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ESS Supercharger DIY Installation
I received my ESS Supercharger last week and started the installation over the weekend. I will post my pictures and lessons learned for any of you who want to do the installation yourself. My car is completely stock including air filters and I did a Pre Installation dyno test of the car and I will have a Post installation dyno done on the same machine. I will post pictures with comments as I make progress. My first impress as I opened the box and inspected the parts is that this is a very high quality kit with all the hardware and hoses as good or better than OEM quality. Very different than my experience with a Paxton kit about 15 years ago! The first step is to remove the intake manifold and that is pretty straightforward. https://cimg3.ibsrv.net/gimg/www.mbw...a63518c80.jpeg
Three dyno pulls. Stock motor and tune, P30 https://cimg1.ibsrv.net/gimg/www.mbw...87b53f352f.jpg Remove air boxes and reach behind to undo the plastic tab on each side of the rear air intake. Make sure you vacuum out all the dirt around the 10 intake bolts before you remove anything. You can leave all the FI parts in place. Unplug all the vacuum hoses front and rear and the wiring pugs in the front, and the fuel line. https://cimg8.ibsrv.net/gimg/www.mbw...3d74976970.jpg There you have it! Now you need to remove the throttle bodies https://cimg8.ibsrv.net/gimg/www.mbw...bbc4bfaab.jpeg Remove the screws and the bottom comes off. You need to feed the rubber grommet through the pan https://cimg6.ibsrv.net/gimg/www.mbw...bff303599a.jpg There are the two throttle bodies. You need to remove the plastic surround to get at the 4 bolts mounting each TB. The plastic rings are held on by two plastic clips you need to release with your fingers or a small screwdriver. https://cimg1.ibsrv.net/gimg/www.mbw...4b3e39bdc1.jpg Next comes the fun part! |
Beautiful build!!! Any desire to unload your stock manifold?
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Thanks for putting this together. Can't wait to see your after results! We can also help with any install questions people may have
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Thanks for sharing! My P31 coupe had about the same power stock so this will be good to see the end results.
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Looking forward to seeing your progress. |
More progress!
I have had other chores but have still made good progress. The supercharge unit is now ready to put on the engine after I finish installing the new power steering reservoir and the tank and pump for the intercooler. I thought the PS tank was plastic but it is TIG welded aluminum with the nice black coating. I have been very impressed with the quality of the kit and the hardware. Here are some updated pictures of my progress. https://cimg8.ibsrv.net/gimg/www.mbw...69699d87fa.jpg
Throttle Bodies, new injectors and fuel rails installed https://cimg9.ibsrv.net/gimg/www.mbw...1876225571.jpg Drive snout installed with the 6# pulley. The 8# is also included in the kit https://cimg2.ibsrv.net/gimg/www.mbw...308b8127d1.jpg Pulley system installed |
Good stuff jumbo, keep those pics coming in. Especially interested in some of the plumbing to the cooler and the blower. Well done. |
Really appreciate the time your taking to update us.
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Thanks. I installed the coolant and PS reservoir behind the front right headlight and both fit right in without problem. They look like factory parts. I will post more pictures later. I am going to install an ESC catch can before installing the SC and am trying to figure out where to mount it. I will take lots of pics as I think many are interested in a less costly can than Weistec. After I figure out the mounting I can drop in the SC! |
Ready to install SC Unit
https://cimg3.ibsrv.net/gimg/www.mbw...585f280f9.jpeg When installing the drive snout line up the three drive dowels and gently tap the shaft and it slips right on https://cimg6.ibsrv.net/gimg/www.mbw...8a91554ab.jpeg View from the rear. The brake vacuum plugs in green, the other hard vacuum line in orange, the right nipple fits hose to the adjacent bypass valve, left nipple takes hose to front of engine, and I have plugged the intake air temp sessor into its hole |
Jimbo thanks for the updates and the pics. Look forward to seeing the progress and the remaining diy pics.
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https://cimg4.ibsrv.net/gimg/www.mbw...98e0af70a0.jpg
The factory PVC after removing the hose https://cimg7.ibsrv.net/gimg/www.mbw...08b863689e.jpg ESC catch can https://cimg2.ibsrv.net/gimg/www.mbw...5410427f8f.jpg Inside filter and dip stick for can https://cimg5.ibsrv.net/gimg/www.mbw...55886124b0.jpg PVC and hose before mounting SC https://cimg2.ibsrv.net/gimg/www.mbw...855f5e92a4.jpg PVC hose on supercharger https://cimg4.ibsrv.net/gimg/www.mbw...8dd6168e6c.jpg I had to use my engine hoist to install the SC as my old back just wasn't strong enough https://cimg9.ibsrv.net/gimg/www.mbw...0f05e98223.jpg Finally settled in place! Now I can hook of the wiring and hoses and put things back together before I remove the front bumper to install the intercooler radiator Made some good progress yesterday and got the unit on the engine! Took me some extra time to figure out where to put the catch can. Will place it on the right side next to the new coolant tank. I purchase an ESC can that appears to be very high quality and similar to the Weistec. I used 3/4 ID hose as that is the closest fit to our PCV valve fittings. I am working on it again today so will have more pictures. ! |
Nice job!
Did you have a part number for the ecs catch can? Nothing seems to come up on their site. |
Kick ass thread, always wanted to do a supercharger to my w204 but didn't. Will watch along with the rest of us, keep up the great post and information. Looking forward in seeing some awesome increases.
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Originally Posted by ritalin
(Post 7447228)
Nice job!
Did you have a part number for the ecs catch can? Nothing seems to come up on their site. |
Awesome thread!
Will subscribe to keep up with your progress. Really nice of you to share all these details. Now waiting to see the outcome on the Dyno! Congratulations |
Great progress! Let us know if you need anything
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If starting a weekend job 3 weeks ago is great progress, I wanna work for East Coast Euro. :rolf:
No offence Jimbo, we all know this is a side project. |
Originally Posted by Jasonoff
(Post 7448856)
If starting a weekend job 3 weeks ago is great progress, I wanna work for East Coast Euro. :rolf:
No offence Jimbo, we all know this is a side project. |
Great thread, thanks for sharing.
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Originally Posted by Big Jimbo
(Post 7449137)
Yes, I am lucky to get one day a week to work on this project. And I do want to thank Ahmad at East Coast Euro for his great advice whenever I have had a question when the directions were not clear. |
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Thanks for the FI harness tip. Ahmad from East Coast Euro suggested that when I ordered the kit so I made them while I was waiting for delivery. The lowest price I found was $8 per harness but $64 well spent. I soldered on the included pigtail and covered with marine grade heat shrink with the glue. I am using the stock air boxes and have to trim the inner edges to clear the supercharger. I will have time to work on it this weekend so will have more pictures. Will also mount the catch can and run the hoses and hopefully finish up in the engine compartment. I installed the serpentine belt which is always a lot of fun. |
Based on the image in post #10, the IAT sensor appears to be reading the air temp directly after the throttle bodies. Is that the position ESS recommend?
If my interpretation of the image is correct, it would be wise to relocate the sensor to be after the charge air coolers - place it close to the head ports. If not, the ECU/tune is only going to recognise the IAT pre-boost which would be way less than ideal - the IAT's after the coolers is the relevant temperature... especially with a twin-screw (unless you are willing to melt engine internals). |
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