MINI Cooper R50 / R52 / R53 1.6L 4-1 Catted Exhaust Header with 200 CPSI High-Flow Cat

SKU: XKV11158
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Fitment & Specs
2002-2006 R50 Cooper / R53 Cooper S; 2005-2008 R52 Cooper / Cooper S / JCW Convertible; 1.6L
1.5" Inlet ¡ 2.25" Outlet
T304 Stainless Steel ¡ Direct Bolt-On ¡ Professional Installation Recommended
Before You Buy: Off-road/racing use only ¡ Professional install recommended
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Description
MINI R50 / R52 / R53 Catted Exhaust Header

4-1 Exhaust Header with 200 CPSI High-Flow Catalytic Converter

Application-specific 2-piece 4-1 exhaust header manifold assembly for listed MINI Cooper R50, R52 and R53 1.6L applications. Constructed from T304 stainless steel, the assembly features an integrated 200 CPSI metallic high-flow catalytic converter, O2/lambda sensor ports, a flexible joint and direct bolt-on connections for the listed vehicle applications.

Product Type Catted Exhaust Header
Header Layout 2-Piece 4-1
Catalyst 200 CPSI High-Flow Cat
Material T304 Stainless Steel
Vehicle Fitment

Confirm Your MINI Chassis & Model Year

Fitment differs by chassis and model year. Use the application table below before ordering.

Model Chassis Years Engine Body Style
MINI Cooper R50 2002-2006 1.6L Hatchback
MINI Cooper S R53 2002-2006 1.6L Hatchback
MINI Cooper R52 2005-2008 1.6L Convertible
MINI Cooper S R52 2005-2008 1.6L Convertible
MINI Cooper JCW R52 2005-2008 1.6L Convertible
Fitment Note: R50 and R53 applications cover the listed 2002-2006 hatchback models, while R52 applications cover the listed 2005-2008 convertible models. Verify your exact chassis, trim, engine, O2 sensor layout and downstream exhaust connection before purchase.

Product Details

Header & Catalyst

  • 2-piece exhaust header manifold assembly
  • 4-into-1 merge collector design
  • Integrated 200 CPSI metallic high-flow catalytic converter
  • O2 / lambda sensor ports
  • Integrated flexible joint / bellows section
  • Direct bolt-on configuration for listed applications

Construction & Dimensions

  • T304 stainless steel construction
  • Approx. 1.5" / 38.1 mm inlet dimensions
  • Approx. 2.25" / 57.15 mm outlet
  • 1.5 mm tubing wall thickness
  • TIG-welded construction
  • CNC-machined flanges / connection points

What This Product Is

Catted Header Assembly

This product combines an application-specific 4-1 exhaust header with an integrated high-flow catalytic converter for the listed first-generation MINI applications.

Not the Same Product As

  • Catback exhaust or rear muffler system
  • Catless racing header
  • Standalone catalytic converter
  • Turbo downpipe
  • Turbo manifold
  • Cold-air intake system
  • Universal exhaust header

Package Includes

  • 2-piece 4-1 exhaust header assembly
  • Integrated 200 CPSI high-flow catalytic converter
  • Flexible joint / bellows section
  • Gaskets
  • Mounting hardware

Compare the supplied components with the product photos and your vehicle's existing exhaust layout before installation.

Installation Notes

Before Installation

  • Confirm R50, R52 or R53 chassis and the correct model year.
  • Verify engine application and factory exhaust connection.
  • Confirm O2/lambda sensor routing and connector clearance.
  • Inspect surrounding wiring, heat shields and engine-bay clearance before final installation.

Installation Guidance

  • Professional installation is recommended.
  • Test-fit all components before final tightening.
  • Confirm gasket and flange alignment.
  • Check the flex section and downstream exhaust alignment.
  • Inspect all connections for exhaust leaks after installation.
  • Recheck fasteners after initial heat cycles where appropriate.

Before You Buy

  • Fits the listed 2002-2006 MINI Cooper R50 and Cooper S R53 hatchback applications and listed 2005-2008 MINI R52 convertible applications.
  • This is a 4-1 catted exhaust header assembly with an integrated 200 CPSI high-flow catalytic converter.
  • It is not a catless header, catback exhaust, rear muffler, turbo downpipe or standalone catalytic converter.
  • Verify chassis, model year, trim, 1.6L engine, O2/lambda sensor layout and downstream exhaust connection before ordering.
  • Professional installation is recommended. Modified or previously repaired exhaust systems may require additional fitment work.
  • Exhaust and catalytic-converter regulations vary by state and locality. Verify applicable emissions requirements before installation or road use.
Shipping & Return

SHIPPING & DELIVERY
Fast Processing & Reliable Transit

  • Processing: Orders are processed and shipped from the nearest available warehouse within 1 business day after payment.
  • Delivery: Estimated delivery time is approximately 3–4 business days after shipment.
  • Shipping - Free shipping on all orders within the contiguous 48 U.S. states.

RETURNS & EXCHANGES
30-Day Hassle-Free Policy

  • Return Window: We offer a 30-day return policy from the date of delivery.
  • Item Condition: Returned items should be unused, uninstalled, and in their original packaging when possible.
  • Return Process: To initiate a return or exchange, please contact our customer service team first to receive authorization and instructions.

WARRANTY
2-Year Limited Replacement Warranty

  • Duration: All products are backed by a 2-year limited warranty.
  • Coverage: This warranty covers manufacturing defects and product failures under normal use, and provides a replacement for qualified cases (repairs are not performed).

CUSTOMER SUPPORT
We’re Here to Help – Contact Us First

  • Priority Contact: For any order-related issues—including returns, warranty claims, or general inquiries—please contact us first before taking further action. We are committed to resolving your concern promptly.
  • Feedback Notice: If you are unsatisfied, we kindly ask that you allow us an opportunity to address the issue before leaving neutral or negative feedback.
  • Email Support: You can reach us at support@XKVracing.com.

What Does an Exhaust Header Actually Do?

The exhaust header is the first section of the exhaust system and mounts directly to the engine. Its role is to collect exhaust gases from each cylinder and route them into the rest of the exhaust system.

Compared to many factory manifolds, header designs often focus on smoother internal flow and more uniform exhaust routing before gases move downstream.

What You May Notice After Installation

Smoother exhaust flow as engine speed increases

More consistent engine behavior across the RPM range

Improved exhaust routing when paired with other intake or exhaust components

Changes in exhaust tone, depending on system configuration

When This Type of Upgrade Is Typically Considered

Addressing airflow limitations in the factory exhaust manifold

Planning coordinated intake or exhaust system updates

Replacing aging or restrictive original components

Build a balanced, performance-focused setup

Factory Manifold vs. Performance Header

Factory Exhaust Manifold

Designed to meet packaging, cost, and emissions requirements
Prioritizes durability and compliance across broad use cases

Performance Exhaust Header

Designed with exhaust flow characteristics in mind
Built for higher exhaust temperatures and specific vehicle platforms
Commonly used as part of an exhaust system configuration

FAST SHIPPING

Ships within 1 business day after payment
3–4 business day delivery

Secure and Reliable Checkout

Secure checkout with major payment options

LOCAL WAREHOUSE

Orders ship from U.S. warehouses when available

Easy Returns and Exchanges

30-day returns for eligible unused items

Parts Warranty

Warranty support for qualified manufacturing defects

Important Notice

Products on this site are intended for off-road, racing, or closed-course use where emissions laws apply. They are not represented as street legal, emissions-compliant, or legal for use on public roads unless explicitly stated.

Some products may remove, replace, relocate, disable, or alter emissions-related components, including but not limited to catalytic converters, EGR, DPF, SCR, DOC, O2 sensors, or related factory systems. Compatible tuning, calibration, or supporting modifications may be required to avoid engine codes or drivability issues.

Professional installation is recommended. Buyers are responsible for verifying product compatibility, local regulations, emissions requirements, and any required tuning or supporting modifications before purchase and installation.

Performance gains, sound changes, airflow improvements, temperature changes, fuel economy changes, fitment, and drivability results may vary. No specific performance gains are guaranteed.

Frequently Asked Questions

What do exhaust headers do? +

Exhaust headers help route exhaust gases away from the engine through individual tubes and collector-style routing. Actual results depend on the vehicle, engine condition, exhaust system, installation quality, and supporting components.

What's the difference between headers and factory manifolds? +

Factory manifolds are typically designed around packaging, durability, emissions requirements, and production cost. Headers or manifold-related exhaust upgrades may use different tube routing, flange designs, or connection layouts depending on the application.

Will headers increase horsepower? +

Headers may support improved exhaust flow where the product is compatible, but horsepower and torque changes are not guaranteed. Results vary by engine setup, tuning, exhaust configuration, vehicle condition, installation, and supporting modifications.

Do headers make the vehicle louder? +

Headers and related exhaust parts can change exhaust tone and may increase sound depending on the rest of the exhaust system. Final sound level depends on the engine, mufflers, catalytic converters, pipe routing, and complete exhaust setup.

Do I need tuning after installing headers? +

Tuning requirements depend on the vehicle, engine management system, O2 sensor setup, emissions equipment, and supporting modifications. Some installations may not require tuning, while modified builds may require professional inspection, calibration, or tuning to support proper drivability.

Are header products street legal? +

Header and exhaust products may be intended for off-road or racing use where emissions laws apply. They are not represented as street legal, emissions-compliant, or CARB-compliant for public road use unless a valid exemption is explicitly stated. Always check local regulations before purchase and installation.

Can I use headers with a stock exhaust system? +

Compatibility with a stock exhaust system depends on the vehicle and existing exhaust configuration. Some vehicles may require additional hardware, gaskets, connectors, adjustment, or fabrication to complete installation.

Are headers hard to install? +

Installation difficulty varies by vehicle. Tight engine bays, old hardware, rust, engine swaps, modified exhaust systems, sensor placement, and clearance around surrounding components can increase installation complexity. Professional installation is recommended.

Will headers affect reliability? +

Reliability depends on fitment accuracy, installation quality, vehicle condition, heat management, gasket sealing, fastener condition, sensor placement, and supporting components. Proper inspection and installation are important.