ESS Tuning Twin Screw Stage 2 (TS2) Supercharger Install Notes [Archive] - BMW E46 330 ZHP For Sale Forum

View Full Version : ESS Tuning Twin Screw Stage 2 (TS2) Supercharger Install Notes

rkneeshaw

05-25-2015, 10:03 AM

Introduction

I'm a DIY kind of guy, and have maybe moderate experience wrenching on cars. I've done a lot of things at one point or another, probably everything except transmission work. So I feel somewhat experienced, but by no means a professional at all. Anyway, I always knew I would tackle the TS2 install myself, and along the way I took notes on things that you could say might be a good supplement the instructions that ESS provides. So here goes.

I thought the install would take about 12-14 hours, but I ran into some challenges along the way and it took me closer to 16-18 hours. Some of my bigger issues involved snapping a stud on the head when tightening down the new ESS manifold to 22ft-lbs, resulting in the need to remove the manifold which ripped the gasket, so I needed to make another gasket, and then removing and ordering a replacement stud from BMW. Then I found out I had the wrong intake boot, which ESS quickly shipped the correct part overnight.

General Recommendations

Not all installations will go smoothly. Regardless if things go perfectly for you or not I suggest investing in a couple things that can help verify a healthy operating kit once you've completed your installation.

Renovelo Bytelogger (http://www.renovelo.com/bytelogger/) - Having a datalogging tool is very important to confirm fuel trims, ignition timing, and if you have a MS45.1 car you can even read your Air Fuel Ratio (AFR) and confirm you're running strong and reliably.

Mityvac vacuum/boost tester (http://www.amazon.com/Mityvac-MITMV8500-Silverline-Automotive-Vacuum/dp/B0002SQYUA) - This little tool is very handy in a number of ways. Hook it to your new ESS manifold and you can confirm proper vacuum levels at idle, and boost levels at WOT. If you have any troubles with the kit what-so-ever, knowing you do or don't have a vacuum or boost leak is invaluable to know before you start throwing new parts at the car.

Recommended OEM Parts to Replace
I believe that if your car has any weak components in the system to start with, a supercharger installation will magnify those. So while you're in there, based on my experience with my car that has 100k miles on it, there are a couple OEM parts you may want to either have on hand or replace. I recommend picking up a fresh set of studs and nuts for the intake manifold in case some break. Pre-cat O2 sensors have about a 100k mile service life, and the DME will use those to keep your car running a healthy fuel mixture. I also suggest getting a fresh o-ring for your oil dipstick in case you need to re-seat it. ESS recommends a fresh fuel filter (which more critically includes the fuel pressure regulator that NEEDS to be working right) and a new or good running fuel pump. This is a great time to change your oil filter housing gasket, because its a huge PITA after the supercharger is installed. Clean your ICV and throttle body while they are in your hands (or replace the ICV if you have doubts about its function, its a real pain to change after the supercharger is installed).

Installation Notes

Removing the stock intake manifold
I couldn't get to most of the bolts to remove it as one big piece, so I ended up removing the DISA, ICV, then the trottle body, and then I could get to the lower 16mm nut and remove the manifold

Removing the IAT plug
I had a hard time removing the intake air temperature sensor plug from my stock manifold. I ended up having to use needle nose pliers to grab onto the edge of it while using a screwdriver to release the clip. Had to lube it up to get it into the ESS manifold.

Trimming the top alternator bolt
The bolt I received that secures the new idler pullies to the alternator and oil filter housing gasket from ESS was slightly too long. Some have had their OFHG crack or shatter presumably because of this. The unthreaded "shoulders" were going to just slightly bottom out
http://i1113.photobucket.com/albums/k513/rkneeshaw/2003%20BMW%20330i%20ZHP/temporary_4_1.jpg (http://s1113.photobucket.com/user/rkneeshaw/media/2003%20BMW%20330i%20ZHP/temporary_4_1.jpg.html)

I used a grinder to slim it down
http://i1113.photobucket.com/albums/k513/rkneeshaw/2003%20BMW%20330i%20ZHP/temporary_5_1.jpg (http://s1113.photobucket.com/user/rkneeshaw/media/2003%20BMW%20330i%20ZHP/temporary_5_1.jpg.html)

Now it fits
http://i1113.photobucket.com/albums/k513/rkneeshaw/2003%20BMW%20330i%20ZHP/temporary_6.jpg (http://s1113.photobucket.com/user/rkneeshaw/media/2003%20BMW%20330i%20ZHP/temporary_6.jpg.html)

Intercooler pump
I was initially sent smooth intercooler hoses with my TS2 kit that couldn't make the bends necessary without kinking. That is what initially led to the way I mounted the intercooler pump. But even after getting the ribbed hoses that can flex properly, I still found this mounting location to work better for me. Make sure to keep the mounting bracket low so that the fog light electrical connector will still have room when you mount the bumper.

http://i1113.photobucket.com/albums/k513/rkneeshaw/2003%20BMW%20330i%20ZHP/temporary_18.jpg (http://s1113.photobucket.com/user/rkneeshaw/media/2003%20BMW%20330i%20ZHP/temporary_18.jpg.html)

Intercooler hoses
The instructions didn't say which port on the ESS manifold needed to go to the pump or the intercooler. I contacted ESS and they recommend connecting the upper port on the manifold to the outlet on the intercooler, and the lower port on the manifold to the inlet on the pump. This is more important than I thought. With the hoses in the wrong configuration I couldn't fill the system with coolant and it ran mostly air in there, which makes it useless. Here is the correct configuration.

http://i1113.photobucket.com/albums/k513/rkneeshaw/2003%20BMW%20330i%20ZHP/IntercoolerHoseRouting.jpg (http://s1113.photobucket.com/user/rkneeshaw/media/2003%20BMW%20330i%20ZHP/IntercoolerHoseRouting.jpg.html)

Fitting the ICV to the ESS manifold
I found this to be difficult to fit properly. The 90 degree hose from ESS needs to be cut down a lot, and even then, the ICV twists in its rubber mount. Its just a weird angle but I guess it works.

Prepping the ESS manifold gasket

The instructions call for using Blue Loctite on the gasket to help it seal. In my experience, 20k miles later when I removed the manifold, the gasket was brittle and crispy everywhere I used the blue loctite. Instead of blue loctite, I recommend something like Permatex High-Tack Spray-A-Gasket Sealant.

Intake Manifold Studs

When I originally installed the ESS manifold and tried to torque it down to the torque specs in the instructions I snapped a stud. I did some research and BMW makes an exhaust stud in an M7x45mm size (BMW part number 07129908199). I can't find any info on the grade of the stud to validate that it is stronger, BUT, the BMW torque specs for these studs are higher than the stock intake manifold studs, so it stands to reason they should be stronger. Also at 45mm they are 10mm shorter than the stock intake manifold studs, which, when you're lifting that manifold in place, you'll come to really appreciate those extra 10mm. And you should be less likely to snap one of these studs.

Installing the ESS manifold
This is not very easy. Take some extra time to lay out the electrical components around the engine bay before you hoof this thing into the car. ICV in the middle, TB and MAF to the drivers side strut tower, and FVV components up front. Whatever length you think you will need for the throttle body and MAF connectors, add a couple inches more. Have someone hold the manifold about 4-6" from its final mounting place to give you a chance to hook up the ICV, FVV vaccum line and electrical connector, and the lower intercooler hose. Then carefully maneuver the manifold into position making sure that the lower intercooler hose routes BELOW the two coolant hoses coming out of the firewall, and be careful not to damage them while maneuvering the manifold into place! I am no professional but I would suggest torquing to something like 16ft-lbs (bentley manual says 11ft-lbs, but its a heavy manifold, so I compromised with 16ft-lbs). I snapped one of the stock intake manifold studs at 22ft-lbs, and yes I verified my torque wrench was accurate.

http://i1113.photobucket.com/albums/k513/rkneeshaw/2003%20BMW%20330i%20ZHP/f99c07a5-b1af-4d3b-9f2e-57ee9d5ce99b.jpg (http://s1113.photobucket.com/user/rkneeshaw/media/2003%20BMW%20330i%20ZHP/f99c07a5-b1af-4d3b-9f2e-57ee9d5ce99b.jpg.html)

Bolting down the fuel rail
When mounting the fuel rail it is best to push it as close to the intake runners as possible while you bolt it down. This is to ensure you can get the injectors angled towards the cylinder head as much as possible. Apparently this can help with some cold starts.

Installing the plastic cover around the brake booster
This is a major PITA. I finally got pissed and used every ounce of force I could muster to twist it in there right. How exactly I did it, I'm not sure, I just know I finally got it down there after about 20-30 minutes of pushing, pulling, sweating, swearing, looking for a punching bag, questioning my choices in life, etc.

Routing the PCV hose
I found the best way was to run it over and behind the top intercooler port on the ESS manifold, and keep it on top of everything. There is room back there even after the cabin air filter tray is reinstalled. Otherwise its hard to get the intercooler hose to gently arch down into the engine bay without kinking.

http://i1113.photobucket.com/albums/k513/rkneeshaw/2003%20BMW%20330i%20ZHP/temporary_3_3.jpg (http://s1113.photobucket.com/user/rkneeshaw/media/2003%20BMW%20330i%20ZHP/temporary_3_3.jpg.html)

Routing the brake booster hose
It wouldn't lay right no matter which way I twisted or tucked it, so I ended up pulling the top section of the brake booster hose off of the Y-junction/valve and cutting off that last 90 degree bend (it's about a 3" length or so that I cut off, including the 90 degree bend). Then I reconnected it to the y-junction/valve and it lays in there real nice now.

http://i1113.photobucket.com/albums/k513/rkneeshaw/2003%20BMW%20330i%20ZHP/temporary_6_2.jpg (http://s1113.photobucket.com/user/rkneeshaw/media/2003%20BMW%20330i%20ZHP/temporary_6_2.jpg.html)

Filling the intercooler with coolant
Not that its difficult, but I'll tell you what I did, not that I'm recommending it, do this at your own risk. I noticed it was filling very slowly, and almost came to a stop, and I was impatient, so I wiped off the end of the hose and wrapped my mouth around that hose and blew into it gently. That forced the coolant down through the pump a bit quicker and allowed me to get a good initial fill on the system. I had to do this a few times until coolant finally dribbled out of the top intercooler port on the manifold. Get it filled, then run the pump for a few minutes per the instructions, and fill again.

Supercharger Oil
I did a lot of research on this. I called Lysholm directly and the correct oil to use is a vortech part number 009028. This is a synthetic oil specifically formulated for twin screw superchargers and is a much thinner oil than the motor oils such as the Castrol TWS 10w-60 that ESS specifies in their instructions. Lysholm says NOT to use anything other than the Vortech 009028 oil, especially not a motor oil. Part number 009028 is about $50 directly from Vortech.

http://i1113.photobucket.com/albums/k513/rkneeshaw/2003%20BMW%20330i%20ZHP/temporary_3_11.jpg (http://s1113.photobucket.com/user/rkneeshaw/media/2003%20BMW%20330i%20ZHP/temporary_3_11.jpg.html)

Turns out this Vortech part number 009028 is actually Nye Synthetic Oil 605, which is also sold as Ford specification ESE-M99C115-A, and GM part number 12345982. Get the GM stuff, its about $12 for a 4oz/120ml bottle. Perfect.

Experience has shown that 4oz/120ml is too much oil for the charger, you'll have oil come out of the snout of the charger and sling all over your engine bay. From what I can tell, the sweet spot is probably about 3oz if filling from empty.

Startup and first drive
The car took two tries to fire up, and it stumbled quite a bit initially for about 5-10 seconds or so. Then the car settled into a nice easy idle. The first few times I accelerated up past about 3k-4k RPM or so there was a little bit of hesitation. I don't know if that was more air working its way out of the fuel system or if the DME was still learning things, or if the throttle is just a lot more sensitive, but it's gone away once I put 50 miles or so on the kit. These may or may not happen to you, because in my case I had the FPR hose connected to the wrong place initially (I left it connected to the intake tube instead of moving it to the ESS manifold like I was supposed to). After correcting that the car idles perfectly and power is nice and smooth.

Conclusion

I love the extra torque and power that this kit provides. The power gains come on very early (like 2500 RPM early) and it just pulls so nicely to redline. The supercharger whine is very subtle compared to my exhaust (cat-less headers and magnaflow cat-back). The LSD is almost a must, I can't imagine not having it. Rainy days are very sideways, and I've found the 3.07 diff gearing in my car to be pretty much perfect because on dry days I still can use first gear. :)

Parting ways

Another nice thing about this kit is that there really aren't any permanent modifications necessary. But there are a couple parts or changes necessary to return the car to stock, or if you sell your used TS2 kit to someone else. You know, just in case...

To return to stock you need:
About 4 1" hose clamps
New PCV hose (11617533398)
New brake booster hose (34336751108)

To resell the kit you need:
Blue Loctite
Intake manifold gasket
Possibly some longer hoses, since I cut mine to length

derbo

05-25-2015, 11:03 AM

Thank you for sharing your experiences with installing the kit. These things are almost never noted in most installs and usually assumed some tiny little modifications to get it to fit properly. Do you have a pic of the horizontal pump pictured in the ESS manual?

cakM3

05-25-2015, 01:13 PM

Thanks for the writeup :thumbsup I intend to do this for my ZHP within the next few years so any information regarding the install is helpful :)

slater

05-25-2015, 05:24 PM

excellent write-up, and THANKS for taking the time to do so - this is exactly the info we crave!

enjoy the boost! i'd love to get a ride/drive in a car like yours.

peter

rkneeshaw

05-25-2015, 05:43 PM

Your welcome guys, I hope this helps others. It was a big DIY job, but worth it in the end :) :) I'll get an "after" dyno done in July and see how it compares to my baseline.

...Do you have a pic of the horizontal pump pictured in the ESS manual?

Not really, I coudln't get the tiny pictures in the instructions to zoom in. I did a quick google search and found something close, this is the way they wanted me to mount it:

19878

My issue was that there was no way to get the hose coming off the top of the pump to route underneath the brake duct. That brake duct seals against the fender lining. So I kept everything above it.

johnrando

05-25-2015, 05:50 PM

+1 to what everyone said. This is awesome information

Sent from mobile

NoVAphotog

05-25-2015, 06:18 PM

+1 to what everyone said. This is awesome information

Sent from mobile
+1

A lot of this seems like info to send to ESS for modification of their M54 kit...

Sent from an HTC One

derbo

05-25-2015, 08:11 PM

Looks like this is how Au2Bahn did it. (Forgot his name but he used to own a zhp here)

I started this winter project with the notion of just rebuilding my Vanos and cooling system overhaul. While I had everything apart in my heated garage, I figured while I was in there, I might as well add an ESS TS2 kit which I planned to install eventually. Since ESS had a holiday promo back in December, I took advantage of it and hence the prolonged winter project. Its taking me longer than normal since I work on it only on weekends, I replace and add things as I go and also work on other projects for friends. Part of the purchase decision was the challenge of doing the install myself. I have always worked on cars since I was 16 and I figured this will be a moderate task and not time consuming like an engine rebuild. I rate the install with 10 being the hardest as a 6. The ESS kit is spot on except for some modifications I did to ensure the TS runs flawlessly without contamination. I was only able to test the car for 3 miles to ensure it was running flawlessly but stupid snow hampered additional test runs and break in period. Im only running it to 4k rpm but at this point, all I can say is :excited:. Its definitely quick!!!! I work on a lot of 335's, from suspension to engine tuning and I dunno.........Im pretty sure I can take them easily. :evil:

Here are some pics of the progress so far:

Started to take off pieces:

http://i993.photobucket.com/albums/af59/estrellajon/BMW/ESS%20TS2%20Upgrade/2010-12-23_21-41-26_516.jpg (http://s993.photobucket.com/albums/af59/estrellajon/BMW/ESS%20TS2%20Upgrade/?action=view&current=2010-12-23_21-41-26_516.jpg)
http://i993.photobucket.com/albums/af59/estrellajon/BMW/ESS%20TS2%20Upgrade/2010-12-26_12-30-32_46.jpg (http://s993.photobucket.com/albums/af59/estrellajon/BMW/ESS%20TS2%20Upgrade/?action=view&current=2010-12-26_12-30-32_46.jpg)
http://i993.photobucket.com/albums/af59/estrellajon/BMW/ESS%20TS2%20Upgrade/2010-12-29_17-50-39_317.jpg (http://s993.photobucket.com/albums/af59/estrellajon/BMW/ESS%20TS2%20Upgrade/?action=view&current=2010-12-29_17-50-39_317.jpg)

Vanos Removed and ready to be rebuilt:

http://i993.photobucket.com/albums/af59/estrellajon/BMW/ESS%20TS2%20Upgrade/2010-12-26_12-30-11_701.jpg (http://s993.photobucket.com/albums/af59/estrellajon/BMW/ESS%20TS2%20Upgrade/?action=view&current=2010-12-26_12-30-11_701.jpg)

Vanos Rebuild Process:

http://i993.photobucket.com/albums/af59/estrellajon/BMW/ESS%20TS2%20Upgrade/2010-12-26_17-09-37_424.jpg (http://s993.photobucket.com/albums/af59/estrellajon/BMW/ESS%20TS2%20Upgrade/?action=view&current=2010-12-26_17-09-37_424.jpg)
http://i993.photobucket.com/albums/af59/estrellajon/BMW/ESS%20TS2%20Upgrade/2010-12-26_15-09-58_511.jpg (http://s993.photobucket.com/albums/af59/estrellajon/BMW/ESS%20TS2%20Upgrade/?action=view&current=2010-12-26_15-09-58_511.jpg)
http://i993.photobucket.com/albums/af59/estrellajon/BMW/ESS%20TS2%20Upgrade/2010-12-26_14-59-58_485.jpg (http://s993.photobucket.com/albums/af59/estrellajon/BMW/ESS%20TS2%20Upgrade/?action=view&current=2010-12-26_14-59-58_485.jpg)
http://i993.photobucket.com/albums/af59/estrellajon/BMW/ESS%20TS2%20Upgrade/2010-12-26_15-00-16_779.jpg (http://s993.photobucket.com/albums/af59/estrellajon/BMW/ESS%20TS2%20Upgrade/?action=view&current=2010-12-26_15-00-16_779.jpg)
http://i993.photobucket.com/albums/af59/estrellajon/BMW/ESS%20TS2%20Upgrade/2010-12-26_14-36-31_831.jpg (http://s993.photobucket.com/albums/af59/estrellajon/BMW/ESS%20TS2%20Upgrade/?action=view&current=2010-12-26_14-36-31_831.jpg)

Vanos Rebuild all done:

http://i993.photobucket.com/albums/af59/estrellajon/BMW/ESS%20TS2%20Upgrade/2010-12-26_17-30-03_850.jpg (http://s993.photobucket.com/albums/af59/estrellajon/BMW/ESS%20TS2%20Upgrade/?action=view&current=2010-12-26_17-30-03_850.jpg)
http://i993.photobucket.com/albums/af59/estrellajon/BMW/ESS%20TS2%20Upgrade/2010-12-28_16-30-09_532.jpg (http://s993.photobucket.com/albums/af59/estrellajon/BMW/ESS%20TS2%20Upgrade/?action=view&current=2010-12-28_16-30-09_532.jpg)

Cooling System off:

http://i993.photobucket.com/albums/af59/estrellajon/BMW/ESS%20TS2%20Upgrade/2010-12-28_12-04-42_106.jpg (http://s993.photobucket.com/albums/af59/estrellajon/BMW/ESS%20TS2%20Upgrade/?action=view&current=2010-12-28_12-04-42_106.jpg)
http://i993.photobucket.com/albums/af59/estrellajon/BMW/ESS%20TS2%20Upgrade/2010-12-28_11-44-55_783.jpg (http://s993.photobucket.com/albums/af59/estrellajon/BMW/ESS%20TS2%20Upgrade/?action=view&current=2010-12-28_11-44-55_783.jpg)

Cooling System Components:

http://i993.photobucket.com/albums/af59/estrellajon/BMW/ESS%20TS2%20Upgrade/2010-12-28_13-24-35_24.jpg (http://s993.photobucket.com/albums/af59/estrellajon/BMW/ESS%20TS2%20Upgrade/?action=view&current=2010-12-28_13-24-35_24.jpg)
Thats an EMP Stewart water pump!!!

http://i993.photobucket.com/albums/af59/estrellajon/BMW/ESS%20TS2%20Upgrade/2010-12-28_15-27-28_177.jpg (http://s993.photobucket.com/albums/af59/estrellajon/BMW/ESS%20TS2%20Upgrade/?action=view&current=2010-12-28_15-27-28_177.jpg)

Now for the fun part:

Intake Manifold Before:

http://i993.photobucket.com/albums/af59/estrellajon/BMW/ESS%20TS2%20Upgrade/2010-12-31_15-13-05_840.jpg (http://s993.photobucket.com/albums/af59/estrellajon/BMW/ESS%20TS2%20Upgrade/?action=view&current=2010-12-31_15-13-05_840.jpg)

Intake Manifold Removed:

http://i993.photobucket.com/albums/af59/estrellajon/BMW/ESS%20TS2%20Upgrade/2011-01-02_19-25-53_438.jpg (http://s993.photobucket.com/albums/af59/estrellajon/BMW/ESS%20TS2%20Upgrade/?action=view&current=2011-01-02_19-25-53_438.jpg)http://i993.photobucket.com/albums/af59/estrellajon/BMW/ESS%20TS2%20Upgrade/2011-01-09_15-43-06_38.jpg (http://s993.photobucket.com/albums/af59/estrellajon/BMW/ESS%20TS2%20Upgrade/?action=view&current=2011-01-09_15-43-06_38.jpg)
http://i993.photobucket.com/albums/af59/estrellajon/BMW/ESS%20TS2%20Upgrade/2011-01-09_15-43-25_911.jpg (http://s993.photobucket.com/albums/af59/estrellajon/BMW/ESS%20TS2%20Upgrade/?action=view&current=2011-01-09_15-43-25_911.jpg)
http://i993.photobucket.com/albums/af59/estrellajon/BMW/ESS%20TS2%20Upgrade/2011-01-02_16-56-42_363.jpg (http://s993.photobucket.com/albums/af59/estrellajon/BMW/ESS%20TS2%20Upgrade/?action=view&current=2011-01-02_16-56-42_363.jpg)

Removed TB, ICV and cleaned thoroughly:

http://i993.photobucket.com/albums/af59/estrellajon/BMW/ESS%20TS2%20Upgrade/2011-01-09_16-56-41_761.jpg (http://s993.photobucket.com/albums/af59/estrellajon/BMW/ESS%20TS2%20Upgrade/?action=view&current=2011-01-09_16-56-41_761.jpg)

New Bigger injectors:

http://i993.photobucket.com/albums/af59/estrellajon/BMW/ESS%20TS2%20Upgrade/2011-01-09_14-54-50_275.jpg (http://s993.photobucket.com/albums/af59/estrellajon/BMW/ESS%20TS2%20Upgrade/?action=view&current=2011-01-09_14-54-50_275.jpg)
http://i993.photobucket.com/albums/af59/estrellajon/BMW/ESS%20TS2%20Upgrade/2011-01-09_15-15-20_467.jpg (http://s993.photobucket.com/albums/af59/estrellajon/BMW/ESS%20TS2%20Upgrade/?action=view&current=2011-01-09_15-15-20_467.jpg)

Air to Water Intercooler installed:

http://i993.photobucket.com/albums/af59/estrellajon/BMW/ESS%20TS2%20Upgrade/2011-01-15_16-21-55_718.jpg (http://s993.photobucket.com/albums/af59/estrellajon/BMW/ESS%20TS2%20Upgrade/?action=view&current=2011-01-15_16-21-55_718.jpg)

IC Pump:

http://i993.photobucket.com/albums/af59/estrellajon/BMW/ESS%20TS2%20Upgrade/2011-01-15_16-20-58_534.jpg (http://s993.photobucket.com/albums/af59/estrellajon/BMW/ESS%20TS2%20Upgrade/?action=view&current=2011-01-15_16-20-58_534.jpg)

Twin Screw Installed:

http://i993.photobucket.com/albums/af59/estrellajon/BMW/ESS%20TS2%20Upgrade/2011-01-16_20-54-38_261.jpg (http://s993.photobucket.com/albums/af59/estrellajon/BMW/ESS%20TS2%20Upgrade/?action=view&current=2011-01-16_20-54-38_261.jpg)
http://i993.photobucket.com/albums/af59/estrellajon/BMW/ESS%20TS2%20Upgrade/2011-01-16_20-54-59_636.jpg (http://s993.photobucket.com/albums/af59/estrellajon/BMW/ESS%20TS2%20Upgrade/?action=view&current=2011-01-16_20-54-59_636.jpg)
http://i993.photobucket.com/albums/af59/estrellajon/BMW/ESS%20TS2%20Upgrade/2011-01-16_20-57-02_584.jpg (http://s993.photobucket.com/albums/af59/estrellajon/BMW/ESS%20TS2%20Upgrade/?action=view&current=2011-01-16_20-57-02_584.jpg)

Running lines and hoses for boost gauge:

http://i993.photobucket.com/albums/af59/estrellajon/BMW/ESS%20TS2%20Upgrade/2011-01-26_16-04-46_709.jpg (http://s993.photobucket.com/albums/af59/estrellajon/BMW/ESS%20TS2%20Upgrade/?action=view&current=2011-01-26_16-04-46_709.jpg)
http://i993.photobucket.com/albums/af59/estrellajon/BMW/ESS%20TS2%20Upgrade/2011-01-26_16-31-53_884.jpg (http://s993.photobucket.com/albums/af59/estrellajon/BMW/ESS%20TS2%20Upgrade/?action=view&current=2011-01-26_16-31-53_884.jpg)
http://i993.photobucket.com/albums/af59/estrellajon/BMW/ESS%20TS2%20Upgrade/2011-01-02_16-57-54_541.jpg (http://s993.photobucket.com/albums/af59/estrellajon/BMW/ESS%20TS2%20Upgrade/?action=view&current=2011-01-02_16-57-54_541.jpg)

In the process of the finishing touches this weekend. I will add additional pics of the final product upon completion.:thumbup:

cakM3

05-26-2015, 04:09 AM

Looks like this is how Au2Bahn did it. (Forgot his name but he used to own a zhp here)

His name is Jon... :thumbsup

Sent from my iPhone5S using Tapatalk

derbo

05-26-2015, 08:05 AM

His name is Jon... :thumbsup

Sent from my iPhone5S using Tapatalk

That was what I thought it was but I wasn't 100% sure.

wertyu78

05-26-2015, 08:45 AM

Great write up and photos! Thanks for the insight.

I wonder how this would sound with a Gruppe M intake.....

derbo

05-26-2015, 08:58 AM

Great write up and photos! Thanks for the insight.

I wonder how this would sound with a Gruppe M intake.....

AWESOME. do it. I'm debating it lol. I wonder if the OBD Cat readiness is set properly with the tune?

wertyu78

05-26-2015, 09:04 AM

AWESOME. do it. I'm debating it lol. I wonder if the OBD Cat readiness is set properly with the tune?

That's a thought. These kits are what, $5k now? Do you happen to know what these are making for power (with headers) on a stock M54?

cakM3

05-26-2015, 09:25 AM

That's a thought. These kits are what, $5k now? Do you happen to know what these are making for power (with headers) on a stock M54?

The ESS M52TÜ/M54 VT1 Supercharger System is the kit you're talking about in your comment. This kit retails for $4295.00. This is the one bullfrogs_M3 recently reviewed...

http://www.zhpmafia.com/forums/showthread.php?15936-Review-(New-Product)-ESS-M54-52-VT1-Supercharger (http://www.zhpmafia.com/forums/showthread.php?15936-Review-(New-Product)-ESS-M54-52-VT1-Supercharger)

The M54B30 Twin Screw Stage 2 (TS2) [the kit I plan to get] retails for $6850 then you add the TS2+ kit for an additional $495......

Boost pressure: 8 PSI
Horsepower: 345 SAE/350 DIN Manual, 335 SAE/340 DIN Auto, (ZHP vehicles +10HP)
Torque: 317 lb-ft/430 Nm Manual, 302 lb-ft/410 Nm Auto

http://www.esstuning.com/products/M54B30-Twin-Screw-Stage-2-(TS2).html (http://www.esstuning.com/products/M54B30-Twin-Screw-Stage-2-(TS2).html)

The TS2+ kit provides:
Boost pressure: 8.5 PSI
Horsepower: 375 SAE/380 DIN
Torque: 342 lb-ft/465 Nm

http://www.esstuning.com/products/TS2%252b-8.5PSI-Boost-Upgrade-Kit.html (http://www.esstuning.com/products/TS2%252b-8.5PSI-Boost-Upgrade-Kit.html)

derbo

05-26-2015, 09:46 AM

wertyu78

05-26-2015, 09:48 AM

345 seems plenty. 300whp :D

Hmm S54 vs TS2...

Looking at the TS3 + costs to build the bottom end with their low comp setup..... Chevy LSX would make more sense $$ wise + power would be better, not to mention the power curve....

Regular TS2 or TS2+ compared to S54..... S54 for sure!

cakM3

05-26-2015, 11:14 AM

Looking at the TS3 + costs to build the bottom end with their low comp setup..... Chevy LSX would make more sense $$ wise + power would be better, not to mention the power curve....

Regular TS2 or TS2+ compared to S54..... S54 for sure!

I haz an S54 ;)

rkneeshaw

05-26-2015, 02:58 PM

Looks like this is how Au2Bahn did it. (Forgot his name but he used to own a zhp here)

Yeah, see, I couldn't do that. The newer TS2 kits have a slightly different type intercooler hoses, they aren't ribbed and don't flex as well I dont think. I tried doing what he did there and the hose would kink and collapse on itself.

rkneeshaw

05-26-2015, 03:03 PM

345 seems plenty. 300whp :D

Hmm S54 vs TS2...

+10hp for ZHP... dont forget the 10hp! lol :)

ESS rates there stuff fairly conservatively too, which I respect a lot. They value not disappointing their customers vs bragging rights.

bullfrogs_M3

05-26-2015, 03:58 PM

Just a heads up on the TS2 systems. ESS purchased the last of the available and remaining cores from the company that made the TS2 body and main supercharger component. That particular company is no longer making them any longer and ESS has all the remaining stock out there that will ever be available.

What does this mean? Once the stock of TS2 systems is out of inventory at ESS, then that's it, no more will ever be available. Period!

So all that being said, this is now a dwindling supercharger system and will (eventually) be a rare system to own/find. When I was at the shop while they were working on my car, I saw about 2 dozen cores sitting on the shelf. They may have had more around the shop but that is just what I personally saw there. From what I gathered talking to them, their main focus moving forward will be on the VT1 kits.

derbo

05-26-2015, 04:17 PM

Hopefully they make a VT2 ;)

Taliben

05-26-2015, 05:55 PM

Why does no one go for the Technique Tuning turbo kit?
http://www.techniquetuning.com/e46zhpman.html
With a thicker head gasket and more boost you're looking at similar numbers with room to grow

derbo

05-26-2015, 06:20 PM

Why does no one go for the Technique Tuning turbo kit?
http://www.techniquetuning.com/e46zhpman.html
With a thicker head gasket and more boost you're looking at similar numbers with room to grow

The ESS has built a nice reputation and it has a 2 year unlimited mileage warranty. This is not mentioned anywhere in regards to the TT turbo kit.
T3/T4 is a nice turbo but I would prefer a GT30R :)

Taliben

05-26-2015, 06:41 PM

The ESS has built a nice reputation and it has a 2 year unlimited mileage warranty. This is not mentioned anywhere in regards to the TT turbo kit.
T3/T4 is a nice turbo but I would prefer a GT30R :)

This is true. I didn't know about the warranty. GT30R would be nice, idk how it would act on such low boost though

derbo

05-26-2015, 06:50 PM

This is true. I didn't know about the warranty. GT30R would be nice, idk how it would act on such low boost though

GT30 can be similar to a T3/T4 depending on the A/R you select. GT30 are ball bearing turbos and have less resistance to spool. They also are water and oil cooled. It would perform far better than an T3/T4 and spool up faster. :)

but back on topic,

ESS TS2 is a lovely kit and one of the most stealthiest kits you can buy for the car. IMO, if I were to boost the M54, I would do it this way simple because of customer support from ESS.

prowlerflyer

05-26-2015, 07:25 PM

My TS2 now has 65k miles without any issues. Yea that ICV hose can be
a pain post installation. I was doing the OFHG, and the process of wrestling it out, knocked the ICV hose out. Boy, that is a pain to get back in. The OFHG is another fun job once the TS2 is installed. Key step, remove the S/C pulley and slide the OFH out forward.

To the TS2 / S54 comparison, the TS2 has a lot more low end torque. It really is perfect daily driver setup. The S54 is a thoroughbred screamer built for the track. The two are very different personalities.

derbo

05-26-2015, 08:29 PM

slater

05-27-2015, 02:57 AM

Why does no one go for the Technique Tuning turbo kit?
http://www.techniquetuning.com/e46zhpman.html
With a thicker head gasket and more boost you're looking at similar numbers with room to grow

i've had a lot of turbocharged cars... personally, i don't like their driveability - or lack thereof - when putting power down mid-corner. it's the lag.

supercharger seems like the answer!

peter

NoVAphotog

05-27-2015, 03:21 AM

To the TS2 / S54 comparison, the TS2 has a lot more low end torque. It really is perfect daily driver setup. The S54 is a thoroughbred screamer built for the track. The two are very different personalities.

Thanks for that. It helps steer me back to my TS2 dream. :)

rkneeshaw

05-27-2015, 03:51 AM

Why does no one go for the Technique Tuning turbo kit?
http://www.techniquetuning.com/e46zhpman.html
With a thicker head gasket and more boost you're looking at similar numbers with room to grow

I went with the TS2 for several reasons:
* Stealthy install. The engine bay looks stock. Great for sleeper mode :)
* Great linear, instant power. no need to tune out turbo-lag, its very drive-able. In fact, it drives just like stock except there is more juice when you lean into the throttle. Very linear power curve.
* ESS has a great reputation with these kits. Many have put over 50k miles on them without a single problem. 2 year warranty. The kit is built with high quality components and customer service has been excellent.

I just found out that ESS has updated the recommended oil for the TS1 and TS2 kit since Castrol 10w-60 TWS is no longer made. I'll update my install notes post once I get the part number.

Also, while they dont' include an oil catch can with the kit, they do say that it is a good idea just to ensure you can keep the laminova cores cleaner. Time to do some shopping for a good affordable catch can kit.

cakM3

05-27-2015, 04:21 AM

... since Castrol 10w-60 TWS is no longer made.

I didn't know that. Where did you hear this??

cakM3

05-27-2015, 04:26 AM

derbo

05-27-2015, 03:58 PM

i've had a lot of turbocharged cars... personally, i don't like their driveability - or lack thereof - when putting power down mid-corner. it's the lag.

supercharger seems like the answer!

peter

Have you driven mid-range powered turbo cars that have the powerband specific to the mid-range? I had a GT2871R turbo Civic and full 16psi was at 2800RPM all the way to 7200RPM. It was no slouch in mid-corners.

Vas

05-27-2015, 06:05 PM

Turbos that are chosen right are a blast. I had a t04 maxima that built full boost at 3k and went to 7k.

rkneeshaw

05-27-2015, 07:12 PM

I didn't know that. Where did you hear this??

Mainly Turner's website:
http://www.turnermotorsport.com/p-1034-bmw-castrol-10w-60-tws-synthetic-oil-e46-m3-e39-m5-e60-m5-e9x-m3.aspx

And a few others:
http://www.zr1.net/forum/showthread.php?p=224620
http://forum.e46fanatics.com/showthread.php?t=626852

But I see a fairly recent post on the interwebs that people have found it showing up at O'Reilly's auto parts stores, so I'm not sure what to think anymore?

When I emailed ESS Tuning this was their response:

Hi Ryan,

You can now use this oil: http://www.vortechsuperchargers.com/page.php?id=30162

Same as we use in on the Vortech chargers.

It can be ordered from ESS or from Vortech

This is special oil for sealed supercharger units

derbo

05-27-2015, 07:37 PM

Mainly Turner's website:
http://www.turnermotorsport.com/p-1034-bmw-castrol-10w-60-tws-synthetic-oil-e46-m3-e39-m5-e60-m5-e9x-m3.aspx

And a few others:
http://www.zr1.net/forum/showthread.php?p=224620
http://forum.e46fanatics.com/showthread.php?t=626852

But I see a fairly recent post on the interwebs that people have found it showing up at O'Reilly's auto parts stores, so I'm not sure what to think anymore?

When I emailed ESS Tuning this was their response:

The weight is the same. Its still 10w60 but it is made by Shell instead of Castrol now due to BMW switching oil brands. Nothing to worry about.

rkneeshaw

05-31-2015, 06:49 PM

I updated the first post with a section regarding the bolt that secures the new idler pullies through the alternator to the oil filter housing gasket. I had to modify that slightly to keep it from bottoming out.

Au2bahn

06-04-2015, 07:56 PM

His name is Jon... :thumbsup

Sent from my iPhone5S using Tapatalk

Should have kept that SCd ZHP. Best kit out there

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johnrando

06-04-2015, 09:00 PM

Hey Jon! Yes, that was sweet.

Sent from mobile

derbo

06-04-2015, 09:40 PM

Should have kept that SCd ZHP. Best kit out there

Sent from my iPhone using Tapatalk

but 997 turbo?!

Au2bahn

06-05-2015, 05:25 AM

Hey Jon! Yes, that was sweet.

Sent from mobile

Hey John. How's Cali treating you? Been awhile man! When are you headed back to east coast?

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Au2bahn

06-05-2015, 05:28 AM

but 997 turbo?!

Hey Derek. Yeah......went back to the Porsche side. Lots of projects planned but will be slow going due to cost. Hahah. Just got wheels and suspension but that's it for this year.

How are things with you ?

Sent from my iPhone using Tapatalk

johnrando

06-05-2015, 12:55 PM

Hey John. How's Cali treating you? Been awhile man! When are you headed back to east coast?

Sent from my iPhone using Tapatalk
Excellent thanks. No time soon. Hope all is well.

Sent from mobile

rkneeshaw

06-05-2015, 07:09 PM

I added a Mishimoto oil catch can to the setup:

http://i1113.photobucket.com/albums/k513/rkneeshaw/2003%20BMW%20330i%20ZHP/temporary_3_8.jpg (http://s1113.photobucket.com/user/rkneeshaw/media/2003%20BMW%20330i%20ZHP/temporary_3_8.jpg.html)

And as you can sort of see in this picture, my intercooler hose that connects to the top intercooler hose barb on the manifold has a desire to kink. I've struggled with that smooth type of hose provided in the latest TS2 kits, it wants to kink so easily. I think I"m going to try to source about a 12 inch section of the ribbed hose they used to provided and splice it in at the top there were its kinking. I thought about a 90 degree elbow for about 5 seconds when I realized it would make it even harder to fill that circuit with coolant.

Sockethead

06-08-2015, 03:20 PM

Good placement for the catch can.... never thought of that...

derbo

06-08-2015, 05:28 PM

Hey Derek. Yeah......went back to the Porsche side. Lots of projects planned but will be slow going due to cost. Hahah. Just got wheels and suspension but that's it for this year.

How are things with you ?

Sent from my iPhone using Tapatalk

Doing great! The Zhp will receive a heart transplant sooner or later. Undecided what I want to do and the savings will continue to save while I do so.

Sent from Mobile

derbo

06-08-2015, 05:29 PM

rkneeshaw

06-11-2015, 04:24 PM

Ave you looked into tool less AN rubber lines? I used this on my old turbo civic setup and it was awesome.

I haven't, do you have a link to this stuff you speak of? My google-foo seems broken.

... I think I"m going to try to source about a 12 inch section of the ribbed hose they used to provided and splice it in at the top there were its kinking. I thought about a 90 degree elbow for about 5 seconds when I realized it would make it even harder to fill that circuit with coolant.

So I'm backing out of this idea. I've had reports from some folks that the ribbed hose they used in the earlier ESS TS2 kits is prone to deteriorating. Probably why ESS is supplying the newer smooth hose. So now I'm back to trying to find some kind of elbow fitting or something, or just letting it ride.

rkneeshaw

06-11-2015, 04:27 PM

By the way, that mishimoto catch can is a fine unit. Very well built, I recommend it.

derbo

06-11-2015, 06:06 PM

I haven't, do you have a link to this stuff you speak of? My google-foo seems broken.

So I'm backing out of this idea. I've had reports from some folks that the ribbed hose they used in the earlier ESS TS2 kits is prone to deteriorating. Probably why ESS is supplying the newer smooth hose. So now I'm back to trying to find some kind of elbow fitting or something, or just letting it ride.

I love Google-Fu. They are called Socket-less AN hoses. They use Barb fittings.

http://aeroquipperformance.com/p-24060-hoses.html

It's not the cheapest of the stuff and I personally used it for coolant lines for my civic's turbo lines. It's the little blue/red one in cute engine bay.

http://img.photobucket.com/albums/v133/crazyxzer0/GT2871R/IMG_9878Small.jpg (http://smg.photobucket.com/user/crazyxzer0/media/GT2871R/IMG_9878Small.jpg.html)

prowlerflyer

06-13-2015, 06:12 AM

So I'm backing out of this idea. I've had reports from some folks that the ribbed hose they used in the earlier ESS TS2 kits is prone to deteriorating. Probably why ESS is supplying the newer smooth hose. So now I'm back to trying to find some kind of elbow fitting or something, or just letting it ride.

Surprising, my stock ESS ribbed hoses are in great shape after 65k miles. They have lived in extreme cold and hot also.

Sockethead

06-13-2015, 06:16 AM

derbo

06-13-2015, 10:46 PM

Not the place for this conversation but that Civic bay looks a lot like my wife's (Kpro) engine bay in her prelude. 325 hp to the front wheels. You guys should have a conversation sometime. She was a big time honda girl. ... Engine swaps, turbo accord, prelude etc.

nice. Yea I had 272whp and it was fun. I'm all for a fun conversation to live hte good ole days, I'm always on facebook messenger /google hangouts. :)

rkneeshaw

06-15-2015, 05:31 PM

Surprising, my stock ESS ribbed hoses are in great shape after 65k miles. They have lived in extreme cold and hot also.

Hmm, that's good to hear. I think someone mentioned that when there is a slight leak near the end of the hose it causes it to disintegrate or something. Wish I had some better facts to point to.

rkneeshaw

06-17-2015, 01:25 PM

Something has been nagging me: ESS started by saying we should use Castrol 10w-60 TWS for the twin screw, and now they recommend the vortech V-3 lubricant. But I wondered if that matched what Lysholm recommends, as they are the real manufacturer of the twin screw unit itself. So I called Lysholm and asked them. They said to ONLY use their special twin screw oil, part number 009028, in their twin screw superchargers. They really didn't tell me more than that, except it costs about $43 per 5.4oz bottle. And that its a special synthetic blend intended to be used with the tight tolerances of these supercharger units. No idea who makes it, what it looks like, or if I can source it from anywhere other than vortech (the parent company who owns lysholm now).

I tried googling it and can find it available through Summit Racing, but that's it, no other info out there.
http://www.summitracing.com/parts/vor-009028

So I ordered some, and I'll take pics and share when I receive it.

bullfrogs_M3

06-17-2015, 06:57 PM

I have some here that I got (from them) when I picked up my car from them, I'll take a pic if you want.

Pics:
http://i1311.photobucket.com/albums/s674/artimasJC/Mobile%20Uploads/8E94AB47-4D6E-4438-8B48-8165315C138C_zpsdlepr1rx.jpg

http://i1311.photobucket.com/albums/s674/artimasJC/Mobile%20Uploads/5A560607-E4FC-42A6-84C5-EEBB7B820606_zpsypjtbduu.jpg

Edit:
Just looked again at your link and my product number and I guess they are different. Sorry about that, hope you can find the right stuff cheaper.

rkneeshaw

06-18-2015, 03:59 AM

Yep I noticed that too, ESS gave you the V-3 lubricant that they told me to get. Thanks for the pics though! I'll post up when I receive the 009028.

prowlerflyer

06-22-2015, 10:40 AM

I saw your other post. Oh no! What happened with the coolant? Suspected bad seal? No coolant in went in the intake, did it? Are you sending the TS2 back to ESS?

Sorry to hear.

rkneeshaw

06-23-2015, 04:21 AM

I saw your other post. Oh no! What happened with the coolant? Suspected bad seal? No coolant in went in the intake, did it? Are you sending the TS2 back to ESS?

Sorry to hear.

Yeah, coolant was leaking from one (or more) of the laminova cores, into the intake, down into cylinder 6, causing misfires every time I tried to fill the intercooler with coolant. Pressure tested it and its supposed to hold over 7 psi but only could hold 1.5psi. Pulled it apart and saw the ends of the laminova cores are heavily damaged, no wonder the o-rings didn't seal. Have to ship the whole intake manifold unit back to ESS. Very frustrating.

http://i1113.photobucket.com/albums/k513/rkneeshaw/2003%20BMW%20330i%20ZHP/temporary_8_3.jpg (http://s1113.photobucket.com/user/rkneeshaw/media/2003%20BMW%20330i%20ZHP/temporary_8_3.jpg.html)

http://i1113.photobucket.com/albums/k513/rkneeshaw/2003%20BMW%20330i%20ZHP/temporary_6_6.jpg (http://s1113.photobucket.com/user/rkneeshaw/media/2003%20BMW%20330i%20ZHP/temporary_6_6.jpg.html)

I suspect that when they installed the end-caps on the manifold that they were not on straight when they started to torque them down, and by smashing the o-rings in there they smashed in the ends of the cores and damaged the o-rings. I still dont know how this passed their pressure test before they shipped it to me...

prowlerflyer

06-23-2015, 06:21 AM

Really sorry to hear that it turned out the way it did. Will be interesting to hear what feedback you get from ESS. Best of luckbest of luck .

rkneeshaw

06-23-2015, 06:52 AM

Really sorry to hear that it turned out the way it did. Will be interesting to hear what feedback you get from ESS. Best of luckbest of luck .

Thanks powerflyer, I hope I've used up all my bad luck during my TS2 install and that things go well from now on :)

rkneeshaw

06-23-2015, 07:05 AM

I had to clear up some confusion on the proper amount of oil to fill the lysholm unit with. Lysholm was saying I should use 5.4oz instead of the 4oz/120ml that ESS has told us to use. So I emailed lysholm and this was their response:

Would the amount of oil used in the 1.6L unit be different if the unit is mounted sideways? Attached is a picture of how this unit sits in my car. The tuner who sold me the supercharger kit has always said to use exactly 120ml/4oz of oil with each oil change. Is that because the unit is mounted sideways, or are they mistaken?

Hi Ryan, considering the mounting position in this application with the unit on its side and the input shaft at the bottom, the 4 oz. oil should be correct. The 5.4 oz. fill amount would be necessary when mounted horizontally.

So official word is: use 4oz/120ml of the vortech P/N 009028 twin screw oil every 15k miles. :thumbup

But, you could probably use 4oz/120ml of the Castrol 10w60 TWS or the Vortech V-3 (009035) lube if you want, because its what everyone has been using for years with no problems.

EDIT: I guess not, lysholm says that the V-3 (009035) lube is different than the twin screw oil (009028), so use it at your own risk

The lubricant for the Lysholm units is completely different from the lubricant for the centrifugal Vortech/Paxton units. We would strongly discourage using the lubricant for one in the other.

johnrando

06-24-2015, 07:12 AM

Thanks powerflyer, I hope I've used up all my bad luck during my TS2 install and that things go well from now on :)

+1

rkneeshaw

06-24-2015, 06:53 PM

Ok guys, check this out. I received vortech part number 009028:

http://i1113.photobucket.com/albums/k513/rkneeshaw/2003%20BMW%20330i%20ZHP/temporary_3_11.jpg (http://s1113.photobucket.com/user/rkneeshaw/media/2003%20BMW%20330i%20ZHP/temporary_3_11.jpg.html)

Made by Nye lubricants. Its their synthetic oil 605.

I did some googling. Apparently Eaton, Saleen twin screw, Jaguar, Mercedes, Ford and GM superchargers all use it.

http://saleenforums.soec.org/showthread.php?t=18447
http://www.svtperformance.com/forums/showthread.php?630092-Changing-the-oil-in-my-eaton-HELP!!&p=8719212&viewfull=1#post8719212
http://www.svtperformance.com/forums/showthread.php?750678-Supercharger-oil-!-!
http://www.jaguarforum.com/showthread.php?t=27601

Even Mercedes Benz uses it as factory fill on their Kompressors:
http://www.pelicanparts.com/techarticles/Mercedes-SLK230/90-ENGINE-Supercharger_Oil_Change/90-ENGINE-Supercharger_Oil_Change.htm

Some good discussions in there about the difference between this Nye Synthentic Oil 605 and motor oils such as 10w-40, TWS 10w-60, etc. Basically regular motor oil is too thick. What is needed for these twin screws is a thinner gear oil.

Especially interesting is that in many of these OEM applications that spec the Nye synthetic 605 or equivalent supercharger oil it is a lifetime fill.

This is a place in the UK selling a 500ml bottle, and in the description it says

A light viscosity, ester oil intended for powdered metal parts and gears with low volatility. Benefits include excellent oxidation stability and low wear characteristics. EP fortified and including a copper deactivator. Synthetic oil 605 is used extensively in automotive superchargers for bearing and gear lubrication.
http://newgateonline.com/synthetic-oil-605-500ml-bottle.html

Apparently Nye Synthetic Oil 605 is also available under GM part number 12345982, or Ford specification ESE-M99C115-A.

I've attached the Nye 605 datasheet and it lists the Ford and GM specs/part numbers too.

20465

I referenced the Ford specification and found this, Motorcraft XL-4, in a convenient 4oz bottle:
https://www.fcsdchemicalsandlubricants.com/main/product.asp?product=Synthetic%20Supercharger%20Flu id&category=Greases

The GM part number is also a 4oz bottle.

The Motorcraft/Ford XL-4 is $22, and the GM packaged stuff is only $12
http://www.amazon.com/Genuine-Ford-XL-4-Synthetic-Supercharger/dp/B000NUERYW
http://www.amazon.com/Genuine-Fluid-12345982-Supercharger-Oil/dp/B000QIR2ZC

So. I paid like $50 to get this "official" vortech part number 009028 to my door, and I should have just ordered the same stuff under GM part number 12345982 for $12. Now we know!

rkneeshaw

07-08-2015, 06:45 PM

rkneeshaw

07-08-2015, 07:21 PM

ok so for those that are curious, the intake manifold gasket appears to be a material from a company called Burgmann. But I can't tell what kind it is.

http://i1113.photobucket.com/albums/k513/rkneeshaw/2003%20BMW%20330i%20ZHP/temporary_3_12.jpg (http://s1113.photobucket.com/user/rkneeshaw/media/2003%20BMW%20330i%20ZHP/temporary_3_12.jpg.html)

Guess if you ever have to remove your TS manifold you will just need to order one from ESS ahead of time. I can tell you from experience, as soon as you bolt that manifold down you won't be re-using that gasket.

Oli77

07-09-2015, 05:20 PM

Its asbestos. You can see the French word for it Amiante.

rkneeshaw

11-08-2015, 07:27 AM

Updated first post with a couple more recommendations.

I've had a few issues that I've been diagnosing over the summer, but I'm getting those dialed in and the kit is really starting to run great!

rkneeshaw

09-15-2016, 04:28 PM

This is so good I have to steal it from sockethead's thread and post it here too

After spending three hours trying to purge the intercooler of air, I gave up for the night. ESS instructions say to pull the top hose off and manually fill the 5/8 hose with antifreeze until it drips out the fitting on the manifold. This method relies on gravity to purge the air out and, as we all know from our cooling systems, this can be a bitch even with a bleeder and an expansion tank.
I thought about it in bed last night and the solution is so simple I'm surprised I didn't think of it sooner. Got the intercooler purged in less than 5 minutes by getting some couplings and extending the return line using two hoses into a small bucket of antifreeze. The air in the return line could escape in the bucket while the suction sucked in all antifreeze.

Here it is in action:

https://vimeo.com/182184408

This is after all the air was purged out...

https://vimeo.com/182184571

L0veZHP

03-12-2017, 08:01 PM

I recently bought a Dinan High Body Throttle, Silicon Hoses, and a Gruppe M intake. I'm not going to by a supercharger yet but when I do I plan on buying a stage 1 twin screw. If I were to install that supercharger would I lose out on my new mods? just a quick question

Sockethead

03-13-2017, 04:59 AM

ESS recommends the stock air box but I'm using a Dinan and Ryan is using the BMW performance intake.
I basically lied and told them I was using the stock airbox. IDK if it's because of that or other factors but it's been a PITA tuning my TS2. I've often wondered what it would sound like with that style intake on it.
The silicone hoses will have to go but you can use the throttle body but the throttle body only adds maybe 5 hp if you're lucky

L0veZHP

03-13-2017, 11:54 PM

Thanks for the heads up! I was just worried because both the throttle body and intake cost a pretty penny. The hoses I wouldn't mind losing out on. But not my throttle body or intake. I rather just stay N/A and keep my parts and let my car last longer and save money. But if i can keep both then I might just get the supercharger in the future.

Sockethead

03-14-2017, 06:22 AM

The stage 1 doesn't add enough HP to jeopardize the engine. You'll be fine. Surprisingly, the engines in our cars can take quite a bit of HP.

L0veZHP

03-14-2017, 03:02 PM

I plan to go stage 1 and stay there. I have an automatic so I don't want to jeopardize the tranmission either. Quick question again. If I buy the supercharger, can i just "plug and play" for a while? I'll probably be getting a custom tune later on for it.

Sockethead

03-15-2017, 07:11 AM

The tune is included with the purchase of the Supercharger as well as the software and cable to download and upload to the DME. It's really easy to use the software and it also reads and resets trouble codes (check engine light)

I wouldn't run the car without a tune. If it happens to be running really lean, it will damage the engine.

rkneeshaw

10-28-2018, 03:51 PM

Found some replacement studs for the intake manifold studs that I believe are stronger, and are 10mm shorter (which you will greatly appreciate if you have to install or remove that manifold). BMW part number (07129908199)

Also, I think using blue loctite on that intake manifold gasket makes it brittle. I did some research and I think the Permatex High-Tack Spray-A-Gasket Sealant would be more appropriate.

First post updated.

Sockethead

10-29-2018, 05:00 AM

I used a thin layer of Permatex silicone. Using loctite on it just didn't make any sense to me. Next time I'm going to use the spray a gasket or nothing at all

rkneeshaw

10-29-2018, 04:55 PM

That Permatex silicone probably isn't such a bad idea. Makes more sense to me than blue loctite.

I did some digging around permatex' website and if we have a paper gasket like this all you need is a light sealant/sealer to help hold the gasket in place and condition it. And as for the rest the gasket should do its job.

Sockethead

10-29-2018, 05:38 PM

Yep, that why I was thinking of just putting it in dry... the studs will hold it in place.
If I do use anything, I usually use Permatex High Tack Gasket Sealant to keep the gasket in place if needed