IMPORTANT NOTES ON YOUR BOV. RECOMMENDATIONS. HOW TO INSTALL YOUR BOV. Step 1:. Step 2:. Step 3:. SPRING ADJUSTMENT. The purpose of the spring is to control the position of the piston at engine idle. Different vehicle setups need different piston pos

<table style="width: 100%;"><tbody><tr><td style="width: 50.0000%;">Product Name:&#xA0;</td><td style="width: 50.0000%;">Big Bubba BPV/Bubba Sonic VTA&#xA0;</td></tr><tr><td style="width: 50.0000%;">Product Description:</td><td style="width: 50.0000%;">50mm Bypass valve/Blow off valve&#xA0;</td></tr><tr><td style="width: 50.0000%;">Product Number:</td><td style="width: 50.0000%;">TS-0204-1203 / TS-0204-1303</td></tr></tbody></table> IMPORTANT NOTES ON YOUR BOV&#xA0;<ul><li style="font-size: 14px;">Use only silicone hose that is the correct size and pressure/vacuum rating for your application when fitting your BOV&#xA0;</li><li style="font-size: 14px;">Ensure that all plumbing is secured with suitable clamps or the correct fittings are used&#xA0;</li><li style="font-size: 14px;">Your BOV should be mounted at least 100mm from any high heat source or adequately shielded</li></ul> RECOMMENDATIONS<ul><li style="font-size: 14px;">Turbosmart recommends that your BOV is fitted and adjusted by an appropriately qualified technician</li></ul> HOW TO INSTALL YOUR BOV<ul><li style="font-size: 14px;">Allow the engine to cool down before installing your BOV</li><li style="font-size: 14px;">Identify a suitable location along the intercooler/intake piping for the BOV &#x2013; this will need to be between the outlet of the turbo and &#xA0;the throttle body ideally between the throttle body and the intercooler (See diagram below).</li></ul><img src="https://attachments.gorgias.help/ZPB9rx1MeRMxWVa3/hc/MNVgn6mGBR71j8BO/2026031700-80649f2c-8083-4fa3-b75d-202370c20bc4-screenshot%202026-03-17%20at%2011.29.47%E2%80%AFam.png" style="width: 683px;" class="fr-fic fr-dib"><ul><li style="font-size: 14px;">Remove the BOV from the weld on adapter by removing the V-Band clamp. The V-band clamp is removed by opening the screw &#xA0;until it has reached the end stop, then pushing the head of the screw in a &#x201C;syringe&#x201D; like motion and lifting the BOV off the weld &#xA0;flange.</li></ul>Step 1:<img src="https://attachments.gorgias.help/ZPB9rx1MeRMxWVa3/hc/MNVgn6mGBR71j8BO/2026031700-f83a2e77-3974-4ef6-98fb-94cc3713a2cd-screenshot%202026-03-17%20at%2011.32.43%E2%80%AFam.png" style="width: 915px;" class="fr-fic fr-dib">Step 2:<img src="https://attachments.gorgias.help/ZPB9rx1MeRMxWVa3/hc/MNVgn6mGBR71j8BO/2026031700-c9cab76b-81ca-44bb-95c8-a90dc9be4142-screenshot%202026-03-17%20at%2011.36.10%E2%80%AFam.png" style="width: 683px;" class="fr-fic fr-dib">Step 3:<img src="https://attachments.gorgias.help/ZPB9rx1MeRMxWVa3/hc/MNVgn6mGBR71j8BO/2026031700-5ad44517-3efa-4776-8f20-443d28021228-screenshot%202026-03-17%20at%2011.37.39%E2%80%AFam.png" style="width: 683px;" class="fr-fic fr-dib"><ul><li style="text-align: left; font-size: 14px;">Weld the adapter onto the intake pipe in your ideal position, then allow the adapter to cool down</li><li style="text-align: left; font-size: 14px;">Put the V-Band clamp over the adapter before re-installing the O-Ring seal and the BOV</li><li style="text-align: left; font-size: 14px;">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 &#xA0;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</li><li style="text-align: left; font-size: 14px;">Identify a standalone vacuum / pressure source from a port after the throttle body and connect with correctly sized hose to the &#xA0;vacuum/boost port on the cap of the BOV. Ensure this line is as short as possible</li><li style="text-align: left; font-size: 14px;">Secure all silicone hose ends with correct clamps</li><li style="text-align: left; font-size: 14px;">Start the engine and check for air leaks in the system</li></ul> SPRING ADJUSTMENTThe purpose of the spring is to control the position of the piston at engine idle. Different vehicle setups need different piston positions to &#xA0;function properly.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 &#xA0;not need to be adjusted if the BOV if being used in a recirculation application or Supercharger application. A 7 InHg spring (TS-0204- &#xA0;2201) is available if higher valve response is needed or your engine&#x2019;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 &#xA0;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 &#xA0;to be closed at idle to prevent unmetered air entering the system. MAINTENANCE&#xA0;<img src="https://attachments.gorgias.help/ZPB9rx1MeRMxWVa3/hc/MNVgn6mGBR71j8BO/2026031700-66bdac90-a427-4f09-b784-b03a1573a612-bigbubba.png" style="width: 683px;" class="fr-fic fr-dib">Turbosmart recommends that the following maintenance procedure is carried out at six monthly intervals or at higher intervals if the &#xA0;environment is very dusty or wet. Regular maintenance will ensure that your BOV is operating at its peak performance and will extend &#xA0;the working life of the product.<ul><li style="font-size: 14px;">Remove the cap of the BOV by rotating in an anti-clockwise direction &#x2013; CAUTION, the cap is under spring force, remove with &#xA0;care!</li><li style="font-size: 14px;">Carefully remove the piston and thoroughly clean the piston and the bore of the BOV &#xA0;Inspect the surface of the piston and the bore of the BOV for scoring or excessive wear, silver coloured marks on the bore are &#xA0;an indication of excessive wear</li><li style="font-size: 14px;">Check the Base O-ring and the Cap O-ring for any damage &#x2013; replace if necessary</li><li style="font-size: 14px;">Lubricate the bore and the piston with Uni-Glide&#x2122;, hydraulic oil or sewing machine oil &#x2013; DO NOT use grease or viscous oils</li><li style="font-size: 14px;">Re-assemble the BOV in the reverse order</li></ul> TROUBLE SHOOTINGThe following points should be checked if you find that your engine is dipping below normal idle, stalling or if the BOV is functioning &#xA0;poorly. Please note, the following checks will cure 99% of problems experienced with a BOV.<ul><li style="font-size: 14px;">Check the vacuum hose for splits, cracks, loose connection, kinking or any obstruction &#x2013; old or fatigued hose may collapse under &#xA0;vacuum causing an obstruction&#xA0;</li><li style="font-size: 14px;">With the engine running remove the vacuum / pressure hose from the nipple in the cap of the BOV, there should a loud hissing &#xA0;sound. The engine should idle poorly, double check by covering the end of the hose with your finger. If this does not occur, the &#xA0;hose could be blocked or crimped. Check the hose and replace if necessary.&#xA0;</li><li style="font-size: 14px;">Ensure that the vacuum / pressure source is not shared and that the vacuum source is directly from the inlet manifold&#xA0;</li><li style="font-size: 14px;">Check the seal between the adapter and the BOV &#x2013; ensure that there is no gap between the BOV base and the weld flange&#xA0;</li><li style="font-size: 14px;">Check the join between the adapter and the intercooler pipe for leaking</li><li style="font-size: 14px;">Failing the above, submit a technical request to <a data-fr-linked="true" href="mailto:tech@turbosmart.com.au" id="isPasted">tech@turbosmart.com.au</a> with information of your engine configuration and photos of installation and one our expert technicians will respond as soon as possible.&#xA0;</li></ul> RELATED VIDEO<iframe width="560" height="315" src="https://www.youtube.com/embed/33HUZM-UkLI?si=jUtVN4pthaFIqsQp" title="YouTube video player" frameborder="0" allowfullscreen>&#xA0;&#xA0;&#xA0;</iframe>

TS-0204-1203 / TS-0204-1303 BigBubba BPV/ Bubba Sonic VTA Instructions

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