Fit Actuator Port Fittings

Fit lower chamber port fittings prior to mounting the wastegate, install 1/8” NPT blank with 3/16” hex key and signal nipple from boost pressure source into lower chamber ports. Port order or orientation is not important, select which suits your packaging requirements. Apply thread lubricant and screw in clockwise until finger tight, then tighten further 1-2 turns for seal. Congratulations, your straight gate is installed and ready for use. Double check all fittings, lines and mountings then proceed to start engine and check for leaks.  See Compressed Gas Wastegate Hookup for further information on hookup.  

NOTE! If you are unsure which port to install fittings into, please refer to ‘Boost Control Hookup’ section, refer to table of contents for page number.   

CAUTION!  Do NOT insert fittings and blank into Top Ports unless advanced boost control methods are to be used as this can affect the performance of the product. See ‘Boost Control Hookup’  

Clocking Actuator

The Actuator can be removed and rotated to three different orientations, each spaced 120 degrees apart. It is secured to the body using three M5 Allen bolts, which must be removed to adjust the orientation. Additionally, a snap ring may need to be removed - ensure this is done carefully to avoid losing the ring. Once the bolts and snap ring are removed, the actuator can be rotated to any of the three positions before reassembly. 

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Compressed Gas Wastegate Hook-Up

Compressed Gas Setup

A boost controller system is required for CO2 Boost Control. The "bottom" port is hooked up to the pressure reference from the turbocharger.  

The Plumbing is as follows

Increase Solenoid

1. Port 1 (Regulated CO2 Supply)
   
2. Port 2 (CO2 "Top Cap")
   
3. Port 3 (Blocked)

Decrease Solenoid

1. Port 1 (CO2 "Top Cap")
2. Port 2 (Vent to Atmosphere)
   
3. Port 3 (Blocked)
   

Although orientation isn't important. The Top Cap requires a Dome Pressure sensor to control the pressure in the "Top Cap".

CAUTION!Do NOT source signal from the intake manifold as this is subject to vacuum and pressure losses across the system and could over-speed the turbocharger.  

Integrated Solenoid Gas Setup 

An Integrated Solenoid Cap is available as a CO2 option. Ports A and B are interchangeable, provided the port and its corresponding solenoid remain paired. For example, Port A must always be used with Solenoid A, and the same applies to Port B and Solenoid B.

Increase Solenoid

1. Port A (Regulated CO2 Supply)
   
2. Solenoid A

Decrease Solenoid

1. Port B (Vent to Atmosphere)
   
2. Solenoid B 
   

Wiring Hookup

The solenoids require a 12V Supply as well as two digitally pulsed outputs from your ECU or Boost Controller. The 12V can be common and can be fused if required. The digitally pulsed output must be run two seperate inputs in the ECU, ensuring that they are correctly labeled as the correct output before running. Polarity isn't important on the solenoid.  

Start Engine and check for leaks.

Congratulations, your CO2 Straight Gate is installed and ready for use. Double check all fittings, lines and mountings then proceed to start engine and check for leaks. 

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HOW TO CHANGE YOUR COMPRESSED GAS SPRING      

The compressed gas straight gate has a variety of springs to suit different boost levels. Turbosmart provides the compressed gas straight gate pre-installed with a 7psi spring. With your wastegate four springs will be provided, 3psi inner, 5psi inner, 7psi middle and 14psi outer. Different spring combinations may be required to suit different boost requirements and tuning.  

Remove Compressed Gas Straight Gate from Manifold

Remove associated plumbing and electrical connectors from the straight gate. Unscrew outlet V-band nut in an anti-clockwise direction to the very end of the thread, squeeze the nut against the V-band in a syringe like motion to expand the V-band over the flange. Repeat for inlet V-band. Remove straight gate.

CAUTION! Allow engine to cool down before removing your compressed gas straight gate. 

Remove Top Cap

CAUTION! Use soft jaws to prevent cosmetic damage

Familiarise Yourself with Cap and Body Notches  

Locate cap and body notches and grooves which dictate the alignment of the cap. These notches are used to locate the cap onto the body and must be aligned prior to compression of the cap onto the body.

CAUTION! Ensure notches are aligned and seated home correctly prior to exerting force to tighten collar, permanent damage will occur if these are not aligned correctly.   

Press Cap onto Body

Using a press or vice, comp the notches are remaining aligned. Once the cap has seated home onto the body, screw the collar down by hand in a clockwise direction. While still in the press or vice, Tighten the collar further with the collar tool until the collar will not turn.  

CAUTION! Maintain downward pressure on cap while tightening collar or non-repairable thread damage will occur.  

Achieving Your Target Boost Pressure

There are various factors involved in achieving your target boost pressure including.  

1. The size of the spring fitted in your wastegate i.e. the boost pressure achieved by the wastegate spring only.  
   
2. The desired level of boost pressure and the difference between this and your wastegate spring pressure. 
3. The size of your turbocharger and wastegate and the resulting exhaust manifold back pressure in your system.
   
4. The amount of dome pressure that is fed into the top cap.

IMPORTANT NOTES ON SETTING THE WASTEGATE SPRING PRESSURE  

A stiffer spring should only be used when necessary. The Compressed Gas Straight Gate different combinations of spring pressures. All springs that are adaptable with the GenV IWG (These are the same springs) are shown in the table below. The tuner can use combinations of up to 3 springs to achieve the following base boost pressures. To aid in the identification of these springs they are supplied colour coded.  The springs chosen should be rated to the lowest boost level desired.  

How to Change Your Straight Gate Wastegate Diaphragm 

Remove Actuator from Body 

Remove fittings from the wastegate as well as the breather hose if fitted. Unscrew outlet V-Band nut in a anti-clockwise direction to the very end of the thread, Squeeze the nut against the V-Band in a syringe like motion to expand the V-band over the flange. Repeat for inlet V-Band. Remove straight gate. Mark the orientation of the valve to the body with tape or a paint pen.  

CAUTION! Allow engine to cool down before removing your straight gate.  

Diaphragm Replacement

The actuator must be removed for ease of disassembly of the diaphragm replacement. The once removed the top cap can come off and the diaphragm can be swapped out. 

Align the valve orientation marks and confirm the diaphragm bead is seated in the groove of the actuator. Install desired spring combination. Configure Wastegate with preferred spring combination of inner, middle and outer springs  

Locate cap and body notches and grooves which dictate the alignment of the cap. These notches are used to locate the cap onto the body and must be aligned prior to compression of the cap onto the body.

CAUTION! Ensure notches are aligned and seated home correctly prior to exerting force to tighten collar, permanent damage will occur if these are not aligned correctly.  

Using a press or vice, compress the cap onto the body ensuring the notches are remaining aligned. Once the cap has seated home onto the bod, screw the collar down by hand in a clockwise direction. While still in the press or vice, Tighten the collar further with the collar tool until the collar will not turn.  

CAUTION! Maintain downward pressure on cap while tightening collar or non-repairable thread damage will occur.  

Reinstall fittings to the cap of the wastegate using fresh sealant.  

HOW TO INSTALL A SENSOR CAP TO YOUR COMPRESSED GAS STRAIGHTGATE

The Compressed Gas Straight Gate comes with a pre-installed magnet on the diaphragm, essential for HE sensor operation. To install the sensor (sold separately), simply remove the top blanking plate and fit the HE sensor in its place. Calibration may be required depending on your system.

CAUTION! Allow engine to cool down before fitting sensor cap

Connect the wires to your data logger accordingly. Use a high-quality connection to reduce noise and calibration fluctuation.

CAUTION! Ensure that the wiring is properly shielded from external heat sources.

To ensure longevity from the sensor, ensure adequate airflow is supplied directly to the sensor to avoid overheating or sensor failure.

Turbosmart HE sensor has an operation temperature window of -40C up to 170ºC (340ºF) junction temperature, for temperatures outside of this window the V_OUT will revert to less than 2.5V

Temperature exposure above 260ºC (500ºF) can cause permanent damage to the sensor.

Calibration*  

Insert the relevant calibration curve into your data logger for the Compressed Gas Straight Gate

1. Wastegate not actuating - Confirm signal hose is plumbed to a pressure only source, confirm preload on valve seat during installation 
   
2. Poor wastegate actuation - Ensure signal hose is not shared and is sourced as close to the compressor as possible, check seal on fittings 
   
3. Poor wastegate actuation - Confirm Top ports are not blocked and free from debris 
   
4. Boost creeping at high rpm - Wastegate flow path is poor, wastegate is too small for the application 
   
5. Failing the above, submit a Technical Request Form with information about your engine, oil type and photos of the installation and one our expert technicians will respond as soon as possible.