How To Install A Magnaflow Muffler On A Mini Cooper S
By Mike Rosania
1. Your Magnaflow exhaust package comes with three pieces—a resonator, center pipe, and muffler section. The front
resonator comes with a mounting flange that bolts right onto your stock catalytic converter. This part connects to a center pipe that is secured with exhaust clamps, which are supplied. And the rear muffler section joins together, exiting the car in the center of the rear bumper. Also, all the parts are stainless steel, which don’t rust or stain—nice job Magnaflow.
2. Now to the installation. You will only need a few common tools to remove your stock exhaust; no exhaust cutters are needed. Make sure you have help installing the system, it is very heavy and you will not want to drop it.
3. First, you will remove the factory skid plate/ heat shield from the chassis, which can be down with a socket wrench. Important—Do Not lose this piece as it will be re-installed after you install your new exhaust system.
4. Now follow the factory exhaust up towards the catalytic converter. You will now need to remove the mid exhaust mounting bracket from the chassis as well using a socket. Make sure you slip the exhaust hangers out of the rubber mounting brushings. Set this piece aside with your head shield as you will be reusing it also.
5. Now find the flange on the catalytic converter. It will have two bolts that you will need to remove. Be careful in this process because your whole exhaust system is only supported by two rear hangers on the muffler. This is where it will be handy to have a helping hand. Have your buddy hold up the front section of the system, otherwise it will crash to the ground.
6. You can now go to the back of the car and free the factory exhaust by removing the hangers from the rubber bushings. Congratulations, your factory exhaust has now been removed. You are one step closer to hearing your car’s new growl.
7. If you have gotten the factory exhaust off, you are pretty much in the clear. You will install your Magnaflow system
in the reverse order of taking the old one off. You can start by matching up the resonator section with the flange to the flange on the catalytic converter and bolting them together. They slip the connecting pipe into the resonator pipe and clamp it down with the supplied clamp. This piece also connects to the factory chassis mount you removed earlier. Be sure to secure the hangers into the rubber bushings.
8. One more step. Connect the muffler section to the connecting pipe. The best way to do this is to slip the exhaust hangers on the muffler into the hanging rubber bushing first, then swing the rear section up and fit it into the connecting pipe. Then all that’s left to do is tighten down the supplied clamp. I would recommend making sure all your connections are tight and you muffler tips exit your bumper straight. Oh yea, and don’t forget to re-install that skid plate/heat shield.
9. You have just installed your Magnaflow exhaust system. Turn the car and make sure you don’t have any exhaust leaks. If everything is good, then you’re golden. Enjoy your Mini’s new throaty growl and boost in horsepower. Keep working on your Mini folks!
Upgrading your Muffler to a Magnaflow exhaust is just one modification that can increase your car’s performance. There exists a plethora of parts that will pick up your car’s pace. Just remember, avoid those speeding tickets. –Mike Rosania
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