Wagner DP Doesn't Fit

ferocity02 · 03-31-2019, 07:48 PM

I got a Wagner catted DP and spent a couple hours trying to get it to fit. After the struggle I found the issue. The rear O2 sensor is not in the right position. It's more on the top of the pipe whereas the stock photos I see show it canted more off to the side. As a result, the rear O2 sensor hits the underside of the car. If I rotate the DP enough for the rear O2 sensor to fit then the front O2 sensor rests directly on the exhaust manifold and the midpipe connections are up to 1" off...

Anyone else had this issue? Kind of bummed out. If you spend this much on a DP I would expect perfect fitment. The VRSF is 1/3 the price and fits much better, not perfect, but close.

Tejay75 · 03-31-2019, 08:51 PM

I have the same issue with my wagner catted downpipe for 2011 n55 135i. I'm in Australia, so my car is right hand drive. I thought it was an issue because my car is rhd. I emailed Wagner in Germany and they said that their design is based off a lhd car. So interesting to hear it's an issue with lhd cars too. I'm trying to get a fabricator to remake the hole so it can be put in without contacting the car. I tried using an adapter and found that taking the sensor out of the exhaust stream just made the 02 sensor not work. I've got my stock cat back on until I can get the Wagner one modified.

ferocity02 · 03-31-2019, 09:06 PM

I doubt there is a change to the floorboard where the O2 sensor is between LHD and RHD.

Does your DP have the cast merges like mine? The stock photos I posted show polished merges. I wonder if it's an updated design.

The difference is minor, but there is so little room that any change in the location of the O2 sensor makes it not fit.

Tejay75 · 03-31-2019, 09:32 PM

I'm not sure if mine has cast or polished merges. It's with the fabricator at the moment. Pretty disappointed. As you've said, with the current position of the hole, the 02 sensor won't fit.

Kevin39 · 04-01-2019, 06:19 AM

Hmm, I didn't have any o2 sensor issues but I did notice it's a little short to reach the mid pipes. If the cat back wasn't rubber mounted, there's no way I'd get them to meet up.

ferocity02 · 04-01-2019, 10:09 AM

Quote:

Originally Posted by Kevin39

Hmm, I didn't have any o2 sensor issues but I did notice it's a little short to reach the mid pipes. If the cat back wasn't rubber mounted, there's no way I'd get them to meet up.

Which version did you install?

Did you maintain the bracket that secures the DP to the transmission?

Kevin39 · 04-01-2019, 11:08 AM

What do you mean which version? It's the Wagner catted DP on a manual rwd e90. I don't know about any different versions.

I don't believe I put the transmission bracket back on. I agree, for the price, this should have fit like a glove

ferocity02 · 04-01-2019, 11:13 AM

I called Wagner, they redesigned the DP about a year ago. The new version, which is what I have, has the cast cat merges and one-piece flange at the midpipe connection. The old version is entirely polished and the mid-pipe connections are separate flanges. See my pictures in the OP.

Wagner says I need an 45 degree O2 sensor extension which they sell for $50. I'm worried that this will definitely cause a CEL.

They had no explanation as to why they moved the rear O2 sensor such that it no longer fits...

Kevin39 · 04-01-2019, 12:40 PM

Ok I see what you're saying. Mine is about 2.5 years old and it's all polished with the two separate flanges at the mid pipe. Yeah I don't know why they would move the O2 for no reason and then not include the fitting you need to make it work. That's strange.

Supermoon · 04-01-2019, 01:37 PM

The older version had a minor fitment issue where the downpipe flanges meet the midpipe flanges.
It caused the passenger side muffler tip to sit lower (or higher I don't remember clearly) so I fixed that by re-welding the tip.
That's probably why they switched to one piece flange but I guess they kinda f'd up in the process.

JoshC222 · 04-01-2019, 05:20 PM

Quote:

Originally Posted by ferocity02

I called Wagner, they redesigned the DP about a year ago. The new version, which is what I have, has the cast cat merges and one-piece flange at the midpipe connection. The old version is entirely polished and the mid-pipe connections are separate flanges. See my pictures in the OP.

Wagner says I need an 45 degree O2 sensor extension which they sell for $50. I'm worried that this will definitely cause a CEL.

They had no explanation as to why they moved the rear O2 sensor such that it no longer fits...

Wow. Wagner's solution to their poor quality was to charge you $50 for a band-aid fix? That's ridiculous. I'd return that junk. Definitely expected more from them given their reputation.

ferocity02 · 04-01-2019, 05:27 PM

Quote:

Originally Posted by JoshC222

Wow. Wagner's solution to their poor quality was to charge you $50 for a band-aid fix? That's ridiculous. I'd return that junk. Definitely expected more from them given their reputation.

Yes, I'm a little disappointed. For nearly $800 this thing should fit like a glove. I purchased it because so many people say its fits well and it appears to have the best chance of not throwing a CEL (not guaranteed though). Instead, they redesign it such that it doesn't fit and you need an O2 adapter that basically guarantees you'll get a CEL...

My plan is to install another O2 bung in a better location. My friend has a TIG welder and I bought the bung on Amazon. I might have to extend the sensor wires a few inches but that's easy.

Tejay75 · 04-01-2019, 11:50 PM

I'm doing the same. I tried a using a fitting and that gave me cel and an slow to read 02 sensor readings. Unfortunately I have to get a fabricator to weld and move the hole to be able to connect the 02 sensor without contacting the car.

Kevin39 · 04-02-2019, 08:10 AM

Quote:

Originally Posted by Supermoon

The older version had a minor fitment issue where the downpipe flanges meet the midpipe flanges.
It caused the passenger side muffler tip to sit lower.

Yep, mine is visibly lower on the passenger side. Bugs the hell out of me

ferocity02 · 04-09-2019, 11:18 AM

I ended up buying a stainless O2 bung on amazon and having a coworker TIG it to the DP. I installed the DP and marked where the O2 sensor would fit, drilled it out, and had him weld the bung on. Then I just capped the O2 bung that Wagner put in the wrong spot. The O2 sensor fits perfectly now, and it can even be installed/removed after the DP is installed. The wires are a bit tight, but did not need to be extended.

Upon installing the DP I found another fuck up from Wagner. The flange at the turbo is too thin. This causes the v-band clamp to be bottomed out before the connection is tight. With the clamp bottomed out, you can still spin the DP by hand. So I cranked down on the clamp and got to where the DP won't spin, but I'm not confident there is a good seal. There is a picture below showing how much thinner the Wagner flange is than the OEM. A new gasket and a new clamp could fix this, or squeezing the clamp slightly in a hydraulic press.

Besides the fitment, which is 0/10 because it doesn't without modification, the DP is a good alternative to the VRSF catless version. It has much less drone while cruising, quieter starts, and no smells. Loudness wise, if stock is a 1 and catless is a 10, this is about a 6.

9krpmrx8 · 04-09-2019, 11:30 AM

This is why i just gutted the stock DP on mine after having a flange break on a cheaper DP.

I don't see how the Wagner or others could be more free flowing than this.

cjdzombie · 04-09-2019, 12:07 PM

Quote:

Originally Posted by 9krpmrx8

This is why i just gutted the stock DP on mine after having a flange break on a cheaper DP.

I don't see how the Wagner or others could be more free flowing than this.

+1 here. I gutted an OEM pipe I got off of Ebay for $50. Perfect fitment and it looks stock.

9krpmrx8 · 04-09-2019, 02:12 PM

Quote:

Originally Posted by cjdzombie

+1 here. I gutted an OEM pipe I got off of Ebay for $50. Perfect fitment and it looks stock.

Yeah this is my best friends "expensive" DP. IMO the stock gutted appears to flow better.

Kevin39 · 04-09-2019, 02:35 PM

That's interesting about the flange. I wonder if they changed anything else with the redesign. I don't recall having that problem with mine that was the older style.

So far it sounds like they moved the bungs, stopped polishing the middle section, and now maybe changed the flange at the turbo.

EvanP246 · 04-15-2019, 07:34 AM

Good day guys, I just came across this thread. I have ordered the Wagner catless downpipe. I’m very disappointed to know that it will not fit without modification.

Does this apply to both catted and catless? This is not acceptable. How can they sell a expensive part that does not fit?

Jeff@TopGearSolutions · 04-18-2019, 04:34 PM

Quote:

Originally Posted by EvanP246

Good day guys, I just came across this thread. I have ordered the Wagner catless downpipe. I’m very disappointed to know that it will not fit without modification.

Does this apply to both catted and catless? This is not acceptable. How can they sell a expensive part that does not fit?

This is actually an anomaly and only affects a very small percentage of 2011 cars, not all, per Wagner. (Don't shoot the messenger). That being said, if you are interested in other brands, there are others to choose from.

03-31-2019, 07:48 PM	#1
ferocity02 Colonel 530 Rep 2,083 Posts Drives: 2013 135is Join Date: May 2014 Location: USA iTrader: (8)	Wagner DP Doesn't Fit I got a Wagner catted DP and spent a couple hours trying to get it to fit. After the struggle I found the issue. The rear O2 sensor is not in the right position. It's more on the top of the pipe whereas the stock photos I see show it canted more off to the side. As a result, the rear O2 sensor hits the underside of the car. If I rotate the DP enough for the rear O2 sensor to fit then the front O2 sensor rests directly on the exhaust manifold and the midpipe connections are up to 1" off... Anyone else had this issue? Kind of bummed out. If you spend this much on a DP I would expect perfect fitment. The VRSF is 1/3 the price and fits much better, not perfect, but close. Attached Images __________________ 2013 135is DCT Carbon Black Metallic Last edited by ferocity02; 03-31-2019 at 07:56 PM..
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03-31-2019, 08:51 PM	#2
Tejay75 New Member 0 Rep 15 Posts Drives: 135i DCT Join Date: Jan 2018 Location: Melbourne iTrader: (0)	I have the same issue with my wagner catted downpipe for 2011 n55 135i. I'm in Australia, so my car is right hand drive. I thought it was an issue because my car is rhd. I emailed Wagner in Germany and they said that their design is based off a lhd car. So interesting to hear it's an issue with lhd cars too. I'm trying to get a fabricator to remake the hole so it can be put in without contacting the car. I tried using an adapter and found that taking the sensor out of the exhaust stream just made the 02 sensor not work. I've got my stock cat back on until I can get the Wagner one modified.
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03-31-2019, 09:06 PM	#3
ferocity02 Colonel 530 Rep 2,083 Posts Drives: 2013 135is Join Date: May 2014 Location: USA iTrader: (8)	I doubt there is a change to the floorboard where the O2 sensor is between LHD and RHD. Does your DP have the cast merges like mine? The stock photos I posted show polished merges. I wonder if it's an updated design. The difference is minor, but there is so little room that any change in the location of the O2 sensor makes it not fit.
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03-31-2019, 09:32 PM	#4
Tejay75 New Member 0 Rep 15 Posts Drives: 135i DCT Join Date: Jan 2018 Location: Melbourne iTrader: (0)	I'm not sure if mine has cast or polished merges. It's with the fabricator at the moment. Pretty disappointed. As you've said, with the current position of the hole, the 02 sensor won't fit.
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04-01-2019, 06:19 AM	#5
Kevin39 Lieutenant 164 Rep 411 Posts Drives: 2011 E90 N55 Join Date: Feb 2016 Location: Indiana iTrader: (0)	Hmm, I didn't have any o2 sensor issues but I did notice it's a little short to reach the mid pipes. If the cat back wasn't rubber mounted, there's no way I'd get them to meet up.
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04-01-2019, 11:08 AM	#7
Kevin39 Lieutenant 164 Rep 411 Posts Drives: 2011 E90 N55 Join Date: Feb 2016 Location: Indiana iTrader: (0)	What do you mean which version? It's the Wagner catted DP on a manual rwd e90. I don't know about any different versions. I don't believe I put the transmission bracket back on. I agree, for the price, this should have fit like a glove
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04-01-2019, 11:13 AM	#8
ferocity02 Colonel 530 Rep 2,083 Posts Drives: 2013 135is Join Date: May 2014 Location: USA iTrader: (8)	I called Wagner, they redesigned the DP about a year ago. The new version, which is what I have, has the cast cat merges and one-piece flange at the midpipe connection. The old version is entirely polished and the mid-pipe connections are separate flanges. See my pictures in the OP. Wagner says I need an 45 degree O2 sensor extension which they sell for $50. I'm worried that this will definitely cause a CEL. They had no explanation as to why they moved the rear O2 sensor such that it no longer fits... __________________ 2013 135is DCT Carbon Black Metallic
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04-01-2019, 12:40 PM	#9
Kevin39 Lieutenant 164 Rep 411 Posts Drives: 2011 E90 N55 Join Date: Feb 2016 Location: Indiana iTrader: (0)	Ok I see what you're saying. Mine is about 2.5 years old and it's all polished with the two separate flanges at the mid pipe. Yeah I don't know why they would move the O2 for no reason and then not include the fitting you need to make it work. That's strange.
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04-01-2019, 01:37 PM	#10
Supermoon Lieutenant 166 Rep 429 Posts Drives: 2011 e92 335xi Join Date: Aug 2015 Location: Seoul iTrader: (6) Garage List 2011 BMW 335i xDriv ... [10.00]	The older version had a minor fitment issue where the downpipe flanges meet the midpipe flanges. It caused the passenger side muffler tip to sit lower (or higher I don't remember clearly) so I fixed that by re-welding the tip. That's probably why they switched to one piece flange but I guess they kinda f'd up in the process. __________________ 2011 E92 335i xDrive Pure Stage 1 \| DV+ & Inlet \| Injen Intake \| M3 Cowl \| ETS 5" FMIC & CP \| Aquamist HFS4 Direct Port \| CSF Radiator \| Wagner Catted DP \| BMW PE \| Apex FL-5 \| Michelin PS4S \| 335is Engine mount \| SDW Monoball thrust arms \| UUC Swaybars & SS Brake lines \| Bilstein B8 \| Dinan Springs & Shock mounts \| Whiteline RSFB \| M3 Rear Control arms \| Manzo Toe arms \| Wavetrac LSD
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04-01-2019, 11:50 PM	#13
Tejay75 New Member 0 Rep 15 Posts Drives: 135i DCT Join Date: Jan 2018 Location: Melbourne iTrader: (0)	I'm doing the same. I tried a using a fitting and that gave me cel and an slow to read 02 sensor readings. Unfortunately I have to get a fabricator to weld and move the hole to be able to connect the 02 sensor without contacting the car.
	Appreciate 0 Quote

04-09-2019, 11:18 AM	#15
ferocity02 Colonel 530 Rep 2,083 Posts Drives: 2013 135is Join Date: May 2014 Location: USA iTrader: (8)	I ended up buying a stainless O2 bung on amazon and having a coworker TIG it to the DP. I installed the DP and marked where the O2 sensor would fit, drilled it out, and had him weld the bung on. Then I just capped the O2 bung that Wagner put in the wrong spot. The O2 sensor fits perfectly now, and it can even be installed/removed after the DP is installed. The wires are a bit tight, but did not need to be extended. Upon installing the DP I found another fuck up from Wagner. The flange at the turbo is too thin. This causes the v-band clamp to be bottomed out before the connection is tight. With the clamp bottomed out, you can still spin the DP by hand. So I cranked down on the clamp and got to where the DP won't spin, but I'm not confident there is a good seal. There is a picture below showing how much thinner the Wagner flange is than the OEM. A new gasket and a new clamp could fix this, or squeezing the clamp slightly in a hydraulic press. Besides the fitment, which is 0/10 because it doesn't without modification, the DP is a good alternative to the VRSF catless version. It has much less drone while cruising, quieter starts, and no smells. Loudness wise, if stock is a 1 and catless is a 10, this is about a 6. Attached Images __________________ 2013 135is DCT Carbon Black Metallic
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04-09-2019, 11:30 AM	#16
9krpmrx8 Clean is the new cool, keep it that way. 808 Rep 1,685 Posts Drives: 11' Alpine White 335i Sedan Join Date: Jan 2016 Location: San Antonio, Texas iTrader: (0)	This is why i just gutted the stock DP on mine after having a flange break on a cheaper DP. I don't see how the Wagner or others could be more free flowing than this. __________________ 2011 335i, FBO, N55+ Turbo, full E85, S55 intercooler, etc. 2015 X5 35i Xdrive
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04-09-2019, 02:35 PM	#19
Kevin39 Lieutenant 164 Rep 411 Posts Drives: 2011 E90 N55 Join Date: Feb 2016 Location: Indiana iTrader: (0)	That's interesting about the flange. I wonder if they changed anything else with the redesign. I don't recall having that problem with mine that was the older style. So far it sounds like they moved the bungs, stopped polishing the middle section, and now maybe changed the flange at the turbo.
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04-15-2019, 07:34 AM	#20
EvanP246 Enlisted Member 56 Rep 34 Posts Drives: 2012 E92 335i DCT Join Date: Feb 2019 Location: Barbados iTrader: (0)	Good day guys, I just came across this thread. I have ordered the Wagner catless downpipe. I’m very disappointed to know that it will not fit without modification. Does this apply to both catted and catless? This is not acceptable. How can they sell a expensive part that does not fit?
	Appreciate 0 Quote