As with everything, read the instructions that come with it. They are pretty clear. See also my notes in another post written yesterday on Bypass valve small points (+ a boom theory!).
And a change in Intercooler will not change your BOV noise significantly, as noise is a function of the amount of air that is being discharged, which is in turn a function of your boost setting and any improvements you might have made in airflow through your induction system. That said, an FMIC setup holds a lot more air in the long plumbing so may prove a bit louder than a TMIC as all the air under pressure tries to find a fast way out. The Turbosmart should be set up on 50:50 or 100% Bypass. Do not set it to 100% VTA unless you want to set up a fuel cut which you won't be able to do without a tuneable ECU. You will get catastrophic backfires and wash all your lube off the cylinder walls with unburnt fuel, and soot up your cats faster than you can say "Meow".
The cap is 6 turns from fully closed out to fully open at the red or black indicator line on the BOV body, under the bottom edge of the cap. Start with it screwed fully in but do not tighten it hard, then unscrew 6 turns only to fully out until you just see the indicator line under the cap lower rim, then turn it in one full turn and start from there, pretty much as VICTA suggests as above. However, I doubt very much that you will need to or should screw it all the way in, as that is far too tight and you will be likely to stall your turbo as the pressure will not be dumped - or not dumped sufficiently.
I run mine on 100% bypass and set to fully out as I need to push all my air back the other way to keep my turbo spinning on throttle lift-off. I don't need to hear a BOV "chuff" noise. It just attracts attention. I get very few backfires. Your settings are unlikely to be the same, however, as I run different boost, exhaust, intercooler and plumbing, but I mention it to show that a full range of adjustments can be experienced, depending on specific setups.
And please fix that dreadful exhaust setup of yours before the cops yellow-sticker you - with good reason!! It has nothing good about it and everything bad.
Last edited by Doug_MPS6; 31-08-2011 at 12:27 PM.
CP_e Standback & PNP; CP_e 3" SS Downpipe; Corksport FMIC with Top-mount K&N filter & OEM Ram CAI; Turbosmart BOV;Dashhawk;Prosport Boost Guage;Sumitomo HTRZIII's in 225/45 x 18