ESS VT2-500 Supercharger Kit Installed! Impressions, pictures, video.

[iPhoneEngineer]

So the codes are:

- P0036: HO2S Heater Control Circuit
- P0056: HO2S Heater Control Circuit (Bank 2 Sensor 2)

Code 56 makes sense because Bank 2 Sensor 2 (a narrowband sensor) has been completely removed. I'm disappointed the other code doesn't clearly state "Bank 1 Sensor 2" as I would expect, because that sensor is also removed.

ESS told me I wouldn't get an SES light from unplugging the sensors, so it is a little concerning that I do; but the codes seem reasonable and ESS refuses to support/further advise me on running without the sensors connected until the relocation is done.

The hesitation does seem to be better, but is not gone completely at least in 2nd gear between 3k and 4kRPM when coming off the throttle (think a series of two close switchbacks). I am assuming the car has some relearning to do as it had probably "adapted" to the result of some incorrect readings from the AA headers, but I'm glad it's not immediately worse or something.

Still waiting on the EGT bung and for the pressurized smoke tester to arrive with Aleks. Once those events occur, the sensor relocation and leak testing will commence and are the final things planned for solving immediate problems with the kit.

[ZStig]

I don't think ess told you that you won't see a SES light, but that you won't go into limp modes like I did. I think my limp mode was primarily from a bad TPS. Anyway, glad to hear that the hesitation is a bit better, hope it completely goes away soon, but don't expect the software to fully adapt until the egt and rear sensors are in.

[iPhoneEngineer]

Originally Posted by Roffle Waffle

I don't think ess told you that you won't see a SES light, but that you won't go into limp modes like I did. I think my limp mode was primarily from a bad TPS. Anyway, glad to hear that the hesitation is a bit better, hope it completely goes away soon, but don't expect the software to fully adapt until the egt and rear sensors are in.

Hey, how did you find out your wideband sensors were in the wrong order? I want to make sure I can finish torquing them down without worrying about possibly having to swap them without good access from below (don't want to take off the reinforcement plate again). I don't have any codes specific to them yet so I think I probably got it right, but I want to know how I can trace the wires to be certain.

[iPhoneEngineer]

Update. Re-checked codes today after an entire week of driving (including a trip to San Francisco), and nothing new has appeared; as much assurance as I'm going to get that I put the wideband sensors in the correct bank.

Hesitation on part-throttle deceleration, even under demanding conditions like coming off of WOT at 4-5kRPM in 3rd, is completely gone . However, the car still produces pops in the exhaust implying there is a certain amount of misfiring or at least rich running going on, but I confirmed with Roffle that this is normal for his car as well. This is a bit annoying because I imagine it must contribute to fouling the plugs and sensors, but at least the drivability is there.

Hesitation on WOT at lower RPM (e.g. driving in 2nd below 2,000RPM and some idiot going 15MPH allows a pass, but downshifting to 1st is really annoying) is NOT completely gone, at least as of a few days ago the last time it happened. Not nearly as common of a driving scenario but perhaps even more annoying because in this scenario the motor basically completely quits for a moment, jerking the car forward violently. I still have hope that the tune will adapt through this now that the sensors are in optimal positions.

Still waiting on the EGT bung to arrive though it has been shipped, so presumably sensor relocation late this coming week. No news about the pressurized smoke tester arriving yet.

[MIKe86]

any change in boost?

[iPhoneEngineer]

Originally Posted by MIKe86

any change in boost?

I haven't tested it since the OEM headers went in, as my assumption is the AA headers flow at least as well and the car doesn't feel any stronger (about 60HP should be recovered when the boost problem is fixed). I think it is possible for some turbo setups to boost lower when the engine is not operating at an optimal AFR (perhaps due to bad O2 sensor reads), but in the case of the belt-driven supercharger I'm pretty sure it can't make a difference.

Looks like I won't be able to get into the shop for the sensor relocation until around September 20th, even though the EGT bung should arrive before then. I expect Alekshops' smoke tester will arrive before then and we'll meet up...

[Beedub]

updates ???? hows car running??

[iPhoneEngineer]

Alekshop received the pressurized smoke tester a couple days ago and scheduled me ASAP. I am heading over tomorrow at 1PM to do the test. If no leaks are revealed (practically inconceivable, but given my luck--could happen), the smaller S/C pulley will be installed as a temporary band-aid fix for attaining the expected VT2-500 power.

The EGT bung is finally in-hand, but the earliest I could get back into the shop to do the sensor relocation is September 20th. The car has never hit limp mode though the SES light continues to report the sensors' heating circuit is disconnected. I still have the impression the tune is not perfect in these same driving situations because the exhaust pops and there is at times very minor hesitation (nothing at all like it used to be, very drivable), but my understanding from Roffle is that this is normal. It will be nice to have the other sensors installed and done.

[iPhoneEngineer]

The smoke tester worked quite well and discovered a leak on the S/C output coupler. The weird thing is the coupler was very well seated on the output, and even after tightening the clamp 2 1/2 turns, it still leaked. We removed the coupler to re-seat it and added TWO brand-new clamps, and now it doesn't leak. We could not find any other leaks (no smoke evident--and the brand-new machine produces very dense smoke), though the machine still reads as though a "0.75mm" leak is present. I think that amount could be lost through the cylinder valves into the exhaust depending on the configuration of the engine when it stopped...it definitely gets through the throttles (maybe by the idle speed control system) since the vacuum reference line spewed smoke if removed from the BPV.

So, we'll see if the car is noticeably more powerful. Within 1-2 days I'll do another boost test video to see if this leak was the only problem or if the car is still under-boosting. The leak was far from gaping--again, we couldn't even see how smoke was able to escape--but I suppose it is possible that it was the only problem...

[ZStig]

hmm. How does the car feel now? faster?

[iPhoneEngineer]

I have noticed an improvement; however, there was heavy traffic on my way back to the office and I got only one opportunity to see higher RPMs in 2nd. At the high end output leveled off a bit and wasn't necessarily much better than before, but I am fairly sure this is due to the DME noticing readings from the O2s that were not rich enough so it pulled timing while adding fuel. If fixing that leak gained me a full 2PSI, the adaptation the DME had previously done will now be wrong and it could be expected to need at least a few redline pulls to fully reveal the improved power.

But, again, the first impression is that the car is stronger even in the mid range. I will do another boost test video probably tomorrow, or on the weekend if I can't manage it tomorrow.

[johanness]

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THAT'S WHY DEM CLAMPS SO IMPORTANT!!
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[iPhoneEngineer]

More: Aleks spent 3 hours with me on the car and even fabricated a bracket to better secure the lower boost pipework (I really don't see how it could be mounted without one, and so am frustrated that the kit doesn't include one). We changed the S/C fluid, and surprisingly, just like Beedub said, the S/C is notably quieter (less rattle) at idle. I had more time with the car on my drive home and am convinced there is a significant power improvement in the mid-range, but top-end power doesn't feel anywhere close to slipping the tires. I'll just keep driving and see how it adapts, do the boost video, get the sensor relocation done next week, and get another dyno in a couple weeks.

[iPhoneEngineer]

Ugh, haha, I recorded a few good runs (including redline in 3rd) and later realized there was no SD card in the GoPro. I will be repeating the video setup tomorrow.

Sensor relocation still on for Tuesday...probably getting the Sparco Pro 2000, too.

[mfanatic325]

Test drove this car today. What a beast

[iPhoneEngineer]

Hehe, I was quite inspired driving mfanatic's car today--an exemplary demonstration of extreme N/A performance! The SS exhaust sounds absolutely amazing at WOT, though it is a bit too loud for me around town.

In fact, today I had my first suspicion that my clutch may be slipping--after the redline runs in 1st-3rd, I smelled what could have been clutch, or possibly the group of motorcycles that passed by in the opposite direction.

[marinb]

Maybe time to get an HPF clutch kit once all that horsepower eats up your stock clutch. =)

http://www.horsepowerfreaks.com/perf...ch/Clutch_Kits

[Finnegan]

I'm glad to see this finally coming together for you. Sounds like Aleks really went the extra mile again too. Based on your experience with the coupler, which looked fine, it seems this kind of pressured smoke test might just be a requirement not an option.

Enjoy!

[iPhoneEngineer]

Originally Posted by Finnegan

I'm glad to see this finally coming together for you. Sounds like Aleks really went the extra mile again too. Based on your experience with the coupler, which looked fine, it seems this kind of pressured smoke test might just be a requirement not an option.

Enjoy!

Absolutely. At least, an objective boost test (video'd gauge or dyno log) to indicate if there is lower than expected boost--but I am now convinced that even hands-on scrutinization of every coupler is completely insufficient for detecting a leak.

Yeah, I'll wait until the clutch is toast, I suppose...unless it becomes clear in the near future that it is seriously slipping when fully engaged. My Supra had a Stage 4 clutch...probably will stick to Stage 1 or 2 here .

[Beedub]

Originally Posted by mfanatic325

Test drove this car today. What a beast

what did you think???

[ZStig]

Originally Posted by johanness

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THAT'S WHY DEM CLAMPS SO IMPORTANT!!
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[iPhoneEngineer]

Originally Posted by johanness

THAT'S WHY DEM CLAMPS SO IMPORTANT!!

Speaking of which--what are the absolute best clamps available? I want something I can really torque the shit out of and be certain is absolutely sealed without worrying about the dreaded "click".

Still planning on the boost test this evening...even I'm in suspense lol.