Product Name:  
Dual Stage  
Product Description:  
Product Number:  
Document Version:  
Dual stage boost controller  
TS-0105-100X  
V1.00 Rev B  
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ABOUT THIS PRODUCT  
Thank you for purchasing your new DSBC. 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.  
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 dials have a left handed thread, be sure not to over tighten as this will damage the boost controller  
Note for sequential turbo systems: Sequential turbo setups can be complex and vary from car to car. Please contact your local  
Turbosmart dealer for more details  
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  
ELECTRICAL CONNECTION  
Refer to wiring diagram below  
Extend and connect one wire through the switch to a fused 12 volt ignition supply Important, failure to connect to an ignition supply  
may cause the battery to go flat and may result in damage to the product  
Note: Polarity is not important  
Connect to ignition  
(+12VDC)  
Toggle switch  
(provided)  
Fuse (1A)  
Extend with provided black  
wire if needed  
Crimp on ring terminal  
connect to ground (0VDC)  
Wire out of the boost controller can be extended to suit with supplied wiring.  
Connect one wire to ground. You may use the ring terminal provided.  
Connect the other wire to an ignition switched positive 12VDC source.  
Install a toggle switch inline with the ignition source wire between the boost controller and the voltage source. Mount toggle  
switch where desired.  
Install a 1A (amp) fuse inline between the boost controller and the voltage source. The fuse to be as close to the voltage  
source as possible.  
Toggling the switch on and off should activate and deactivate the second stage in your boost controller respectively.  
Having the switch in the “OFF” position will deactivate the higher boost setting.  
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) 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 the DSBC Tee piece 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, and then attach the boost controller onto the bracket with the supplied screws  
Make sure the boost dials are turned completely anti-clockwise before making adjustments.  
Boost dials  
Drawing 1  
Boostcontroller
rt  
Wastegate Arrow  
2
) EXTERNAL WASTEGATE SETUP  
Allow the engine to cool down before installing your boost controller  
Locate the bottom port on the external wastegate and the pressure source port (refer Drawing 2)  
Install the DSBC Tee piece in the wastegate pressure line with the wastegate arrow pointing towards the bottom port on the  
wastegate  
Secure all silicone hose ends with hose clamps  
Mount your boost controller bracket onto the vehicle, and then attach the boost controller onto the bracket with the supplied screws  
Make sure the boost dials is turned completely anti-clockwise before making adjustments.  
Drawing 2  
Boost dials  
Vent  
External wastegate  
Boost controller  
DSBC Tee Piece  
Wastegate  
Arrow  
Bottom port  
Turbocharger  
Pressure source port  
Located before the throttle  
body)  
(
2
3
) PARALLEL TWIN TURBO SETUP  
Allow the engine to cool down before installing your boost controller  
Locate the wastegate actuator ports on both turbochargers and a pressure source port (refer Drawing 3)  
Remove the factory boost control solenoid if fitted from the boost pressure supply line  
Install the DSBC Tee piece in the wastegate pressure line with the wastegate arrow pointing towards the wastegate actuators. Be  
sure to keep the hoses joining the wastegate actuators at equal lengths  
Secure all silicone hose ends with hose clamps  
Mount your boost controller bracket onto the vehicle, and then attach the boost controller onto the bracket with the supplied screws  
Make sure the boost dials is turned completely anti-clockwise before making adjustments.  
Drawing 3  
Arrow  
Pressure source  
(Located before  
the throttle body)  
Boost dial  
Boost controller  
Equal lengths  
DSBC Tee Piece  
T Piece  
Wastegate actuators ports  
Turbochargers  
SETTING BOOST PRESSURE  
IMPORTANT NOTES ON BOOST PRESSURE ADJUSTMENT  
Adjustment to your boost controller is made by rotating the Boost Dials  
Rotate in a clockwise direction to increase boost and the reverse direction to decrease boost  
Before making any adjustment, the Boost Dials will need to be fully closed (anti-clockwise)  
rd  
th  
Step 1: Apply full load to the engine in a high gear (at least 3 or 4 gear) at full throttle and note the boost pressure  
Step 2: To increase the low boost setting, rotate the Low Boost Dial clockwise (maximum of 1 complete revolution at a time)  
Step 3: Apply full load to the engine and note the boost pressure  
Step 4: Compare the actual boost pressure with the desired boost pressure. If the actual pressure is below the desired pressure,  
return to step 2. If the actual is above the desired boost then decrease by rotating the Boost Dial anti-clockwise and return  
to step 3.  
Step 5: Once the low boost setting is complete, follow step 2 to step 4 on the High boost dial.  
BOOST SPIKING  
If boost spiking occurs and is undesirable for your application, the gate system can be removed to give you a less aggressive boost  
curve. This modification is only required in a minimal number of applications.  
Boost spike curve  
Ideal boost curve  
3
IMPORTANT NOTES ON GATE SYSTEM REMOVAL  
The gate system can be removed by the following steps.  
Perform this modification on a clean bench so that the ball and spring are not lost  
Allow the engine to cool down before removing the boost controller from your vehicle  
Identify the input nipple with the restrictor at the end on the DSBC tee piece. Loosen the input nipple and remove the ball and  
spring.  
Check that the internal air passages are clear and free from debris  
Re-install the boost controller by following the instructions for your setup  
You will need to re-adjust your boost settings after the removal of the gate.  
Drawing 4  
Ball  
Spring  
Input Nipple with  
small hole  
DSBC Tee piece  
Wastegate Arrow  
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TROUBLE SHOOTING  
The following points should be checked if you find that your engine is developing excessive boost, the boost pressure is fluctuating or  
the desired boost level cannot be achieved. Please note, the following checks will cure 99% of problems experienced when fitting a  
Turbosmart boost controller.  
Check that the boost controller is installed so that the arrow points toward the wastegate actuator  
Check the joining hoses for splits, cracks or loose connection and are the correct size for the application  
Check to see if the boost controller is blocked or contaminated with dirt or debris  
Ensure that there is nothing but the boost controller in the hose between the pressure source and the wastegate actuator, ie tee  
pieces for boost gauge or to factory boost solenoid.  
Pressure test the wastegate actuator for leakage, the diaphragm or housing may be cracked or split  
Check that the wastegate is operating correctly  
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DO NOT USE ANY TURBOSMART PRODUCT UNTIL YOU HAVE CAREFULLY READ  
AND UNDERSTOOD THE FOLLOWING AGREEMENT.  
Please call if you have any questions or do not understand this agreement. Refer to our brochure, website or catalogue for  
terms and conditions and further information regarding your product. Turbosmart appreciates your business and pride  
ourselves on our customer service. We are always happy to offer you advice and will provide you with help in any way we can.  
The purpose of this agreement is to avoid any problems or hard feelings.  
We sometimes make mistakes, as do our dealers, distributors and suppliers. Even customers can sometimes order the wrong  
parts. Do not use, modify, install, trial assemble, nick, drop, scratch or adjust any part until you first check for any damage.  
Damage must be reported immediately. NO EXCEPTIONS. If there are any components missing please contact your  
authorised reseller immediately upon receipt of your shipment. Missing components must be reported within five (5) business  
days of receipt. Parts returned for any reason MUST BE IN RESALABLE CONDITION. It is YOUR responsibility, “THE  
CUSTOMER” to carefully package any returns to avoid shipping damage. Insurance is highly recommended. Credit cannot be  
issued for damaged goods.  
Turbosmart Pty Ltd warranties the quality of the products it designs and manufactures to be free of defects in material and  
workmanship. This limited warranty is extended only to the original purchaser and may not be transferred or assigned. This  
limited warranty applies to any product, which after careful inspection by Turbosmart Pty Ltd, after receipt of the product from  
our authorised reseller, is found to have a defect in either material or workmanship. Any modifications to the product will void  
any and all warranties and will not be exchanged. Before installation, check new car warranty. Turbosmart Pty Ltd is not  
responsible for voiding any original manufactures warranty.  
All warranty claims must be returned to the authorised reseller, you must return the product and sales receipt, at your own  
expense, accompanied by a letter stating the reason for the claim. Proof of purchase must be provided with any warranty claim  
and will be verified with the authorised reseller from which the product was purchased.  
If all the above procedures are followed, and the product is found to be defective in either workmanship or material, Turbosmart  
Pty Ltd shall either repair or replace the product, at its sole discretion, and sole cost. This limited warranty does not cover or  
apply to any personal injury, labour charges or any other incidental costs or damages caused by the defective product. The  
individual purchaser acknowledges and agrees that the disclaimer of any liability for personal injury is a material term for this  
agreement and the individual purchaser agrees to indemnify Turbosmart Pty Ltd and to hold Turbosmart Pty Ltd harmless for  
any claim related to the item of the equipment purchased. Under no circumstances will Turbosmart Pty Ltd be liable for any  
damages or expenses by reason of use or sale of any such equipment.  
THIS LIMITED WARRANTY IS THE ONLY EXPRESS WARRANTY, WHICH APPLIES TO TURBOSMART PTY LTD  
PRODUCT AS EXPRESSLY GIVEN IN LIEU OF ANY OTHER WARRANTY EXPRESSED OR IMPLIED, INCLUDING THAT  
OF MERCHANTABILITY. ANY IMPLIED WARRANTY INCLUDING THAT OF MERCHANTABILITY AND/OR FITNESS FOR A  
PARTICCULAR PURPOSE IS HEREBY LIMITED BY THE SAME TERMS AND TIME LIMITATIONS SET FORTH IN THIS  
LIMITED EXPRESS WARRANTY AND OTHERWISE EXCLUDED.  
EXCEPT FOR THOSE OBLIGATIONS ASSUMED HEREIN, TURBOSMART PTY LTD ASSUMES NO OTHER OBLIGATIONS  
IN CONNECTION WITH THE SALE OF ITS PRODUCTS.  
IN THE EVENT THAT THE INDIVIUDAL PURCHASER DOES NOT AGREE WITH THIS AGREEMENT THE BUYER MAY  
PROMPTLY RETURN THIS PRODUCT, IN A NEW AND UN-USED CONDITION, WITH A DATED PROOF OF PURCHASE,  
TO THE PLACE OF PURCHASE WITHIN SIXTY (60) DAYS FROM THE DATE OF PURCHASE FOR A FULL REFUND.  
THE INSTALLATION OF THIS PRODUCT INDICATES THAT THE INDIVIDUAL PURCHASER HAS READ AND  
UNDERSTOOD THIS AGREEMENT AND ACCEPTS ITS TERMS AND CONDITIONS.  
Happy motoring!  
The Turbosmart Team  
Turbosmart Pty Limited P.O.Box 264 Croydon, NSW, 2132 Australia ABN: 69 081 069 794  
Tel: +(612) 9798 2866 Fax: +(612) 9798 2826 Email: [email protected]  
www.turbosmart.com.au www.turbosmartusa.com www.turbosmart.co.nz  
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