Fitting instructions Flap exhaust system C 63 AMG

Transcription

1 Fitting instructions Flap exhaust system C 63 AMG

2 The product described in the instructions was developed, produced and checked considering the necessary safety requirements. In order to ensure a proper and safe function and to rule out danger for persons and objects, this product must be installed appropriately. Only trained, qualified staff, having the necessary technical experience and tools, should do the installation. Therefore you have to read and completely understand these instructions. Before you start please check the content of the supplied parts as detailed below. 2 Please be advised that the Brabus flap-sports exhaust can only be used in combination with Brabus rear diffusor, article-no & Included in delivery of Brabus flap-sports exhaust for C63AMG: 1x Exhaust system , consisting of 1x Pre-silencer VSD 2x Rear-silencer ESD 1x Tailpipe left ERLB 1x Tailpipe right ERRB

3 Mechanical assembly set / control valve ( ) 1x Back pressure valve ZT0063 1x Control valve ZT0064 1x Control valve bracket x Low pressure pipe (plastic) x Sticky socket WU x T-hose connector 4mm WU x Clamp WU x Double sided cable jacket 12x20x24 WU ,5 m Kevlar-jacket N-S ,5 m Low pressure hose 3,5mm BE x Screw M6x10 WU x Washer M6 WU x Lock nut M6 WU x Cone washer x Button x Wiring harness incl. electronic control unit for exhaust flap control, x CAN-Adapter (Y) 000-CAN-06 3 Wiring harness Button

4 Preparation: - Lift the car on a suitable platform at the Mercedes-Benz prescribed lifting positions with due regard to valid safety guidelines. - Remove the standard rearbumper insert as per Mercedes-Benz workshop instructions. - Remove the standard exhaust system by unscrewing the 2 clamps in the front area. 4 - Remove the front left underbody cover and the front left wheelarch-lining (only the rear part).

5 - Fit the delivered pre-silencer using the standard clamps. - Attach the brackets supplied to the exhaust rubber supports. Connect the rear-silencers to the pre-silencer using clamps supplied and to the brackets using assembly material (washers, spring washers and nuts) supplied. Only pre-tighten the connections in order to be able to align the exhaust system after assembly. - Connect 25.6 long pieces of low pressure hose supplied to each exhaust flap and secure them using clamps supplied. 5 - Cut two 25.6 long pieces of kevlar jacket supplied and attach these to each of the previously connected low pressure hoses.

6 - Route the protected hoses above the exhaust heat-shields to the middle of the rear axle body, connect both to one of the t-distributors supplied. Secure the connections using clamps supplied and attach the t-distributor to the upper strut of the rear axle using cable ties Connect a 5.9 long piece of low pressure hose to the previously attached t-distributor and secure the connection using a clamp. - Connect a long piece of plastic pipe to the end of the previously attached low pressure hose and secure the connection using a clamp. - Route the plastic pipe above the rear axle to the car s underbody (left side).

7 - Route the pipe along the brake pipes to the front of the car, attach it to the brackets of the brake pipes. - Route the pipe into the front left wheelhouse and topwards through the holes within the body. 7 - Route the pipe into the engine bay and fixate it within the wheelhouse using adhesive brackets and cable ties supplied. Carefully clean and disgrease the bonding areas before!

8 - Attach the bracket of the electric valve supplied according to images below using the screw supplied, attach the valve to the bracket. - Connect the end of the plastic pipe to a 3.5 long piece of low pressure hose and secure the connection using a clamp. 8

9 - Connect a 6 long piece of low pressure hose to the inlet of the valve and secure the connestion using a clamp. Connect the outlet of the valve to the angled hose supplied and the back pressure valve supplied (take care for correct direction, according to fig. below!). - Connect the outlet of the back pressure valve to a 20 long piece of plastic tube. Route the tube through the plastic insert shown (drill hole) to the intake manifold. 9

10 - Cut the standard back pressure hose shown which is located below the left airfilter housing and connect both ends to a t-distributor supplied. Connect the previously routed plastic tube to a short piece of low pressure hose and to the t-distributor. Make sure all connections were securely made! 10

11 Overview about electrical connections to be made: control unit To cigar lighter plug to valve 11 To OBD port, solder parallel to cable out of PIN 16 (power supply) to centre-console button To CAN distributor within driver s footwell cable housing (see figure next page), connect to free port or already assigned port using Y-cable supplied.

12 Position of CAN distributor - Remove the driver s side entrance panel and fold up the carpet in order to get access to the white CAN-distributor. - Route the CANbus- wiring (cable green-white/ green) to the white CAN-distributor. Attach the CAN-plug to a free port of the CAN-distributor or-if all ports are already engaged, solder the single wires parallel to those of a plug which is attached to the distributor Remove the left lower dashboard cover. - Attach the electronic control unit to the lower dashboard cover using the delieverd velcro tape. - Route the connector of the electric valve through the fuse and relay box into the engine bay and connect it to the electric valve. - Solder the red cable of the harness parallel to the cable out of PIN16 of the OBD plug and isolate the soldering area sufficiently. Standardly the flap exhaust control is done by the additional button supplied that gets attached within the center console. If the client wants to maintain the additional 12V plug (cigar lighter plug) and does not want the flap exhaust button to be installed, please proceed as described on page 17. If the button is not installed, the exhaust flaps can only be controlled by the steering wheel buttons (up/ down). If this is the case there is no visible information about the flap position, an optical information about the position is only given by the LED within the flap control button. In this case only the exhaust loudness gives information about the flap position. Attach the stick-on label with the operation hints to a visible area of the dashboard.

13 Further procedure when the client wants to have the button in the center console: - Route the wire with the 4-pole yellow plug and the brown/red wire to the centre console. - Remove the gear selector lever, the lower trim of the centre console and the ashtray unit according to MB workshop instructions. - Solder the brown and red wire parallel to the power supply of the 12V socket. Carefully isolate the soldered areas. Remove the 12V socket and place it in a free area below the ashtray unit (must remain connected, otherwise a fault will be shown) Attach the flap exhaust button supplied to the assembly position of the 12V socket and connect it to the 4-pole socket of the Brabus harness. - Re-fit all previously removed trim parts and the gear selector lever.

14 Further procedure when customer wants to keep the 12V socket: - Remove the gear selector lever, the lower trim of the centre console and the ashtray unit according to MB workshop instructions. - Remove the ashtray unit, disconnect the plug of the 12V socket. - Solder the brown and red wire parallel to the power supply of the 12V socket. Carefully isolate the soldered areas. - Re-connect the plug of the 12V socket and re-attach the ashtray unit and the gear selector lever When the flap exhaust button does not get attached, the 4-pole yellow socket of the Brabus unit remains disconnected. - Re-fit all trim parts and perform a function check. Perform a test-drive and re-check the clamp connections of the exhaust system. Function description: The car always starts with the exhaust flaps switched quiet (flaps closed) and can be switched loud by pushing the exhaust control-button. Whenever the car is standing, the flaps are closed, also when the system was previously switched loud.

15 Overwiew of flap control-connections: 15 Attention: While assembly please make sure the small switch on the control unit is switched to position 3!

16 Schematic description of low pressure circuit with length values specifications. elektischer Anschluß electric connection Umschaltventil select valve 150 mm Rückschlag non 150 mm ventil return valve 500 mm 500 mm Leitung Saugrohr zu Serien Unterdruckspeicher rail intake manifold to serial vacuum tank 90 mm 90 mm Schelle: clamp: Unterdruckschlauch 3,5 mm vacuum rail 3,5 mm Unterdruckleitung (Kunststoff) 4000 mm vacuum rail (plastics) Kevlar Schutzschlauch kevlar fiber protection sleeve mm Auspuffklappe Auspuffklappe exhaust flap exhaust flap 150 mm 650 mm 150 mm 650 mm 650 mm 650 mm 650 mm 650 mm 650 mm 650 mm