Prodrive Boost Controller Installation

[pixel67]

Guys, I am in search of some guidance on this. You would think something with only 3 connections would be easy to figure out and well documented somewhere but that doesn't seem to be the case. I had this installed by another shop and ran into an issue where even though the tune has 4 switchable maps with different boost settings, I am only seeing wastegate pressures regardless of map selection. I have verified through ecutek logs that it is indeed loading the map selection and have verified the harness connectivity. This is the only illustration i could find on installation and it isn't specific to this vehicle:




Mine is not set up this way at all. They mounted it up front and the harness is facing forward. Port 3 is connected to the turbo inlet, Port 2 is connected to the base of the wastegate (all other holes are plugged), and Port 1 is actually connected back to the vacuum block with a T connector that is shared with AEM Failsafe. Here is a video showing the above connections.

[ame="http://www.youtube.com/watch?v=AOrQlo1pZ5o"]Turbo frs boost controller - YouTube[/ame]

Any and all feedback is welcome.

[rb6freak]

Have you checked the two wire cable to make sure the connection is functional? Chances are that the wiring was extended.

Port 1 can be left to vent to atmosphere, just point it down so no fluid gets trapped.

[pixel67]

Originally Posted by rb6freak

Have you checked the two wire cable to make sure the connection is functional? Chances are that the wiring was extended.

Port 1 can be left to vent to atmosphere, just point it down so no fluid gets trapped.

At one time the harness was a problem and it threw CEL. Fixed the harness and current is passing through it now. I am more concerned about port connections. Port 1 is currently running back to the vacuum block. Port 3 is currently connected to turbo inlet.

[rb6freak]

Originally Posted by pixel67

At one time the harness was a problem and it threw CEL. Fixed the harness and current is passing through it now. I am more concerned about port connections. Port 1 is currently running back to the vacuum block. Port 3 is currently connected to turbo inlet.

That is correct. Port 3 for the compressor charge pipe (not intake), and port 2 for the WG bottom nipple, the side closest to the pipe.



I.e. the left nipple on this WG.

[King Tut]

Originally Posted by pixel67

At one time the harness was a problem and it threw CEL. Fixed the harness and current is passing through it now. I am more concerned about port connections. Port 1 is currently running back to the vacuum block. Port 3 is currently connected to turbo inlet.

Can't you log that value and see what it is doing as boost increases with EcuTek? I don't have any personal experience with an EBCS tied into the ECU, but I know @Sportsguy83 and @jamesm do.

[pixel67]

Sadly, I believe it is a turbo owner education issue (big surprise, right?). Port 3 is connected to the turbo, port 2 is connected to the wastegate, however port 1 is plumbed back to the vacuum block. The Vacuum block connection threw me off as well as the mix of terminology (turbo inlet, compressor housing).

[Sportsguy83]

Originally Posted by pixel67

Sadly, I believe it is a turbo owner education issue (big surprise, right?). Port 3 is connected to the turbo, port 2 is connected to the wastegate, however port 1 is plumbed back to the vacuum block. The Vacuum block connection threw me off as well as the mix of terminology (turbo inlet, compressor housing).

They seemed to have connected it correctly. Only thing I would have done it leave 1 VTA.

It would seem a custom map issue? are the custom maps enabled? If its a locked tune, only your tuner can verify all custom maps are active in maps 1,2,3,4 and not only in debug mode, logabble but not active.

[rb6freak]

Originally Posted by pixel67

Sadly, I believe it is a turbo owner education issue (big surprise, right?). Port 3 is connected to the turbo, port 2 is connected to the wastegate, however port 1 is plumbed back to the vacuum block. The Vacuum block connection threw me off as well as the mix of terminology (turbo inlet, compressor housing).

The fact that you have WG spring pressure means your hose is plumbed corectly and doing its job. If the Pro-drive is left unplugged then it just let's air through, hence WG spring pressure. It will just act as a boost reference line.

Its either the tune or a bad cable / connector. When you had the CEL initially it was most likely because you unplugged the factory connector and the tune didn't compensate for that.

Do your part and triple check that cable to make sure you have a signal on both lines. If you do, you're good to go at pointing the finger at the tuner (assuming your pro-drive is working).

[pixel67]

Originally Posted by Sportsguy83

They seemed to have connected it correctly. Only thing I would have done it leave 1 VTA.

It would seem a custom map issue? are the custom maps enabled? If its a locked tune, only your tuner can verify all custom maps are active in maps 1,2,3,4 and not only in debug mode, logabble but not active.

Thanks for the feedback guys. I think i believe the issue is two-fold.

1. I am a dumbass and should have done more homework on boost control fundamentals before messing with it on my car.
2. When i fixed the harness connection, I also replaced the vent on top of the wastegate with a plug so it is sealed.

So even though i fixed it in #1, I broke it again in #2.

Leave it to me to learn everything the hard way...

[Sportsguy83]

Originally Posted by pixel67

Thanks for the feedback guys. I think i believe the issue is two-fold.

1. I am a dumbass and should have done more homework on boost control fundamentals before messing with it on my car.
2. When i fixed the harness connection, I also replaced the vent on top of the wastegate with a plug so it is sealed.

So even though i fixed it in #1, I broke it again in #2.

Leave to me to learn everything the hard way...

It's all good. You are learning and not blowing up the car so at least that is good
#2 definitely, VTA.

[rb6freak]

One more thing. Slip that WG hose in thermal sleeve. With the amount of exhaust heat near that hose it will eventually crack. Fire sleeve, thermal wrap, whatever its called. Just buy a few feet of 1/2 or 5/8 ID hose and cut to length, slip over hose.

[pixel67]

Thought you guys might be interested in the result. This time i was going to make changes one at a time so I can see the effect. I reinstalled the vent on the wastegate and took it out for a short spin but that didn't seem to help drivability at all. It was still running rough as hell so I removed the connection between port 1 and the vacuum block, put an elbow on the solenoid connection and capped off the T connection, and bam! Back to running as smooth as it was before. We still have some work to do on injector scaling so there is some low end bog as it runs quite rich. But at least it doesn't feel like it is going to cut out. Took it out for a quick spin and boost control appears to be functional but it only raising it to 8psi so far on map 4. We may have to make some compensations for backpressure as my wastegate is now recirculated and two high flow cats are in place.

So, any ideas why plumbing port 1 back into the vacuum block would cause such erratic behavior?

[Bigmaxy]

The only reason I can think of it being a problem could be that the air coming from Port 1 is being fed into the engine after the throttle body. I've usually seen it described as being plumbed back into the inlet after the maf but before the throttle body. I'm no expert though. Just trying to understand it myself.

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