hi all
I thought I want to share my project with others. a lot of people doubt this project but somehow I manage to make a successful retrofit to my W210 E320 using a C32 supercharger.
please check attached images.
first of all below is the part that I used for this project:
1. C32 supercharger complete set with intake runners. injectors, fuel rail, intercooler.
2. C32 heat exchanger and hoses
3. Johnson CM30 pump
4. C32 thermostat
5. Drive belt 6 ribs K1145
7. custom supercharger pulley (80mm)
8. custom idler pulley.
9. w210 radiator tank
10. E55 throttle body
11. E55 air mass sensor
12. KNN orion Air filter
13. custom intake pipe
14. a few silicone hoses
15. some hose for valve ventilation
16. some fittings.
17. AEM FIC 6
18. eurocharged shorty header
19. full custom stainless steel exhaust
20. AMG muffler
21. ebay bypass valve with 3 springs setting.

I got this idea after kleeman installation instructions, which on my opinion is a very similar.kleemann set would cost $10K while this project only cost me around $4K
the main differences is just the blower.
so if you have any plan to retrofit a supercharger, please study the kleemann instructions closely.
I have done this long time ago, but at that time I did no remap, I simply replace my injector to a 27lbs injectors and the car runs well. but the afr ratio is not right.
after a few years I decided to re-do it and this time I am using the stock C32 injectors, fix some piping, and remap the fueling using AEM FIC.
before I did the remap myself, a lot of sellers refuse to answer my questions since im planning to install it on a Mercedes. but when I said I was planning to install it on a Toyota, they answer a lot of questions.
the end result is pleasing, this is the first time I do a remap on a car, so I am kinda new with this piggy back thing.
I have not done any dyno yet, but I can tell that my car is much more powerfull than my friends E430.

so this is the pictures. I hope this can explain a lot. sorry for my English.




one IMPORTANT remap note : my car has no o2 sensor from factory meaning it always run on open loop. therefore if you do what I did, you have to tune the closed loop yourself, I have no experience tuning close loop.

the installation step is very close to kleemann instructions. the only big sacrifice that I should do it cutting the airpump bracket. all other thing is returnable to stock setup.

 

 

Have more information on the bypass valve part of this swap? I’m planning on doing this but with a v8.

 

Nothing special on the bypass valve, got it from ebay, its vacuum controlled.
Doing this on a v8 would not be too hard, mechanically would be perfect fit, for piggy back, you could use AEM FIC 8, it works well with mercedes

 

How many pounds of boost did you end up running? I’m rebuilding the supercharger and getting it ported soon.

 

With 80mm pulley i was having 9psi max boost, but after i installed a shorty header from eurocharged, my boost drops to 7psi max, but i dont feel any difference in terms of power. Im thinking to make a 78mm pulley and hoping to get back the boost to 9psi, but im kinda wooried if it will push the engine too hard because the stock c32 has 74.5mm pulley and 14.5 psi boost, with 9.0 compression. A stock e320 has 10.0 compression.
I never dynoed the car so i have no idea what is horsepower result but i owned another w124 e320, and after this project my stock e320 feels soooo sloowwww

 

so after a few runs and test, i found out that on 5500rpm, im hitting somekind of limiter on WOT, first i thought it is the fuel pump not supplying enough fuel, but after doing more research i realize i forgot to set a MAF clamp, i am very sure on WOT and high RPM, the maf signal would jump to MAX which is 5V.
after reading more post from others, i found that 4.85 volts is the max reading mercedes ECU would tolerate, above that value it will set a limiter and throwing codes.
i guess this is what happen to my map.
i set the clamp to 4.85volts today and test it soon and see how it goes.

i also replace my differential using S320 diff, it is 210mm diff with 3.27 ratio, it is a step larger than the stock e320 diff in terms of size. the ratio is taller as well. the stock diff ratio is 3.07.
in order to fit this diff i need to replace the EGS as well, so i bought a diff from a 1997 c230 which has 3.27 diff ratio that has single rear speed sensor.
The stock e320 has two rear wheel speed sensor and i am just guessing that the EGS from c230 would work.
i installed the diff today with c230 EGS, plug the diff speed sensor. surprisingly it runs perfectly!!!
i can tell that the car pulls harder now. im so happy with this finding so next if i want to play around with my diff, i just need to match the transmission ratio, diff ratio and the correct EGS.
i have managed to make a note on few EGS part number, so now i know what part number match rear diff ratio.

 

Awesome build, and in Jakarta no less.

 

Why not just use the OEM C32 air intake system? I have a 40k mile C320 4matic black on tan I want to do this on, and I was wondering why the custom intake is needed on this application?

 

the c32 ecu system use MAP sensor for reading engine load (pressure sensor), it is a small device in terms of size compared to MAF sensor.
the M112 NA engine use MAF sensor to read engine load, there is noplace for the MAF sensor if i use the c32 intake system.
you can look closely on the c32 intake system and i am sure u would realize it.
i also did a comparison with weistec and kleeman supercharger system for NA m113 engine, they also maintain the MAF sensor, therefore they didnt use the M113K intake system.

 

hi. I have a similar project only with w219. I put m112.949 plus supercharger, c32 injections. 7g tronic gearbox. I want to wear AEM FIC 6. I'm waiting for delivery. Pulley 78mm. Is there a big problem in configuring AEM? Over a year I was looking for a tuner that would do stage 3 in my ME2.8 and I didn't get it so that's why I decided to mount AEM. Can you suggest something?

 

IMHO AEM is one of the easiest piggy back to use and install. I didnt have problem with it and pretty happy with the result, just make sure you have a fresh o2 sensor on both down pipes on the first tune.
Up to today, the car is still going strong with the last tune and no problem at all.
I didnt get to tune the ignition timing because i dont find it necessary.
One more thing i figure out is AEM can alter signal from MB very well so thats the main reason i use it.
Doing stage 3 has nothing to do with supercharger, you need to tune your ECU according to your phisycal engine upgrades that you applied.
The size of pulley and manifold pressure result, engine internals, headers, and all other upgrades will need specific ecu tune.
My suggestion is try focus on tuning the AFR and see how it goes, aim for 14 at idle and goes richer on higher rpm and high TPS, my target AFR at WOT is 11.5 with 99 octane.
i am not an experienced tuner but i happy with the result and at the end i didnt alter the ignition at all, from my knowledge mercedes always adjust the ignition timing base on knock sensors
​​​​​​I think as long as the gas is high octane, running low boost 5-9psi is safe
​​​Maybe somebody else who is expert on AEM can give better result.

 

Hi Brabus, I might end up trying this on my 2004 E320. Is this possible to do without changing the ECU? Also how difficult would you say this install is to get it all working? Is it a realistic summer project?

 

The physical swap would be easy if you have the complete part list. You definitely need piggy back or AEM FIC6, remember you will be tuning close and open loop, so it will take some time to get it dialed in. Data logging and fine tuning will be crucial, just to get it up and running is easy.


​

 

I plan on doing this to my car as well. I have a few questions though, so you have the tune still? What program did you use? I don’t have any experience tuning but I have a lot of experience working on the physical components of the car. If you were to redo this, would you recommend using a full C32 amg motor (for the forged internals)? I would have no problems putting the supercharger and supporting parts together physically, but I am more worried about the tuning part.

 

You have informed me earlier about the year of your car which is 02, for 02 cars i found better soluton for engine swap, let me explain
Mid 01 and up, mercedes renew its electrical and ecu system, before its ME2.0 and from 01 onwards its ME2.8 and EGS52
the good thing is ME2.8 is very flexible in terms of tuning and customizing according to the designated chassis. Lets say ME2.8 from w220, w211 is easily adaptable to all other models as long as its has ME2.8 from factory, which i suppose your car which 02, would be ME2.8

So this open up your options for engine swap, you can get any engine from any mercedes that has ME2.8 and installed the ECU that came with the engine.
​​​​​​as informed earlier, your car is w208, so buying a whole set of key and ECU is not possible without so much coding and your VIN number would change to the donor car VIN if it is scanned on SDS.

So for ME2.8 car, if you are going to install a supercharger on the stock E320 engine is more troublesome then doing a complete swap from C32 or E55 in terms on ECU tuning.
If i were you, i would swap a complete AMG engine, buy the matching ECU from the donor car, virginize the ECU and install it in your car. Again make sure it is all ME2.8, no wire cutting needed, all plug and play
Second step, find a friend with SDS, and plug it in, scan the MESFI control unit, the moment your car recognize that the ME control unit has changed (provided its a virgin ECU) it will ask you wether you want to synchronize it with your car VIN number and all other data base on your EIS (key control module) which is the main information for your car.
Do it, and it will sync all the data and your vin number to the virgin ECU (which is the Donor ECU).
Once its done, you can start the engine and after 50 starts, it will be completely married.
No tuning needed, nothing.
As simple as this
Off course you still need to mechanically fit the complete AMG engine to your car and install all the supporting accesories such as intercooler, water pump etc, but the tuning part is done.
Even after this is done, you can further customize the ECU to suits better in your car, by going through the adaptation menu on SDS.
So if you are not familiar with SDS, i recommend find somebody who own it and know how to work around the program.
Its very simple.
​

 

Hello brabus i hope you are fine, i am making the same project for my Manual Chrysler Crossfire, how many hp have you made having that car for 8 years, and could you explain me about the custom idler pulley?

 

Honestly i never dino the car, so i dont know how many hp i gained, i got 9psi of boost on the intake, so by simple math it should be around 300-320hp.
The car pulls so strong i dont need dyno to justify the power.
For the idler pulley, please look closely on the drive belt pattern, the stock idler pulley is grooved, and since we add supercharger on top, i use longer drive belt from the alternator wrapped to the supercharger and back to the idler pulley, thats why i made one with no groove
Please check below image

 

Its like 3mm less than the stock idler pulley for putting more space?

 

Hello Brabus. It is possible for you to send me the maps from fic6. Together with the setting. I will be grateful

QUOTE=Brabus388;7759487]



so after a few runs and test, i found out that on 5500rpm, im hitting somekind of limiter on WOT, first i thought it is the fuel pump not supplying enough fuel, but after doing more research i realize i forgot to set a MAF clamp, i am very sure on WOT and high RPM, the maf signal would jump to MAX which is 5V.
after reading more post from others, i found that 4.85 volts is the max reading mercedes ECU would tolerate, above that value it will set a limiter and throwing codes.
i guess this is what happen to my map.
i set the clamp to 4.85volts today and test it soon and see how it goes.

i also replace my differential using S320 diff, it is 210mm diff with 3.27 ratio, it is a step larger than the stock e320 diff in terms of size. the ratio is taller as well. the stock diff ratio is 3.07.
in order to fit this diff i need to replace the EGS as well, so i bought a diff from a 1997 c230 which has 3.27 diff ratio that has single rear speed sensor.
The stock e320 has two rear wheel speed sensor and i am just guessing that the EGS from c230 would work.
i installed the diff today with c230 EGS, plug the diff speed sensor. surprisingly it runs perfectly!!!
i can tell that the car pulls harder now. im so happy with this finding so next if i want to play around with my diff, i just need to match the transmission ratio, diff ratio and the correct EGS.
i have managed to make a note on few EGS part number, so now i know what part number match rear diff ratio.[/QUOTE]

 

Hello Brabus one urgency thing about the slip pulley and belt? , could you show me if you still have the car how did you do i am still stuck, please help meee!

 

Even the belt i put the wrong one idk how many in cm its the belt 6 ribs K1145 from inch to cm

 

please look closely on my first few posts, you can see how i manage to arrange the belt, i didnt use the pulley next to the supercharger pulley, from alternator, it goes directly to the supercharger pulley (better grip on the pulley) less slip, the idler pulley was replaced with a pulley without a groove and smaller size.
​​​​​​the belt is easyly found on ebay fpr that size

 

Can I ask you a huge favor for the link so that maybe I could use the strap? because being in Italy and having ordered the belt with the same measurement they gave me a much smaller one because here we use cm and not inches, then with 9psi the belt and the whole distribution slips?

 

Please let me know, i Need that information of you can!