Turbosmart TS-0101-110X User manual

Product Name:
All New Boost Tee Manual
Boost Controller
Product Description:
Product Number:
Manual Boost Controller
TS-0101-110X
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ABOUT THIS PRODUCT
Thank you for purchasing your new Turbosmart Boost Tee. This new model now has some great new features. These include:
•
The option of either a slow boost ramp rate for sensitive setups or fast depending on Boost Tee configuration. This is achieved with
either the restricted nipple as well as ball and spring.
•
•
A wider boost adjustment range for wastegates with low spring base pressures.
A new mounting bracket to make it easier to mount.
IMPORTANT NOTES ON YOUR BOOST CONTROLLER
Use only
silicone
hose
that
is
the
correct
size
and
pressure
rating
for
your
application
when
fitting
your
boost
controller
–
other
hoses
will be affected
by
heat
and
will
eventually
crack
or
split
which
could
cause
excessive
boost
pressure
and
engine
damage
•
•
•
•
•
•
Ensure that all plumbing is secured with clamps or cable ties.
Your boost controller should be mounted at least 100mm from any heat source
A Turbosmart
Fuel
Cut Defender
may
need
to
be
used
in
conjunction
with
your
boost
controller
–
refer
to
www.turbosmart.com.au
The boost dial has a left handed thread, be sure not to over tighten as this will damage the boost controller.
Please note
that
the
one
turn
(click)
of
the
boost
controller
dial
does
NOT
correspond to
1
PSI
change
in
boost
pressure.
RECOMMENDATIONS
•
•
•
•
Turbosmart recommends that the Air Fuel ratio is checked once boost pressure is set
Turbosmart recommends that boost pressure is set using a Dynamometer and not on the street
Turbosmart recommends that an accurate boost gauge be permanently fitted to the vehicle
Turbosmart recommends that your boost controller is fitted and adjusted by an appropriately qualified technician
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HOW TO INSTALL YOUR BOOST CONTROLLER
TOOLS REQUIRED
General mechanic
tools
1
Internal Wastegate Setup
Allow the
engine
to
cool
down
before
installing
your
boost
controller
•
•
•
Locate the pressure source port and the wastegate actuator port on the turbocharger assembly (refer drawing 1)
Remove the factory boost control solenoid if fitted from the boost pressure supply port while leaving the solenoid connected to the
ECU
•
•
•
•
•
Install your boost controller in the wastegate pressure line with the wastegate arrow pointing towards the wastegate actuator
If your wastegate actuator has additional ports, these will need to be blocked
Secure all silicone hose ends with hose clamps
Mount your boost controller bracket onto the vehicle, then attach the boost controller onto the bracket with the supplied screws
Make sure the boost dial is turned completely anti-clockwise before adjusting.
Boost dial
Boost Tee
Wastegate actuator port
Pressure source port
(Located before the
throttle body)
Compressor
Housing of Turbo
Note
!
Hose clamps/cable ties on all hoses
connections
Drawing 1
1

HOW TO INSTALL YOUR BOOST CONTROLLER cont.
2
External Wastegate Setup
Allow the
engine
to
cool
down
before
installing
your
boost
controller
•
•
•
•
•
•
Locate the
bottom port
on the external wastegate and the pressure source port (refer Drawing 2)
Install the
Boost
Tee
in
the
wastegate
pressure
line
with
the
wastegate
arrow
pointing
towards
the
bottom
port
on
the
wastegate
Secure all silicone hose ends with hose clamps
Mount your boost controller bracket onto the vehicle, then attach the boost controller onto the bracket with the supplied screws
Make sure the boost dial is turned completely anti-clockwise before adjusting.
Bottom port
Vent
External wastegate
Pressure source port
Boost dial
(Located before the
throttle body)
Boost Tee
Note
!
Hose clamps/cable ties on all hoses
connections
Drawing 2
3
Parallel Twin Turbo Setup
Allow the
engine
to
cool
down
before
installing
your
boost
controller
•
•
•
•
Locate the wastegate actuator ports on both turbochargers and a pressure source port (refer Drawing 3)
Remove the factory boost control solenoid if fitted from the boost pressure supply line
Install your
boost
controller
in
the
wastegate
pressure
line
with
the
wastegate
arrow
pointing towards
the
wastegate
actuators.
•
Be
sure to keep the hoses joining the wastegate actuators at equal lengths
•
•
•
Secure all silicone hose ends with hose clamps
Mount your boost controller bracket onto the vehicle, then attach the boost controller onto the bracket with the supplied screws
Make sure the boost dial is turned completely anti-clockwise before adjusting.
*
Note for sequential turbo systems: Sequential turbo setups can be complex and vary from car to car. Please contact your local Turbosmart dealer for more details
Boost Tee
Boost dial
T Piece
Pressure source
Located before
(
the throttle body)
Equal lengths
Wastegate actuators ports
Compressor Housing of
Turbo
Note
!
Turbochargers
Hose clamps/cable ties on all hoses
connections
Drawing 3
2

SETTING BOOST
PRESSURE
2
Boost Spiking
1
Important notes on Boost Pressure
Adjustment
If boost spiking occurs and is undesirable for your application,
the gate system can be removed to give you a less aggressive
boost curve. This modification is only required in a minimal
number of applications.
•
Adjustment to your boost controller is made by rotating
the
Boost
Dial.
Please
note
that
the
one
turn
(click)
of
the boost controller dial does NOT correspond to 1
PSI change in boost pressure.
Bo
•
•
Rotate in a clockwise direction to increase boost and the
reverse direction to decrease boost
Before making any adjustment, the
Boost Dial
will need
to be fully closed (anti-clockwise)
S
t
ep 1:
Apply
full
load
to the
engine in
a
high
gear (at
least
r
d
th
3
or 4
gear)
at
full
throttle
and
note
the
boost
pressure
Step 2:
To
increase
boost
rotate
the
Boost Dial
clockwise
(maximum of 1 complete revolution at a time)
Step 3:
Apply
full
load
to
the
engine
and
note
the
boost
pressure
Step 4:
Compare
the
actual
boost
pressure
with
the
desired
boost pressure. If the actual pressure is below the
desired pressure, return to step 2. If the actual is
above the desired boost then decrease by rotating
the
Boost Dial anti-clockwise
and return to step 3.
Ide
3
Important notes on Gate system removal
The gate system can be removed by the following steps.
Perform this modification on a clean bench so that the ball and
spring are not lost
Drawing 4
•
•
•
•
•
Allow the engine to cool down before removing the Boost
Tee from your vehicle
Identify the input nipple with the restrictor at the end.
Loosen the input nipple and remove the ball and spring.
Check that the internal air passages are clear and free
from debris
Re-install the
boost
controller
by
following
the
instructions
for your setup
You will need to re-adjust your boost settings after the
removal of
the
gate.
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TROUBLE SHOOTING
The following
points
should
be
checked
if
you
find
that
your
engine
is
developing
excessive
boost,
the
boost
pressure
is
fluctuating,
or
the desired boost level cannot be achieved. Please note, the following checks will cure 99% of problems experienced when fitting a
Turbosmart boost controller.
•
•
•
•
Check that the boost controller is installed so that the arrow points toward the wastegate actuator
Check the joining hoses for splits, cracks or loose connection and are the correct size for the application
Check to see if the boost controller is blocked or contaminated with dirt or debris
Ensure that
there
is
nothing
but
the
boost
controller
in
the hose
between
the
pressure
source
and
the
wastegate
actuator,
ie
tee
pieces for boost gauge or to factory boost solenoid.
•
•
Pressure test the wastegate actuator for leakage, the diaphragm or housing may be cracked or split
Check that the wastegate is operating correctly
3