Hybrid and Basic Boost Controller

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Hybrid and Basic Boost Controller Installation and Set-Up Instructions

Please read this and the FAQ, before attempting to install!

1. Never increase boost without the available fuel supply to support it. Please read the FAQ for details on monitoring your progress.
2. The controller is shipped at a low boost adjustment to protect your engine. Follow the instructions below to adjust it. Do not change the adjustment before installing the controller.
3. When adjusting the controller, you will find it necessary to uncoil the vacuum hose leading from the boost source to the controller. Do this by rotating the vacuum hose about the end of the controller.
4. Note that the controller has a very small orifice on the end with the elbow attached. It is located on the side of the elbow in one of the dimple recesses. This orifice must not be blocked if the controller is to operate correctly. (See Diagrams)

1.Locate the wastegate on your turbo system. Most will have an integral design like the one in the illustration. Attached to the wastegate will be a vacuum line or hose. Remove the hose from the wastegate and plug the hose. A large, short, sheet metal screw works well for this purpose and will not work loose. DO NOT DRIVE THE VEHICLE WITH THE WASTEGATE DISCONNECTED. If you have an adjustable wastegate, set it to it’s lowest boost setting. Most factory wastegates are NOT adjustable. You’d know if you had one.
Click this link to view and print the first diagram

2. Attach a length of vacuum hose from the elbow end of the controller to the wastegate nipple. This is the nipple that you just removed the vacuum hose from. Tie wrap it in place, so it can not fall off. Also tie wrap any intermediate fittings that you had to add. If you need extra hose length, vacuum couplings may be obtained at your auto parts store. There are also adapters available to match the inside diameter of the hose to the wastegate nipple, although vacuum hose will stretch considerably.
Click this link to view and print the second diagram
Click this link to view and print the last diagram

3. Locate a boost source using the diagrams as a guideline. Now run a piece vacuum hose between the boost source and the straight end of the controller. A drop of oil on the brass tip will aid in adjusting the hose later. Do not use the original wastegate line as your boost source. The best place to use is a nipple on the turbocharger output, if you have one. If there is already a line attached, install a vacuum tee (as close to the nipple as possible). Alternate sources include the intake manifold, or the pipe between the turbo and throttle. Do not tie wrap this hose yet. You will need to rotate the hose about the nipples later.

4. Check all connections to ensure that they will stay on during testing. Now start the vehicle and drive moderately for a few minutes. Notice the boost level while you drive. If you have followed the instructions, you will now have a peak boost that is the same or LOWER than the stock boost setting. If this is true, then proceed to step 5. If boost is higher, check your connections before adjusting the controller. If boost remains higher that stock BREIFLY accelerate in a higher gear (to avoid wheel spin) and note the boost. If boost exceeds your target limit, let off the accelerator immediately and adjust the controller as follows: Loosen the lock nut and rotate the end counter clockwise (makes the controller longer) relative to the rest of the controller, two turns. Hold the opposite end of the controller while doing so. Re-tighten the lock nut and repeat step 4. If you have to lengthen the controller further, be careful that the two pieces do not separate or small pieces may fall out.

5. If you are at this step, then the boost is currently at a stock or lower threshold. Loosen the locking nut and turn the brass tip end clock wise, relative to the opposite end(makes the controller shorter), one turn. Re-tighten the lock nut. Accelerate again in a higher gear and note the new boost setting. Repeat until you have reached your target boost level. Note: it may take a few turns before you begin to see a change. Be patient, do it a turn at a time to avoid overboost. It only takes a half hour or so to complete the adjustment. After a turn or two, you will find that the line from the boost source to the controller becomes twisted. Turn it about the brass tip while holding the controller still. This will relieve the twisting.

6. When your adjustment is completed, tie wrap all connections, and tighten the lock nut.

7. Use caution when driving your newly adjusted vehicle. Control problems may appear during rapid acceleration that were not apparent at the lower, stock boost level.

The Boost Controller will support boost pressures in excess of 15 psi, but should you find that you cannot reach your desired boost level, the controller may be modified in the following ways. If these methods do not increase the boost limit, you may have reached the flow limits of your system.

1. Separate the two halves of The Boost Controller to allow removal of the locking nut. This will allow you to tighten the controller an extra turn. Note: It is imperative that you replace the internal components of the controller in the position that you found them. The spring goes on the elbow end, closest to the wastegate.

2. Place a washer at the spring end of the controller to increase the spring load.

3. Slightly stretch the spring to increase it’s pressure on the aperture.

It is not recommended that you replace the spring, because you may find that the threshold has been raised too high by the new spring.

1. The boost overshoots my target before settling to a lower level. This is called “spiking”. Ensure that you have provided the shortest path possible between the boost source and the controller, and between the controller and the wastegate.

2. The Controller worked great at first, but now my boost level is reduced each time I step on the throttle. Check the breather hole on the elbow end of the boost controller for obstruction. Use the illustrations to find it and make sure the hole is clear by inserting a very slender pin or needle.

3. I melted my pistons because I tried to run 20 more pounds of boost without the fuel to support it. Sorry, but you didn’t read the FAQ or the precautions. Any method of raising the boost (bleed, electronic controllers, adjustable wastegates) must be used with caution. The fuel to support the extra air must be present. Use an inexpensive air/fuel gage or EGT probe to monitor your progress. We offer Air/Fuel gauges for this purpose.

The Boost Controller FAQ

1Can I use the Boost Controller with my performance “chip”?

Yes, although the gains will probably be of a lower magnitude than those of unmodified cars. This is because many chip manufacturers have already raised the boost to the upper limit of what the factory fuel system can support. Additional gains can be found by using the Boost Controller if the chip manufacturer allows the boost signal to reach the wastegate before peak boost is achieved. This is usually the case, as the factory boost controller cannot respond fast enough to control “spiking”.

2Will you back up my factory warranty should I become overzealous and damage my engine?

Yeah, right! Unfortunately, carelessly increasing the boost without monitoring air/fuel ratios or exhaust temperature may damage your engine. For $35 it is not possible for us to accept responsibility for your actions should damage occur. However, there are many good exhaust temperature (Pegasus Racing has a good one) and air/fuel gages available (we have one), to monitor your progress. Check the values at WOT at stock boost levels and then slowly increase the boost. When you notice a drop in O2 sensor voltage, or a rapid increase in EGT, you have reached the limits of your computer’s capabilities. You will need to add more fuel. There are too many ways to do this to cover here. Get a good book on the subject. This same risk is present with an electronic controller or a chip. As those companies must also limit their responsibility, so must we. We will replace the controller with an identical one, should a defect in workmanship be discovered. One benefit of the Boost Controller is that it is easily removed should a warranty issue arise. However, we do not endorse this action as it would be dishonest.

3How high can I raise the boost?

Provided you have the fuel to accommodate the extra boost, the Boost Controller will allow you to raise the boost limit to over 15psi. Actual limits of the controller are dependent on variables, which include turbo size and wastegate actuator parameters. The included instructions describe methods to modify the controller, should you find that you are unable to reach your target boost with the stock controller configuration. Also, keep in mind that some turbo systems will cut fuel delivery above a preset factory limit, usually 14.7psi.

Note: Although most factory turbo systems will easily accept boost inceases of 20-30%, air/fuel mixtures should be monitored when raising boost above factory limits. This applies to any boost controller. It is a good idea to use one of the gauges mentioned above and raise the boost SLOWLY. Again, we can not be held responsible for damage caused by overzealous boost adjustment.

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