Product Name:  
Product Description:  
Product Number:  
Big Bubba BPV/Bubba Sonic VTA  
50mm Bypass valve/Blow off valve  
TS-0204-12XX / TS-0204-13XX  
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IMPORTANT NOTES ON YOUR BOV  
Use only silicone hose that is the correct size and pressure/vacuum rating for your application when fitting your BOV  
Ensure that all plumbing is secured with suitable clamps or the correct fittings are used  
Your BOV should be mounted at least 100mm from any high heat source or adequately shielded  
RECOMMENDATIONS  
Turbosmart recommends that your BOV is fitted and adjusted by an appropriately qualified technician  
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HOW TO INSTALL YOUR BOV  
Allow the engine to cool down before installing your BOV  
Identify a suitable location along the intercooler/intake piping for the BOV – this will need to be between the outlet of the turbo and  
the throttle body ideally between the throttle body and the intercooler (See diagram below).  
Good position  
Bad Position  
Throttle body  
Intercooler  
Inlet manifold  
Turbocharger  
Engine  
Remove the BOV from the weld on adapter by removing the V-Band clamp. The V-band clamp is removed by opening the screw  
until it has reached the end stop, then pushing the head of the screw in a “syringe” like motion and lifting the BOV off the weld  
flange.  
Step 1:  
Step 2:  
Step 3:  
Pull down  
Lift off  
Bolt head  
Squeeze  
Weld the adapter onto the intake pipe in your ideal position, then allow the adapter to cool down  
Put the V-Band clamp over the adapter before re-installing the O-Ring seal and the BOV  
Open the V-Band clamp and place in position. Tighten the V-Band clamp screw until it is finger tight then turn an additional 2.5  
turns or 4 Nm (3 ft/lbs) with an allen key. Be sure not to over tighten the screw as this will cause damage to the V-Band clamp  
Identify a standalone vacuum / pressure source from a port after the throttle body and connect with correctly sized hose to the  
vacuum/boost port on the cap of the BOV. Ensure this line is as short as possible  
Secure all silicone hose ends with correct clamps  
Start the engine and check for air leaks in the system  
SPRING ADJUSTMENT  
The purpose of the spring is to control the position of the piston at engine idle. Different vehicle setups need different piston positions to  
function properly.  
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The Big Bubba BPV is preinstalled with a spring which will hold 12 InHg (TS-0204-2202) and is designed to be OPEN at idle. It does  
not need to be adjusted if the BOV if being used in a recirculation application or Supercharger application. A 7 InHg spring (TS-0204-  
2201) is available if higher valve response is needed or your engine’s vacuum level is very low.  
The Bubba Sonic VTA is preinstalled with a spring which will hold 17 InHg (TS-0204-2203) with the cap at its lowest position and is  
designed to be closed at idle. A 21 InHg (TS-0204-2204) spring is available if your engine produces high vacuum and the valve needs  
to be closed at idle to prevent unmetered air entering the system.  
Outlet  
MAINTENANCE  
Body  
Weld flange  
Plumb back fitting  
O-Ring seal  
Swivel Nipple  
Cap  
Spring  
Inlet  
Piston  
Indicator O-Ring  
O-Ring seal  
V-Band clamp  
Turbosmart recommends that the following maintenance procedure is carried out at six monthly intervals or at higher intervals if the  
environment is very dusty or wet. Regular maintenance will ensure that your BOV is operating at its peak performance and will extend  
the working life of the product.  
Remove the cap of the BOV by rotating in an anti-clockwise direction – CAUTION, the cap is under spring force, remove with  
care!  
Carefully remove the piston and thoroughly clean the piston and the bore of the BOV  
Inspect the surface of the piston and the bore of the BOV for scoring or excessive wear, silver coloured marks on the bore are  
an indication of excessive wear  
Check the Base O-ring and the Cap O-ring for any damage – replace if necessary  
Lubricate the bore and the piston with Uni-Glide™, hydraulic oil or sewing machine oil – DO NOT use grease or viscous oils  
Re-assemble the BOV in the reverse order  
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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 / pressure 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. If this does not occur, the  
hose could be blocked or crimped. Check the hose and replace if necessary.  
Ensure that the vacuum / pressure source is not shared and that the vacuum source is directly from the inlet manifold  
Check the seal between the adapter and the BOV – ensure that there is no gap between the BOV base and the weld flange  
Check the join between the adapter and the intercooler pipe for leaking  
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DO NOT USE ANY TURBOSMART PRODUCT UNTIL YOU HAVE CAREFULLY READ  
AND UNDERSTOOD THE FOLLOWING AGREEMENT.  
Please call if you have any questions or do not understand this agreement. Refer to our brochure, website or catalogue for terms and conditions and further information  
regarding your product. Turbosmart appreciates your business and pride ourselves on our customer service. We are always happy to offer you advice and will provide you  
with help in any way we can. The purpose of this agreement is to avoid any problems or hard feelings.  
We sometimes make mistakes, as do our dealers, distributors and suppliers. Even customers can sometimes order the wrong parts. Do not use, modify, install, trial  
assemble, nick, drop, scratch or adjust any part until you first check for any damage. Damage must be reported immediately. NO EXCEPTIONS. If there are any  
components missing please contact your authorised reseller immediately upon receipt of your shipment. Missing components must be reported within five (5) business  
days of receipt. Parts returned for any reason MUST BE IN RESALABLE CONDITION. It is YOUR responsibility, “THE CUSTOMER” to carefully package any returns to  
avoid shipping damage. Insurance is highly recommended. Credit cannot be issued for damaged goods.  
Turbosmart Pty Ltd warranties the quality of the products it designs and manufactures to be free of defects in material and workmanship. This limited warranty is extended  
only to the original purchaser and may not be transferred or assigned. This limited warranty applies to any product, which after careful inspection by Turbosmart Pty Ltd,  
after receipt of the product from our authorised reseller, is found to have a defect in either material or workmanship. Any modifications to the product will void any and all  
warranties and will not be exchanged. Before installation, check new car warranty. Turbosmart Pty Ltd is not responsible for voiding any original manufactures warranty.  
All warranty claims must be returned to the authorised reseller, you must return the product and sales receipt, at your own expense, accompanied by a letter stating the  
reason for the claim. Proof of purchase must be provided with any warranty claim and will be verified with the authorised reseller from which the product was purchased.  
If all the above procedures are followed, and the product is found to be defective in either workmanship or material, Turbosmart Pty Ltd shall either repair or replace the  
product, at its sole discretion, and sole cost. This limited warranty does not cover or apply to any personal injury, labour charges or any other incidental costs or damages  
caused by the defective product. The individual purchaser acknowledges and agrees that the disclaimer of any liability for personal injury is a material term for this  
agreement and the individual purchaser agrees to indemnify Turbosmart Pty Ltd and to hold Turbosmart Pty Ltd harmless for any claim related to the item of the  
equipment purchased. Under no circumstances will Turbosmart Pty Ltd be liable for any damages or expenses by reason of use or sale of any such equipment.  
THIS LIMITED WARRANTY IS THE ONLY EXPRESS WARRANTY, WHICH APPLIES TO TURBOSMART PTY LTD PRODUCT AS EXPRESSLY GIVEN IN LIEU OF  
ANY OTHER WARRANTY EXPRESSED OR IMPLIED, INCLUDING THAT OF MERCHANTABILITY. ANY IMPLIED WARRANTY INCLUDING THAT OF  
MERCHANTABILITY AND/OR FITNESS FOR A PARTICCULAR PURPOSE IS HEREBY LIMITED BY THE SAME TERMS AND TIME LIMITATIONS SET FORTH IN  
THIS LIMITED EXPRESS WARRANTY AND OTHERWISE EXCLUDED.  
EXCEPT FOR THOSE OBLIGATIONS ASSUMED HEREIN, TURBOSMART PTY LTD ASSUMES NO OTHER OBLIGATIONS IN CONNECTION WITH THE SALE OF  
ITS PRODUCTS.  
IN THE EVENT THAT THE INDIVIUDAL PURCHASER DOES NOT AGREE WITH THIS AGREEMENT THE BUYER MAY PROMPTLY RETURN THIS PRODUCT, IN A  
NEW AND UN-USED CONDITION, WITH A DATED PROOF OF PURCHASE, TO THE PLACE OF PURCHASE WITHIN SIXTY (60) DAYS FROM THE DATE OF  
PURCHASE FOR A FULL REFUND.  
THE INSTALLATION OF THIS PRODUCT INDICATES THAT THE INDIVIDUAL PURCHASER HAS READ AND UNDERSTOOD THIS AGREEMENT AND ACCEPTS  
ITS TERMS AND CONDITIONS.  
Happy motoring!  
The Turbosmart Team  
Turbosmart Pty Limited P.O.Box 264 Croydon, NSW, 2132 Australia ABN: 69 081 069 794  
Tel: +(612) 9740 2866 Fax: +(612) 9798 2826 Email: instructions@turbosmart.com.au  
www.turbosmart.com.au www.turbosmartusa.com www.turbosmart.co.nz  
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