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Old 9th December 2007, 08:15   #1
darren_dallas
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Smog Checked - Passed

All,

Since it appears I am one of the first people to need a smog check on a modified E60 M5, I thought I would post some details about my configuration and how I was able to successfully pass my smog check.

Config:

Evosport headers
Stock secondary cats
Rear O2 sensors moved (extended) behind stock secondary cats
Active Autowerke ECU
Dinan Exhaust (just added this week)

My original setup had high-flow race cats in place of the stock secondary cats which was throwing an "inefficient cat" code at both rear O2 sensors.

In addition, the tuner (Stett Performance) who worked on my car numerous times did a very poor hack job on the wiring to extend the O2 sensors and also tried to use one of the front O2 sensors as a rear (without telling me) and cross-threaded one of the sensors as well. There is a list of about 4 other things Stett did which was very poor and unprofessional, but I'll start another thread about that shortly.

To make everything work properly, we removed the hacked wiring job from Stett and trashed his poor wiring and messed up O2 sensors. We replaced the entire wiring setup with a new 525i O2 wiring harness because it is a very long wiring harness compared with the E60 M5 rear O2 wiring harness.

This also allowed all the wiring connections to be redone so the fuses in the engine bay would stop blowing (once again thank you Stett for your quality work). Once all that was cleaned up, the codes were cleared and the car driven normally for about 20+ miles. It was then hooked back up and check for errors/faults and thankfully there were none.

We proceeded successfully with the smog check and now I'm back in good graces with the state.

If anyone needs more information please PM me or post in here. The bottom line...the stock secondary cats seem to a good enough job of burning down to meet emmissions requirements.

Hope this helps others.

Regards,

Darren
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Old 9th December 2007, 18:11   #2
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Darren, how do you like the everyday sound level of the evosport headers with the dinan exhaust and stock cats? I was thinking of going this route with the AA softwars as well. Do these mods work well together? Also, I have heard a lot of good things about Stett on the boards and am suprised they didn't do a good job.
Jason
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Old 9th December 2007, 18:20   #3
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Thanks for the write up, Darren. Sorry for your hassles, but glad you eventually found a good shop.

One question: if I understand your new setup correctly, you now have (properly) relocated 02 sensors AND replacement of the stock 2ndary cats. Do you know which resulted in the reversal of the error codes? Combination of both or just one of the changes?
Thanks.
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Old 9th December 2007, 19:15   #4
darren_dallas
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Quote:
Originally Posted by JBW View Post
Darren, how do you like the everyday sound level of the evosport headers with the dinan exhaust and stock cats? I was thinking of going this route with the AA softwars as well. Do these mods work well together? Also, I have heard a lot of good things about Stett on the boards and am suprised they didn't do a good job.
Jason
Jason,

I have extensive experience with Chad Stett throughout the project life my E60 M5 so far. I can tell you without a doubt it has not been a good experience any step of the way. A number of members on this board have been following my journey with Stett and know the frustration I've been going through for many months. The list is long:

1. Ordered new tires 3 weeks in advance of when I would need them, Chad failed to check to ensure all the tires sizes were correct when delivered and I found out one of the tires was the incorrect size when I picked up the tires and tried to have them installed.

2. Broken plastic cover after Chad removed it and reinstalled it. Yet he failed to call it to my attention.

3. Bad NOS seliniod installation which would cause fuse to blow each time system was armed (not intermittent, every time), yet Chad returned car to me indicating it was working. Obviously he didn't test any of his work.

4. Two very obvious issues on the interior of my car's leather (one on the door and the other on the dash) after Chad had my car for a few days. He was the only person working on the interior of my car.

5. When installing the secondary cats, Chad lost the bolt holding up the exhaust cross bar (it's the small perpendicular metal section just past the secondary cats, yet before the resonator I believe) in his shop and rather than buying a $20 replacement set he just decided to weld the items together

6. Install of incorrect O2 sensor (used front O2 sensor as a rear sensor for some reason and didn't tell me).

7. Bad wiring harness for O2 sensor installation blows fuses. Upon inspection, Chad's soldering points are identified as the culprit.

8. Missing numerous undercarriage bolts and engine compartment bolts. My dealer was in shock to how many of these were missing throughout the car's upper and lower engine area. By the way, Chad is the only person who has worked on this car.

9. Missing side M5 grills after Chad removed and installed them. Later he figured out he had not installed them completely since the backing was still in the car's body frame, but the grills were missing.

I have a list of a few other things as well, but I hope this gives you a decent idea. I need to make a list anyway as I'm going after him for a few items. It cost me $1800 to reverse the damage done by Chad.

Ironically, there a few other DFW M5/M3 owners who have had similar experiences with Chad Stett and it's not pretty. I would be willing to bet if the M3 owners (because that's all that really use him) were to check their cars, I am confident they'll find numerous mistakes and "hack" jobs performed on their cars due to Chad's incompetence and short cuts.

As a one-man-show he is not able to stay current on BMW training and he really has no experience on these E60 M5's. Maybe he's decent on the prior generation M3 cars, but new/late model M5's and the upcoming M3's should stay away.

Regards,

Darren

Last edited by darren_dallas; 9th December 2007 at 19:54.
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Old 9th December 2007, 19:17   #5
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Congrats Darren! I have the same setup as you so this is good
news. Sorry to hear about the crazy problems you had but in
the end the idea of using a 525i harness as a replacement is
information we can all benefit from.
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Old 9th December 2007, 19:19   #6
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Quote:
Originally Posted by bonehead View Post
Thanks for the write up, Darren. Sorry for your hassles, but glad you eventually found a good shop.

One question: if I understand your new setup correctly, you now have (properly) relocated 02 sensors AND replacement of the stock 2ndary cats. Do you know which resulted in the reversal of the error codes? Combination of both or just one of the changes?
Thanks.
Bonehead,

It was the combination for me. With headers you definitely need the stock secondary cats for proper burn down, plus I had an improper/bad O2 wiring setup from my tuner (Chad Stett).

If you extend the O2 wiring harness properly the first time then you should be fine I'm guessing.

What I don't know is how much the Active Autowerke ecu tune helps here. Does it lean it out a bit more so therefore the cats don't have to work quite as hard? I have no idea. I doubt Active (or any ecu tuner) can lean out the mixture that much to make a difference, so I bet the stock ecu would be fine as well in this setup.

Regards,

Darren
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Old 9th December 2007, 19:21   #7
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Damn...this is really bad.

Quote:
Originally Posted by darren_dallas View Post
Jason,

I have extensive experience with Chad Stett throughout the project life my E60 M5 so far. I can tell you without a doubt it has not been a good experience any step of the way. A number of members on this board have been following my journey with Stett and know the frustration I've been going through for many months. The list is long:

...
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Old 9th December 2007, 19:24   #8
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Quote:
Originally Posted by JBW View Post
Darren, how do you like the everyday sound level of the evosport headers with the dinan exhaust and stock cats? I was thinking of going this route with the AA softwars as well. Do these mods work well together? Also, I have heard a lot of good things about Stett on the boards and am suprised they didn't do a good job.
Jason
Jason,

So far I thoroughly enjoy it! The sound is truly quiet compared to the headers with Eisenmann race. Cold start is barely louder than stock in the morning, cruising speed is wonderful and no cabin intrusion whatsoever.

But, when you get on it, she screams above 5,000 rpms. The sound is slightly deeper than the e-race yet has a nice high-reving v10 sound to it.

Cheers,

Darren
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Old 9th December 2007, 23:18   #9
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Darren, Would it be possible to tell us what the gas levels were from your smog check? Also, does Texas require you to smog your car on a dyno?

In California we have to smog on a dyno and the results are provided along with a comparison of average/minimum/maximum NO2, CO, HC (I cant actually remember the gasses they check for but I think it is nitrogen oxide, carbon monoxide, and hydrocarbons).

Thank you.
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Old 9th December 2007, 23:27   #10
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Darren,

I am sorry to hear of your troubles....

I am considering the headers and can you comment / speculate if this set up will throw codes?
  • E60 525i O2 Sensor wiring harness
  • Move the rear O2 sensor to behind the stock secondary cats while leaving the front O2 sensor connected to the header
Do I need someone to drill a hole and add a bung behind the secondary cats?

Thanks man.
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