M156 Supercharger Installation Manual
Contents
1. KLEE sein LID rk si 11 g gt lt 5 4 ALA 09 3888 ST N H eye 17 2 gt Cc 2 gt Cc 2 3 Y Cc F 2 2 9 gt U CO LO rl gt Tr Kan O T gt gt O gt COMFORT POWER BY KLE EMANN This instruction manual provides a step by step process for installing the KLEEMANN M156 supercharger system It is recommended that you read the instruction manual completely before starting the installation of the kit to gain an overview of the entire process If questions arise during the installation you are welcome to contact us directly We are ready to provide answers and assistance It is essential for all involved that the installation is done correctly the car performs flawlessly and the customer is satisfied It is of the utmost importance that only KLEEMANN programs the ECU Any other supplier what ever they may make should not be utilized for programming Using an alternative source for ECU programming will void the KLEEMANN warranty immediately and entirely KLEEMANN s programming utilizes features no other supplier utilizes keeping all factory safe running strategies in place The installation will be simplified with the use of just a few specialized tools It is recommended2. Step 54 Instal the air box side edge as shown Assemble and install the air boxes front panel and intake tubes Tuesday March 19 13 Step 55 Completed installation Step 56 Verify that the vehicle starts and idles with the OE ECU Check all your work ONLY after verifying that the vehicle starts and idles without issue A should you send in the ECU for programming Programming the ECU first presents a variable for diagnosis of problems that will only complicate fault finding Verify air fuel ratio under all operating circumstances Contact KLEEMANN if anything is out of specification Tuesday March 19 13 Notes Tuesday March 19 13 Vacuum Line Diagram M156 SC Schematic layout only not shown to scale or orientation All OE vacuum consumers must be connected to the VAC ATMOS port ONLY The VAC ATMOS BOOST port is for testing or GGE purposes ONLY SC bypass valve is connected to the VAC ATMOS port ONLY Tuesday March 19 13 KLEE wei Vacuum Atmosphere signal OE MAP Sensor OE Air Injection Switchover OE Tank Ventilation SC Bypass Valve Any other OE Vacuum Consumer varies by chassis supercharger Vacuum Atmosphere Boost signal Test Port Boost GGE Accesory Belt Routing Diagram M156 SC KLEEMANN Tuesday March 19 13 SC Belt Routing Diagram M156 SC KLEEM NN Tuesday March 19 13 SC Intercooler Diagram M156 SC KLE EMANN
3. lt Schematic layout only not shown to scale or orientation supercharger radiator pump Tuesday March 19 13
4. new intake manifold gaskets Be sure the crank breather hose is placed in the position as shown Install the manifold bolts Tuesday March 19 13 Step 3 Attach the fuel lines from the splitter to the fuels rails Reconnect all hoses and wiring connectors Step 38 Cut the tank ventilation line as shown Tuesday March 19 13 Step 39 Cut the brake booster line as shown Step 40 Install the quick coupler onto the brake booster line and connect it to the 12 mm line on the supercharger manifold assembly The proper line port is located under the throttles Tuesday March 19 13 Step 41 Install the belt alignment tool onto the bracket attached to the alternator in step 8 with the provided bolt Align the tool so it is tangent and touching the supercharger drive pulley Tighten the two bolts on the tensioner bracket attached to the alternator Remove the alignment tool Step 42 Install the dynamic belt tensioner onto the tensioner bracket alternator Tuesday March 19 13 Step 43 Install both belts A Step 44 Install the hoses on the KLEEMANN power steering reservoir The original metal pipe can often be reused if it is flipped 180 if not use hose from the kit Attach the reservoir to the bracket installed in step 10 Fill reservoir with the proper oil to MIN HOT level as indicated on the dipstick A Tuesday March 19 13 Step 45 Install the OE switchov
5. that you have the following tools at the ready Crank Pulley Wrench MB 112 589 00 40 00 MBZ Star Diagnosis or similar diagnostic tool AutoLogic etc KLEEMANN belt alignment tool Air Fuel Ratio tool preferably wide band Boost pressure gauge 0 1 bar 0 15 psi Kleemann A S Kleemann USA Inc Rugmarken 27B 3455 Fillmore Ridge Heights DK 3520 Farum Colorado Springs CO 80907 Denmark USA phone 45 70 109 109 phone 1 719 473 6441 fax 45 70 109 108 fax 1 719 578 0345 sales kleemann dk sales kleemannusa com Tuesday March 19 13 Factory Engine Bay The engine compartment should be in as built condition A A Step 1 Remove the nose cover inlet tubes air filters and the Y piece on the inlet housing Tuesday March 19 13 Step 3 Remove all hoses and tubes Remove the 10 bolts witch hold the manifold to the cylinder heads Check that the inlet manifold is completely free and Lift it off the car Temporarily cover the intake ports with wide easy release tape Set the OE manifold aside for now you will be removing components from it later Step 4 Remove the power steering tank its hoses and replace the 2 bolts in the cam chain housing Remove all 3 engine lifting brackets eyes Tuesday March 19 13 Step 5 Remove crank pulley harmonic damper Step 6 After removing the original crank pulley please check the radial oil seal for damage If damaged replace the seal if serviceable insta
6. bber grommet around the throttle wiring harness Be extremely careful to not damage the wiring Wrap the wiring harness were the grommet was with cloth tape Tuesday March 19 13 Step 25 Install the fuel pressure sensor into the KLEEMANN fuel splitter block Install the splitter block on the firewall W204 W212 Step 26 Place the KLEEMANN supercharger manifold assembly on a clean work bench use a large cloth on the bench surface to protect the manifold finish Place the intake air temperature sensor into intake runner 5 as shown Tuesday March 19 13 Step 27 Take one of the throttles it does not matter which one and drill a 9 mm hole in the bolt location shown Step 28 Tap the ventilation port with a 10 x 1 5 mm tap Using the square boss to the left of the ventilation port as a guide for straightness and height cut the port and the square boss with a hack saw Remove approx 3 4mm of material from the square boss Lightly countersink the hole Clean the port well with brake cleaner and a blow gun and air dry Make sure there are no chips or debris in any portion of the throttle Install a 10 x 1 5 mm cap screw with Loctite 271 Do this step for BOTH throttles Tuesday March 19 13 Step 29 Install the first throttle as shown leave bolts slightly loose Move the throttle blade to full open with your fingers check to make sure it opens and closes fully and without interference Tighten the bolt
7. er valve for the variable length manifold runners Attach the valve to the wiring harness and find a suitable place for it to lay The valve no longer has any function but it must be connected electrically to prevent fault codes Loop a small section of 4 mm hose onto the barbs to keep debris out Step 46 Install the hose for the secondary air injection system as shown A Tuesday March 19 13 Step 47 Remove the Bumper cover Install the intercooler radiator beneath the front bumper The intercooler radiator should be centrally located on the bumper brackets are screwed directly to the underside of the bumper beam Install the intercooler water pump on the right side Use the supplied brackets Be sure to allow adequate clearance for hoses not to pinch or chafe Refer to the intercooler diagram at the back of the manual for proper hose routing Wire the intercooler pump with the supplied relay kit to a KOEO key on engine on power source It is imperative to use the relay kit as the pump draws high amperage DO NOT direct wire the intercooler pump to ANY OE system damage will result The small port on the intercooler reservoir is not used Cap and clamp it with the provided hardware gt gt gt Step 48 Fill the intercooler system with a 50 50 mix of anti freeze and water Energize the pump to self bleed top up coolant as bleeding occurs Mercedes Benz It is recommended that a 50 50 mix of anti fre
8. eze and water be used in the intercooler Orange ethylene glycol is preferred Anticorrosion Antifreeze AGENT Protects radiator and engine from corrosion and freezing and raises the boiling point Corresponds to MB Specifications for Service Products sheet No 325 0 Part Number 103 0002 One U S Gallon 3 785 LITRES WARNING HARMFUL OR FATAL IF SWALLOWED OR INHALED Read carefully other cautions on back panel LF B Tuesday March 19 13 Step 49 In order to use the OE air box tops they must be modified Drill out the two inboard holes of the upper tops to 7 mm Insert the supplied rivet nuts and secure using a rivet gun Bolts will be fed from the top side of the air box use care that the inserts are fastened into the air boxes correctly N MA BURRS ti Step 50 Trim the nose panel to the scribe line as shown This edge will be visible to the eye when installed so use care while cutting Tuesday March 19 13 Step 51 Mark the lower halves of the air boxes as shown Cut on the indicated line all the way through Step 52 After the primary cross cut dress the air box edges with a file 0 u LA m Pri b a P 4 x an on 2D ve Tuesday March 19 13 Step 53 Turn the lower halves of the air boxes over and remove the ribs as shown
9. ll the Kleemann crank pulley Tuesday March 19 13 Step 7 Install the two Kleemann idler pulleys outboard of the OE idler pulleys along with the brace Step 8 Install the belt tensioner bracket witch is mounted on the outboard side of the alternator Do not fully tighten the mounting bolts you will align this bracket later Tuesday March 19 13 Step 9 Remove the two bolts indicated by the arrows Step 10 Install the power steering oil reservoir bracket as shown Tuesday March 19 13 Step 11 This hose is normally directed to the left Cut the clamp and remove the hose Install one end of the 8mm hose from the Kleemann kit Place the hose neatly in front of the radiator fan Do cut the other end yet Step 12 Remove clamp from hose A Remove hose assembly B Insert the hose from step 11 fully into hose A reuse the OE clamp Tuesday March 19 13 Step 13 Install the intercooler water tank with the provided bracket as shown W209 shown other chassis are similar Step 14 Remove the OE cloth tape from the wiring harness at the location shown Tuesday March 19 13 Step 15 Move the wires for the fuel pressure sensor to the rear of the engine compartment as shown Reapply cloth harness wrap to the harness Step 16 The harness should now look like this Tuesday March 19 13 Step 17 Remove the fuel injectors from the OE fuel rail Check the injector o rings to
10. p and bottom for damage Replace any damaged o rings and set the injectors aside Remove the fuel pressure sensor and set it aside Install the OE fuel rail back onto the OE manifold for safe keeping O Rings Upper MB 014 997 68 45 Lower MB 016 997 77 45 Step 18 Remove the throttle body cables from the metal bracket on the front of the OE intake manifold Tuesday March 19 13 Step 19 Lubricate the o rings on both ends of the fuel injectors and install the injectors into the two KLEEMANN fuel rails ane H 2 Pe 7 io S a ei gt Hie T san FEN k a PERT A e PN EN Bm em en a CE t pe TA Ae CPT SD F nn bn 4 ALS 1 Step 20 Install the the two KLEEMANN fuel rails onto the supercharger manifold assembly The feed ports of the rails should face the back of the manifold assembly throttles Tuesday March 19 13 Step 21 Remove the intake air temperature sensor from the OE manifold Step 22 Remove OE MAP sensor A and the variable length intake runner valve B from the OE manifold Tuesday March 19 13 Step 23 Remove the intake manifold lower cover of the OE intake manifold to expose the two throttles Remove the two throttles from the plenum Step 24 Using a razor knife cut off the ru
11. s fully A ull poner Step 30 Lubricate the the o rings throttle side of throttle adaptor plate then install the throttle adaptor plate as shown Plug in the throttle wiring harness to the first throttle Check for interference between the first throttle and the throttle adaptor plate correct adjust as required Tuesday March 19 13 Step 31 Drill a9 mm hole in the second throttle body at the location shown Step 32 Install the bolts in the second throttle body hand tighten them so there is still the possibly for the throttle body position to be adjusted on the adaptor plate Tuesday March 19 13 Step 33 Test install the inlet housing plate check to make sure all holes are in alignment and the second throttle is fully seated in the plate Carefully remove the plate and tighten the bolts on the second throttle Install the plate agin and check again that the plate is aligned and that both throttles have full range of movement with no interference of any kind Step 34 Install the inlet housing as shown Plug in the second throttle and route the cable under the inlet housing Install the 3 plastic pipes into the fittings on the throttle adaptor Tuesday March 19 13 Step 35 Install the elbow snap fitting for the crank breather hose turning it inwards as shown A Pace breather hose under bridge pipe as shown B Step 36 Place the supercharger assembly onto the engine use
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