Boost Controller - Need help installing

[grinder]

Right chaps

i have a boost controller in the garage that needs fitting

although i have NO idea

its a very simple unit - a dial with 3 wires coming of it that go into a little box

colours are RED/BLACK/YELLOW

now i assume red/black are power - but this yellow wire - where the hell does that go ??

all pip said about it was :

Hi grinder
the yellow wire goes to the blue/white wire that goes to the duty solenoid
Cheers
Pip

does this make any sense to you guys ??

Ta

stu

( will get some pics up once i get the off the camera )

[grinder]

pic 1 :

[grinder]

pic 2 :

[grinder]

pic 3 :

[Den]

The duty solenoid is the small one by itself bolted onto the right hand intercooler mount, this controlls the boost pressure. It has a blue connector and two vaccum/pressure lines comming out of it. I would presume it hooks into one of the wires on this blue connector.

[grinder]

top man !!

now then - would you take the wire out - and then put the yellow wire into it or what ??

i have no idea how this thing works - and pips answer didnt really inspire me

[Den]

I\'ve had a look in the fsm and as far as can tell one of the wires in that blue connector is a +12v feed from the main relay and the other wire goes to the ecu. I think you would have to cut the wire that goes to the ecu and attatch that yellow wire from your boost controller to the cut wire from the blue connector.

Basically the ecu grounds this wire \'x\' amount of times per second to cap the boost at a stock level. Once you put the yellow wire from the new controller in its place you are taking over control of the boost pressure.

I\'m going to start stripping my car this afternoon so i\'ll check the duty solenoid with a multimeter and find out if i\'m right or not. I should be able to tell you for sure tonight.

[grinder]

thanks Den ,

like pip says - something to do with a blue/white wire - so if there is one in there - looks like we are on the right track

big thanks

stu

[Den]

Looks like pip is spot on I\'ve had a look this afternoon and there is a blue/white wire and a black/white wire. The black/white wire is showing a constant +12v with the ignition on so the blue/white wire must go to the ecu. If you cut the blue/white wire and attatch the new yellow wire to the connector/solenoid side of this cut wire you should be in business.

I think it would be best to do this at the ecu then you won\'t have the hassle of feeding wires through the firewall or cutting the harness in the engine bay. In the fsm it says its pin 3R (at least i think its an R !) These pics should help you out.



26 pin connector at ecu :

[grinder]

thanks for that Den ,

i know that you said go for the ecu end - but not 100% sure about this

im panicing about putting my A/F gauge on the ecu loom

im not bothered about putting wires thru the firewall - thats no problem to be honest - as the boost pipe runs thru there

so if i was to do this at the ecu end - i take it the all i need to do - is cut ( ekkkk sounds bad ) the wire just before it enters the ecu - and connect the yellow wire to the wire from the ecu ??

or..

see next post with pics

[grinder]

so if i go thru the fire wall - i can do it like this :

( i take it i have got the yellow wire on the correct end of the cut ?? )

and if so - just i just wrap tape around the other end ??

[Den]

Your nearly there mate but the wire needs to go on the other side of the cut. If you were to do it at the ecu you would tape up the cut wire from the ecu connector and attatch the yellow wire to the harness side of the cut wire.

At ecu :



If you do it in the engine bay you need tape up the harness side of the cut wire and attatch the yellow wire to the solenoid side of the cut wire.

In engine bay :



Basically when you are done the ecu will have nothing to do with controlling the duty solenoid, you will be controlling it directly with the new boost controller.

Good luck !

[grinder]

AHHHHHHHHHHHHHHHHHHHHHHH that makes some sense

right then - just out of interest - what can go wrong if i do this wrong ?

am i likely to kill or destroy anything ??

and your diagrams make SOOOOOOOOOO much sense - its superb - we would have been here months without them !

big thanks Den - i just need to get everything else on the car sorted out now

ta

stu

[Den]

No problem stu, anytime mate. Your only worry should be overboosting, which is down to how much you turn the boost up.

If you have wired anything wrong and the solenoid gets no signal the wastegate will open at the pressure of the actuator spring which is approx 5-6 psi. If this happens that is all the boost you will see (unless your running an aftermarket filter or straight pipes etc then you will get some creep if you have an unported wastegate).

  As your increasing the boost i\'m guessing your running an fcd ? While your setting up the controller i would disconnect this, its much safer to hit boost cut rather than overboosting and detonating. I must have hit the cut at least 10 times while setting up my mbc with no ill effects.

 I would wire the controller up, disconnect the fcd and then slowly turn the boost up a little at a time. This way you can be sure of not overboosting. The boost cut is around 8.5 psi, once you hit it reinstall the fcd and turn the boost up at your own risk !:) (make sure you are actually just at or below the boost cut pressure before you reinstall the fcd)

If you havn\'t at least got a larger fuel pump i would not go any higher than 9 at an absolute maximum. Even then you might pushing your luck.

Have fun !

[TRex]

Den, top advise to the man.. oh, and killer illustrations! :god