Kompact Instructions Hyundai 130n

Product Name:

BOV Kompact Hyundai i30N

TS-0203-1036

Product Description:

Product Number:

Document Version:

V1.00 Rev A

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IMPORTANT NOTES ON YOUR BOV

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 Kompact series BOV is designed for use as a factory replacement

Ensure the engine is cold prior to installation.

RECOMMENDATIONS

- Turbosmart recommends that your Blow off valve (BOV) is fitted by an appropriately qualified technician

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KIT CONTENTS

Please check that the following items have been provided in your BOV packaging

Part

Description

Turbosmart Kompact Series BOV

Hose Clamp

Use

Main unit

Fix plumb back hose to BOV

M6 Flange Bolts

Mount BOV to turbocharger compressor cover

Black off VTA trumpet to convert to pure plumb back.

Turbosmart sticker

Blanking plug

Turbosmart Sticker

Figure 1 - Kit Contents

TOOLS REQUIRED

5mm hex key

Screw drivers

Pliers

Socket Set

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ABOUT YOUR KOMPACT SERIES BOV

A direct fit high performance replacement for the factory all plastic unit, the Turbosmart Kompact BOV suits the Hyundai i30N. The

Turbosmart unit is made of billet aerospace grade aluminium with high temperature seals that allows for minimal leakage and a

complete seal across the bypass aperture providing as much performance as possible.

Benefits include:

•

Direct fit upgrade for the factory BOV on Hyundai i30N

Packaged with a blanking plug to switch the unit into pure vent to atmosphere or plumb-back modes

All billet CNC construction and attractive anodized finish

Manufactured, assembled and validated in-house at Turbosmart HQ

Swivel Nipple

Connected to the factory

control solenoid

Plumb Back Port

Recirculates excess air to

turbocharger inlet

Vent to Atmosphere Port

Only on “Dual Port” Models)

(

Vents excess air to

atmosphere

Flange Mounting Holes

Bolt to charge pipe through

adapter plate

Sealing O-Rings (Underneath)

Ensures the valve does not leak

compressed air

Adapter Plate

Converts the shape of the

Factory flange to the inlet of the

Turbosmart BOV

Figure 2 – i30N Kompact BOV Overview

FITTING YOUR EM SERIES BOV

Align adapter plate with

Identify Diverter valve location

Take note of the orientation of the adapter plate with the

trapezoid passage to be placed against the matching port on the

charge pipe and the circle port to be against the BOV. Ensure O-

rings are in place and fit together with the four supplied bolts.

Identify the location of the factory BOV assembly, The Hyundai

i30N factory bypass valve is located under the airbox of the

vehicle, Remove the factory air box to allow access for the

fitment.

It may be possible to access the valve from underneath the

vehicle.

NOTE!

It may be required to remove auxiliary components to

access the diverter valve, ensure you consult your local

specialist or a service manual for correct disassembly

procedures.

Plumb back hose

Mount your new Turbosmart Kompact BOV

Align your new Turbosmart Kompact BOV with the flange on the

charge pipe, the bolt pattern will only allow the BOV to be fitted

in one direction, ensure Both O-rings are correctly seated in their

grooves and tighten down the bolts.

Diverter Valve

Located under air

box.

Remove the OEM diverter valve

Remove the recirculation hose from the valve by loosening the

hose clamp, similarly, remove the signal hose from the top of the

valve by first releasing the spring action hose clamp.

Recirculation hose

Re attached the recirculation hose onto the BOV and tighten the

hose clamp. Align the swivel nipple on the cap of the BOV and

attach the signal hose.

Congratulations, your Turbosmart Kompact Series BOV is

installed and ready for use. Double check all connections and

mounting screws. Start your engine and check for leaks.

Signal hose

Remove the four bolts holding the diverter valve to the charge

pipe and remove from the engine bay.

ADJUSTING YOUR BOV (DUAL PORT ONLY)

The aim of the adjustment on the Dual port is to make sure that the piston is hard closed at idle and that the piston closes fast enough

to minimise backfiring and not stall the engine. In most cases, the cap is in the correct position from factory.

INSTALL THE BOV WITH THE FACTORY SETTING FIRST BEFORE PERFORMING ANY ADJUSTMENT.

Adjustment to the BOV is made by rotating the cap. To increase the spring force on the piston, rotate the cap clockwise in the direction

of hard as marked on the top of the cap. To decrease the spring force on the piston, rotate the cap anticlockwise in the direction of

soft as marked on the top of the cap - CAUTION - Do not rotate the cap beyond the O-Ring groove.

•

Start with the BOV cap at the maximum soft position (The indicator O-Ring should be completely covered by the edge of the cap)

With the engine at idle the exhaust port should be closed off by the piston – the piston should be hard against the seat and not

floating or moving

•

Free rev the engine and back off quickly, the engine should return to normal idle speed – if the engine drops below idle or stalls

increase the spring tension by one turn

•

Repeat this process until the engine free revs and returns to normal idle speed

Test drive the car and ensure that when decelerating or changing gears that the engine has minimal backfiring and no stalling. If

backfiring is excessive or stalling is noticed then check all connections made during the installation, otherwise increase the spring

tension

TROUBLE SHOOTING

The following points should be checked if you find that your engine is dipping below normal idle, stalling or if the BOV is functioning

poorly. Please note: the following checks will cure 99% of problems experienced with a BOV.

Check the vacuum hose for splits, cracks, loose connection, kinking or any obstruction – old or fatigued hose may collapse

under vacuum causing an obstruction.

With the engine running remove the vacuum / boost hose from the nipple in the cap of the BOV, there should a loud hissing

sound. The engine should idle poorly, double check by covering the end of the hose with your finger – otherwise the hose is

blocked.

Check to see if the BOV is blocked or contaminated with dirt or debris.

Ensure that the vacuum / boost source is not shared and that the vacuum source is directly from the inlet manifold.

Check the seal between the charge pipe flange and the BOV. Make sure the supplied O-Rings are installed properly and

the BOV Flange is secured on the compressor cover flange with the 3 supplied screws.

Ensure the spring clamps are secured on silicon hoses and fittings.

If the valve does not open properly or is slow to react, it could be due to the mapping of the drive by wire system from such

things as aftermarket chips and engine tunes. Check with the tuner that the mapping of the throttle is the same as OEM.

The valve may not open if the engine is just free reved. Check that the valve operates by driving the vehicle.

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