Synchronic Blow-Off Valve TUNING MANUAL

INDEX I. SB001 Diagram II. Installing and Removing the Recirculation Fitting III. Installing and Removing Mounting Flanges IV. Filtering the Inlet V. Connecting to a Vacuum Source VI. Recirculating the Discharge VII. Adjusting for Response VIII. Anti-Stall Valve Kit IX. Mounting Flange Options 2

I. PARTS LIST AND DIAGRAM SB001 1. Recirculation Fitting (1.25 OD) 2. Recirculation Fitting Set Screw (M4 x.7) 3. Weld-On Mounting Flange 4. Mounting Flange Set Screws 5. Port A (4-5 mm ID hose) 6. Port B (4-5 mm ID hose) 7. Port C (4-5 mm ID hose) 8. Pre-Load Adjustment 7. 6. 8. 5. 1. 2. 4. 3. 3

II. INSTALLING AND REMOVING THE RECIRCULATION FITTING a. Begin by removing set screw (2) with hex bit size M2. If you plan on completely removing the Recirculation Fitting, make sure to remove the set screw and store it away in a safe place for later use. b. When re-installing the Recirculation Fitting, it is recommended to apply some motor oil or grease around the o-ring to ease in installation and aid the o-rings in sealing. You can put a light coat of RTV silicone to the mating side of the fitting to insure a vacuum seal for very sensitive MAF systems. III. INSTALLING AND REMOVING MOUNTING FLANGES a. Begin by removing the two set screws (4) with bit size M1.5 (1/16). b. Then, take the stainless steel mounting weld flange (3) that comes pre-installed and pull it loose. It may be hard to remove if it is the first time you are removing it. You may need to twist and turn it in order to get it out. If you plan on using a pair of pliers to remove it, make sure you tape the ends of the pliers, or use cloth to keep from scratching or damaging the flange. c. If you are switching to one of the other alternative mounting flanges, you will need to transfer the o-ring to the new flange if one is not already provided for you. d. Upon reinstallation, you should NOT use grease or oil on the o-rings to reinstall. Use water instead (not alcohol) to aid in installation. e. Reinstall set screws, preferably with non-permanent Loctite, and do not over tighten them. 4

IV. FILTERING THE INLET a. If you do not plan on recirculating the discharge of the BOV back after an air filter, or after the MAF, it is highly recommended that you filter the inlet of the BOV. b. One choice would be to purchase a small filter, such as a K&N, with a 1.25 inlet. c. Another alternative would be to sandwich thin foam between the Recirculation Fitting (1) and the BOV s housing. V. CONNECTING TO A VACUUM SOURCE a. You will need to locate a vacuum source that is directly connected to the intake manifold after the throttle body. It is preferable that the Synchronic BOV have its own vacuum source. If you need to tee the vacuum source, please insure that the straight section of the tee is in direct communication with the Synchronic BOV. See diagram below. You will also want to make sure that the vacuum source to the BOV is not shared with other pneumatic actuators such as wastegates, EGR valves, etc. b. Once you have plumbed a vacuum signal source near the Synchronic BOV, you will tee the connection and connect both Ports A (5) and B (6). Depending on the placement of the source port on the intake manifold that you are using for vacuum, you may want to plumb the hoses that go to Ports A (5) and B (6) as close to the intake manifold as possible before connecting them together with a tee. 5

CORRECT INTAKE MANIFOLD VACUUM SOURCE INCORRECT INTAKE MANIFOLD VACUUM SOURCE 6

VI. RECIRCULATING THE DISCHARGE a. The Synchronic BOV comes complete with all of the components necessary to install it into a system recirculated. b. In a speed density system (MAP sensor) you can recirculate the discharge of the BOV between the air fi lter and compressor inlet. c. In a mass air fl ow metered system (MAF) you can recirculate the discharge of the BOV between the MAF and the compressor inlet. MASS AIR FLOW SENSOR COMPRESSOR INLET BOV DISCHARGE d. In a mass air fl ow metered system (MAF), where the turbocharger is blowing through the MAF, you can install the Synchronic BOV anywhere between the compressor discharge and the MAF. In this scenario you do not have to recirculate the discharge of the BOV, but should fi lter the discharge. COMPRESSOR DISCHARGE BOV INLET BOV INLET MASS AIR FLOW SENSOR 7

VII. ADJUSTING FOR RESPONSE a. There should not be a need to adjust the Synchronic BOV. However, you are welcome to try the following configurations so long as the result does not produce compressor surge. i. Vacuum only to Port A (5) ii. Vacuum only to Port B (6) iii. It is not necessary to adjust the pre-load spring (8). It is best for response to leave this as loose as possible. This feature is for future applications. If you choose to adjust the pre-load to change response, clockwise is more preload and counter clockwise is less preload. 8

VIII. ANTI-STALL VALVE KIT (optional sold separately) The anti-stall valve is designed for use in installations where you want to vent the Synchronic BOV to atmosphere, but cannot due to a sensor such as a MAF that meters the air. This kit can also be used in installations where you do not want charge air to bypass the turbo under vacuum conditions. 12. 11. 10. 9. 9. Anti Stall Valve 10. Anti Stall Spring 11. Anti-Stall Spring Retainer Bolt 12. Anti-Stall End Cap Begin by removing the Recirculation Fitting (1) by unscrewing set screw (2). Assemble the anti-stall valve onto the SB001 in the order shown with the following components 9, 10 and 11. Insure that the Retainer Bolt (11) is threaded all the way to the bottom of travel and hand tight. It is recommended that you remove the mounting flange and hold the valve down on its seat by pressing down on the back of the valve with your fingers to keep it from spinning in order to apply moderate torque to the Retainer Bolt (11). Push on the bolt up and down and insure that there are no obstructions to the movement of the valve. You may even want to connect ports A & B to vacuum, while uninstalled and rev the engine to confirm that the valve is moving up and down freely. 9

IX. MOUNTING FLANGE OPTIONS 1. 2. 3. 1. SB001.1A Aluminum Weld-On Mounting Flange, SB001.2A Stainless Steel Weld-On Mounting Flange 2. SB001.3A Aluminum Greddy Type S, Type R and HKS Racing Mounting Flange 3. SB001.4A Aluminum HKS SSQ Mounting Flange 10

NOTES 11