2MCHCAR

Hi All,

In California, every two years your car has to pass a smog inspection before registration tags are given. The smog inspection requires the smoke sniffer test, visual inspection, and ALL smog sensor monitors report "Ready" status (checked via OBD-II). My registration tags expire May 8th, so I decided to do my inspection early. Here's the rest of my story:

• My configuration: 5.0L M113 V8 with a Kleemann Supercharger (Gen 2 Eaton M112 with the bigger injectors) and matching Kleemann ECU Tune. My battery has not been disconnected for over 3 months, 3,000 miles.
  
• I went to get my car Smogged and the technician told me it failed because all of the Smog Monitors were not in the ready state, other than that everything else was good. The technician told me to drive 70 miles and that should fix it.
• I used my hand held OBD-II reader and saw that the Catalyst, EGR, and Secondary Air Pump Monitors were reporting incomplete. I did notice that I no longer hear the secondary air pump going off when I cold start the car (it sounds like a mini jet engine). I drove 70 miles and checked the monitors again; the 3 monitors still reported incomplete.
• I took my car to my independent Mercedes Mechanic and had it for a week. He called me and he told me he's stumped. He's verified that the secondary air pump, the relay, and the fuse are in working order. He used his DAS computer and said he can activate the secondary air pump via the SAM (I think that was what he said) and that the DAS is not reporting any issue with the air pump. He says the ECU just doesn't command the air pump to activate during cold starts and probably doesn't command the readiness monitor tests.
• I gave him the Supercharger installation guide (Manual V8 ver.2.pdf) and he went over all the connections and wiring. He suspects that the ECU is the issue so he ask me to contact Kleemann and ask what their opinion is about this issue since they re-tuned the ECU for Supercharger use.
• Cory said that the secondary pump not turning on during cold start is normal for my configuration (SC and upgraded injectors) and he's seen cars take up to 1500 miles to set the readiness monitors.
  
• I took my car to my other Mercedes mechanic, he checkout everything and said the same thing my other mechanic said.

So I have driven 2,000 miles this week and tried several online Mercedes guides for setting the readiness monitors. So with a combined 5,000 miles since the battery has been last disconnected, EGR, Secondary Air pump and catalyst monitors still say incomplete!

Have other Supercharger owners ever experience secondary air pump issues or trouble setting ALL the smog readiness monitors?

Have any ideas what to do?

I'm willing to even drive from LA to Colorado Springs,CO (Kleemann HQ) if it help diagnose the issue.

NismoPower

Take it to a dealer or any one with a das and force the test.
Pm me your email and ill send u a pdf on how to do it.

2MCHCAR

PM sent!

Nobody else has responded to this thread so I guess this is an isolated issue. Any help you can provide would be appreciated NismoPower!

NismoPower

Hello!
I emailed you the info, good luck.

togaclk55

One of the downsides of living in Cali, hope you get your issue solved

2MCHCAR

Problem Resolved!

I did a road trip to Kleemann HQ in Colorado and had Cory do his thing! After 2 weeks here is what was found:

• The vacuum lines were not routed correctly and affected the functioning of the Secondary Air Pump.
• The Kleemann ECU tune was not set correctly and caused the EGR and Catalyst tests not to run. It took Cory and the Denmark ECU Programmer a week of continuous testing to get the settings right.

While my car was over there, I had Cory look over the entire SC installation. Here is what he found:

• He said that DC Performance did a pretty good job with the install. The only issues he found was the relay for the Intercooler pump was not in the fuse box (in order to prevent water from shorting it) and the vacuum lines not being properly installed.
• During the dyno testing, he saw that I was losing fuel pressure after 5K RPMs. My car has the bigger injectors (E55K) and was maxing out the stock fuel pump. Cory installed a boost-a-pump to the fuel pump and it fixed the problem.

Cory retested the car and here is the final numbers:


The dyno graph is really different from the one I received from DC. But the Kleemann Graph looks about right!

I have to say, if your interested in installing a Kleemann SC you have to take it to Cory! He has installed over 300 M113 V8 SC, he has excellent Customer Service and is a true professional!

Here's a teaser pic of my next round of mods!

Moedy

Glad you got it all worked out. Those are some impressive numbers for a clk500 on just the kleemann supercharger alone!

400HP55

where did you get those headers from?

betrezra

I'm glad you got it worked out.
I too had a wonderful experience with the guys @ Klee USA.
Cory has to be the most laid back automotive professional I've ever met.
He was super patient with all my problems.

JonMBZ

Sounds expensive hopefully DC will have some sort of reimbursement for their incorrect installation.

ashutt

DC Performance shut their doors in the last 30 days so you will have no luck there. They did a Dyno for me and diagnosed my SC water pump relay was out but it took them two days to get to and I had to stay overnight in LA because they "forgot" I was coming from Las Vegas that day. Cost me $140 for a crappy hotel. I was not pleased.

2MCHCAR

Thank you sir!

Those are VRP headers I sourced from the Classified Section. I'm dropping off my car tomorrow and will create a new thread in the non-///AMG W209 forum with the results!

Cory is super patient and a TRUE professional!

Yeah, DC is out of business so I'm SOL, but in the end it wasn't too much $$$ to fix.

daisyfresh

As a fellow California AMG owner, thank you for posting your story. Definitely is helpful knowing that the Kleeman gets through our strict smog tests.
I'm not an ace when it comes to knowing California vehicle code, but I was under the impression that all after market parts needed to have a CARB number to get past visual. To my knowledge the Kleeman S/C doesn't have one. How'd you get around this?

MarcusF

For the W208, California has the Kleemann supercharger for M113s registered as part number 1132085508. That part number is covered by CARB EO number D-528, D-528-1, & D-528-2. I've never checked the W209 listing. Maybe a W209 owner knows.

Klinh

I wonder if he able to pass Cali smog test since Cory sorted out all the issues.

daisyfresh

Marcus. You just made my day/life. Just found it on the Arb.ca.gov site. I have been stressin lately with my first world problem. Been tryin to decide whether to keep on battling the government with my motor swapped mustang or s/c the clk and ditch the headache. I really want to get down to just one money pit. You just made that decision for me.

http://arb.ca.gov/msprog/aftermkt/de...eo/D-528-2.pdf

Thank you Grey Davis!

MarcusF

Glad to be of help. That sight is VERY useful. What I don't see is the W209 listing.

BonitaBeast

I wish Cory and Kleemann was just a drive away from me..... My install wouldn't be taking more than a month to do.

betrezra

Bonita - Roger that.... Cory/Brandon are the best.

1 Month.... try 6 months for my install. LOL...... you are fine compared to my escapade.