Kleemann 2003 G55 Project - S/C!!
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2017 G63 Edition 463, 2008 G55k
Yet another step closer! With a bit of massaging and no cutting, all the hoses went on and everything fit just as Cory said they would. We are just filling her up with coolant and we'll be turning the key shortly!!! A bit of trimming of the engine cover is being done now. After that, the cover will sit lower down and the oil cooler will no longer be in the way.
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2017 G63 Edition 463, 2008 G55k
It's alive!!!!!!!!!
reviews shortly!!!! It sounds like a monster!!!!!!!!
I'm missing a fuel pressure gauge so I can't adjust the regulator properly but I'll be taking her out for a test drive in a bit. Middle of the work day for me so I can't do everything I want right now.
Good thing is, one click and she started right up!!!
reviews shortly!!!! It sounds like a monster!!!!!!!!
I'm missing a fuel pressure gauge so I can't adjust the regulator properly but I'll be taking her out for a test drive in a bit. Middle of the work day for me so I can't do everything I want right now.
Good thing is, one click and she started right up!!!
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2017 G63 Edition 463, 2008 G55k
Not yet. Engine is misfiring at idle. Presently checking for any air leaks near MAF, rechecking all vacuum connections, exhaust leaks, coil pack installation, O2 sensor installation, resistor installation.
Anyone have any other ideas? I just wanna knock out as many possibilities here.
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2017 G63 Edition 463, 2008 G55k
Think I found the culprit!!!! Fuel system line not correct. Fuel pressure was dropping below 30psi!!! I think that will cause some misfiring at idle.
Had it redone today. Update soon.
Had it redone today. Update soon.
Last edited by BonitaBeast; Oct 3, 2012 at 07:01 AM.
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From: A Canadian in Dubai, United Arab Emirates
'05 C200K SS, '05 Kleemann CLK500K, '08 Hummer H3 & '92 Z34 5sp (track car in Canada)
Looking real good man, real good 
You need to get the oil-cap/filler extension so the cap sits level with the new cover, I added it to mine and it looks great, just like it belongs there.
Keep us updated with your progress pal!
*** EDIT ***
Here is the part number so you don't have to go searching around;
A1120100064
Good luck.
You need to get the oil-cap/filler extension so the cap sits level with the new cover, I added it to mine and it looks great, just like it belongs there.Keep us updated with your progress pal!
*** EDIT ***
Here is the part number so you don't have to go searching around;
A1120100064
Good luck.
Last edited by Kevwood; Oct 3, 2012 at 10:10 AM. Reason: added part number
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Thread Starter
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2017 G63 Edition 463, 2008 G55k
Looking real good man, real good You need to get the oil-cap/filler extension so the cap sits level with the new cover, I added it to mine and it looks great, just like it belongs there.
Keep us updated with your progress pal!
*** EDIT ***
Here is the part number so you don't have to go searching around;
A1120100064
You need to get the oil-cap/filler extension so the cap sits level with the new cover, I added it to mine and it looks great, just like it belongs there.Keep us updated with your progress pal!
*** EDIT ***
Here is the part number so you don't have to go searching around;
A1120100064
Thanks! Placing the order as we speak.....
Finally fit the engine cover properly. Notice the cutout by the oil cooler.
And repositioned this badge
The under bumper bar, skid plate and original grill are also on but I haven't taken pics of that yet; probably tomorrow. I guess I'll have to work remotely again tomorrow
I have to get this baby done! I can't seem to concentrate on anything else...... Fingers crossed. I pray tomorrow she starts up and idles perfectly.
Last edited by BonitaBeast; Oct 3, 2012 at 10:22 AM.
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2017 G63 Edition 463, 2008 G55k
Fuel System update
Looks like I'll be redoing the entire fuel system configuration tomorrow. I simply "masked" the gigantic mess of a fuel line configuration that the installer did. I drew a diagram of how it was installed and sent it over to Cory. As I suspected it was completely and utterly WRONG!!
I have a new diagram to follow from Cory. Needless to say, I will not be starting her up tomorrow morning. This is 100% the reason why my fuel pressure was going crazy low!
Updates when I'm done with the reconfiguration and relocation of the regulator, pump and hoses!!!
I have a new diagram to follow from Cory. Needless to say, I will not be starting her up tomorrow morning. This is 100% the reason why my fuel pressure was going crazy low!
Updates when I'm done with the reconfiguration and relocation of the regulator, pump and hoses!!!
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From: A Canadian in Dubai, United Arab Emirates
'05 C200K SS, '05 Kleemann CLK500K, '08 Hummer H3 & '92 Z34 5sp (track car in Canada)
You'll get there dude, I don't know anyone who has nailed one of these systems the first time, poor Jeff was left with a hell of a mess and mine took an eternity to get back to me before I had to clean up a bunch of crap.
Hang in there, it's worth it in the end
Hang in there, it's worth it in the end
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From: A.D., U.A.E
2000 (W202 C200) & 2000 (W202 C55)
Did you measure the Voltage of the Mass...?, it should NOT goes over "4.85",, and the Lambda should be "0.84", and Not go below than that,, and
the vacuum should be "0.5bar" in idle,, do you have a Fuel booster with a kit....??
ZAYED,,
the vacuum should be "0.5bar" in idle,, do you have a Fuel booster with a kit....??
ZAYED,,
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2017 G63 Edition 463, 2008 G55k
-Yes for Voltage only at idle and minor revving. Nowhere near 4.85v.
-Fuel Pressure was dropping too much upon minor revs so I knew something was up.
-The engine didn't sound as I expected so I shut the car off and checked everything again.
-What I found was the fuel system was installed completely incorrectly!!!
-That's what I'm resolving now.
Here's what I found:
Incorrect Fuel System Install! Talk about wanting to murder someone......
Re-doing correctly at this moment!!!!
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2017 G63 Edition 463, 2008 G55k
At the end of the exercise........ The problem is solved!!!
Just hooking everything up permanently. Relocated the Fuel pump and regulator and re-ran the fuel lines. Started her up and NOW it sounds GOOD!! Idle sounds 1000x better! I'm just having all the hoses secured and a bracket for the fuel pump fabricated and welded to secure it to its final resting place. I'm also replacing all the clamps on the hoses tomorrow just to make sure. Pressure adjustment, I'll do tomorrow as well. When everything is nice and "toyt" I'll be able to do the final pressure adjustment and voltage check on the MAF lead. Should be ok though since I used a fixed resistor instead of the KLeemann Variable resistor that has been known to go bad.
Here's a shot of the regulator relocation and shots of the rest of the front end changes I did to the truck:
The regulator on the right side of the picture will be upright when done. It's still on a tilt as shown here so we could secure all the hoses.
Grill and Underbar shots:
Pardon the filth that covers the truck in this picture. That's what happens when I car sits for more than a month.....
Just hooking everything up permanently. Relocated the Fuel pump and regulator and re-ran the fuel lines. Started her up and NOW it sounds GOOD!! Idle sounds 1000x better! I'm just having all the hoses secured and a bracket for the fuel pump fabricated and welded to secure it to its final resting place. I'm also replacing all the clamps on the hoses tomorrow just to make sure. Pressure adjustment, I'll do tomorrow as well. When everything is nice and "toyt" I'll be able to do the final pressure adjustment and voltage check on the MAF lead. Should be ok though since I used a fixed resistor instead of the KLeemann Variable resistor that has been known to go bad.
Here's a shot of the regulator relocation and shots of the rest of the front end changes I did to the truck:
The regulator on the right side of the picture will be upright when done. It's still on a tilt as shown here so we could secure all the hoses.
Grill and Underbar shots:
Pardon the filth that covers the truck in this picture. That's what happens when I car sits for more than a month.....
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From: A.D., U.A.E
2000 (W202 C200) & 2000 (W202 C55)
Very gooooood news...,, seems to me from beginning you well beat it my friend....,, good place of the Regulator,,
Pls. waking the monster & let it Breath......
ZAYED,,
,, seems to me from beginning you well beat it my friend....,, good place of the Regulator,, Pls. waking the monster & let it Breath......
ZAYED,,
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2017 G63 Edition 463, 2008 G55k
Thanks for the words of encouragement. I needed them exactly at that point. I was literally ready to hurt someone.
Now I can see the light at the end of the tunnel. As cheesy and cliche as it sounds, I think you guys know exactly what I mean.
No one around me (physically) seems to understand what the heck I'm going through, so it's nice to hear actual cases of successes and flops and mishaps and installer stories. At least I know there are others out there who have gone through the same thing and in the end got things working properly.
Jeez... I just re read that and I feel like it's page right out of an AA meeting...
Anyway, I'm hoping to update with some good news later today.
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From: Seattle, WA
99 ML430, 01 CLK55, 07 R63, 15 E63 Wagon
Freaking awesome man! Can't wait to see pictures of it OUTSIDE!
If you don't mind me asking, was the labor really expensive for you, seems like you've got quite a few hours racked up? I forgot what country are you in?
If you don't mind me asking, was the labor really expensive for you, seems like you've got quite a few hours racked up? I forgot what country are you in?
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2017 G63 Edition 463, 2008 G55k
We'll see about the labor. Let's just say, I went through a shop that has its own mechanics but also contracts speciality mechanics for certain projects.
I used the shop's mechanics for the basic stuff like painting rims, grill, installation and welding of headers and downpipes, etc AND the contract guys to do the actual Supercharger install. I had problems with the supercharger install guys so I wanna see them try to charge me. I had to make the corrections myself even if I had super details instructions of everything they needed to do. Let's just say, that's a part of the bill I won't be paying anytime soon. If anything, they should pay me for the work I did. They can try to fight me about it.
On a side note. Just started her up again. Sounds a lot better at idle now but my fuel pressure now is on the high side. I can't seem to get it to go below 70psi even with the regulator adjustment knob. I'm able to get it to spike up but when I back off counter clockwise like it says in the manual, it normalizes at 70 psi. It might be the gauge that's messed? Gonna take it for a spin and see what happens.
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From: Seattle, WA
99 ML430, 01 CLK55, 07 R63, 15 E63 Wagon
What country are you in? I don't recognize the license plate.
Generally speaking, is labor expensive there? Labor's damn expensive here in the US compared to let's say China or Indonesia.
Generally speaking, is labor expensive there? Labor's damn expensive here in the US compared to let's say China or Indonesia.
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2017 G63 Edition 463, 2008 G55k
Oops sorry. I'm in the Philippines. Labor isn't expensive here at all. We're probably around the labor rates of Indonesia. Yes, I know how crazy labor rates are in the US.
So I just took it out for a road test. Something's still not kosher. Idle is still rough. Better than when the pressure was low but still rough. Now I also have sawing up and down of the idle like there's a vacuum leak but I can't find any leaks anywhere.
I still can't seem to lower the fuel pressure now. No matter how much I back out the FPR adjustment screw counter clockwise, the pressure is pegged at 70psi. Too high.
I do notice smoke coming out of my left side headers/downpipe connection. I'm hoping it's not a leak. Maybe it's the new gaskets just seating? If these had a leak, That would surely cause the behavior I'm noticing with the car now. So maybe, I AM hoping it is a gasket leak or headers leak. This can be repaired and hopefully the problem is solved!
That's it for now. Hope to find something soon.
Last edited by BonitaBeast; Oct 5, 2012 at 12:00 AM.
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2017 G63 Edition 463, 2008 G55k
Checked for exhaust leaks. Didn't find any. Took it for another road test. ECU seems to be adjusting. No smoke seems to be coming out of the manifolds or headers any longer. May really have been the gaskets seating. No more weird odor of asbestos either. Car is running ok but still feels down on power. Idle was still "hunting/sawing". Might be leak somewhere in the MAF I thought.
Got back to shop and Found an abs vacuum hose unplugged. Plugged it in and idling got better! I just did I hard reset now (unplugged battery). Hopefully it resets it and idle will be better.
Putting the airboxes back. Hoping this will solve the hunting issue.
But Now my a/c is not getting cold!!! Will this ever end........
Got back to shop and Found an abs vacuum hose unplugged. Plugged it in and idling got better! I just did I hard reset now (unplugged battery). Hopefully it resets it and idle will be better.
Putting the airboxes back. Hoping this will solve the hunting issue.
But Now my a/c is not getting cold!!! Will this ever end........
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2017 G63 Edition 463, 2008 G55k
The car is down on power. Still sounds like a misfire at idle and is idling way to low ~600 rpm. I would think idle would be higher and closer to 1000rpm. Fuel pressure is high at 70psi but I think it might be the gauge. Haven't been able to check the Voltage of the maf lead but based on the car running way rich (smells of gas and down on power) I don't have to worry about the voltage being over 4.8V.
Back to square one!
Back to square one!
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From: A.D., U.A.E
2000 (W202 C200) & 2000 (W202 C55)
If it running much rich, means; need to regulate the Fuel pressure or the ECU does NOT reads the mixture properly, during to the back MAF
signal to ECU,,
Do you measure the Lambda.....??
ZAYED,,
signal to ECU,,
Do you measure the Lambda.....??
ZAYED,,
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2017 G63 Edition 463, 2008 G55k
No lambda measurement yet. I'm still waiting on my wideband sensor to come in.
Would anyone know what the effects of too high a resistor or too low a resistor on the MAF lead would have on how the car idles?
