ZHP ESS TS2 Project - (PICS)

[Au2bahn]

I started this winter project with the notion of just rebuilding my Vanos and cooling system overhaul. While I had everything apart in my heated garage, I figured while I was in there, I might as well add an ESS TS2 kit which I planned to install eventually. Since ESS had a holiday promo back in December, I took advantage of it and hence the prolonged winter project. It took me longer than normal since I work on it only on weekends, I replace and add things as I go and also work on other projects for friends. Part of the purchase decision was the challenge of doing the install myself. I have always worked on cars since I was 16 and I figured this will be a moderate task and not time consuming like an engine rebuild. I rate the install with 10 being the hardest as a 6. The ESS kit is spot on except for some modifications I did to ensure the TS runs flawlessly without contamination. Its definitely quick!!!! Here are some pics of the process:

Started to take off pieces:




Vanos Removed and ready to be rebuilt:


Vanos Rebuild Process:






Vanos Rebuild all done:



Cooling System off:



Cooling System Components:


Thats an EMP Stewart water pump!!!


Now for the fun part:

Intake Manifold Before:


Intake Manifold Removed:





Removed TB, ICV and cleaned thoroughly:


New Bigger injectors:



Air to Water Intercooler installed:


IC Pump:


Twin Screw Installed:




Running lines and hoses for boost gauge:




Final install stages:


Oil Separator since the oem CCV is gone:


Ran SS hoses for durability:




Ran SS hoses for durability:





Rest of engine components installed:



......and DONE!

[kayger12]

Now THAT's what I'm talking about.

Great project thread!

[Marcus-SanDiego]

And this, my friends, is why I love the projects forum.

[danewilson77]

Mind blown.

[mimalmo]

Very nice! Did you get some before & after dyno numbers?

[Au2bahn]

Thanks and No....I have not done any dynos yet. I will definitely post as soon as I do.

Currently, it runs very very strong hitting 9psi at full boost using an AEM digital boost gauge.

All the mods are not seen from the outside.....but I have definitely shocked a few M3's, 550's and Carrera's. My car shows the unique lines of the ZHP using OEM add ons as much as I can except for the wheels and a drop.

[Oli77]

[Mtnman]

Ok. Now im extremely jealous. Especially the fact you keep most of the exterior OEM. and i thought a normal ZHP was sneaky fast...... Excellent job.

[05ZIPPYZHP]

Beautifully done.... The attention to detail is also something to be proud of: taping off inlets, sealing up ports with rags and placing everything off the ground. Excellent job

[Marcus-SanDiego]

Thanks and No....I have not done any dynos yet. I will definitely post as soon as I do.

Currently, it runs very very strong hitting 9psi at full boost using an AEM digital boost gauge.

All the mods are not seen from the outside.....but I have definitely shocked a few M3's, 550's and Carrera's. My car shows the unique lines of the ZHP using OEM add ons as much as I can except for the wheels a drop.

Jon, that's great stuff.

Are you going to the Virginia Mafia meet in 12 days?