Boost controller.....

vwbuge · #1 08-09-2003, 04:41 AM

OK, I think I have the time to install this boost controller from Dawesdevices. It has been sitting around for too long. I installed a boost guage some time ago, so I think I'm ready. Any pictures of your installs would be great! Any suggestions or comments would be appreciated. (hose routing, ALDA adjustment to correct fuel delivery..etc) Current boost setting seems to be around 7psi. It seems a bit low compared to what I've heard from others here. Maybe because I have a CA car...I don't know. Pics would be great!!!!!!

speedy300Dturbo · #2 08-09-2003, 06:13 AM

Install it inline with the wastegate hose. You might need some plastic vacuum adapters to get it to fit properly. Use hose clamps to secure everything tightly.

vwbuge · #3 08-09-2003, 10:58 AM

Speedy,
After posting this last night I did a search and found your picture. What about the ALDA? How many turns to adjust to correct fuel delivery? What about plumbing it into the boost source? the directions say something about not using the wastegate hose?

speedy300Dturbo · #4 08-09-2003, 05:43 PM

Well the boost controller mounts inline with the wastegate hose. No problems there. Before you adjust the boost, do some 0-60 runs and some 60-80mph highway testing. Next, get your boost to spec (around 13 psi). Do the same tests and compare numbers.

Next, remove the protective cap from the ALDA, give the screw 1/4 turn counterclockwise and test again. Repeat until you have SOME visible smoke at full boost, but not too much. I don't know how many turns counterclockwise will do it, as every car is a bit different.

#5 08-09-2003, 06:40 PM

This is what I did to my Calif. Car.
Went to auto grave yard and bought an exhaust manifold, and intake maniflod, a air cleaner and mount and four oil lines. From a 84 non trap car and removed that beast. The plastic horse shoe hose would't fit so now I will get a small K & N filter and run it on turbo and get a 24o oil seperator.
Now no Trap to mess up my Turbo or engine.
Good luck.
Charlie

vwbuge · #6 08-09-2003, 08:05 PM

I plumbed everything inline. i used the pieces of the old wastegate hose for the nipples on each end then plumbed the device in the middle with adapters and supplied hose. i had to crank it about 3-4 turns and I adjusted the ALDA about 1/2 turn. The boost now runs up to 8 when acclerating hard (up from 7) then "peaks" or jumps between shifts to 10. The car puffs VERY little smoke. I guess I should turn up the device a little more and watch the ALDA. What is it with the jumping of the guage to 10..?????

speedy300Dturbo · #7 08-09-2003, 08:59 PM

You have a boost "spike" which is common when running relatively low boost pressure. Crank it up to 12 or 13 and it should be gone...

vwbuge · #8 08-09-2003, 10:41 PM

Thanks Speedy. I'll try and fool with it first thing in the morning.
One more question. Do you think it is that much of an advantage with more airflow. Like a K and N or something. I have my air cleaner lid flipped upside down so there is about a 3/4 inch gap at the top for free air to flow. So far I hate the noise.

coachgeo · #9 08-09-2003, 10:50 PM

Quote:

Originally posted by speedy300Dturbo
You have a boost "spike" which is common when running relatively low boost pressure. Crank it up to 12 or 13 and it should be gone...

isnt 13 just at the max margine of boost. Do you feel your going to loose some longevity of the engine running at the Max?

What do others think about 13psi and longevity.... ?

and, to clarify, this is a 617 turbo we are speaking about right?

vwbuge · #10 08-10-2003, 12:00 AM

Yes it is a 3.0 litre 617.
i don't think I'll run 13 psi but opt for around 10-11. I think the turbocharger and engine are rated for 14.7 max

speedy300Dturbo · #11 08-10-2003, 12:35 AM

OOPS... major mistake I made here. I keep thinking of the 603 motor! (which is supposed to produce around 13 psi). Spec on the 617 is 0.7-0.8 bar, which is 10.15 to 11.6 psi! Sorry for my mistake!

coachgeo · #12 08-10-2003, 12:39 AM

Quote:

Originally posted by speedy300Dturbo
OOPS... major mistake I made here. I keep thinking of the 603 motor! (which is supposed to produce around 13 psi). Spec on the 617 is 0.7-0.8 bar, which is 10.15 to 11.6 psi! Sorry for my mistake!

thanks for clarifying very important info. to be correct.

to jar my memory and for archive purposes; the over boost device on the 617 kills the alda changes at what level of boost?

speedy300Dturbo · #13 08-10-2003, 12:52 AM

According to the manual, the overboost sensor will releive excess boost at 1.1 bar, (~16psi) give or take 0.15 bar.

coachgeo · #14 08-10-2003, 01:04 AM

Tanks much Speedy300D!!!

RunningTooHot · #15 08-12-2003, 01:49 AM

The device you are installing is simply a modified version of a pressure relief valve that is available at Graingers. It does not allow your wastegate to see any pressure up until the relief valve opens; thus it limits ‘wastegate creep’ and allows the boost to increase a bit more rapidly.

If you use this relief valve in conjunction with a pressure regulator, when plumbed properly, it can make a real difference by not only limiting wastegate creep, but also allowing you to control the boost pressure without having to mess with the wastegate spring.

Now for the downside… I just got through changing all the fluids & checking everything over before I embark on my long haul kamikaze run. I checked my boost pressure, and found that I was peaking at almost 18 PSI, and spiking to 20 when it upshifts!!! (I thought she was running a little too good for a diesel.) I am changing the pressure regulator tomorrow. It either failed, or became plugged. Lesson learned: If you have anything other than a simple open line running between your manifold & the wastegate, keep your eyes on it. If the line becomes plugged, you’re going to see some serious pressure!

Glenn

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