Product Name:	GenV IWG (Twin Port) Wastegate Actuator
Product Description:	GenV IWG (Twin Port) Wastegate Actuator Suit Garrett G25 14 Psi
Product Number:	TS-0625-3143

Important Notes on Your Internal Wastegate Actuator

1. Turbosmart accepts no responsibility whatsoever for incorrect installation of this product which is potentially hazardous and can cause serious engine damage or personal injury.
   
2. Consult your local specialist before setting your desired boost pressure, setting boost beyond your engines capability may result in engine damage.
   
3. Use only high-quality fittings ensuring maximum sealing reliability. Optional Turbosmart Fitting kit available.
   

Recommendations

1. Allow for adequate cool airflow around the diaphragm housing
   
2. DO NOT Mount the wastegate so that the top diaphragm housing is less than 100mm from a heat source
   
3. Turbosmart recommends that your wastegate is fitted by an appropriately qualified technician.
   
4. 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.
   
5. Turbosmart recommends that boost pressure is set using a dynamometer and not on public roads.
   
6. Turbosmart recommends that a boost gauge be permanently fitted to the vehicle.
   

Kit Contents

Tools Required

1. 10mm open end spanner
   
2. Square drive ratchet wrench
   
3. Torque wrench (3/8” drive)
   
4. Non-marking spanners to tighten fittings
   
5. 3/16” hex key
   
6. Turbosmart IWG collar tool
   

Suggested Sealants

1. Loctite 243 Thread Locker
   
2. Loctite 567 Thread Sealant
   

Fitting Your GENV Wastegate

Mounting your New Turbosmart Gen V IWG Wastegate

Slide the actuator head through the turbocharger mounting bracket, be sure the ball joint assembly has been removed form the actuator canister otherwise the unit cannot be assembled onto the bracket. Once mounted on the bracket, secure nuts to hold actuator in place, be sure at this point to determine the orientation of the actuator as it can be flipped 180º on the actuator bracket to allow for fitting clearance, or aligning the actuator to your liking without need to disassemble the actuator.

CAUTION! Ensure nuts are tightened. 

Install Actuator through bracket.

Install the ball joint

Applying Actuator Preload / Ensuring Wastegate Flap is Close

CAUTION! This step is important!

Start Engine and Check for Leaks

How to Change Your GENV Wastegate Spring

1. Remove Wastegate From Turbocharger
   
2. Remove boost pressure source hose from the wastegate
   
3. Remove preload from wastegate by undoing preload nuts
   
4. Remove ball joint locking nut
   
5. Remove rod from actuator and turbo assembly
   
6. Remove ball joint assembly
   
7. Remove wastegate actuator from bracket

CAUTION! Allow engine to cool down before removing your GenV wastegate.

Remove Top Cap

CAUTION! Use soft jaws to prevent cosmetic damage.  

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.

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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 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 Gen V Wastegate

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How to Use A Sensor Cap On Your GENV Wastegate 

Wiring

Your new Turbosmart sensor cap comes with sensor pre-installed into the cap with unterminated wires for you to fit the connector of your choice.

Wire	Note	Rating
Red	Sensor Supply (Vsup)	4.5-5.5 Vdc
Black	Sensor Ground (V0)	0V
White	Sensor Output (Vout)	0-Vsupply

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

Rod Travel (mm)	VOUT
0	0.439
2	1.21
4	1.58
6	1.84
8	2
10	2.13
12	2.21
14	2.27
16	2.32
18	2.36

NOTE! For best results, each wastegate should be calibrated to your setup.

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TroubleShooting

1. Wastegate not actuating - Confirm signal hose is plumbed to a pressure only source, confirm preload 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 no obstructions in actuator rod path.
4. Boost creeping at high rpm - Wastegate flow path is poor, wastegate is too small for the application, ensure ball joint is not seized
5. Failing the above, submit a Technical Support Query Form with information about your engine, oil type and photos of the installation and one our expert technicians will respond as soon as possible.