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Old 06-18-2016, 08:15 AM   #1
Fizban
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E46 328CI ESS TS2 problems + Dyno results

Hello,
I've recently installed an ESS TS2 on my 328CI model 2000.
I had, and still have, issues with this set up.
First, ESS sent me the wrong injectors (315cc for B32), and no bracket for the throttle cable.
I talked to them and they sent me the correct injectors (240cc) and the throttle cable bracket.
I also got a 95mm pulley size, while i read here that people with 328 got 88mm pulley size for their kit.
After installing the kit and overcoming several problems. I drove the car for around 1000kms. I felt that the car is not really giving 320hp, since i had a car with that power level. So I installed a boost gauge, which confirmed that the boost is maximum of 5 PSI as redline. I also felt that there is suddenly more power after 6000 rpms.
I decided to goto the dyno.

As you can see in the pics. The car is running very rich at boost (10.5:1), probably reducing the power all the way till 6000 rpm, then the AFR goes pretty lean for a boosted setup (thats why i felt more power after 6000 rpm).
You can also see that the dyno boost gauge also confirms that the boost is lower than the expected 8 PSI.

Anyone with the same set up has dyno results to compare boost/ afr/ power with me? Anyone has idea if maybe there is a leak somewhere under boost?
Maybe the car is running rich since the ECU was tuned for 8 PSI of boost?
I tuned my other car myself under boost and i tuned it to every level of boost , not just a fixed boost , so i dont think its logical. But who knows?

I emailed Hans about it, including the dyno results yesterday. Also asked about the pulley size 2 weeks ago but he didnt reply.


Thanks





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Last edited by Fizban; 06-18-2016 at 08:37 AM.
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Old 06-18-2016, 11:23 PM   #2
cosmos328Ci
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Yes, that is too rich, robbing you of power and torque.


When I had the TS2 setup on my M52TU28 engine, I put down about 265 at the wheels but mine went a lot leaner than yours but did not run rich like yours.
My boost gauge show around 8psi with the 88mm pulley.

There is something wrong with AFR.

Which dyno did you use?
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Old 06-19-2016, 12:12 AM   #3
Fizban
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Thanks for the reply. I used Dynapack.
Hopefully ESS will reply back with a solution.
Do you think it might be a leak?

Last edited by Fizban; 07-11-2016 at 03:30 AM.
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Old 06-20-2016, 10:17 AM   #4
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Have you smoke tested the setup to check for leaks, especially at the intake manifold?
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Old 06-20-2016, 10:18 AM   #5
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Hopefully checking it next week.

Last edited by Fizban; 06-20-2016 at 10:19 AM.
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Old 06-22-2016, 07:40 AM   #6
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Seems strange you would have a boost leak that goes away with more boost?
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Old 06-22-2016, 07:52 AM   #7
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It doesnt go away. The boost is lower across the RPM range. If there is a leak, it might explain this behavior.
What i do not understand is the rich mixture, because the ECU should be tuned also at lower boost.
The strange thing is that after 6000rpm the afr goes leaner. Maybe the injectors are too small for the job.

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Old 06-22-2016, 08:40 AM   #8
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BTW, people from ESS tuning havent replied yet. But some of them are on vacations, as it seems.

Last edited by Fizban; 06-22-2016 at 08:40 AM.
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Old 07-11-2016, 03:29 AM   #9
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We checked the system yesterday.
We played a bit with the bypass valve and checked clearance. We went for a drive after disconnecting the vacuum line to the bypass valve and blocked the hold in the vacuum outlet. The car saw 6.6 PSI and felt stronger. Then we connected the vacuum again and still saw almost same result, which leads us to suspect something is fishy with the valve. Maybe in doesnt close properly or its too weak to to boost level and it opens a little under boost?

Last edited by Fizban; 07-11-2016 at 03:30 AM.
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Old 08-08-2016, 04:27 AM   #10
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Updates:
ESS sent me a new bypass valve and a 90mm pulley instead of the 95mm.
We replaced the valve and there was no real change. So we replaced the pulley. Now we are seeing around 7.3 PSI and still the car feels it can give more.
I took the car for a drive at night and recorded logs. There results are attached.

You can see that at 3000 RPM the mixture goes very rich (0.68 to 0.71) until 5300 rpm and then goes leaner until it reaches 0.97 at 6800rpm. max boost was 7.4 PSI.

ESS recommended me to switch to M3 fuel pump because of the leaner mixture at higher level but my fuel pump is new OEM and before i am spending $400 on a new pump, i am going to check fuel pressure and see if the pump is really the issue.

Also, the boost is not high enough. according to AJ i should see 9psi at max rpm.

I believe that timing should be advanced since my CR is 9:1 instead of original 10.2:1.

AJ told me that he can provide me a map with less fueling for target RPM i provide him. But i also think advancing the timing at 3 degrees will give more power due to the lower CR.

Any thoughts?
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Old 08-08-2016, 06:18 AM   #11
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Why did you lower your compression ratio? Are you auto or manual?
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Old 08-08-2016, 06:22 AM   #12
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I did not myself.
The previous owner had a turbo installed and they lowered the cr. I bought the car after the turbo was removed.
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Old 08-08-2016, 06:28 AM   #13
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What camshafts and do you have the factory fpr? If you are manual transmission, you could add a lot more boost and get someone else to tune it.
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Old 08-08-2016, 06:37 AM   #14
Fizban
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I have a manual trans. How much boost are we talking about?

I think we found the problem.
ESS sent me the 330 kit by mistake. So they send me the correct injectors and brackets, but they forgot that the 328 uses a 620ohm resistor on the MAF signal.
So i guess what is why i see strange issues with the tune.
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Old 08-08-2016, 06:41 AM   #15
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That would do it.

I was running 16psi with 9.4 compression ratio on my 3 litre. I changed to 42lb injectors, 65mm pulley, and aeromotive 340 fuel pump. Custom tuned.
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Old 08-08-2016, 06:44 AM   #16
Fizban
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Cool! How much power did you see with that configuration? You used original original pistons? Mine are original, machined to 9:1 .
Who did the tune? Can i do it my self with the Gellato cable?
I've tuned my previous car myself and it was pretty fun. 360HP and 41kgm.

Last edited by Fizban; 08-21-2016 at 12:17 PM.
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Old 08-21-2016, 12:17 PM   #17
Fizban
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update - I've installed the 620 OHM resister ESS told me i needed and the mixture now seems more logical. 0.85 all the way to redline.
Now i still have the issue of the lower boost target than 8 psi.
At start they sent me a 95mm pulley. I got around 6 PSI of boost. Then they sent me a 90 mm pulley and i get now 7.5 PSI.
Maybe i need a smaller pulley because of my reduced C/R?

Last edited by Fizban; 08-21-2016 at 12:17 PM.
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Old 08-21-2016, 06:42 PM   #18
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Quote:
Originally Posted by Fizban View Post
update - I've installed the 620 OHM resister ESS told me i needed and the mixture now seems more logical. 0.85 all the way to redline.

Now i still have the issue of the lower boost target than 8 psi.

At start they sent me a 95mm pulley. I got around 6 PSI of boost. Then they sent me a 90 mm pulley and i get now 7.5 PSI.

Maybe i need a smaller pulley because of my reduced C/R?

if you have low C/R, why dont you put the TS3 setup? (65mm pulley + bigger injectors + M3 e46 fuel pump + custom tune or ESS TS3 tune)?
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Old 08-24-2016, 03:09 AM   #19
Fizban
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I have a 328 and ESS are not tuning TS3 to this car.
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Old 08-24-2016, 04:05 AM   #20
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Quote:
Originally Posted by Fizban View Post
I have a 328 and ESS are not tuning TS3 to this car.
Its not that they do not tune the 328 for TS3 its because you have MS42 DME not MS43 DME.

Been through this a while ago, so I just bought the TS3 pulley (60mm) and tuned with E85 (so no low compression pistons).

Good luck with your setup.
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