Why Choose an Akrapovič Exhaust for Your E63 AMG?

Upgrading the exhaust system on a Mercedes-AMG E63 is one of the most satisfying modifications you can make. The Akrapovič exhaust is widely regarded as a top-tier choice because it combines premium materials—such as lightweight titanium and high-grade stainless steel—with precision engineering. The result is a noticeable improvement in both power and sound. Owners often report a deeper, more aggressive exhaust note without the drone that plagues lesser aftermarket systems. Additionally, the weight savings from the titanium construction can be significant, contributing to improved handling and acceleration. If you are serious about getting the most out of your E63, this installation will reward you with a more thrilling driving experience every time you press the start button.

This guide takes you through the entire process, from gathering the correct tools to performing the final sound check. We have included torque specifications, fitment tips, and safety reminders gathered from experienced technicians to ensure your installation is as smooth as possible. Whether you are a seasoned DIYer or a first-time exhaust installer, following these steps carefully will help you achieve professional-level results.

What You Will Need: Tools, Materials, and Safety Gear

Before you start, assemble everything in one place. Running back and forth for tools mid-installation is frustrating and increases the chance of mistakes. The list below covers not only the obvious items but also a few extras that will make the job easier.

Exhaust System and Hardware

  • Akrapovič Exhaust System (full system or slip-on, depending on your chosen configuration)
  • Replacement exhaust gaskets (Akrapovič usually includes new gaskets; verify your kit)
  • Anti-seize compound for bolts and hangers
  • Penetrating lubricant (e.g., WD-40 or PB Blaster)

Tools

  • Socket Set – metric sizes, including extensions and universal joints
  • Torque Wrench – capable of reading in Nm and ft-lbs (range 20–100 Nm ideally)
  • Jack and Jack Stands – a low-profile racing jack is helpful for the E63’s ground clearance
  • Cutting Tool – if your Akrapovič kit requires cutting the factory pipes; a reciprocating saw or plasma cutter works
  • Trim Removal Tools – for pulling off plastic covers or heat shields without damage
  • Pry Bar or Rubber Mallet – for stubborn rubber hangers
  • Breaker Bar – for seized bolts, common on exhaust connections
  • Safety Glasses and Mechanic’s Gloves

Work Environment

Perform the installation on a level, well-ventilated surface—ideally a garage with a concrete floor. If the car has been driven recently, let the exhaust cool completely before starting; you do not want to burn yourself on hot catalytic converters or mufflers.

Safety First: Critical Precautions

Working under a vehicle carries inherent risks. Never rely solely on a jack. Always use jack stands rated for the weight of the E63. Ensure the parking brake is fully engaged and consider chocking the rear wheels. Disconnect the negative battery terminal to prevent any accidental electrical shorts, especially if your E63 has electronic exhaust valves or sensors near the exhaust system. Wear safety glasses when cutting or grinding, and gloves to protect against sharp metal edges.

Step 1: Prepare the Vehicle

  1. Disconnect the Battery – Locate the negative terminal under the trunk floor or underhood, depending on your model year. Loosen the clamp and move the cable away from the terminal.
  2. Raise the Car – Use the jack to lift the rear or the entire side of the car, depending on your access needs. Place jack stands under the designated lift points. Lower the car onto the stands and give it a gentle shake to confirm stability.
  3. Remove Underbody Covers – The E63 has several plastic covers and heat shields below. Use a trim tool or socket set to remove them. Keep the hardware organized—store each set of bolts in labeled bags or place them on a magnetic tray.
  4. Lubricate Exhaust Hangers and Bolts – Spray penetrating lubricant on all rubber hangers and any bolts you plan to loosen. Give it a few minutes to work, especially if the car is from a snowy region where corrosion is common.

Step 2: Removing the Stock Exhaust

Factory exhaust systems are often one long piece from the catalytic converters back. Depending on your E63’s year, you may need to split the system at a flange or cut the pipes. The Akrapovič installation manual will specify which approach is needed. If cutting is required, measure twice before you cut.

2.1 Unbolt the Muffler Section

  1. Locate the flange bolts connecting the rear muffler section to the mid-pipe. Use the socket set with a breaker bar if necessary. Some bolts may be studs with nuts; spray them again if they resist.
  2. Remove the rubber hangers from the mounting studs using a pry bar or your hands. A bit of soapy water on the hanger bushings can help them slide off.
  3. Slide the muffler section out from under the car. It may be heavy; ask a helper to support it or use a transmission jack.

2.2 Remove the Mid-Pipe / Resonator Section

  1. If the system is two-piece, unbolt the mid-pipe from the downpipes or catalytic converters. On many E63 models, there are four bolts (two per side) connecting to the cats.
  2. Lower the mid-pipe carefully. It often has integrated resonators and may require you to tilt it to clear the rear axle or subframe.
  3. Remove any remaining hangers and brackets. Keep the original hardware if the Akrapovič kit uses the same mounting points – some kits reuse factory bolts.

2.3 Remove the Exhaust Valves (If Applicable)

Your E63 AMG likely has electronically controlled exhaust flaps. The stock valve actuators may need to be unbolted and transferred to the Akrapovič system. Disconnect the electrical connectors carefully—use a flat-head screwdriver to release the locking tab. Wrap the connectors in shop towels to keep them clean during the installation.

Step 3: Inspect and Prepare the Akrapovič Exhaust

Lay out each component of the new system on a clean surface. Check the instruction manual – Akrapovič provides a detailed PDF on their website for each kit. Verify that all clamps, springs, and gaskets are present. Some kits use V-band clamps, others use bolted flanges. Apply a thin layer of anti-seize to all bolt threads that will contact aluminum or titanium parts to prevent galling.

If your kit includes a carbon fiber tailpipe finisher, handle it carefully—scratches are easy to make and hard to fix. Wipe the pipe ends with a clean rag before assembling.

Step 4: Installing the Akrapovič Exhaust

Installation is essentially the reverse of removal, but with a few critical differences. Follow the kit instructions in order: typically, you install from the front (catalytic converters) to the rear (tailpipes).

4.1 Mount the Mid-Pipe Section

  1. With the car still raised, slide the front section (downpipes or mid-pipe) into position. Use new gaskets supplied in the kit. Do not tighten bolts fully yet.
  2. Connect the pipes to the catalytic converter flanges. Tighten the bolts by hand, then use the torque wrench. Akrapovič’s torque spec for M8 bolts is typically around 25 Nm (18 ft-lbs); for M10, you’ll see 40 Nm (30 ft-lbs). Always consult the specific manual for your vehicle.
  3. Install any springs or V-band clamps per instructions. For V-bands, tighten the nut until the clamp seats evenly, then torque to spec (usually 12-15 Nm).

4.2 Attach the Rear Muffler / Silencer

  1. Slide the rear muffler section onto the mid-pipe connection. Use the provided springs and bolts. On many Akrapovič kits, springs are used to allow a slight movement—do not force them together; they should align smoothly.
  2. Insert the exhaust hangers into the rubber bushings. A tip: spray silicone lubricant on the rubber hangers to ease installation. Push the hanger studs into the bushings until they click into place.
  3. Reinstall any heat shields or brackets that mount over the exhaust. The Akrapovič system often has brackets that attach to the chassis to prevent movement.

4.3 Transfer the Exhaust Valve Actuators

If your kit uses the factory actuator motors, bolt them onto the new valve housing. Ensure the actuator lever engages correctly with the valve shaft. If the kit includes new actuators, connect the wiring harnesses as per the manual. Use zip ties to secure the wiring away from the hot exhaust pipes.

4.4 Connect the Tailpipe Tips

Slide the chrome or carbon fiber tips onto the muffler outlets. Most are held in place by a set screw. Do not overtighten—just snug enough to hold the tip in the desired position. Check the alignment: the tips should be centered in the bumper cutouts and even on both sides. Adjust as needed.

Step 5: Final Checks and Adjustments

  1. Torque All Fasteners – Go back over every bolt, clamp, and bracket. Torque to the specifications in the manual. Never skip this step—loose bolts can lead to rattles or exhaust leaks.
  2. Check for Clearance – Spin the driveshaft by hand (if accessible) to ensure nothing is contacting it. Also verify that the exhaust does not touch the subframe, sway bar, or heat shields when the car is at ride height.
  3. Reconnect the Battery – Clean the terminals if needed, then attach the negative cable.
  4. Start the Engine and Inspect for Leaks – While the car is still on jack stands, start the engine and let it idle. Listen for any hissing or tapping sounds that indicate a leak at a flange. Run your hand (carefully) around the connections—you can feel air escaping. If you suspect a leak, shut off the engine and re-torque the bolts. Small gaps can be sealed by tightening, but if a gasket is displaced, you may need to disassemble and reposition it.
  5. Actuate the Exhaust Valves – If your car has a button to open/close the valves, cycle them a few times while the engine is running. Watch the valve arms to ensure full travel. If they stick, check the actuator alignment.
  6. Final Tip Alignment – With the exhaust warm, the hangers may settle. Loosen the tip set screws slightly, adjust the tip position to perfectly center in the bumper opening, and retighten.

Step 6: Lower the Vehicle and Test Drive

Once you are satisfied with the fit, clearance, and sound, lower the car off the jack stands. Reinstall all underbody covers and heat shields. Take the car for a short test drive in a safe area. Listen for unusual rattles or vibrations at different RPMs. Let the car cool completely after the drive, then perform one final check on all visible connections—thermal expansion can sometimes loosen bolts a bit.

Important: The exhaust system will settle and develop its final tone over the first few hundred kilometers. A slight blueing of the titanium tips is normal as the material heats up; this adds character and is not a defect.

Troubleshooting Common Installation Issues

Even with careful work, sometimes things don’t go perfectly. Here are a few frequent challenges and solutions:

  • Can’t get a flange to line up – Loosen all bolts and clamps on the entire system, not just the one you’re working on. With everything loose, you can wiggle the pipes to align them. Tighten from front to back.
  • Exhaust tip sticks out too far or not enough – Most Akrapovič systems have adjustable tip depth. Loosen the set screw, slide the tip in or out, and retighten. Check with the car at normal ride height.
  • No sound from the exhaust valves – Verify electrical connection and actuator arm movement. Some E63 models have a fuse for the exhaust flaps; check your owner’s manual. If using aftermarket controllers, ensure they are wired correctly.
  • Check engine light comes on – This usually indicates an exhaust leak or a disconnected O2 sensor. Double-check all sensor connections. If the leak is small, you may need to replace a gasket.

Maintenance and Care After Installation

Akrapovič exhausts are built to last, but they require occasional care. Clean the tailpipe tips with a non-abrasive metal polish or cleaner specifically for titanium. Avoid harsh chemicals that could damage the finish. Inspect the rubber hangers annually for cracks or sagging. If you drive in salty winter conditions, wash the underside of the car regularly to remove corrosive road salt. The exhaust clamps should be re-torqued after the first 1000 kilometers as the system settles.

For further guidance, refer to these trusted sources:

  • Akrapovič Official Website – Access the official installation manual and vehicle-specific fitting instructions.
  • MBWorld Performance Forum – A community of experienced owners who share tips and tricks for aftermarket exhausts on the E63 AMG.
  • FCP Euro – A reliable source for OEM hardware, gaskets, and specialty tools you might need during the installation.
  • YouTube Installation Videos – Visual walkthroughs from professional installers can complement this written guide.

Conclusion

Installing an Akrapovič exhaust on your E63 AMG is a project that delivers immediate and lasting rewards. The combination of reduced weight, increased horsepower, and a more refined yet aggressive exhaust note transforms the driving character of the car without compromising daily drivability. By following this comprehensive guide—paying attention to torque specs, alignment, and electronic connections—you can complete the installation with confidence. If at any point you feel unsure, do not hesitate to contact a qualified performance shop. The satisfaction of hearing your new exhaust for the first time, knowing you installed it yourself, is well worth the effort.