Gen 4

Description:

The 1.8T BCS (Boost Control System) is designed to work with all throttle-by-wire Audi and Volkswagen 1.8T engines.  Compatible models include the A4, Beetle, Passat, Jetta, Golf and GTI.  The BCS provides user adjustability of maximum boost.  At the minimum setting, the boost is held to the stock level of 6 PSI and the car will drive exactly like a stock car.  As the boost setting is increased, the allowable boost is increased in precise increments.  At the maximum setting, the boost is allowed to reach 14.5 PSI. This boost increases horsepower by 30 hp and the low-end torque is increased by 45 ft-lbs.

The BCS includes a ten segment, three color LED boost gauge that reads in 1.5 PSI increments from 1 to 14.5 PSI.   The display is electronically filtered to provide a smooth reading.

The BCS offers an alternative to aftermarket re-programming of the ECU.  With the BCS, the stock ECU programming is maintained.  This helps to preserve smooth and predictable drivability.

The BCS is easy to install.  Its small size makes it easy to fit in the center console.  The six wires leading from the BCS are all connected to the car’s wiring harness at one location.

Features:

	Maximum boost adjustable from the driver's seat
	Maintains stock ECU programming
	Boost gauge reads manifold pressure from 1 to 14.5 PSI in 1.5 PSI steps
	Low cost
	Miniature size
	Easy to install

Example Wiring Diagram:

These connections are for the Passat.  Detailed instructions for all 1.8T models are included with each unit.

All wire connections are made to the wiring harness near the engine computer.  The wires are identified by color code and ECU connector location.

Connections:

All connections are T-taps except the GRAY/BLUE and YELLOW/WHITE wires.  Those wires are cut.  Each side of the cut wires are connected to wires on the BCS wire harness.

Adjustment Procedure:

The 1.8T BCS has a rear panel adjustment that is used to fine tune the calibration for the specific model and engine code of your car.  If the setting is too high or too low, your car will not make full power.   After completing the installation of the BCS, the rear panel calibration can be set on a short test drive.  Begin with the setting on maximum (100).  If your car does not pull strongly all the way to redline, reduce the setting until it does.  If you experience surging (a cyclic variation in power) reduce the calibration setting a little bit.

Troubleshooting Guide:

The following chart can be used to troubleshoot installation problems with the 1.8T BCS.  VDC indicates the voltages that should be measured with respect to chassis ground.  By making the measurements on the BCS wires with a piercing probe you can be sure that the wire is connected to the right place and that the connection is good.

Display Characteristics:

Mechanical Characteristics:

(dimensions in inches)