My ESS TS2 install, it all starts NOW! :)

[fmzip]

As some of you may know, I purchased Elio's TS2 kit. For those who haven't been following along:

http://forum.e46fanatics.com/showthread.php?t=518834




Had my baseline dyno run today. After the first pull and smoke coming out of the left rear wheel,maybe the strap was on the exhaust. :yikes:Hmmm.

Second run, coming to the end car maxs out at 150hp now theres flames shooting out of my caliper wtf?? :hmm:Jack up the car, wheel spins freely. Maybe the ebrake was stuck.

Next run, coming to an end the rotor is glowing red, real nice red flames coming out of my caliper.....:censor:
Take the wheel off, brake pads look fine. Take my brand new cross drilled rotor off that is now a nice glazy looking color, what do we find??? The smoldering remains of the ebrake pad....clean everything up, here's the results. One run in 4th, one in fifth. I guess these first runs all should have be done in 4th since it hits top speed in 5th before it hits redline, duh! Such a noobie on this stuff but oh well! Does this look normal/good? Car has 68K on it completely stock....old plugs, coils, fuel filter and fuel pump. All these items will be replaced in the process.

http://home.comcast.net/~francisminelli/bmw/dyno1.jpg
http://home.comcast.net/~francisminelli/bmw/dyno.jpg

[sheefo2k]

goodluck with the installation..

[Activ3]

Looks good!

[fmzip]

Baseline DYNO

http://home.comcast.net/~francisminelli/ESS/dyno1.jpg

[fmzip]

Started the project today! Since the car had 68K on it, I replaced the fuel pump, plugs, boots and coils. Still need to replace the fuel filter......

I then removed the ECU to send out to ESS. Then I took the bumper off and mounted the intercooler and pump. Here are some pics:

http://home.comcast.net/~francisminelli/ESS/plasma%20coils.JPG

[fmzip]

http://home.comcast.net/~francisminelli/ESS/cooler.JPG

[fmzip]

http://home.comcast.net/~francisminelli/ESS/bench%20ess.JPG

[fmzip]

http://home.comcast.net/~francisminelli/ESS/side%20car.JPG

[fmzip]

Sending the ECU to ESS tomorrow! :)

[ken330i]

wow! looking good so far. i can't wait to see it finished.

[Navin323i]

Sending the ECU to ESS tomorrow! :)

Our ECU's will probably arrive there at the same time (mine is being shipped out tommorrow as well). :thumbsup:

[m3on20z]

What's up Fern!

If you need help with anything, be sure to let me know! I'm not mechanically inclined at all, but I'd love to watch. :D

Hopefully everything goes smooth for you. :thumbup:

-Amar

[mcr_driver]

grats on the kit hope you enjoy s/c power :excited: i was when i got my s/c installed on my sedan

[EIAlfonso]

:cry::cry:
Good Luck, wondering when you were going to start

Power wise you look fine, even the 4K dip is there.

Make sure you get AFR's next time, it's really the most important part of the dyno run.

Oh and please show us what's behind the hood on the wall

[fmzip]

Hey Elio......

I'll make sure that I don't crop "her" out in the next pic. That's an autographed poster of Cheryl Bachman about 15 years ago :)

Hey Amar...I still have that Zaino sitting here for you too! You have a Benz now? E55, E350, E500? I had an 05 E320 for a couple years....it was white with a blue interior.....Love the white Benz!

Fran

[fmzip]

Navin......you mentioned the decal for the engine covers ships from somewhere else? Where is that? I'm thinking of pulling the trigger on the carbon fiber covers :)

[Navin323i]

Navin......you mentioned the decal for the engine covers ships from somewhere else? Where is that? I'm thinking of pulling the trigger on the carbon fiber covers :)

I have no idea... ESS is taking care of all that (they just told me that the engine cover decal would ship separately from the S/C and engine cover). :)

[fmzip]

I may have changed my mind on the covers.....this looks pretty nice....

Like to have some color:

http://i151.photobucket.com/albums/s136/mtech99/IMG_2050.jpg

[m3on20z]

Hey Elio......

Hey Amar...I still have that Zaino sitting here for you too! You have a Benz now? E55, E350, E500? I had an 05 E320 for a couple years....it was white with a blue interior.....Love the white Benz!

Fran

Oh yeah, we'll definitely have to meet up and I'll pick up the Zaino too! I actually got the lowest model Benz they had at the time (C230), but I have big plans for it during the Spring/Summer. :thumbup:

Maybe I'll get my DPE's and coilovers by the time you get the kit up and running, and we can meet up then. :)

And sorry about butchering your name, I knew it began with an 'f" and ended with an "n". :(

[fmzip]

Which to get? This still looks nice too:
http://home.comcast.net/~francisminelli/ESS/Z4%2015.jpg

[bernstem]

I have never been a fan of plain carbon fiber for engine covers. The engine bay is boring enough already so some color looks good, but it has to match the rest of your car. Looks like your interior is grey so no worries there. Plan on a BBK in a matching color, custom trunk for your ICE in the same color, etc...

[fmzip]

Although, my car is grey and black.....the ESS covers look really nice too. They are $100 more.........what to do??

[Navin323i]

Which to get? This still looks nice too:
http://home.comcast.net/~francisminelli/ESS/Z4%2015.jpg

Wow... that's different than the other ESS CF engine covers I've seen... i was only aware of 2 kinds... one that just says ESS with the lines like the OEM BMW cover, and the other one which has a decal that says, "Supercharged by ESS Tuning".

Yeah, you have a tough choice... the red one you posted looks nice, especially if your goal is to add more color to your engine bay. :)

[fmzip]

So which one are you getting Navin? Maybe the guys from ESS can chime in as to what is available.

This picture came off the installation CD I got from ESS

[Navin323i]

So which one are you getting Navin? Maybe the guys from ESS can chime in as to what is available.

This picture came off the installation CD I got from ESS

I actually posted the pic of the CF engine cover in the opening post of my S/C thread in the FI forum (you probably overlooked it earlier) :)

See Post #1 here...

http://forum.e46fanatics.com/showthread.php?t=557165

[fmzip]

I knew I saw that picture somewhere! I'm having a tought time deciding, there is a big difference in price between the two....I may have to be practical on this!

What gauges did you decide on? I have a spare ashtray which I plan to use since I have NAV.

[Navin323i]

I knew I saw that picture somewhere! I'm having a tought time deciding, there is a big difference in price between the two....I may have to be practical on this!

What gauges did you decide on? I have a spare ashtray which I plan to use since I have NAV.

Good luck on the CF engine cover purchase! Either way you won't go wrong! :)

I decided on the VDO Vision Series gauges. I saw Stuart's (330i ZHP) gauge setup earlier this past weekend (he has the boost, oil temp, and oil pressure gauges mounted in the LeatherZ gauge panel that gets placed in the sunglass holder area) and I really liked that setup... I could see the gauges PERFECTLY and they didn't seem too low or anything.

In fact, I was at a car shop open house and they wound up having a brand new VDO oil temp gauge still in it's original packaging so they gave me a good discount on it and I purchased it. So I only need the boost and oil pressure gauges now.

My mechanic is going to help me out by installing whatever sensors/wires/tubing needed so that I can take my time to purchase the other 2 gauges and all that would be needed at that time would be to connect the gauges to the wiring he puts in place this week.

[fmzip]

I was reading your posts and I was going to suggest you run the wires etc while you were doing the install.

I just ordered a uuc gauge plate that I will make fit where the ashtray was. I was curious if Stuart was able to get the leather z "block" to fit with his setup or not......

[Navin323i]

I was reading your posts and I was going to suggest you run the wires etc while you were doing the install.

I just ordered a uuc gauge plate that I will make fit where the ashtray was. I was curious if Stuart was able to get the leather z "block" to fit with his setup or not......

Yeah, if you mean the leather gauge panel that LeatherZ sells then yes, Stuart has that setup in his car... basically that panel replaces the sunglass holder area as you already know. :)

I've never seen the UUC gauge plate... pics?

[fmzip]

The UUC panel is just silver.....it can be painted any color. It goes in the same spot as the Leather Z kit. This is a pic of Tim's car. I am planning to do the same.

Maybe you could get a carbon fiber overlay if you go with the UUC one! ;)

http://www.e46fanatics.com/members/tim330i/gauges/pmti0003_1024.jpg

http://forum.e46fanatics.com/attachment.php?attachmentid=141534&stc=1&d=1125184772

[fmzip]

Ended up ordering the Radenergie CF engine covers from Nick!

Red it is! :)

[Navin323i]

The UUC panel is just silver.....it can be painted any color. It goes in the same spot as the Leather Z kit. This is a pic of Tim's car. I am planning to do the same.

Maybe you could get a carbon fiber overlay if you go with the UUC one! ;)

http://www.e46fanatics.com/members/tim330i/gauges/pmti0003_1024.jpg

http://forum.e46fanatics.com/attachment.php?attachmentid=141534&stc=1&d=1125184772

Is that where the UUC silver one normally gets installed? If so then it's not the same spot as the LeatherZ one... the LeatherZ one installs where the sunglass holder is whereas in that pic of Tim's car the silver panel is where the ashtray resides.

Congrats on the engine cover! Can't wait to see pics when it's all done! :-)

Oh, and I actually am seriously thinking about getting the gauge panel wrapped in CF. :shhh: :)

[fmzip]

This is the spot for the UUC panel, same as leatherZ. To put it in the ashtray, it needs modification. Here is another picture:


http://forum.e46fanatics.com/attachment.php?attachmentid=141534&stc=1&d=1125184772

[fmzip]

Here's my ashtray area before:

http://home.comcast.net/~francisminelli/ESS/ashtray%20before.jpg

[fmzip]

Taking it apart:

http://home.comcast.net/~francisminelli/ESS/climate%20control%20removal.jpg

[fmzip]

I dremeled the entire ashtray apart, UUC gauge panel is on its way:

http://home.comcast.net/~francisminelli/ESS/ashtray%20mod.JPG

[Lay2Low]

Looks great, congrats on the TS2!

[Navin323i]

That looks great, Fran! One question though... what would you do if you needed to plug something in your cigarette lighter... is that no longer an option for you?

[fmzip]

Everthing is hardwired in my car, cellphone cradle, radar detector etc. I have one of these if necessary, it plugs into your glovebox where your flashlight goes:

http://www.amazon.com/BMW-Genuine-Au...410323&sr=1-11

http://ecx.images-amazon.com/images/I/41MzoRapgBL._SS400_.jpg



That looks great, Fran! One question though... what would you do if you needed to plug something in your cigarette lighter... is that no longer an option for you?

[spartanwarrior]

Looking really good:thumbsup:

[330i ZHP]

cool - keep us updated with the install

why is the heat exchanger so dinged up?

[fmzip]

cool - keep us updated with the install

why is the heat exchanger so dinged up?


This is a used kit....it's close to the road

[fmzip]

Well....got the manifold off! The mystery bolt was extremely hard to find, Bentley manual to the rescue! It was easy to get off once I found it! I snapped a pretty good picture which should give the next person a better idea where it is!

I used a deep 3/8 16mm socket, swivel then an extension



http://home.comcast.net/~francisminelli/ESS/mystery%20bolt.JPG

[fmzip]

Then the last connections under the manifold:

http://home.comcast.net/~francisminelli/ESS/final%20fitting.JPG

[fmzip]

Here's me thinking of 50% more HP!! :)

http://home.comcast.net/~francisminelli/ESS/gitty.JPG

[ken330i]

Fran, I didn't see your saliva drifting down, howcome? haha. j/k bro. Looking good so far.

[fmzip]

Thanks Ken........The pic was taken after I was drool-free :)

[fmzip]

...

[Navin323i]

Here's me thinking of 50% more HP!! :)

http://home.comcast.net/~francisminelli/ESS/gitty.JPG

:rofl:

GREAT job on the install thus far, Fran!

On a separate note, ESS sent me a free limited edition T-shirt (XL size) with my order (see my S/C thread (with the subject heading "It's OFFICIAL...") for the pics of the shirt), and I may have to order a second one in XXL size just to see which one fits me better... if you're interested in the one that doesn't fit me (assuming it fits you) just let me know and I'll sell it to you for the same price I bought the 2nd shirt for (I'm waiting to hear back how much the shirt is). :)

[kerisabe]

lookin good so far, all the best. please keep us updated on the install!

[330i ZHP]

Well....got the manifold off! The mystery bolt was extremely hard to find, Bentley manual to the rescue! It was easy to get off once I found it! I snapped a pretty good picture which should give the next person a better idea where it is!

I used a deep 3/8 16mm socket, swivel then an extension



http://home.comcast.net/~francisminelli/ESS/mystery%20bolt.JPG

That bolt was a biotch to get to.

lookin good so far, all the best. please keep us updated on the install!

+1

[fmzip]

couple of questions...... Since I have 68K on the car, should I get a new ICV while I am at it? Whats the easiest way to clean the head where the new gasket will be seated?

[TxZHP04]

couple of questions...... Since I have 68K on the car, should I get a new ICV while I am at it?

I did but I don't know that it's essential. Cleaning the existing ICV may be plenty. I went new because I wanted extra insurance against having to pull the manifold again any time soon to fix an old part that had failed.

[Navin323i]

I did but I don't know that it's essential. Cleaning the existing ICV may be plenty. I went new because I wanted extra insurance against having to pull the manifold again any time soon to fix an old part that had failed.

What's an ICV? Is this something I should have had replaced in my step tranny car or is cleaning it sufficient enough? My car just hit 60k miles.

[Custom3]

nice thread...good luck

[TxZHP04]

Idle control valve. If you didn't clean it or replace it while the manifold was out, I wouldn't worry about it.

[Navin323i]

Idle control valve. If you didn't clean it or replace it while the manifold was out, I wouldn't worry about it.

Thanks for the heads up, Darren... I'll double check with my mechanic tommorrow and see if he cleaned, replaced, or did nothing with the ICV (FINALLY pick up my car tommorrow!! :woot: )

[fmzip]

What do you guys think this is from? Antifreeze?

http://home.comcast.net/~francisminelli/ESS/whats%20this.JPG

[330i ZHP]

i wonder if the coolant sensor was leaking at some point? Or if you have the waterpump, or the antifreexe changed - maybe the mechanic let some get out.

[fmzip]

All my wires are taped up...Also installed the oil distribution block from LeatherZ, ran the wires for the oil temp, oil pressure and boost gauges.....

http://home.comcast.net/~francisminelli/ESS/pullies.jpg
http://home.comcast.net/~francisminelli/ESS/disti%20block1.JPG

[fmzip]

Where is this supposed to mount? I see where it gets plugged into for both vaccum and electrical but how does it get mounted???

http://home.comcast.net/~francisminelli/ESS/where%20to%20mount.JPG

[330i ZHP]

i cant remember - but arent those wires too bundled???

referring to the wires loomed, taped and zip tied

[fmzip]

I will do a dry mount first.....I believe I have plenty slack with all the individual wires.......Might be the camera angle. All the individual connections are not in that picture, I have them out of the way. You can actually see one label in the right hand side of the picture, all other connections reach the master cylinder bay. Shortest one is the ICV which still should be plenty long

[fmzip]

And where does this mount??

http://home.comcast.net/~francisminelli/ESS/where%20to%20mount2.jpg

[fmzip]

This gives you a better perspective of the length of each connection, the shortest is the ICV.

http://home.comcast.net/~francisminelli/ESS/wire%20length.jpg

http://home.comcast.net/~francisminelli/ESS/wire%20length2.jpg

[fmzip]

I did but I don't know that it's essential. Cleaning the existing ICV may be plenty. I went new because I wanted extra insurance against having to pull the manifold again any time soon to fix an old part that had failed.


Mine looks clean, extremely clean.......Would it really be necessary to pull the entire manifold off if the ICV fails in the future??

[TxZHP04]

Mine looks clean, extremely clean.......Would it really be necessary to pull the entire manifold off if the ICV fails in the future??

Removing the manifold would most likely be the easiest way. Look at your pics, getting to it from underneath would be a nightmare.

[fmzip]

Removing the manifold would most likely be the easiest way. Look at your pics, getting to it from underneath would be a nightmare.

It doesn't look too bad here, provided I could access the clamps to the ICV
http://home.comcast.net/~francisminelli/ESS/side%20view.jpg

[330i ZHP]

looking good

[elite53]

I just zip tied both those pictured items to the closest hose or bundle of wires I could find so they wouldn't move around. They dont have an actual mounting point like they did on the stock manifold.

[Lemonsqr]

What do you guys think this is from? Antifreeze?

http://home.comcast.net/~francisminelli/ESS/whats%20this.JPG
That is coolant...looks like your thermostat housing gasket might be leaking. I would change it if I were you.

[fmzip]

I just zip tied both those pictured items to the closest hose or bundle of wires I could find so they wouldn't move around. They dont have an actual mounting point like they did on the stock manifold.

That is coolant...looks like your thermostat housing gasket might be leaking. I would change it if I were you.


Thanks for the input guys...I will make sure I take care of both as directed!

I just got back from my machine shop. I am going to have a custom faceplate made to hold three gauges in the ashtray area. Should have it back in a few days. We decided to andodize it a burnished black to blend with the dash pieces.

I may have him build up 10-20pcs if there is interest in an ashtray mounted gauge solution for the Nav owners in the forum.

[fmzip]

Decided not to take any chances.....just ordered a new thermostat housing, waterpump, gaskets and an idle control valve.

Once I am done, I hope the only time "I" will be popping the hood will be to look at "IT" :)

[fmzip]

Here's a tip for the next person who tackles this project. A somewhat time consuming part is to tape up all those wires. A cleaner, much faster way would be to spend a few bucks on this 1/4'' Flame Retardant Slit Wire Loom! I was thinking about this stuff as my 41 year old back was aching yesterday with a roll of electrical tape in my hand

http://www.wiringproducts.com/index1.html

[330i ZHP]

That is exactly what I used - in black of course

[330i ZHP]

and I also used the same brand and style cloth based tape BMW uses when I needed to use tape

[fmzip]

^^^^^ ah....you are as anal as me I see! :)

The only thing making this "tape job" acceptable is that it will never be seen. I just need to keep saying that to myself and it will all be okay....;)

[330i ZHP]

it will - and like you said - all the extra time I put into the cloth tape cant be seen

[MarvelPhx]

I love seeing threads like this... DIY teaches people how to graduate from just being a driver to being a OWNER!

[fmzip]

I love seeing threads like this... DIY teaches people how to graduate from just being a driver to being a OWNER!
Your website has been a huge help! I was toying with tackling this type of project for many years dating back to 1990 with my 5.0 Mustang GT.

Your site as well as this one gave me the needed confidence to take my BMW apart and put it back together again!

Thanks, many thanks! :)

[Navin323i]

I love seeing threads like this... DIY teaches people how to graduate from just being a driver to being a OWNER!

I don't know if I can fully agree with this statement... some people like myself aren't able to do this particular S/C DIY due to medical reasons, therefore I require assistance from a professional... I still consider myself both a driver and owner. :)

I have done more simpler DIY's such as interior trim install and it was very gratifying to me once I completed the project myself. :)

[ken330i]

now, it makes me think whether I should DIY my future SC or not. It's always true some where in the line there's a problem or two that's so hard to figure out in most of the so called, "In depth" installation.

[fmzip]

now, it makes me think whether I should DIY my future SC or not. It's always true some where in the line there's a problem or two that's so hard to figure out in most of the so called, "In depth" installation.

Ken,

Here was my feeling on to DIY or pay a professional. From what I read on the forums, quite a number of people ran into install problems when they hired a professional. Unless I could find an installer that had experience with FI on BMW's, I was commited to DIY.

I think if you have a Bentley manual, the appropriate tools, metric hex bits, torx bits, 3/8 and 1/2in metric sockets wrenches, a real floor jack, jack stands and expereince working on cars, you can tackle it. When I say experiece, I mean experience.

Just to give you an idea of my experience, I am 41, I've pulled engines swapped trannys etc. Even with that kind of experience I was still intimidated by the pletheroa of lines, hoses and electrical connections underneath the hood of the car. The thing that I questioned was do I still have the patience to do this kind of work! The most important thing you need that you will not find in your tool box is patience and time.

Fortuantely, I have no time constraints on finishing this project which has helped me immensely. This allows me to thoroughly read and comprehend the install instructions before I proceed. I would suggest if you are contemplating a DIY, get yourself the install manual from ESS and read it over. It really is one of the most thorough install manuals I have seen. There are a few vague areas, like finding the hidden manifold bolt that I took a picture of! Other than that and the mounting of the few items I snapped pictures of, it looks alot more complicated than it really is.

We're here for ya Ken if you decide to tackle it!

[fmzip]

Stuart.....did you find that split loom locally at a auto parts store?

[silver330ciman]

Nice progress. I was a bit confused about some electrical connections myself, but they all seem to match up nicely, even the couple that aren't as clearly listed in the ESS manual. Oh and I'd keep the pulley off until you're ready to put the belt in there. Keep us posted!

[330i ZHP]

I don't know if I can fully agree with this statement... some people like myself aren't able to do this particular S/C DIY due to medical reasons, therefore I require assistance from a professional... I still consider myself both a driver and owner. :)

I have done more simpler DIY's such as interior trim install and it was very gratifying to me once I completed the project myself. :)

Your last sentence completely makes his point - you have the pride of knowing you did stuff to your car yourself - we ALLLLLL understand you have your limitations (I think people who dont own E46's yet know too,...jk bud). So no one is knocking you for not doing the install. But Todd is 100% right, doing it yourself and getting everything working is such a high...its incredible. I am scared and excited all at the same time about taking my engine apart soon. I will either fail and have to call on "professionals" that in the past have made matters worse - or I will be successful and be happy as a lark.

/rant

now, it makes me think whether I should DIY my future SC or not. It's always true some where in the line there's a problem or two that's so hard to figure out in most of the so called, "In depth" installation.

Do it yourself - less problems I think and if there is a problem - you will know where and what to look for instead of relying on a "professional" to fuk things up more.

Ken,

Here was my feeling on to DIY or pay a professional. From what I read on the forums, quite a number of people ran into install problems when they hired a professional. Unless I could find an installer that had experience with FI on BMW's, I was commited to DIY.

I think if you have a Bentley manual, the appropriate tools, metric hex bits, torx bits, 3/8 and 1/2in metric sockets wrenches, a real floor jack, jack stands and expereince working on cars, you can tackle it. When I say experiece, I mean experience.

Just to give you an idea of my experience, I am 41, I've pulled engines swapped trannys etc. Even with that kind of experience I was still intimidated by the pletheroa of lines, hoses and electrical connections underneath the hood of the car. The thing that I questioned was do I still have the patience to do this kind of work! The most important thing you need that you will not find in your tool box is patience and time.

Fortuantely, I have no time constraints on finishing this project which has helped me immensely. This allows me to thoroughly read and comprehend the install instructions before I proceed. I would suggest if you are contemplating a DIY, get yourself the install manual from ESS and read it over. It really is one of the most thorough install manuals I have seen. There are a few vague areas, like finding the hidden manifold bolt that I took a picture of! Other than that and the mounting of the few items I snapped pictures of, it looks alot more complicated than it really is.

We're here for ya Ken if you decide to tackle it!

+eleventy millionz

Stuart.....did you find that split loom locally at a auto parts store?

Yes - the local NAPA store had the split loom and the cloth wrap

[Navin323i]

Your last sentence completely makes his point - you have the pride of knowing you did stuff to your car yourself - we ALLLLLL understand you have your limitations (I think people who dont own E46's yet know too,...jk bud). So no one is knocking you for not doing the install. But Todd is 100% right, doing it yourself and getting everything working is such a high...its incredible. I am scared and excited all at the same time about taking my engine apart soon. I will either fail and have to call on "professionals" that in the past have made matters worse - or I will be successful and be happy as a lark.



I agree. :thumbsup:

Check out my pics in my thread, Stuart... only thing that I'll need my mechanic to address is the PS reservoir tank needing to sit lower... other than that... WOW! That one word sums up how I feel right now. :D

[TxZHP04]

Congrats Navin! Glad this has all come together to your satisfaction.

- oops, wrong thread!

[Navin323i]

Congrats Navin! Glad this has all come together to your satisfaction.

- oops, wrong thread!

:rofl: Thanks Darren! I'm sure Fran won't mind... we've been posting so much in each other's threads that even I get confused sometimes which thread is which, LOL.

By the way Fran, you look a lot YOUNGER than 41 (I would never have guessed that to be your age). :thumbsup:

[330i ZHP]

damn - Fran is 41 - he has me beat by a year...he does look young

[elite53]

damn - Fran is 41 - he has me beat by a year...he does look young

That new TS3 you just bought will make you look years younger too.:rofl:

[Navin323i]

damn - Fran is 41 - he has me beat by a year...he does look young

Stuart here on the other hand looks old enough to be my dad... j/k. :D

I'm a very old 34 by the way, Fran. :)

[330i ZHP]

That new TS3 you just bought will make you look years younger too.:rofl:

nothing will make me look younger but losing weight and having hair replanted like a garden....

i just play like a yungun

[elite53]

Keep those dark tinted windows rolled up and nobody will know the difference.:) Fresh air is overrated anyways.

[fmzip]

:rofl: The winter wooly adds 10 years....I'm pretty bald underneath!

Never the else, I'll take the kudos anyway I can get them!

[Navin323i]

nothing will make me look younger but losing weight and having hair replanted like a garden....

i just play like a yungun

Congrats on the TS3 purchase! Was this recent?

[DrM3]

do work

[fmzip]

TS3 Stuart??? Really??

[330i ZHP]

yep - collecting the parts and I will pull the motor and trans after the wedding and start the tear down and re-build.

[fmzip]

Congrats Stuart!! Is the TS3 going to be a DIY??

[fmzip]

Replaced the ICV, thermostat housing, and water pump tonight.

Interesting comparison of the water pumps, the old one is on the left.......the internals look like something I made in shop class!

Super easy DIY....gotta love the O-rings, it makes life very easy!

http://home.comcast.net/~francisminelli/ESS/no%20pumps.jpg
http://home.comcast.net/~francisminelli/ESS/pump%20comparison.jpg

[330i ZHP]

Congrats Stuart!! Is the TS3 going to be a DIY??

yes - hopefully it wont take too long

Replaced the ICV, thermostat housing, and water pump tonight.

Interesting comparison of the water pumps, the old one is on the left.......the internals look like something I made in shop class!

Super easy DIY....gotta love the O-rings, it makes life very easy!

http://home.comcast.net/~francisminelli/ESS/no%20pumps.jpg
http://home.comcast.net/~francisminelli/ESS/pump%20comparison.jpg

what brand is the new pump?

[fmzip]

Stuart.....the Brand is GEBA, Made in Germany, bought it from Bavarian Autosport under the BMW part number.

Thinking ahead, I need to tap in for a boost gauge. The labels on the intake for the vacuum lines say "orig fuel pump reg" and on the other it is "T"'d and is labeled "EGR and exhuast flap". I have something to plug into each of those connections already.

Can I just add another "T" on the one that says "fuel pressure regulator" and pick up vaccum for the boost gauge there?

[fmzip]

HELP!!!

I am stuck....I have too many vaccum lines and not enough connections.

The first pic I circled a hose which leads up around back of the firewall and used to plug into my intake. Where it is to connect to now, I do not know. The second picture, I believe is the EGR valve as pictured in the ESS install manual. This connects to the TS2. The third pic is for the fuel pressure regulator which is clearly labeled on the TS2. The four pic is for the exhaust flap which is clearly labeled on the TS2. I also need to hook up a boost gauge.

So I have 5 vaccum lines with only three connections....HELP!!! I am stuck.

http://home.comcast.net/~francisminelli/ESS/vaccum1.jpg
http://home.comcast.net/~francisminelli/ESS/vaccum2.jpg
http://home.comcast.net/~francisminelli/ESS/fuel%20pressure%20hose.jpg
http://home.comcast.net/~francisminelli/ESS/canister.jpg

[aggieE46]

For the gauge, you'll just have to T into something. Probably the FPR, but don't quote me on that. I've only worked on turbo'd cars, not S/Cd.

As for the first picture, if it just went into the intake, it can PROBABLY just T in somewhere as well.

[fmzip]

Gotta love this forum! DKE46T "Dave" saw I was in need of some help. He stopped over and we managed to get it in!

Thanks again Dave! It's looking good! It amazes me how this thing "just" fits in there!

Thanks Stuart for pointing out to make certain to connect that lower hose "first" before you actually seat the manifold! It's real tight back there!

http://home.comcast.net/~francisminelli/ESS/Home%20stretch.jpg
http://home.comcast.net/~francisminelli/ESS/Home%20stretch%202%20.jpg

[330i ZHP]

moving right along - did you figure out the vacuum lines? I dont remember touching any lines on the exhaust side of the motor

[fmzip]

Stuart, that picture of the unit on the exhaust side was to show where the vaccum line begins. It connected to the bottom side of the OEM intake.

Dave and I went to Autozone and picked up some vaccum fittings. They obviously need to connect somewhere, we're assuming the vacuum fitting on the TS2 labeled "EGR and exhaust flap", leaving the vaccum line for the fuel pressure regulator independant of everything.

Hopefully ESS can chime in for a defintive answer

[dke46T]

Thanks Fran i'm glad to be a part of this, the unit fits nice and snugg as it should. A few more little things and your ready to go..... Dont forget about the silicone coupler ill have to stop by and grab that so I can fab up what we talked about.

Talk to you soon.

Dave

[fmzip]

Dave and I were trying to brain storm on a way to dress up/replace the silcone sleeve. It's an eyesore!

[dke46T]

Dont worry we will def get that taken care of. I think I have all the material for it if not ill order some up tommorrow. I think the sleeve will match nicely with the lip of the SSR GT3's after a little polishing.

[fmzip]

A polished sleeve would be awesome if you can pull it off....

:)

[dke46T]

Ohh oh is this a challenge ??? Hmmmm... I know I have some heavy duty aluminum foil somewhere. LOL ... Dont worry its all Under Control.

[fmzip]

Aluminum foil may look better than that silicone sleeve!! I'll take it!

:)

[dke46T]

Give me a call tom sometime... Hope to hear from you soon.

[elite53]

The vacuum line in picture #1 connects to the electric valve in picture #2. I think its called the Exhaust Gas Recirculation valve.

The black and white checkvalve in picture #2 connects to the lower vacuum line coming off the back of the intake manifold. The one with the T-fitting in it. One side of the T-fitting is for the check valve and the other is for your exhaust flap valve shown in picture #4

The hose in picture #3 goes to the upper vacuum hose on the intake manifold marked Original Fuel Pressure Regulator.

[dke46T]

There you go Fran just like we had stated about the vacum lines.... Thanks for the help elite53....

[330i ZHP]

you go elite53 - i remember now that i had to block off the flapper valve thing - since i didnt have one

[dke46T]

Hope all is well Fran lets get this thing finished up you know you would have rather had the top down driving to work today ??? Its like 80 Deg outside and not a cloud in the sky......

Dave

[MarvelPhx]

Also, I believe the black "tank" is your charcoal filter and should be connected to the fuel vent purge valve which then connects the vacuum side of the TS on the bottom of the intake elbow so it sees vacuum.

[fmzip]

Also, I believe the black "tank" is your charcoal filter and should be connected to the fuel vent purge valve which then connects the vacuum side of the TS on the bottom of the intake elbow so it sees vacuum.

If you still have your install manual, picture number 30 shows the Fuel vent purge valve. The vaccum connection is a quick disconnect fitting shown in picture 138 which is a 3/8 line that goes under the car.

[fmzip]

The vaccum lines in pictures 1 and 2 were connected to the intake as shown in the install manual in picture 41.

I guess the only question is where did the "blank tank" connect to originally? And isn't it the exhaust flap gizmo??

[fmzip]

For the gauge, you'll just have to T into something. Probably the FPR, but don't quote me on that. I've only worked on turbo'd cars, not S/Cd.

As for the first picture, if it just went into the intake, it can PROBABLY just T in somewhere as well.

Just an FYI for others....ESS specifically states to not connect anything to the vaccum line Labeled "original fuel pressure regulator" other than the original fuel pressure regulator. A boost gauge needs to be connected to the other vaccum fitting

[fmzip]

Ahhhhhhhhhhh....figured it out! The EGR valve actuator is snapped! The EGR valve vaccum line connects to this acuator and then the ACTUATOR vaccum line connects to the manifold.

This would have been a vaccum leak!

Thanks for the help guys, forced me to look real hard at it!

Guess I will need to get a new one ASAP
http://home.comcast.net/~francisminelli/ESS/where%20to%20mount.JPG
http://home.comcast.net/~francisminelli/ESS/Broken.jpg

Dave....I'll give you a buzz this weekend.

[330i ZHP]

Connecticut Law Is In Effect....sounds scary

[HighBoostin330]

Connecticut Law Is In Effect....sounds scary

What is Connecticut Law? :hmm: Educate me Stuart. :)

[dke46T]

Sounds good Fran im glad you looked over everything before getting everything together and then finding a problem...

Dave

[fmzip]

Connecticut Law Is In Effect....sounds scary

What is Connecticut Law? :hmm: Educate me Stuart. :)

Look at the piece of paper in the pic of the broken actuator.

In Connecticut, we have to submit an application to the State in order to suck more air through our intakes......depending on the volume of air, the appropraite tax then gets levied.

Never year they are implimenting the "Air we Breathe" Tax...... :)

[330i ZHP]

What is Connecticut Law? :hmm: Educate me Stuart. :)

I was reading the paperwork in the PIC

Look at the piece of paper in the pic of the broken actuator.

In Connecticut, we have to submit an application to the State in order to suck more air through our intakes......depending on the volume of air, the appropraite tax then gets levied.

Never year they are implimenting the "Air we Breathe" Tax...... :)

Really??? wtf...that is some funny isht

[fmzip]

Just messin with ya on both accounts....:)

[330i ZHP]

oh, ok

[Lemonsqr]

Just messin with ya on both accounts....:)
:thumbsup:nice, almost got me on that FI Tax!:rofl:

[330i ZHP]

Fran - is it running yet?

[fmzip]

Got a little bit of work done today......

Gotta say, this panel was not at all fun to get back in.

http://home.comcast.net/~francisminelli/ESS/panel.jpg
http://home.comcast.net/~francisminelli/ESS/panel%20installed.jpg

[fmzip]

I got my faceplate back from the machine shop....talk about tight tolerances, there were just a few millimeters of aluminum at the bottom of the facelplate once the holes were made.

Tim......I still don't know how you accomplished this with a dremel!
http://home.comcast.net/~francisminelli/ESS/gauges%20in%20ashtray.jpg

[fmzip]

http://home.comcast.net/~francisminelli/ESS/gauges%20in%20ashtray%20just%20fit.jpg

[fmzip]

http://home.comcast.net/~francisminelli/ESS/ashtray%20back.jpg

[fmzip]

Fran - is it running yet? Getting closer Stuart......by weeks end at the latest!

:thumbsup:nice, almost got me on that FI Tax!:rofl: Scary part is it's almost very believable! Better delete my post before the politicans buy into by idea!

[HighBoostin330]

FYI, I have the hole drilled as it is required for the TS3 kit. The Performance BMW intake costs a pretty penny, so AJ said it wasn't worth it and just instructed us to have the airbox drilled.

BTW, what email address are you emailing AJ at? I have sent him a couple of emails, but have yet to hear back from him. :(

http://img.photobucket.com/albums/v175/AzN2k4/airboxhole.jpg

[fmzip]

FYI, I have the hole drilled as it is required for the TS3 kit. The Performance BMW intake costs a pretty penny, so AJ said it wasn't worth it and just instructed us to have the airbox drilled.

BTW, what email address are you emailing AJ at? I have sent him a couple of emails, but have yet to hear back from him. :(

http://img.photobucket.com/albums/v175/AzN2k4/airboxhole.jpg

I sent you his email via PM.... thanks for the photo, I am headed to the garage to rip that hole!

I was contemplating the BMW Performance Intake myself, it is too much money.....

[HighBoostin330]

I sent you his email via PM.... thanks for the photo, I am headed to the garage to rip that hole!

I was contemplating the BMW Performance Intake myself, it is too much money.....

Great minds think alike. ;)

[330i ZHP]

I didnt have to remove that panel (didnt even know it could come out)

[fmzip]

Something doesn't look right....looks like the intercooler needs to go up a few inches since this shroud doesn't reach it's mounting point.


http://home.comcast.net/~francisminelli/ESS/cooler1.jpg
http://home.comcast.net/~francisminelli/ESS/cooler2.jpg
http://home.comcast.net/~francisminelli/ESS/cooler3.jpg

[TxZHP04]

I think most of us just ditch the shroud. I think Todd cut his to fit, you might check his DIY. I didn't reinstall mine... maybe if I'm feeling ambitious one weekend and have nothing else to do.

[HighBoostin330]

I just wanted to update you about AJ notifying me of a European Air Filter for our cars which does not have the foam piece on the paper intake filter. The below picture shows the new air filter without the foam on the left and the old air filter with the foam removed with leftover adhesive foam residue. The second picture is of the box the new paper intake filter came in. I used a Mahle LX343 filter. I hope this helps. :)

http://img.photobucket.com/albums/v175/AzN2k4/Old-newairfilter.jpg

http://img.photobucket.com/albums/v175/AzN2k4/AirFilter.jpg

[fmzip]

Thanks for the heads up.....but what does this mean to me? :)

I think I just put a Mann filter in if I am not mistaken; I swear it looks like the one on the left.......

[fmzip]

I think most of us just ditch the shroud. I think Todd cut his to fit, you might check his DIY. I didn't reinstall mine... maybe if I'm feeling ambitious one weekend and have nothing else to do.

I noticed in the ESS instructions they have theirs reinstalled but make no mention of how they did it.....Thanks for the heads up on Todd's site, looks like he cut the lower half off.

[330i ZHP]

I had to dremel mine to fit - you will have to cut a notch in the lower shroud to make it fit properly - I also cut small notches for the hoses to pass through

[fmzip]

Just curious, did everyone use "distilled" water to mix 50/50 with the coolant as per the instructions for the intercooler? What's the reasoning behind this?

[TxZHP04]

Just curious, did everyone use "distilled" water to mix 50/50 with the coolant as per the instructions for the intercooler? What's the reasoning behind this?

Same reason you do this with your radiator - tap water contains impurities that can be harmful to your cooling system. And yes, I always mix with distilled water.

[330i ZHP]

+1

[fmzip]

As you can see, I haven't been under the hood in 20 years, used to use a garden hose and Prestone II in the old'n day!

They carry distilled water at the grocery store, right?? :)

[330i ZHP]

yes

[fmzip]

Well, I modified the shroud, more work than it's worth I think....
http://home.comcast.net/~francisminelli/ESS/modified%20shroud.jpg

[fmzip]

Installed a new fuel filter too.....


http://home.comcast.net/~francisminelli/ESS/fuel%20filter.jpg

It's starting to look like it's ready to run!

http://home.comcast.net/~francisminelli/ESS/almost%20there.jpg

[Minnoe07]

Yea, I definitely just ditched the shroud. It definitely didn't seem functional enough for me to spend the time to dremel it to keep. :eek:

Install is looking good.

[fmzip]

Yea, I definitely just ditched the shroud. It definitely didn't seem functional enough for me to spend the time to dremel it to keep. :eek:

Install is looking good.


Thanks.....

Got the gauges installed today, UPS delivered the Redline power steering fluid and oil filter.....might be able to start it up tomorrow! :thumbsup:

http://home.comcast.net/~francisminelli/ESS/gauges%20wired.jpg
http://home.comcast.net/~francisminelli/ESS/gauges%20installed.jpg

[330i ZHP]

lookin good

[fmzip]

YES!!!!!!! Started her up....purrs like a kitten!!

Couple minor issues, the low oil light stays on, (just did an oil change 7 qts oil Mobil1 0w40) the vdo oil pressure gauge is pinned, boost gauge blips slightly revving it up (is this normal on boost or is mine line kinked?)

Not really sure where I went wrong.....the VDO dual sending unit, does it matter which terminal is used for the factory connection and the oil pressure gauge??? That is the only thing I can think of......

Never the less, I can't wait til tonight to take it for a spin!! :) :) :)

[330i ZHP]

sounds like you have a ground issue for one...that would explain the oil light and gauge issues.

and if you rev it enough at idle the boost will start to build

[sheefo2k]

Goodluck man!!!

hey btw is this the same kit from leatherZ??
how did you get the gauges to fit there??

[fmzip]

^^^ I had this panel custom made.....if there is enough interest, I can get a batch run.

Well the issue with the gauges was just swappingthem on the sedning unit. They then worked fine, until I turned on my headlights, then the temp gauge pinned, and the pressure gauge goes to zero...something is odd.

More importantly, I drove it! WOW does it pull.

I have an SES light so I will pull the code too see what it is, pretty bummed about that. I disconnected the battery for awhile but the SES light stayed on, must be in memory???

[HighBoostin330]

^^^ I had this panel custom made.....if there is enough interest, I can get a batch run.

Well the issue with the gauges was just swappingthem on the sedning unit. They then worked fine, until I turned on my headlights, then the temp gauge pinned, and the pressure gauge goes to zero...something is odd.

More importantly, I drove it! WOW does it pull.

I have an SES light so I will pull the code too see what it is, pretty bummed about that. I disconnected the battery for awhile but the SES light stayed on, must be in memory???

Where are you tapping your source voltage from?

[fmzip]

Code was 19 0A 12......Coolant Temp, I was low on coolant which must have set it off. 12 is exhaust camshaft position sensor....I think that may be an old code since I know I replaced that sensor, either on this car or my 01 530.......so I think all is good! :)

On to the gauges...:)

Since this is a used TS2, do I have to go the 200 mile break in, the break in is for the TS2, not my engine, correct?

[fmzip]

Where are you tapping your source voltage from?
I followed Todd's install from his site, since I don't have an ashtray, I used the brown ground wire for the cig lighter, the little gray and brown wire for the 12 V source for the Lamps, and fuse number 6. From what I just noticed, my fuse 6 is labeled cabrio soft top, obviously not the same as Todd's.

What's odd is if I pull that wire on fuse 6 and turn on the lights, the gauges still pin???? I am in the garage as I type, so any ideas, let me know!

Thanks

[HighBoostin330]

I followed Todd's install from his site, since I don't have an ashtray, I used the brown ground wire for the cig lighter, the little gray and brown wire for the 12 V source for the Lamps, and fuse number 6. From what I just noticed, my fuse 6 is labeled cabrio soft top, obviously not the same as Todd's.

What's odd is if I pull that wire on fuse 6 and turn on the lights, the gauges still pin???? I am in the garage as I type, so any ideas, let me know!

Thanks

Well I just thought that you tapped a wire that has fluctuating voltages should the conditions change, such as you pressing a certain button and what not. But that does not seem to be the case. I think Stuart suggested that it might be a grounding problem?

[fmzip]

And the answer is.........

If you look at my wiring, the red wires should be ground and the black wires should be 12V......

I obbviously rushed on this, followed Todds pics only, didn't even look at the marking on the spade lugs!!:yikes:

All is good!

Need to slap on the front bumper and I think I am done! Dyno coming soon!

So yes/no to the break in period???

[HighBoostin330]

And the answer is.........

If you look at my wiring, the red wires should be ground and the black wires should be 12V......

I obbviously rushed on this, followed Todds pics only, didn't even look at the marking on the spade lugs!!:yikes:

All is good!

Need to slap on the front bumper and I think I am done! Dyno coming soon!

So yes/no to the break in period???

Awesome you figured it out. :)

I don't believe there should be a break-in as the previous owner should have broken in the supercharger already. Just drive it a bit easy for the first 50 miles or so.

[fmzip]

Hard to stay out of it!!! It is so smooth....I can see how people become boost junkie's, I already want more!

:) I feel like a little kid again! :pimpin:

[330i ZHP]

it is addictive - btw, I found that I had to wire the lighting to a switched 12v so the gauges were fully lit and I could still have the interior lighting at the lowest setting....at the lowest with the grey wire controlling the gauge lighting i couldnt see the gauges.... at their brightest (12v switched constant) they match the lowest setting on the other lighting

you should be fine - I was told part of the break in was for the dme to learn the new air and fuel curves...or driving style...or something...damn, I cannot believe how many of these little details I have forgotten over the past year

my biggest problem is the power pulls all the way to when the rev limiter kicks in - the motor just seems to want to keep going...so if I am not paying attention...i hit the limiter when being aggressive against another car

[HighBoostin330]

it is addictive - btw, I found that I had to wire the lighting to a switched 12v so the gauges were fully lit and I could still have the interior lighting at the lowest setting....at the lowest with the grey wire controlling the gauge lighting i couldnt see the gauges.... at their brightest (12v switched constant) they match the lowest setting on the other lighting

you should be fine - I was told part of the break in was for the dme to learn the new air and fuel curves...or driving style...or something...damn, I cannot believe how many of these little details I have forgotten over the past year

my biggest problem is the power pulls all the way to when the rev limiter kicks in - the motor just seems to want to keep going...so if I am not paying attention...i hit the limiter when being aggressive against another car

That is true. :( When I had my centrifugal, when I felt it pushing the hardest, I knew I was close to redline. With this, it is deceiving. Good thing for rev limiters. :rofl:

[sheefo2k]

dont i m soo happy!! i miss the days when I put in my kit.

It was so much ****ing fun!! lol

BTW post more pictures of your gauge panel and I might be very intrested.

[lkstaack]

^^^ I had this panel custom made.....if there is enough interest, I can get a batch run.
I'ld be interested. LeatherZ told me they wouldn't do any more custome panels like that.

[fmzip]

it is addictive -

you should be fine - I was told part of the break in was for the dme to learn the new air and fuel curves...or driving style...or something...damn, I cannot believe how many of these little details I have forgotten over the past year

my biggest problem is the power pulls all the way to when the rev limiter kicks in - the motor just seems to want to keep going...so if I am not paying attention...i hit the limiter when being aggressive against another car


That is true. :( When I had my centrifugal, when I felt it pushing the hardest, I knew I was close to redline. With this, it is deceiving. Good thing for rev limiters. :rofl:

I agree, the pull never stops......I found the rev limiter immediately!

I'ld be interested. LeatherZ told me they wouldn't do any more custome panels like that.


BTW post more pictures of your gauge panel and I might be very intrested.

I'll post some more pics, Not really sure what more you'd like to see, just let me know. The panel was fabricated out of aluminum on the latest CNC, I sprayed it a textured flat black which blends very well with the factory dash components.

I guess you could wrap it in leather but to be honest, that's what I didn't like about the leatherz one. I'd rather the piece look plastic like the rest of the dash to be unobtrusive.

It appears that leatherz makes their pieces out of wood from the pic I saw on Todd's website. There is no way to easily make this piece out of anything other than metal which is why leatherz is unwilling to fabricate it. If you look at the pics, the vdo gauges have zero clearance to fit in there.

I still have no idea how Tim made this work from a UUC aluminum gauge panel with a dremel tool. He was the inspiration for me going this route! :)

If you guys want one, let me know. It will be $75 each finished or bare.

[330i ZHP]

hmmm, now...what to do with the V1 that is already mounted there

[elite53]

:rofl::rofl::rofl: Ha Ha...Me and my rev-limiter have a love/hate relationship. If I'm not careful I'm gonna wear that sucker out.

[fmzip]

hmmm, now...what to do with the V1 that is already mounted there

Get the Stealthone while they are still producing it!

[fmzip]

Here's a bit more detail on the gauge panel, let me know what else you guys would like to see
http://home.comcast.net/~francisminelli/ESS/guage%20texture.jpg

[330i ZHP]

it does look good - here is the modded ashtray I make and sell to other e46 fanatics....maybe I will do your mod in the wagon...oops, did i just let the next trick out of the bag?

http://im1.shutterfly.com/procserv/47b5d624b3127cce931045595bf400000016108BZtGjVw0cS

[fmzip]

I saw your concealed display in your ashtray, it looks great. I already had my bass control knob hidden in there, now I need a place to mount that!

I just got my stealthone yesterday, there is one listed on Ebay if you are interested:

http://cgi.ebay.com/ebaymotors/ws/eBayISAPI.dll?ViewItem&sspagename=ADME%3AB%3ASS%3AUS%3A1123&viewitem=&item=220227348044

[fmzip]

The car is all back together and is running great......Here's a little video my GF's son took with his phone, you can see the clutch start slipping once I hit 4th gear, then I back off, then the video ends

TS2 Vid (http://home.comcast.net/~francisminelli/ESS/TS2%20video.3g2)

I think I need a new clutch! With DSC off, the revs keep climbing out of control sometimes when I floor it....

What a crappy position to be in.......;):thumbsup::thumbsup:

[TxZHP04]

:thumbsup:The car is all back together and is running great......I think I need a new clutch! With DSC off, the revs keep climbing out of control sometimes when I floor it....

Here's a little video my GF's son took with his phone, you can see the clutach start slipping once I hit 4th gear and then the video ends

TS2 Vid (http://home.comcast.net/~francisminelli/ESS/TS2%20video.3g2)

What a crappy position to be in.......;):thumbsup::thumbsup:

My stock clutch was slipping initially too. Then it seemed to quit. Dunno, but I'm holding off on the clutch upgrade until I know it's really necessary - and until I can decide if I want to go with a lightweight flywheel or not.

[330i ZHP]

waiting to hear whether i like it or not????

[fmzip]

Yes Stuart.......the verdict?? :)

I think I will try to get it dyno'd tomorrow. The slipping is random, I defintiely cannot light up the tires no matter what. I had the clutch slip at 90Mph shifting to 4th with DSC off. This is defintely the weak link....

I swear I hear it pinging with WOT on occasion. I am running Mobil 93. Could be the exhaust rattling or my CATS begging for mercy?? I don't know.

I would like a clutch that has a soft pedal, I defintely do not want a chatter'r or a heavy pedal. Have you narrowed down any choices Stuart?

[330i ZHP]

i bought the clutchmasters fx300 (stage III) clutch with the JB Racing lightweight flywheel...obviously it is sitting on the basement rec room floor...along with all the other TS3 parts

[fmzip]

^^^^ awesome!!!

I believe you've crossed over Stuart, that BMW is entering race car status!

[fmzip]

So, the question is, should I tackle the clutch or outsource it? I really find no pleasure getting underneath the car....how much should labor be on a clutch job?

Stuart, is the Clutch Masters FX300 the best of both worlds clamping force and a fairly soft pedal? Who did you buy it from?

[330i ZHP]

i dont know the labor on the clutch - ask asaed the 1st ts3 in the US about the pedal feel. He tells me it is very close to OEM...anything has to be better than the sachs clutch i used to have - ugh that thing was hard to push in

i will have to give you the name of the vendor - it was cheapest by $200 than any other source

[EIAlfonso]

Fran good to see she's running

Clutch labor is around $400

[TxZHP04]

I was quoted $600 for clutch + flywheel.

[fmzip]

Fran good to see she's running

Clutch labor is around $400

I am so glad I bought the from you Elio! It really is a great setup. It was pretty interesting getting into the 2001 530I after driving the 330cic, where did all my torque go??? :)


i dont know the labor on the clutch - ask asaed the 1st ts3 in the US about the pedal feel. He tells me it is very close to OEM...anything has to be better than the sachs clutch i used to have - ugh that thing was hard to push in

i will have to give you the name of the vendor - it was cheapest by $200 than any other source


I am going to play follow the leader here, if it has a stock feel, I'm in on the clutch! I am definitely going to replace the flywheel while I am at it, I am sure it's glazed. Is a lightweight flywheel really beneficial or are you guys choosing that specifically for the TS3?

Please PM the name of the supplier as soon as you can. Thanks! :thumbsup:

[fmzip]

Fran good to see she's running

Clutch labor is around $400

I am so glad I bought the from you Elio! It really is a great setup. It was pretty interesting getting into the 2001 530I after driving the 330cic, where did all my torque go??? :)


i dont know the labor on the clutch - ask asaed the 1st ts3 in the US about the pedal feel. He tells me it is very close to OEM...anything has to be better than the sachs clutch i used to have - ugh that thing was hard to push in

i will have to give you the name of the vendor - it was cheapest by $200 than any other source


I am going to play follow the leader here, if it has a stock feel, I'm in on the clutch! I am definitely going to replace the flywheel while I am at it, I am sure it's glazed. Is a lightweight flywheel really beneficial or are you guys choosing that specifically for the TS3?

Please PM the name of the supplier as soon as you can. Thanks! :thumbsup:

[Asbjorn@ESS]

Yes Stuart.......the verdict?? :)

I think I will try to get it dyno'd tomorrow. The slipping is random, I defintiely cannot light up the tires no matter what. I had the clutch slip at 90Mph shifting to 4th with DSC off. This is defintely the weak link....

I swear I hear it pinging with WOT on occasion. I am running Mobil 93. Could be the exhaust rattling or my CATS begging for mercy?? I don't know.

I would like a clutch that has a soft pedal, I defintely do not want a chatter'r or a heavy pedal. Have you narrowed down any choices Stuart?

The DME software will need a few 100 miles to fine tune everything, if the baseline ignition setting is border line high for your fuel it will adapt down in no time.

[HighBoostin330]

i dont know the labor on the clutch - ask asaed the 1st ts3 in the US about the pedal feel. He tells me it is very close to OEM...anything has to be better than the sachs clutch i used to have - ugh that thing was hard to push in

i will have to give you the name of the vendor - it was cheapest by $200 than any other source

I have no idea on the labor of the clutch since the entire engine and drivetrain was apart and putting it together was all part of the engine rebuilding process.

I drove my friend's 330 and the Clutchmasters pedal feel is slightly stiffer than the OEM clutch. I have tried three clutches and it is by far the best one I have used. I picked the FX300 because it can hold the power of the TS3 and still be smooth and have the similar feel to the OEM clutch. :)

[330i ZHP]

Clutchmasters FX300 Clutch Kit for a 2005 BMW 330i



Made for the street-track dual use vehicle, Clutchmasters' FX300 Clutch replacement kit is made with a reinforced pressure plate, and steel-backed kevlar clutch disks, which results in an increase of 110% over stock in terms of holding capacity.

Clutchmasters engineers all of their kits to maintain regular pedal pressure while increase clamping force, this is important, since you do not want to put added stress and risk malfunction to other drivetrain components, especially the thrust bearing.

All Clutchmaster kits include everything (except the flyweel) you should replace while doing the job, including the pressure plate, clutch disk, throw-out bearing, pilot bearing or bushing and alighnment tool.


2005 BMW 330i
Engine: 3.0L
Showing 1-2 of 2 products
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FX300 Steel Back Heavy Duty Street Clutch Kit
Part Number: 03-049-HDTZ


Note: Fits Early Models with 5-Speed Transmission


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Retail Price: $895.99
Original Sale Price: $777.66
Price With Extra 10% OFF!: $699.89
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FX300 Steel Back Heavy Duty Street Clutch Kit
Part Number: 03-051-HDTZ


Note: Fits Later Models with 6-Speed Transmissions


No Reviews:
Be the first to review the FX300 Steel Back Heavy Duty Street Clutch Kit.

Retail Price: $895.99
Original Sale Price: $777.66
Price With Extra 10% OFF!: $699.89
You Save: $196.10


Usually ships in 2 to 3 business days. Details
Report A Lower Price Click Here

[330i ZHP]

http://www.performancecenter.com/clutches/clutchmasters-fx300-clutch-kit

that price was so good - that walter couldnt get it cheaper from his source - so he was going to contact them to be a dealer

[fmzip]

Thanks Stuart, I found that site last night. Just ordered it!

As for the flywheel, could you guys give me pros and cons of OEM/lightweight versions?

AJ, should I wait then to get it dyno'd?

Thanks for all the help and support guys, it's really appreciated! :)

[dke46T]

I would wait to get it dyno'd since you dont want to have a slipping clutch on the dyno and then having to redyno it after the clutch gets swapped out.

[fmzip]

Hey Dave! How ya been??

As long as I am not hammering thru gears, it really won't slip. You think I should wait though? I really want to make sure my install was done correctly.....

[TxZHP04]

Hey Dave! How ya been??

As long as I am not hammering thru gears, it really won't slip. You think I should wait though? I really want to make sure my install was done correctly.....

Better to wait until you know it's not slipping. Otherwise, if you're not making the expected numbers, you then have to decide whether it's from a slipping clutch or an install issue. Better to minimize the number of variables... especially if you're paying as much for dyno runs as Derek. Waiting to dyno will also allow plenty of time for the DME to adapt.

[fmzip]

Thanks for the advice guys....I will wait until the clutch is done.

From another thread:

Also, for anyone with a 5-spd, there's the Luk DMF019 for a few $$ less.

What is the upside of going with a LW flywheel instead of this $385 replacement from Autozone? Could someone explain this to me?

[lca40]

What is the upside of going with a LW flywheel instead of this $385 replacement from Autozone? Could someone explain this to me?

It will free up HP and give you quicker revs. Very much worth it IMO.

[fmzip]

It doesn't appear I can order the DMF019 Autozone Flywheel....Looks like vaporware!! Damn!

Found it on Ebay for $472.....

http://cgi.ebay.com/ebaymotors/ws/eBayISAPI.dll?ViewItem&category=33732&viewitem=&item=150231640378&_trksid=p3907.m29


maybe I should just get the LW flywheel???? I'm slowly going to the otherside, aren't I???? Next will be a TS3! lol!


Aluminum Flywheel 10.0 lbs.
JB Racing p/n 520-140-240 Price: $532.00

[HighBoostin330]

It doesn't appear I can order the DMF019 Autozone Flywheel....Looks like vaporware!! Damn!

Found it on Ebay for $472.....

http://cgi.ebay.com/ebaymotors/ws/eBayISAPI.dll?ViewItem&category=33732&viewitem=&item=150231640378&_trksid=p3907.m29


maybe I should just get the LW flywheel???? I'm slowly going to the otherside, aren't I???? Next will be a TS3! lol!


Aluminum Flywheel 10.0 lbs.
JB Racing p/n 520-140-240 Price: $532.00

Believe me. It will not chatter if you have your idle raised to 900RPM. Here is a video of my car inching through traffic.

http://www.youtube.com/watch?v=haCKg2argmg

[TxZHP04]

It doesn't appear I can order the DMF019 Autozone Flywheel....Looks like vaporware!! Damn!

Found it on Ebay for $472.....

http://cgi.ebay.com/ebaymotors/ws/eBayISAPI.dll?ViewItem&category=33732&viewitem=&item=150231640378&_trksid=p3907.m29


maybe I should just get the LW flywheel???? I'm slowly going to the otherside, aren't I???? Next will be a TS3! lol!


Aluminum Flywheel 10.0 lbs.
JB Racing p/n 520-140-240 Price: $532.00

http://www.autozone.com/R,APP1018576/vehicleId,2646801/initialAction,partProductDetail/store,5774/partType,00906/shopping/partProductDetail.htm

Will it not take the order? I had no problems getting the DMF053 for the 6 speed.

I'd encourage you to go LW though... just so I can have some additional feedback before doing the same. :P

[fmzip]

[
Will it not take the order? I had no problems getting the DMF053 for the 6 speed.

I'd encourage you to go LW though... just so I can have some additional feedback before doing the same. :P


No, it will not take the order...I love the honesty! :rofl:

Believe me. It will not chatter if you have your idle raised to 900RPM. Here is a video of my car inching through traffic.

http://www.youtube.com/watch?v=haCKg2argmg

How do I raise the idle to 900RPM's? Do I have to have the ECU programmed again? Or is this something I can do with a laptop and some guidance?

[elite53]

I have the UUC 8.5 lbs flywheel and it doesn't chatter at all. It is completely silent just like stock. It all depends on the car though, some do some don't. I am using a mix of Redline 75w140ns and MT90. It is supposed to keep chatter to a minimum.

Don't raise your idle till you know if your car is one that chatters in order to keep it as stock as possible. If you still have gearbox chatter after trying this fluid mix then ESS will raise your idle for you for around $100 bucks which will almost certainly stop the chatter.

[fmzip]

^^^^Thanks Man! So what's the magic mix ratio

[330i ZHP]

i think it is 50/50 or one and one

[HighBoostin330]

How do I raise the idle to 900RPM's? Do I have to have the ECU programmed again? Or is this something I can do with a laptop and some guidance?

AJ can do the raised RPM for you. I haven't tried the tranny fluid mixture. Get the LWFW. :4ngie:

[fmzip]

Oh the peer pressure!

Guess I am getting the JB Racing LW Flywheel! :thumbsup:

[fmzip]

i think it is 50/50 or one and one

Isn't 50/50 the same as 1:1, are you messing with me or do they both come in differnt sizes??:confused:

[330i ZHP]

i dont know to be honest - and no, I am not messing with you... i m re tall did

[330i ZHP]

i dont know to be honest - and no, I am not messing with you... i m re tall did

[fmzip]

i dont know to be honest - and no, I am not messing with you... i m re tall did

:rofl::rofl: what???

[elite53]

^^^^Thanks Man! So what's the magic mix ratio

Dump in the whole bottle of 75W140NS and then fill it up the rest of the way with the MT90. The tranny holds 1.1qt so you won't use much of the MT90.

If you think the car feels fast now.....Your going to S yourself when you put in the lightweight flywheel. It really brings the car to life....

[aggieE46]

Zing! I don't know why people can't just read the site :)

Dump in the whole bottle of 75W140NS and then fill it up the rest of the way with the MT90. The tranny holds 1.1qt so you won't use much of the MT90.

If you think the car feels fast now.....Your going to S yourself when you put in the lightweight flywheel. It really brings the car to life....

[elite53]

Well...To be fair, He may not have seen it. He's not shopping for a UUC flywheel. I think he's looking for the JB Racing one.

[330i ZHP]

Well...To be fair, He may not have seen it. He's not shopping for a UUC flywheel. I think he's looking for the JB Racing one.

+1

[fmzip]

I was going to reply "what site" since I did not see anything mentioned on JB racing's website, thanks for the clarification!

[aggieE46]

Good point.

[fmzip]

Here are some shots of the finished project

http://home.comcast.net/~francisminelli/ESS/finished.JPG
http://home.comcast.net/~francisminelli/ESS/finished2.JPG
http://home.comcast.net/~francisminelli/ESS/finished3.JPG

[330i ZHP]

looking good - i have decided to drop the rear subframe from my car and do the TMS subframe support kit before doing the engine build. I am going to buy a mid-rise lift and a welder this week....I am also thinking about buying the other diff - since I will have the diff out of the car as well.

[fmzip]

I just ordered my JB racing lightweight flywheel from Turner Motorsports a few minutes ago......I was looking at all the rear subframe support items they were selling too!

With all that power of a TS3 something may give and the weak link of the subframe is already well known. I think you are making a very wise decesion. Which kit did you get? Did you look at the video showing the stress of the subframe?

Yikes!

http://www.turnermotorsport.com/html/detail.asp?PRODUCT_ID=TDR4675412

[330i ZHP]

I remember the huge difference when I went from the 3.07 to the 3.46 - I love the pull out on the highway with the 3.46....

with the SC (and the future build specs) do you think I will regret going to the 3.07 again?

Right now - my 1st gear is worthless...spins and is revved out immediately and I am having to shift to 4th before the end of the 1/4...

Will my car be less quick on a roll drag race and a race from a dig with the 3.07???

[fmzip]

I remember the huge difference when I went from the 3.07 to the 3.46 - I love the pull out on the highway with the 3.46....

with the SC (and the future build specs) do you think I will regret going to the 3.07 again?

Right now - my 1st gear is worthless...spins and is revved out immediately and I am having to shift to 4th before the end of the 1/4...

Will my car be less quick on a roll drag race and a race from a dig with the 3.07???

Geez....I don't know Stuart, if it was me I'd consider going back to the 3.07's. You think your shifting fast now??? Wait til the TS3 is in with a LW Flywheel.

Yes you car will be less quick on both fronts going back to higher gears but the adder power of the TS3 is going to make that statement irrelevant. You are going to have so much more power at your disposal, you will be begging for the 3.07's. It will make you 6spd more usable....

I think it's time for you to go for top speed and modify the 6 spd ratio....6th gear needs to get up to .35 . You have that welder now, just add a few teeth;)

[boxy]

Wow such a clean engine bay you have..

[ken330i]

Fran, congratulations! your FI is finally accomplished. I am so happy for you.

[fmzip]

Wow such a clean engine bay you have..

Funny story about the engine bay.....So I finish the install, then I decide the engine bay needs a clean up. I use this stuff I got from Autozone called Purple Power. This crap makes all the aluminum in the engine bay have this white oxidized look. Worst part, all the polished aluminum on the supercharger is gone. I am really pissed since I got this beautiful CF engine covers on the way to put on what looks to be a 1972 corroded engine! :bawling: :banghead:

So I go back to Autozone and buy some Black Magic engine bay one step cleaner and detailer.....no difference on the aluminum although this stuff does give a nice sheen.

Back to Autozone, I get some aluminum Mag cleaner. This crap is very corrosive, contains hydrochloric acid! It is to be used on non coated aluminum and rinsed very quickly.

So I spray it as accurately as I could on the aluminum engine pieces and the unpolished area of the supercharger and rinse it off within 15 seconds.....All is good again. :)

Then I took Mother's Billet Polish to the supercharger and hand polished that out for well over an hour......:censor:

Moral of the story, don't use Purple Power in your engine bay!

[fmzip]

Fran, congratulations! your FI is finally accomplished. I am so happy for you.


Thanks Ken...


Had some fun with a Lexus GS430 today, I had the guy sctratching his head, "why can't this V8 keep up??.......:)

Defintely need that clutch ASAP! I also ordered an exhaust side camshaft sensor, got the same fault code today.

[Navin323i]

Congrats Fran on the great job you did installing this yourself! :bow:

Also my thanks to you again for helping me out with my secondary tank vent hose issue... this should be officially resolved tommorrow when I see my mechanic (see my other thread for the details). :)

[fmzip]

Congrats Fran on the great job you did installing this yourself! :bow:

Also my thanks to you again for helping me out with my secondary tank vent hose issue... this should be officially resolved tommorrow when I see my mechanic (see my other thread for the details). :)

Thanks Navin and you are welcome.

Glad your issue looks to be getting resolved.

[ken330i]

get a better clutch and you are almost set. You might need a BBK as well.

[fmzip]

get a better clutch and you are almost set. You might need a BBK as well.

Yep....I was pondering a BBK (also pondering a TS3!, maybe next year)

[ken330i]

Fran, you are way ahead of me. TS3 is going to be sick fast! They always say current power is always not fast enough.

The next car you will chew is going to be an M3, right? I like what the other fanatic says about his SC. He said something like this, "...when my gas pedal hits the floor, it's Game Over baby!" :thumbsup:

[fmzip]

Fran, you are way ahead of me. TS3 is going to be sick fast! They always say current power is always not fast enough.

The next car you will chew is going to be an M3, right? I like what the other fanatic says about his SC. He said something like this, "...when my gas pedal hits the floor, it's Game Over baby!" :thumbsup:

I like that quote! :)

I can see how easily I can get sucked into the power frenzy! It would be something to feel the power of the TS3 in an E46!

[fmzip]

If I were to go with a TS2+, do I have to get headers? Since it's a cabrio, I'd rather not.

[330i ZHP]

You can add the cams and the smaller pulley along with the tuning - but the limiting factor will be the exhaust manifold

I loved the sound of the setup with the headers and my stock exhaust - before the SS stuff came in - in fact I really regretted buying the SS setup based on the sound with the ZHP exhaust and the amount of $$ spent on the SS

[fmzip]

I was reading over your thread Stuart. I defintely do not want to have a loud car. Maybe I should just get the headers and a ZHP muffler. From what I understand, the piping is the same. SInce I don't have a lift, do you think I should tackle the headers or not?

In regards to installing the cams, did you end up tackling that or did you have someone do it? Trying to get an idea of labor to have cams installed, any idea?

[EIAlfonso]

Headers $200
Cats $200
Labor $600

Cam $900
Labor $800

These are estimates but should give you an idea

Plus ESS pulley and software and then you need to figure out what to do about the CEL for the cats.

[aggieE46]

If you can install the TS2, you can install the headers. Tackle it yourself.

[fmzip]

Headers $200
Cats $200
Labor $600

Cam $900
Labor $800

These are estimates but should give you an idea

Plus ESS pulley and software and then you need to figure out what to do about the CEL for the cats.

Hey there Elio....

Do the cats have to be removed? Can you explain $$ estimates in your post in a little more detail for me?

[EIAlfonso]

Hey there Elio....

Do the cats have to be removed? Can you explain $$ estimates in your post in a little more detail for me?

The cats are part of the headers in our cars, when you remove the oem headers you are also removing your cats. The other aftermarket headers do not have the cats built in to them

My estimates are the inexpensive way to go, other than DIY, as an example ebay headers are about $200 or less, maganflow cats are about 100 each (you will need two) and the labor to install both is about $600. If you decide to get SS headers and some Random Technologies Cats then you're talking about $1,500 for the headers and cats plus labor.

More aggressive cams, which are needed to take advantage of the TS2+, could easily run over a $1,000 plus the labor to install the cams is another $700 to $1,000.

Once the OEM cats are removed and new cats are installed later down the exhaust stream then they do not heat up as quick which your post cat 02 sensor picks up as a fault and in turn throws your CEL/SES. Then you need to figure out what to do based on th emmissions test in your state. This is where it gets a bit tricky all you might need is $5 worth of non foulers or a few hundred dollars in labor and software, and you still may run into trouble with the CEL.

[330i ZHP]

Aj can program the ECU to not monitor the 2nd O2 sensor

I didnt install the cams and regret it 100% - they charged me $800 and for that amount I could have bought the tools (which I now have) and did the work myself and saved $400.

The headers - again, I was going to do it myself - but while I was having the cams installed - I gave the same shop the nod to install the headers (quoted $500) charged $800....IRK!!!!!!!!!!!!!!!!

[330i ZHP]

i tore the rear suspension, diff and subframe out of the sedan this evening....I will post pics later or tomorrow....

[330i ZHP]

btw - i dont mean tore - i mean removed

[fmzip]

btw - i dont mean tore - i mean removed
LOL that's what I figured......Do you have emissions testing where you're at? We do here in CT.

So the real question is, if I go the header route, I'd need cats but will it pass emissions testing

[330i ZHP]

If it is obd2 - dont they just plug in the obd2 port to check for CEL's? You can have hollowed out cats installed or high flow cats like from SS or from Summit racing

[330i ZHP]

also - even though I have cats I am lucky and because my car sits low...they refuse to take it on the rollers..so they give me a two year waiver each time (in both cars...:) )

[fmzip]

I believe they plug into the port but if I am not mistaken, I thought there was a sniffer too.

I am very concerned about it being loud with headers. Having a convertible ups the db's very easily. Maybe I should just pass on the headers all together. :(