My UK ESS TS2 installation

[maxnathan]

Here is how the story begins:

After purchasing the TX1 from ESS in Feb` 2006 I made a rather rash decision to sell it after 4 months of use! :hmm: Why would anyone do such an insane thing, i hear you asking......Well simple.......The impending arrival of the Twin screw supercharger was all the reason i needed to sell my beloved TX kit to a rather nice bloke in the US of A...(Thanks Jason!:clap: )

Now comes the difficult bit.......the long and dry spell without boosting caused major withdrawal symptoms such that i had to waste some money on Carbon fibre parts instead of saving up for the TS2:eek: Nevertheless, the kit finally arrived just before Christmas :excited:

After much deliberation. i decided to employ the services of Simpson Motorsport UK since they are the official distributors of ESS in Britain. They`ve also got a lot of race car preparation experience and have fitted a number of ESS kits. It was a difficult decision since i had fitted the TX kit myself . However the TS is a new system and so i wanted to make sure that i would have the neccessary expert backup in case something went wrong. Anyway, i managed to get involved in the entire process of installing my TS ;something akin to cutting the umbilical cord of my newborn baby.:rofl:

What follows are details of the installation that we felt needed clarification / elaboration:

Thanks to Todd`s clear DIY we estimated a 9 hour installation time. The initial bits were simple : Removing the bumper and installing the intercooler and marine pump. We had to switch the L -shaped brackets around and use the dremel such that there was enough clearance to refit the black radiator guard. This is so much easier than fitting those rigid pipes in the TX2 system.

http://i25.photobucket.com/albums/c59/maxnathan/DSCF0793.jpg

Next was the removal of the intake manifold, revealing a number of tubes and pipes. This was made worse by the unraveling of the engine wire harness and the "crazy spider" appearance of the harnesses. One very important tip here - make sure you either label or memorise where each harness fits cos there`s no room for making the wrong connection as i found out later :banghead: The DISA valve connector is not used.

http://i25.photobucket.com/albums/c59/maxnathan/DSCF0809.jpg

http://i25.photobucket.com/albums/c59/maxnathan/DSCF0797.jpg

http://i25.photobucket.com/albums/c59/maxnathan/DSCF0798.jpg

http://i25.photobucket.com/albums/c59/maxnathan/DSCF0801-1.jpg

When it came time to fitting the manifold and TS, we were stunned by how beautiful the whole kit looked....:bow:
http://i25.photobucket.com/albums/c59/maxnathan/DSCF0794.jpg

[maxnathan]

We only queried the weight of the TS compared to the stock manifold and that there was no extra supporting bolt to the crankcase like on the original manifold.

http://i25.photobucket.com/albums/c59/maxnathan/DSCF0803.jpg

Also there was the question of the Black canister and rubber piping near the starter motor.....Where were we to connect this to? A quick call to Hans ( and there were plenty of quick calls to Hans!) and we were told to fit it into the boost line orange snap connector. The other orange snap connector goes to the fuel pressure regulator.

http://i25.photobucket.com/albums/c59/maxnathan/DSCF0804.jpg

The bosch 30# injectors fitted into the ESS manifold well though they would have been a more snug fit if the aluminium spacers were machined down by 1mm. One of the most difficult parts of the install involved attaching the suction jet tubing, fuel purge vent tubing and lower intercooling pipe to the TS kit before lowering it down completely and securing it. We decided that a custom lattice work gasket sealant pattern was in order......

http://i25.photobucket.com/albums/c59/maxnathan/DSCF0802.jpg

It is surprising how well the TS manifold sits on the crankcase. We decided to fit the idle valve and throttle body to the TS before lowering it into the car.
Note how the CNC power steering canister and ESS radiator hose are so close to the TS pulley......but such is the precision engineering involved in this kit!! :yikes:

http://i25.photobucket.com/albums/c59/maxnathan/DSCF0806.jpg

The new belt was a tad difficult to fit and it is very tight.
Then came the moment of truth......After uploading my Asbjorn -modified DME data ( for 99RON) via the CarTune software and adaptor, i nervously turned the key ...............to our dissapointment the car started spluttering and idling was attrocious!! :cry: To cut a long story short, a few hours later, we realised that the Cam Shaft sensor connector was plugged into the idle valve connector and vice versa...ooopppppss:eeps: after this quick correction , i started up the car again and all was well ! She was purring like a cat!!!!:str8pimpi I was amazed at how soft the whistling of the Ts was. You can hardly hear it especially if you`re in the cabin........

We then proceeded to fit the UUC evo3 short shift after which i had the chance to savour the TS2 .........:excited:
And i was smitten.......those painful memories of the initial mix-up and the long 6 month wait for the TS dissapeared instantly!!! This kit is well worth its price . The TX system was addictive but the quick and smooth delivery of the peaked torque wave in the TS is phenomenal ! After the initial 100 mile break-in period , the CEL came on but then mysteriously dissapeared after 50 more miles. My car feels frighteningly fast at WOT and i can`t wait to get it dynoed. Also i`ve averaged 38mpg ........go figure:hmm: Just look at how clean this installation looks.......:woot:

http://i25.photobucket.com/albums/c59/maxnathan/DSCF0820.jpg

Anyway, thanks for reading my long-winded story . I hope you find this account of some use .I really could go on and on about how the TS makes me feel....... Thanks to ESS and the guys at Simpsons Motorsport , my 330 is boosting like there`s no tommorrow and i hope she`ll stay that way until stage 3........:4ngie:

[2K5 325i]

Cool post!

I wish I had the $$$ and the balls to do a S/C install!
-Chris

[MachRc]

AHHH congrats Max!!!!!!!!!:woot: :woot: :woot:


It must be so damn exciting especially after the long wait!!!!!!!!:excited: :excited: :excited:


now Im the one with boost envy!!:)

[RedBarron]

Nice i want one soo bad.

[Ervin87]

Congrats.
Post some video clips.

[rollotono]

Thank you for the nice write-up. I plan to install the TS2 later this year and would really love more testimonials such as yours. It would be great to have more videos with timing 20-60, 40-80, etc. to get a good feel for how much quicker the car will be with the TS2.

1. do you have the upgraded clutch? Is that a concern of yours?
2. did you install the LSD or change gearing? How is the traction during WOT from a standing start

Thanks again,
T

[KOTHB]

Congrats.

Still waiting for mine.

[EIAlfonso]

Congrats.
Post some video clips.

I would be interested in that also.

How long did the install take? Minus the error in installation.

Also did you Dyno before you received your kit?

Thanks for the write up.

[Limited_Slip]

Wow!

[668Ci]

cool writeup. I noticed you have a vdo oil pressure sender with dual output and the oil distribution block. Where did you source these if you don't mind me asking. Thanks!

[kerisabe]

Beautiful.. enjoy...!

[maxnathan]

Thanks for the postitive comments:

We hope to take a short video of my car tomorrow - weather permitting ( at the moment its been raining non stop for weeks:( )

I have the standard BMW clutch but am going to test a Z4 in Simpsons tommorrow with the M5 clutch/light flywheel combo :excited: I have been keeping an eye out for clutch slip but so far so good ( car has 13000 miles at present........watch this space)

I did actually dyno my car before but with an ECU remap and K&N filter - 237bhp and 225 lbs/ft........will post dyno post TS hopefully in Feb?

The VDO gauges and connections were sourced from Leather Z:thumbsup: Forgot to mention that the clearances for the distribution block are tight and it should NOT touch the TS

Unfortunately the install took a total of 14 hours because of the error but otherwise should be 10 hours tops.........

No plans for an LSD yet but who knows.....
In WOT, the DSC light comes on mostly but then its been pretty slippery around these parts lately...for the most i am very satisfied with the grip and acceleration:4ngie:

Lastly i`d also like to thank Amy ,(whom i forgot about :confused: - ) for helping in the install..........

[vrtymfg]

:drool: :drool: :drool: I want one sooo bad.....might be able to convince the wife by the end of the summer:idea:

[EIAlfonso]

So what was the free gift they were giving?

[Dirtboy]

Nice! :D

I hope my install goes easy when my TS arrives.

Can you tell me a bit more about the CarTune software and adaptor?

[Mc 007]

very good work!

[maxnathan]

So what was the free gift they were giving?
Hans has promised to send me a t-shirt..........:rofl:


Nice!

I hope my install goes easy when my TS arrives.

Can you tell me a bit more about the CarTune software and adaptor?
The Cartune programme will be e-mailed to you. Then you use the ESS DME adaptor and connect it via serial port to your computer. Using Cartune , you download the original DME, e-mail it back to ESS and after they alter it, its sent back to you for uploading into the car. They`ll also give you a code number so that you`re able to write to your DME. This only works with the MS43 versions i.e 3 wired MAF sensor......

[EIAlfonso]

Hans has promised to send me a t-shirt..........:rofl:



The Cartune programme will be e-mailed to you. Then you use the ESS DME adaptor and connect it via serial port to your computer. Using Cartune , you download the original DME, e-mail it back to ESS and after they alter it, its sent back to you for uploading into the car. They`ll also give you a code number so that you`re able to write to your DME. This only works with the MS43 versions i.e 3 wired MAF sensor......

T Shirt NOOO!!!:cry:

Did you get a maintenance book, or any extra fittings or maybe a spare belt? Oil? with the kit?

What was the cost of the adaptor?

Thanks

[Dirtboy]

The Cartune programme will be e-mailed to you. Then you use the ESS DME adaptor and connect it via serial port to your computer. Using Cartune , you download the original DME, e-mail it back to ESS and after they alter it, its sent back to you for uploading into the car. They`ll also give you a code number so that you`re able to write to your DME. This only works with the MS43 versions i.e 3 wired MAF sensor......

Do you know if a serial to USB adapter will work? My laptop doesn't have a serial port...

[maxnathan]

Do you know if a serial to USB adapter will work? My laptop doesn't have a serial port...

I don`t see why not...( my educated guess)

T Shirt NOOO!!!

Did you get a maintenance book, or any extra fittings or maybe a spare belt? Oil? with the kit?

What was the cost of the adaptor?

Thanks

Nope......no free belt or maintenance book.
It would be good if ESS can give us some information on maitenance of the cooling system and oil level in the TS etc.:)
The adaptor costs US99

Also here are some amateur vids of my car ( sorry about the horrible quality)

http://www.youtube.com/watch?v=DQ3fx2TqOzA
http://www.youtube.com/watch?v=JUwYpwJvn-o
http://www.youtube.com/watch?v=2gcCWdCW4I8
http://www.youtube.com/watch?v=vAGiB0d4BSU
http://www.youtube.com/watch?v=QkHjpYtZUto

http://www.youtube.com/watch?v=5_eSYcLgD4s
http://www.youtube.com/watch?v=vsP48LX31Ug
http://www.youtube.com/watch?v=x_7ltGS8PTA

When i get a better videocamera.............

[EIAlfonso]

Did you receive any type of support bracket for the manifold?

Did you install it?

[MarvelPhx]

Oil level in the TS: 10mm below the centerline of the snout. I used a wooden skewer to check it by removing the top fill cap. You can't really overfill it, the compressor has a overflow drain in the center of the pulley bolt and it will basically level itself by slowly draining out there. Just make sure you don't put too little in. It is the same 10w-60 Castrol oil used in a M3 engine.

[aggieE46]

When am I coming over to help you install yours?????? :evil:

Did you receive any type of support bracket for the manifold?

Did you install it?

[maxnathan]

Did you receive any type of support bracket for the manifold?

Did you install it?

We didn`t get a support bracket eventually. So far i think that shouldn`t be a problem. I`ve had to tighten my manifold bolts again since there was this loud screeching noise from the engine........We also machined the aluminium spacers from 11.3cm to 10.3cm and the new injectors then `snap` perfectly into the manifold


Next step is to install my boost gauges and take a few reading during a dyno session..........

[gwatson]

Next step is to install my boost gauges and take a few reading during a dyno session..........

Let me know what yougo for Maxandhow you install it.

G

[Asbjorn@ESS]

We didn`t get a support bracket eventually. So far i think that shouldn`t be a problem. I`ve had to tighten my manifold bolts again since there was this loud screeching noise from the engine........We also machined the aluminium spacers from 11.3cm to 10.3cm and the new injectors then `snap` perfectly into the manifold


Next step is to install my boost gauges and take a few reading during a dyno session..........

Hi Max, I think you mean 11.3mm to 10.3mm. The reason there is a 1mm clearance at the bottom of the injector seat is to avoid "bottoming" the injector in the seat. It should sit a little off the bottom when installed, just like on the OEM intake to avoid transferring the engine vibrations directly to the injector. I don't really think this matters, but the way we ship it is exactly like the OEM injector set up, with identical clearances etc.

It's always a good thing to recheck the main manifold->head torque after the system is run in. If you get a leak here it will sound like a "whistle" due the high vacuum in the manifold.

We designed the system from the ground up without support brackets of any kind. We did make one for race applications, etc. But it is not required and it will add a bit to the install time due to space restrictions of fitting a bracket underneath the manifold.

[EIAlfonso]

When am I coming over to help you install yours?????? :evil:

I plan on having Stett Performance do the install, however you get to take it through the gears:yikes::4ngie::excited:

[EIAlfonso]

We designed the system from the ground up without support brackets of any kind. We did make one for race applications, etc. But it is not required and it will add a bit to the install time due to space restrictions of fitting a bracket underneath the manifold.

... We did develop a bracket early on that links the intermanifold to the previous lower mounting point of the OEM manifold, but it not necessary as it supports no weight or torsional loading. We still include the piece in the kits regardless, however, it is optional to install this piece as installing it will lengthen the install time.

I'm a bit confused by these contradicting statements, so there is no optional bracket? Are we talking about the same thing?

What exactly was this piece?

[Asbjorn@ESS]

I'm a bit confused by these contradicting statements, so there is no optional bracket? Are we talking about the same thing?

What exactly was this piece?

The bracket is available, but it is quite hard to put in and it is not neccessary at all. We designed this bracket to support the extra weight and torsion of the 2.3L Lysholm in our TS extreme edition, but since the new 1.6L has higher RPM capabilities we no longer need the heavier 2.3L and extra support to make 400+rwhp. If you want the support bracket I will be happy to supply you with one without charge. Just keep in mind it will add to the complexity of the install and there really is no need for it with our very strong, self supporting TS manifold design.

[EIAlfonso]

The bracket is available, but it is quite hard to put in and it is not neccessary at all. We designed this bracket to support the extra weight and torsion of the 2.3L Lysholm in our TS extreme edition, but since the new 1.6L has higher RPM capabilities we no longer need the heavier 2.3L and extra support to make 400+rwhp. If you want the support bracket I will be happy to supply you with one without charge. Just keep in mind it will add to the complexity of the install and there really is no need for it with our very strong, self supporting TS manifold design.

Thx for the quick reply

If it doesn't delay my shipment I would like to have this option availabe to me, if you could include it with my shipment I would appreciate it.

Thanks again.

[Asbjorn@ESS]

Thx for the quick reply

If it doesn't delay my shipment I would like to have this option availabe to me, if you could include it with my shipment I would appreciate it.

Thanks again.

Sure, no problem:)

[maxnathan]

Asbjorn , Thanks for that explanation......it makes sense:thumbsup:

So far my car has been driven more than 600 miles after the TS installation and i can say that i love revving the beast just to feel the wave of torque ...

Now i hope the TS3 conversion won`t cost an arm and a leg........:4ngie:

[aggieE46]

Hehe, almost as good.

I'm getting my TSE3 next weekend, you'll have to take mine out for a ride, too. Hopefully this weather will let up so I can get her clean.

I'm a bit confused by these contradicting statements, so there is no optional bracket? Are we talking about the same thing?

What exactly was this piece?

[maxnathan]

Well, 1000 miles already and i`m still smiling.:excited: ......all manner of boost envy has nearly dissapeared.

The next step is to dyno the car probably in the next 2 weeks......after i recheck all connections and install my denso iridiums IK22.

Anyone out there with the TS2+ kit? Any reports on how this feels? I`m already considering going for this kit although i`m not to sure whether you need the headers. I`m all for better headers but the extra noise might be too much for me........

Oh yes .........here are some shots of the much awaited complementary t-shirt.......very nice:pimpin:

http://i25.photobucket.com/albums/c59/maxnathan/DSCF0848.jpg

http://i25.photobucket.com/albums/c59/maxnathan/DSCF0847.jpg

[zulu4]

ah... 50,000miles durability testing had to be completed before they sent you the t-shirt eh? :rofl:

...joking....

on a more serious note, i've asked ESS about switching to one step colder plugs like IK22s, but Asbjorn's response back then was that the TS kit was designed to be used with stock plugs.

any particular reason why you intend to go one step colder?

[maxnathan]

No real reason as to why i decided to change to Denso IK22 apart from how most folk here love it.......

If it is a problem then its not too difficult to change back....

This is all about neatness and organisation..........

http://i25.photobucket.com/albums/c59/maxnathan/DSCF0852.jpg



Check out how burnt the old sparks are........love the look of the Denso`s

http://i25.photobucket.com/albums/c59/maxnathan/DSCF0854.jpg



All in all took me 1hr to fit..........There were no tricky bits but the ignition coils clips took a little while to figure out

http://i25.photobucket.com/albums/c59/maxnathan/DSCF0856.jpg



Oh yes, use plenty of anti-seize

http://i25.photobucket.com/albums/c59/maxnathan/DSCF0855.jpg



Theoretically, the cold plugs should be more efficient and smoother but i`ll let you know if thats the case........in any case given the condition of the original sparks, there has to be some advantages....

For the anoracks out there, will post a short vid of what she sounds like now.....

[M3_Jaydee]

congrtats!

[ritos530i]

Actually the colder plugs will make it run rough at little.
I went 2 colder and it runs rough at idle but when i get on the pedal it all goes away.
Very neat work area.

[MachRc]

Well, 1000 miles already and i`m still smiling.:excited: ......all manner of boost envy has nearly dissapeared.

The next step is to dyno the car probably in the next 2 weeks......after i recheck all connections and install my denso iridiums IK22.

Oh yes .........here are some shots of the much awaited complementary t-shirt.......very nice:pimpin:

http://i25.photobucket.com/albums/c59/maxnathan/DSCF0848.jpg

http://i25.photobucket.com/albums/c59/maxnathan/DSCF0847.jpg

forget about boost envy!!

thats a real cool shirt that ESS is sending out max!!! !:)


AHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHH :excited:

[maxnathan]

Shirts yours if you want jason...........

For a price of course:4ngie:

[maxnathan]

Since theres a lot of talk about rough idle, i decided to take a short vid of my car......

Few pointers....

1. This is a true cold start first thing in the morning, Temp reading 7 deg

2. My car has IK22 cold start plugs which should mean a slightly lumpier start fo a few seconds

3. I couldn`t resist stepping on the throttle

4. You can hear me shut the door an the rest is noise from within the cabin...........

http://www.youtube.com/watch?v=PfZ7D7r6z8k

[MarvelPhx]

Watched the vid. I don't see anything abnormal. Am I missing something?

Looks like a normal cold start even without a TS, stable higher idle coming down as it warms up, etc.

[maxnathan]

^^^^^^

No, you didn`t miss anything important.....the idle is rough to start off but thats being very pedantic.....

I do notice a little `roughness` to start but its all subjective and more importantly momentary. As you can see its super-quiet with the door close........:pimpin:

Don`t get me wrong, i`m not unhappy with the idle by any means....in fact its very similar to the M3 csl at idle :4ngie:

[MarvelPhx]

Since you have had more time to enjoy the TS, how is everything goin now?

[maxnathan]

I`ve done more than 2000 miles with the TS2 and am thoroughly pleased with it.........:str8pimpi .

So much so i`m waiting for my next shipment of goodies to `up` the ante a little......the race is on between dirtboy and myself :4ngie:

I wonder how long Fedex will take this time :banghead:

[Dirtboy]

So much so i`m waiting for my next shipment of goodies to `up` the ante a little......the race is on between dirtboy and myself :4ngie:



:eeps: What race? What are you waiting for from FedEx? :hmm:

:)