ESS Twin Screw Install

[speddmn]

Latest update 3/10- post#3, it runs!
Hey everyone, wanted to get a thread started now to document the supercharger install I'll be embarking on next week. So I guess a good place to start is with what I've got in store:
First - the kit from EAS, Kevin has been awesome to work with! Unfortunately EAS doesn't list it on their site anymore but this is the Kit I ordered - http://www.esstuning.com/products/M5...%28TS1%29.html

Options on the tune were to 1: remove the secondary o2 sensor reading and eliminate the speed limiter, I'm not insane but I figured why not.

I also grabbed a set of m54b30 headers from ebay which most people seem to have had good luck with, those are already in hand and they appear to have a very good finish.

Finally I snagged a set of UUG motor mounts and one of their in-house boost gauges from ECS tuning where i've previously had good luck ordering suspension components.

Here's the car: 2005 z4 3.0i automatic with 48K on the clock. The only other things I'm considering as a part of this project are transmission mounts and perhaps a diff rebuild but I'm not too hung up on that, I'm almost inclined to say i'll just upgrade/replace the dif if I manage to blow it up... I do want to keep the car streetable. Current mods are AngryCop mangnaflow exhaust, Megan Racing coilover setup, Carbon engine cover (that I hope still fits!), 10mm spacers and 318i wheels that I had powdercoated gloss white. Some misc smaller cosmetic things like the lip, laminx, cf wrap on the dash etc...) and a sh*t load of time spent correcting the paint!





Always open to feedback and advice from the FI guys!

[speddmn]

Turns out the instructions are on a thumb drive and you ship the ecu in... Drrrrrrrrr
Aaand we're off - got the headers installed last night, typical ebay craftsmanship, going to have to machine up a 3/8" spacer to make the front bank connect to the existing mid pipe but the rest went pretty smoothly. Disassembling and new plugs today






The factory exhaust manifolds have got to be the most inefficient design ever on the m54, Yuuuuck!

Update - new plugs, made all of the wiring adjustments, got the manifold prepped for install. Went to drop the manifold/sc on but the holes for the studs on either end are a bit smaller than the rest of the holes on the manifold so we couldn't get the unit angled in right, we're going to open the holes up a little bit this week so it'll fit.

[speddmn]

reserved2

some more update shots - Guido, we made your hose (or our rip off of it)



Tightening bolts, routing the belt and so on


Speaking of belt, that is one tight clearance!


In, but cover-less


Buttoned up for now



Still working on that exhaust spacer to make the cheap headers work, waiting for the DME to come back from ESS and we need to mount/locate a suitable position for the ECS boost gauge (plumbed it last night)

Update 3/10 IT RUNS!!!
Got the exhaust spacer in, got the motor mounts in, UPS/ESS found my DME and so on, also got the laminx on this weekend.
Exhaust spacer (far pipe) to get the header to section 2


Motor mount comparison


drilling off the heatshield on the pass motor mount arm, without cats the temp shouldn't be a problem (and I needed the clearance)



And new Laminx on the tails!


Oh and here's proof it runs!

[GuidoK]

Are you going to do the install yourself?

[Beedub]

these twin screw kits are awesome... id LOVE an alpina roadster s with ts2....

[pokeybritches]

The diff should be fine. If you have issues, they were present before the install. The only thing you may want is an LSD.

[Exist]

Where did you get the lip?

[speddmn]

Originally Posted by GuidoK

Are you going to do the install yourself?

Yep

[speddmn]

Originally Posted by Exist

Where did you get the lip?

eBay, they're not particularly pricey

[speddmn]

Originally Posted by pokeybritches

The diff should be fine. If you have issues, they were present before the install. The only thing you may want is an LSD.

Thanks pokey, needed some reassurance

[XSpartan]

the Carbon engine cover looks amazing, do you mind me asking where can i get one

[GuidoK]

Originally Posted by speddmn

Yep

Have you already read the manual?
There are some pointers that are not in the manual:

1. Get a fuel hose from a 5 series m54b30 (that is the fuel hose that connects to the fuel rail); these are a bit longer. I think mine came from an E39.

2. In the manual it says that you have to bend the (stainless) piping from the fuel rail so that it fits around the new manifold. I used some heat from a propane torch to soften up the stainless steel in order to prevent the piping to kink.

3. Be sure to check that you get the z4 kit and not the e46 kit (they have the same order number). The E46 kit has a longer bolt that goes in the oil filter housing (to fasten the bracket with the belt rollers), and first of all that does not fit the z4 very well (the z4 has a subframe in front that sits in the way to install the longer bolt), but second: the longer e46 bolt has not enough thread on it so that if you torque it down in the oil filter housing, the unthreaded part splits open the oil filter housing! (and that goes pretty much unnoticed). I was able to weld the oil filter housing again (I have an AC tig welder), but it's obviously best to prevent that .
(if you get an e46 kit you'll also need to swap the plug that sits in the hole where the e46 has its temperature sensor)

4. I had to make this hose from some small flexible tubing:

It's for venting the gas tank, but that original hose will be to brittle to bend etc.

And you should probably get an engine crane. The supercharger+manifold is pretty heavy to mount on the threaded studs of the cilinder head in a controlled manner. This obviously depends on how big and strong you are, but a small engine crane makes it easier and less likely that you damage the paint in the engine bay.

[psygnosis]

Did you red out your backup lights?

[speddmn]

Thank you sooooooooooooo much for the tips dude!

[speddmn]

Originally Posted by psygnosis

Did you red out your backup lights?

Yes, i used knockoff laminx and it's fading already, upgrading to the good stuff this winter

[speddmn]

Originally Posted by XSpartan

the Carbon engine cover looks amazing, do you mind me asking where can i get one

Got it from this seller
http://www.ebay.com/sch/ph_racing/m....1&_ipg=&_from=

[GuidoK]

Originally Posted by speddmn

Thank you sooooooooooooo much for the tips dude!

It also may be smart to refurb/clean your startermotor in the process. You know, to clean out the excessive carbon from wear from the brushes and maybe to clean and relubricate the one-way bearing on the drivegear.

When you've removed the manifold it's really easy to get to

[psygnosis]

Originally Posted by speddmn

Yes, i used knockoff laminx and it's fading already, upgrading to the good stuff this winter

I picked up some pre cut red film on ebay a while back for the orange parts and it still looks great. Lucky me I guess.

[speddmn]

bump for oc

[speddmn]

Bump for new content - also can someone with DME modification experience answer me this: If I have 'deleted' the secondary o2 sensors in my tune do I need to have them plugged in to the harness at all? Or can I just tape off the plugs and leave the sensors out?

[speddmn]

Just a status update, it gets annoying when UPS loses your DME...

[speddmn]

TTT! Major updates in post #3