This document is to be used as a guide for the installation of a TurboXS D ual Stage Boost Controller to a turbo charged vehicle.  It is recommended that the installation of the product be carried out by a qualified mechanic. 

The TurboXS D ual Stage Boost Controller is to be installed in series with the pressure line running from the positive pressure side of the turbo to the waste gate actuator system.   

Note, vehicles fitted with a factory electronic boost control system need to have the electronic boost control system disabled prior to installation of the TurboXS D ual Stage Boost Controller.  There should not be more than one (1) boost control system controlling the boost pressure of a turbo charged vehicle. 

• D ual Stage Boost Controller & mounting bracket.
• Electrical Plug and Wiring Loom. 
• 6mm pressure hose.  (not shown)
• 2 X 12mm hose clamps.
• 2mm Hex Key. 
• Control Switch. 
• 3 X Crimp Receptors (connected to Control Switch).
• 2 X Crimp Eyelets.
• 4 x M4 Screw, Nut & Washer (not shown).
   

1/   Locate the waste gate actuator.  Note, it is usually mounted on the turbo.   

2/   Identify the flexible pressure hose running from the positive pressure side of the turbo to the waste gate actuator.   

3/   Mount the D ual Stage Boost Controller to the vehicle chassis in a location such that it can be reached by the flexible pressure hose running from the positive side of the turbo when disconnected from the waste gate actuator.   

Note : When mounting, ensure these is enough room for connection of the hoses and the electrical plug.  

4/ Remove the pressure hose fitted to the waste gate actuator and insert it over the silver colored nipple of the boost controller.  Note the inlet direction arrow on the boost controller.  Use the pre-existing hose clamp to secure the hose onto the boost controller.   

5/  Take the extension hose and fit it onto the blue colored nipple.  Fit the other end to the waste gate actuator.  Use the supplied hose clamp to secure the hose onto the nipples.

Caution : Failure to properly secure the Boost Controller nipples to the pressure hose can result in the disconnection of the waste gate actuator supply pressure.  If this occurs, the turbo boost pressure can rise to a dangerous level and could result in severe engine damage. 

6/     Connect the Electrical Plug to the D ual Stage Boost Controller.  Ensure the rubber gasket is located between the Plug and the Boost Controller and secure with the screw. 

7/     The Green Earth wire needs to be connected to an earthed part of the vehicle chassis.   Unwrap the Green Earth wire and route it to the Vehicle Earth location.  Cut the wire to length leaving some excess.  Save the remaining wire.  Remove 5mm of insulation from the wire and crimp one of the Crimp Eyelet Connector to it.  Screw the Eyelet Connector to the Vehicle Earth location. 

8/     The Control Switch is to be installed inside the vehicle cabin.  Identify a suitable mounting location and drill a ½" (12.7mm) hole.  Ensure there is enough space behind the hole to fit the body of the switch and the wiring connections.  Fit the switch. 

9/    Unwrap the violet wire bundle from the Electrical Plug and route the wire to the switch.  Cut the wire to length leaving some excess.  Save the remaining wire.  Remove 5mm of insulation from the wire and crimp one of the Crimp Receptacle Connectors to it.  Connect this Receptacle Connector to the central spade terminal of the Control Switch, labeled "ON A CC."  

10/  Take the excess violet wire, strip 5mm of insulation from one end and crimp another Crimp Receptacle Connector to it.  Connect the receptor to the spade terminal on the Control Switch labeled "SUPPLY VOLTS".  Route and connect this wire to a suitable +12 volt fused voltage source.  Ensure this source is connected through the vehicle's ignition system.  Note the maximum current drawn by the system is 0.5 amps.   

11/   Take the remaining length of Green Earth wire and strip 5mm of insulation and crimp the Crimp Receptor Connector onto it.  Connect this Receptacle to the spade terminal labeled "EARTH GROUND ".  Route the other end to a suitable Vehicle Earth location, cut to length, strip 5mm of insulation and crimp the remaining Crimp Eyelet Connector.  Screw this Eyelet Connector to the Vehicle Earth location.   

12/   Review and ensure wiring is as per Assembly Diagram, secure all wires and check connections. 

Note : When wiring is complete and correct, the Control Switch will illuminate when the toggle is in the Stage Two (2) Boost Control position.  When the Control Switch toggle is in the Stage One (1) Boost Control position it will not illuminate.   

A d j usting the Boost Controller  

The D ual Stage Boost Controller has two (2) boost pressures which are adjusted via the adjusting screws located internally on the top of the TurboXS D ual Stage Boost Controller.  Each of these boost pressures need to be adjusted individually.  When wiring is complete and correct, the switch will illuminate to indicate that the second or higher boost stage is activated.  When not illuminated the unit is on the first or lower boost stage.   

Note : The vehicle will require a calibrated boost gauge to be fitted in order that the turbo boost pressure can be monitored while adjustment is carried out.   

1/     Ensure that the Control Switch is thrown such that the second boost stage is de-activated.  ie :- the switch illumination of OFF.  

2/     With both of the ad j usting screws initially fully closed (ie : unable to be wound any further in the clockwise direction), wind the first stage ad j usting screw (lower assembly) three (3) turns in the counter-clockwise direction.  This will reduce the vehicle's turbo lag and increase the first stage boost pressure by approximately one (1) to two (2) psi.   

3/     Once a one (1) psi increase in boost has been registered, each single complete turn of the adjusting screw in the counter-clockwise direction will result in a one (1) psi increase of the boost pressure.  The boost pressure can be decreased by winding the adjusting screw in the clockwise direction.  Set the first stage boost pressure to the desired level.   

4/     Throw the Control Switch to activate to second boost stage.  ie :- the switch illumination is ON.   

5/     Wind the second stage adjusting screw (upper assembly) two (2) turns in the counter-clockwise direction.  This will increase the second stage boost pressure by approximately one (1) to two (2) psi. 

6/     The boost pressure can be decreased by winding the adjusting screw in the clockwise direction.  Set the second stage boost pressure to the desired level.     

Caution : No internal engine components can be warranted at greater than original equipment specifications.  This product is for racing use only.  Not applicable nor intended for use on emission controlled vehicles. 

End of Installation Guide.