MANUAL INSTALLATION OF

KLEEMANN AMG 55 Boost Kit Stage 4 MERCEDES-BENZ ENGINE 113

Introduction These fitting instructions constitute a helping hand for the installation of the KLEEMANN Compressor System. It is recommended to read the instructions before installing the kit, so that you can gain an overview of the entire installation before you begin. If questions arise during the installation, you are welcome to contact us. KLEEMANN A/S will be ready

to answer questions and provide assistance. Please do not hesitate to call us with any inquiries. It is essential to all of us that the final installation results in a properly tuned car and a satisfied customer.

Yours faithfullySoren Jess

President, KLEEMANN A/S

Kleemann Guarantee After installing the KLEEMANN Compressor System please fill in the warranty form. Send or fax a copy to KLEEMANN, keep a copy for yourself and

give the original to the customer. For the Kleemann warranty to be effective the form must be returned to KLEEMANN after the 1500 km service.

Professional and qualified persons should only carry out the installation. The responsibility for correct installation rests solely with the mechanic installer, and KLEEMANN A/S is not responsible for injuries that may be inflicted upon equipment or persons due to insufficient installation. The installation instructions and the belonging instructions are only intended as a guide and cannot be regarded as exhaustive. The information in these instructions has been carefully revised and is considered correct. However KLEEMANN A/S assumes no responsibility for the contents in case of inaccuracies, and KLEEMANN A/S cannot under any circumstances be made responsible for any loss or damage occurring as a direct or indirect consequence of the application of the material. KLEEMANN A/S is not under obligation to update the material or inform the purchasers about any updates. Copyright law protects this material. Any copying modification or change is not allowed. The material may only be used to the extent agreed with KLEEMANN A/S.

1

2

Throttle Body Installation Last updated September 2007

1. Remove the air box and belt

2. Remove the inlet manifold screws

3. Loosen the hose clamps and dismount the inlet manifolds

4. Disconnect the fuel lines and breather hoses on the left bank of cylinders

5. Disconnect the breather hose on the right bank of cylinders

6. Disconnect the electrical connector for the throttle body (TB),

7. Remove the TB

8. Remove the fuel rail and bolts

9. Disconnect the bypass valve electrical connector. Label the connector ends for correct re-installment. Because the TB-electrical connector has the same plug.

10. Disconnect the Air Temperature sensor

3

11. Remove the air injection hoses

12. Disconnect MAP sensor plug on the right side of the throttle housing

13. Disconnect the plug for the magnetic clutch

14. Disconnect the vacuum line for the air injection valve, both the left and right side

15. Disconnect the air injection line

16. Remove the small bolt as shown with an arrow

4

17. Attach the suction device and empty out the intercooler circuit

18. Label and disconnect vacuum lines from MAP sensor

19. Remove the bolts for the SC manifold and remove the SC from the engine

20. Label and disconnect the intercooler line on both sides.

22. Undo bolts for the intercooler unit and dismount the intercooler

5

23. Disconnect the vacuum line on SC inlet housing

24. Undo the bolts to remove the SC inlet manifold

25. Using the supplied gasket, install the KLEEMANN manifold and torque bolts to 20nm

26. Clean all sealing surfaces and reinstall the intercooler unit using the supplied sealant. Torque the bolts to 20nm.

6

27. Once the intercooler unit is installed, reinstall the SC on the car. Torque the bolts to 25nm. Reinstall the fuel rail and connect all sensors, etc.. Make sure that the plugs for both TB and Bypass valve are made easy to access when installing the SC

28. Install the TB using the supplied gasket and the new bolts. Apply a small bead of the sealant to the head of each bolt on the TB adapter plate. TB torque: 20nm - use Loctite 243. Once the TB is installed use the supplied wiring harness to connect the TB to the factory harness. (Att. picture 9)

29. Drill a 9mm hole in the OE Intake pipe and use a 10x1 mm thread tap to fit the supplied 90° pipe connector for the vacuum line. - use Loctite 243

30. Install the aluminium adapter to the loose valve breather hose as shown.

7

31. Using the supplied Teflon hose, attach it to the breather hose as shown

32. Route the breather hose as shown or in the best way possible without any bends to the line

33. Fit the breather hose to the 90° pipe connector on the intake pipe.

34. Installation completed and ready for tests.

8