BMW E46/E39 Headers Install How-To Tips & Tricks Catless Headers

Within this video I show you how I install headers on E46 and E39, while avoiding the usual problems with them.

[@gregm7508]

Learning how to restore my z3 - I learn the most from this channel. Thanks a lot

[@Nathan_Johnson7723]

Didn’t even think about moving the bank 1 sensor to the downstream bung. Mine wasn’t hitting but it’s close to the bank 2 so I’ll move it so it doesn’t burn out. You mentioned everything I struggled with installing dna headers so great how-to video.

[@OLearysBMW]

DNA motoring was one of the better companies to buy from. But I too had issues with them later on. First time dealing with them, O2 sensor clearance for upstream was great. I had to cut and rotate flanges however. Fast forward years later, terrible fitment issues, even down to the cylinder head flanges, bolt holes needed enlarged.

[@brycemmcclure]

Thank you so much. Most helpful header install video out there. Well thought out explanations. This might be the only video I've found that actually explains the purpose of all 4 sensors and why the downstream sensors are no longer needed after installing catless headers. We need more people making these videos who know what they are doing instead of amateurs documenting how they stumble through the process with poor camera angles. If I were installing an AFR wideband sensor and gauge does it make a difference which header bank I use?

[@OLearysBMW]

Hey there, Thank You for the kind words. When it comes to AFR, I myself enjoy reading all cylinders collectively. So I like to see AFR sensors placed accordingly. But I think reading either bank could be fine, as long as the opposing bank stays happy.

[@wannabezhp]

Best video I've seen to date about installing ebay / chinease headers. Keep up the great work bro

[@theskiegringaseen]

This video was beyond helpful! Thank you so much for the detailed explanations and showing what you are talking about. Saved me a few dollars on new o2 sensors as my downstream sheared off. I also had a laugh seeing you lay atop the engine yanking on the headers ahaha, as a 6'6 dude I could never!

[@deraposo]

Congrats! I saw all the videos in youtube about this and yours is the only one that really goes straight to the problems(O2 sensors mainly) and how to solve them, really good talk and explanation! 1 - Amazing video that all like me who are trying to change to decat headers must see; 2 - Headers can be cheap but its a lot of hard work(€€) and not for amateurs with few tools or no garage. Believe me, its must harder then u think; 3 - Mine is a e46, so the space is really problematic and stressful. U must cut the flanges of O2 sensors to fit and use the hammer in the firewall. 4 - Amazing how this shit still be selled for years all around the world and the fabricant doesnt change this little issues... From Lisbon Portugal, Happy New Year 😎🚘💥

[@OLearysBMW]

Thank You for your kind words! I appreciate that, Happy New Year 🎉🎊🧨

[@keviny7963]

Wish this video existed while I was looking into headers for my e46. Nice work!

[@NorthernChev]

I actually have a Secondary Air Pump Solenoid code and had no idea where it was. Now I do! Thanks.

[@davidpise4510]

You are legend!! Thanks for sharing your hard learned knowledge! 🔥♥️

[@OLearysBMW]

Not a problem, I'm glad you enjoyed this video, 😁

[@richarddenney9984]

Love your videos so much I'm currently building the same orient blau wagon like your working on, started out just doing the manual swap based off your videos, now the motor is out I'm doing all the gaskets

[@seankaine2411]

Bro I hope you make more videos. I love how you got straight to the point..💯💯💯

[@michaelblacktree]

Great video! My experiences have been similar. On my E46 I used the stock E46 gaskets, with the heat shield part removed. But the E36 gasket looks like a cleaner install. I also had to stack gaskets on one of the downpipes. I used metal gaskets, to help prevent leaks. The composite gaskets that come with the cheapie headers are garbage.

[@OLearysBMW]

Yessir, I believe I commented on your one video attempting to warn you ahead of time. Those gaskets blow apart quick, haha

[@flapwheat]

Great video. Did you have to lengthen your front oxygen sensor leads to reach the connectors?

[@OLearysBMW]

@@flapwheat Typically not

[@agdwhite5421]

Great video, i installed those on my 328ci, what a pain in the ass 😂 removing the original ones, fitting the new headers, relocating the hole for the O2 sensor and adapting my mid section to fit took me around 13 hours 🤯

[@OLearysBMW]

Fun stuff, right?? Glad you got it done 👍👍

[@agdwhite5421]

@@OLearysBMW Yes... My favorite part was to screw all these bolts... I had issues reaching them and i felt retarded 😂

[@OLearysBMW]

@@agdwhite5421 Ahh, especially the ones toward the rear.

[@user-nl5pu7ep7d]

how did you get the mid section to fit? im trying to install them on my 328 but the bank 1 header hits the engine mount

[@OLearysBMW]

@@user-nl5pu7ep7d You have to take a hammer to the heat shield of it, or remove the heat shield. I show it at; 13:31

[@NorthWestSamurai]

Very informative video, great work Tyler thank you.

[@NorthernChev]

You know, the flanges at the bottom of my stock manifolds have deteriorated since the last time I changed the guibos. I'ma thinkin' I'm gonna NEED these next time I'm under there for the job. How are they for overheating things in that vicinity under the hood?

[@andy_actually_]

that transition at 10:15 was to funny lol

[@cmongimme]

Incredible knowledge! Do you also have any experience installing headers in an N52 E86 z4?? Thanks

[@1richbish]

Great video... I wish someone would do this for RHD so i can see what I need to do!

[@jackmasci701]

10:20 is my favorite part

[@OLearysBMW]

Lol, nice and comfy. 😁🤣

[@RolandDobranszky]

Hi Lary, i have a question, if i change the headers, i need to change the rest of the exhaust pipes or the connection between the header and the rest of the pipes will be connect properly? So it works great with the rest of the exhaust system? Can you help with this question? Nice video!!! I have a 525i e39 :)

[@OLearysBMW]

@@RolandDobranszky you may or may not have to cut and rotate the mounting flanges of your exhaust to bolt up.

[@RolandDobranszky]

@@OLearysBMW thx! Have a good day!

[@OLearysBMW]

@RolandDobranszky Not a problem at all, Thank You!

[@leveluplife8585]

Great video, thinking about doing this to my x5 e53 in prep for a VF supercharger

[@cuthereat12]

Hey, very informative video. I'm in the process of installing new headers. I noticed that you relocated the upstream o2 sensors to the downstream location. Were you able to plug it back into the upstream harness or you had to lengthen the wire?

[@OLearysBMW]

No lengthening is generally required.

[@ianfarley4773]

I just recently got a 325i with headers idles like crap on a cold start. No o2 sensors plugged in so do I just follow what you mentioned in the video? Thanks for reading :)

[@OLearysBMW]

Definitely want upstream sensors within the system.

[@UntouchableDog]

So even though the bolts will be a little hard to get to, the stock gaskets with the heat shield will still fit?

[@vinderosa8362]

Since your moving the o2 sensor further down will it plug back into the harness the same or is there a different way to put it back in?

[@user-do3sk8xx9v]

This installation could potentially damage the engine support bushing ?

[@paulteran6924]

I been thinking of doing this. But I don’t know if I need an engine mount lift.

[@OLearysBMW]

You can use floor jack and block of wood on AC compressor bracket, that's what I've done for this video.

[@skrsys]

Really great video! When you shorten the bung for the o2 sensor, do you need to tap it to accept the sensor? If you get a chance a video on this process would be very helpful.

[@OLearysBMW]

Hello! The entire bung is threaded.

[@skrsys]

@@OLearysBMW That's good to know, thanks for the reply.

[@OLearysBMW]

@@skrsys not a problem, just leave a chunk for your sensor to thread into, nothing too long or too short. 👍

[@JuarezRichard]

Great video! Were can I get a flash tool to turn off the secondary O2 sensors? Thanks in advance!

[@OLearysBMW]

You'll need to use a tuning software to go in and edit the fields, then flash the car. I use Tuner Pro and MS4x flash tool. If you don't have the time to learn/tune the car yourself, you can contact someone who tunes.

[@revaztkemaladze7250]

The catalyst is e46 m54. I want to install bmw e60 M54. Is it the same ?will go without modification?

[@acedrive328]

Nice tips,I in search of E46 340 2 back trailing arms Diff Rear calipers Axles No subframe.thanks

[@approachinglight7092]

Great video man, my car came with a possibly m52 non tu manifolds and the exhaust has been extended, do you know for sure whether the m52 headers are much shorter than the m52tu/m54 ones?

[@OLearysBMW]

Factory M52 manifolds are used commonly amongst racecars, they are shorter than M52TU/M54 and have a 3-bolt flange

[@approachinglight7092]

@@OLearysBMWI think these are what I have, thank you.. if I wanna go that route I'll probably have to order e36 headers correct?

[@OLearysBMW]

@approachinglight7092 Those M52 manifolds flow just fine man, as to why they're used for SPEC race class and what not

[@cmongimme]

Are Supersprint headers high quality?? Thanks

[@keviny7963]

Do you have the e36 gasket part number?

[@iAmKyleD]

What’s the headers u have!? Part list?

[@SizzaE60]

Hey man I have a question that I haven’t been able to get answers for ever. You seem knowledgeable on this. I have a 2004 E60 530 with the M54B30. These should bolt straight up to the motor right? I’m gonna need to fabricate an adapter to get it to fit my exhaust but they should fit into my motor right?

[@OLearysBMW]

Yes. An M54 is a M54.

[@SizzaE60]

@@OLearysBMW ok, now I’m just worried about my motor Mount clearance because it’s in a completely different spot than e39/46. It’s right under the bigger header, I was worried about o2 fitment until you said you can use the Down streams. Would it matter if I put one sensor on the top plug and another on the bottom on the other header?

[@OLearysBMW]

@@SizzaE60 as long as you have one upstream sensor per header. Bank 1 and Bank 2 must stay separate

[@aidan1885]

What strut bar is that in the e46 at the end of the video? Looks really nice

[@OLearysBMW]

Ahh, I haven't unveiled that yet 😁 it's from Dusan Strut Works. With custom powder coat I had my good friend do. I also have a trunk brace, same company. They will be shown later during E46 rear subframe/mounting point reinforcement.

[@JermWahBeam]

You are amazing

[@AyrtonsLoafers]

I know you know what your doing and you’ve done it a million times. But I’m so wary of damaging brittle vac/cooling stuff I’ve never thought of climbing over my engine.

[@duncancirip3266]

Bro I ain’t even touch mine doing Valve cover gasket and it snapped on me. If one of those annoying skinny brittle lines break on you, cut up a plastic straw, tape both sides around with some electrical tape and your all good :)

[@cadenbalibrera9015]

You mention having a cell tell you get a tune who or where would I find a good reliable tuner?

[@OLearysBMW]

There are loads of tuners for these DMEs, just have a gander online.

[@idokwatcher2062]

Schmiedman sells Alpina B3 headers and 200CEL catalytic converter package. It is best bang for the buck for E46 and remain street legal.

[@GlozaMr]

were you able to retain the AC lines or did you have to remove them or re-route them? thank you.

[@OLearysBMW]

Zero issues with AC lines. Sometimes gotta bend them for clearance of your hands, but that's all.

[@GlozaMr]

@@OLearysBMW thank you

[@RCincorporated]

Great video on this. I just had my headers installed. The one thing I’m having an issue with is my upstream O2 sensor. I burn too much oil therefore it seems as if I kill the O2 sensors fast and I recently stared getting the EML light. Is there a way to fix this issue with the O2 sensor without changing engines?

[@OLearysBMW]

I would first figure out where the oil consumption stems from. I would do a compression test, just to see where that stands. If the compression is low on some cylinders I have a couple things you can try before assuming the rings are shot. Which I don't see often on these engines.

[@RCincorporated]

@@OLearysBMW Thanks for answering. I’ll do a compression test on it. It runs very well and has lots of power but I never done a compression test on the car. I can get back with an update on my results. I do have 220K miles on it so hopefully the rings are not the issue.

[@OLearysBMW]

@@RCincorporated No problem! 220k may seem high but these engines love it. I have over 274k on my daily driver E46, and I don't baby that car at all.

[@RCincorporated]

@@OLearysBMW Lol same here. It’s my daily and I treat it well, but I do give him hell. I love this car and want keep it until I need a new motor. Are you located in LA by any chance?

[@OLearysBMW]

@@RCincorporated I'm over in Pennsylvania

[@jonathaanjaakop]

Do I have to use 24 struts ? When original exhaust manifolds only have 16 ? I'm not sure I want to drill 8 more holes into it, or will it leak if I don't ?

[@OLearysBMW]

You'll be fine to use the 16.

[@FELIPE8226M]

Great informative video!

[@metno_]

Hey, so if the upwards 02 sensor were to fit, would you even need to run the lower ones, since they just check the health of the cat?

[@OLearysBMW]

Nope. I still leave them out, as they'll get coded out with corresponding header tune regardless.

[@benedusi]

How about the e60 with the m54b30, is it the same?

[@Tudorrevival118]

Do you put a blank off plate over the removed secondary air pump check valve mount?

[@OLearysBMW]

Yes, you want to plug/blank that port on the cylinder head.

[@ArbenZilci]

Awesome video thank you

[@OLearysBMW]

Not a problem, Thank You for watching

[@nunyabusiness7405]

where did you get these headers?

[@kjellsonneveld1532]

Hi, great video but i got a question. I'm building a turbocharged e46 at the moment and my goal is to pass the emission test in my country, can i weld a cat somewhere in my single exit exhaust system and just put the 4 sensors in front and after the cat or does this not work like that? Someone help me plssss🤣

[@OLearysBMW]

Yes, you can add a cat. Can't say for certain if the original downstream sensors will recognize an aftermarket cat to be sufficient, though. I would tune the car to delete downstream sensors, to keep the engine light off, but still install a downstream sensor to pass the visual inspection. One cat = one downstream sensor.

[@kjellsonneveld1532]

Aah okay! I think i will do that. Thanks for responding, this helps alot!

[@anthonyk]

Does the engine need to be lifted up in the E39? I see it sorta was. How do you go about doing that if needed?

[@OLearysBMW]

Yes, it's needed. Using a jack under the AC compressor bracket works wonders.

[@dakota6541]

So with the downstream flanges I can use 328 headers on a 528 but not m54 headers without cutting/welding

[@OLearysBMW]

Correct.

[@reza_dc2]

how do you get the o2 sensors coded?

[@RandyCordovaCordova]

I installed some headers from ebay and now the car starts but wont continue running. Would you have an idea as to why it doesnt turn over?

[@OLearysBMW]

Potentially have the upstream O2 sensor plugs crossed or the ground wire from engine mount arm not fastened.

[@FnGcode]

Hey what’s up man quick question I know after you install the headers the check engine light but what codes did ur car pop up ?

[@OLearysBMW]

Depends. If you opted to not run downstream sensors, then it will obviously throw codes for downstream sensors (Bank 1 Sensor 2, Bank 2 Sensor 2). If you have other codes or car is running rough, you may have mixed up the plugs for the upstream sensors. As they're the same plug. What codes are you having?

[@FnGcode]

@@OLearysBMW I’m having p0056 p0036 and yes I removed the downstream sensors is that the reason just wanted to be sure

[@OLearysBMW]

@@FnGcode yep, 👌 you'll suffer no performance loss. Just an annoying light until you code the car.

[@FnGcode]

@@OLearysBMW alright awesome thanks for taking the time and replying to me I appreciate it have a good day 👌🏾🙏🏾

[@OLearysBMW]

@@FnGcode Not a problem at all, you as well my man ❤️

[@gbc_julian8958]

whenever i move the upstream o2 sensor to the bottom one do i use the upstream plug or the downstream plug of the wiring harness

[@OLearysBMW]

Upstream, obviously. The plugs are physically different. Do not mix up Bank 1 and Bank 2. Same upstream plugs.

[@gbc_julian8958]

@@OLearysBMW ok thank you i will attempt this install next week lol

[@ingegneriafacile]

you are marvellous!

[@avgskater]

Will these headers work for a facelift or are they different

[@OLearysBMW]

That is redundant when it comes to header fitment.

[@unknownyouth7759]

i recently installed some catless headers but the engine mount doesn’t really fit under the headers is there any tips on what i can do?

[@OLearysBMW]

Did you modify the heat shield, like I showed in the video?

[@unknownyouth7759]

@@OLearysBMW yea i finished the job already i just had to beat the shield down a bit but the header rests right on the mount

[@1richbish]

Please tell me how you removed the exhaust manifold bolts 😢 I'm currently stuck trying to remove the rear ones

[@OLearysBMW]

I use an one inch extension and deepwell 11mm typically. All depends on your tools.

[@OLearysBMW]

Or if you're meaning the bottom ones that grab the exhaust, they're typically rotted depending on your climate. I usually have to snap them off with extractor sockets.

[@1richbish]

​@@OLearysBMWI got them off! Took me nearly an hour per bolt .. what a nightmare... Now I'm thinking about some aftermarket headers for an easier install

[@eightpenny6379]

Do you think I can do the same headers on M54B30 in 2004 X5?

[@OLearysBMW]

Yes.

[@eightpenny6379]

@@OLearysBMW Thanks! I was wondering. Just subbed because of all your great instructions.

[@kevinmcgannon1630]

A+ content. Thank you

[@OLearysBMW]

Thank You, you're welcome 😁

[@irvinzuniga353]

where you get those headlights ?? for the silver e46.

[@OLearysBMW]

Not available to buy. I built them.

[@tweedjohnny8740]

The only thing I would have seen you do is rap the header is wrap it to help reduce heat soak to the engine block.

[@OLearysBMW]

Wrapping the headers leads to cracking, allows too much heat entrapment.

[@donnyn.1126]

What kind of rtv are you using? Wont it get too hot for the rtv?

[@OLearysBMW]

Permatex Optimum Grey. As mentioned. Works good, I've been using it for years directly on exhaust manifold gaskets. Also, it's easy to remove/scrape off once fully cured, if the time ever comes.

[@tweedjohnny8740]

Awesome content, truly informative. I think before I do this I will go turbo. Thank you

[@AlexisJavier18]

That engine only used two oxygen sensors?

[@OLearysBMW]

Did you not listen to a word I said? Lol. It used 4.. the downstreams are not needed on E46 with catless headers. You tune them out.

[@desipranksterz7909]

I've been looking for some headers that would be direct bolt on and no modifications anyone have recommendations on who to buy from?

[@OLearysBMW]

Racing Dynamics or Bimmerbrakes

[@jesselogel6771]

What are the part numbers for the gaskets?

[@vtx1300c74]

literally all e36 gaskets work

[@gbc_julian8958]

also where can i find e36 manifold gasket

[@OLearysBMW]

Probably anywhere that would sell exhaust manifold gaskets for a E36. Autozone, FCP Euro, O'Reilly's, Advance Auto, NAPA.. etc. Example model; 1996 BMW 328i

[@gbc_julian8958]

@@OLearysBMW ok thank you

[@HARLEM430]

Great video

[@OLearysBMW]

Thank You

[@31acruz]

What is the benefit of installing headers? what are the cons of installing headers?

[@OLearysBMW]

Benefits; More free flowing exhaust, allows for more diverse power band Cons; if not running premium grade fuel, exhaust is more smelly. Also will fail smog tests if your area does that.

[@mr9chris]

Where are you located bro? feel like bringing my car to you for this job. Lol

[@OLearysBMW]

Pennsylvania

[@mr9chris]

@@OLearysBMW thanks for the quick reply you’re across the country I’m in LA California 😭😫

[@OLearysBMW]

@@mr9chris You forgot that in the land of KZbin, we're all millionaires. I'll have your car shipped over here, no questions asked. (Yes, I'm kidding)

[@mr9chris]

@@OLearysBMW hehe man I wish, Great video dude!

[@OLearysBMW]

@@mr9chris Thank You, man. 😁

[@addisonaugustin327]

how are you passing inspection?

[@GimmeRetro]

He probably doesn't live in a state that requires that nonsense. They still exist.

[@Ars_fabs]

Is it the same with a 330xi??

[@OLearysBMW]

The same concept, yes. The xi has a different front subframe, etc. But I've installed headers on them as well, basically the same process.

[@justsaiyan8897]

Legend.

[@IsmaelAlejandro-y5n]

what brand are these ?

[@OLearysBMW]

They came from a parts car, not sure. All these cheap China headers are hit or miss.

[@franciscoramos6676]

Will these e36 gaskets fit an 04 330i ?

[@OLearysBMW]

Yes.

[@franciscoramos6676]

@@OLearysBMW thank you

[@lilwoody1889]

Can someone link the headers?

[@OLearysBMW]

They're harder to find now, the EPA has fined some suppliers of headers. You can still find them at Pro Tuning Lab, "for offroad use only."

[@truet608]

The cut at 10:14 caught me off guard lmao

[@OLearysBMW]

Works a treat! 👌🤣

[@Oksxnd_y]

10:10 skipped ten seconds forward to 10:20 and this dude was on his car😭😭 I do the same gng

[@ClipBallerr]

My gaskets came seperated lol 😂

[@OLearysBMW]

That's hilarious, 🤣

[@ClipBallerr]

@@OLearysBMW also thx for this video man. took notes in my notebook and tmro im going to trim the o2 flanges. what did u use?

[@OLearysBMW]

@@ClipBallerr Grinder with cut off wheel. Then a sanding disc if I had to touch up for flatness.

[@ClipBallerr]

@@OLearysBMW ok thank you man! one more question. The bolts at the exhaust flange, the 15mm ones. am i supposed to reuse the ones from my old cats cuz theyre rusty as hell. or is there a part number for them i tried to look it up and couldnt find anything for some reason

[@OLearysBMW]

@@ClipBallerr those are studs, not bolts. They will remain with the cats.. I typically just snap them. No reason to play around, they won't get re used.

[@whotfislvk]

what flange bolt did you use?

[@micheal_bmw]

Just bought headers for my bmw m54b30 and I wasn't wanting to unhook engine belts to put headers in is that possible

[@OLearysBMW]

Belts?

[@micheal_bmw]

bolts my bad @@OLearysBMW

[@OLearysBMW]

@@micheal_bmw It's practically a must. Use a floor jack with chunk of wood on AC compressor bracket, remove passenger motor mount nut, jack up. If equipped, you'll want to remove clutch fan and shroud to get more height. You'll also benefit from removing the motor mount arm itself.

[@steviepere1822]

Would i pass inspection after getting coded cel ?

[@OLearysBMW]

I can't offer advice to forcefully pass inspection, as that's illegal. But, if someone tuned the DME to show the monitors as 'ready', at all times. Then *perhaps* one would pass the typical emissions system inspection.. *perhaps*. Perhaps may also mean; probably, or more than likely, strong possibility. But I wouldn't know. As I don't condone these modifications for a street car. Thanks for watching. 😉

[@steviepere1822]

@@OLearysBMW thanks i get you keep it up brotha good details

[@OLearysBMW]

@@steviepere1822 Not a problem at all, man. Typically whenever the downstream circuits are disabled, it sets them to 'ready' by default. But can always check with a scanner before inspection time, just to see.

[@idokwatcher2062]

Just get some 200CEL catalytic converters and put them in section 1 of exhaust like M3 had. Or one big catalytic converter and merge two banks of the engine with a Y pipe.