Weistec True Downpipes

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1 Weistec True Downpipes Installation Guide, W212, W218, AWD E CLS63

2 WARNING! IF YOU ARE NOT EXPERIENCED IN THE AREA OF AUTOMOTIVE MECHANICS, WE STRONGLY URGE THAT YOU REFER THIS INSTALLATION TO A CERTIFIED INSTALLER OR TECHNICIAN. 1

WEISTEC M157 True Downpipes Thank you for your purchase of the Weistec M157 True Downpipes for your Mercedes 63 AMG equipped with the M157 Engine.

3 WEISTEC M157 True Downpipes Thank you for your purchase of the Weistec M157 True Downpipes for your Mercedes 63 AMG equipped with the M157 Engine. We appreciate your business, and we know you will enjoy your product. For your benefit, please read the following instructions completely and thoroughly before attempting to install the M157 True Downpipes. Many questions we have received from customers about the installation of our products that could have been easily solved by information listed in the accompanying installation guide. We want you to enjoy the product in its fully functional state, and reading this tutorial is the first step to getting you on your way to a more rare and powerful AMG. We strongly urge that you also have at least one person to help you install the M157 True Downpipes, as it is a complex install. Again, thank you for choosing Weistec Engineering! 2

4 Table of Contents I. Tools Required... 4 II. Engine and Transmission Removal... 5 III. Downpipes IV. Torque specifications

5 I. Tools Required Hydraulic Jack Service lift Engine and Transmission Stand 1/4 Drive Ratchet 12" Long 1/4" Drive Extension 6.5mm 1/4 Drive Deep Well Socket 8mm 1/4 Drive Deep Well Socket 10mm 1/4 Drive Deep Well Socket 17mm 3.8" Drive Deep Well Socket 10mm Open End Wrench 13mm Open End Wrench 14mm Open End Wrench 15mm Open End Wrench 17mm Open End Wrench 1" Open End Wrench 8mm Ratcheting Wrench 10mm Ratcheting Wrench 3/8 Drive Ratchet 13mm 3/8" Drive Socket 16mm 3/8 Drive Deep Well Socket 17mm 3/8" Drive Deep Well Socket 19mm Heavy Duty Deep Well Socket T-25 1/4" Drive Torx Bit T 30 1/4" or 3/8 Drive Torx Bit T-45 3/8" Drive Torx Bit T-50 3/8" Drive Torx Bit E-8 3/8" Drive Reverse Torx Bit E-14 3/8" Drive Reverse Torx Bit Flat Head Screw Drivers Wire Cutter Crimping Pliers Wire Stripper Pushpin Removal Tool 6mm Drive Hex Bit 8mm Drive Hex Bit Mechanics Rags Vacuum Painters Tape Fluid evacuator Impact Gun (Optional) Crimp Style clamp tool Torque Wrench 4

6 II. Engine and Transmission Removal Parts Call Out 1. Null 2. Engine covers 3. Engine air intake duct 4. Air filter housing 5. Foam fuel injector covers 6. Refrigerant line 7. Bulkhead 8. Fuel line 9. Fuel distributor 10. Heater shutoff valve 11. Purge line 12. Coolant hose 13. Coolant hose 14. Vacuum line 15. Coolant hose 16. Coolant hose 17. Coolant hose 18. Oil cooling lines 19. Vent line 20. Cooling air lines 20L. Cooling air line 20R. Cooling air line 21. Radiator 22. Cold air intake 23. Radiator crossmember 24. Torsion bar linkage 25. Stabilizer bar 26. Brake caliper 27. Suspension strut 28. Transmission 29. Wiring harness 30. Steering coupling 31. Front axle carrier 31a. Screw/bolt 32. Electrical line 33. Bracket 34. Cross strut 5

35. Bracket 36. Diagonal struts 37. Supporting struts 38. M13/5. Coolant circulation pump 39. Refrigerant line 40. Low-temperature circuit coolant expansion reservoir 41. Coolant line 42.

7 35. Bracket 36. Diagonal struts 37. Supporting struts 38. M13/5. Coolant circulation pump 39. Refrigerant line 40. Low-temperature circuit coolant expansion reservoir 41. Coolant line 42. Coolant hose 43. Coolant line 44. Coolant hose 45. Coolant expansion reservoir high temperature cooling system A80. Intelligent servo module for DIRECT SELECT M42. Electric transmission oil pump Y58/1. Purging switchover valve 6

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1. Turn front wheels straight ahead and secure steering wheel 2. Put transmission in neutral and release parking brake 3. Disconnect ground from batter 4.

10 1. Turn front wheels straight ahead and secure steering wheel 2. Put transmission in neutral and release parking brake 3. Disconnect ground from batter 4. Secure vehicle on a lift IF PROPER MERCEDES PROCEDURE IS NOT FOLLOWED, THE VEHICLE MAY BE PERMANENTLY DAMAGED AND/OR MAY FALL OFF THE LIFT 5. Remove lower engine compartment paneling 6. Drain coolant 7. Remove engine covers 8. Remove front section of the upper engine cover 9. Drain coolant from intercooler system 10. Remove both intake ducts 11. Remove airboxes 12. Discharge AC 9

11 13. Disconnect refrigerant line (6) at upper engine compartment connecting point and close off openings with plugs 14. Remove purge line (11) at purging switchover valve (Y58/1) 15. Disconnect vacuum line (14) on bulkhead (7) connecting point and place to one side 16. Remove coolant hose (12) on heater shutoff valve (10) and bulkhead (7) and remove upwards 17. Disconnect bleed line (19) at connecting point 18. Disconnect coolant hose (42) to the low-temperature circuit coolant expansion reservoir (40) 19. Disconnect coolant line (43) from distributor below the high-temperature cooling system coolant expansion reservoir (45) 20. Remove coolant hose (44) on the coolant circulation pump (M13/5) 21. Remove coolant hose (13) at coolant pump and cooler (21) and place to one side 22. Remove coolant hoses (15, 16) at coolant lines for charge air cooler 23. Remove coolant hose (17) at thermostat housing and cooler (21) and remove 24. Remove cold air intake 25. Fasten cooler (21) to upper radiator crossmember (23) and secure against falling down 26. Disconnect engine wiring harness on the vehicle side 27. Remove front wheels 28. Remove torsion bar linkage (24) from stabilizer bar (25) 29. Remove brake calipers (26) from steering knuckles and fasten with attached lines to suspension strut (27) 30. Remove electrical line to intelligent servo module for DIRECT SELECT (A80) and unclip on transmission (28) 31. Remove shift rod from range selector lever on transmission (28) 32. Disconnect electrical line on electrical transmission oil pump (M42) and unclip on transmission (28) 33. Remove heat shield 34. Disconnect transmission control electrical connection and place wiring harness (29) outside the working area 35. Disconnect exhaust system at center muffler connecting point on rear muffler 36. Remove steering coupling (30) 37. Disconnect refrigerant line (39) at lower connecting point and close off openings with a stop plug 38. Remove electrical line (32) at rack-and-pinion steering, unclip on front axle carrier (31) and set aside 10

12 39. Disconnect lower oil cooling lines (18) of transmission (28) at connecting point and close off openings with stop plug 40. Remove oil lines to engine oil cooler and close off openings with a stop plug 41. Disconnect oil lines at connecting point to engine oil cooler and close off openings with a stop plug 42. Disconnect electrical connections from rpm sensors, right front brake pad contact sensor and front axle damping valve unit electrical connection on left and right and unclip electrical lines at brackets 43. Remove suspension strut (27) from steering knuckle 44. Remove bracket (33) for front level sensor link rod from crow strut (34) 45. Remove bracket (35) for the lower engine compartment paneling 46. Relieve fuel pressure over diagnostic socket Please be aware that the fuel system may retain fuel pressure that can be extremely dangerous if removed suddenly. Proceed with caution. Please be aware of dripping fuel that may get on parts that can be affected. Please cover fuel line with a shop rag in this case. 47. Remove fuel line (8) and fuel distributor (9) and close off opening using suitable stop plugs 48. Remove strut between RH and LH side of underfloor 49. Remove diagonal strut (36) of front axle carrier (31) 50. Remover supporting strut (37) of front axle carrier (31) 51. Remove coolant lines (20L, 20R) for engine mount 52. Support front axle carrier (31) with lifting platform and aggregate mount and secure whole engine transmission unit against slipping and falling down with a tensioning strap 53. Remove rear engine crossmember with rear engine mount 54. Remove drive shaft from transmission output flange/transfer case 55. Remove screw/bolts (31a) on front axle carrier (31) from longitudinal members 56. Lower engine transmission unit with front axle carrier (31) 11

13 III. Downpipes Parts callout Turbochargers 1. Turbocharger with exhaust manifold 1a. Nuts 1b. Nuts 2. Exhaust Pipe 3. Locking plate 4. Null 5. Clamp 6. Clamp 7. Shield 8. Shield 9. Bracket 12

14 Parts call out Charge Air Ducts 1. Nuts 1l. Nuts 1r. Nuts 2. Lower charge air ducts 2l. Lower charge air duct on the left 2r. Lower charge air duct on the right 3. Null 4. Air cleaner housing 5. Charge air cooler 1. Drain engine oil 2. Detach clamp (6) on shield (7) 3. Remove refrigerant line on AC compressor 13

15 4. Remove shield (7) on engine support 5. Remove shield (8) on cylinder head 6. Remove charge air ducts by: a. Loosen clamp between upper charge air duct (1l, 1r) and air filter housing (4) b. Loosen clamp between upper charge air duct (1l, 1r) and turbocharger c. Remove screw/bolt for upper charge air duct (1l, 1r) on cylinder head cover d. Remove upper charge air duct (1l, 1r) e. Remove air filter housing (4) f. Detach engine oil cooling oil lines from oil filter hosing and bracket on engine and lay to the side outside the working area g. Loosen clamp between lower charge air duct (2l, 2r) and charge air cooler (6) h. Loosen clamp between lower charger air duct (2l, 2r) and turbocharger i. Remove screw/bolts for right lower charge air duct (2r) from cylinder head j. Remove screw/bolts for lower charge air duct on the left (2l) from cylinder head and oil filter housing k. Remove lower charge air duct (2l, 2r) l. Check boot and rubber seal for cracks or damage and replace if necessary m. Check clamps for damage and replace as necessary 7. Remove bracket (9) between exhaust pipe (2) and cylinder head 8. Remove exhaust pipe (2) 9. Remove lock washer (3) on turbocharger with exhaust manifold (1) 10. Unscrew nuts (1a, 1b) on turbocharger with exhaust manifold (1) 11. For 4matic vehicles only Remove engine mount brackets from engine block and install the Weistec Billet Engine Mount Brackets and Weistec Supplied Engine Mounts using the supplied studs, bolts, and nuts. DO NOT REUSE THE BLUE RUBBER ENGINE MOUNT COVERS FROM THE OEM ENGINE MOUNTS 12. Install Weistec True downpipes in reverse order. Be sure to use the hardware provided with the Weistec True Downpipes to bolt them onto the turbochargers. Torque to 18ft-lbs 13. Install AC Line into AC compressor before installing the engine and transmission back into the vehicle 14

16 IV. Torque specifications 15

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18 Thank you from Weistec Engineering! Always enjoy the added horsepower and torque of the Weistec M157 True Downpipes responsibly. Use best judgment when driving, and remember to have fun! NOTES: 17

Weistec M157 WMI System

Weistec M157 WMI System Installation Guide 2012-2013 E63 2014+ E63 4matic(S) 2011-2013 CLS63 2014+ CLS63 4matic(S) 2015+ S63 AMG (Without ABC Suspension) This product is legal in California for racing