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Tools Needed:
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Scissors
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Vacuum Caps
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Pliers
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There are two ways to install a boost controller. The way I will go over first gives full control of boost to the valve. The way covered at the bottom controls boost with a combination of input from the ECU and Valve.
Before you can begin installing your manual boost controller (MBC), you must first remove certain boost control solenoid (BCS) components. Start with the line connected to the intake pipe. Look on the bottom of the air intake just behind the MAF. You will see a small 6mm vacuum line going to the BCS on the left side of the airbox. Disconnect this line and cap it as shown below. With the port capped, remove the other end of the hose, and put it aside. Turn your attention back to the BCS on the airbox. There will be 2 lines connected still. Locate the one that is attached to the wastegate actuator on the turbo. Disconnect both ends of that hose.
You are now ready to begin installing your MBC. Remove the last line from the BCS and install it on the side of the MBC without the small breather hole. In the case of the Dawes controller, it's the straight side. Shown below is the manifold pressure line installed on the MBC with the stock clamp. I opted not to replace this line due to its difficult location. If your hose looks deteriorated, you should replace it.
On the other end of the controller, install enough vacuum line to reach the wastegate actuator. Secure the hose with a ziptie as shown below.
Partially close a ziptie on the hose that goes to the actuator. Then, connect the line to the actuator and secure it with the partially closed ziptie. Before you go out and test the new valve, it should be set. This can be done in one of two ways. One is with a hand pump hooked up to the straight side of the MBC. Keeping adding pressure until the valve opens and pressure will no longer build. That will give you a rough idea of your boost level. To adjust it, first loosen the 16mm jam nut on the controller. One turn shorter is one psi more. One turn taller is one psi less . Once you are happy with the boost level, you are ready for a test drive and some final adjusting. If you do not have access to a hand pump, the valve can be adjusted by using a calibrated boost gauge on a test drive. At full acceleration determine your boost level. If your desired boost level is exceeded, immediately let off the throttle, stop, and adjust the valve. If you do not have a hand pump or a calibrated boost gauge, this mod is not for you.
I mentioned in the beginning an alternate installation method. If you wish the ECU to retain some control, install the MBC in the middle of the stock BCS to Actuator line using vacuum T's. The downside , is that it does not control boost spikes as well.
If you opted for the first method of installation, you now have a BCS with nothing hooked up to it. This is nothing to worry about. As long as you leave the connector plugged in, the car will not know. If you disconnect it you will get a check engine light. If for whatever reason you wish to remove the BCS, a 40 ohm at 5 watt resistor will keep the check engine light off.