A Few Problems with the Installation of the ESS VT550 SCer Kit

herrubermensch · 1st September 2009, 18:16

I am about 75% of the way through the installation now, having spent two half-days on the project, and here are the issues I have run into and their resolution.

First, the ESS crank pulley does NOT work with the Evosport crank pulley. It doesn't sit flush on the face and, thus, extends about a half inch further out on the Evosport than stock. Resolution: Put the stock pulleys (which I kept!) back on. Further problem: Power steering pulley won't come off, and two bolts broke off in my water pump. In any event, with the stock crank pulley, there IS sufficient clearance for the Zionsville overflow tank, so that will NOT have to be relocated. Whew!

Second, the ESS crank pulley does NOT fit with the Zionsville SPAL fan in its normal location on the aluminum shroud. It DOES fit if you simply rotate the position of the fan on the shroud up and over about an inch. This allows you to use one of the existing threaded locations on the shroud for the fan bolts; just need to install three others. So this is a relatively easy fix as well. Whew!

Third, when I installed the new fuel injectors, the fuel rails are lifted up from their stock location and, thus, their bolt holes do not line up with the screw mounts. Now, the ESS people recognize this as a possibility and include spacers and bolts to make up the difference. PROBLEM: The spacers (basically thick washers) do NOT FIT. The washers are too big. Moreover, even if they were the right size, the fuel rails are now at an angle to the screw mounts, so they are not going to fit no matter what. I am emailing Roman about this today, as this is an engineering failure that prevents the kit from achieving its "bolt on" goal. I'll post some pics tomorrow that show exactly what I'm talking about. Has anyone run into this problem? If so, how did you solve it? Raza? Edwin? Jerry?

Fourth, my radiator hoses are getting the heck squeezed out of them by the SCer bracket, not so much that they are closed, but they clearly have been narrowed by compression. The ESS manual says not to worry about this, but I am a little concerned. Essentially it is the return hose for the radiator, the hose for the overflow tank and the air conditioning line that all are squeezed pretty tightly together. It took a real he-man effort to get the lower bracket bolts and the tensioner bracket bolts in all the way.

Other than the foregoing, I have to say the bracketry and the overall engineering of the kit is quite good, right down to one of the spacers for the bracket having one edge ground down to clear the VANOS oil line on the passenger side. Nicely done. If I can just get the spacer situation for the fuel fails resolved, I'm pretty close to having the ESS part of the equation done!

--Peter

ECB · 1st September 2009, 18:47

Quote:

Originally Posted by herrubermensch

Edwin?

Install starting tomorrow.
Peter-
Thanks for your input. I'm assuming my Rogue crank pulley will not be compatible either. That's interesting about the fuel injectors.

Raza- any issues with your injectors?

herrubermensch · 1st September 2009, 18:52

Quote:

Originally Posted by ECB

Install starting tomorrow.
Peter-
Thanks for your input. I'm assuming my Rogue crank pulley will not be compatible either. That's interesting about the fuel injectors.

Raza- any issues with your injectors?

Don't know for sure about the Rogue crank pulley, but the ESS crank pulley clearly has been designed to work with the stock pulley, and each aftermarket pulley maker has a slightly different edge on the face of their crank pulleys.

razahyde · 1st September 2009, 19:04

Quote:

Originally Posted by herrubermensch

I am about 75% of the way through the installation now, having spent two half-days on the project, and here are the issues I have run into and their resolution.

First, the ESS crank pulley does NOT work with the Evosport crank pulley. It doesn't sit flush on the face and, thus, extends about a half inch further out on the Evosport than stock. Resolution: Put the stock pulleys (which I kept!) back on. Further problem: Power steering pulley won't come off, and two bolts broke off in my water pump. In any event, with the stock crank pulley, there IS sufficient clearance for the Zionsville overflow tank, so that will NOT have to be relocated. Whew!

Second, the ESS crank pulley does NOT fit with the Zionsville SPAL fan in its normal location on the aluminum shroud. It DOES fit if you simply rotate the position of the fan on the shroud up and over about an inch. This allows you to use one of the existing threaded locations on the shroud for the fan bolts; just need to install three others. So this is a relatively easy fix as well. Whew!

Third, when I installed the new fuel injectors, the fuel rails are lifted up from their stock location and, thus, their bolt holes do not line up with the screw mounts. Now, the ESS people recognize this as a possibility and include spacers and bolts to make up the difference. PROBLEM: The spacers (basically thick washers) do NOT FIT. The washers are too big. Moreover, even if they were the right size, the fuel rails are now at an angle to the screw mounts, so they are not going to fit no matter what. I am emailing Roman about this today, as this is an engineering failure that prevents the kit from achieving its "bolt on" goal. I'll post some pics tomorrow that show exactly what I'm talking about. Has anyone run into this problem? If so, how did you solve it? Raza? Edwin? Jerry?

go to home depot or something like that and get spacers that do fit, i ran into the same thing and even though it looks a little mis aligned, everything still works fine. im ghetto and used the rubber rings from my oem fuel injectors as spacers....

Fourth, my radiator hoses are getting the heck squeezed out of them by the SCer bracket, not so much that they are closed, but they clearly have been narrowed by compression. The ESS manual says not to worry about this, but I am a little concerned. Essentially it is the return hose for the radiator, the hose for the overflow tank and the air conditioning line that all are squeezed pretty tightly together. It took a real he-man effort to get the lower bracket bolts and the tensioner bracket bolts in all the way.

i thought the same thing at first, but if you have the hoses right behind where they should be, it works just fine and flow is just fine.

Other than the foregoing, I have to say the bracketry and the overall engineering of the kit is quite good, right down to one of the spacers for the bracket having one edge ground down to clear the VANOS oil line on the passenger side. Nicely done. If I can just get the spacer situation for the fuel fails resolved, I'm pretty close to having the ESS part of the equation done!

--Peter

-R

Mfreakin5 · 1st September 2009, 19:10

am I the only one who thinks you shouldn't have to ghetto rig anything on a kit that costs $10k? I'd be interested to see what ESS has to say about this...

Roman@ESS · 1st September 2009, 19:19

The kit was designed to work on a stock car. We do not guarantee any compatability with other aftermarket parts. The fuel rail spacers we supplied can be modified to work or the rail can be spaced easily with shims. Our test car has different injectors then the 2002+ US cars. This was something we found out right before we starting shipping. The spacers we made seem to be a little off. We will have a fix for this ASAP and it will be included in kits very soon. we will also send the revised spacers to any customer that has recieved a kit and wants them.

gsfent · 1st September 2009, 23:46

Thanks Peter. Very helpful info.

I am planning to start the install Friday, and I have most of the long weekend to compete it.

I note the EVosport pulley issue, I have the same. I think I saved the original, I will have to hunt it down. Any reason the Evo pulley can't be machined slightly so the SC pulley sits flush? Since I do not have Zionsville, is the slight difference any concern, or is it an issue regarding belt alignment? Raza? Roman? AJ?

Will do a Home Depot run if necessary for spacers if necessary, although I like Raza's solution.
Will try to take some pics also.
Regards,
Jerry

razahyde · 1st September 2009, 23:51

Quote:

Originally Posted by Mfreakin5

am I the only one who thinks you shouldn't have to ghetto rig anything on a kit that costs $10k? I'd be interested to see what ESS has to say about this...

i wouldnt call it ghetto rigging, it is essentially the same thing as getting rubber spacers. everything else pertaining to the kit was spot on, if you saw how precise everything was you would know how much work went into it.

herrubermensch · 2nd September 2009, 00:07

Quote:

Originally Posted by gsfent

Thanks Peter. Very helpful info.

I am planning to start the install Friday, and I have most of the long weekend to compete it.

I note the EVosport pulley issue, I have the same. I think I saved the original, I will have to hunt it down. Any reason the Evo pulley can't be machined slightly so the SC pulley sits flush? Since I do not have Zionsville, is the slight difference any concern, or is it an issue regarding belt alignment? Raza? Roman? AJ?

Will do a Home Depot run if necessary for spacers if necessary, although I like Raza's solution.
Will try to take some pics also.
Regards,
Jerry

Hey Jerry. I thought about trying to work with the Evosport pulley, but I'm not sure that even machining the lip is going to work, as the ESS pulley sits a good 1/2-1" from the bottom of the crank pulley when inserted. I would be worried about allignment even with machining. It just doesn't fit, and I didn't want to spend the time or money to figure out exactly why. I liked my original water pump pulley better anyway, so this just gave me an excuse to put all of the original pulleys back on. Would have been great except for the two bolts that broke off in the water pump and for the power steering pulley that seems irrevocably fused to the power steering pump! I've tried everything on that damn pulley to no avail. I may have to replace the power steering pump just to replace the pulley!

The real problem with my fuel rails is not just a spacing issue, it's an offset issue. The rails with the new injectors installed are not just higher than the bolt holes, they are offset by about half an inch. I want to see what ESS is going to do for me on this point with the new shims, though, like you, I like homemade solutions such as Raza's and may very well have to resort to that.

razahyde · 2nd September 2009, 00:10

Quote:

Originally Posted by herrubermensch

Hey Jerry. I thought about trying to work with the Evosport pulley, but I'm not sure that even machining the lip is going to work, as the ESS pulley sits a good 1/2-1" from the bottom of the crank pulley when inserted. I would be worried about allignment even with machining. It just doesn't fit, and I didn't want to spend the time or money to figure out exactly why. I liked my original water pump pulley better anyway, so this just gave me an excuse to put all of the original pulleys back on. Would have been great except for the two bolts that broke off in the water pump and for the power steering pulley that seems irrevocably fused to the power steering pump! I've tried everything on that damn pulley to no avail. I may have to replace the power steering pump just to replace the pulley!

The real problem with my fuel rails is not just a spacing issue, it's an offset issue. The rails with the new injectors installed are not just higher than the bolt holes, they are offset by about half an inch. I want to see what ESS is going to do for me on this point with the new shims, though, like you, I like homemade solutions such as Raza's and may very well have to resort to that.

get some spacers from home depot and call it a day, it really doesnt need to be thought about more then that. ESS is going to send you the same thing, spacers. Or if you were fed up with your car as i was, 2 of th Orings from the oem injectors work just fine for each screw...