for BMW: E46 M3 Definitive Exhaust Guide

I've been fascinated (or at times disappointed) with the various exhaust options available for the E46 M3, and at times obsess over the various details of the construction of the available systems. However, through this I was able to learn a lot about the available exhaust components for the E46 and figure this would help others when choosing a solution for their car. This actually took a lot longer than I anticipated, but it should have a fairly up to date list of exhausts made for the E46 M3.

Feel free to let me know if there are any I missed. I can also add video links to it (with everyones help!).

A few tips for those who are not up to date with the lingo or don't know the layout of the stock exhaust system.

The M3 exhaust is laid out in the following pathway:

Headers - Section 1 - Section 2 - Section 3

It's designed by Arvin-Meritor and their white paper can be seen here:

http://ift.tt/1FNcpdv

Headers:

US cars came with the 200-cell cats built into the header contain 1 EGT bung, 2 pre cat and 2 post cat sensor bungs.

Euro cars came with headers without cats built into them. The factory cats are located in section 1.

Section 1:

This is the section immediately after the headers, and consists of a pair of parallel S-pipes.

US cars came with only one resonator.

Euro cars came with 200-cell catalytic converters and EGT bungs built into section 1. CSL euro cats are lighter due to thinner piping for weight saving purposes.

Section 2:

Longer portion of the mid section that connects to the muffler. There is a factory H-Pipe crossover in the beginning of this section, and a tiny straight through resonator halfway down on this section.

Section 3:

This is the actual muffler, including tips. The stock muffler weighs 56lbs and the CSL is claimed to be lighter 5-10lbs lighter. The muffler is not valved internally and is a very good flowing muffler. It features perforated tubes and one crossover chamber.

Table Of Contents:

Headers

Section 1

Section 2

Section 1 & 2 Combo

Section 3 - Muffler

Headers

US Factory Headers

Price: Seen these go for as low as $100.

Notes: Removal and/or further downstream relocation of catalytic converters improves sound and power.

Euro/CSL Headers

Price: $550 - $750

Notes: Guaranteed perfect fit. Doesn't gain the most power, doesn't gain the least but you won't run into fitment issues as it's OE. Same design as US headers, with maybe slightly longer primaries.

Achilles Equal Length Headers

Price: Custom

Notes: Truly equal length, but look to be one of the best made headers for the S54.

Active Autowerke Headers

Price: $1295

Notes: Polished. AA is several generations into this now. I'm not too familiar with the past ones, but I think they are on generation 4 or 5 now.

aFe Twisted Steel Headers

Price: $1495

Notes: This is a rather recent release. Looks promising.

Agency Power Headers

Price: $9000 - $1200 new and $500 - 650 used

Notes:

Bimmerworld 'PaceSetter' Headers

Price: $590

Notes: Made for BW by Jet-Hot. Comes ceramic coated.

BMW PTG Race Headers

Price: $3500

Notes: Inconnel and oversized. No one on this forum has installed this to my knowledge.

ebay Headers/JVT/M3ANONE

Price: $100 - $600

Notes: Ebay headers are a hit or miss. M3ANONE headers are eBay headers modified by a forum member to fit correctly. He also coats them. JVT are slightly better than non-brand ebay headers, but are still ebay headers which are a hit or miss in general.

MEANONE

JVT

CPI Single Step Headers

Price: $1195

Notes: This is one of the most recent E46 M3 performance product releases.

Epic Motorsports Headers

Price: $1999

Evosport Headers

Price: $1400

Notes: Coated.

Friedrich Headers

Price: $1700

Notes: Odd header design from Europe. Can be found on the German ebay site.

Dixis Spirit Headers

Price: $3000 - $10,000+

Notes: Full titanium and Inconnel are also available.

Kromer Kraft Headers

Price: Unknown

Notes: Mysterious custom header that is claimed to be used in this video, to achieve the sound.

Custom M3 Headers - YouTube

A better picture is below, but it's for an S5x engine. However, design is for the most part similar.

Macht Schnell Performance Headers

Price: $1195

Notes: Coated.

Turner Equal Length Stepped Header

Price: N/A

Notes: I think it's been discontinued as it's no longer on their site.

Race Marquee Systems 'RMS' Headers

Price: Used around $1100

Notes: Huge oversized 2.5", large primaries, comes with reducer to adapt to stock section 1. Designed mainly for FI applications.

RD Sport Headers

Price: $2500

Schmiedmann Headers

Price: $695 (shipped from Europe)

Notes:Made in Europe, similar to RD Sport design.

Sound of Speed Headers

Price: $1400

Notes: Made in Italy.

Status Gruppe Headers

Price: $810

Notes: Made in the USA.

*Supersprint is a little confusing because they have two piping sizes for their headers and section 1 counterparts. Stock diameter is 2.25" (adequate for most, even for low boost FI and compatible with stock headers and section 1) and their oversized increases the headers to 2.5" along with a matching 2.5" section 1.

Supersprint Stainless Steel Headers

Price: ~ $1800 new and $800 - $1200 used.

Notes: Stock replacement, works with stock section 1.

Supersprint Stepped Headers Version 1

Price: ~ $2800 new and $1200 - $1500 used.

Notes: The V1 is Supersprint's first stepped header design in the oversized 2.5 diameter tubing. This requires a oversized section 1 to mate to it. SS makes a 2.5" section 1 with optional hi-flow cats.

Supersprint Stepped Headers Version 2

Price: ~ $2800 new and $1200 - $1500 used.

Notes: The V2 was made after enthusiasts requested that the same stepped header was to be made in a 2.25" setup, which allowed it to be compatible with the stock section 1, and many other options.