Product Name:  
Product Description:  
Product Number:  
BOV Controller Unit Only  
Electronic BOV controller  
TS-0304-1003  
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IMPORTANT NOTES:  
Please thoroughly read and understand these instructions before commencing this installation.  
RECOMMENDATIONS  
Turbosmart recommends that your BOV controller is fitted and adjusted by an appropriately qualified technician  
Turbosmart recommends that a boost gauge be permanently fitted to the vehicle  
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Please check that the following items have been provided in your BOV Controller Kit  
Quantity  
Description  
BOV Controller Unit  
Use  
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BOV Controller  
2
m
2 core wire  
Connect BOV Controller to solenoid  
Insulating soldered joints  
Surface mounting BOV controller  
Mounting BOV controller  
Mounting BOV controller  
Controls pressure to BOV  
Connects solenoid to hose  
Mounting the solenoid  
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Heat shrink  
Double sided adhesive  
M3 X 30 Screws  
M3 Nuts  
3 Port solenoid  
1/8 NPT nipples  
Solenoid Bracket  
M3X20 SHCS  
5 amp Fuses  
M6 Nut  
Mounting bracket to solenoid  
To protect the BOV controller and solenoid from voltage problems  
Secure solenoid bracket to car  
M6 X 25 SHCS  
M6 Washer  
Secure solenoid bracket to car  
Secure solenoid bracket to car  
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Cable ties  
Securing vacuum tube and wires  
For ground connection  
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Crimp ring terminal  
Hose clamps  
8 way wiring loom  
Securing all pressure lines  
Connects BOV Controller to devices and power  
FUNCTIONALITY  
The BOV controller works by detecting a negative voltage change in throttle position. It then energises the solenoid to vent all of the air  
out of the BOV cap, causing a pressure differential between the piston of the BOV and the cap which will vent pressure from the intake  
system. There are 2 parameters that can be adjusted to tune the controller for optimum performance; duration and sensitivity. The green  
LED shows that the BOV controller is on. The yellow LED shows when the solenoid is activated.  
Duration adjustment  
Sensitivity adjustment  
Power LED  
LAYOUT  
Activation LED  
Mounting Holes  
INSTALLATION  
Mount the unit away from any heat source and moisture. Wire up the unit as per diagram. Do not connect the unit to a power supply  
which will have a greater voltage than 14V DC. Unused wires must be insulated with electrical tape so that they do not touch  
other wires or the chassis  
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. ORANGE = +5V (For external TPS) OPTIONAL if your engine does not have a OEM TPS  
. GREEN = 0V (For external TPS) - OPTIONAL if your engine does not have a OEM TPS  
. WHITE = TPS signal Input  
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. YELLOW = Solenoid trigger signal  
. GREY = Disable Trigger wire (Ground to disable Controller) - OPTIONAL  
. BROWN = Enable Trigger wire (Ground to keep solenoid energised) - OPTIONAL  
. BLACK = Controller Ground  
. RED = +12V (USE SUPPLIED 5A Fuse inline)  
Looking into BOV  
Controller  
SOLENOID CONNECTION  
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Wire from solenoid:  
Connect to Ignition activated  
Supplied 5A fuse  
Yellow wire from control unit  
(
1) Vent to atmosphere  
Wire from solenoid  
(
nipple on BOV  
2) To pressure  
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3) To pressure source  
Electrical connection  
Connect one wire of the solenoid to a fused (use supplied fuse) ignition activated 12V power source and connect the other wire to the  
Solenoid trigger signal (Yellow) on the BOV controller unit. Polarity is not important.  
Pressure connection  
Port 1: Vent to atmosphere.  
Port 2: To pressure nipple of BOV.  
Port 3: To pressure source e.g. Intercooler piping (Make sure the pressure source is not shared and that it is from the same part of the  
pipe work as the BOV)  
THROTTLE POSITION CONNECTION  
The BOV controller can be wired to the existing throttle position sensor on your vehicle. Connect the white wire to the signal output wire  
from the existing throttle position sensor.  
(OPTIONAL) For vehicles without a standard throttle position sensor (such as the 12V Cummins Diesel engine), an external one can be  
wired in. The ORANGE AND GREEN must be used to power the external throttle position sensor if one needs to be installed as the  
TPS requires a 5V power supply and not a 12V power supply.  
SWITCHED INPUT CONNECTION (OPTIONAL)  
If your vehicle does not have a standard throttle position sensor and you do not want to install an external throttle position sensor, a  
double throw switch can be used to activate the BOV. The switch needs to ground the GREY WIRE ONLY when the accelerator pedal  
is pressed in and needs to ground the BROWN WIRE ONLY when the accelerator pedal is released.  
ADJUSTING YOUR BOV CONTROLLER  
DURATION: The duration is the length of time that the solenoid blocks the pressure signal to the BOV. The longer the duration, the  
longer the BOV will not have pressure supplied to the cap, essentially keeping the BOV open. The controller also has an override  
function which reactivates the BOV once it detects positive throttle movement, independent of what the duration is set at.  
SENSITIVITY: The sensitivity setting determines how the BOV controller reacts to throttle movement. The controller will only activate on  
negative changes in throttle. The higher the sensitivity setting, the lower the negative change in throttle movement needs to be before  
the solenoid will activate the BOV e.g. a change from 4V to 3.5V will not activate the valve but from 4V to 3V will activate the valve.  
(OPTIONAL IF SWITCHED INPUT CONNECTION METHOD IS NOT USED) ENABLE FUNCTION: Grounding the BROWN WIRE  
activates the enable function which allows the BOV controller to keep the solenoid activated. Even though the unit is still reading  
changes in throttle position, it will not respond to them, not allowing pressure to reach the top of the BOV. The yellow LED will stay on  
when this function is activated. This function can be used to limit boost as the BOV will not have any pressure keeping it closed. It can  
also be used as an over boost safety feature when connected to another device such as a data logger or ECU which can ground the  
wire if a over boost scenario is reached.  
(OPTIONAL IF SWITCHED INPUT CONNECTION METHOD IS NOT USED) DISABLE FUNCTION: Grounding the GREY WIRE will  
activate the disable function which disables the BOV controller. The BOV controller is still switched on but will not respond to changes in  
throttle position, keeping pressure to the top of the BOV, not allowing the BOV open. This can be used when the BOV is not required to  
be functional e.g. when using cruise control, the BOV will not actuate on sudden throttle changes cresting hills.  
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ONE YEAR LIMITED WARRANTY  
Turbosmart is a company built on Customer Satisfaction and Service. That is why all of our products go through regimented test procedures before they are  
packaged and shipped. Turbosmart stands behind its products for one full year after purchase. Terms of Warranty, Service and Returns are as follows:  
Limited Warranty: Turbosmart warrants its products to be free from defects in material and workmanship under normal use and if properly installed for a period  
of one year from date of purchase. If found to be defective, it will be replaced or repaired if returned prepaid along with proof of date of purchase. This shall  
constitute the sole remedy of the purchaser and the sole liability of Turbosmart to the extent permitted by law, the foregoing is exclusive and in lieu of all other  
warranties or representations whether expressed or implied, including any implied warranty of merchantability or fitness. In no event shall Turbosmart be liable  
for special or consequential damages. This warranty is only valid on products purchased from Turbosmart Authorized Dealers.  
Service: After the warranty period has expired, repair service is charged based on a minimum and maximum charge rate. (Contact Customer Service for current  
rate).  
Returns: When returning a Turbosmart product for repair, it must be accompanied by a completed Customer Warranty Form and RMA number. To access this  
form please go to our website www.turbosmartonline.com and you will find it on the Downloads page.  
THE TURBOSMART PLEDGE  
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 authorized 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.  
Warranty as to Defects Australian Consumer Law  
1.1  
We warrant for a period of twelve (12) months from the date of supply of the Goods and/or Services that if due to the fault of Turbosmart the Goods  
and/or Services (as the case may be) provided by Us are defective then We will, as determined by Us do one or more of the following:  
1.  
In the case of Goods; the replacement of the Goods, the supply of equivalent Goods, the repair of the Goods, the payment of the cost of  
replacing the Goods or of acquiring equivalent Goods, or the payment of having the Goods repaired; or  
2.  
In the case of Services; the supplying of the Services again, or the payment of the cost of having the Services supplied again.  
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You will only be entitled to the benefit of the warranty set out in this pledge, if You have not wholly or partially caused or contributed to the defect  
to the Goods by the misuse of the Goods or the failure to use the Goods in accordance with any specifications or instructions applicable to the Goods.  
The warranty contained in this pledge is provided by Turbosmart Pty Limited of 32 Milton Street North, Ashfield NSW 2131, Australia, Telephone:  
+
(61) 1300 735 506, Email: [email protected].  
In order for a You to make a claim on the warranty You must within twelve (12) months of delivery of the Goods or Services give written notice to Us  
at the address specified in clause 1.3 above of the details of any defects in respect thereof. Any Goods referred to in a notice given pursuant to this  
clause should be left in the state and condition in which they were delivered until such time as We or Our duly authorised agent have inspected the  
Goods with such inspection to be carried out within a reasonable time after service of such notice. If the Goods are not so left in the state and condition  
in which they were delivered then the You shall be deemed to have accepted the Goods and the warranty contained in this pledge shall not apply.  
You shall be responsible for all expenses associated with making a warranty claim under this pledge however if the Goods and/or Services are found to  
be defective due to Our fault then We shall reimburse You for any expenses incurred by You in making a warranty claim upon receiving evidence  
satisfactory to Turbosmart to support such expenditure.  
The benefits to You given by the warranty contained in this pledge are in addition to other rights and remedies of You have under a law in relation to  
the Goods or Services to which the warranty relates. In accordance with the Australian Consumer Law We makes the following statement: “Our goods  
come with guarantees that cannot be excluded under the Australian Consumer Law. You are entitled to a replacement or refund for a major failure and  
compensation for any other reasonably foreseeable loss or damage. You are also entitled to have the goods repaired or replaced if the goods fail to be  
of acceptable quality and the failure does not amount to a major failure.”  
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EXCEPT AS PROVIDED BY LAW, THIS LIMITED WARRANTY IS THE ONLY EXPRESS WARRANTY, WHICH APPLIES TO TURBOSMART 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 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 SEVEN (7) 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  
Ph: +61 1300 735 506 Fax: +61 1300 735 509 Email: ins[email protected]  
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