Product Name: | Compressed Gas Wastegate |
Product Description: | GenV Compressed Gas Wastegate |
Product Number: | TS-0552-1242
|
Important Notes on Your New Compressed Gas External Wastegate
- Turbosmart
accepts no responsibility whatsoever
for incorrect installation of this product which is potentially
hazardous and can cause serious engine damage or personal
injury
- The GenV external wastegate is designed for use with a turbocharger
that does not have an internal wastegate.
- Consult your local specialist before setting
your desired boost pressure,
setting boost beyond your
engines capability may result in engine damage.
- Use only high-quality fittings ensuring maximum sealing reliability.
Optional Turbosmart fitting kit available.
Recommendations
- Allow for
adequate cool airflow around the top diaphragm housing
- DO NOT Mount the wastegate so that the top diaphragm housing is less
than 100mm from a heat source
- DO NOT wrap the body of the wastegate with
exhaust wrap
- Fitting
your GenV wastegate may require fabrication or modification to your exhaust
manifold. Turbosmart recommends that your wastegate
is fitted by an appropriately qualified technician.
- Turbosmart
recommends that the engines Air/Fuel ratio is checked while setting the desired
boost pressure, as any increase in boost pressure can cause the engine to run “LEAN”, resulting in possible
engine damage.
- Turbosmart
recommends that boost pressure is set using
a dynamometer and not on public roads.
- Turbosmart
recommends that a boost gauge be permanently fitted to the vehicle.
Kit Contents
Part | Description | Use |
1 | Turbosmart GenV Wastegate | Main Unit |
2 | Valve Seat | Valve Seat |
3 | Inlet V-Band Clamp | Inlet V-Band clamp |
4 | Inlet Weld Flange | Inlet V-Band weld flange |
5 | Outlet V-Band Clamp | Outlet V-Band Clamp |
6 | Outlet Weld Flange | Outlet V-Band Weld Flange |
7 | Collar Tool | Adjusting actuator and changing springs |
8 | Spring Kit | 4 x Springs **(1x Spring pre installed)** |
9 | Fitting Kit | 2x 1/8” NPT Nipple, 1/8” NPT blanking plugs **(1x
pre-installed) |
10 | Turbosmart Sticker | Turbosmart Sticker |
- 3/8" square drive deep socket
- Square drive ratchet wrench
- Torque wrench (3/8" drive)
- Non-marking spanners to tighten fittings
- 3/16" hex key
- Supplied collar tool
- 14mm 12-point (double hex) socket
- Flat blade screwdriver
- Small hammer
SUGGESTED
LUBRICANTS AND SEALANTS
- Loctite 243 Thread locker
- Loctite 567 Thread Sealant
- Resbond 907TS Red
- Penetrating oil
Mounting your new Turbosmart Wastegate
The GenV
series of wastegate is a direct fit replacement for the 4th Gen wastegate
range and no modification is necessary provided packaging space is sufficient. The
weld flanges should be welded to your exhaust system. The weld
flanges are compatible with Stainless Steel
and Mild steel welding rod
material. For best results an attempt should be
made, if space allows, to mount
the GenV Wastegate at an angle to the
exhaust flow to allow for better flow than a 90 degree mounting. See
the schematic diagrams below for examples of mounting positions.
CAUTION! Do not place the actuator cap near a significant heat source as this could shorten the life of the diaphragm.
(Best Flow) Symmetric mounting allows an excellent flow of
exhaust to the Straight Gate
(Good Flow) Angle mounting allows a good flow of exhaust
flow to the Straight Gate.
(Poor Flow) 90 Degree mounting gives poor exhaust flow to
the Straight Gate and in some circumstances may contribute to over boosting.
Not Recommended - Less than 90 Degree Mounting. An angle mounting as shown in not recommended
and gives extremely
poor exhaust flow to the Straight Gate which can contribute
to poor boost control and over boosting.
Fitting the GenV Wastegate
Prior to mounting the Straight Gate, place
v-band over weld on flange by unscrewing the nut on the v-band as
far out as possible and then squeezing the bolt in a syringe motion to expand
the v-band (squeeze the dots together below). Once the v-band is in its fully
expanded position, slide the v-band over the flange to allow for the wastegate
to be installed.
Using the 3/8” deep socket and a torque wrench Tighten
the V-Band to 7N.m (5 ft/lbs). Ensure the wastegate is home correctly while
torquing the nut to not have a false torque as this will likely contribute to
exhaust leaks.
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 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 GenV wastegate is installed
and ready for use. Double check all fittings, lines and mountings then proceed to
start engine and check for leaks.
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’
Basic Wastegate Hook-Up
Basic Setup
If no boost
controller is being used connect the boost pressure source to
the “bottom” port as shown. The boost
only pressure source should be sourced
from as close to the compressor side of the
turbo as possible. The “top” ports of the wastegate should be left
open, It is possible in harsh environments to blank one port
and connect a hose to the other port that can be ran to a area
less likely to allow contamination into the actuator.
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.
Start Engine and check for leaks.
Congratulations,
your GenV wastegate is installed and ready for use. Double check all fittings,
lines and mountings then proceed to start engine and check for leaks.
The GenV wastegate has a variety of springs to suit different boost levels. Turbosmart provides the GenV wastegate pre-installed with your choice of either 7psi or 14psi springs depending on the part number. 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 Wastegate from Manifold
Remove
boost pressure source hose from the wastegate as well as the breather hose is
fitted. 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 GenV wastegate being careful not to
drop or lose the valve seat.
CAUTION! Allow engine to cool down before removing your GenV wastegate.
Remove Top Cap
Prior to
removing the GenV wastegate cap, remove all fittings from the
1/8”NPT ports. Press down with light to medium load on the cap in a
press or vice. Unscrew locking collar with the large end
of the provided collar tool in an anti-clockwise direction until completely
disengaged and slowly remove tension from the press or
vice allowing the spring to expand, finally remove cap when the
spring has stopped expanding.
CAUTION! Use soft jaws to prevent cosmetic damage
Configure wastegate with preferred spring combination of inner, middle and outer springs
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.
Reinstall
fittings to the cap of the wastegate using fresh Loctite 567 thread
sealant.
Reinstall
GenV Wastegate
Pace V-band
over weld on flange by unscrewing the nut on the V-band as
far out as possible and then squeezing the bolt in a syringe
motion to expand the V-band. Once the V-band is in its fully
expanded position, slide the v-band over the flange to allow for the
wastegate to be installed.
Do not
forget to put the valve seat into the body before mounting the unit on
the exhaust manifold. Using the 3/8” deep socket and a torque
wrench tighten the V-Band to 7N.m (5 ft/lbs).
Achieving Your Target Boost Pressure
There are
various factors involved in achieving your target boost pressure including.
- The size of
the spring fitted in your wastegate i.e. the boost pressure achieved by the
wastegate spring only.
- The desired
level of boost pressure and the difference between this and your wastegate
spring pressure.
- The size of
your turbocharger and wastegate and the resulting exhaust manifold back pressure in your system.
Turbosmart
recommends the ideal setup for achieving your target boost pressure is to use
the GenV Wastegate in conjunction with a
Turbosmart e-Boost controller.
IMPORTANT
NOTES ON SETTING THE WASTEGATE SPRING
PRESSURE A stiffer
spring should only be used when necessary. The GenV Wastegate allows for
different combinations of spring pressures. All springs
that are adaptable with the GenV Wastegate 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. If
this colour coding is not clear please use the dimensions
in the following table to identity the wastegate spring. Please see
the following detailed instructions on setting your GenV Wastegate’s spring
pressure. The springs chosen should be rated to
the lowest boost level desired.
How to Change Your GENV Wastegate Diaphragm
- 74mm (WG38,
WG40): TS-0550-3059
- 84mm (WG45,
WG50): TS-0550-3060
- 98mm
(WG60): TS-0550-3061
CAUTION! Ensure diaphragm is contained within the groove prior to cap re-assembly.
Pay
attention not to rotate diaphragm.
Remove
Wastegate from Manifold
Remove
boost pressure source hose from the wastegate as well as the
breather hose is 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 GenV wastegate
being careful not to lose the valve seat. Mark the orientation
of the valve to the body with tape or a paint pen.
CAUTION! Allow engine to cool down before removing your GenV wastegate.
Remove Top
Cap
Prior to
removing the GenV wastegate cap, remove all fittings from the
1/8”NPT ports. Press down on the cap in a press or vice. Unscrew
locking collar with the large end of the provided collar tool in
an anti-clockwise direction until completely disengaged and slowly
remove tension from the press or vice allowing the spring to
expand, finally remove cap when the spring has stopped
expanding.
CAUTION! Use soft jaws to prevent damage.
Diaphragm Replacement
Use
the supplied tool in the diaphragm replacement kit, engage the
diaphragm aligning the splines and grooves. Use a 25mm spanner on
the tool to prevent the diaphragm from spinning. Use a
12 point 14mm socket through the centre of this
tool onto the valve
retaining cap. Undo the valve retaining cap by
rotating anti clockwise.
Remove the
valve retaining cap and spring washer, Sit the wastegate
on down so that the valve is elevated and supported. Using a
small flat blade screwdriver to pry one edge of the split in
the valve circlip out and up, work your way around the circlip until it is
removed. Take note of the orientation of the diaphragm, lift the
old diaphragm over the valve and discard. Use this opportunity
to thoroughly clean the wastegate removing any dirt from the
actuator, ensure the diaphragm groove is free of debris and fit
your replacement diaphragm over the valve.
Sit the new
valve circlip on top of the valve ensuring it is concentric,
Use the valve retaining cap on top of the circlip to lightly
press the new circlip over the valve into place, Confirm the circlip is
located correctly in the circlip groove of the valve, adjust if
necessary. Let the valve drop down into the diaphragm, sit the new spring
washer onto the nipple of the valve with the outside of the
cone away from the valve. Apply a dab of
blue 243 Loctite to the
lower threads of the valve retaining cap and screw into the diaphragm.
Support the diaphragm with the supplied tool and tighten the
valve retaining cap to 20N.m (15ft/lbs)
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
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, 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.
Reinstall GenV wastegate
Place
v-band over weld on flange by unscrewing the nut on the v-band as
far out as possible and then squeezing the bolt in a syringe
motion to expand the v-band (squeeze the dots together below).
Once the v-band is in its fully expanded position, slide the v-band
over the flange to allow for the wastegate to be installed. Do not
forget to put the valve seat into the body before mounting the unit on
the exhaust manifold. Using the 3/8” deep socket and a torque
wrench Tighten the V-Band to 7N.m (5 ft/lbs).
Boost Control Hookup on the GENV Wastegate
WARNING! Changing your connection method can cause a higher than expected increase in boost pressure. Turbosmart recommends adjusting your boost controller back to its minimum setting and measuring the new minimum boost pressure achieved by the new setup before increasing your boost again.
IMPORTANT! Refer to your boost controller instructions for most suitable connection method to an external wastegate.
Boost Tee
Setup
When using
your GenV wastegate in conjunction with a Turbosmart Boost Tee, fit the controller
between the boost pressure source and
“bottom” port as shown. Ensure the
arrow on the Boost Tee is pointing towards the wastegate. The “top” ports of the wastegate should be
left open, It is possible in harsh environments to blank one port and connect a
hose to the other port that can be run into a area less
likely to allow contamination into the
actuator. Refer to the instructions supplied with your
Boost Tee for further detail if necessary.
e-Boost 2
Connection Methods
Turbosmart
recommends using the GenV Wastegate in conjunction
with the Turbosmart e-Boost. The first method of
installation is a one port
connection. If the desired boost level is not achieved i.e. boost level is too
low, or not controllable, it is recommended that the
wastegate spring be changed to a spring which
is closer to the desired boost pressure or to
trial a 2 port connection method. There are 3
different 2 port connection methods that can be trialled to achieve different
results. The 2 port method (1) can be used if there is
high exhaust manifold back pressure forcing the valve open. The 2 port method
(2) allows the user to achieve the maximum boost
pressure their turbo system is capable of. If a wide range of boost pressures
is desired i.e. 5 – 40 PSI, a 2
port connection with a 4 port
solenoid (sold separately – TS-0301-2003)
might be needed. All unused ports and vents must have
the pressure nipple installed
and a piece of silicon connected and routed to an area which is shielded from
dust and water.
Single Port
Connection
- Port 1 of
solenoid vent to atmosphere
- Port 2 of
solenoid to bottom port of wastegate
- Port 3 of
solenoid to Pressure only source
Two Port Connection method (1)
(For
controlling boost on a turbo system with high back pressure)
- Connect the
bottom port of the wastegate and Port 1 of the solenoid to a Pressure only
source
- Port 2 of
the solenoid to the top port of the wastegate
- Port 3 of
solenoid vent to atmosphere
Two Port
Connection method (2)
(For
obtaining maximum boost pressure on your turbo system)
- Port 1 of
solenoid to Top port of wastegate
- Port 2 of
solenoid to Pressure only source
- Port 3 of
solenoid to Bottom port of wastegate
Two Port
Connection method (3)
For
obtaining a wide range of boost pressures e.g. 5 – 40 PSI,
note that this method of boost control may not provide a
smooth boost curve)
- Port A of
solenoid to Top port of wastegate
- Port B of
solenoid to Bottom port of wastegate
- EX port of
solenoid vent to atmosphere
- IN port of
solenoid to Pressure only source
Compressed
Gas Connection Methods
For
obtaining a wide range of boost pressures with an external high-pressure source
for maximum boost.
- Port 1 of
Increase solenoid
A to
regulated compressed gas source
- Port 2 of
Increase solenoid
A to
Top port of Wastegate and Port 1 of Bleed Solenoid B
- Port 2 of
Bleed solenoid
B vent
to atmosphere
- Port 3 of
both solenoids plugged.
- Bottom Port
of wastegate to Boost pressure only source.
Advanced Features on the GENV Wastegate
Orientation of the Actuator
Turbosmart
provide the GenV wastegate with the actuator ports symmetrical
to the centreline of the body, in some applications it may be
advantages to clock the actuator to allow clearance for fittings
and hoses.
Locate the
slave collar between the actuator and the body underneath
the heat shield, A tab on the heat shield will be folded down into a
groove on this collar. Using a flat blade screwdriver, pry this
tab out of the groove allowing the collar to be loosened.
Using the
small end of the supplied collar tool undo the slave collar 1
complete revolution (anti-clockwise as viewed from the bottom).
One tab on the heatshield at the back of the wastegate is folded
up to locate on the actuator, rotate the actuator to desired
location ensuring the folded tab aligns with a groove in the bottom
of the actuator. It is possible to fold down this tab and use another
if the actuator cannot be positioned correctly on the original
tab.
CAUTION!
- Turbosmart does NOT recommend altering to position of the actuator once the wastegate has been used.
- It is recommended that the actuator be clocked without a valve seat installed to prevent twisting the diaphragm.
Tighten the
collar using a torque wrench on the 3/8” square drive provided
in the collar tool perpendicular to the
length of the tool to 25N.m
(18ft/lbs). Fold
down a tab onto the slave collar to prevent the
collar from coming loose during use.
Water
Cooling
Turbosmart’s GenV wastegate is equipped with water cooling ports to
keep the wastegate cool in the most extreme conditions and keep
consistent actuator temperature.
Identify
the water cooling ports on the bottom of the actuator adjacent to
the water cooling symbol engraved in the actuator. Port order
is not important and may be reversed.
Fit
water cooling port fittings Prior to mounting
the wastegate, install
1/8” NPT fittings
into the water ports, apply thread lubricant and
screw in clockwise until finger tight, then tighten
further 1-2 turns for
seal. Choose feed and drain source for the water and connect to
the wastegate. Turbosmart recommends -4 SAE fittings
and hose compatible with coolant.
CAUTION! Confirm water is only used on the water ports of the wastegate, damage to your engine may result in failure to correctly connect water cooling.
HOW TO
INSTALL A SENSOR CAP TO YOUR GENV WASTEGATE
CAUTION!
- Ensure diaphragm is contained within the groove prior to cap re-assembly.
- Pay attention not to rotate diaphragm.
- Cool air flow is required around the actuator to keep the sensor in its operating window.
Remove
Wastegate from Manifold
Remove
boost pressure source hose from the wastegate as well
as the breather hose is 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 GenV wastegate being careful not to lose the valve seat. Mark
the orientation of the valve to the body with tape or a paint
pen.
CAUTION! Allow engine to cool down before removing your GenV wastegate
Remove Top
Cap
Prior to
removing the GenV wastegate cap, remove all fittings from the
1/8”NPT ports. Press down on
the cap in a press or vice.
Unscrew locking collar with the large end of the provided collar tool
in an anti-clockwise direction until completely disengaged
and slowly remove tension from the press or vice allowing
the spring to expand, finally remove cap when the spring has
stopped expanding.
CAUTION! Use soft jaws to prevent damage.
Diaphragm
Replacement
Use the
supplied tool in the diaphragm replacement kit, engage the
diaphragm aligning the splines and grooves. Use a 25mm
spanner on the tool to prevent the diaphragm from spinning.
Use a 12point 14mm socket through the centre of this tool
onto the valve retaining cap. Undo the valve retaining nut.
Clear any
Loctite and debris from the thread in the diaphragm support,
Note careful not to get chemicals onto the diaphragm as this may
damage the diaphragm.
Sit the new
spring washer into the valve retaining cap with the centre of
the washer pointing out of the cap. Apply a dab of blue 243
Loctite to the lower threads of the valve retaining cap and screw
into the diaphragm. Support the diaphragm with the supplied
tool and tighten the valve retaining cap to 20N.m (15ft/lbs)
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.
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
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.
Reinstall fittings to the cap of the wastegate using fresh
Loctite 567 thread sealant.
Reinstall GenV Wastegate
Place V-band over weld on flange by unscrewing
the nut on the V-band as far out as possible and then squeezing the bolt in a
syringe motion to expand the V-band. Once the V-band is in its fully expanded
position, slide the v-band over the flange to allow for the wastegate to be
installed.
CAUTION! Do not forget to put the valve seat into the body before mounting the unit on the exhaust manifold. Using the 3/8” deep socket and a torque wrench tighten the V-Band to 7N.m (5 ft/lbs).
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 VOUT 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 product
family you have
*NOTE! For best
results, each wastegate should be calibrated to your
setup.
Troubleshooting
- Wastegate
not actuating - Confirm signal hose is plumbed to a pressure only source,
confirm preload on valve seat during installation
- Poor
wastegate actuation - Ensure signal hose is not shared and is sourced as close
to the compressor as possible, check seal on fittings
- Poor
wastegate actuation - Confirm Top ports are not blocked and free from debris
- Boost
creeping at high rpm - Wastegate flow path is poor, wastegate is too small for
the application
- 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.