ZHP ESS TS2 Project - (PICS)

[Au2bahn]

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. It took 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. Its definitely quick!!!! Here are some pics of the process:

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://i993.photobucket.com/albums/af59/estrellajon/BMW/ESS%20TS2%20Upgrade/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

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

Vanos Rebuild Process:
http://i993.photobucket.com/albums/af59/estrellajon/BMW/ESS%20TS2%20Upgrade/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://i993.photobucket.com/albums/af59/estrellajon/BMW/ESS%20TS2%20Upgrade/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://i993.photobucket.com/albums/af59/estrellajon/BMW/ESS%20TS2%20Upgrade/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://i993.photobucket.com/albums/af59/estrellajon/BMW/ESS%20TS2%20Upgrade/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://i993.photobucket.com/albums/af59/estrellajon/BMW/ESS%20TS2%20Upgrade/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

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

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

Intake Manifold Removed:
http://i993.photobucket.com/albums/af59/estrellajon/BMW/ESS%20TS2%20Upgrade/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://i993.photobucket.com/albums/af59/estrellajon/BMW/ESS%20TS2%20Upgrade/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

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

New Bigger injectors:
http://i993.photobucket.com/albums/af59/estrellajon/BMW/ESS%20TS2%20Upgrade/2011-01-09_14-54-50_275.jpg
http://i9[IMG]http://i993.photobucket.com/albums/af59/estrellajon/BMW/ESS%20TS2%20Upgrade/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

IC Pump:
http://i993.photobucket.com/albums/af59/estrellajon/BMW/ESS%20TS2%20Upgrade/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_20-54-59_636.jpg
http://i993.photobucket.com/albums/af59/estrellajon/BMW/ESS%20TS2%20Upgrade/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

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://i993.photobucket.com/albums/af59/estrellajon/BMW/ESS%20TS2%20Upgrade/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

Final install stages:
http://i993.photobucket.com/albums/af59/estrellajon/BMW/2011-02-13_14-28-49_293.jpg

Oil Separator since the oem CCV is gone:
http://i993.photobucket.com/albums/af59/estrellajon/BMW/2011-02-13_13-29-24_792.jpg

Ran SS hoses for durability:
http://i993.photobucket.com/albums/af59/estrellajon/BMW/2011-02-13_13-30-02_774.jpg
http://i993.photobucket.com/albums/af59/estrellajon/BMW/2011-02-13_13-30-14_77.jpg
http://i993.photobucket.com/albums/af59/estrellajon/BMW/2011-02-13_13-29-52_249.jpg

Ran SS hoses for durability:
http://i993.photobucket.com/albums/af59/estrellajon/BMW/2011-02-13_13-30-02_774.jpg
http://i993.photobucket.com/albums/af59/estrellajon/BMW/2011-02-13_13-30-14_77.jpg
http://i993.photobucket.com/albums/af59/estrellajon/BMW/2011-02-13_13-29-52_249.jpg


Rest of engine components installed:
http://i993.photobucket.com/albums/af59/estrellajon/BMW/2011-02-13_14-13-06_132.jpg
http://i993.photobucket.com/albums/af59/estrellajon/BMW/2011-02-13_17-57-33_757.jpg

......and DONE!
http://i993.photobucket.com/albums/af59/estrellajon/BMW/2011-02-13_14-29-07_473.jpg

[kayger12]

Now THAT's what I'm talking about.

Great project thread!

[Marcus-SanDiego]

And this, my friends, is why I love the projects forum (http://www.zhpmafia.com/forums/forumdisplay.php?48-Projects).

[danewilson77]

Mind blown.

[mimalmo]

Very nice! Did you get some before & after dyno numbers?

[Au2bahn]

Thanks and No....I have not done any dynos yet. I will definitely post as soon as I do.

Currently, it runs very very strong hitting 9psi at full boost using an AEM digital boost gauge.

All the mods are not seen from the outside.....but I have definitely shocked a few M3's, 550's and Carrera's. My car shows the unique lines of the ZHP using OEM add ons as much as I can except for the wheels and a drop.

[Oli77]

:praise


:theman

[Mtnman]

Ok. Now im extremely jealous. Especially the fact you keep most of the exterior OEM. and i thought a normal ZHP was sneaky fast...... Excellent job.

[05ZIPPYZHP]

Beautifully done.... The attention to detail is also something to be proud of: taping off inlets, sealing up ports with rags and placing everything off the ground. Excellent job:applause2:applause2

[Marcus-SanDiego]

Thanks and No....I have not done any dynos yet. I will definitely post as soon as I do.

Currently, it runs very very strong hitting 9psi at full boost using an AEM digital boost gauge.

All the mods are not seen from the outside.....but I have definitely shocked a few M3's, 550's and Carrera's. My car shows the unique lines of the ZHP using OEM add ons as much as I can except for the wheels a drop.

Jon, that's great stuff.

Are you going to the Virginia Mafia meet in 12 days?

[Au2bahn]

Thanks Marcus. I was thinking of coming down for that meet. Its about 3 hours south of where I am. I know you're flying in. Ill try to make it. I know some ZHP guys from Northern VA are coming down.


Jon, that's great stuff.

Are you going to the Virginia Mafia meet in 12 days?

[Marcus-SanDiego]

Jon, absolutely. You should come down. You're about 150 miles away (I'm guessing). I'm 3000 miles away. Therefore, make it happen, Jon!

Sign up in this thread (go to the list and add your name): http://www.zhpmafia.com/forums/showthread.php?1079-ZHP-Mafia-Family-Reunion-June-10-2011-thru-June-12-2011-in-Williamsburg-Virginia

[Au2bahn]

Ok. Now im extremely jealous. Especially the fact you keep most of the exterior OEM. and i thought a normal ZHP was sneaky fast...... Excellent job.

Thanks. ZHP is already pretty quick. But I like sleeper cars which makes it a blast to drive. It really is a different beast once it hits full boost along with that SC whine. Normal driving is like any other ZHP.


Beautifully done.... The attention to detail is also something to be proud of: taping off inlets, sealing up ports with rags and placing everything off the ground. Excellent job:applause2:applause2

Yeah. I really took my time. I even cleaned up the ports when I took off the stock intake manifold. I took it to a Deutsche Marque car show and won first place. I got a perfect score on the engine compartment alone.

[Au2bahn]

LOL. Im signing up


Jon, absolutely. You should come down. You're about 150 miles away (I'm guessing). I'm 3000 miles away. Therefore, make it happen, Jon!

Sign up in this thread (go to the list and add your name): http://www.zhpmafia.com/forums/showthread.php?1079-ZHP-Mafia-Family-Reunion-June-10-2011-thru-June-12-2011-in-Williamsburg-Virginia

[Marcus-SanDiego]

LOL. Im signing up

Great. Now promise that you will take me for a spin your ZHP.

[Au2bahn]

Of course!! But only you :-)


Great. Now promise that you will take me for a spin your ZHP.

[danewilson77]

Of course!! But only you :-)

Wut?

Droid + Tapatalk = FTW!

[spencers]

:drool

[billschusteriv]

Wow! Nice thread!

[Alphatek45]

Speechless... Nicely done! Id like to see the numbers too.

[az3579]

Of course!! But only you :-)

Aww, come on man... me too, pleeeeeeease! Maybe this will sway my decision to stay stock...

[JohnnyGraphic]

I remember when this unit first came out. Absolutely stunning kit and performance! I was tempted to get one, but us Californian's are stuck-No CARB certification.

Great job on the install and the pics too. Your engine bay is operating room clean!!

Johnny

[zhpnsnv]

Awesome job. I will consider this if my zhp ever becomes a weekend only toy. M3 power for much less $. Actually it's probably got more than m3 power.


Sent from my iPhone using Tapatalk

[Au2bahn]

Thanks!!!! Definitely a solid kit. I did extensive research and ESS was top of the line F/I kit with no issues and close to stock looking as possible. Although not an M, definitely more power and I realized this in real world experience :-). Besides ZHPs are rarer.

[Marcus-SanDiego]

Besides ZHPs are rarer.

And you forgot: not very special. :biggrin

[Au2bahn]

Lol. Oh yeah that too.

[danewilson77]

Lol. Oh yeah that too.

+1

Droid + Tapatalk = FTW!

[CERF04ZHP]

Jon, I am envious of you. ESS S/C and 3.64 rear end... Dayyyyyyyyyyyyyyum.
Great picture thread. Loving the attention to detail and thorough cleaning of each and every part.
It must really pull hard after 3k or so...
In fact, I think you should send some of your better high-res. pictures of the finished product to ESS to showcase on ther website. Your's look better than what they currently have up there.
Nice job man!

[Au2bahn]

Thanks Channing. Cleaning all the components was part of the fun. I took the time to replace parts while Im in there and clean areas that were hard to reach. ESS S/C is a solid product. The car definitely pulls hard after 3k but its the instant boost right from first gear what it does best.

Some mafia folks has seen it in person at the meet last weekend. Try to make it next year.


Jon, I am envious of you. ESS S/C and 3.64 rear end... Dayyyyyyyyyyyyyyum.
Great picture thread. Loving the attention to detail and thorough cleaning of each and every part.
It must really pull hard after 3k or so...
In fact, I think you should send some of your better high-res. pictures of the finished product to ESS to showcase on ther website. Your's look better than what they currently have up there.
Nice job man!

[zhpnsnv]

Jon - what did you do for software after the TS install?

[Au2bahn]

Its ESS custom program. I had to send my DME to ESS in AZ. They re-program based on what I have and the S/C. So if I install headers, I have to send the DME back to ESS for tuning and O2 sensor delete.

Installing the S/C removes the DISA and CCV. Two common problems in my opinion.


Jon - what did you do for software after the TS install?

[zhpnsnv]

Gotcha. Have you had inspection/emissions issues? The TS2 ZHP that I drove was having emissions problems because the tune was messing (somehow) with the o2 sensors. Chris, who's on this board somewhere, has to send his DME back for some sort of update, I think.

And I believe you about the 335s. The car I drove felt much quicker, to me, than a 335.

[static667]

That thing is just plain sick. I got to witness it in person at the meet. Very slick.

[Au2bahn]

I had emission inspections done 2 months ago with no issues. Upon installation, I ensured all areas that I felt would be prone to leaks were sealed properly. Once a setup encounters a slight leak, the car will run rich and cause emission issues. I ran into a enthusiast in one of the meets in NOVA and he had an ESS as well. He told me he was running rich for months. When I looked at it, the EGR hose was disconnected for some reason. He emailed me back 2 weeks later stating that his CEL never came back and the car ran better.

The 335's do have potential with the right mods. I've been installing upgrades on my buddies 335. PITA to work on but its starting to get quick.


Gotcha. Have you had inspection/emissions issues? The TS2 ZHP that I drove was having emissions problems because the tune was messing (somehow) with the o2 sensors. Chris, who's on this board somewhere, has to send his DME back for some sort of update, I think.

And I believe you about the 335s. The car I drove felt much quicker, to me, than a 335.

[Au2bahn]

Yep....you were there!!! I remember you. :-)



That thing is just plain sick. I got to witness it in person at the meet. Very slick.

[kayger12]

Car is absolutely sick. Was my favorite car in Williamsburg.

Glad I was able to see it in person.

[Au2bahn]

Thanks Keith!!! Let me know when you guys sell the CF diffuser. I will be the first customer.


Car is absolutely sick. Was my favorite car in Williamsburg.

Glad I was able to see it in person.

[kayger12]

Haha. Deal.

[JohnnyGraphic]

Wish #1-Money for S/C.
Wish #2-CARB certification for California.

[CERF04ZHP]

Jon - just a couple quick Q's:
1.) With the 3.46 rear end, what are kind of RPM's are you turning at 80mph?
2.) I was poking around on the ESS website... for your project, did you also opt for their performance camshafts, or just use the factory ZHP cams?

[billschusteriv]

Didn't get any time to talk to you during the meet Jon, but it was nice to see you and the car come down. It looked and sounded great.

[Au2bahn]

Thanks Bill. I didnt get a chance to make my way over on your side. Were close so Im sure one of the meets, we'll catch up.



Didn't get any time to talk to you during the meet Jon, but it was nice to see you and the car come down. It looked and sounded great.

[Hornung418]

Jon, I was looking for you when we went on the cruise. We went through a nice tunnel, I thought it would be magical if you passed all 20 of us at WOT...but then I found out you had left earlier :( Oh well, there's always BimmerFest East ;)

[Au2bahn]

On the 3.46 diff, I can definitely tell higher rpms. I believe Im around 3k on 6th gear at 80mph. Definitely quicker through the first 3 gears but kills my top end especially with S/C since it gets there a lot quicker. I may go 3.38 lsd soon.

I haven't done SC cams yet. That would be a TS2+ upgrade which requires the TS2+ kit and headers. That would be my next project. I should have done it when I had my vanos off. But I was already over budget on the project. The ZHP alpina cams works well with the SC so right now Im happy with it.


Jon - just a couple quick Q's:
1.) With the 3.46 rear end, what are kind of RPM's are you turning at 80mph?
2.) I was poking around on the ESS website... for your project, did you also opt for their performance camshafts, or just use the factory ZHP cams?

[Au2bahn]

Yeah, had to leave early. I would have loved to join the cruise. Bimmerfest coming up!!! Ill be there.



Jon, I was looking for you when we went on the cruise. We went through a nice tunnel, I thought it would be magical if you passed all 20 of us at WOT...but then I found out you had left earlier :( Oh well, there's always BimmerFest East ;)

[Muggzie]

Damn that's awesome now I wanna get my ts2 project going be been getting to busy to start but that sick man good job on the write up an pics

[Au2bahn]

A few weeks ago, I upgraded to an OEM BMW Performance SSK. I love the shorter shifts. A little bit shorter throw than the OEM shifter that came with our cars. Since OEM selector rods are one sided and the SSK is more precise, I feel a little play when shifting. Im not a big fan of UUC but their DSSR is the only design that makes sense to me so I had to try it. It also weighs 3 times more than the stock ones.

No way around it but the exhaust pipe, heat shield and transmission bracket had to come off.
http://i993.photobucket.com/albums/af59/estrellajon/BMW/DSSR-SSK_upgrade/2011-07-01_13-42-01_349.jpg

This is how it looks with all the pieces are out of the way.
http://i993.photobucket.com/albums/af59/estrellajon/BMW/DSSR-SSK_upgrade/2011-07-01_13-42-44_459.jpg

This is the original selector rod:
http://i993.photobucket.com/albums/af59/estrellajon/BMW/DSSR-SSK_upgrade/2011-07-01_14-03-06_715.jpg

Shifter from the bottom:
http://i993.photobucket.com/albums/af59/estrellajon/BMW/DSSR-SSK_upgrade/2011-07-01_14-03-25_378.jpg

This is the difference between OEM ZHP (Top) and BMW Performance SSK (Bottom). Notice the curve and longer length from the ball center:
http://i993.photobucket.com/albums/af59/estrellajon/BMW/DSSR-SSK_upgrade/2011-07-01_14-31-46_256_1.jpg

Side by side pic of OEM selector rod (Top) and UUC DSSR (Bottom):
http://i993.photobucket.com/albums/af59/estrellajon/BMW/DSSR-SSK_upgrade/2011-07-01_14-05-44_956.jpg

DSSR secured into the shifter:
http://i993.photobucket.com/albums/af59/estrellajon/BMW/DSSR-SSK_upgrade/2011-07-01_18-12-43_414.jpg
http://i993.photobucket.com/albums/af59/estrellajon/BMW/DSSR-SSK_upgrade/2011-07-01_18-13-35_199.jpg

Overall, its definitely tighter and slop has been eliminated.

[Muggzie]

Would the m3 kit work on the zhp or would they not be comparable?

[static667]

Now I'm considering the DSSR for mine. I have the BMW Performance kit and I didn't have the curve in my shifter. It's probably something new they started and I got an old unit off the shelf. :(

[Au2bahn]

Its different. The closest "M" shifter that will work is from a Z3M.



Would the m3 kit work on the zhp or would they not be comparable?

[Au2bahn]

There are two types of BMW Performance SSK. Apparently, The BMW Performance kit you got is the exact same as the OEM ZHP shifter. Its still good but there is also a BMW Performance SSK which is a bit shorter than the ZHP one. Based on my research, the one I have (curved one) is only for 6 speed transmissions.



Now I'm considering the DSSR for mine. I have the BMW Performance kit and I didn't have the curve in my shifter. It's probably something new they started and I got an old unit off the shelf. :(

[VA//M3]

Jon, I saw you yesterday blowing through traffic on RT 7 yesterday :o -- I promptly followed. :eeps

Quick question. What did you do with the lower CCV valve port on the dipstick tube?

Plugged it up?

Been really thinking about going ESS. Not sure what to expect performance wise though...

[Au2bahn]

Say whaaat? There was no traffic. Was that you in the coupe? :-)

Yes, the CCV hose that goes to the dipstick tube is now plugged.

Twin Screw is awesome. The problem is, once I got used to more power, I look for more ways to add more.



Jon, I saw you yesterday blowing through traffic on RT 7 yesterday :o -- I promptly followed. :eeps

Quick question. What did you do with the lower CCV valve port on the dipstick tube?

Plugged it up?

Been really thinking about going ESS. Not sure what to expect performance wise though...

[danewilson77]

^Horsepower is addicting.

[Au2bahn]

.......and never enough



^Horsepower is addicting.

[VA//M3]

Say whaaat? There was no traffic. Was that you in the coupe? :-)

Yes, the CCV hose that goes to the dipstick tube is now plugged.

Twin Screw is awesome. The problem is, once I got used to more power, I look for more ways to add more.

yep, that was me! I was going to follow you once you made a right on belmont ridge and then take ryan rd to my place but loundoun county parkway was more of a direct shot for me.

Traffic wasn't bad but you have alot of faith on virginia drivers-- a place where 70 mph has everyone shaking lol and also a place where most everyone is accustomed to 55mph and can't judge speeds very well from looking at their mirrors.

When I first started driving here I used to drive very aggressively and pass everyone etc. like I did In california or Oklahoma. But over here I get people getting in front of my lane and not paying attention to their rear view mirrors and tons of shenanigans. I've had a lot of close calls because of other drivers stupid decisions around here so I drive like a grandma 70% of the time.

But since you were leading the way I figured why the hell not and figured you were most likely to get hit instead of me :biggrin Probably not since a old mercedez almost pulled out in front of me after you blew by him... lol

Interesting,

I might delete my CCV valve soon and install a catch can. Was that part of the ESS kit? I wonder if I could just get the catch can and hoses.

[Testarossa]

Awesome build. Love the mods that go with the car!!!

[rickflairne]

If you don't mind me asking, what was the promo they (ESS) was offering?

[Scorpius]

like the commercials.....THATS AMAZING...
wow man. nice job. (a 6 out of 10??? you gotta be kidding. I could see the heart beating in there...makes me shiver thinking about it.)

[SoarinZHP]

This is the shizz. Nice work!

[M0nk3y]

^Horsepower is addicting.


.......and never enough

Story of my life.

Great thread OP. Truly a awesome build

[Au2bahn]

Thanks. Its really a nice sleeper. It is amazing how these M54B30 motors perform with FI together with the stock ZHP cams.


Next winter project will be headers, TS pulley and exhaust cam upgrade.



like the commercials.....THATS AMAZING...
wow man. nice job. (a 6 out of 10??? you gotta be kidding. I could see the heart beating in there...makes me shiver thinking about it.)


This is the shizz. Nice work!

[Au2bahn]

After a couple thousand miles on the TS2, I noticed a slight surge up top the rpm range. Hardly noticeable but enough to bug me knowing it exists. After some research, I have concluded that the exhaust gases is unable to keep up with the added boost the supercharger is generating. Before I upgrade my TS pulley and exhaust cam to increase more boost, I purchased a set of Magnaflow headers to keep up with the increased flow. Although its not cheap, I want to ensure its very good quality, not produce rasp or drone and be legal enough in my state. I will keep the ZHP exhaust to control the sound level. I may also do before and after dyno so I can see if its worth the upgrade.

I will most likely have it ceramic coated to reduce heat. This will be part of an upcoming project so stay tuned................

[danewilson77]

Sounds exciting A2B. Well done.

HTC Thunderbolt+TT

[johnrando]

Sounds exciting A2B. Well done.

HTC Thunderbolt+TT

+1

[Hornung418]

Mmmmm Magnaflow headers...not sure that they're worth the cost but if it's what you need to stay legal than that's what it takes!

Can't wait to see the out come!

[Mtnman]

Yeah. Awesome jon. This is me typing jealously......

Sent from my DROID2 GLOBAL using Tapatalk

[Au2bahn]

This is the only way to add headers and be legal and system "ready". Cheap headers will show the system as "not ready" and wont be able to pass state emissions. The magnaflow headers is 49 state legal except for Cali.

After I do dyno before and after then I can report it here.



Mmmmm Magnaflow headers...not sure that they're worth the cost but if it's what you need to stay legal than that's what it takes!

Can't wait to see the out come!

[Hornung418]

Yeah I know the whole deal. One of the downfalls of the MS45.1 DME. No Euro coding :( Looking forward to the results, Jon!

[Au2bahn]

So.....euro coding do not require all these non-sense?


Yeah I know the whole deal. One of the downfalls of the MS45.1 DME. No Euro coding :( Looking forward to the results, Jon!

[Hornung418]

Euro cars only ever got MS43 DMEs and they had several emissions standard coding one of which was catless.

[Go Horns!]

You get the headers on yet? I'm wondering if I should ask Santa for a set of Magnaflows for Christmas.

[Au2bahn]

You get the headers on yet? I'm wondering if I should ask Santa for a set of Magnaflows for Christmas.

I just got it back from Swain Tech Coatings as I had it ceramic coated which took a month to get back. I will be starting the install this weekend. I will be taking some pics along the way.

[prowlerflyer]

Really interested to hear your impressions of adding headers with the TS2. I have a TS2, but with stock headers. ESS seemed to feel headers would really wake up things a bit. Does the Magnaflow headers have attached cats? I thought that the Supersprint ones were the only smog legal ones because of the integral cats. $4k from Turner is a bit too rich for my blood right now for the SS ones.

Sent from my DROIDX using Tapatalk

[Au2bahn]

Ill definitely post up on first impressions after the header install. The Magnaflow headers comes with integral race cats that's legal in 49 states and opens up the flow for my TS setup. I did tons of research including the Supersprint where the cats are located down stream . Based on my research and folks I know locally who has the Supersprint had mixed reviews on the CEL turning on at times but not all encounter this. Also, some systems do not show a ready state and therefore unable to pass emissions to get the car registered. Based on reviews on the Magnaflow with folks with a supercharger, they definitely noticed a difference AND shows the system as ready for emissions. I will give my own feedback once its on but right now the Swain coating on it looks top notch.



Really interested to hear your impressions of adding headers with the TS2. I have a TS2, but with stock headers. ESS seemed to feel headers would really wake up things a bit. Does the Magnaflow headers have attached cats? I thought that the Supersprint ones were the only smog legal ones because of the integral cats. $4k from Turner is a bit too rich for my blood right now for the SS ones.

Sent from my DROIDX using Tapatalk

[cakM3]

After having the pleasure of driving Steve's TS2 I know what I will be doing to my ZHP sometime in the future.....all I can say is that having one can be addicting...:biggrin

[Au2bahn]

Do it Charlie!!! Its definitely addicting especially the sound at 5k rpm's.


After having the pleasure of driving Steve's TS2 I know what I will be doing to my ZHP sometime in the future.....all I can say is that having one can be addicting...:biggrin

[cakM3]

Yeah but the sound my ///M makes at 6000 is raw and brutal....what got me when Steve let me try his ZHP was the outright acceleration....man was it fast! Loved it :^)

Nothing better than having a ZHP that can hang with any stock ///M... FTW :thumbsup

[Au2bahn]

Update pic of BBK upgrade installed a month ago. Excellent performance at the track as well as the street. Definitely noticeable during street usage; however, I will upgrade the pads to Hawk Performance Ceramic. I dont like the brembo pads it came with. Very dirty.

http://i993.photobucket.com/albums/af59/estrellajon/Snapbucket/6e2174e5-e7cc-4233-844b-f1c526d09c14.jpg

[Au2bahn]

Headers came in last week from Swain. Didn't get a chance to work on it yet so here they are ready to be installed. Still waiting for gaskets and new bolts from ECS.

http://i993.photobucket.com/albums/af59/estrellajon/Snapbucket/64C9E69B-orig.jpg
http://i993.photobucket.com/albums/af59/estrellajon/Snapbucket/C1C5A761-orig.jpg
http://i993.photobucket.com/albums/af59/estrellajon/Snapbucket/CF858A8E-orig.jpg

[danewilson77]

Very nice update. Looking really good. Perfect in fact.

HTC Thunderbolt+TT

[Au2bahn]

Thanks Dane. Ill make sure to document the header install and engine bay touch up.


Very nice update. Looking really good. Perfect in fact.

HTC Thunderbolt+TT

[Hornung418]

Looks good, Jon!

Courtesy of Gingerbread...

[az3579]

Update pic of BBK upgrade installed a month ago. Excellent performance at the track as well as the street. Definitely noticeable during street usage; however, I will upgrade the pads to Hawk Performance Ceramic. I dont like the brembo pads it came with. Very dirty.

http://i993.photobucket.com/albums/af59/estrellajon/Snapbucket/6e2174e5-e7cc-4233-844b-f1c526d09c14.jpg

Definitely good to hear. I plan on ordering with my next paycheck...


Have you found pedal feel to be significantly better?

[Au2bahn]

Thanks Justin.


Looks good, Jon!

Courtesy of Gingerbread...


Yes. Definitely better. I did not think I would notice on street use; since I had good pads before the BBK upgrade. Noticeable on hard braking and from high speed, especially after the pads are bedded. I definitely recommend upgraded pads though. I know it will be even better.


Definitely good to hear. I plan on ordering with my next paycheck...


Have you found pedal feel to be significantly better?

[az3579]

Hawk Ceramics are definitely going in once I get this kit. Then I'll swap in the pads that came with it for track use.
What pads did it come with, exactly? I thought they were OEM 135/330i pads designed for this caliper?

[Au2bahn]

They are OEM for the 135's but made by brembo for these calipers. It has the brembo logo on them. They have that OEM "soft" feel and dust like crazy but works well.

[az3579]

I just hope they're resistant to fading; don't want to have to get an entirely different set of pads for the track...
Do you have plans for the track?

[Au2bahn]

Hmmmm. I took it to FATT (Fridays at the track) at Summit Point earlier this month. I would say the OEM pads did fade a bit towards the end of the day.

[Au2bahn]

I've taken these pics awhile back while doing the headers and exhaust install. Sorry, Got really busy the past 2 months. Removal and Install of headers took about 2 hours. although, I soaked the O2 sensors in fuel for 24 hours to loosen any residue then sprayed with MAF cleaner.

Starting to remove pieces to better leverage exhaust manifold removal:
http://i993.photobucket.com/albums/af59/estrellajon/BMW/Exhaust/DSC01080.jpg

OEM exhaust manifold removed:

http://i993.photobucket.com/albums/af59/estrellajon/BMW/Exhaust/DSC01066.jpg
http://i993.photobucket.com/albums/af59/estrellajon/BMW/Exhaust/DSC01067.jpg
http://i993.photobucket.com/albums/af59/estrellajon/BMW/Exhaust/DSC01068.jpg
http://i993.photobucket.com/albums/af59/estrellajon/BMW/Exhaust/DSC01069.jpg

With new Swain Tech Coated Magnaflow headers:

http://i993.photobucket.com/albums/af59/estrellajon/BMW/Exhaust/DSC01071.jpg
http://i993.photobucket.com/albums/af59/estrellajon/BMW/Exhaust/DSC01072.jpg
http://i993.photobucket.com/albums/af59/estrellajon/BMW/Exhaust/DSC01077.jpg
http://i993.photobucket.com/albums/af59/estrellajon/BMW/Exhaust/DSC01073.jpg

Magnaflow 16533 cat-back exhaust:

.....Stock ZHP exhaust removed
http://i993.photobucket.com/albums/af59/estrellajon/BMW/Exhaust/2012-02-12_15-15-47_12.jpg

New exhaust:
http://i993.photobucket.com/albums/af59/estrellajon/BMW/Exhaust/2012-02-19_11-41-21_511.jpg
http://i993.photobucket.com/albums/af59/estrellajon/BMW/Exhaust/2012-02-19_11-41-35_518.jpg

[mimalmo]

Very nice!

[Mtnman]

Damn Jon. Your car is so F'in clean. even under the valve cover...not a spec of dust. Dayuuum. post more. asap.

[Au2bahn]

Thanks Dave. Definitely more exhaust pics soon.

My next project after this will be M3 mirrors. I bought it like 3 months ago. I still have to do some custom work on it to make it fit.



Damn Jon. Your car is so F'in clean. even under the valve cover...not a spec of dust. Dayuuum. post more. asap.

[Au2bahn]

Thanks Eli

[derbo]

is that cats on that header?! Holy crap those headers are $2000+ MSRP for 3 cylinders?! Too bad they arent CARB (California) Legal.

Looking great Jon!

Those Brembos for 135i brakes definitely have BMW Dust and BMW feel to it. I use these for daily and then use Carbotechs for track days. :) They arent cheap....

[Au2bahn]

Thanks derek. Yeah they are high flow cats and aren't cheap. In Virginia, This is the only way to have headers and show system ready when it comes to emissions time.



is that cats on that header?! Holy crap those headers are $2000+ MSRP for 3 cylinders?! Too bad they arent CARB (California) Legal.

Looking great Jon!

Those Brembos for 135i brakes definitely have BMW Dust and BMW feel to it. I use these for daily and then use Carbotechs for track days. :) They arent cheap....

[derbo]

I probably wouldn't gotten them if they were california legal.....

cant wait to see dyno numbers!

[Mtnman]

Jon, you gonna put it on the dyno before the meet?

Sent from my DROID3 using Tapatalk

[Au2bahn]

Definitely will be dynoing soon. Within 3 weeks. I finally pieced everything back today with the new cat-back and headers. The car was on jack stands for 2.5 months. I was away for 3 weeks during the holidays, then came back to a new job and have been very busy since.

I know for sure, there will be a difference on the dyno with the headers and cat-back exhaust. Took it for a run today and........oh momma.......its quick. I cant hear the SC whine anymore after 5k rpms. Did a dyno before this change which was 304rwhp. I will be happy at 315rwhp so I can justify the cost. If not.....oh well.



Jon, you gonna put it on the dyno before the meet?

Sent from my DROID3 using Tapatalk

[derbo]

304whp.. :D.

Jon would you happen to have Dyno plots to show? :) I would love that setup.....

[Au2bahn]

Yes I do. I will scan then post a before and after.

....to be continued



304whp.. :D.

Jon would you happen to have Dyno plots to show? :) I would love that setup.....

[johnrando]

Awesome. So, the SC was before the headers and it's at 304 HP? Then you added headers and have yet to dyno that?

[Newjack]

Hey Jon, do you have any pictures of your boost gauge? I'm curious where you put it.

[Au2bahn]

Awesome. So, the SC was before the headers and it's at 304 HP? Then you added headers and have yet to dyno that?

Correct. I just need a free weekend to get an appointment. Maybe by next weekend.



Hey Jon, do you have any pictures of your boost gauge? I'm curious where you put it.

I did lots of research and ended doing this set-up based on line of sight. I also went with AEM due to its accuracy and build quality. I tried cheaper brands and it was reading like 11psi. Yeah right. The other side is reserved for an AFR gauge later on.

http://i993.photobucket.com/albums/af59/estrellajon/BMW/boost2.jpg
http://i993.photobucket.com/albums/af59/estrellajon/BMW/boost1.jpg

[Au2bahn]

Updated Magnaflow exhaust pics. Post #90 (http://www.zhpmafia.com/forums/showthread.php?3096-ZHP-ESS-TS2-Project-%28PICS%29&p=153190#post153190) (sorry for the slow response. Very busy these days).

[Newjack]

Boost gauge is so sick.

[Au2bahn]

Of all projects I have done to the ZHP, this project has been the most time consuming. I followed the DIY from Rogue Engineering which focuses on the base plate modifications. The rest was for me to figure out. A dremel tool is required and used extensively.`

I used material I found lying around my garage that I no longer need. In this case, I used an old drill case which was perfect for creating my motor adapters.
http://i993.photobucket.com/albums/af59/estrellajon/BMW/M3%20Mirror%20Custom%20Upgrade/2012-03-11_11-58-13_27.jpg
http://i993.photobucket.com/albums/af59/estrellajon/BMW/M3%20Mirror%20Custom%20Upgrade/2012-03-17_11-29-53_264.jpg

I had to shave off the plastic screw-in extensions on the M3 mirror base plate.
http://i993.photobucket.com/albums/af59/estrellajon/BMW/M3%20Mirror%20Custom%20Upgrade/2012-03-18_08-46-49_422.jpg

After several test fittings and orientation of motor to adapter, I was able to narrow down to +/- 5% movement for fine tuning later on. Once I got the motor aligned with mirror and test fitted to the mirror housing, I drilled the screw holes on the adapter.
http://i993.photobucket.com/albums/af59/estrellajon/BMW/M3%20Mirror%20Custom%20Upgrade/2012-03-18_08-49-08_31.jpg

I temporarily screwed in the motor (Old motor is broken so I was using this for my tests) so I can place nuts on the other side. I used J-B weld to hold the nuts in place.
http://i993.photobucket.com/albums/af59/estrellajon/BMW/M3%20Mirror%20Custom%20Upgrade/2012-03-18_09-19-03_374.jpg
http://i993.photobucket.com/albums/af59/estrellajon/BMW/M3%20Mirror%20Custom%20Upgrade/2012-03-18_09-26-35_993.jpg

I had to modify the original foam that goes into the frame since the M3 base also has the foam. I used both for better waterproof protection and eliminate wind noise just in case.
http://i993.photobucket.com/albums/af59/estrellajon/BMW/M3%20Mirror%20Custom%20Upgrade/2012-03-17_15-51-39_116.jpg
http://i993.photobucket.com/albums/af59/estrellajon/BMW/M3%20Mirror%20Custom%20Upgrade/2012-03-17_15-57-00_589.jpg

This is how the final product looks like with the new motor installed in the housing.
http://i993.photobucket.com/albums/af59/estrellajon/BMW/M3%20Mirror%20Custom%20Upgrade/2012-03-18_18-32-32_852.jpg
http://i993.photobucket.com/albums/af59/estrellajon/BMW/M3%20Mirror%20Custom%20Upgrade/2012-03-18_18-33-50_812.jpg

The outcome came out perfect. My side mirrors works again and perfectly. My driver side motor has been inoperable for 2 years now.
http://i993.photobucket.com/albums/af59/estrellajon/BMW/M3%20Mirror%20Custom%20Upgrade/2012-03-18_19-37-59_742.jpg
http://i993.photobucket.com/albums/af59/estrellajon/BMW/M3%20Mirror%20Custom%20Upgrade/2012-03-18_19-38-44_494.jpg
http://i993.photobucket.com/albums/af59/estrellajon/BMW/M3%20Mirror%20Custom%20Upgrade/2012-03-18_19-47-35_947.jpg

[Hornung418]

BAMF status. Looks mad cool, Jon!

[Au2bahn]

Thanks man. It was a fun project.


BAMF status. Looks mad cool, Jon!

[danewilson77]

Great work.

HTC Thunderbolt+TT

[derbo]

awesome! Its amazing that you said that is the most time consuming, when I would've thought the supercharger is.. :)

[cakM3]

Of all projects I have done to the ZHP, this project has been the most time consuming. I followed the DIY from Rogue Engineering which focuses on the base plate modifications. The rest was for me to figure out. A dremel tool is required and used extensively.`

I used material I found lying around my garage that I no longer need. In this case, I used an old drill case which was perfect for creating my motor adapters.
http://i993.photobucket.com/albums/af59/estrellajon/BMW/M3%20Mirror%20Custom%20Upgrade/2012-03-11_11-58-13_27.jpg
http://i993.photobucket.com/albums/af59/estrellajon/BMW/M3%20Mirror%20Custom%20Upgrade/2012-03-17_11-29-53_264.jpg

I had to shave off the plastic screw-in extensions on the M3 mirror base plate.
http://i993.photobucket.com/albums/af59/estrellajon/BMW/M3%20Mirror%20Custom%20Upgrade/2012-03-18_08-46-49_422.jpg

After several test fittings and orientation of motor to adapter, I was able to narrow down to +/- 5% movement for fine tuning later on. Once I got the motor aligned with mirror and test fitted to the mirror housing, I drilled the screw holes on the adapter.
http://i993.photobucket.com/albums/af59/estrellajon/BMW/M3%20Mirror%20Custom%20Upgrade/2012-03-18_08-49-08_31.jpg

I temporarily screwed in the motor (Old motor is broken so I was using this for my tests) so I can place nuts on the other side. I used J-B weld to hold the nuts in place.
http://i993.photobucket.com/albums/af59/estrellajon/BMW/M3%20Mirror%20Custom%20Upgrade/2012-03-18_09-19-03_374.jpg
http://i993.photobucket.com/albums/af59/estrellajon/BMW/M3%20Mirror%20Custom%20Upgrade/2012-03-18_09-26-35_993.jpg

I had to modify the original foam that goes into the frame since the M3 base also has the foam. I used both for better waterproof protection and eliminate wind noise just in case.
http://i993.photobucket.com/albums/af59/estrellajon/BMW/M3%20Mirror%20Custom%20Upgrade/2012-03-17_15-51-39_116.jpg
http://i993.photobucket.com/albums/af59/estrellajon/BMW/M3%20Mirror%20Custom%20Upgrade/2012-03-17_15-57-00_589.jpg

This is how the final product looks like with the new motor installed in the housing.
http://i993.photobucket.com/albums/af59/estrellajon/BMW/M3%20Mirror%20Custom%20Upgrade/2012-03-18_18-32-32_852.jpg
http://i993.photobucket.com/albums/af59/estrellajon/BMW/M3%20Mirror%20Custom%20Upgrade/2012-03-18_18-33-50_812.jpg

The outcome came out perfect. My side mirrors works again and perfectly. My driver side motor has been inoperable for 2 years now.
http://i993.photobucket.com/albums/af59/estrellajon/BMW/M3%20Mirror%20Custom%20Upgrade/2012-03-18_19-37-59_742.jpg
http://i993.photobucket.com/albums/af59/estrellajon/BMW/M3%20Mirror%20Custom%20Upgrade/2012-03-18_19-38-44_494.jpg
http://i993.photobucket.com/albums/af59/estrellajon/BMW/M3%20Mirror%20Custom%20Upgrade/2012-03-18_19-47-35_947.jpg

Thanks Jon for sending me this PM! I was wondering just how I was going to do this. I'll be following your example when doing my mirrors. It was a BIG HELP :thumbsup

I agree this of all mods will be the most time consuming to do due to getting the mirror motors aligned properly and modifying the mirror baseplates... Excellent work Jon :like

[Au2bahn]

Thanks guys. The supercharger was also time consuming but I felt like I spent a lot of time on these mirrors. It was frustrating at times just to get the mirrors to align properly. Basically, assemble and disassemble over and over just to get it right. PLUS, I dont know why BMW used delicate ribbon connector on our cars. That alone added time.

[cakM3]

Agreed, but all that work on the mirrors provided excellent results :)

[Au2bahn]

Im glad I was able to assist in some way Charlie. Let me know if you have any questions. Im sure you will feel the same frustrations I experienced. Remember when you create the adapters to give yourself some wiggle room for fine adjustments on the mirrors.


Thanks Jon for sending me this PM! I was wondering just how I was going to do this. I'll be following your example when doing my mirrors. It was a BIG HELP :thumbsup

I agree this of all mods will be the most time consuming to do due to getting the mirror motors aligned properly and modifying the mirror baseplates... Excellent work Jon :like

[cakM3]

I will Jon, and thanks :thumbsup

[johnrando]

Great work, and looks good! Do you still get "tilt down in reverse"? I heard some of the functionality goes away, but it's doesn't matter to some as they look great and still function.

[Au2bahn]

Yes, everything still works. Im using the same motors, just had to modify how it fits in there.


Great work, and looks good! Do you still get "tilt down in reverse"? I heard some of the functionality goes away, but it's doesn't matter to some as they look great and still function.

[webster]

congrats, great job on the mirrors. i really want M3 mirrors. they are so much better looking than the ZHP ones...

[cakM3]

Jon,

I think what you showed on post #107 is the perfect solution for those wanting to incorporate OEM M3 side mirrors to their non-M 3-series. I plan to put theory to practice in a few days when doing mine this week. I will also be taking pictures throughout the process as you have. If I have any questions I will be sure to text you. Looking forward to doing this, thanks again Jon :thumbsup

[Au2bahn]

Anytime Charlie. I think so too. With this solution, you're able to make adjustments. On the adapter plates, you can use a dremel to create a "path" for the screws so it you can twist it for adjustments prior to tightening them. Start with one adapter, make the appropriate adjustments until its perfect on the mirrror housing then "flip" to create your second adapter and replicate the screw holes.


Jon,

I think what you showed on post #107 is the perfect solution for those wanting to incorporate OEM M3 side mirrors to their non-M 3-series. I plan to put theory to practice in a few days when doing mine this week. I will also be taking pictures throughout the process as you have. If I have any questions I will be sure to text you. Looking forward to doing this, thanks again Jon :thumbsup

[Au2bahn]

I finally got my car dynoed today with the headers and cat-back exhaust installed. I kinda of missed the cold weather when I got this done today. It was high 80's here in Northern Virginia. The gains were OK at 311whp compared to 304whp before headers and exhaust

Car on the dyno with the owner of Mach V Motorsports
http://i993.photobucket.com/albums/af59/estrellajon/BMW/2012-03-23_14-44-10_734.jpg
http://i993.photobucket.com/albums/af59/estrellajon/BMW/2012-03-23_14-43-37_571.jpg

Here are the results:

Before with TS2 only:
http://i993.photobucket.com/albums/af59/estrellajon/BMW/304hp-1.jpg

Results After with TS2 plus headers and cat-back. I kinda of expected more but its OK. Was 7whp worth the cost? :dunno

http://i993.photobucket.com/albums/af59/estrellajon/BMW/311hp-1.jpg

Update: I spoke with AJ from ESS in regards to my dyno results. Basically my A/F was running rich between 4k and 6k so I asked him what needs to be done to address it. I will be sending my DME to ESS for a re-tune to lean it out a bit on this range. Probably due to more exhaust flow and DME not programmed to address this. AJ claims I should pick up additional torque and additional 10whp.

http://i993.photobucket.com/albums/af59/estrellajon/BMW/a2f.jpg

[BCS_ZHP]

Jon,
It's all worth it, how many others have a supercharged, headered, modified exhaust ZHP that can mlegally pass Virginia emissions?. Not many, but you are in that unique club.

[cakM3]

Jon,

Stats look good :thumbsup

[Au2bahn]

Post 122 updated.

[MiniD]

That is one beautiful ZHP!

[imola red zhp]

Looking good....
sent from Dennis' Droid using tapatalk

[cakM3]

Jon,

I think you need to update your sig pic....now that you have OEM M3 side mirrors installed :)

Love the progress on your ZHP :thumbsup

[Au2bahn]

Bruce.....true but its at this point, its more expensive to sell it. Not that I am. It will be jut be part of the stable.


Jon,
It's all worth it, how many others have a supercharged, headered, modified exhaust ZHP that can mlegally pass Virginia emissions?. Not many, but you are in that unique club.

Oh yeah!! thanks for the reminder Charlie. Doing it right now.


Jon,

I think you need to update your sig pic....now that you have OEM M3 side mirrors installed :)

Love the progress on your ZHP :thumbsup

[Au2bahn]

Hmmmm......Signature is limited to 500 characters.

[derbo]

Looking great Jon! That A:F definitely needs to be retuned in the middle! Looks like you will definitely see a lot more torque in the middle RPMs.

[Au2bahn]

Thanks Derek. Yeah, thats what ESS mentioned as well. I already took the DME off my car ready to be sent this week.




Looking great Jon! That A:F definitely needs to be retuned in the middle! Looks like you will definitely see a lot more torque in the middle RPMs.

[derbo]

You probably will get better mpg too. Looks like the tune is running rich to be conservative.


Sent from my iPhone using Tapatalk

[tripod06]

why is this car so sick? it just is. thats the only answer!

[cakM3]

Bet Jon has a blast driving it :) Jon....looks like I'll be finally getting mine back this weekend :biggrin

[Au2bahn]

Bet Jon has a blast driving it :) Jon....looks like I'll be finally getting mine back this weekend :biggrin

Sweet!!!. Take some pics. I can't wait to see the final product. But yes I'm having a blast driving it especially with my new tune from ESS.

Sent from my DROID RAZR

[tripod06]

p.s. your BBK is about the next to sexiest thing to a bomb girl about to take her bra off for you...

[cakM3]

Jon, you are the man :theman

Love going through your build thread....love that ESS TS2 and your solution to mount the OEM M3 side mirrors. Thanks for all your help :thumbsup