Hello members of the forum!
I make this thread to help anyone who has a problem tuning his m111 car that has smaller supercharger pulley and bigger crank pulley.
My car is a c200 compressor w203 with the 111.955 2.0 engine, m45 supercharger and the sim4le ecu.
The problem that I ran when I started tuning my car with 2 pulleys is that the injectors were maxed out after 4000 rpm and i had like afr 13.5 until 6000rpm which is very lean.

If you don't want to read the whole explanation, the solution is to install 390cc injectors and a rising rate fuel pressure regulator and set the base fuel pressure at 3 bar.

But here is the explanation
In order to fix this problem you have to install bigger injectors and tune the ecu. But that proved to be not so easy on this car.
If you install 350cc injectors is tunable, if you install 390cc as I installed is not easily tunable.
When i installed bigger injectors and tuned the ecu all the problems started. The car was uncontrollably rich at very light throttle part load, ecu couldn't give less fuel.
This happens because for this ecu siemens never leaked damos/a2l files. So we can't tune it easily. This leaves us to have access only to the fuel map. But the fuel map is not the proper way to tune injectors. You have to know where the injector constant and the minimum pulse width are inside the tune.
We don't know where these constants are inside the tune, so that's why the ecu is so hard to tune.

BUT, I found a solution for all us that want to make our cars have as perfect fueling as possible even at high rpm.
The solution is to install a rising rate fuel pressure regulator with vacuum/boost reference.
Our cars have 295cc injectors from factory at 3 bar and they run like a 3.8 bar steady fuel pressure regulator.
Injector flow is fully dependent on the differential pressure (ΔP) on the injector. The formula of ΔP is ΔP = Fuel pressure on the rail - (intake manifold pressure - atmospheric pressure)
Another useful formula to understand what happens is the following: new injector flow cc = old injector flow cc x sqrt(new fuel pressure/old fuel pressure)

Generally atmospheric pressure is around 1000hPa. Also, 1000 hPa = 1bar.

Firstly, you have to understand how the oem system works.
The oem injectors are 295cc at 3 bar. The car has 3.8 bar fuel pressure regulator so 3.8 bar at the rail.
At idle the engine has vacuum, so intake manifold pressure of around 550 hPa, the ΔP = 3.8 bar - (0.55 - 1) = 3.8 - (-0.45) = 4.25 bar.
If you apply the injector cc formula, the oem effective injector flow is 351cc at idle.
If on the oem system you install the 390cc injectors at idle the flow will be 438cc.
This is still controllable from the oem ecu if you tune the fuel map.

But, on light throttle the car goes to 300 hPa intake manifold pressure. This means the oem injectors act as 361cc and the bigger as 477cc.
Here is where the trims become uncontrollable, the short trims go to -25% and it destroys the self adaptation of the car. When this happen 2 times, the car throws P0101 error and it throws the maf sensor out of the equation. Then you have only lambda correction and reduced power.
Car's ecu has inside logic that compensates for the ΔP of course.

This is where the rising rate fuel pressure regulator (FPR) is needed. We need to make the big injectors to behave as close to the oem as possible.
The job of a rising rate fuel pressure regulator is to maintain a standard ΔP on the injectors. You take a line out of the intake manifold, and you plug it in the vacuum boost reference or the FPR.
The FPR modifies the rail pressure accordingly so that it keeps a steady ΔP, in contrary with the oem system where the rail pressure is steady and the ΔP changes.

I adjusted my FPR at 3 bar ΔP. So my injectors have in every condition (idle, full throttle, light part load throttle) an effective flow of 390cc.
This now is much more controllable. Oem injectors at light throttle have 361cc of effective flow, and the bigger injectors in my system have 390cc.
At idle oem injectors have 351cc, the bigger have 390cc.

This now can be tuned. If in the fuel map, you reduce the low load part by 11-15% you will have a perfect result without any excessive trims and lambda corrections, inside the -7 to +7% correction at idle and low load and around -2 to +2% at higher load. At full load these cars dont have correction, as they are narrowband, they go in open loop mode. Open loop = car applies what the map says blindly without lambda correction and they apply only the self adaptation of the part load everywhere.

In order to install the FPR you will have to remove the oem fuel filter that has the fuel pressure regulator inside, and install a filter from the pre facelift m111 car that it is a simple filter without regulator. Then, the output of the filter will go to the inlet of the pressure regulator. Then the pressure regulator sends fuel to the engine and to the return line. In the attachments you will find a schematic of this and some photos of the system installed on the car.
I used an AEM fuel pressure regulator and the EV14 390cc bosch 0280158124 injectors.
At around 90-92% duty cycle you can be at 11.9 afr at full rpm with my setup.

My car has replica supersprint headers, 63.5mm full exhaust with c350 muffler to be quiet, stage 1 cams, 215mm kleemann crank pulley and 70mm supercharger pulley. Prior to the camshafts i got 233hp. My car is automatic.
When i tune for the camshafts and make a dyno, i will upload the final results.
Now im working on rescaling the maf, because after 5300 rpm my maf sensor saturates

 

Wowza! This is an excellent post, one of the best I’ve ever seen. Thank you so much for sharing your knowledge!

I do wonder: how are you able to tune the fuel map if you do not have access to the damos/a2l files?

Also, are you using a hard vacuum line for the rising rate FPR?

 

thank you so much! It took me almost a year to realize what was happening and I was getting this p0101 error. So now that I found it I thought that would be proper to share this knowledge

Despite not having a damos/a2l in the ECM titanium the fuel map is available for example. So some maps are available. Also if you compare the software of the Sim4le with the sim4lke you would be able to find some more maps. Sim4lke has a damos available. But the ecu has a billion differences. I have made a small map pack of this ecu that I would be happy to upload here if someone is interested. But yeah, I’m not sure for everything that I have found inside the tune. The thing that I know is that works for me

Also, yeah I have installed a hard line going from the intake manifold to the FPR and at the point where it connects to the fpr and the intake manifold, for 4 cms I have used a soft line in order to be able to plug it in to them

 

Omg, I didn’t know the SIM4LKE files were released! 5 years ago I was looking everywhere and couldn’t find one.

How are you uploading the maps to the ECU? Are you doing it on bench or using a handheld computer with the OBD2 port?

 

Yeah the damos for SIM4LKE is available. I upload it in the attachments for you You need WinOLS 4+ to open it. You can open it also with the test version of WinOLS 5.

For uploading the tune to the ECU I use a china clone kess v2.
Kess v2 uploads the tune via OBD.

 

Thank you, thank you, thank you so so much!!!!

You have made me really happy with your help. You are an exemplary gentleman and scholar!

I also have a KESS v2 clone, lol. You have given me the confidence to start tuning my C230K!

 

I assume you haven’t changed the ignition timing on your car?

 

Wow, I never succeed to get ECM Titanium running with the SIM4LE bin file I read out with the Galletto reader. Was able to see some fuel maps in WinOLS, but no axis identification. So I dropped the double pulley set-up and used only the C230 kompressor. on my 200.

 

sorry for the late reply, life happens hahah

i have changed it yes. I have stage 1 cams on my car so I have tuned the whole timing advance maps.

OEM car has 18.5 degrees at redline, I have done it around 24 degrees if I go more than that I get knock.

at m271 max ignition timing at redline is 14-15 without knock if you have crank and supercharger pulleys.

 

I have found many maps for the SIM4LE in winols that work. If you want I can share.
I was on the verge of giving up my double pulley setup also…
the worst thing were the injectors to get tuned. And with stock injectors I had at maximum 13 afr. I couldn’t get lower.

 

I’m happy that it helps
if you want you can send me DM, I can help you with the tuning of this ECU for free of course

Also, for everyone that reads this thread just to be clear, the M111 evo engine has the SIM4LE ecu and the m271 engine has the SIM4LKE ecu (which is a much more modern and better ecu)

 

That would be great!

Even with charger pulley only, I'm stuck at 13.3 from 4800+.

 

Here you are
https://drive.google.com/file/d/1-P7...ew?usp=sharing
I dont attach it because for some reason it fails to attach my zip on the forum.

I have attached my original file and the maps that i have find. You may have to offset the maps if you have another software.
If you have any questions, tell me

 

Thanks a lot !!! Awsome job !
I will revive my winols over the holydays. I really miss the double pulley torque

PS: Back in the days I got a bin file from a friend with double pulley ~11psi tuned by a mail-in-tune and found only 2 maps were changed and only the 2 last lines with a big jump to the 3rd line and I decided not to pay 400€ for such a tune.

PS2: Not 100% sure in this statement, but the M111 engine has the older SIM4LE ECU which doesn't have CAN pins, the newer SIM4LKE does have CAN. So a cheap programmer for the k-line is enough.

 

With the two pulleys the car literally transforms it has so much more torque.

The two maps that he changed I bet they are the ignition advance mapsthese cars when you give more advance, they get very big gains in hp. But In order to give more advance you have to have better free flow headers (Supersprint or something) so you don’t get knock. Stock European manifold is trash. With the more free exhaust system that I have, the intercooler and 215mm crank and 70mm supercharger pulley I get max 10psi of boost

m111 has the older Sim4le ecu that’s right. But both sim4lke and Sim4le have can bus pins. That’s how they communicate with the cluster, esp etc. But both also for diagnosis and read/write tune, they use Kline protocol
kessv2 clone reads and writes both reliably. The only drawback is that kess v2 doesn’t give you the area with the DTC maps. For these you have to desolder the am29f400

 

DTC maps? Like to disable certain diagnostic trouble codes?

You can’t read/write the am29f400 when it is still on PCB?

 

Yes. I don’t need it yet, I don’t have dtcs that I want to disable but for some people are useful.

You can partially read the am29f400 through obd with the kess. But if you want full read you must desolder. You can’t read it on the board, because I think that the board has some security features that don’t let you do this

 

I tried to find the CAN lines from the ECU in the Mercedes wire plan and didn't find it, on the SIM4LKE they are pin 41/42.
Today I looked again into WIS not from ECU wire plan but from CAN wire plan and found it on pin 1/2

I just looked to the old data I could see in WinOLS (I don't like it at all) here are the maps I found back in the days, no idea what they are. The lower area is stock tune and the changed upper are for double pulley (as stated by the tuner).

map1

map2

map3

map4

map5

 

When I open my pc that has WIS I will check the can pins of Sim4le.

i can’t understand much from the pictures because I don’t know the location of the maps that you sent inside the flash. if you could send your file and the maps that you have find, we could be able to exchange ideas
tuner is right, the down is the stock the up is the change that he did if he increased the values. If he decreased values the down is the tuned and the up is the stock

 

You are right sim4le has in pin 1 can c high and in pin 2 can c low

 

I understand now. Thank you for teaching me. It’s annoying to know that it must be desoldered… oh well.

 

I hope you all had a nice Christmas!

I searched for my old WInOLS stuff and forgot everything, just re-installed the Galletto soft and will read out the ECU again, first try I get a low voltage warning, right now at the charger at freezing temps.
Haven't found a working WinOLS on my harddrives, must find a new free version.
To get this running would be a big step forward. ols is way to expensive if you want to tune your own car.

 

Here is my ECU file, if somebody likes to check it. It is an unmodified SIM4LE readout from a M111Evo 2.0. Haven't found my old WinOLS install file yet.

 

The first map looks identical to the base fuel map and it looks like it was increased around high load high rpm.
this ecu has no information, im finding a hard time tuning it
i found another fuel map identical and then 8 maps identical to ign part and full as well as duplicate PUC maps
Fuel map duplicate 1 - 194F2
Full Load Ign Duplicate 1 - 12A49
Full Load Ign Duplicate 2 - 19A49
Full Load Ign Duplicate 3 - 20A49
Full Load Ign Duplicate 4 - 27A49
Part load ign duplicate 1 - 12C41
Part load ign duplicate 2 - 19C41
Part load ign duplicate 3 - 20C41
Part load ign duplicate 4 - 27C41
PUC TCO DUPES -
121A8
12236

191A8
19236

201A8
20236

271A8
27236

Im not sure if its for emissions modes or limp or calibrations, but right now i just tried to increase the original base fuel at top end and add -10 degrees of timing at low load (on the original maps Ntinosath uploaded) for some pops and bangs and im not sure whats wrong
its a wierd issue, i increased rev lim park and uploaded, started the car, revved it up and it had some quiet ish crackles (im catless) but after 1 or 2 mins it completely goes away and its just faint burbles. It does this hot or cold start, some light crackles on decel but after a minute nothing. If anyone has an idea i dont mind trying it and reporting back

 

I got a 98 slk 230 is there any tuning for these prefacelift as i know it has a me 2.0 and not the 2.8 im framiliar using the galleto 1260 as I have a 03 tuned 32 and a m112k swapped c320 that is heavily modified. Im trying to get a tune for long tubes I picked up as I know you dont need a tune for these i just dont want the cel for cats and also id like to do a smaller pulley and upgraded pump and injectors for e just a simple little fun build. Also would anyone know anything on upgrading the stock ic figured that be a worth option while adding boost as both my m112k cars have split cooling and upgraded heat exchangers being air to water where as the 111k is air cooled so I'd like to upgrade the intercooler if possible and keep it as close as oem looking or the least amount of fab work unless there's no other option then if anyone has a ic they used and had to fab up piping im open to suggestions as this is my first m111k car so I know nothing about these engines really