People with ESS twinscrew....

[elite53]

I'm installing my TS2 right now but I can't figure out how the new hose clamps for the powersteering tank work. It looks like they need a special tool to clamp them on. What did you guys do with yours?

[silver330ciman]

I'm installing my TS2 right now but I can't figure out how the new hose clamps for the powersteering tank work. It looks like they need a special tool to clamp them on. What did you guys do with yours?

I ended up not using the clamps supplied by ESS since I had the same problem trying to crimp tighten those. Ended up picking up the screw type clamps and have been doing a good job so far. GL man.

[Lemonsqr]

I ended up not using the clamps supplied by ESS since I had the same problem trying to crimp tighten those. Ended up picking up the screw type clamps and have been doing a good job so far. GL man.

+1 Give us a review when done. Enjoy and welcome to the club.

[paraklas]

Did the same thing here. Screw type clamps

[Asbjorn@ESS]

They are designed to presslock using a normal diagonal cutter.

[330i ZHP]

i used screw type clamps as well

[TxZHP04]

Good info here. The installation looks pretty straightforward, any of you DIY'ers have any other tips, tricks, or things to watch out for during the install?

My kit arrived yesterday and it's driving me nuts not having time to install it just yet. Hopefully I can start this weekend or at least by Monday.

[330i ZHP]

Make certain you install the hoses for the cooler before installing the intake or at least before installing the TB and all the wiring and hoses

[330i ZHP]

oh yea, and label all the connectors since some have identical wiring and plugs

[Maestroxl]

While wrapping the wires, make sure you separate them and make them long enough.
install your firewall piece before you put the charger in.

[elite53]

Nice.....thanks for the tips guys. Back to work. :4ngie:

[Minnoe07]

If the oil dipstick gets in the way, unbolt it and pull it out.

Better than busting it. Ask me how I know....

+1 on the screw type clamps.

[elite53]

Well...I just got the intake manifold out. :censor: I'm gonna take a couple Chill****** before I go any farther. There's no turning back now!!! Thanks for the advice and tips everyone.

[MarvelPhx]

You can do it. Use my DIY and take yer time. Get some help putting the TS on the block and, as for the clamps, either use a blunt nose cutting pliers or like others have said a standard hose clamps works as well.

Welcome to the club!

[paraklas]

Wrap the DISA plug (which is identical with another plug) with electrical tape in order to seal the connectors since it will not be used.

Carefully bent the fuel supply tube because it's easy to break it.

While preparing the head for the new gasket, cover the intake ports in order to prevent debris entering the engine.

Connect the idle control valve plug before lowering the manifold completely

Inspect that all connections are ok and no wires/hoses are pressed while lowering the manifold.

[elite53]

Thanks for the encouragement Marvelphx. I actually have been useing your DIY along with the instructions supplied with the kit. No one thing has been particularly hard so far, but it has been fighting me every step of the way. Once they put these cars together they aparently don't want them to come back apart. :confused:

Thank you everyone else for the tips. If you can possibly think of any more (no matter how small they may seem) keep them coming. I'de really like to get this right the first time.

[TxZHP04]

Thank you everyone else for the tips. If you can possibly think of any more (no matter how small they may seem) keep them coming. I'de really like to get this right the first time.

+1

I'm within a couple of days of starting my install now too. :excited:

[elite53]

Hey TxZHP04- I just found a misprint in the ESS instructions that I wanted to warn you about. When you are hooking up the front heat exchanger it says to connect the longest hose to the inlet side of the pump and the second longest hose to the far connection on the heat exchanger. This should be reversed or else the one on the heat exchanger won't reach its destination and you will get to do it twice like I just did. A smart person would have figured this out before they ran all the hoses and made all the connections but...I'm not as smart as I thought I was. :bawling:

[TxZHP04]

Thanks for the heads up on that. I actually noticed that when looking over the instructions last night and wondered if it was going to work.

I think they changed the hose routing at some point. Perhaps the install manual didn't get updated accordingly.

[paraklas]

The belt routing in the manual was also wrong. I don't know if they fixed it but here it is:

In the ESS manual:
http://img250.imageshack.us/img250/56/beltroutingtskitig6.jpg

Updated route:
http://img528.imageshack.us/img528/963/beltroutingkg2.jpg

[TxZHP04]

The belt routing has been updated in the manual.

Thanks, and keep 'em coming.

[stimpee]

The belt routing in the manual was also wrong. I don't know if they fixed it but here it is:

In the ESS manual:
http://img250.imageshack.us/img250/56/beltroutingtskitig6.jpg

Updated route:
http://img528.imageshack.us/img528/963/beltroutingkg2.jpg


Your updated belt route is physically impossible...

EDIT: I think the modified placement of the idler near the alternator is probably correct, as it matches the way I did it on my Twin Screw design, however the placement of the belt on the P/S pulley is not possible as you have it in your picture!

[TxZHP04]

Yeah, pretty obvious (to me anyway) that the belt can't wrap around the PS pulley as drawn.

For those who prefer pics to diagrams...

http://www.vmwerks.com/gallery/gallery.asp?action=viewimage&categoryid=32&text=&imageid=2425&box=&shownew=

VMWERKS, thanks for all the great pics you guys took during the TS3 install!

[stimpee]

Understood, just didn't want to see some poor suckah trying to figure out how to get the belt on that PS pulley that way!!!

:D

[TxZHP04]

Understood, just didn't want to see some poor suckah trying to figure out how to get the belt on that PS pulley that way!!!

:D

And that's what this thread is all about, clarifying things that might not be quite so obvious to everyone. :thumbsup:

[Asbjorn@ESS]

I am not sure where the updated belt route diagram came from? It is not from us. Our manual diagram is correct, I just double checked.

[paraklas]

it is possible and that's the way I have it. Hans guided me to route the belt like that I did not imagine it!

P.S the diagram is my design

placement of the belt on the P/S pulley is not possible as you have it in your picture!
It's possible, there's a 5mm gap between the outer sides of the belt. It was physically impossible to route the belt like the original diagram, it was beyond the tensioner's limit!

[TxZHP04]

it is possible and that's the way I have it. Hans guided me to route the belt like that I did not imagine it!

P.S the diagram is my design


It's possible, there's a 5mm gap between the outer sides of the belt. It was physically impossible to route the belt like the original diagram, it was beyond the tensioner's limit!

The problem is that the error in the diagram is TOO obvious. The red line (belt) going down from the alternator pulley to the PS pulley should go to the right side of the PS pulley, not the left. As it's drawn, the belt doesn't actually wrap around the pulley. No biggie, I knew what you meant. In fact, until Steve pointed it out, I hadn't really noticed the error.

[paraklas]

The red line (belt) going down from the alternator pulley to the PS pulley

it's late.
I'm tired.
/me goes to bed right now

better now eh?
http://img101.imageshack.us/img101/5096/suckatphotoshopdj6.jpg