What are the best tips for installing Remus exhausts on luxury cars?

You’ve just taken delivery of a beautifully engineered Remus exhaust for your Audi RS, BMW M, or Porsche—handmade in Austria, perfect welds, and that distinctive deep tone waiting to be unleashed. Now comes the moment of truth: getting it on your car without scratching that £2,000+ masterpiece.

Table of Contents

Here’s what separates a successful installation from a frustrating one: high-end vehicles demand high-end technique. Remus systems for premium cars like the Audi RS3, BMW M3, and Porsche models are precision-engineered with tight tolerances, valve systems, and connections that reward patience and punish rushing . Whether you’re fitting a full GPF-back system or an axle-back exhaust, these tips will save you time, money, and the heartbreak of damaged components. One owner’s missing spring turned into a $400 welding bill—don’t let that be you .

TL;DR;

Installing a Remus exhaust on a high-end vehicle requires attention to detail beyond basic DIY. Critical steps: check all components before starting—missing springs or parts are common . Spring installation demands the correct tool to prevent injury and damage . Valve operation must be verified after fitting; incorrect flap behaviour can cause drone or poor performance . Alignment is everything—loosen all connections before tightening to ensure perfect positioning . ECU tuning may be required for full systems to prevent warning lights and maximise gains . Most importantly, check for leaks at clamped connections—some Remus systems have flared ends that can kink and leak under clamp pressure .

Key Takeaways

Inspect Before Installing: Lay out every component and verify against the parts list—missing springs or hardware are frustratingly common
Spring Tool Essential: Remus springs have serious tension; their DIY installation tool prevents injury and makes the job possible
Check Valve Function: After installation, verify exhaust flaps operate correctly—wrong behaviour causes drone and poor performance
Loose Fit First: Assemble everything loosely before final tightening to achieve perfect alignment and clearance
Beware Clamp Leaks: Some Remus mid-pipes have flared ends that can kink and leak—check carefully and consider welding if issues arise
ECU Tuning: For axle-back and cat-back systems, ECU tuning is “advisable” to prevent CEL lights and unlock full performance
Cutting Required: Many Remus systems need cutting of the stock exhaust—measure twice, cut once
Warranty Responsibility: You’re responsible for ensuring your Remus complies with UK road laws—EC-approved systems are legal, modifications may not be

Before You Start: The Inspection That Saves Headaches

You’ve unboxed your beautiful Remus system, and it looks perfect. But don’t install yet.

Check Everything Against the Parts List

One G80 M3 owner learned this the hard way: after months of waiting for their Remus Race exhaust, they discovered missing springs for the valve control system . Installation halted, frustration mounted.

What to verify:

All pipes and muffler sections present
Valve actuators and springs included
Clamps and mounting hardware
Tailpipe set (often ordered separately)
Instructions and any EC approval documents

Inspect for Manufacturing Issues

Another M3 owner discovered their Remus mid-pipes had flared ends that, when clamped, caused kinking and exhaust leaks . The only fix? $400 worth of TIG welding.

Check specifically:

Pipe ends for excessive flare
Clamp fitment before tightening
Valve mechanisms for free movement
Carbon fibre inserts for damage

“When you insert the pipes into one another the clamping force kinks the flared out piece. The only way to fix this was to weld all the pipes together.” — G80 M3 owner

Tools of the Trade: What You’ll Need

The Critical Tool: Remus Spring Hook

Remus systems often use high-tension springs to connect pipe sections. These springs are very difficult to install without the correct tool . Attempting with pliers or screwdrivers risks:

Slipping and damaging paintwork
Slipping and damaging your hands
Twisting springs out of shape

Remus offers a dedicated DIY sport exhaust installation tool (SKU: SHMC100) that makes spring installation “simple and safe” . It’s designed specifically for their systems and eliminates the danger.

Basic Toolkit

Tool	Purpose
Socket set	Various sizes for exhaust mounts
Combination spanners	For tight spaces where sockets won’t fit
Torque wrench	Critical for correct clamp tightness—over-tightening causes kinks
Penetrating oil	For seized bolts (PlusGas or equivalent)
Wire brush	Cleaning threads before installation
Copper slip	On threads to prevent future seizing
Jack and axle stands	Safety first—never work under an unsupported vehicle
Coping saw	If bumper trimming required for tailpipe clearance

Chart: Remus Installation Success Factors

This chart visualises the key factors that determine a successful Remus exhaust installation on high-end vehicles.

Step-by-Step Installation Tips

Step 1: Vehicle Preparation

Safety first: Chock the front wheels, jack the rear, and support on axle stands . One forum member wisely places wheel ramps under their car as backup even with stands—paranoia is healthy when tonnes of metal are involved .

Battery disconnect: For vehicles with electronic exhaust valves, consider disconnecting the battery to prevent electrical issues during installation.

Step 2: Removing the Stock Exhaust

Penetrating oil is your friend: Spray all mounting bolts, flange nuts, and rubber hanger mounts the night before . UK road salt loves seizing exhaust hardware.

The two-steps-forward-one-back technique: For stubborn nuts, “keep doing the nut back up a short way and then undo a little bit more at a time so you are effectively clearing the crud out of the threads and not likely to shear them” .

Spring removal: If your stock system uses spring connections, note how they’re oriented—you’ll thank yourself later.

Step 3: Preparing the Remus System

Trial fit without clamps: Before any tightening, offer up all components to verify they’ll reach and align correctly. This is especially important for full systems with multiple sections.

Thread preparation: On high-end vehicles, unused mounting threads may be corroded. “Wire brush the threads and then apply some copper slip. Using the method of easing the nut on and off gradually cuts the corrosion out of the thread” .

The cutting decision: Many Remus axle-back systems require cutting the stock exhaust . Measure three times, cut once. Remus specifies exactly where to cut—follow their instructions precisely.

Step 4: The Critical Alignment Phase

The golden rule: LOOSE FIT FIRST

“If it doesn’t sit straight, try loosening the lower clamps and wiggling it about.” — Experienced fitter

Assemble everything with clamps finger-tight only. This allows you to:

Rotate pipes for optimal clearance
Adjust muffler angle for perfect tailpipe positioning
Ensure valve actuators have clearance
Verify nothing contacts bodywork or suspension

Spacers are acceptable: If you need to space the exhaust out on mounting brackets by 5-10mm, that’s “absolutely fine”—owners have done this for years without issues .

Step 5: Spring Installation

This is where the Remus spring tool proves its worth. The tension on these springs is significant .

Technique:

Hook the spring into one mounting point
Use the spring tool to stretch the spring to the second mounting point
Guide it carefully into place
Wear gloves—if the spring slips, your knuckles will find the nearest hard surface

Step 6: Clamp Tightening

This step has caught out multiple owners. Remus specifies torque values—typically around 40ft/lb for some systems . But here’s the catch:

“The reason for the leak was the ends on the Remus exhaust were flared out more than they should have been. When you insert the pipes into one another the clamping force kinks the flared out piece.”

Prevention:

Inspect pipe ends before tightening
Tighten gradually, checking for distortion
If you see kinking starting, stop immediately
Consider having a muffler shop verify the seal

One owner’s solution: “We were no where near the 40ft/lb that was recommended by Remus” yet still experienced leaks, ultimately requiring welding .

Step 7: Valve Function Check

Modern Remus systems for high-end vehicles include integrated exhaust valves . After installation, verify proper operation:

What to check:

On cold start, both valves may open initially then close
In comfort mode, valves should be closed or partially closed
In sport mode, valves should open fully
Listen for vacuum leaks or actuator noise

A BMW G31 owner noticed their Remus behaved differently than stock: “With the Remus, on a cold start I have exhaust gas coming out both sides and then it calms down and seems to click which to me the flap is closed however I can still feel a bit of exhaust gas coming out” . This may be normal design difference.

Step 8: Final Checks Before First Start

Clearance check: “In case the exhaust system touches the cowling or other parts repeat the adjustment”
All fasteners tightened to specification
Tools removed from engine bay and workspace
Tailpipe alignment verified from rear

The Tuning Question: ECU Remapping

When It’s Advisable

Remus explicitly states: “When installing REMUS axle-back and cat-back or catalyst delete tubes on vehicles which are used for closed road driving, it is advisable to tune the ECU for a maximum gain in performance and to ensure that the CEL does not come on” .

This applies to:

Axle-back systems (muffler only)
Cat-back systems (full system from catalytic converter back)
GPF-back systems (for vehicles with gasoline particulate filters)

Why Tuning Matters

Modern high-end vehicles have sensitive ECUs that monitor exhaust flow, backpressure, and emissions. Changing the exhaust can trigger:

Check engine lights
Reduced performance modes
Incorrect fuel trims
Missed power gains

The Techlusion Alternative

For older vehicles or those seeking simpler solutions, products like Techlusion fuel controllers offer a middle ground—”not as smart as a PC or a remap but will do for now” .

Real Owner Experiences: Learning from Others

The Leak Nightmare

A G80 M3 owner’s detailed account should be required reading:

“Originally I had the exhaust fitted as an axle back since the mid pipes they sent had OPF written on them and they had a hole in them with a male threaded piece. I wasn’t sure if I should use those or wait on the correct midpipe. Turned out those midpipes are the same for euro and US spec cars.”

The real issue emerged later:

“A buddy of mine who also bought the Remus race exhaust reached out to me and said he has been having exhaust leak, he was hearing a hissing sound. He told me to check for any leaks and surely I had the same issue.”

The cause? Flared pipe ends that kinked under clamp pressure. The fix: “$400 to have my exhaust tig welded” .

Lesson: Check all clamped connections thoroughly after installation.

The Drone Surprise

A BMW G31 540i owner installed a Remus axle-back exhaust expecting “OEM-like” behaviour in comfort mode. Instead:

“I’m finding that the exhaust is louder than I thought it would be! I’m on the fence with it tbh, love the loud cold starts and when I want to accelerate but I’m getting drone at lower rpms, it seems very boomy.”

The touring body style with open boot space may amplify resonance—”so much so my wife said her ears were ringing” .

Solutions considered:

Soundproofing material to trunk floor
Checking valve operation
Allowing exhaust to “bed in” over miles

The Alignment Challenge

One GS owner fitted a Remus decat and end can, only to find:

“It doesn’t sit straight!! It feels as if its pivoting on the mount thats on the pillion footpeg, and as a result is touching the pannier frame.”

The fix? “Using a spacer on the pillion peg mounting bolt is absolutely fine. That’s how I’ve had mine fitted for years” .

Lesson: Don’t be afraid to use spacers for perfect alignment.

The BMW 1 Series Resonance Victory

A resourceful Chinese owner of a BMW 118i fitted a Remus twin-exit system and encountered the dreaded 1500-1700rpm resonance. Their solution:

“I added a custom exhaust hanger—welded to the mid-pipe brace to hold the exhaust down. Cold start resonance improved dramatically, hot start greatly improved.”

DIY resonance fix: Adding extra support to exhaust mid-sections can transform drivability.

Comparison: Remus Systems by Vehicle Type

Vehicle Type	System Complexity	Special Considerations	Common Issues
Audi RS3 8V	GPF-back system, 70mm to 76mm pipe upgrade	Requires complete system—front section, sport exhaust, tail pipes all together	Cutting may be required; ECU tuning advisable
BMW G80 M3	Full cat-back with valve control	Check pipe ends for flare issues; verify all springs included	Clamp leaks; kinked pipes; missing hardware
BMW G30/G31 5 Series	Axle-back with valve control	Touring models may experience more cabin drone	Flap operation verification; boot resonance
BMW E36 318is	Simple axle-back	Older vehicles need thread cleaning; may use different mounting positions	Corroded threads; bumper trimming
Seat Leon Cupra	Axle-back with connection tube	Requires cutting stock exhaust; no rear skirt mods needed	Alignment critical

UK Legal Considerations

EC Approval Status

Many Remus systems for high-end vehicles carry EC approval . This means they’re designed to meet European noise and emissions standards when fitted as intended.

The Audi RS3 system explicitly includes “(EEC-) approval” . The Seat Leon Cupra system carries “(EC-) approval” .

When Approval Is Lost

Your legal responsibility doesn’t end at purchase. Remus’s disclaimer is worth reading:

“The buyer shall be solely responsible for obtaining all whatsoever approvals and permissions required by the respective national law for suchlike products and shall be solely responsible for ensuring that the products manufactured by REMUS comply with the approvals required for the respective usage in the country of destination.”

This means:

If you modify the system, approval may be invalid
If you add non-approved components, you lose legal protection
Track-only use requires different considerations

The Tuning Impact

If you install an axle-back system and also tune the ECU, the combination may affect road legality. Some tunes alter emissions behaviour, potentially invalidating type approval.

Your MOT and Insurance

MOT: EC-approved systems should pass noise testing when fitted as intended
Insurance: Any exhaust modification must be declared—failure voids your policy

FAQ Section

1. Do I need special tools to install a Remus exhaust on my high-end vehicle?
The Remus spring installation tool (SHMC100) is highly recommended—spring tension is significant and difficult to manage with generic tools . Otherwise, standard socket sets, spanners, and a torque wrench suffice.

2. Will my Remus exhaust require ECU tuning?
For axle-back and cat-back systems, Remus states ECU tuning is “advisable” to prevent CEL lights and maximise performance . For full systems with downpipes, it’s essential.

3. Why is my new Remus exhaust causing drone in the cabin?
Touring/estate models may experience more resonance due to open boot space . Check valve operation, consider soundproofing, or add custom hangers . Some bedding-in period may help.

4. How do I know if my exhaust valves are working correctly?
On cold start, observe exhaust flow from tailpipes. In comfort mode, valves should restrict flow. In sport mode, they should open fully. If unsure, have a specialist verify with diagnostic tools .

5. What should I do if my Remus pipes leak at the clamps?
Inspect for kinking—some Remus pipes have flared ends that deform under clamp pressure . If kinked, welding may be the only permanent fix. Consider professional exhaust shop assessment.

6. Can I use spacers to improve exhaust alignment?
Yes—experienced owners have used spacers on mounting brackets for years without issues . Ensure bolts are sufficiently long and properly torqued.

7. Is my Remus exhaust road legal in the UK?
If your system carries EC/ECE approval and is fitted as intended (no modifications), it should be road legal . Verify your specific system’s approval status before assuming legality.

8. How much cutting of the stock exhaust is required?
Many Remus axle-back systems require cutting the original exhaust . The exact location varies by vehicle—follow the included instructions precisely. Measure twice, cut once.

9. What’s the warranty on Remus exhausts?
Remus offers 24 months warranty on EC-approved systems . Warranty may be void if improperly installed or modified. Buy from authorised UK dealers for full coverage.

10. Where can I buy genuine Remus exhausts in the UK?
Remus UK operates its own website (remusuk.com) with official product listings. Authorised retailers include Demon Tweeks, Sportsbikeshop, and specialist performance dealers.

References

Have you installed a Remus exhaust on your high-end vehicle? What car do you drive, and what installation tips would you add? Drop a comment below and share your experience—the triumphs, the challenges, and the lessons learned!

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