Turbo
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Category: Engine Control
Manual Boost Modifications
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Boost Control Solenoid (BCS) Theory of Operation:
The wastegate is mechanically set to effectively dump exhaust gases around the turbos exhaust impeller. This action effectively stabilizes the boost at an intake manifold pressure of 10 PSI.
The BCS is an alternative pathway for air pressure, AWAY from the wastegate. This means it is a "wastegate signal bypass" system. The air pressure port, on the side of the turbos compressor outlet is configured as a "T". One port of the "T", containing the boost pressure signal from the turbos compressor outlet is fed to the wastegate actuator diaphragm. The other port on the "T" goes to the BCS.
When the BCS is actuated, electrically, by pin 32 of the EEC, it opens, allowing the boost pressure signal to be diverted through the other port on the BCS, to the turbos compressor housing inlet. The turbo inlet is a low pressure area, not under boost pressure. This effectively "bleeds" off the boost signal, that the wastegate actuator has acting upon its diaphragm.
So, with the BCS energized, the wastegate only gets 10 PSI on the diaphragm, even though there is 15 PSI of pressure in the intake manifold.
Taking control of the boost
The manual method of raising the boost is to replace the BCS, with a device with a bigger opening than the stock BCS. This bypasses more air away from the wastegate, allowing the engine to develop more boost.
You can use an adjustable regulator valve, or items with a fixed internal diameter. Adjustment is made until the desired amount of boost is reached.
Actual methods to raise the boost, pick one.
You can usually find a spot in the wiring at the kick panel, where you can just move a pin to have the connection made by the stock wiring. This is preferable to cutting and splicing thge stock wiring. Spend some time figuring it out. It's worth it, and also, very stealthy. The only real giveaway is that you must move the EGRV solenoid closer to the turbo. I keep both pieces on the bracket and move it to about where the stock BCS was. Keeping the hoses short, eliminates boost overshoot in the lower gears, and when you first get on it.
You can pick the "goo" out of the top of the overboost switch and then adjust it. They're usually set to 17.5 psi.
With this mod the wastegate never opens until the boost setting is reached, then it slams it open. Drivability is GREATLY improved with this mod, since you get more boost lower in the RPM range.