So you want to give your BMW e46 a performance boost by installing aftermarket headers, but you’ve heard that it requires dropping the entire engine out of the car to access them. The thought of that level of work probably gives you nightmares of blown gaskets, scratched cylinder walls, and a garage that looks like a bomb went off in it. The good news is, with some patience and the right tools and technique, you absolutely can install e46 headers without removing the engine. It’ll still be a tricky job, but with some elbow grease and by following some proven tips from those who have gone before you, your e46 can have a new set of free-flowing headers installed in a weekend without the headache of a full engine drop. Sound good? Then roll up your sleeves, grab your wrenches, and let’s get to it. The power and sound you’ve been dreaming of is within your reach if you’re willing to get your hands dirty.
Evaluating Your Options for E46 Headers
When it comes to e46 headers, you’ve got a few choices to consider. Stock headers will work fine for most daily driving, but if you’re looking to increase performance, aftermarket headers are the way to go.
High-flow cat-back exhausts pair well with performance headers to maximize power gains. Stainless steel headers like those from Remus or Dinan are corrosion-resistant and long-lasting, though pricier. For budget-friendly performance, pacesetter or OBX headers can bump up your BHP for a fraction of the cost.
For the best power gains, go with headers that are specifically tuned for your E46 engine model. M54B30 engines, for example, will benefit most from headers optimized for the 3.0L 6-cylinder. You’ll also need to decide between shorty and long tube headers, which trade off high-end power vs. low-end torque.
Installing headers yourself is challenging but doable. You’ll need basic tools and mechanical skills, patience, and a free weekend. The job requires removing components to access the stock headers, then reinstalling everything with the new headers. If that sounds daunting, a certified mechanic can handle installation for a few hundred dollars.
In the end, E46 headers are a great performance mod and vital for anyone serious about tuning. Do some research on your options to find what suits your needs and budget. With the right headers installed, you’ll be enjoying more power and an even sweeter six-cylinder sound from your BMW.
Do E46 Headers Require Engine Removal?
The good news is, removing the engine isn’t always necessary to install performance headers on your BMW E46. Whether or not you’ll have to lift the engine depends on a couple of factors.
First, it depends on your level of mechanical skill and experience. If you’re pretty handy under the hood, removing and reinstalling the engine may not intimidate you. However, for a first-timer, it’s definitely easier to install the headers without pulling the engine.
It also depends on how much space you have to work with. The E46 engine bay can be cramped, making it difficult to maneuver the new headers into place, bolt them up, and connect all the necessary hoses and wiring with the engine still in the car. If you have small hands and patience, it’s doable, but removing the engine will provide much more room to operate.
Finally, it depends on which headers you choose. Shorty headers that only extend partway into the exhaust ports are easier to install without removing the engine. Long tube headers that run all the way to the catalytic converters will likely require dropping the engine to install.
So while it may be possible to put headers on your E46 without an engine hoist, assess your own skills and the complexity of the job before deciding. If in doubt, it’s best to remove the engine—it’ll make for an easier install and ensure the best, leak-free fit for your new high-performance headers.
CCV Reroute for 6.7 Powerstroke When Upgrading Headers
To install headers on your BMW E46 without dropping the engine, you’ll need to reroute the charge cooler vent (CCV) hoses. The stock headers use these hoses, but aftermarket headers require rerouting them. This may seem daunting, but with some patience, it can be done.
First, locate the ccv reroute 6.7 powerstroke hoses under the intake manifold. There will be two hoses connected to the side of the manifold—one coming from the charge cooler in front of the radiator and one leading to the intake. Use a flathead screwdriver to loosen the hose clamps securing these hoses.
Next, remove the hoses from the intake manifold and charge cooler. Be very careful not to damage the fins on the charge cooler. Have a bucket handy to catch any coolant that may spill.
Now you need to determine the best path to reroute the hoses over the new headers. The most common method is to use 90-degree silicone couplers to redirect the hoses over the valve cover. You may need to trim the hoses to the proper length. Secure the new path in place with hose clamps.
Ensure there are no kinks or sharp bends in the hoses that could restrict airflow before reconnecting them to the charge cooler and intake manifold. Start the engine to check for leaks and ensure no error codes appear. Take the vehicle for a test drive to verify normal operating temperature.
If done properly, rerouting the CCV hoses allows you to install aftermarket headers without the hassle of dropping the engine. However, it does require patience and mechanical skills to complete. If you get stuck or don’t feel comfortable doing this yourself, consult a trusted mechanic. They can install the headers and ensure your E46 continues to run optimally for years to come.
Step-by-Step Guide to Installing E46 Headers Without Removing the Engine
Installing headers on your BMW E46 without removing the engine is totally doable for a DIY enthusiast. Here’s how to tackle this upgrade step-by-step:
Gather Your Supplies
You’ll need a few essential tools and parts:
-New performance headers (make sure they’re specifically for your E46 model year and engine)
-Socket wrench set
-Extensions for the socket wrench
-Penetrating oil like WD-40
-Exhaust manifold gaskets
-High temperature RTV sealant
Loosen the Exhaust Clamps
Spray the exhaust clamps and flanges with penetrating oil and let it soak in. Use the socket wrench to loosen the clamps connecting the exhaust manifold to the midpipe. Don’t remove them yet, just loosen them.
Remove the Exhaust Manifolds
Remove the bolts connecting the exhaust manifolds to the cylinder head. Have a helper support the weight of the manifolds as you remove the final bolts so they don’t fall. Remove the manifolds and exhaust gaskets.
Install the New Headers
Place the new exhaust gaskets and a bead of RTV sealant on the cylinder head. Install one header at a time, starting with the bolts closest to the firewall. Have your helper support the weight again as you install the remaining bolts. Tighten the bolts in the sequence recommended in the header instructions.
Reconnect the Exhaust
Slide the exhaust midpipe onto the headers and tighten the clamps to secure it in place. Start the engine and check for any exhaust leaks. Tighten or replace clamps as needed. Take it for a test drive to enjoy the new performance sound from your headers!
With some patience and a helping hand, you’ll be enjoying improved performance and throaty engine notes from your new E46 headers in no time. Let the wrenching begin!
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Conclusion
So there you have it. Installing headers on your BMW e46 is totally doable as a DIY project without pulling the engine. With some patience, the right tools, and by following the steps carefully, you’ll be enjoying the throaty roar of a freer-flowing exhaust in no time. While it may seem intimidating to dive under the car and start removing components, take it slow and don’t forget to reference diagrams to keep everything straight. Before you know it, you’ll be cruising with style and wondering why you didn’t upgrade your exhaust sooner. The performance and sound improvements are well worth the effort for any BMW enthusiast. Time to get wrenching!
