Hallman Manual Boost Controller Installation

Hallman Boost Controllers are one of the best, and most trusted manual boost controllers on the market today. The Hallmans are made out of high quality aluminum and stainless steel to provide a long life for the controller. The directions below have been written specifically for the Hallman Manual Boost Controllers, although they can be followed for almost all manual controllers.

Prior to installing a Hallman Boost Controller, or any manual boost controller, it is important to have already added a high flowing exhaust and an aftermarket air intake/ air filter. This will ensure the car is able to breath, and will allow the turbo to spool easier.

It is imperitive to have installed an aftermarket boost gauge. Most stock boost gauges are not accurate, even at stock boost levels, and lose further accuracy once stock boost is increased. Without an aftermarket boost gauge you risk damage to the engine from overboosting.

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Step 1:

Find your wastegate actuator which is usually attached to the turbo, unless you are using an external wastegate. The wastegate actuator will have a vacuum line port that runs to a boost source. The boost source is usually either the turbo's compressor housing, the intercooler pipes, or the intake manifold. This vacuum line is where the manual boost controller will be installed. If there is a T fitting in the vacuum line between the boost source and the wastegate actuator, it will have a separate vacuum line that runs to the boost control solenoid. If you have the T fitting, remove the line that runs to the solenoid, but leave the solenoid plugged in. The following image will help you identify the wastegate actuator and vacuum line port:

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The barb on the Hallman boost controller that connects to the wastegate actuator will have a small hole drilled into it. It is important to leave this hole open, and never switch the wastegate barb and the boost barb.

The Hallman boost controllers come with approximately 3 feet of vacuum line that you can cut into 2 pieces of desired lengths. The first piece will connect from the boost barb on the controller to your boost source. The second piece will connect from the wastegate barb on the controller to the wastegate vacuum port. Tip: if you have difficulty sliding the vacuum lines onto the barbs, use a little bit of oil to lube the barbs. Block off any open boost sources with vacuum caps and use cable ties to secure all vacuum line connections. We recommend using Premium Fuel with all turbo cars, especially once you have increased your stock boost.

Step 2:

Now that the boost controller is installed, it's time to test the car. We recommend leaving the adjustment knob exactly where it was when you received and installed your Hallman when you begin testing. Turning the adjustment knob clockwise increases boost, turning the adjustment knob counterclockwise decreases boost. This step is very important to keep an eye on your boost gauge to make sure you do not overboost and cause any damage to your motor.

Drive your car in an isolated area where you will be able to stop and go several times without interfering with traffic. Slowly press the gas and watch your boost gauge climb. If the boost gauge does not hit your target, increase the boost. If the boost begins to exceed your target, decrease the boost. Repeat the steps as necessary. It typically takes between 5 to 10 adjustments to get the boost exactly on your target. We recommend starting by adjusting the boost knob in 1/2 turn increments, and as you get close to your target you may need to make smaller adjustments. Never adjust more than 1/2 a turn at a time.

Each car has a maximum safe boost level, depending on upgrades to the vehicle and the characteristics of the fuel system, specifically how much fuel your pump and injectors can provide. It is important to research and know what the maximum boost level your specific car can safely run.

External Wastegates

If your car has an external wastegate, the installation is the same as previously described. The only difference is the location of the vacuum port on the wastegate. Connect the boost controller to the side port of the wastegate. The top port should vent to atmosphere when using the boost controller. See the figure below:

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Twin Turbo Installation

The installation in a twin turbo is the same as previously described, except there will be two wastegate actuators that a single boost controller should be installed between. Connect a vacuum line between the two vacuum ports on the actuators using a T fitting. The boost controller wastegate barb then connects to the leg of the T fitting as shown in the image below:

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DSM Installation - 2.0L Mitsubishi Eclipse, Eagle Talon, Plymouth Laser

On 1G DSMs there is an elbow with a port on the top thta has a vacuum line that runs between the wastegate actuator and the boost solenoid on top of the airbox. On 2G DSMs the vacuum line is located on the side of the compressor housing. Disconnect the line on the top of the elbow for 1G's or at the compressor housing for the 2G's. Disconnect this line from the wastegate actuator. You will find a T fitting in this line that runs another source to the boost solenoid located on top of the airbox for 1G's and behind the airbox for 2G's. Disconnect the vaccum lines running to/ from the solenoid. On 1G's you can completely remove the solenoid, but on 2G's leave the solenoid plugged in to keep from getting a check engine light. Use vacuum caps to close off any open vacuum sources on the airbox. Connect the wastegate barb of the boost controller to the wastegate actuator. Connect the boost source barb of the boost controller to the top of the compressor elbow for 1G's or to the compressor housing for 2G's.

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Toyota Supra 3.0L Install

Find the wastegate actuator and the VSV. Only one wastegate is used for both turbos. There are two wastegate actuators, but only one runs to the actual wastegate, which is the correct one. Disconnect the vacuum line from the correct actuator to the VSV. Use vacuum caps to plug off the actuator and the VSV ports. Find the line running from the bottom actuator port to the compressor housing. Remove this line and connect the boost controller with the boost source barb connected to the housing and the wastegate barb connected to the bottom actuator port.

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3S Installation - Mitsubishi 3000GT & Dodge Stealth

Find the intercooler Y-pipe that connects to the throttle body and intercooler piping. The vacuum line connects to the port on the side of the Y-pipe. From this port the line runs to a distributor that runs 3 lines: 1 to each wastegate and 1 to the boost control solenoid. Remove the line that runs to the solenoid and the line that runs into the Y-pipe. The boost source barb of the controller connects to the Y-pipe port. Use a T fitting between the two wastegate actuator lines and connect the boost controller wastegate barb to the leg of the T fitting.

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Subaru Impreza WRX 2.0L Install:

Find the wastegate actuator which is a gold colored canister on top of the turbo. A vacuum line runs between the actuator and the compressor housing. A T fitting is located in this line with another line running to the boost control solenoid, which can be removed. Connect the controller boost source barb to the compressor housing, and the wastegate barb to the actuator.

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*All images used with permission from Hallman Boost Controllers