It has definitely been a while since I’ve posted any updates on the car. Let me tell you that the last few weeks have been a cluster of diagnosing things and figuring out minor problems here and there. But I’m happy to say that last weekend I was out on track with no issues, and surprisingly minimal heat soak. Very happy with my Z4.
So let me get you up to speed. Over the winter I purchased ESS Tuning’s last TS2 Kit. It’s a positive displacement Whipple (W100AX) charger with an ESS manifold and upgraded injectors. The key difference between TS1 and TS2 is the integration of a cooler into the manifold. A water pump circulates water to a front mount (setrab) cooler that then feeds to (laminova) cores within the manifold. The best way to summarize is that there are 3 cylindrical radiator type cores that have this water (coolant) fed through them to cool the air as it passes through the manifold.
I was looking to supercharge for a while now and through countless hours of research both on this forum along with others and chatting with owners of SC systems I decided the TS2 was the best fit for me. As I said the kit included an air to water cooler that feeds right into the manifold which for now is the best option for me to supercharge on the track. Intake temps will always be an issue, but this seems like a reasonable solution. 11Tenths Racecraft installed the charger along with the other goodies.
At the time of install we replaced the clutch and flywheel with a replacement stock unit (I should mention the car was at 165,000Kms on the stock clutch). I installed a steward high flow water pump. Which was a fun install because the bracket in front of the motor (front clip) completely blocks the removal of the pump so I had to practically remove the entire front clip of the car just to change it. We installed a CSF rad and Radium catch can kit. Obviously the goal was better cooling throughout. We also installed an RTD shifter and in my own time I installed an AEM X AFR and Boost gauge in the ashtray.
Now onto the issues…
Lets start with:
Tune:
1st tune – DISA error and o2 sensor heat error (CEL) (disa is removed with this manifold)
2nd tune – o2 sensor error (CEL)
3rd tune – o2 sensor removed in tune (no-CEL) since I have no secondary O2s
All good for now, gotta keep an eye out as I had one lean CEL which hasn’t resurfaced.
The supercharge coolant setup:
The ESS system included no reservoir for the cooling system. Essentially fill the hose best you can, run and refill. This was an issue since you cannot guarantee getting all the air out, nor is it easy to do since the hoses are insanely stiff. Luckily 11Tenths came up with a great solution. The TS2 kit came with a relocation kit for the E46 hydraulic steering. Since the Z4 has electric steering this reservoir wasn’t needed. 11Tenths fabricated some fittings for the reservoir was well as a bracket and it is now in line for the cooling system. This allows air to escape and me to monitor the coolant!
Coolant leak:
1st leak - At first the SC cooler (setrab) was leaking. The hoses are very stiff so I suspect during install the fittings came loose. I tightened them and added an extra oring. Seems to be ok.
2nd leak – custom hose. The hose from the motor to the rad is custom made by ESS to clear the charger. It was rubbing against the front clip bracket so we ground that down to make room. Although the leak is gone, I’m currently driving around with a spare hose just to be safe for track/trips etc.
Pulley/whipple oil leak:
1st- the supercharger was leaking oil from the pulley wheel. This is actually common since there is an overfill drain hole. In this setup the supercharger is on its side so the oil fill level isn’t quite the same. Luckily oil is a standard ford/gm part # so I grabbed some extra. The oil leak has since stopped, and the gea rtrain is still lubricated as per the oil fill window.
2nd – the pulley vibrated 2 of 4 bolts loose with only one holding it on. This was easy enough. Put in new bolts, locktite blue and they seem to be ok. Stressful though.
Other stuff:
Custom headlight halos stopped working after all the work was done. Turns out that a ground came loose but it took a while for me to trace that. It’s all fixed and working.
RTD shifter:
There was some slack when it was in between gears. The allen bolt for the Neutral area adjustment came loose. I re-centered as per instructions and tightened it down. Hasn’t been a problem.
Track stuff:
Went through my EBC red stuff pads again. They lasted 5 track days on the front. I’ve bitten the bullit and switched to PAGID RS29 on the front. I will let you know how they hold up. They are phenomenal feel and stopping power, but I hope they last longer as they were double to price of other pads. I had no choice as I was at the track and it was all the local performance shop had in stock for my front brake setup.
I’ll come back to post my feelings on the supercharger at a later date as I’m only starting to really enjoy it now that all this stuff has been worked out.
For now though, dyno results:
Couldn’t have asked for a more linear power band.
306.9 RWHP – Rear wheel horsepower
293.1 RWTQ – Rear wheel torque
(approx.: 361HP Crank (136hp over stock)
(approx.: 345 LB/FT Crank (123hp over stock)
https://youtu.be/SX0Uh2ZKtkE