My ESS TS1 install experience [Archive]

Lemonsqr

05-01-2007, 11:02 AM

So this is just a short writeup on my DIY install experience of my ESS twinscrew stage 1 supercharger. Read this if you are thinking about doing the install yourself and it will save you some time and headaches.

The kit was put together very well. Everything needed for the install was included except for the electrical tape needed to tape up the wire harness.

Roadbumps:
1)The bracket for the idle control valve (ICV) did not line up exactly with the holes on the TS body so I have to machine the hole on the bracket to fit.
2)The plug from the wiring harness to the ICV needed to be lengthened. This helps tremendously when lowering the TS mani into place.
3)Make sure to reinstall the dipstick BEFORE installing the TS mani. It is a heck of a lot easier to do it this way.
4)A new hole had to be machined into my power steering fluid resevoir bracket to move the resevoir back away from the pulley. Without machining the bracket, the resevoir either sits way too high and hits the hood, or literally comes into contact with the pulley.
5)Had to trim the air fliter/MAF to throttlebody connector to get everything to fit.

Other than these 5 roadbumps, the install was smooth although I spent a lot of time wrestling with reinstalling the shield/cover that seperates the engine compartment and the brake booster/DME harness.:banghead:

The car fired up with no problems and runs smoother than before the install. The whine of the TS is so :drool: it is hard to not go WOT until after the recommended 200mile break-in. I have gassed it a few times to feel the torque and it was nice. Overall either on or off boost, it feels like I have a new car!:excited: Cant wait till the 200 mile mark to start really having fun!:excited: :excited: :4ngie:

GodSendsDeath

05-01-2007, 11:08 AM

lol I thought it was a 500 break in mark. But congrats you inpatient speed demon.

Lemonsqr

05-01-2007, 11:16 AM

lol I thought it was a 500 break in mark. But congrats you inpatient speed demon.

:rofl: Well I guess I will drive off boost until 500...:(

The Nebulizer

05-01-2007, 11:36 AM

:rofl: Well I guess I will drive off boost until 500...:(

I think I would have to take a road trip to nowhere to burn off those miles.
Congrats on the TS - nice info for those installing.

Dirtboy

05-01-2007, 11:44 AM

Every thing that you said I had to go through as well. Hopefully you got the newer idler pullies that don't squeal...:eeps:

Lemonsqr

05-01-2007, 12:29 PM

Every thing that you said I had to go through as well. Hopefully you got the newer idler pullies that don't squeal...:eeps:

I havent had any squealing problems from the pullies...when did they start squeeling for you? Hopefully they will fix the problem with the ICV bracket holes for later editions so it will be one less thing to deal with. Also maybe make the intake connector better fitting although i prefer it to be slightly larger so you can trim it to fit. Not easy if it is too small and wont reach:eek:

Asbjorn@ESS

05-01-2007, 12:40 PM

Roadbumps:
1)The bracket for the idle control valve (ICV) did not line up exactly with the holes on the TS body so I have to machine the hole on the bracket to fit.
2)The plug from the wiring harness to the ICV needed to be lengthened. This helps tremendously when lowering the TS mani into place.
3)Make sure to reinstall the dipstick BEFORE installing the TS mani. It is a heck of a lot easier to do it this way.
4)A new hole had to be machined into my power steering fluid resevoir bracket to move the resevoir back away from the pulley. Without machining the bracket, the resevoir either sits way too high and hits the hood, or literally comes into contact with the pulley.
5)Had to trim the air fliter/MAF to throttlebody connector to get everything to fit.

1. There are 2 versions of this bracket from BMW, one is slightly narrower than the other and requires a redrill of one of the holes (one size bigger) to fit on the TS attachment points. I will make sure they put this in the manual.
2. Yes, this makes it easier, but if you pull the wire out of the harness and tape it by itself you do not need to extend it.
4. Again, small variances on the BMW parts used as this is not a precision part from them. We normally just enter both attachment bolts and push it backwards to it's correct position as it bends quite easy, then torque down the bolts.
5. This is supplied a little to long on purpose as we had a few instances of the precut one being a little to short on some cars.

I also do recommend a 500 mile break-in, but you can start pulling it to redline once in a while after 200 miles.

Also, we are currently testing a 7.5PSI boost upgrade for the TS1 which might be available shortly!:shhh:

Maestroxl

05-01-2007, 01:03 PM

Welcome to the Totally screwed club buddy.

MXL

Dirtboy

05-01-2007, 01:22 PM

I havent had any squealing problems from the pullies...when did they start squeeling for you?

It started squealing after about 250 miles and 4 laps on the Nürburgring.:(

Asbjorn@ESS

05-01-2007, 02:00 PM

It started squealing after about 250 miles and 4 laps on the Nürburgring.:(

Have you received the new version metal pullies yet?

Lemonsqr

05-01-2007, 02:31 PM

1. There are 2 versions of this bracket from BMW, one is slightly narrower than the other and requires a redrill of one of the holes (one size bigger) to fit on the TS attachment points. I will make sure they put this in the manual.
2. Yes, this makes it easier, but if you pull the wire out of the harness and tape it by itself you do not need to extend it.
4. Again, small variances on the BMW parts used as this is not a precision part from them. We normally just enter both attachment bolts and push it backwards to it's correct position as it bends quite easy, then torque down the bolts.
5. This is supplied a little to long on purpose as we had a few instances of the precut one being a little to short on some cars.

I also do recommend a 500 mile break-in, but you can start pulling it to redline once in a while after 200 miles.

Also, we are currently testing a 7.5PSI boost upgrade for the TS1 which might be available shortly!:shhh:

why did you have to say this??!now you got me all excited :excited: please post once it is available and thanks for your comments and breakin recommendations.

Lemonsqr

05-01-2007, 02:33 PM

Welcome to the Totally screwed club buddy.

MXL

Yeah thanks!:hi: I'm totally screwed because boost is like drugs....once you get a little you want more more more!!!:P

Maestroxl

05-01-2007, 02:56 PM

boost is like drugs....once you get a little you want more more more!!!:P

:eek::eeps:

MarvelPhx

05-01-2007, 03:05 PM

Welcome to the Totally screwed club buddy.

MXL

You stole my line!!!! :cry:

Lemon:

I don't know how different your car is, but all I did was flip the bracket on the ICV and it bolted right up. Same with the PS reservoir, I just slid it over and down and tightened. The ICV wire just has to be seperated from the rest of the harness before taping, then it is plenty long. I didn't extend any wiring.

And...

Welcome to the Totally Screwed Club! :hi:

Maestroxl

05-01-2007, 03:12 PM

You stole my line!!!! :cry:

As a member myself I can. hèhè

MXL

MarvelPhx

05-01-2007, 03:24 PM

As a member myself I can. hèhè

MXL

Agreed!

We should get every member to post a pic of themselves in the ESS Totally Screwed shirt!

Dirtboy

05-01-2007, 03:25 PM

Have you received the new version metal pullies yet?

No, I haven't got them yet. Have they been sent out?

These new ones are being sent out with all the current kits right?

Asbjorn@ESS

05-01-2007, 03:27 PM

No, I haven't got them yet. Have they been sent out?

These new ones are being sent out with all the current kits right?

Yes, all kits from March production and on have the updated pullies.

I will check status on yours ASAP.

e34m5

05-01-2007, 03:51 PM

Asbjorn:

Is that 7.5psi a function of a smaller pulley perhaps..Oh say 90mm maybe :4ngie:

Maestroxl

05-01-2007, 04:15 PM

We should get every member to post a pic of themselves in the ESS Totally Screwed shirt!Agreed, as soon as I get my XL-size shirt......or lose some weight...

MXL

Lemonsqr

05-01-2007, 04:17 PM

Have you received the new version metal pullies yet?

I was under the impression that plastic pullies are better than metal ones. The reason why I say this is because the supercharger on my honda came with metal (aluminum) pullies. Over the miles, a groove was worn into the pullies that contributed to belt squeal because the groove causes a looser belt. After switching to the updated highdensity plastic pullies, no groove after thousands of miles and no squeal.

MarvelPhx: Great tagline and thanks for the welcome as well. Yeah, like Asbjorn said, there are slight variations between the e46 years and I got stuck with the year (2001) that needed to make slight changes to fit the kit. but what can I say, "I'm totally screwed" but I delt with it.:craig:

330i ZHP

05-01-2007, 04:38 PM

I am starting to lose my patience waiting to be a part of the totally screwed club... Asbjorn...what's the status???

LemonSqr - congrats on getting your kit in and installed. I hope you enjoy it.

Asbjorn@ESS

05-01-2007, 04:45 PM

I was under the impression that plastic pullies are better than metal ones. The reason why I say this is because the supercharger on my honda came with metal (aluminum) pullies. Over the miles, a groove was worn into the pullies that contributed to belt squeal because the groove causes a looser belt. After switching to the updated highdensity plastic pullies, no groove after thousands of miles and no squeal.

MarvelPhx: Great tagline and thanks for the welcome as well. Yeah, like Asbjorn said, there are slight variations between the e46 years and I got stuck with the year (2001) that needed to make slight changes to fit the kit. but what can I say, "I'm totally screwed" but I delt with it.:craig:

The difference is not in the metal vs. plastic, it is because the metal ones have a smaller diameter and provides more belt clearance between the pulleys thereby eliminating the noise issue found on some cars.

If you use a cheap metal pulley they might wear, the one we use is OEM Lexus and extremely good. The older plastic one was OEM BMW and also very good, just a little to large to provide the proper clearances on some cars. If you do not get any belt noises with the plastic ones there are no need to change them out. If you do, just shoot us an email and we will ship you the metal ones. Belt noise is more commonly found on TS2 and TS2+ kits with plastic idlers due to their smaller SC pulleys. The TS1 is not as affected, and normally is silent even with the plastic idlers.

Asbjorn@ESS

05-01-2007, 04:47 PM

I am starting to lose my patience waiting to be a part of the totally screwed club... Asbjorn...what's the status???

LemonSqr - congrats on getting your kit in and installed. I hope you enjoy it.

We do have lots of satin kits ready to ship out at once, but we are still not satisfied with the black coloring on the latest anodizing prototype. They are working on a new formula, and we should receive some parts back later this week. If you are fine with the satin kit (IMO it looks better), then we can ship at once. Just let me know.

330i ZHP

05-01-2007, 04:53 PM

Asbjorn@ESS

05-01-2007, 05:36 PM

lets do it...satin it is - you have my approval...please ship the ts2, the ts2+ kit, the cams and let me know what the totals (broken out if possible - since it has been a while since we talked)

Thank you. i guess it is too late to ship today? lol

OK, we will get right on it. I will let you know as soon as it ships.

You will receive an email invoice with the exact costs broken down.

330i ZHP

05-01-2007, 05:38 PM

you have everything in stock, right? so i assume assembly and pressure testing and then packaging... do you have an eta on shipment?

to the OP - sorry for thread jacking...

Lemonsqr

05-01-2007, 05:44 PM

you have everything in stock, right? so i assume assembly and pressure testing and then packaging... do you have an eta on shipment?

to the OP - sorry for thread jacking...

No problem. ;) My intent on this thread was to share what I learned from my install. Not really looking for feedback, although all the positive feedback I have been getting back is great:thumbup:

330i ZHP

05-01-2007, 05:54 PM

my friend - I am happy as a lark for ya..btw, I tried to figure out where you live using the coordinates..are you in Texas near Houston?

Any pics of your setup btw?

bigjae1976

05-01-2007, 08:21 PM

Congrats.

I'm really debating on whether I should get the TS1 or TS2. What made you decide to get the TS1 vrs the TS2?

Asbjorn@ESS

05-02-2007, 12:36 AM

Congrats.

I'm really debating on whether I should get the TS1 or TS2. What made you decide to get the TS1 vrs the TS2?

If you don't regularly see temps of 90+F where you live the TS1 @ 7.5PSI will be your best bang for the buck. We do not normally sell it in a 7.5PSI configuration yet as testing haven't been completed, but it works excellent so far so official release might be soon. You can even request the TS1 with the 7.5PSI pulley now, but it is not officially guaranteed yet so it is on your own risk.

If you live in a hot climate and plan to go for 320+whp in the future (TS2+/TS3) then it is easier just getting the intercooled TS2 to start out with, but you can also upgrade the TS1 to TS2, it is just a little extra work to retrofit the Laminovas to the manifold.

bigjae1976

05-02-2007, 04:37 AM

How much work is involved in upgrading from TS1 to TS2? Do I have to remove the entire manifold again to install the laminova cores?

Lemonsqr

05-02-2007, 09:34 AM

Congrats.

I'm really debating on whether I should get the TS1 or TS2. What made you decide to get the TS1 vrs the TS2?

It was a combination of $ and the fact that around here (Chicagoland), I wouldnt be able to enjoy the extra power as much. Traffic and road layout sux! But if I outgrow the TS1, then the TS2 upgrade may be needed:4ngie:

330i ZHP: I was in Lake Jackson, TX, but not now. Fixed the coordinates. Thanks.

Asbjorn@ESS

05-02-2007, 01:58 PM

How much work is involved in upgrading from TS1 to TS2? Do I have to remove the entire manifold again to install the laminova cores?

You have to remove the manifold, remove the end caps, install the Laminova cores, install new end tanks for the circulation system, install water hoses, pump, front mount heat exchanger, smaller SC pulley and send the DME in for a software flash to TS2 spec. Everything is very straight forward and the parts just bolt right in, but it does take some time.

bigjae1976

05-02-2007, 02:29 PM

It was a combination of $ and the fact that around here (Chicagoland), I wouldnt be able to enjoy the extra power as much. Traffic and road layout sux! But if I outgrow the TS1, then the TS2 upgrade may be needed:4ngie:

Thanks for the info.

You have to remove the manifold, remove the end caps, install the Laminova cores, install new end tanks for the circulation system, install water hoses, pump, front mount heat exchanger, smaller SC pulley and send the DME in for a software flash to TS2 spec. Everything is very straight forward and the parts just bolt right in, but it does take some time.

So upgrading from TS1 to TS2 is pretty much like doing most of the install over again?

Lemonsqr

05-02-2007, 03:57 PM

Thanks for the info.

So upgrading from TS1 to TS2 is pretty much like doing most of the install over again?

Youre welcome. For me it was more because of the fact that I couldnt really let the bimmer stretch its pistons on the roads around here rather than the extra $ for the TS2.

Yeah, it will be like doing the install all over again, but you will not have to swap injectors, tape the wiring harness, swap parts onto new manifold and little things like that. But you will definitely have to take the mani off.

I was just wondering why they didnt design the mani so that the cooling cores and coolent hose endplate could be on the front end of the mani (rather than by the firewall) so upgrading would be easier:hmm:

bigjae1976

05-02-2007, 05:32 PM

You've helped me a lot...thanks again!

Asbjorn@ESS

05-02-2007, 06:09 PM

I was just wondering why they didnt design the mani so that the cooling cores and coolent hose endplate could be on the front end of the mani (rather than by the firewall) so upgrading would be easier:hmm:

Both end tanks are replaced. There is no way to install the cores with the manifold in the car, it needs to come off.

imgreen

07-12-2007, 02:50 PM

If you don't regularly see temps of 90+F where you live the TS1 @ 7.5PSI will be your best bang for the buck. We do not normally sell it in a 7.5PSI configuration yet as testing haven't been completed, but it works excellent so far so official release might be soon. You can even request the TS1 with the 7.5PSI pulley now, but it is not officially guaranteed yet so it is on your own risk.

If you live in a hot climate and plan to go for 320+whp in the future (TS2+/TS3) then it is easier just getting the intercooled TS2 to start out with, but you can also upgrade the TS1 to TS2, it is just a little extra work to retrofit the Laminovas to the manifold.

Any updates on this upgrade kit? I m thinking of the TS1 as well now :D What is the lead time from ordering to shipping these days?

Asbjorn@ESS

07-12-2007, 03:03 PM

Any updates on this upgrade kit? I m thinking of the TS1 as well now :D What is the lead time from ordering to shipping these days?

Currently the TS1 and TS2 lead times are ~3weeks.

323guy

09-24-2007, 01:29 PM

Currently the TS1 and TS2 lead times are ~3weeks.

Hey Asbjorn, then I should expect my TS1 kit to be shipped shortly? (Order #1399).

And congrats to Lemonsqr to getting Screwed.

:hi:

Asbjorn@ESS

09-24-2007, 01:33 PM

Hey Asbjorn, then I should expect my TS1 kit to be shipped shortly? (Order #1399).

And congrats to Lemonsqr to getting Screwed.

:hi:

Hi Bill,

Your kit is scheduled to ship out on Wednesday 26.

323guy

09-24-2007, 01:38 PM

Hi Bill,

Your kit is scheduled to ship out on Wednesday 26.

:excited: Awesome. :thumbsup:

Lemonsqr

09-24-2007, 02:51 PM

Hey Asbjorn, then I should expect my TS1 kit to be shipped shortly? (Order #1399).

And congrats to Lemonsqr to getting Screwed.

:hi:

Thanks :hi: You will soon be screwed as well my friend! Asbjorn and those guys at ESS are very responsive, but feel free to PM me if you are doing the install yourslef and are running into install questions or just want to chat about your install experience.

330i ZHP

09-24-2007, 03:08 PM

same here if you need help on a DIY install - and marvelphx will likely be one of your points of contact

MarvelPhx

09-25-2007, 04:14 AM

Who me??? :eek:

Get the kit in so I can welcome you!

silver330ciman

09-25-2007, 04:34 AM

Waiting for the gasket, pullies, etc for my TS to be installed...Any good news Asbjorn? I emailed you and Hans regarding the status. Thanks for the great support so far by ESS team!

And thanks ahead to those who are screwed from the ones to be screwed. lol.

amunoz27e

09-25-2007, 07:29 AM

Asbjorn, when is the TS coming out for the e46 coupes 325ci M54 engine?

Asbjorn@ESS

09-25-2007, 09:50 AM

Asbjorn, when is the TS coming out for the e46 coupes 325ci M54 engine?

It has already been out for quite some time:

http://www.esstuning.com/default.asp?c=shop&cat=93&subcat=101&subcat2=176&id=

aggieE46

09-25-2007, 09:59 AM

Any word on my software, yet? :hi:

Asbjorn@ESS

09-25-2007, 11:03 AM

Any word on my software, yet? :hi:

I will get to work on it ASAP. It might take a couple days since you requested custom tuning. I will let you know as soon as it is ready.

aggieE46

09-25-2007, 11:40 AM

Did Chad let you know all the details? PM me or email me if you need any info. Thanks!

I will get to work on it ASAP. It might take a couple days since you requested custom tuning. I will let you know as soon as it is ready.

silver330ciman

09-26-2007, 12:15 AM

Hi Asbjorn,
Sorry to post to here, but I was wondering if my parts have shipped from Norway. Please email me if possible. Thanks.

Asbjorn@ESS

09-26-2007, 03:23 AM

Yes, parts have shipped out using FedEx to Japan. Including one extra head gasket.

silver330ciman

09-26-2007, 04:05 AM

Yes, parts have shipped out using FedEx to Japan. Including one extra head gasket.

Extra, meaning two total? :) If not, could you send me an extra one for insurance? I emailed Hans for that and the tracking #. Thanks. You guys have been very helpful. I hope the install goes smoothly for me.

323guy

09-28-2007, 02:30 PM

Yes, parts have shipped out using FedEx to Japan. Including one extra head gasket.

:hi: Asbjorn,

So these are shipped from Norway. Will there be customs duties owe by me when they show up at my door?

Thx, Bill

330i ZHP

09-28-2007, 02:46 PM

in my case there was - $127 to FedEX for customs

323guy

09-28-2007, 02:52 PM

in my case there was - $127 to FedEX for customs

OK. Thx.

323guy

11-01-2007, 01:54 PM

Hi Bill,

Your kit is scheduled to ship out on Wednesday 26.

Hey Asbjorn, :hi:

Thanks for all your assistance during the install. I did have a question about the disabling of the crankcase vacuum sensor causing the 'Service Engine Soon' warning lite to be permenantly on now. So this is something I have to live with until the lite burns out? :drama:

330i ZHP

11-01-2007, 01:58 PM

why do you have a light? I dont have any...what went wrong

Lemonsqr

11-01-2007, 02:38 PM

Hey Asbjorn, :hi:

Thanks for all your assistance during the install. I did have a question about the disabling of the crankcase vacuum sensor causing the 'Service Engine Soon' warning lite to be permenantly on now. So this is something I have to live with until the lite burns out? :drama:

:hmm: dont recall this being something that happened on my install....

323guy

11-01-2007, 03:41 PM

why do you have a light? I dont have any...what went wrong

My mechanic, whom talked to Asjborn daily during the install on my 323 ran into several minor issues during the install process. The mechanic tells me the install disables the crankcase vacuum line sensor. Therefore the cpu thinks the sensor failed and turns on the light. he also tells me he had to trim the fan to solve clearance issues. I would have thought those issues would have made it into the installation guide. :hmm: And I would think a new software load would take care of the engine Light being on permenantly due to a planned disabled sensor. :hmm: Anyway, installation manual problems aside - the customer service provided by ESS Tuning, i.e. Asjborn was great!!! Other than the light issue - my car is running great. I only have 15 miles on it after 2 days however. Looking forward to getting over 200miles so I can get over 2500rpms. Great product. :hi:

Dirtboy

11-01-2007, 03:55 PM

The only connection that is bypassed in the install is the DISA valve on the stock intake. I don't remember seeing any "crankcase vacuum line sensor" I've never heard of a sensor like that either...

323guy

11-01-2007, 04:22 PM

The only connection that is bypassed in the install is the DISA valve on the stock intake. I don't remember seeing any "crankcase vacuum line sensor" I've never heard of a sensor like that either...

I'm just repeating what I thought I heard.:hmm: The shop did tell me they would give Asbjorn a call and see what he thought. We'll see.

Asbjorn@ESS

11-01-2007, 04:44 PM

Hey Asbjorn, :hi:

Thanks for all your assistance during the install. I did have a question about the disabling of the crankcase vacuum sensor causing the 'Service Engine Soon' warning lite to be permenantly on now. So this is something I have to live with until the lite burns out? :drama:

There is no such thing as a crankcase vacuum sensor on your engine. The CEL should obviously not be on. Check the error codes and report back to me what codes causes the CEL.

323guy

11-01-2007, 05:37 PM

There is no such thing as a crankcase vacuum sensor on your engine. The CEL should obviously not be on. Check the error codes and report back to me what codes causes the CEL.

:hi: Asbjorn,

I just spoke to Jack at J&J Motorsports and he says bring it in the morning and they'll read the code & give you a call. Apparently - Jack runs the place but isn't the mechanic whom did the install. Thanks again for the quick reply. With Jack being the only guy intown here that the local BMWCCA recommends and now he's familiar with your product you may see some additional orders out of my little town. Cheers.

Minnoe07

11-02-2007, 05:42 PM

Just sounds like your mechanic got something mixed up. Definitely don't have to disable any sensors and you shouldn't get a light coming up either. No clearance problems here either.

MarvelPhx

11-03-2007, 02:29 AM

Yes, the only sensor left disco'd is the DISA valve (which is removed entirely). This is will store a code, but will not throw the CEL. If you have a CEL, something else is wrong.

323guy

11-07-2007, 11:28 AM

Yes, the only sensor left disco'd is the DISA valve (which is removed entirely). This is will store a code, but will not throw the CEL. If you have a CEL, something else is wrong.

From local BMW dealers printout of DME fault codes:
>
>
> DME - (124) 7c Activation soleniod valve, intake
> manifold (DISA) (OBDII:P1593) -- Short circuit to
> negative or open circuit - Currently present....
>
> DME - (246) F6 Flow rate, sec.-air system too low,
> bank 2 (OBDII:P1421;EUIII:P0410) - Secondary air too
> low, bank 2 - CARB fault - currently not present -
> Sporadic fault....
>
> THE BMW dealer summarized it as: "Found FC's for DISA
> VALVE SND SECONDARY AIR INJECTION. Since supercharger
> installed DISA VALVE is now gone. Secondary air could
> be caused by supercharger install."

The install sage continues even at this moment. :censor:

I'm stuck in the middle between my (BMW trained) mechanic saying the install removed the parts and ESS is saying it ain't their fault. :argue:

The local BMW dealer test drove the car and said it now has the torque of a 330 (I have 2000 323i/automatic) I do find the torque to be increased. I don't notice any higher end HP...i.e. accelleration at highway speeds, i.e. 100k/h+ isn't any better than stock. The noise from the SC is sounds like an old VW bug. The engine always feels taxed when revving. Overall, the performance is way below my expectations. :banghead:
My minimum expectations - had a 1999 323is (automatic) w/ headers, exhaust, chip,CAI, pulleys and from a dead start & pedal to floor I would be thrown into my seat, tires would chirp in 1,2,3 gears....not 4th. Yes it was a E36 not a E46 like I have today.

My mechanic is going to remove the sensor box from the old manifold and just plug it in to the connector going to the DME and see if this clears up the CEL. And check the other codes too. I've asked him to check the boost/fuel pressure. I would love to see it on a dyno cause it don't feel like 250hp at all.

Understand my SC box arrived completely damaged in the shipping process from Norway. I sent pictures to ESS and emailed them & phone called them. The most obvious part that was damaged was the pulley which was attached on the end of the SC itself...so it was external. ESS replaced the pulley 2 weeks later coming from Norway. So looks I'm still spending $ with the local mechanic to get this one working. :tsk:

Lemonsqr

11-07-2007, 11:39 AM

This sounds like a pretty bad experience...GL, hope everything turns out...

330i ZHP

11-07-2007, 11:40 AM

mine is definitely a BIG difference - hell, my car is almost running in the 12s at the track (it was a 94deg day and I am hoping with the cool weather that it will do 12s)

EIAlfonso

11-07-2007, 12:37 PM

MarvelPhx

11-07-2007, 12:55 PM

Secondary air is not touched with the TS install. Its not even on the same side of the engine as the TS. Something else is wrong there, but even so, 2ndary air will not affect performance, neither will the DISA missing.

323guy

11-07-2007, 01:05 PM

Most, if not all, of the problems usually associated with the kit are install errors. Just keep an open mind and work with ESS to guide you in the right direction, this is just part of the modding process.

Did you get a baseline dyno? Once everything is sorted you should take it and get it dynoed to confirm proper operation.

Good Luck

The installed began Oct 9. Last week was the first time I'd seen the car at all. So trust me when I say I am keeping an open mind – and hence why I took the car to a 3rd party for diagnostics… the dealer and provided the local mechanic the printouts & posted them here - even though the mechanic has the exact same BMW DME fault reading machine as the dealer. Hindsite being 20/20 no I didn’t dyno before. But I found out the closest dyno is 75 miles away in Waterloo…fine. I want to see what the dyno says once the all faults are cleared up and get the guessing out of the equation. Something doesn't compute at this point and I want to get to the bottom of it. Thx.

Asbjorn@ESS

11-07-2007, 01:37 PM

The installed began Oct 9. Last week was the first time I'd seen the car at all. So trust me when I say I am keeping an open mind – and hence why I took the car to a 3rd party for diagnostics… the dealer and provided the local mechanic the printouts & posted them here - even though the mechanic has the exact same BMW DME fault reading machine as the dealer. Hindsite being 20/20 no I didn’t dyno before. But I found out the closest dyno is 75 miles away in Waterloo…fine. I want to see what the dyno says once the all faults are cleared up and get the guessing out of the equation. Something doesn't compute at this point and I want to get to the bottom of it. Thx.

As instructed by our tech on email :

1. Check boost pressure, verify it is correct.
2. Check fuel pressure, verify 44PSI idle and 58PSI full load.
3. Check AF ratio, if not correct you need a new MAF sensor.

The secondary air error has to be related to a malfunction with your secondary air pump or a disconnected wire to it. Check both. It will however not affect performance, it is stricly an emissions thing. We can even turn of it's presence in the DME as not all cars use this.

The 323 TS1 is a HUGE increase in power over stock, also at high speeds. Something is not correct with your install/hardware, once you have checked the above points we can diagnose further and lead you in the correct direction. Worst case we have to send you a tech.

aggieE46

11-07-2007, 03:01 PM

Asbjorn, sorry to thread hijack. Chad will probably leat you know, but I verified that the light never comes on. I'm currently trying to throw a CEL to make sure it actually works. Please shoot me an email back and let me know if there's anything I can try. I haven't heard back from you the last few times I've sent anything.

Asbjorn@ESS

11-07-2007, 03:07 PM

MarvelPhx

11-07-2007, 03:21 PM

The installed began Oct 9. Last week was the first time I'd seen the car at all. So trust me when I say I am keeping an open mind – and hence why I took the car to a 3rd party for diagnostics… the dealer and provided the local mechanic the printouts & posted them here - even though the mechanic has the exact same BMW DME fault reading machine as the dealer. Hindsite being 20/20 no I didn’t dyno before. But I found out the closest dyno is 75 miles away in Waterloo…fine. I want to see what the dyno says once the all faults are cleared up and get the guessing out of the equation. Something doesn't compute at this point and I want to get to the bottom of it. Thx.

If your tech has the same computer as BMW, then he would have seen that the secondary air flow error was causing the CEL. The DISA valve error is a shadow code and therefore will not trigger a CEL. So he either misread it or didnt see the code in the first place. The dealer then saw it correctly and that secondary flow error is what is causing your CEL (since it directly affects emissions controls). Every TS removes the DISA valve and noone gets a CEL for it as it doesn't affect emissions.

What I don't get is, since you have the TS1, there is no reason to even mess with that side of the engine. If I had to guess, I would bet that the electrical connector or wire to the pump got jacked on the install or, much less likely, the pump failed at a bad time. The TS install itself doesn't involve touching the 2nd air pump or anything attached to it.

I am just trying to say that not all technicians are perfect, no matter how they sell themselves. From all my experiences and talking with tons of FI companies and customers, like 95% of problems turn out to be install errors.

Keep going over the install, make sure it is correct and you may surprise yourself. It will work out. The kit is very well made.

323guy

11-07-2007, 05:54 PM

If your tech has the same computer as BMW, then he would have seen that the secondary air flow error was causing the CEL. The DISA valve error is a shadow code and therefore will not trigger a CEL. So he either misread it or didnt see the code in the first place. The dealer then saw it correctly and that secondary flow error is what is causing your CEL (since it directly affects emissions controls). Every TS removes the DISA valve and noone gets a CEL for it as it doesn't affect emissions.

What I don't get is, since you have the TS1, there is no reason to even mess with that side of the engine. If I had to guess, I would bet that the electrical connector or wire to the pump got jacked on the install or, much less likely, the pump failed at a bad time. The TS install itself doesn't involve touching the 2nd air pump or anything attached to it.

I am just trying to say that not all technicians are perfect, no matter how they sell themselves. From all my experiences and talking with tons of FI companies and customers, like 95% of problems turn out to be install errors.

Keep going over the install, make sure it is correct and you may surprise yourself. It will work out. The kit is very well made.

Yes - I'm aware human error is easy to do. Hence, why in my frustration, on day two of getting the car back I took it to the BMW dealer to have the fault codes read and then took them to the mechanic.... I knew something ain't correct somewheres. :hmm: Regarding ESS Tunings support to date very good. They have insured me all will be right in the end and I realy believe they will live up to their word. They just got off the phone with me telling me I must be satisfied with the product. They suggested the fuel pump could be the cause the of the lack of HP at highway speeds.

My biggest issue has been the time involved without the car...I just got it back last Friday and took it to dealer Monday and back to shop today, my appointment time... but he needs it overnight...again. This is the part that is very old. The shop time has been really lengthly:tsk:

323guy

11-08-2007, 10:33 AM

EIAlfonso

11-08-2007, 10:45 AM

323guy

11-08-2007, 12:11 PM

Your larger injectors are flowing more fuel than before, I believe about 20%

You need to subtract 20% from your indicated mileage to arrive at the actual number.

21.2 * .8 = 17 MPG

http://forum.e46fanatics.com/showthread.php?t=482174

Wow - working in the sensor business for over 20 years I just assumed the gas flow was being measured by a sensor, like that's hard:hmm:, and that mpg is calculated for real. Not via a hardcoded parameter in a table.

MarvelPhx

11-08-2007, 02:50 PM

Something I should mention is I did reset the gas mileage on the computer when I received the car and as of yesterday morning, after 120miles of which 80% was city traffic, I live in the city, the mpg was 21.2. Before the install it was 18. I did notice that since there is more torque at the low speeds I am pressing much less on the gas pedal to maintain the in city speed limits of 35mph. This is NOT something I expected. In fact, I expected the inverse. Any others with mpg comments one way or the other?

The reason has to do with how the KOMBI/IKE (instrument cluster) calculates that MPG value. It relies on a signal from the DME regarding fuel injector pulses. The pulses are counted, run thru a constant value stored in the cluster, and displayed. The cluster doesn't know the injectors are bigger unless you tell it they are by changing the constant stored within.

There isn't any "fuel flow rate" sensor in the car.

As for my TS, when I am just tooling around town, my mileage is pretty close to stock. When I am on it a lot, I get about 16mpg. My 3.38 LSD gears cost me WAY more gas than the TS does.