New-to-me 1992 735iL – the fun begins!

[Cactuar]

Hi all, I have a quick question. If I want to replace the catalytic converter, mid muffler and rear muffler on my car (also the exhaust manifold gaskets), does it require welding? Providing I can support the system, could I do it myself?

Part #1 here https://www.realoem.com/bmw/enUS/sho...diagId=18_0884
Parts #1 and #2 here https://www.realoem.com/bmw/enUS/sho...diagId=18_0885

[theBMWbeast]

It all unbolts. Any particulars as to why you’re replacing basically the entire system sans headers?

[CroughtonE32]

No welding. I had to replace my cat a few years ago. I settled on DEC. They make a direct fit. One for 48 states for about 400 dollars and a 50 state for about 800 dollars. Not sure of the pricing now. I went for the 48 state because I'll never register in California and Florida actually has no inspections any longer. So I would have gone with the cheaper one anyway. It's been perfect. I decided to do everything at once just for age. I watched him do the work and everything bolts together. It was a one man job. I did help him a little by holding things up for him while he installed the new rubber hangers. That new rubber hanger on the rear box is a pain in the ass to get in. It barely stretches but once it's on that rear muffler doesn't move at all. I took a picture that day. You can see the perfect fit.

https://hosting.photobucket.com/albu...psqygcuwld.jpg

Just thought.................without a lift this would be a very tough job. Also this Cat comes with both pipes going right up to the exhaust manifold. All in one piece.

[Cactuar]

There is an annoying drone in my car and I'd like to rule out the exhaust completely. Also when I smoke tested my exhaust system I could see drips of mineral oil (used to generate the smoke) on the lower part of the rear muffler, so it's not sealed. And the exhaust in general is rusty. I'd like a perfect OE sound.

It's good to hear that the parts bolts on. I'm not sure if I can source a DEC cat in Canada but Jeff if you say the fit is perfect it might be worth importing one. The original cat is NLA.

[letank]

There is an annoying drone in my car

Drone can be some rubbing at certain rpm range! due to vibrations.

recheck all rubber hangers. The middle one failed a few days ago... smelling an acrid burn... I thought of something plastic...

[vr117]

Just because it bolts together don't mean it won't fight you coming apart!! I also live in an area that uses high amounts of salt have a cutting tool ready and able and also a torch. and the manifold studs like to break as well upon removal so have a means to extract them if your gonna tackle it yourself. quite honestly not trying to sway you from doing the job but if its really rusted weigh your options this isn't impossible but it can be a daunting job on jack stands price out a few exhaust shop prices in your area it may save you aggravation in the long run if its really rusty

[kce1900]

The original was in one piece, but I doubt that you can still get it that way. BMW rear and centre mufflers seem to be separate parts now that have to be welded together. Aftermarket may be different.

@Cactuar, are you planning to go with a new BMW exhaust system or aftermarket? Original muffler part are available, but expensive. The catalytic converter appears to be NLA.

[Cactuar]

Vr yeah I know, it can be a pain! I'm weighing the options... I have absolutely zero trust in shops to do the right thing and treat my car right. That's why I'd really like to do it myself.

@Kce: Yeah that's why I asked if it had to be welded, because I don't see any joints or clamps between the stock mufflers. It seems to be welded. I would go with BMW parts for the mid and rear mufflers. I'd have to go with an aftermarket supplier for the cat section.

Did you get your rear muffler installed?

[kce1900]

Yes, I did. I had it done by my usual mechanic.

[Cactuar]

Great. Car is nice and quiet?

I need to find a good euro mechanic close to me... Not easy in a rural area!

[CroughtonE32]

JF,
You posted where these were a couple of months ago. I ordered and two came from Latvia this morning. Thrilled to be replacing my home made E32 M30 front plate with this original. Worth the wait, thank you.
Jeff

[Cactuar]

Nice! Can't wait to see it on your car.

Vr I tried the ball joint separator you recommended (different brand off Amazon) and it worked great. I couldn't get the forks to slip fully under the pitman arm but it still worked. Made a loud pop

[vr117]

Nice! Can't wait to see it on your car.

Vr I tried the ball joint separator you recommended (different brand off Amazon) and it worked great. I couldn't get the forks to slip fully under the pitman arm but it still worked. Made a loud pop

yea if unprepared it will give you a shock lol glad I was able to help and I totally understand the no one will do it better on my baby mentality than me I have it myself most of us on the forum here do as well .but truth be told even I turned to someone with more skill and experience during my stalling saga for help!!! building a relationship with a local technician you trust when your outside your comfort zone is not a bad thing at all even if its just to ask questions and tap their wealth of knowledge .exhausts are like legos they fit together only one way but the problem is is it easier to buy the tools you need to do the job without hassle or pay the labor to someone you trust that is the question because if that exhaust has been there 30 years and is rusted bad the studs will break coming apart its more common than you know especially in the rust belt and the hours you spend trying to correct that a shop that has the tools a lift and knowledge can knock it out in a third of the time whatever you choose I'm here to help if you need me

[Cactuar]

I have to go to the local shop tomorrow to get my idler arm bushing pressed in. The mechanic is good but not familiar with BMWs. I'll discuss it with him and see if he has interest in this type of work.

By the way, when recording footage for the center link replacement, the joint on the pitman arm made such a loud pop when it released (like a gun shot), it actually broke the external mic input on my camera! I'll use my phone to record audio with the external mic and combine it with the footage in editing. But yeah that thing was super loud, glad I was wearing ear protection.

[vr117]

Yea Holy crap it goes off like a rocket launcher lol I remember the first time I encountered it doing a control arm replacement on a Mercedes C CLASS several years ago I had to take a min and compose myself afterwards lmao

[CroughtonE32]

Just detailed and had my guy switch out the front tag.

[Cactuar]

Lovely pictures.

You should send your ownership story to the BMW Group Classic youtube channel, they are looking for such stories. https://www.youtube.com/watch?v=IQt2CwKScpg

[vr117]

Your Car looks great!!! my sons 1990 535i is the same color

[CroughtonE32]

Your Car looks great!!! my sons 1990 535i is the same color

VR177 is correct. This is the wrong thread for me to be posting pictures of my ride. I only wanted to show you how the new tag looked since you gave me the link to buy it in Latvia. I deleted all those pics and put them where they belong in the "show your ride" thread. Funny thing is I only paid about 35 bucks for two of those tags. They must have sold quickly because I looked yesterday for a friend who wanted one, and the 7er is going for $299.00. Al the others he's selling are still under 40 bucks. Guess he wanted a little extra $$$$ for that last set.
Jeff

[vr117]

The old Bronzitbeige metallic. Goes back a long way. Younger people don't seem to like the color..

my kid is 20 and absolutely loves everything about his E34 535i he daily drives it !!! it was a Highschool graduation gift best 800 bucks I ever spent this is the day it came home in fall 2019

- - - Updated - - -

sorry Cactuar not trying to jack your thread lol removed the photo

[CroughtonE32]

my kid is 20 and absolutely loves everything about his E34 535i he daily drives it !!! it was a Highschool graduation gift best 800 bucks I ever spent this is the day it came home in fall 2019

- - - Updated - - -

sorry Cactuar not trying to jack your thread lol

I took your advise and moved those pics. You made me realize I was jacking the thread. I appreciate the subtle reminder. I am glad your son loves his E34. We need to keep these things on the road.
Jeff

[vr117]

To be all honest I threw that in as a joke because we went a little off topic lol Jeff we all love these cars so much !!! I loved the pictures you posted so did he from his post you were showing off the plate he advised where to get I’m the guilty party if anything I just thought it was cool to show that there are some of the younger generation that appreciate the color as well!!! I removed my photo because it was unnecessary

[Cactuar]

Short update... I got the new idler arm bushing pressed by a shop and am ready to reinstall the refreshed steering components. However, I got bit by the "while I'm there" bug and will do a front suspension refresh at the same time.

I've been making a parts list with the help of Moroza in private messages. I'm going with Lemforder bushings, Sachs strut inserts and BMW spring pads/strut mounts.

Dropping the front end is something I've been wanting to do, just enough to reduce the fender gap. I remembered this thread about using E24 M6 springs. According to e30luv318i the springs from a 635 should work just as well as M6 springs. I decided to go with Lesjofors 4008419 springs. They are affordable and in stock. They should lower the front of my car a bit without affecting comfort. Also they are cheap enough to run an experiment and check if it's a viable solution for E32 (735 specifically) owners to lower their cars. I can always go back to stock if it doesn't work or have the inner coils on my stock springs compressed.

I'm also ordering parts for a braking system refresh, my car badly needs it. The brake fluid is quite dark... Anyway, I will post updates when I get the parts and make some progress.

[vr117]

I did not lower my car but I will tell you this I did verbatim to my front and rear suspension and steering as well as flushed the brakes it makes a night and day difference in the handling of the car it rides like brand new and I’m sure it will make you pleased!!! Just a suggestion as far as the brake bleeding if you don’t already own one either a motive European bleeder or swaben power bleeder will make the job a million times easier and is a great tool to add to your collection they aren’t expensive.also not sure if you did this your build thread is huge and I haven’t been through it all but new brake hoses are inexpensive and a worthy update to the car if they are original as well as to make your life easier for future bleeds buy 4 new bleeder screws and swap them because they like to snap and a quality set of line wrenches will be helpful as well .I spent several days before the bleed soaking the bleeder screws in seafoam deep creep before attempting to crack them and on the day of the job I used crc freeze off penetrating fluid which freezes the metal and mine cracked free without breaking saving me from the nightmare I had with my parts car where all 4 bleeder screws cracked due to rust

[Cactuar]

Great tips thanks vr! I did not yet replace the brake hoses but it was definitely on my list (I chose Corteco hoses). I'll add the bleeder screws to the list, glad I didn't order from FCP yet.

I'll look into a power bleeder too. Can it work on Japanese cars too, maybe with a different cap? Then I could service our family van with it.