Why Supercharge the F80 M3?

The BMW F80 M3, with its S55 twin-turbo inline-six, is already a formidable performer. However, for enthusiasts seeking a sharper throttle response, linear power delivery, and a distinct mechanical roar, a centrifugal supercharger offers a transformative upgrade. The ESS VT2-625 supercharger is engineered specifically for the S55 platform, delivering approximately 625 horsepower to the crank without the complexity of upgrading the factory twin-turbos. This guide provides a step-by-step, professional-level instruction set for installing the ESS VT2-625 system, ensuring a reliable and powerful result.

What’s in the ESS VT2-625 Kit?

Before starting, verify your kit contains all the essential components. The standard ESS VT2-625 system includes:

  • Vortech V3 Si or Paxton supercharger head unit
  • Custom cast aluminum mounting bracket and idler pulleys
  • Serpentine belt – oversize for supercharger drive
  • High-capacity intercooler core with cast end tanks
  • Mandrel-bent charge piping with silicone couplers and T-bolt clamps
  • Reinforced intake system with high-flow air filter
  • ESS-specific ECU calibration (required – via flash or handheld device)
  • Optional fuel system upgrade: Injector Dynamics ID1050x or higher flow injectors and a fuel pump relay kit
  • Installation hardware, bolts, washers, and detailed instruction booklet

Important: ESS requires a flashed ECU tune for the VT2-625. Running the supercharger without the correct calibration risks serious engine damage. If you purchased a used kit without a tune, contact ESS to obtain the proper calibration file.

Tools and Materials Required

Gather the following tools before beginning. Having everything on hand reduces installation time and frustration.

Essential Hand Tools

  • 3/8" and 1/2" drive ratchet set with metric sockets (8-19mm)
  • Combination wrenches (8-19mm) – especially a 15mm for belt tensioner
  • Torx sockets (T25, T30, T40) for various S55 fasteners
  • Flathead and Phillips screwdrivers
  • Pry bar (small) for releasing tensioner
  • Trim removal tools (optional but helpful)
  • Magnetic pickup tool for dropped bolts

Torque Wrenches

  • 3/8" drive torque wrench (10–60 Nm range)
  • 1/2" drive torque wrench (40–200 Nm range)

Consumables and Safety Gear

  • High-performance engine oil (Mobil 1 0W-40 or equivalent) – 8 liters
  • BMW-approved coolant (or distilled water + concentrate) – 6 liters
  • Shop towels, brake cleaner, threadlocker (Loctite blue)
  • Safety glasses and mechanic’s gloves
  • Ramps or jack stands (safe lift points)
  • Battery terminal puller and memory saver (optional)
  • Radiator support removal socket (10mm flex-head)
  • Belt tensioner tool for S55 (available from ECS or Bimmerworld)
  • Coolant pressure tester for bleeding
  • OBD-II scanner to check for fault codes after installation

Preparation Steps

Thorough preparation prevents delays and ensures safety. Follow these steps in order.

  1. Park on a level surface and engage the parking brake. Chock the rear wheels.
  2. Disconnect the negative battery terminal using a 10mm wrench. Wrap the terminal in a shop towel to prevent accidental contact.
  3. Remove the engine cover (pull upward at the front tabs) and the cowl trim under the windshield (two screws and clips).
  4. Drain the coolant from the lower radiator hose using a catch pan. Also drain the engine oil if you plan to replace it while the intercooler is out (recommended).
  5. Clean the engine bay with a degreaser and compressed air. Debris falling into open intake ports can cause severe engine damage.

Removing the Stock Components

The S55 engine is tightly packaged. You must remove the stock air intake system, intercooler, and charge pipes to create space for the supercharger bracket and intake system.

1. Remove the Factory Air Intake System

  • Unclip the intake snorkel from the front turbo inlets (two Torx T25 screws per side).
  • Detach the MAF sensor connectors and remove the entire airbox assembly.
  • Set aside the rubber boots and clamps – they may be reused for the new intake.

2. Remove the Intercooler

  • Unbolt the front bumper or at least release the upper clips and pull the bumper forward enough to access the intercooler bolts. The service manual recommends removing the bumper fully, but with patience you can reach all four intercooler bolts (10mm) from above.
  • Disconnect the charge pipe from the throttle body (two T30 bolts) and slide the silicone coupler off.
  • Lift the intercooler out from the top. Note the foam seals – they will be reused with the ESS intercooler.
  • Remove the two lower charge pipes (driver and passenger side) by loosening the T-bolt clamps at the intercooler and turbo outlet ends.

3. Remove the Belt and Tensioner

  • Use a 15mm wrench to pivot the belt tensioner clockwise and slip the belt off the supercharger pulley (stock car does not have a supercharger – remove the accessory belt if you still have it). For VT2-625, the belt drive is completely replaced with a longer belt routed over the new supercharger pulley.
  • Remove the tensioner assembly (two 13mm bolts) if you need more access to the bracket area. Keep the tensioner for reuse; you will install it in a new position per the ESS manual.

Installing the ESS VT2-625 Supercharger: Step-by-Step

1. Mount the Supercharger Bracket

The cast aluminum bracket replaces the factory alternator bracket location. It also houses the idler pulley for the new belt path.

  • Position the bracket over the existing bolt holes on the cylinder head. Use the provided M8 bolts (12.9 grade) and apply Loctite blue.
  • Tighten to 22 Nm (16 ft-lb) in a crisscross pattern.
  • Install the new idler pulley onto the bracket. Torque the center bolt to 30 Nm (22 ft-lb).

2. Mount the Supercharger Head Unit

  • Lift the supercharger unit into position. It sits on the driver side of the engine, alongside the valve cover.
  • Align the supercharger mounting flange with the bracket studs. Slide the unit onto the studs and secure with the provided nuts.
  • Torque the M10 nuts to 45 Nm (33 ft-lb).
  • Attach the oil feed line (from the engine block) and the oil drain line (back to the oil pan). The kit includes a -3AN feed line with a restrictor – connect it hand-tight then 1/4 turn with a wrench. The drain is a -6AN line with a banjo fitting at the pan. Torque all AN fittings to 12 Nm (9 ft-lb) – do not overtighten.

3. Install the New Intercooler and Charge Piping

  • Place the ESS intercooler into the factory location. Reuse the foam seals around the edges.
  • Secure the intercooler with the factory bolts – torque to 10 Nm (7 ft-lb).
  • Route the new charge pipes. The driver side pipe connects from the supercharger outlet to the intercooler. The passenger side pipe connects from the intercooler to the throttle body. Use the supplied silicone couplers and T-bolt clamps.
  • Do not fully tighten all clamps until the routing is verified and nothing contacts the fan or belts. Once satisfied, torque T-bolt clamps to 6 Nm (55 in-lb).
  • Install the blow-off valve (BOV) supplied with the kit. The BOV diaphragm should face upward to prevent moisture ingress.

4. Install the Air Intake System

  • The ESS air filter mounts to a carbon fiber or aluminum tube that connects to the supercharger inlet. Use the supplied rubber coupler and clamp.
  • Secure the filter in a location that pulls cold air from behind the bumper or grille. Do not let it rest against the radiator or frame – use the bracket provided to hold it steady.
  • Reconnect the MAF sensor (if your tune requires MAF signal – many ESS tunes use speed density, so the MAF may be removed. Follow the included wiring diagram.)

5. Belt Installation

  • The ESS kit includes a new serpentine belt. Follow the belt routing diagram in the manual. Typical path: crankshaft pulley → supercharger pulley → idler pulley → tensioner → alternator.
  • Use a 15mm wrench to pivot the tensioner and slip the belt onto the supercharger pulley last.
  • Check belt tension – it should deflect about 5mm with moderate thumb pressure. If too loose, the tensioner may need adjustment (some kits provide an adjustable arm).

Fuel System Upgrades (If Applicable)

ESS recommends upgrading the fuel system for consistent fuel delivery at higher boost pressures. The VT2-625 kit at 625 hp requires at least upgraded injectors and often a low-pressure fuel pump controller.

  • Install the injectors: Remove the fuel rail (two 10mm bolts per side). Pull out the factory injectors and replace with the supplied ID1050x or equivalent. Use new O-rings lubricated with engine oil.
  • Fuel pump controller: The ESS harness includes a relay that triggers the secondary fuel pump when boost exceeds 2 psi. Mount the relay in a dry location near the battery, connect to the battery positive post, and ground to chassis. Wire the trigger signal to a pressure switch or the ECU boost signal.
  • Double-check all fuel connections for leaks before attempting to start the engine.

Electrical Connections and Sensors

Proper electrical connections ensure the supercharger integrates seamlessly.

  • Supercharger drive magnet (if Vortech unit): Some ESS kits include an electric fan or a drive pin connector. Connect the two-wire harness to the supercharger body – polarity does not matter.
  • IAT sensor: The charge pipe usually has a bung for an intake air temperature sensor. Move the factory IAT sensor from the intercooler to that bung (or use a new sensor supplied).
  • MAP sensor: The ESS tune uses a 3-bar or 4-bar MAP sensor. Unplug the factory MAP and plug in the new sensor; secure it with a zip tie to prevent vibration.
  • Boost gauge (optional): You can tap into a vacuum line from the intake manifold to run a mechanical boost gauge.
  • Check all wiring for chafing against the belt, moving components, or sharp edges. Use loom and tape as needed.

Fluid Refill and System Bleeding

Now that the mechanical installation is complete, refill all fluids.

Engine Oil

  • Fill with 7.5 liters of 0W-40 or 5W-50 (ESS recommends synthetic racing oil). Start the engine briefly to fill the oil filter, then top off to the maximum mark.

Coolant

  • Refill with a 50/50 mixture of BMW-approved coolant. Use a coolant funnel to bleed air from the system. The S55 has a bleeder screw on the top of the expansion tank – open it until no bubbles appear.
  • Run the engine with the heater on high until the thermostat opens. Check for leaks at the intercooler and hoses.

Initial Startup and Tuning

Do not start the engine without loading the ESS tune. If you are using a handheld flash tuner (e.g., BootMod3 or ESS’s own tool), follow the manufacturer’s instructions to flash the ECU before starting. If the tune is already loaded on the ECU from a previous owner, verify it is the correct version for your injectors and boost level.

  1. Turn the ignition on for 10 seconds (without starting) to prime the fuel system.
  2. Start the engine. It may idle rough for a few seconds as air bleeds from the supercharger oil system. Listen for knocking, rattling, or belt chirping.
  3. Let the engine reach operating temperature (90°C). Check for coolant leaks, oil leaks, and unusual noises.
  4. Turn off the engine and inspect all belt pulleys for alignment. The belt should ride in the center of each pulley groove.

Test Drive and Monitoring

After the initial idle, it’s time to road test the installation.

  • First 20 miles: Drive gently – no full throttle, keep boost below 5 psi. Allow the supercharger bearings and rings to seat.
  • Gradually increase load: Perform a few 4-5k rpm pulls in 3rd gear, then let the car coast. Check for boost leaks (listen for hissing) and ensure the BOV opens cleanly.
  • Log parameters: If you have a tuner or data logging device, monitor IAT, fuel trims, boost pressure (target 10 psi), and oil pressure. IATs should not exceed 140°F (60°C) under sustained load – if they do, consider an additional heat exchanger or water-methanol injection.
  • Check belt tension after the drive: Retorque all supercharger mounting bolts to spec. The belt may stretch slightly – retension if necessary.

Conclusion and Resources

Installing the ESS VT2-625 supercharger on your F80 M3 transforms the car into a true high-performance machine. The centrifugal design offers a progressive, linear power curve that complements the S55’s character. This guide covers the core installation steps, but always refer to the ESS Tuning official instructions for model-specific torque values and belt routing. Additional support can be found on the F80 Bimmerpost forum, where many owners share their experiences and tuning advice. For professional tuning, consider reaching out to Performancetuning or your local BMW specialist. With meticulous installation and proper break-in, the VT2-625 will deliver many miles of exhilarating performance.