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Old 10-06-2003, 08:03 PM
kowached kowached is offline
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Location: MI
Join Date: Jun 2003
Posts: 77
Mein Auto: 1998 540iA Sport
Aftermarket 540i Catalytic Converter Info

DIY Forum was looking kind of weak, thought I'd add a nugget of info.

If you are looking for aftermarket Catalytic Converters on your E39 540i, here are some options:

Carsound 53005 2.25" in/out, round body, no air, $67/each:

Or you could pay more for the IDENTICAL converter with a polished case, Carsound makes Magnaflow, they are the same thing.

Magnaflow 54305 2.25" in/out, round body, no air, $80/each:

Make sure that you exhaust guy is very comfortable with blind welding in tight spots, otherwise make him drop the system to ensure that there are no leaks around the converters. Leaks may throw the O2 sensors off. I doubt that you will find a good welder at anyplace besides a custom exhaust shop, the guys at Midas and Minekie probably are not cut out for this job.

If you don't know of a really good local exhaust guy, here is decent place to start:

So here are your choices:
- $600/side for BMW Cats + installation.
- $67/side for Carsounds + $100-$150 for installation.

I can tell you to avoid IMCO Cats in a 540i, I had a pair of IMCO High Flow Cats (75115) installed once. The drivers side converter started rattling within 3 weeks, the ceramic brick was loose from the metal casing. I went back to the shop and had Carsounds (53005) installed, like they should have had them do originally (but thatís another story). The owner was apologetic and said that he was just trying to get his customer the best value, just tipped the welder $20, otherwise no charge for the Carsounds.

IMCO Cats:
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E39 - 1998 540iA Sport (11/97 Production)
E30 - 1989 M3 (44k miles)
1979 Triumph TR7, still have my first car ;-)
Past cars:
E21 - 1980 320i (sold at 130k)
E23 - 1986 735i

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