ALV40 Anti Lag Valve Instructions

Product Name:

Gen V ALV Valve

Gen V Antilag Valve

TS-055X-14XX

V1.00 Rev A

Product Description:

Product Number:

Document Version:

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IMPORTANT NOTES ON YOUR ANTILAG VALVE

-

Turbosmart accepts no responsibility whatsoever for incorrect installation of this product which is potentially hazardous and can cause serious

engine damage or personal injury.

-

Antilag produces excessive heat in the exhaust system and may shorten the life of your exhaust manifold and turbo

Consult your local specialist before setting your setting your antilag valve, setting antilag levels beyond your engines capability may result in

engine or turbo damage.

-

Use only high-quality fittings ensuring maximum sealing reliability. Optional Turbosmart fitting kit available.

Turbosmart’s ALV valve is recommended for race applications only.

RECOMMENDATIONS

-

Allow for adequate cool airflow around the top diaphragm housing

DO NOT Mount the ALV so that the top diaphragm housing is less than 100mm from a heat source

DO NOT wrap the body of the ALV with exhaust wrap

Fitting your Gen V ALV may require fabrication or modification to your exhaust manifold. Turbosmart recommends that your ALV is

fitted by an appropriately qualified technician.

-

Fitting the ALV to your turbocharger system introduces fresh air into the exhaust system post engine and therefore air fuel ratios will show as

lean.

-

Turbosmart recommends that antilag settings are set using a dynamometer and not on public roads.

Turbosmart recommends that a boost gauge be permanently fitted to the vehicle.

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KIT CONTENTS

Please check that the following items have been provided in your Gen V ALV kit.

Part

1

Description

Turbosmart Gen V ALV

Valve seat

Use

Main unit

2

Valve seat

3

Inlet V-band clamp

Inlet hose adapter

Outlet V-band clamp

Inlet weld flange

Collar tool

Inlet V-band clamp

Inlet Hose adapter

Outlet V-band clamp

Inlet V-band weld flange

4

5

6

7

Adjusting actuator and changing springs

2x 1/8” NPT nipple, 2x 1/8” NPT blanking plugs **(1x pre-installed) **

O-Ring seal for inlet

8

Fitting kit

9

Inlet O-ring

1

0

Turbosmart sticker

1

5

3

6

7

4

9

2

8

Figure 1 - Kit Contents

Important Note: The outlet weld flange is sold separately, purchase accordingly, see page 3.

1

CONTENTS

KIT CONTENTS................................................................................................................................................................ 1

TOOLS REQUIRED .......................................................................................................................................................... 2

SUGGESTED SEALANTS................................................................................................................................................ 2

GEN V ALV OVERVIEW ................................................................................................................................................... 3

FITTING YOUR GEN V ALV............................................................................................................................................. 3

Control Hookup ............................................................................................................................................................. 5

Vacuum Pump............................................................................................................................................................... 6

Compressor................................................................................................................................................................... 7

Tuning Strategies .............................................................................................................................................................. 8

HOW TO CHANGE YOUR GEN V ALV SPRING.............................................................Error! Bookmark not defined.

HOW TO CHANGE YOUR GEN V ALV DIAPHRAGM..................................................................................................... 8

-

----------------------------------------------------------------------------------------------------------........................................................ 11

HOW TO INSTALL A SENSOR CAP TO YOUR GEN V ALV ........................................................................................ 11

TROUBLE SHOOTING ................................................................................................................................................... 14

TOOLS REQUIRED

-

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 SEALANTS

-

Loctite 243 Thread locker

Loctite 567 Thread Sealant

Penetrating oil

2

GEN V ALV OVERVIEW

“Top” Port

1/8” NPT

Master Collar

“Bottom” Port

1/8” NPT

Inlet V-Band

Inlet Weld Flange

Outlet V-Band

Outlet Weld flange

(Sold separately)

Figure 2 – Gen V ALV Overview

GEN V ALV Accessories

TS-0550-3098 ALS 4-1 Weld flange (for 4 cylinder/V8/4 outlet pipes)

TS-0550-3099 ALS 3-1 Weld flange (for 3 cylinder/V6/3 outlet pipes)

TS-0550-3100 ALS 2-1 Weld flange (for 2 cylinder/2 outlet pipes)

TS-0505-3001 WG40 Inlet Weld Flange (for single outlet)

TS-0550-3101 Inlet Weld Flange AL

TS-0550-3102 Inlet pipe adapter 1-3/4" OD

TS-0550-3103 Inlet pipe adapter 1-1/2" OD

TS-0552-3001 WG40 Valve Seat

TS-0552-3003 WG40 Inlet/WG45 Outlet V-Band

TS-0552-3004 WG40 Outlet V-Band

TS-0550-3062 WG38/40 CG Sensor Cap Black

TS-0550-3063 WG38/40 CG Sensor Cap Blue

TS-0550-3057 HE Sensor Replacement

TS-0550-3076 WG40 weld purge bung

TS-0550-3080 V-Band Replacement Nut - 2 Pack

TS-0550-3059 WG38/40 CG Diaphragm Replacement kit

TS-0550-3009 WG38/40 Actuator Collar

TS-0550-3093 WG Diaphragm replacement tool

FITTING YOUR GEN V ALV

3

ALV

Mounting your New Turbosmart Gen V ALV

(Anti Lag Valve)

1

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 tubes should be plumbed into the turbo manifold

as close to the exhaust port of the engine for maximum efficiency.

Turbosmart Weld flanges are designed to accept 19mm (3/4”)

tube, large diameter tubes with the least amount of restriction will

achieve a higher amount of usable energy in the manifold.

Turbo pressure

source

Turbo

CAUTION!

Do not place the actuator cap near a significant heat source

as this could shorten the life of the diaphragm.

CAUTION!

Turbo

Compressor

housing

Use of the Antilag valve produces excessive heat in the

exhaust manifold and turbo and may result in shorter than

expected life.

ALV

Fitting the Gen V ALV

2

Prior to mounting the Gen V ALV, 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 ALV to be installed.

ALV

Runners

Control

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). Ensure

the Anti Lag Valve is home correctly while torqueing the nut to

not have a false torque as this will likely contribute to exhaust

leaks. Ensure O-Ring is in place on the inlet compressed air side

of the valve.

Turbo

Flange

Plumbing the antilag valve into the exhaust port maximises the

thermal energy from the exhaust to increase the flame front with

fresh air and unburnt fuel.

Connect the inlet of the ALV to the charge intercooler piping pre-

throttle body, having the pipe and attached at and angle in the

direction of flow may help the efficiency of the system.

4

Fit Actuator Port Fittings

3

Fit lower Top and Bottom port fittings prior to mounting the ALV,

install 1/8” NPT blank with 3/16” hex key and signal nipple into

opposite side 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.

NOTE!

If you are unsure which port to install fittings into, please

refer to ‘Control Hookup’ section, refer to table of contents

for page number.

Control Hookup

4

Depending in the control strategy of the antilag valve, the

hook-up method may vary, below is a couple of examples

but is not limited to.

WARNING!

Antilag results in a reduction of vacuum produced which

affects the effectiveness of vacuum assist brake boosters.

IMPORTANT!

Antilag requires advanced tuning techniques and specific

controls, Turbosmart recommends this system be setup by

professionals only.

5

Vacuum Pump

4.1

When using your Gen V Anti Lag Valve in conjunction with a vacuum pump, fit a 4-port solenoid (sold separately – TS-0301-2003)

with normally open ports to the bottom port of the solenoid to the bottom port of the valve. Plumb the top port to the switched port A

of the solenoid to activate the valve. Your ECU should be configured to open the valve when ALS operation is desired.

•

Port A of solenoid to Top port of ALV

Port B of solenoid to Bottom port of ALV

EX port of solenoid vent to atmosphere

IN port of solenoid to Pressure only source

4

port

Port A of solenoid to

Top Port

Solenoid

EX Port of solenoid

vent to atmosphere

IN port of Solenoid

Vacuum only

source to

Gen V Anti Lag

Valve

Port B of solenoid to

Bottom Port

ALS Manifold

6

Compressor

4.2

When using your Gen V Anti Lag Valve in conjunction with a air compressor, fit a 4-port solenoid (sold separately – TS-0301-2003)

with normally open port B to the Top port of the solenoid to the Bottom port of the valve. Plumb the Bottom port to the switched port

A of the solenoid to activate the valve. Your ECU should be configured to open the valve when ALS operation is desired.

•

Port A of solenoid to Bottom port of ALV

Port B of solenoid to Top port of ALV

EX port of solenoid vent to atmosphere

IN port of solenoid to Pressure only source

4

port

Port A of solenoid to

Bottom Port

Solenoid

EX Port of solenoid

vent to atmosphere

IN port of Solenoid

Compressor

pressure only

source

Gen V Anti Lag

Valve

Port B of solenoid to

Top Port

ALS Manifold

Start Engine and Check for Leaks

5

Congratulations, your Gen V ALV is installed and ready for use. Double check all fittings, lines and mountings then proceed to start

engine and check for leaks.

7

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Tuning Strategies

CAUTION!

-

Tuning your antilag valve should be done by a professional

Antilag valve is for race applications only

The use of antilag creates excessive heat in the exhaust manifold and can shorten the life of turbo, exhaust manifold and related

systems

Activation and Shut Down

Tuning

1

2

Criteria should be established within the ECU to control the

antilag valve, a minimum throttle percentage and delay to arm

the system with arming achieved when throttle is released with

an active time limit set.

Each engine and set up will require different parameters to

achieve the desired results. Typically, a combination of ignition

retard, ignition cut, and fuel trim can be used to increase and

decrease the effectiveness of the system

It is a good idea to have limits set up to shut down the antilag

system if too much heat is being produced. Exhaust temperature

sensors and engine temp should be monitored and allowed to

deactivate the system if bordering dangerous levels.

Outputs should be set up to open and close the valve when

enabled.

NOTE!

For best results any bypass valves in the system should be

forced closed when in enabled.

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HOW TO CHANGE YOUR GEN V ALV DIAPHRAGM

Gen V ALV replacement diaphragm kit:

ALV : TS-0550-3059

CAUTION!

-

Ensure diaphragm is contained within the groove prior to cap re-assembly.

Pay attention not to rotate diaphragm.

Remove ALV from Manifold

spring to expand, finally remove cap when the spring has

stopped expanding.

1

Remove boost pressure source hose from the ALV 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 Gen V

ALV being careful not to lose the valve seat. Mark the orientation

of the valve to the body with tape or a paint pen.

CAUTION!

Use soft jaws to prevent damage

CAUTION!

Allow engine to cool down before removing your Gen V

ALV

Remove Top Cap

2

Prior to removing the Gen V ALV 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

8

ensure the diaphragm groove is free of debris and fit your

replacement diaphragm over the valve.

Valve retaining

cap

Loctite

243

Spring washer

Pry circlip up

over the valve

Diaphragm Replacement

3

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 cap by rotating in

an anti-clockwise direction.

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)

12point 14mm

socket

Diaphragm tool

(25mm hex)

Spring washer

(Outside UP)

Valve Circlip

Valve Stem

Remove the valve retaining cap and spring washer, Sit the ALV

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 ALV removing any dirt from the actuator,

9

Clockwise to tighten

Anti-clockwise to loosen

Press cap onto body

5

**As viewed from above**

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.

Hold still

Align the valve orientation marks and confirm the diaphragm

bead is seated in the groove of the actuator. Install desired spring

combination.

Configure ALV with preferred spring combination of inner,

middle and outer springs

Familiarise Yourself with Cap and Body

Notches

4

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

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

Reinstall Gen V ALV

6

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 ALV to be installed.

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.

Do not forget to put the valve seat into the body before mounting

the unit on the ALV manifold. Using the 3/8” deep socket and a

torque wrench Tighten the V-Band to 7N.m (5 ft/lbs),

1

0

-

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HOW TO INSTALL A SENSOR CAP TO YOUR GEN V ALV

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 ALV from Manifold

1

Remove boost pressure source hose from the ALV 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 Gen

V ALV being careful not to lose the valve seat or O-Ring. Mark

the orientation of the valve to the body with tape or a paint pen.

CAUTION!

Allow engine to cool down before removing your Gen V

ALV

Remove Top Cap

2

Diaphragm Replacement

2

Prior to removing the Gen V ALV 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.

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

cap by rotating in an anti-clockwise direction.

CAUTION!

Use soft jaws to prevent damage

12point 14mm

socket

Diaphragm tool

(25mm hex)

TS-0550-3007

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.

1

Familiarise Yourself with Cap and Body

Notches

3

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

Loctite 243

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.

Spring washer

(Outside UP)

Valve Circlip

Valve Stem

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)

Press cap onto body

Clockwise to tighten

Anti-clockwise to loosen

4

**As viewed from above**

Using a press or vice, compress the cap onto the body

ensuring the notches are remaining aligned, use spacers to

ensure the wire from the sensor it not crimped or damaged

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.

Take care not to damage the wire during assembly.

Align the valve orientation marks and confirm the diaphragm

bead is seated in the groove of the actuator. Install desired

spring combination.

Configure ALV with preferred spring combination of inner,

middle and outer springs

1

2

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

Wire

Red

Note

Rating

Reinstall Gen V ALV

Sensor Supply (Vsup

)

4.5-5.5 Vdc

0V

5

Black Sensor Ground (V )

0

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 ALV

to be installed.

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.

Ensure that the wiring is properly shielded from external heat

sources.

CAUTION!

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.

CAUTION!

Do not forget to place valve seat into the body before

mounting the ALV on the exhaust manifold. Use a 3/8”

deep socket and torque the V-Band to 7N.m (5 ft/lbs)

Wiring

6

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.

1

3

Calibration*

7

*NOTE! For best results, each ALV should be calibrated to

your setup.

Insert the relevant calibration curve into your data logger for

the product family you have

Turbosmart Gen V ALV

3

2

1

0

.5

2

Valve Lift (mm)

0.75

V

OUT

-

2.221

2.138

2.03

.5

1

0

1

3

4

5

6

8

9

1

.5

.75

.5

0

1.88

.25

.5

1.692

1.454

1.126

0.683

0.118

0.003

-20

-15

-10

-5

0

Standardised Lift (mm)

.75

.25

0

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TROUBLE SHOOTING

-

ALV not actuating - Confirm preload on valve seat during installation

Poor ALV actuation - Ensure signal hose is connected to a quality pressure source, check seal on fittings

Poor ALV actuation - Confirm ports are not blocked and free from debris

Failing the above, submit a technical request to tech@turbosmart.com.au with information of your engine configuration and

photos of installation

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