GenV wastegate actuator instructions universal

Product Name:

Gen V IWG (Clevis)

Gen V IWG

Product Description:

Product Number:

2

TS-06XX-XXXX

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V1.00 Rev A

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Document Version:

IMPORTANT NOTES ON YOUR INTERNAL WASTEGATE ACTUATOR

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

engine damage or personal injury.

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

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Allow for adequate cool airflow around the diaphragm housing

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

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.

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KIT CONTENTS

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

Part

1

Description

Turbosmart Gen V IWG

Rod Kit

Use

Main unit

2

Rod or Rods for fitment to Specific Application

3x springs: 1x inner, 1x middle, 1x outer (1x spring pre-installed)

2x 1/8” NPT nipple, 4x 1/8” NPT blanking plugs (1x pre-installed)

1x Clevis kit for specific application

3

Spring kit

4

Fitting kit

5

Clevis Kit

6

Turbosmart Sticker

Turbosmart Position Sensor

IWG Actuator Collar Tool

Turbosmart sticker

7

Turbosmart HE Sensor (Sensor Cap Model Only)

Remove actuator collar to change spring

8

Figure 1 - Kit Contents

1

CONTENTS

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

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

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

GEN V WASTEGATE OVERVIEW.....................................................................................................................3

FITTING YOUR GEN V WASTEGATE................................................................................................................4

Applying Actuator Preload / Ensuring Wastegate Flap is Closed................................................................4

HOW TO CHANGE YOUR GEN V WASTEGATE SPRING....................................................................................5

ACHIEVING YOUR TARGET BOOST PRESSURE ................................................................................................6

HOW TO USE A SENSOR CAP ON YOUR GEN V WASTEGATE ..........................................................................7

TROUBLESHOOTING......................................................................................................................................7

TOOLS REQUIRED

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10mm open end spanner

Square drive ratchet wrench

Torque wrench (3/8” drive)

Non-marking spanners to tighten fittings

3/16” hex key

Turbosmart IWG collar tool

SUGGESTED SEALANTS

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Loctite 243 Thread locker

Loctite 567 Thread Sealant

2

GEN V WASTEGATE OVERVIEW

“Top” Air Port

HE Sensor

1/8” NPT

(Sensor model only)

“

1

Bottom” Air Port

/8” NPT

Master Collar

Mounting Studs

Ball Joint

Preload Locking Nut

Clevis

Figure 2 – Gen V Wastegate Overview

3

FITTING YOUR GEN V WASTEGATE

Mounting your New Turbosmart Gen V IWG

Wastegate

1

Slide the actuator head through the mounting bracket, be sure

the ball joint assembly has been removed from 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

Applying Actuator Preload / Ensuring

Wastegate Flap is Closed

3

CAUTION!

This step is important

In order to ensure the actuator does not suffer any

stiction/temperature creep issues or the wastegate flap does not

stay slightly open, it is important to apply a small amount (2mm/

0.078”) of preload to the wastegate actuator.

To correctly preload the wastegate, ensure wastegate flap is in

the full closed position by holding the actuator flap as far closed

as possible, wind the adjuster nut onto the back face of the

actuator flap as shown below until hand tight

Figure 3 – Install Actuator through bracket

To apply (2mm/0.078”) preload, simply turn the adjuster nut 2 full

turn in the clockwise direction.

To lock the actuator in this position, turn the locking nut by hand

until finger tight, then proceed to tighten nut firmly to secure

actuator in place. (6.5Nm / 4.8 ft lb)

Figure 4 – Actuator secured onto bracket

If a regulated air source is available on-hand, apply the air

pressure of the spring installed to the actuator (5, 7 or 14psi) and

observe the rod, the rod should begin to move slowly and freely

over the range of travel as air pressure increases. If the rod does

not move at all with increasing air pressure, proceed to

troubleshooting.

Install the ball joint

2

Once the actuator has been mounted to the bracket, install the

ball joint onto the main shaft out the actuator, orientation of the

ball joint is not important. Use the flats machined into the ball joint

to hold the ball joint in place as you tighten the nut on the main

shaft to prevent unnecessary movement of the ball joint during

operation.

Start Engine and Check for Leaks

4

Congratulations, your Gen V wastegate is installed and ready for

use. Double check all fittings, lines and mountings then proceed

to start engine and check for leaks.

4

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HOW TO CHANGE YOUR GEN V WASTEGATE SPRING

The Gen V wastegate has a variety of springs to suit different boost levels. Turbosmart provides the Gen V wastegate pre-installed

with a 14psi spring. With your wastegate 3 springs will be provided, 5psi inner, 7psi middle and 14psi outer. Different spring

combinations may be required to suit different boost requirements and tuning.

Remove Wastegate From Turbocharger

Remove Top Cap (cont.)

1

2

Remove boost pressure source hose from the wastegate

Remove preload from wastegate by undoing preload nuts

Remove ball joint locking nut

Remove rod from actuator and turbo assembly

Remove ball joint assembly

Remove wastegate actuator from bracket

CAUTION!

Allow engine to cool down before removing your Gen V

wastegate

Remove Top Cap

2

Prior to removing the Gen V wastegate cap, remove all fittings

from the 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

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

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.

5

Reinstall Gen V Wastegate

5

Install wastegate actuator assembly to bracket

Install ball joint assembly

Install ball joint lock nut

Install rod to ball joint and turbocharger

Apply wastegate preload

Lock adjuster nuts

Connect wastegate signal lines and check for leaks

If an adjustable air source is available, connect to signal ports

and check for smooth free operation of wastegate, if wastegate

does not move with increasing air pressure, proceed to

troubleshooting.

Press Cap onto Body

4

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.

ACHIEVING YOUR TARGET BOOST

PRESSURE

There are various factors involved in achieving your target

boost pressure including.

CAUTION!

Maintain downward pressure on cap while tightening collar

or non-repairable thread damage will occur.

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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

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exhaust manifold backpressure in your system.

Turbosmart recommends the ideal setup for achieving your

target boost pressure is to use the Gen V 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 Gen V

Wastegate allows for different combinations of spring pressures.

All springs that are adaptable with the Gen V 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 Gen

V Wastegate’s spring pressure. The springs chosen should be

rated to the lowest boost level desired.

Reinstall fittings to the cap of the wastegate using fresh Loctite

567 thread sealant.

Table 1: Spring Chart

Location

Pressure

Inner

Middle

7psi

Outer

14psi

5psi

●

5

psi

●

7

●

12psi

14psi

19psi

21psi

26psi

●

6

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HOW TO USE A SENSOR CAP ON YOUR GEN V WASTEGATE

Wiring

CAUTION!

7

To ensure longevity from the sensor, ensure adequate

airflow is supplied directly to the sensor to avoid

overheating or sensor failure.

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.

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*

8

Rod Travel (mm)

V

OUT

0

2

4

6

8

0.439

1.21

1.58

1.84

2

Wire

Red

Note

Rating

Sensor Supply (Vsup

)

4.5-5.5 Vdc

0V

10

12

14

16

18

2.13

2.21

2.27

2.32

2.36

Black Sensor Ground (V )

0

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.

NOTE! For best results, each wastegate should be calibrated

to your setup.

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TROUBLESHOOTING

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Wastegate not actuating - Confirm signal hose is plumbed to a pressure only source, confirm preload 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

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Poor wastegate actuation – Confirm no obstructions in actuator rod path

Boost creeping at high rpm - Wastegate flow path is poor, wastegate is too small for the application, ensure ball joint is not

seized

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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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