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Thread: Exhaust leak?

  1. #1
    Join Date
    Jan 2023
    Location
    NY
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    2003 540i

    Exhaust leak?

    Anyone have an idea what this sound is? https://photos.app.goo.gl/NaSXY9mRxsfDihr46

    Weird ticking noise when I’m above 2,000 rpm’s. Seems like it only makes the noise when under load, can’t get it to make the noise when in neutral. Can hear it best from the driver footwell
    Also makes the noise on cold start, but goes away when the rpm’s drop

  2. #2
    Join Date
    Jan 2023
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    NY
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    My Cars
    2003 540i
    Just did a cooling overhaul, belt and tensioner recently was hoping it was the waterpump making noise but it didn’t fix it. seagreen told me it could be SAP injection pipe o orings so I changed those too with no luck. Should I try hooking up a vacuum to blow air through the exhaust with some soapy water? Or does anyone have any other ideas

  3. #3
    Join Date
    Feb 2022
    Location
    PA
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    1995 325i, 2002 540i
    I would suggest taking it somewhere and getting the exhaust smoke tested. It'll make any leaks obvious, even on the very hard to see headers. I have a smoke machine, bought the cheapest one on amazon, and its been exceptionally useful in diagnosing issues. If you work on your car a lot its a worthwhile investment imo.

  4. #4
    Join Date
    Jan 2023
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    NY
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    2003 540i
    Brought it to a shop today and they’re pretty sure it’s my cats going bad. Definitely not what I wanted to hear 🤦🏼*♂️ at 70,000 miles I would’ve thought the cats would be good for another 100,000 miles.

  5. #5
    Join Date
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    hiss by my window
    FYI regarding aftermarket cats and exhaust shops: OE cats are $$$$ because they contain a lot of the precious catalyst metals. Aftermarket versions have far less (the reason they cost so much less) and are often inferior and short lived. The OE cats are often worth more in scrap than what the new aftermarket ones cost.
    The originals typically last the life of the car. I'd be damn sure* I needed cats before replacing them and if possible source OE units, new or used. Do NOT let the exhaust shop make off with the old ones as they are likely worth several hundred bucks.
    Whatever you do find and repair the problem that has made your cats fail (usually over rich running) or you'll be facing this again.
    Good luck.
    * rattles could just be the heat shields or mounting points

    If you can leave two black stripes from the exit of one corner to the braking zone of the next, you have enough horsepower. - Mark Donohue

  6. #6
    Join Date
    Jan 2023
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    2003 540i
    The cats definitely have a little rattle to them. https://photos.app.goo.gl/gjUFBL9BLtaHLadq5

  7. #7
    JimLev's Avatar
    JimLev is offline Artifically Aspirated Moderator
    Join Date
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    Location
    Sundance Mesa, NM
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    00 540/6, '16 Highlander
    All I hear is the wrench hitting the CAT’s.
    Do you have a code for CAT efficiency?

  8. #8
    Join Date
    Jan 2023
    Location
    NY
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    2003 540i
    There’s definitely a rattle, it’s a little harder to hear in the video. Sounds like there’s a couple ball bearings in the exhaust. Unfortunately I don’t know how to read codes other than a basic obd code reader, and on those I have no codes. I get a SAP bank 1 and 2 engine light every once in awhile but then it turns off after a couple days

  9. #9
    Join Date
    Jan 2023
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    NY
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    2003 540i
    Does anyone have used cats they would sell? I can get a good deal on oem being a bmw parts guy, but it’s still way more than I’d like to pay. Or are there any good universal cats that I could get welded in?

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