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In order to achieve this goal, AMG engineers are involved at the earliest concept phase when the Mercedes-Benz development team designs a new model. Only in this way can we integrate AMG high-performance technology and tailor it to the car’s performance profile. The key questions that our engineers ask are: What do we expect of the longitudinal dynamics? And of the lateral dynamics? What requirements are to be placed on sportiness? And which on comfort? The answers to these questions result in the fundamental set-up of the car.
In the next step, they get down to the details — and thus to answering questions such as: Which components must be changed compared with the original series car in order to achieve the required performance and dynamics? This naturally applies first of all to the suspension including axles, brakes and dampers; secondly to the complete drivetrain including transmission and engine; and thirdly to body modifications such as increasing its stiffness and enhancing aerodynamics.
But the depth of development at Mercedes-AMG goes far beyond that: When we design a single body part, we always do so with the goal of improving defined driving characteristics. Almost every improvement involves modifying or developing other components. The result of this chain reaction is a high-performance automobile with more than 500 original AMG parts.
Following extensive tests on test benches, racetracks and roads in all climate zones, the car finally behaves exactly as we defined it at the beginning. Or in other words: just like a genuine Mercedes-AMG.
In contrast to large-series production, Mercedes-AMG in-line 4, V8 and V12 engines are traditionally assembled by hand according to the "One Man — One Engine" philosophy. A single AMG technician assembles the complete engine and is therefore responsible for everything from the installation of the crankshaft in the engine block to the assembly of the camshaft and the cables and oil fill-up – his signature is then put on the engine plate.
During the assembly process, each engine absolves various tests in which it is examined for water and oil leakages. The entire fuel system is also tested for leaks – to the extent that even individual gas molecules can be detected. All the engine functions are then examined on the cold test bench, using simulated resistances and pressurization as well as the very latest resonance and airborne noise measurement methods. And finally a fully automatic image processing system is used to check the delivery condition of the completed engine.
The assembly process is also controlled and documented by the AMG Trace System. This system provides full documentation of various process parameters such as the tightening torques of all bolted connections, fluid levels, component and batch information and test results. Special PCs are mounted on the assembly trolleys, which have a wireless link to a documentation database. They display the relevant online information depending on the assembly stage. This state-of-the-art system guarantees exemplary production quality at the highest level. At the same time its unique architecture combines the traditional approach to AMG engine production with the production trends of the future.
The Mercedes-AMG high-performance engines for the different car models are built in the engine shop, which covers an area of 9950 square meters and occupies two stories. The production procedures are designed for maximum flexibility. Depending on the order intake, production can be rapidly adapted in line with current market conditions.
Only highly qualified technicians with many years of experience are employed in the Mercedes-AMG engine shop. The utmost precision and attention to detail are a matter of course during the hand-assembly process. All work stages are subject to the stringent Mercedes-Benz quality criteria which also apply to all other series-production engines. After all, even an AMG high-performance engine must exhibit the reliability and long operating life typical of a Mercedes.
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