Total Boost Controller General And Vehicle Specific PDF Installation Manual

BEFORE INSTALLING THIS PRODUCT:
• Make sure to follow all the vehicle specific instructions carefully or damage to the product can result.
• Make sure that the TBC-1 wire harness does not interfere with any moving parts under the hood. Failure to do so may result in shorts.
• Make sure to follow the vacuum hose connections carefully or serious damage to your engine could result.
• Make sure that you remove the two orange caps and one red cap from the solenoid manifold before installing.
• If your vehicle is not listed in this manual please call our customer service department for specific instructions for your vehicle.
• BEFORE INSTALLING read entire manual and verify that the kit contains all the parts necessary for installation. See the TBC-1 Parts List table in the back of this manual for the list of materials provided in this kit. Disconnect the Negative cable of the battery BEFORE proceeding with installation. Failure to do so may result in severe damage to the unit or the engine.WORLD electronics is NOT responsible for any damages to the
engine, vehicle or TBC-1, caused by an installation error. Installation of this product should only be performed by an experienced installer. Installation requires many skills, please refer installation to a qualified, experienced installer.

INSTALLING THE TBC-1 KIT:
1. Disconnect the Negative cable from the battery. *NOTE: When the negative battery cable is disconnected, you may erase data in your audio or navigation components. Please be sure to write down all security parameters before disconnecting the battery.
2. Locate the ECU (Electronic Control Unit) by looking up your vehicle in the Vehicle Specific Wiring and Vacuum Hose Connection Guide starting on Page 51 and finding the letter that represents the location in the ECU Location Drawing on Page 49.
3. Locate a suitable location through the firewall to route the wire harness (the hole must be at least –” in diameter to accommodate the harness connectors. See the diagram below regarding which wires are routed through the firewall. If an existing hole is not found, then a hole must be drilled through the firewall with a 5/8” drill bit. Use the supplied rubber grommet (part number WE-6000.0009) and route the wires through the grommet and hole. Make sure that a grommet (existing or supplied) is used when routing the harness through the firewall or shorts can occur as shown in figure below. Failure to abide by this precaution may cause a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

4. Using the Vehicle Specific ECU and Vacuum Hose Connection Guide (see page 51), locate your vehicle model and year. Following the guide, connect the TBC-1 harness to the ECU according to the features desired. *NOTE: you only need to connect the wires that are needed for the features you intend to use. See the chart below to determine the connections that are required to utilize desired features. Refer also to the General Wiring Diagram on the next page.

5. Wrap all connections with electrical tape.
6. Mount the Solenoid under the hood, near the wastegate on the firewall or inner fender. The solenoids are mounted using the solenoid mounting hardware (part WORLD electronics Total Boost Control (TBC-1) Customer Service: 800-523-0427 Page 46 of 63.

7. Mount the Pressure Sensor under the hood away from high heat but close to the intake manifold of the engine using the supplied strap bracket (part number WE-6000.0013). Mount all TBC engine compartment components (pressure sensor and solenoid) away from excessive heat. Failure to do so can cause damage to the components and render the unit inoperative. Route all wiring away from excessive heat. Failure to do so can cause the wire to melt rendering the unit inoperative.
8. Connect the wire harness connectors to the Pressure Sensor and the Solenoid (the harness connectors are opposite so that the wrong connector cannot be used). Connect the ring tongue terminal from the Pressure Sensor connector to a suitable screw for grounding to the vehicle chassis. (Make sure this is a good ground connection) NOTE: Make sure the connectors go together correctly and “snap” for a good connection.
9. Disconnect the existing vacuum hose/hoses from the wastegate actuator to the existing wastegate solenoid valve or VSV (Vacuum Switching Valve). Plug up the port going to the wastegate actuator on the existing solenoid valve (see your specific vacuum hose diagram in the Vehicle Specific Wiring and Vacuum Hose Connection Guide).
10. Connect the vacuum hoses to the Solenoid and the Pressure Sensor according the Vehicle Specific Wiring and Vacuum Hose Connections Guide starting on Page 11. If your vehicle turbo system has been modified (i.e. after-market components added) please see the General Vacuum Hose drawings for single and dual port wastegate types. NOTE: Make sure to place the supplied hose clamps (part number WE- 6000.0016) on every vacuum hose connection….

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