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100 bhp per Litre







Updated:
24 April 2007



First, a little background on MAP Sensors and Speed/Density ECU's

The Chrysler "MAP" or Manifold Absolute Pressure sensor generates a variable signal voltage proportional to manifold (absolute) pressure, (not a variable frequency signal). The typical signal voltage of such a MAP sensor, generates ranges 0.5 volt DC at lowest pressure (vacuum) to just under 4.9 vDC at maximum (boost) pressures.  In the Mopar Speed/Density-based ECU system, the MAP sensor provides critical information used to determine air density, which in turn can determine the correct Air/Fuel ratio. Understanding its interaction with the ECU will be one focus of our performance modifications.

The MAP sensor is produced in various vacuum/pressure ranges, depending on the intended engine application. The 3-Bar MAP sensor can measure boost levels up to 29 PSI and replaces the standard Mopar Turbo I/II 2-bar MAP (14.5 PSI) sensor. The stock Normally Asphyxiated TBI uses a 1-bar MAP for its required range of 30 - 0 inches Hg vacuum. Tthe chart below may be helpful :

Map Sensor Vacuum  Boost (Pressure) Engine Application
1-Bar 30 - 0 in Hg 0 (NA)
2.2/2.5 TBI/NA
2-Bar 30 - 0 in Hg 0 - 14.5 psi
2.2/2.5
Turbo I/II/III/IV

(boost levels below 14.5 psi)
3-Bar 30 - 0 in Hg 0 - 29.0 psi
Typically used with Custom ECM calibrations

(boost levels up to 29 psi)


Hitting the Wall: Over-boost = Fuel Cut-Out

Regardless of whether 1, 2 or 3-Bar MAP sensors are used, each range of MAP sensor still generates a signal between 0.5 to 4.9 vDC, depending on engine load. On a stock Chrysler 1990-91 TURBO I SBEC the ECM monitors the 2-BAR MAP voltage for over-boost (fuel cut-out) shutdown.  Safe, rapid, engine shutdown automagically occurs (via the ASD/Fuel Pump relay) whenever manifold boost pressure exceeds the factory-programmed set point within the SBEC.

This occurs roughly somewhere around 4.74 vDC (MAP sensor signal output) or approximately 12 - 14 psi relative manifold pressure (Mopar factory calibrations vary by year and turbo/drivetrain configuration). 

If you have bypassed the ECM wastegate control and you actually "hit the wall" it can be a little surprising. It's not like bouncing the spark when you hit the rev limiter, for hitting the over-boost wall actually shuts down everything and leaves it down, until you restart the engine. For the Average Joe, this is a good thing, as it would prevent a  closed wastegate failure from destroying the engine. Remember, the stock fuel injection and ECM will lean out at anything above 14.7 psi, don't defeat the shutdown feature without having CAREFULLY read the fuel section.

The Solution: "Fuel-Cutout" Defense

But you aren't the Average Joe, and you've taken care to feed enough high octane fuel at higher boost levels, right? So how do solve the overboost, fuel-cut dilema? They go by different names, such as fuel-cut defender, cut-out raiser, cut-out bleed, boost-cruncher, but they all server the same purpose:

Name Type  Comments Relative Cost Weblink
Zener Diode  MAP electrical connector Fixed-value, Zener Diode clamps 2-Bar MAP; signal totally defeating cutout Dirt Cheap
DIY project

Dodgegarage.com:
How to
MAP Bleed Valve Mechanical valve in MAP vacuum line Adjustable, typically under hood Gus Mahon's brilliant low-buck "Cut-Out Raiser" solution
Dawes Devices

Cut-Out Eliminator
Boost-Cruncher In Car and underhood electrical connection at MAP Adjustable, electronic clamp, with
three indicator LED's. Typically mounted inside car.
mid-priced solution
Forward Motion

by
Carroll Supercharging
Boost Cruncher
Fuel Cut Defender

(FCD)

In Car and underhood electrical connection at MAP Adjustable, electronic clamp, with
IN (SAFETY)/OUT (DEFEAT) Switch and two indicator LED's. Typically mounted inside car.
mid-priced solution TurboXS
"FCD"
Fuel Cut Defender
3-Bar MAP
with Custom Calibrations
typically
under hood
Typically installed as part of total upgrade package (see below) Most expensive
FWD Performance

 

Zener Diode Mod to MAP sensor signal

A very inexpensive (unless you don't increase fuel flow) way to defeat the over-boost shutdown is to use a fixed-value 4.7 vDC Zener Diode (a buck or so at any local Radio Shack). When properly wired to your 2-Bar MAP sensor, this will effectively 'hold' the MAP signal below overboost shutdown defeating the cut-out, regardless of how high actual boost levels increase.  Gary Donovan's TheDodgeGarage.com shows you how to install the Zener Diode.

MAP Bleed Valve, a.k.a. the "Cut-out Raiser"

The late Gus Mahon introduced us to the adjustable mechanical MAP Bleed valve in his "Cut-out Raiser", which Darren Dawes now offers Gus Mahon's "Cut-out Raiser" as the "Cut-Out Eliminator," at a reasonable price.

Boost Cruncher (BC)

Another way to "hold" or "clamp" the MAP output is to get a Boost-Cruncher from  Forward Motion. Developed by Carroll Supercharging the Boost-Cruncher,  works on the same principle as the fixed-value Zener Diode put permits remote mounting, say within your glove box or on your console. More importantly, since it is user-adjustable within a 2.5 to 4.9 vDC range, the "BC" provides more flexibility for retaining over-boost safety-shutdown, but now at desired higher boost levels. "BC" is compatible with 1, 2, or 3-bar MAP sensors. It also provides a yellow LED indicator to show when it's "clamping" threshold has been reached.

Fuel Cut Defender (FCD)

The Fuel Cut Defender, from TurboXS (better known for their well-made Blow Off (compressor bypass or dump) Valves and mechanical Boost Controllers) is conceptually identical to the Boost-Cruncher (above). It does feature a handy switch that permits the unit to be IN or OUT of operation.

Custom ECM Calibrations using 2-bar or 3-Bar MAP sensors

Mopar Performance, FWD Performance and Turbos Unleashed all offer reprogrammed ECU's or custom calibrations. First popularized by Mopar Performance in their Super 60 Kit, these custom calibration ECU's achieve higher than 2-bar ECM (wastegate) controller boost levels without resorting to 4.7 vDC zener diodes or adjustable bleed valves to "trick" the ECU. These can be relatively expensive, but they are designed to be installed as a comprehensive upgrade package that typically include: an intercooler, larger fuel injectors (with adequate fuel pump),  larger turbo, and larger exhaust. Reprogramming the ECU permits modification of engine management functions like: over-boost cutout, wastegate solenoid control, spark advance and air/fuel tables, and various temp sensors.  But frequently, upgrading to a +15 psi custom calibration  will require upgrading the MAP sensor from a 2-Bar to a 3-Bar unit.

 Next --->   How to: Install a 3-Bar MAP