E6Turbo and Intercooled engine installation / operation / maintenance suplement.

• The turbocharger waste gate and dump valve servo's should be mounted inside the airplane.  The push / pull cables are mounted through the firewall with the attached 2 nuts and lock washer in a location to reach the servos inside.  The length of the cables should not be a determination of where to place the servos.  Order the exact length you need and return the existing cables for a $30 credit each.  It is VERY important that these servos (and the ECU) are mounted so they are accessible for inspection and adjustment.   Behind the rudder pedals, or up on the inside firewall are not such places.  A universal location for all airplane models are the copilot right sidewall of the airplane. 
• Servo's are mounted to the floor, sidewall or tunnel side with small nut-plates or on a bracket.  Mount them side by side such that the wires will reach each other.
• The servo's are wired in parallel and should operate in separate directions when powered.  Test with a 12V battery.  The servos will stop by themselves at the end of it's travel and will move again in the opposite direction, if polarity is reversed.
• The positive wire on the dump valve servo will cause the servo to extend and close the dump valve, increasing the boost available to the engine.
• Positive on one wire of the exhaust waste gate servo should cause it to retract / pull on the cable.  This will increase the boost level of the engine
• After the servo's are installed, (if you need different length cables for your airplane, order them from Spruce part # A-1550 - specify your length) they should be in the cabin area of the aircraft.  The linkages should carefully be adjusted with the following criteria:  The cables should have gradual bends and operate smoothly. The adjustment should be made with the valves closed (pull on the turbo exhaust waste gate and push on the dump valve behind the engine)  Then tested with a 12V battery to verify that the servo can move its full travel without any binding.
• The waste gate servo has a slotted clevis at the turbo to make up for the fact that the servo travel is slightly more than the linkage.  Be 100% sure the servo is operating without strain / binding.
• This installation is left to the builder because we feel that the best place for the servo's is inside the cabin.  The installation is critical for safe and reliable operation of the boost control system.  With the parts installed correctly and wired to the boost controller, the system is very nice in operation, controlling the MAP accurately and smoothly as you climb / descend. 

ROUTING OF THE VERY IMPORTANT VACUUM HOSES:  There is one hose between the intake manifold and MAP sensor and a separate one for the fuel regulator, on the firewall side.  Leave the one for the MAP sensor alone. Then install a metal, 1/8 female firewall penetration fitting.  Install a brass street fitting on each side of the firewall, each with two 1/8 NPT to 1/8 barb fittings.  Run the hose for the fuel regulator to one barb on the firewall and the other one from the manifold.  Do the same on the inside, running one to the EIS MAP sensor and the other to the turbo controller.  The key is to install a metal firewall penetration and the proper fittings on each side to eliminate unsupported plastic T's in the hoses.  Use the braided silicone hose and small spring clamps everywhere.  You want your vacuum hoses to last the life of the engine since a leak here will seriously disturb the turbocharger boost controller. 

Follow the guide for the boost controller to wire the unit into your airplane.  Be sure to only use braided silicone vacuum tubing for long life to feed the MAP pressure to it and aircraft quality wiring of the servo's and controller.  You do not want to undermine the importance of these wires / hoses.

IMPORTANT NOTE:  If you have, or are installing an intercooler on your turbo engine (now mandatory), you need to relocate the induction temperature probe from the "dump valve" prior to the cooler, to a location after the cooler.  This way the temperature measured is in line with wat the engine is ingeting. 

Suggested intercooler shroud made from sheet metal
RV-7 INTERCOOLER

IMPORTANT NOTE:  If you have an intercooler, or are installing one, be sure the air temperature probe is relocated to a location somewhere between the exit of the intercooler, and the inlet to the engine.  This is nessesary in order for the probe to read the air temperature, after it has been cooled by the intercooler and prior to entering the engine intake manifold.  Some engines shipped had the intercooler added at the last minute and the probe was not relocated.  The intercooler scoop is from http://www.chassisshop.com/ and is part# C42-030

WHERE TO FIND FIREWALL PENETRATING VACUUM HOSE FITTINGS: 

It took a bit of searching but McMaster Carr has the following:   5483T92 Nickel-plated Miniature Threaded Pipe Fitting, 1/8" Npt  Bulkhead   -    44555K159 Brass Double-barbed Vacuum Tube Fitting, Branch Tee  For .17" Tube Id X 1/8" Nptf Male Pipe   -  44555K147 Brass Double-barbed Vacuum Tube Fitting, 90 Deg Elbow
For .17" Tube X 1/8" Nptf Male Pipe   -  Dennis Glaeser

ALLEN FULMER'S TURBO CONTROL SERVOS INSTALLATION
Cable will be 5 to 6 feet.  I thought they would fit right next to the rudder peddles but I think it is just too close and exposed an area.  Here they will be protected frominadvertent "kicking", etc. http://picasaweb.google.com/afulmer1/MountingTurboServos