How to Install a Manual Boost Controller on a Passat

Written by jeff slater
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How to Install a Manual Boost Controller on a Passat
(turbo image by Elijahu from Fotolia.com)

The Passat is a mid-sized vehicle created by Volkswagen to fill the gap between its Golf hatchback and popular Jetta. First sold in 1973, the Passat underwent several major design changes leading up to the current model, internally designated as the "B7". It was originally equipped with a thrifty 1.3L OHV (overhead valve) 4-cylinder engine that developed a meagre 54 horsepower, however over time cylinder count and engine capacity grew to include six and even an 8-cylinder engine of up to 4 litres in size. Turbocharged variants also appeared using the "2.0T" and "1.8T" nomenclature common on a wide range of Audi vehicles. These motors were both gasoline and diesel based, and although not speed demons in stock trim -- with the included turbo system -- they could be made significantly faster relatively easily.

Skill level:
Easy

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Things you need

  • Manual Boost Controller (MBC) Kit

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Instructions

  1. 1

    Attach one side of the manual boost controller to the vacuum hose coming off the wastegate actuator (located on the back of the turbocharger unit).

  2. 2

    Connect the other side to the boost source outlet nipple.

  3. 3

    Secure the controller with a heavy duty twist tie (included in the kit) away from the exhaust manifold.

  4. 4

    Do a third gear pull by flooring the throttle when rpm is at approximately 2000 until redline on a closed stretch of road or track. This will set a baseline and determine the vehicle's exact factory boost setting.

  5. 5

    Adjust the turbo boost setting on the MBC by slowly turning the knob in the desired direction. (typically clockwise will increase boost pressure and counter-clockwise will retard boost)

  6. 6

    Complete several full-throttle passes to attain a specific boost setting.

Tips and warnings

  • 2-3 psi (pounds per square inch) of added boost will provide a substantial power increase and is within the limits of the factory fuel system.
  • Adding a high-flow intake and exhaust system will maximise gains and allow for faster turbo spool-up times.
  • An excessive boost increase can potentially cause severe engine damage, proceed with caution.

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