by Tony Wang | wangstar@mindspring.com
December 4th, 1998 - Revision 1.5: Updated installation to include VSV disable.
Updated operating instructions. Observations removed until I can put the '2
on a dyno and get hard data.
November 30th, 1998 - Version 1.0
DISCLAIMER: This is what I did, what you do to your car
is your responsibility.
WARNING: This device can be very dangerous if improperly
installed or operated. You'd be amazed at how many times the word "fire" comes
up in the instructions.
PREFACE
These instructions assume you have some type of cone air filter installed already.
If you don't have one, you should really consider putting in one of those first,
as you need the extra breathing if you plan on increasing boost.
The installation is fairly simple but of course it helps alot if you've tinkered under the hood before. Moving at a cautious pace I completed this installation in about two and a half hours. Knowing how to dismantle the interior speeds things up alot.
Installation
Operation
PARTS
Wiring
NOTE: The three pin connector on the DSBC is the accessory connection
to other Blitz components. It is not used in this installation.
1. DISCONNECT THE NEGATIVE TERMINAL ON THE BATTERY FIRST.
Don't forget to clear your security code if you have the factory stereo system.
2. Disassemble the center divider.
There are four screws in the center storage compartment; remove these and the
compartment should lift off. Set it aside. Now remove your shifter knob and
shift boot. The knob unscrews and the boot may be removed by gently pushing
forward on the bottom edge; there are four clips which hold it in, two top and
two bottom. Set these aside. Next look along both sides of the divider; you
will notice four plastic screw caps. Pry these off with the small flat screwdriver
and remove the screws underneath. The center divider should now lift off easily,
set it aside.
3. Disassemble the lower dash panel.
There are four screws, roughly one at each corner which hold it on. Remove the
screws and slide the panel downwards and towards you and it should come right
off.
4. Remove the metal plate beneath the steering column.
There are 3 bolts and two nuts which hold it on. Use the 10mm socket and the
plate will come right off.
5. At this point you should be able to see the ignition harness.
Take the wire harness that came with the Blitz kit and tap the RED wire into
ignition power; I have a Blitz Dual Turbo Timer and tapped the power line from
that instead. You could also tap stereo wiring, I suppose.
6. Run the harness along the left side of the center divider.
You may find it helpful to unclip the exisiting bundle of wires and clip the
Blitz wires inbetween the divider wall and the existing bundle. You can unclip
the existing bundle by squeezing the grey plastic clips with pliers and sliding
them out.
7. Run the harness into the engine compartment.
Peel back the firewall carpeting behind the drivers seat and you will see a
rubber grommet which wires run through. Take the utility knife and cut a small
(no more than 1/2") slit in the grommet. Take the end of the Blitz wires and
slide it through the slit and into the engine compartment. Slide it in about
1.5 feet, then bundle the slack with a zip tie or electrical tape and tape it
to the firewall. Tidy things up with the wire and tuck it under the appropriate
carpeting.
8. Mount the unit.
Depends on where you want it. I put mine in the left center air vent along with
my TT. It required a bit of cutting but nothing major, just the pull-out plastic
vent. Another popular spot is below the fog light switch; my TT was originally
located there.
Running the Vacuum Hose
If you already have a vacuum line running up to the dash, tap your existing
line to connect to the Blitz unit and skip this section. If you trashed the
tiny vac-T that came with (like me) the DTT kit you can take a 1/8" vac-T,
slide a tiny bit of 4mm silicone hose over the ends, and the vinyl Blitz hosing
will fit squeeze in perfectly.
1. Run the vacuum hose.
Take the 14 feet of 4mm hosing and run it along the center divider similar to
the Blitz wire harness. Cut a slit in the grommet and stick one end of the hose
through.
2. Install the vacuum T.
On the right side of the rear engine compartment wall you will see a small sensor
with a hose running into it. This is the stock boost sensor. Unplug the hose
going into the stock sensor and cut it halfway between the white filter and
the sensor end of the hose. Install the 1/8" vacuum T.
3. Connect the hose.
Run the hose from the grommet around the left and then rear edges of the engine
compartment to your newly installed T. Use zip ties to secure the hose, but
be careful not to pinch or kind the hose. Plug it in and make sure it's nice
and tight.
Valve Unit Installation
1. Install the "OUT" hose.
Cut two feet of the 6mm Purosil hosing. Take a look at the left side of the
turbo. You'll see a fitting with a black 6mm hose coming off it- this leads
to the wastegate. Slide the hose off the fitting and stick the now loose end
someplace where you can grab it again easily. Replace it with the 6mm hosing
you just cut- but slide one of the hose clamps over the end first (so you won't
have to slide it all the way down later). This part isn't easy, it takes patience,
dexterity, and more patience. You may find it helpful to put a drop of silicone
lubricant on the end of the fitting; just don't get any on the hose or you'll
never get a good grip.
2. Install the "IN" hose.
Slide a hose clamp down one end of the remaining 2 feet of 6mm hosing. Next
take one of the 6mm hose barbs from the Blitz kit and secure it to the hose.
Now find the hose you disconnected from the turbo and attach it to the other
end of the hose barb. Use the stock spring clamp to secure it to the barb.
3. Connect IN and OUT hoses to the valve unit.
Slide hose clamps over the ends of your IN and OUT hoses and connect them to
the appropriate fittings on the valve unit. Done! That wasn't so bad, was it?
Disabling the Turbo VSV
In my original instructions I stated that it was not necessary to disable the
VSV. I was dead wrong on this- you must disable the VSV if the DSBC is to function
properly. I apologize for posting incorrect information and I'll be more careful
in the future. Here is how to disable the VSV.
1. Locate the VSV.
Slide under the car and look up at the engine. In the mid-rear you will see
a canister shaped object and next to it an electric valve with two hoses coming
off it. This is the VSV. The hose of interest is the "U" shaped hose.
2. Plug the VSV.
Disconnect the "U" shaped hose from the VSV unit. Slide the hose clamp
further down the hose, as far down to the bend as possible. Slide the 1/8"
vacuum cap over the naked fitting on the VSV, and slide the 5/32" vacuum
cap over the open end of the hose. The VSV is now disabled- don't boost your
engine when it's cold now...
Note: I did all of this without jacking the car up and with one hand. Depending
on the diameter of your skull you may have to elevate the car on ramps or jack
stands to get enough room to work.
The Blitz unit offers two levels of adjustment: Gain and Ratio. Gain controls
the overall boost response by constantly modifiying the pressure coming from
the actuator into the wastegate. Ratio controls the boost curve by adjusting
how quickly and when the wastegate is allowed to open. Ratio also affects your
maximum boost.
GAIN
To enter Gain Set mode, press and hold the MODE button for at least two seconds.
The unit will beep and you will see "1234M" flash on the display. The default
gain is 5. Set the value by turning the volume knob. You can adjust the value
anywhere from 0 to 100. Be very careful with gain, as setting it too high could
cause overboosts leading to engine damage and possibly detonation.
I spoke with Blitz and the gain setting is intended to compensate for the varying spring stiffnesses of external wastegates. The recommended setting for the SW20 is 0.
RATIO
You can program four different ratios into the DSBC at one time. This allows
you to switch boost curves "on the fly", somewhat useful, in the sense of city
and highway modes. To set a ratio, first select a channel by turning the mode
knob until you see either 1, 2, 3, or 4 on the display. When you've selected
your desired channel, press the mode button once. The channel number will begin
to blink and you are in Ratio Set mode. Press the volume button until the words
"boost" or "peak" do not appear. A number will appear in the main display area;
by default all channels are set to 0. Turn the volume button to adjust the value.
The value can be anywhere between 0 and 100.
According to Blitz, the Ratio is the percentage of boost which will be utilized. This in turn will affect your maximum boost; I was told that with a setting of 25, boost should max out around 0.60 kg/cm2.
WARNING/ALARM
Turn the knob until the display turns red. The word "WARN" will be blinking
on the display. Here is where you set the warning value. Turn the volume knob
to select a warning pressure; anywhere from 0 (off) to 2.50 kg/cm2. Press the
volume knob once now to set the warning ratio. The warning ratio is the amount
of power reduction that will occur when the warning value is exceeded.
Note: The value you set here is NOT a boost limiter! It is quite easily possible
to exceed the set value (and by large amounts) depending on your ratio setting.
The DSBC will regulate boost to below the warning value and will prevent boost
spikes.
SCRAMBLE/CUTOFF
Scramble mode provides additional boost when accellerating under extreme conditions.
It works in conjuction with the warning preset. Turn the mode button until you
see "L" blinking on the display. In the main display area you will see "P 0".
"P" indicates that you are setting scramble power. Turn the volume knob to adjust
the scramble power; this is power in ADDITION to the ratio setting of whichever
channel you are in; so if you are in channel 1, set to 25, and set scramble
power to 10, your scramble mode boost power will be 35. Also note that you can
set negative scramble power also.
Press the volume knob and you should see "C 0". "C" is the
cutoff time for scramble mode. The value you set here is the time in seconds
that your scramble power will be applied once you hit warning mode.