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Author Topic: DIY Installations: SLK55 AMG Exhaust Manifold and Headers (R171, R172)
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Post DIY Installations: SLK55 AMG Exhaust Manifold and Headers (R171, R172)
on: March 8, 2012, 08:11
Quote

<h1 style="text-align: center;"><strong>Exhaust Headers</strong>
<strong> Do-It-Yourself (DYI)</strong>
<strong> Instructions</strong>
<span style="color: #ff0000;"><strong>Mercedes-Ben</strong>z</span>
<span style="color: #ff0000;"> SLK55 ///AMG</span></h1>
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This procedure is made specifically for the R171 SLK55 AMG, but the same concept can be used on the R172 SLK55 AMG, as well as all V8 Mercedes-Benz AMG’s or base V8 models.

Estimated Time:
•Estimated Removal Time for Both Stock Manifolds is 6 Hours.
•Estimated Installation Time for a Pair of New Headers 6 Hours.
<div style="border: 1px solid gray; padding: 5px 5px 5px 5px; background-color: #fff821;"><strong><span style="text-decoration: underline;">WARNING:</span></strong> THIS PROCEDURE SHOULD BE CONDUCTED BY A TRAINED AND CERTIFIED TECHNICIAN USING APPROVED LIFTING DEVICES. THIS IS FOR ILLUSTRATION PURPOSES ONLY. IT IS ONLY INTENDED TO GIVE YOU AN IDEA OF WHAT IS NEEDED TO DO SUCH A REPAIR OR MODIFICATION. KNOWING THE JOB DETAILS SHOULD HELP YOU NEGOTIATE A BETTER DEAL FOR GETTING THIS MOD DONE BY A CERTIFIED TECHNICIAN.</div>
<h2><span style="color: #000000;"><strong><strong>TEXT INSTALLATIONS:</strong></strong></span></h2>
NOTE: For these installations to make sense, scroll down to the pictorial installations below.

<strong>STEP.1.</strong> Remove the air intake duct at shown positions (remove both sides).

<strong>STEP.2.</strong> Remove front engine cover. <strong>(a)</strong> Start by lifting the front portion up. <strong>(b)</strong> Pull up and towards the front of the car.

<strong>STEP.3.</strong> Remove the rear engine cover by lifting and rocking the cover slowly up and down.

NOTE: Move this harness backwards out of the way as you pull up the cover.

<strong>STEP.4.</strong> Remove the bottom 3 aerodynamic skid plates using an 8mm socket ratchet (not shown). NOTE: Cover air intake with a clean rag to prevent unwanted material from entering.

<strong>STEP.5.</strong> Spray and soak the (4) exhaust manifold nuts from the top. Jack up the car and soak the bottom (4) exhaust manifold nuts from the bottom with a WD-40 (or similar). Also spray the bolts holding the front pipe (downpipe) by the exhaust manifold and by the resonators. WAIT 30 MINUTES THEN PROCEDE TO STEP.5.

WARNING: TO AVOID BURN INJURY and DAMAGING BOLTS, THE ENGINE AND EXHAUST SYSTEM MUST BE COOL. PARK THE VEHICLE THE PRIOR NIGHT IN A POSITION WITH ACCESS THE NEXT DAY TO THE FRONT SIDES OF THE VEHICLE. AND LEFT HAND

<strong>STEP.6.</strong> Unplug the beige colored exhaust sensor plug (for the post- cat oxygen sensor) and free it from around the shown line.

<strong>STEP.7. (a)</strong> From the bottom: Cut the brown high temp zip tie using (do not damage surrounding harnesses). <strong>(b)</strong> From the bottom: Unplug the black colored exhaust sensor plug (for the pre-cat oxygen sensor). <strong>(c)</strong> From the top (driver side firewall): Cut black zip tie that is securing the same harness to location shown.

<strong>STEP.9.</strong> Separate the front exhaust pipe from the rear exhaust pipe using a 13mm socket/ratchet and 13mm wrench.

<strong>STEP.8.</strong> Separate the front exhaust pipe from the exhaust manifold. Use a ratchet with at least a 10” extension and an External Torx Socket E-12.

<strong>STEP.10.</strong> Remove retaining bracket using a 13mm wrench. Then remove the front pipe (downpipe) completely out of the way. (I broke the bolt. Lightly Hammer the bolt out and replace it with a standard M8 bolt)

TOP: working from the engine bay.

<strong>STEP.11.</strong> Use a 10mm socket and a small ¼ inch ratchet to remove the top (4) brass nuts. (TIP: For best leverage, lean over the front bumper cover and start with the front nut, working your way to the back. If one of the studs comes out with the nuts, no big deal, install it with manifold later) BOTTOM: working from below.

<strong>STEP.12.</strong> Use a combination of 10mm short wrenches or/and small ¼ inch ratchet with a long 10mm socket, to remove the top 4 brass nuts. (TIP: The engine mount is in the way. That will force you to access the front two nuts from the front bottom side of the car. Access the rear two nuts from behind the engine mount. Move around for best leverage. Larger wrenches might not fit around all bottom nuts because of the tight spacing between the nut and manifold)

<strong>STEP.13.</strong> The exhaust manifold should almost free fall at this point. Remove it from the bottom side.

<strong>STEP.14.</strong> The old exhaust manifold gaskets (shown) come out separated, (2) per cylinder. The new ones will come (2) bonded together. You only need to order (4), not (8) for each exhaust manifold.

<strong>STEP.15.</strong> Grab your aftermarket exhaust headers, and position into place (access from the bottom side of the car.)

<strong>STEP.16.</strong> Place the new gaskets on the studs. Slip over the exhaust manifold and hand tighten the top (4) nuts. Then hand-tighten the bottom (4) nuts. Using a 10mm socket tighten the nuts in an X pattern from top front to bottom rear. (NOTE: Be careful not to over tighten and break the studs)

<strong>STEP.17.</strong> Repeat the same steps for the passenger side manifold.

<strong>STEP.18.</strong> Install the front pipe (downpipe) by reversing the removal steps. Make sure to plug in the sensor plugs and install new zip ties into place, (NOTE: Use high temperature zip ties to prevent them from drying and cracking. This is caused by the heat generated from the downpipe and the close proximity to the harnesses)

<strong>STEP.19.</strong> Install rear air box engine cover (this is a good time to change your air filters). Install the front engine cover. Then install the air ducts. Install the bottom skid plates.

<strong>STEP.20.</strong> Triple check everything, in, under, and around the engine bay and around the car. Start up your car, warm it up (it will smell a little bad because of the WD-40, it will burn off eventually). Take it for a test drive; enjoy the increased power and the brutal exhaust sound.

 
<h2><strong><strong>PICTORIAL INSTALLATIONS:</strong></strong></h2>
[scribd id=84439293 key=key-1rs5zn48ebq4nukv5kyj mode=list]

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