Boost controller help

[truckinwagen]

many stock TD manifolds have a pressure release valve on them(not really a BOV, as the function is very different)

if you plan on boosting past stock levels, you should disable/remove the release valve, as it will vent all the extra boost.

[rabbitman]

many stock TD manifolds have a pressure release valve on them(not really a BOV, as the function is very different)

if you plan on boosting past stock levels, you should disable/remove the release valve, as it will vent all the extra boost.

That's kinda what I said

[brandon5]

Really? i thought that was the wastegate? Can i disable it without taking it out?

[rabbitman]

Follow the 3/8" rubber hose on the compressor and it will lead you to the wastegate actuator.

[Syncroincity]

Did the boost controller come with a in-line pill for the boost line? You need this for it to work... It will be a small piece, in & out nipples, and a pinhole orifice in the side of it. That is your calibrated leak. What you need to do is put the pill & the adjustable valve in the boost sense line (small rubber hose, coming from the turbo outlet that goes to the wastegate actuator can. Picture #3 is looking right at it. This tells the wastegate when to open). The order of hose connections should be; Turbo Outlet - Pill in - Pill out - Boost Control valve in - Boost valve out - Wastegate in.

The valve regulates how much boost sense pressure gets dumped out by the pill. This "fools" the wastegate into staying closed longer, which builds more boost. The more restricted the valve (usually turned "in") more sense line pressure leaks out,  the higher the boost pressure builds, until the wastegate reads 8 psi and opens... the line pressure at the wastegate will never actually change; it stays at the factory setting. This won't eliminate that pressure relief (BOV) from stepping in and killing the boost, take that off and block off the hole, you'll never build boost while that is attached to the intake manifold, it'll just vent.

Just make sure the pill is between the turbo and the valve. Start with the valve wide open, then adjust in small increments until you see the boost build up to where you want.  An Exhaust Temp gauge is also highly recommended when tuning up these motors... Go slow with the adjustments, or you'll be walking home.


Have fun!

[brandon5]

So your pretty much saying i have to take it out or disable it? And the ports actually do line up i assembled everything my self. Thanks for the detailed reply Syncroincity ill be sure to re-read it tomorrow and see what i have to work with. Im way to tired to think about this right now.

Thanks everyone. If i get it workin ill be sure to post up a video with proof.

[Syncroincity]

Quote from Harry Mann in another post;

"The BOV is there to limit boost runaway if the wastegate fails, usually set to about 12 psi on VW TDs, and because peeps like to boost a bit more than that usually, they either block it or remove it and blank the inlet manifold hole off. Else it self defeats the overboost work. I find a wine bottle cork (of the synthetic kind) fits perfectly in the BOV."

[rabbitman]

I wonder if it's a aaz bottom with a 1.6 head?

[brandon5]

Its not its a 1.9 head. But i have both the intake side by side and they were the exact same.

[brandon5]

Shoooooot man maybe i was on drugs at the time. Ugh that makes me mad, kinda wanna punch a baby in the face. How difficult do you think it would be to swap the manifolds out? Will my car be slower with the manifold i have now?

[Syncroincity]

Swap won't be very difficult, but those Allen bolts in the middle are hard to reach with the exhaust manifold in place, probably best to take it off first. Find the right intake, and order the correct gasket. Your car will be limited to 12psi boost thru that intake with the BOV in the system, unless you block it off...

[brandon5]

Whats the easiest way to block it off? and i have the right manifold in my trunk. im just a retard kinda. Well thanks guys im gonna try and swap that out then crank boost. Does that mean the wastegate is on the t3?

[brandon5]

Do you mean the top part of the intake? i think it'll fit. Am i harming the engine running it with this intake? Cause i might wait till i can afford a temp gauge for the down pipe, so i can kill 2 birds with one stone. And is there a site i can order the bolts for the exaughst mani from?

[brandon5]

Yeah thats what i meant. I hope i dont strip any bolts taking this out... Whats the easiest way?

[brandon5]

Bump