Turbosmart BOOST TEE - User Manual

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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:
• 2 ramp rates of boost to give you the option of a fast rise in boost or a slightly tame rise for more sensitive setups.
• 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 effected 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
• 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
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 a 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 making adjustments.
Product Name: BOOST TEE
Product Description: Manual Boost Controller
Product Number: TS-0101-1001
Wastegate actuator port
Boost Tee
Pressure source port
(Located before the
throttle body)
Compressor
Hose clamps
Boost dial
Wastegate Arrow
Drawing 1

Summary

About This Product

New Features of Boost Tee

Highlights the new features of the Turbosmart Boost Tee, including ramp rates and mounting bracket.

Important Installation Notes

Crucial safety and installation guidelines for using silicone hose, securing plumbing, and mounting location.

Product Recommendations

Turbosmart's advice on air-fuel ratio checks, dyno tuning, boost gauges, and qualified technicians.

How to Install Your Boost Controller

Tools Required for Installation

Lists general mechanic tools needed for the installation process.

Internal Wastegate Setup Guide

Detailed instructions for installing the boost controller with internal wastegates, including component placement.

Boost Controller Installation Guide

External Wastegate Setup

Step-by-step guide for installing the boost controller with external wastegates, referencing diagram 2.

Parallel Twin Turbo Setup

Instructions for installing the boost controller on parallel twin turbo systems, referencing diagram 3.

Setting Boost Pressure

Boost Pressure Adjustment Procedure

Step-by-step guide for adjusting boost pressure using the boost dial, emphasizing clockwise rotation to increase.

Managing Boost Spiking

Explanation of boost spiking and how to modify the gate system for a less aggressive boost curve.

Gate System Removal Steps

Procedure for safely removing the ball and spring from the boost controller's input nipple.

Troubleshooting Boost Controller Issues

Common Problems and Solutions

Diagnosing and resolving issues like excessive or fluctuating boost pressure and incorrect hose connections.

Turbosmart Product Agreement

User Agreement and Disclaimer

Agreement outlining terms of use, warranty, and liability for Turbosmart products before installation.

Warranty Claim Process

Details the process for returning products for warranty claims, including required proof of purchase.

Overview

1. Function Description
2. Important Technical Specifications
3. Usage Features
4. Maintenance Features

The Turbosmart Boost Tee (TS-0101-1001) is a manual boost controller designed to enhance engine performance by allowing precise adjustment of boost pressure. This device offers several features aimed at improving control and ease of use for various engine setups.

Function Description:

The primary function of the Boost Tee is to regulate the boost pressure delivered by a turbocharger to the engine. By installing the controller in the wastegate pressure line, it manipulates the signal sent to the wastegate actuator, thereby controlling the exhaust gas flow past the turbine and, consequently, the boost level. This manual control allows users to fine-tune their engine's performance, achieving desired boost levels for optimal power delivery. The device is compatible with both internal and external wastegate setups, as well as parallel twin-turbo configurations.

Important Technical Specifications:

• Product Name: BOOST TEE
• Product Description: Manual Boost Controller
• Product Number: TS-0101-1001
• Ramp Rates: Features two ramp rates for boost, offering options for a fast rise in boost (more aggressive) or a slightly tamer rise (for more sensitive setups). This allows for customization based on driving style and engine characteristics.
• Boost Adjustment Range: Provides a wider boost adjustment range, particularly beneficial for wastegates with low spring base pressures. This expanded range offers greater flexibility in achieving specific boost targets.
• Mounting: Includes a new mounting bracket designed for easier installation, improving the overall user experience.
• Thread Type: The boost dial utilizes a left-handed thread. This is an important detail to note during adjustment to prevent overtightening and potential damage to the controller.
• Hose Compatibility: Requires the use of silicone hose of the correct size and pressure rating for the application. Other hose types may degrade due to heat, leading to cracks, splits, excessive boost pressure, and potential engine damage.
• Heat Resistance: The boost controller should be mounted at least 100mm away from any heat source to ensure its longevity and proper operation.

Usage Features:

• Installation Flexibility: The manual provides detailed instructions for three common setups:
  • Internal Wastegate Setup: Involves locating the pressure source port and wastegate actuator port, removing the factory boost control solenoid (if fitted), and installing the Boost Tee with the wastegate arrow pointing towards the actuator. Any additional actuator ports must be blocked.
  • External Wastegate Setup: Requires locating the bottom port on the external wastegate and the pressure source port. The Boost Tee is installed in the wastegate pressure line with the arrow pointing towards the bottom port.
  • Parallel Twin Turbo Setup: Involves locating wastegate actuator ports on both turbochargers and a pressure source port. The Boost Tee is installed in the wastegate pressure line, ensuring hoses joining the wastegate actuators are of equal lengths. A T-piece is used to connect to both actuators.
• Boost Adjustment: Adjustment is made by rotating the Boost Dial. Clockwise rotation increases boost, while anti-clockwise rotation decreases it. Before any adjustment, the dial should be fully closed (anti-clockwise). The process involves applying full load to the engine in a high gear (3rd or 4th), noting the boost pressure, adjusting the dial, and re-checking until the desired boost is achieved.
• Boost Spiking Mitigation: If undesirable boost spiking occurs, the internal "gate system" (ball and spring) can be removed to achieve a less aggressive boost curve. This modification is only recommended for a minimal number of applications and requires re-adjustment of boost settings afterward.
• Safety Recommendations: Turbosmart strongly recommends checking the Air Fuel ratio once boost pressure is set, setting boost pressure using a dynamometer (not on the street), permanently fitting an accurate boost gauge, and having the boost controller fitted and adjusted by an appropriately qualified technician.
• Hose Security: All plumbing must be secured with clamps to prevent leaks and ensure consistent performance.

Maintenance Features:

• Pre-Installation Checks: Before installation, it is crucial to allow the engine to cool down.
• Hose Integrity: Regularly check joining hoses for splits, cracks, or loose connections, and ensure they are the correct size for the application.
• Cleanliness: Inspect the boost controller for blockages or contamination with dirt or debris.
• Wastegate Functionality: Verify that the wastegate actuator is free from leakage (diaphragm or housing cracks/splits) and that the wastegate itself is operating correctly.
• Gate System Removal (Maintenance/Modification): If the gate system is removed to address boost spiking, perform the modification on a clean bench to prevent loss of the ball and spring. After removal, check that internal air passages are clear of debris.
• Post-Modification Adjustment: Always re-adjust boost settings after any modification, such as gate system removal.

The Turbosmart Boost Tee is a robust and versatile manual boost controller designed for enthusiasts and professionals seeking precise control over their turbocharged engine's performance. Its thoughtful design, including adjustable ramp rates, wide adjustment range, and easy mounting, makes it a valuable upgrade for various applications. Adherence to installation and usage guidelines, particularly regarding hose selection, heat management, and professional adjustment, is crucial for optimal performance and engine safety.

Turbosmart BOOST TEE Specifications