ESS TS3 Engine Rebuild

I've also completed my quad exhaust conversion today, just need to make some plates to allow fine adjustment of the tailpipe position. The right side hangs slightly lower than the left.... Lol. However, as it is, it's sooooo much better than just a single sided twin pipe. The sound is awesome from the supersprint race cans, much more deep and throaty than my previous miltek, and it's efffing loud. This maybe because I also replaced the front section cats with straight through pieces.

Will take some pics soon
 
Alun1976 said:
Hi Byron,

I've installed the aeromotive 340 and left the wiring as it is for the moment. However when I install the rebuilt TS3 engine I will be uprating the wiring to the pump to ensure maximum fuel flow. So, does that mean the OEM fuel pump being 400lph is actually better than the aeromotive?
Click to expand...


no no.... its no better or worse imo and the AERO pump can support different types of fuel to like e85..... the aero WILL need Beefed up wiring otherwise it won't perform properly..... more pics please when you have time, really great to read this BTW...
 
Alun1976 said:
I've also completed my quad exhaust conversion today, just need to make some plates to allow fine adjustment of the tailpipe position. The right side hangs slightly lower than the left.... Lol. However, as it is, it's sooooo much better than just a single sided twin pipe. The sound is awesome from the supersprint race cans, much more deep and throaty than my previous miltek, and it's efffing loud. This maybe because I also replaced the front section cats with straight through pieces.

Will take some pics soon
Click to expand...

pics!!!

i often wonder why so many people prefer the quad exhaust , it just adds weight imo..... wish the z4m didn't come with this tbh.....
 
I love a build with photos 8)

So what kinda power are you hoping to achieve and I guess the main aim of the build is to make the engine as reliable as possible with a supercharger?
 
Beedub said:
Alun1976 said:
I've also completed my quad exhaust conversion today, just need to make some plates to allow fine adjustment of the tailpipe position. The right side hangs slightly lower than the left.... Lol. However, as it is, it's sooooo much better than just a single sided twin pipe. The sound is awesome from the supersprint race cans, much more deep and throaty than my previous miltek, and it's efffing loud. This maybe because I also replaced the front section cats with straight through pieces.

Will take some pics soon
Click to expand...

pics!!!

i often wonder why so many people prefer the quad exhaust , it just adds weight imo..... wish the z4m didn't come with this tbh.....
Click to expand...

I reckon the old system that was originally on the car with both the manifold cats and front cats weighed more than my decatted quad system and e36 M3 manifold. I could have replaced the front cats with straight pipes and kept it twin pipe and that would have definteliy saved weight, but I think it looks so much more aesthetically pleasing with the quad pipes. I am a little disappointed with the supersprint race backboxes though, as the drone inside the cabin is terrible compared to my previous miltek. It maybe the makeshift brackets I've made transferring the drone inside the cabin. I'm going to make some proper brackets with some neoprene or similar rubber inbetween the bracket and car body to see if that helps with the drone.

It also feels like the new system may have reduced power as well. I'm not sure if it actually could reduce power but it doesn't quite feel as though it has the same poke as it did before. I may be wrong though, and also yesterday was probably the hottest day so far this year and that may have been the slight difference in power. I will see how things go.

The new system may be much more suited for the TS3 engine install.
 
Mark-Z4 said:
I love a build with photos 8)

So what kinda power are you hoping to achieve and I guess the main aim of the build is to make the engine as reliable as possible with a supercharger?
Click to expand...

ESS quote 470hp and 540Nm torque using the 14psi pulley. I am leaning towards purchasing the 15psi pulley though, so should be slightly more horses than 470hp. :) I am slightly concerned about the gearbox though, what's everyones thought? It's a standard z4 3.0 six speed gearbox.

Hopefully it will be reliable as possible. This is my first ever engine build, it may go horribly wrong, who knows, but I am following everything by the book the best I can. Finger crossed.
 
Alun1976 said:
Mark-Z4 said:
I love a build with photos 8)

So what kinda power are you hoping to achieve and I guess the main aim of the build is to make the engine as reliable as possible with a supercharger?
Click to expand...

ESS quote 470hp and 540Nm torque using the 14psi pulley. I am leaning towards purchasing the 15psi pulley though, so should be slightly more horses than 470hp. :) I am slightly concerned about the gearbox though, what's everyones thought? It's a standard z4 3.0 six speed gearbox.

Hopefully it will be reliable as possible. This is my first ever engine build, it may go horribly wrong, who knows, but I am following everything by the book the best I can. Finger crossed.
Click to expand...

your doing great.... wouldn't worry to much about the gearbox, usa z4m owners are putting big power through these cars, a number of turbo charged cars running 600whp on the stock box.... it seems very strong.... mines been fine with proper but respected use.... each lb of boost seems to be good for around 25-30hp according to ESS....

ess just relaeased another stage for the s54 S/C system.... the 575hp unit.... :| :| :| :| :|
 
You probably need a clutch upgrade though :wink:
sachs performance or something like that.
I think the gearbox will hold, although 540Nm is A LOT of torque. (more than 10% more torque than the ESS VT2-575 makes), so everything in front of the diff is put to the test :) (after the diff it's more a matter of power)

Quad exhausts look great, but don't have any real power advantages. That is purely a matter of piping diameter, how the dampers (internal flow) are constructed etc.
Quad exhausts (aka 2 backboxes) might be nessesary to get the necessary legal reduction in sound pressure for a stock car.
But it does add weight; about 10kg or so.
 
I will say it again fantastic thread.

Where are you getting your tolerance of fit information from. And associated where limits??

Good luck to you and well done for having a go :thumbsup:
 
Machine monkey said:
I will say it again fantastic thread.

Where are you getting your tolerance of fit information from. And associated where limits??

Good luck to you and well done for having a go :thumbsup:
Click to expand...

Thanks MM. All info is taken from the BMW workshop manual.

http://workshop-manuals.com/bmw/z_series_e85/z4_3.0i_m54_roadst/3_technical_data/11__engine_(m54)/21__crankshaft_with_bearing/1_td__crankshaft_and_bearings_m54/

CP pistons quoted me the correct PTW clearance.
 
Can i just ask some maybe stupid questions.... And there may be answered in the thread but i have missed them.

The pistons are the ordinal pistons and have had coatings added to the crown and skirt. I guess to help with extra heat and stress. Was there no need for forged pistons or with a different crown profile?
Your using uprate gudgeon pins and forged con rods? And you are using uprated bolts on the con rods? Also what other bolts are you going replace head bolts so on???
The crank bearings are they new coated items or reused?? I have rebuilt an engine years a go on my pug 205 the bearings in that where just some sort of white metal??

Also crank cams are they staying the same? I am guessing a forged crank is MEGA £££££ And with the vanos cams are a bit pointless??

Love what your doing and would love to be doing the same this time next year :thumbsup:

Sorry for all the questions.
 
Beedub said:
your doing great.... wouldn't worry to much about the gearbox, usa z4m owners are putting big power through these cars, a number of turbo charged cars running 600whp on the stock box.... it seems very strong.... mines been fine with proper but respected use.... each lb of boost seems to be good for around 25-30hp according to ESS....

ess just relaeased another stage for the s54 S/C system.... the 575hp unit.... :| :| :| :| :|
Click to expand...

the 3.0 hass a different gearbox than the M i suppose, he could swap his one for a z4M/e46M3 gearbox if needed.
 
Machine monkey said:
Can i just ask some maybe stupid questions.... And there may be answered in the thread but i have missed them.

The pistons are the ordinal pistons and have had coatings added to the crown and skirt. I guess to help with extra heat and stress. Was there no need for forged pistons or with a different crown profile?

Forged low compression 9:1 CP pistons. Crown coating designed to keep the heat in the exhaust gas rather than soaking into pistons. Skirt coating to help reduce friction and heat into the piston.

Your using uprate gudgeon pins and forged con rods?
Forged con rods and gudgeon pins where supplied with the pistons to suit.

And you are using uprated bolts on the con rods?
ARP2000 conrod bolts

Also what other bolts are you going replace head bolts so on???
ESS recommend stock head bolts but I'm debating whether to go with a raceware or ARP head stud upgrade, since I'm weary that the threads in the block my pull out when torquing.

The crank bearings are they new coated items or reused??
New crank bearings that have been coated with cermalube. I bought this from camcoat in Warrington and applied the coating myself after thorough cleaning, slight surface etching, cleaning again, then spraying and finally baking in the oven for a hour. I used the same process to do my pistons and new big end bearings.

I have rebuilt an engine years a go on my pug 205 the bearings in that where just some sort of white metal??
Not sure on that one to be honest

Also crank cams are they staying the same?
Uprated Schrick cams 248/256 are being used. These are what ESS recommend. The crank is the original 3.0. It has no scouring and is within tolerance. ESS don't recommend replacing or upgrading the crank but you can if you like, but like you say they will be mega bucks.

I am guessing a forged crank is MEGA £££££ And with the vanos cams are a bit pointless??

Love what your doing and would love to be doing the same this time next year :thumbsup: Nice one

Sorry for all the questions.
Click to expand...
.
No probs
 
Lightning87 said:
Beedub said:
your doing great.... wouldn't worry to much about the gearbox, usa z4m owners are putting big power through these cars, a number of turbo charged cars running 600whp on the stock box.... it seems very strong.... mines been fine with proper but respected use.... each lb of boost seems to be good for around 25-30hp according to ESS....

ess just relaeased another stage for the s54 S/C system.... the 575hp unit.... :| :| :| :| :|
Click to expand...

the 3.0 hass a different gearbox than the M i suppose, he could swap his one for a z4M/e46M3 gearbox if needed.
Click to expand...

its the same.... bar clutch setup....
 
Thanks for the reply. You must be spending a few quid hear!! Good on ya really nice to see someone doing it them selves.

Have you thought about a LSD? I just got one for mine mfactory it has good reviews and another member has one. I have not put mine in yet but will be soon. I can report back my findings.
 
Machine monkey said:
Thanks for the reply. You must be spending a few quid hear!! Good on ya really nice to see someone doing it them selves.

Have you thought about a LSD? I just got one for mine mfactory it has good reviews and another member has one. I have not put mine in yet but will be soon. I can report back my findings.
Click to expand...

I have the E46 M3 rear end and LSD installed. I was looking into getting a spare M3 LSD to strip in down and rebuild with coated internals. I have been led to believe that the coatings massively reduce the frictional losses in the diff, so will be an excellent power upgrade (if its true) since there are up to 15% losses in the drivetrain. The chap at camcoat highly recommended coating the internals of the diff. He said he had done his and it made a massive improvement. Hard to believe just from a one thou thickness of coating, but I'd like to give it a try.

It's costing me a small fortune, but the way I see it is, I enjoy driving the car (it's exhilarating) and once everything has been done it will be more or less a new car as everything has been upgraded and the engine rebuilt. So, it would cost me a fortune to buy a new car anyway, and then I would have mediocre parts on a new car. Instead, I will have quality parts on my Z, and all the power I need to keep me smiling. :)
 
Alun1976 said:
Machine monkey said:
Thanks for the reply. You must be spending a few quid hear!! Good on ya really nice to see someone doing it them selves.

Have you thought about a LSD? I just got one for mine mfactory it has good reviews and another member has one. I have not put mine in yet but will be soon. I can report back my findings.
Click to expand...

I have the E46 M3 rear end and LSD installed. I was looking into getting a spare M3 LSD to strip in down and rebuild with coated internals. I have been led to believe that the coatings massively reduce the frictional losses in the diff, so will be an excellent power upgrade (if its true) since there are up to 15% losses in the drivetrain. The chap at camcoat highly recommended coating the internals of the diff. He said he had done his and it made a massive improvement. Hard to believe just from a one thou thickness of coating, but I'd like to give it a try.

It's costing me a small fortune, but the way I see it is, I enjoy driving the car (it's exhilarating) and once everything has been done it will be more or less a new car as everything has been upgraded and the engine rebuilt. So, it would cost me a fortune to buy a new car anyway, and then I would have mediocre parts on a new car. Instead, I will have quality parts on my Z, and all the power I need to keep me smiling. :)
Click to expand...

great outlook!!! i concur!!
 
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