billy Boat or the cheap route with a TopSpeed Pro-1 and possibly a Vibrant bottle resonator to replace the stock Y-res.
    I took mine out completely.

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