GenV Wastegate Standard / Motorsport / High Pressure InstructionsUpdated 21 days ago

IMPORTANT NOTES ON YOUR EXTERNAL WASTEGATE

• 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 GenV External Wastegate is designed for use with a turbocharger that does not have an internal wastegate.
• 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

• Allow for adequate cool airflow around the top diaphragm housing.
• DO NOT Mount the wastegate so that the top diaphragm housing is less than 100mm from a heat source.
• DO NOT wrap the body of the wastegate with exhaust wrap.
• Fitting your GenV wastegate may require fabrication or modification to your exhaust manifold. 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.
  

KIT CONTENTS

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
• Resbond 907TS Red
• Penetrating oil

WHAT IS AN EXTERNAL WASTEGATE

What is a wastegate?

Internal or external, a wastegate is a boost-controlling device that operates by limiting exhaust gases going through the turbocharger,  controlling the maximum boost pressure produced by the turbocharger itself. A wastegate consists of an inlet and outlet port, a valve  and a pressure actuator.

How a wastegate works?

A pressure actuator, controlled by boost pressure determines whether the wastegate is open or shut. In its resting position, a  wastegate is shut, and as the boost pressure builds, force is applied to the actuator. When the boost pressure exceeds the spring  value, the actuator will progressively open the wastegate, bypassing some of the exhaust gases therefore maintaining the boost  pressure at the set level. To put it simply - a wastegate prevents the boost pressure from climbing indefinitely and consequently  blowing the engine.

When is an external wastegate required?

Most of the factory turbo systems feature an internal wastegate made to handle stock boost levels. The most common reason for  investing in an external wastegate is fitting an after-market turbo or better control of the boost and consequently the power output of  your engine. Additionally, most large frame turbochargers are not equipped with internal wastegate systems.  Most tuners will recommend an external wastegate for any engine producing 400hp or more, as running high boost through a factory  internal wastegate can overpower the actuator spring, limiting maximum boost level. Aftermarket external wastegates feature bigger  inlet and outlet ports, higher pressure springs and bigger actuator diaphragms to effectively control high boost pressure.

WHAT’S NEW

Our new wastegates are a direct fit upgrade to all 4th-generation Turbosmart wastegates and feature our unique collar-locking system,  variable actuator cap and base, strap-type V-band clamps, liquid-cooling, 1/8″ NPT ports, and are provided with a range of springs.  They are also available in Motorsport and compressed gas-only versions for those requiring specific applications.

Modular 

The 5th series wastegate range has been designed for maximum user-adjustability, without compromising performance. We designed  our new unit to allow actuators to be interchangeable across the range. So, if you need a large wastegate in a tight space you can  run a smaller actuator on the larger body. Additionally, if you decide to upgrade your new wastegate to a motorsport or compressed  gas-only actuator you can with an upgrade kit.

Adjustability 

The unique variable adjustment design allows the wastegate actuator base to be oriented independently from the weld flanges. The  cap is also completely independent and indexable in 12 different positions compared to the actuator base and body. This allows the  wastegate to be fitted in confined positions without compromising packaging for fittings or aligning the cap.

Upgrades and Servicing

Due to the modular construction, the new range is also upgradeable and completely serviceable, as all components can be removed  or upgraded. Components have been tested for over one million cycles so reliability will be rock-solid.

Flow and Thermal Performance

Our new range of wastegates out-flow all competitors thanks to our world-leading engineering and simulation abilities. Thermal  performance has been improved drastically compared to our nearest rival, and all wastegates feature liquid cooling ports for further  thermal performance if required.

Control

For fine-tuning, boost performance, a selection of springs will be supplied with each wastegate. All wastegates feature 1/8″ NPT ports  for maximum response and flow while maintaining a high level of compatibility for fittings.

GenV WASTEGATE VARIANTS 

GenV WASTEGATE OVERVIEW

FITTING YOUR GenV WASTEGATE

Mounting your New Turbosmart Gen V Wastegate

The Gen V series of wastegate is a direct fit replacement for the  4th gen wastegate range and no modification is necessary provided packaging space is sufficient.

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 an attempt should be made, if space allows, to mount the Gen V Wastegate at an angle to the exhaust flow to allow for better flow than a 90 degree mounting. See the schematic diagrams below for examples of mounting positions. 

CAUTION!

• Do not place the actuator cap near a significant heat source as this could shorten the life of the diaphragm.

Best flow - Symmetric mounting

Symmetric mounting allows an excellent flow of exhaust to the wastegate.

Good Flow - Angle mounting

Angle mounting allows a good flow of exhaust flow to the wastegate. 

90 Degree mounting

90 Degree mounting gives poor exhaust flow to the wastegate and in some circumstances may contribute to over boosting.

 Not Recommended - Less than 90 Degree Mounting 

An angle mounting as shown in not recommended and gives extremely poor exhaust flow to the wastegate which can contribute to poor boost control and over boosting.

Fitting the GenV Wastegate

Prior to mounting the Gen V Wastegate, 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 wastegate to be installed.

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 wastegate is home correctly while torqueing the nut to not have a false torque as this will likely contribute to exhaust leaks.

Fit Actuator Port Fittings

Fit lower chamber port fittings prior to mounting the wastegate, install 1/8” NPT blank with 3/16” hex key and signal nipple into lower chamber 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 ‘Boost Control Hookup’ section, refer to table of contents for page number.

CAUTION!

• Do NOT insert fittings and blank into Top Ports unless advanced boost control methods are to be used as this can affect the performance of the product. See ‘Boost Control Hookup’

Basic Wastegate Hook-up

Basic setup

If no boost controller is being used connect the boost pressure source to the “bottom” port as shown. The boost only pressure source should be sourced from as close to the compressor side of the turbo as possible. The “top” ports of the wastegate should be left open, It is possible in harsh environments to blank one port and connect a hose to the other port that can be ran to a area less likely to allow contamination into the actuator.

CAUTION! 

• Do NOT source signal from the intake manifold as this is subject to vacuum and pressure losses across the system and could over-speed the turbocharger. 

Start Engine and Check for Leaks

Congratulations, your GenV wastegate is installed and ready for use. Double check all fittings, lines and mountings then proceed to start engine and check for leaks.

HOW TO CHANGE YOUR GenV WASTEGATE SPRING

The GenV wastegate has a variety of springs to suit different boost levels. Turbosmart provides the GenV wastegate pre-installed with your choice of either 7psi or 14psi springs depending on the part number. With your wastegate four springs will be provided, 3psi inner, 5psi inner, 7psi middle and 14psi outer. Different spring combinations may be required to suit different boost requirements and tuning.

Remove Wastegate From Manifold

Remove boost pressure source hose from the wastegate as well as the breather hose is fitted. Unscrew outlet V-band nut in an 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 GenV wastegate being careful not to drop or lose the valve seat.  

CAUTION! 

• Allow engine to cool down before removing your Gen V wastegate

Remove Top Cap

Prior to removing the Gen V wastegate cap, remove all fittings from the 1/8”NPT 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