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Thread: Boost Controllers

  1. #11
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    I think the MCM boys leave the factory one in place to avoid throwing codes.

    The only reason I've not purchased is my turbo has 330,000+ km under it's belt and I'm not sure whether to go hybrid or VGT next. The GFB Controller won't work with a variable vane turbo.

  2. #12
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    I have the GFB G-Force.
    Nice little device. I use it on a 300TDi tho, not a TD5.
    Dunno how well it'd work on a TD5.

    Only problem with it is that you have to work with duty cycles, not absolute values like we're used too.
    That is, you don't set (say) a maximum pressure(eg. 20psi) to work with, but you have to experiment with whatever duty cycles do to the system.

    it's a bit of a PITA to get it setup the way you want it to work for 'ya.

    Doesn't really spool up all that much quicker than a std (for me 300Tdi) turbo.
    All it really allows for is you can set up a maximum boost pressure(ie. for me that's about 22psi) for when you need it.

    As already said by others earlier, it controls the wastegate, but it does so at 30Hz(30x/sec) so when you set maximum duty cycle, the turbo pressure doesn't pulse up and down madly.

    it does help, especially with the Tdi.
    I've tweaked my IP a little to get just a tad more fuel through .. just below the point of blowing too much smoke.
    Early Jan we went camping, and I fitted a new battery before we headed off. I totally forgot that the G-Force controller has it's memories linked to battery power. disconnect battery, memory loss, and it defaults to standard pressure values(as it says it does).
    On the camping trip with a bit of weight in the Tdi, the thing struggled badly, up hills, EGTs skyrocketed .. etc.

    Can't remember when, but maybe late Feb, early March, I somehow remembered the G-Force memory loss problem(having disconnected the battery way back).
    Went into it's memory banks(I think there are 7 all up), and set it back to my fave memory, and voila! .. boost is back, power is back, and EGTs now way back down(at least 100degrees on average).

    Up until I remembered the memory loss aspect of the controller, I started to contemplate new, bigger intercoolers, or clean out the old, etc ... I had visions of pulling the bottom IC hose and striking it rich with the amount of residual oil in there.
    I probably have a fair amount of oily residue in the IC and all that, but the point I'm making was that the controller's memory loss, and hence it defaulting back to std parameters, was the issue.

    The only human readable value you set on the controller is the maximum boost pressure, I've set mine to 22Psi, so that if the controller allows it to cycle up to this point it can't boost past this point.
    And you don't get the dreaded ... boost/no-boost/boost cycling .. every second, as you could with a full manual controller.

    I read about the D-Force, and decided to save my $'s and just go with the G-Force model, as I already have an EGT readout.

    The only other anomaly that's confused me with the G-Force is the difference in turbo pressure I see between it, and my boost pressure gauge.
    Both readings come from the inlet manifold, from the same t-piece, but I see 2psi less pressure from the G-Force as I do with my electronic boost gauge.
    One day I'll find a dial type boost pressure gauge and fit it between the two and figure out what's going on.
    So at the moment I'm only using any boost pressure readings as a guide, until I can work out what's going on.
    But the issue with that tho is that on the GFB I see 22psi(where I set it to max out) and OTOH, on my 1Gauge boost gauge I see 24Psi recorded.
    I'm hoping that the 1Gauge is wrong, but it could easily be the GFB that's not correct .. I just don't know.

    Fitting was pretty easy, I tapped into the wastegate hose, cable tied the tiny controller valve to the inner wing, some wires into the cabin, along with the vacuum hose. I reckon maybe 2 hours work all up.
    The other thing to note is the size of the head unit. I have it set on the drop down cubby on the drivers side, just in front of my left knee, double sided taped there. It drops down with the fuse box-cubby cover. Been there for nearly a year now, and is ideal.
    Thing I don't like is the brightness of the display. around town it's ok, as the street lighting over powers it, but on a dark country road where you want as little interior light as possible, it'd be blinding if it were up in the line of sight(hence why I put it down there).
    I can't find any way to adjust screen brightness.
    Size of the head unit is about the size of your palm. That is, no fingers, no thumb .. just your palm, and that's how big the unit is. Maybe 15mm thick too. Not heavy either, as the double sided tape holding it precariously on the rounded edge of the fuse box cubby lid attests too.

    Hope that helps.

  3. #13
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    Quote Originally Posted by Keppmeister View Post
    I guess it stops the waste gate creeping open as the boost starts coming on by isolating the supply . The duty solenoid is able to regulate from there and bleed boost pressure off to intake side of the turbo as needed to maintain pressure selected at a very rapid rate if needed . The EGT function incorporated seems cool. Beats having to buy an extra gauge and plenty of other features
    A Td5 Discovery leaves the factory with this kind of wastegate control as standard.
    2014, MY14 Discovery TDV6, Fuji White (2018-Now)
    2003, Discovery 2a, Td5 Manual, Zambezi Silver (2012-2018)
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  4. #14
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    Quote Originally Posted by Keppmeister View Post
    Yeah true , the ecu will limit max boost with fuel cut unless you have a chip or flashed Ecu . But looks like an easy way to make adjustments to boost and monitor exhaust gas temps and boost all in one unit . If only It did oil pressure too.

    The Discovery 2 TD5 looks like it has a standard basic boost control valve plumbed in. I wonder if I will get engine codes if it is bypassed for the aftermarket unit to work as it will have to take its place ?

    No their won't be any engine codes unless overboost is triggered.

    The stock MAP sensor is good for more pressure than the default ecu tune will allow, most tuners can now rescale the relevant table to accommodate more boost which would normally trigger an overboost scenario.

    The benefit of a boost controller sitting between the waste gate modulator and the turbo is that the boost controller will prevent boost hitting the wastegate prior to the desired boost level being hit - the factory modulator could also do this if the appropriate tables in the ECU were re-calibrated but this appears to be something that none of the tuners have yet figured out how to do (or I'm unaware of it if they have).

    The reason why it's better to increase boost in this manner rather then 'winding in' the actuator arm, is that shortening that arm reduces the maximum opening angle that the wastegate can achieve, this can then lead to flow issues and boost creep.

  5. #15
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    I'm going to have to give it a go I think . I have made adjustments manually to waste gate actuator arm but this is a better way to do it for the reasons you just explained there BennehBoy . Cheers for the input. It is a 17 year old tech the factory boost controller, things have come a long way since then

  6. #16
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    Quote Originally Posted by Keppmeister View Post
    I'm going to have to give it a go I think . I have made adjustments manually to waste gate actuator arm but this is a better way to do it for the reasons you just explained there BennehBoy . Cheers for the input. It is a 17 year old tech the factory boost controller, things have come a long way since then
    I'm about to fit a ball and spring one to mine, I've got a turbosmart actuator on which is supposed to open at 26psi but is actually letting 29-30psi build... which is way too much for the amount of fuel that the engine can actually consume. I'll be dropping the springs in my wastegate down to around 22/3 psi and then tweaking with the boost controller. Base map is about 235bhp at the moment, but am aiming for more Yes it's dumb but it's fun.

  7. #17
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    I've left the forge actuator quite "relaxed" and fitted one of these Mechanical Boost Controller - Universal Fitment | eBay between the modulator and valve, this setup IMO can bring out the most of the unadjusted boost map and std turbo
    Discovery Td5 (2000), manual, tuned

  8. #18
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    Quote Originally Posted by sierrafery View Post
    I've left the forge actuator quite "relaxed" and fitted one of these Mechanical Boost Controller - Universal Fitment | eBay between the modulator and valve, this setup IMO can bring out the most of the unadjusted boost map and std turbo

    Looks good. All we have to do now is convince them to ship from UK to AU
    D4 MY16 TDV6 - Cambo towing magic, Traxide Batteries, X Lifter, GAP ID Tool, Snorkel, Mitch Hitch, Clearview Mirrors, F&R Dashcams, CB
    RRC MY95 LSE Vogue Softdash "Bessie" with MY99 TD5 and 4HP24 transplants
    SADLY SOLD MY04 D2a TD5 auto and MY10 D4 2.7 both with lots of goodies

  9. #19
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    Looks good. All we have to do now is convince them to ship from UK to AU
    Look on oz ebay but make sure you enter "boost valve" as if you enter Dawes valve it magically adds $100 or so to the price! LOL.
    Regards Philip A

  10. #20
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    There are cheaper chinese versions too but if i was there i'd buy one made in australia like this BLACK Manual Boost Controller *Tee Bleed Valve Petrol Diesel Turbo Skyline WRX* , fitted between the modulator and the valve you can ''relax'' the rod to 13-14 threads to have more travel of the wastegate which will provide smooth creepless boost then adjust it as to bring up the MAP to 240Kpa strictly below the factory set overboost limit...took me a while untill i managed to set mine well but now it's perfect.... though i have a forge wastegate actuator which helps as well.
    Discovery Td5 (2000), manual, tuned

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