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Turbosmart TS-0565-1002, Quick Start Manual

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Turbosmart TS-0565-1002 Quick Start Manual Download Page 2

 

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CONTENTS 

 

KIT CONTENTS

.......................................................................................................................................................... 1 

TOOLS REQUIRED

 .................................................................................................................................................... 3 

SUGGESTED LUBRICANTS AND SEALANTS

 .......................................................................................................... 3 

PART NUMBERS

 ....................................................................................................................................................... 3 

QUICK START GUIDE

................................................................................................................................................ 3 

HOW TO USE

 ............................................................................................................................................................. 3 

MAINTENANCE

.......................................................................................................................................................... 3 

TEMPERATURE

 ......................................................................................................................................................... 3 

BASIC TUNING PARAMETERS

 ................................................................................................................................. 4 

WHAT’S NEW

 ............................................................................................................................................................ 4 

STRAIGHT ELECTRONIC WASTEGATE OVERVIEW

 ............................................................................................... 5 

FITTING YOUR GEN V WASTEGATE

 ........................................................................................................................ 6 

Mounting your new Turbosmart Electronic Straight Wastegate

 ......................................................................... 6 

Fitting the Straight Gate

........................................................................................................................................ 7 

 Connecting Your Wastegate

 ................................................................................................................................ 8 

Tuning

 ................................................................................................................................................................... 9 

ADVANCED FEATURES ON THE STRAIGHT WASTEGATE

 .................................................................................. 10 

TROUBLESHOOTING

 .............................................................................................................................................. 12 

 

 
 

 

Summary of Contents for TS-0565-1002

Page 1: ... removing the end cap off the actuator Allow for adequate cool airflow around electronic actuator paired with water cooling DO NOT Mount the electronic wastegate so that the electronic actuator is less than 100mm from a heat source DO NOT wrap the body of the wastegate with exhaust wrap Fitting your Electronic Straight Wastegate may require fabrication or modification to your exhaust manifold Turb...

Page 2: ...AINTENANCE 3 TEMPERATURE 3 BASIC TUNING PARAMETERS 4 WHAT S NEW 4 STRAIGHT ELECTRONIC WASTEGATE OVERVIEW 5 FITTING YOUR GEN V WASTEGATE 6 Mounting your new Turbosmart Electronic Straight Wastegate 6 Fitting the Straight Gate 7 Connecting Your Wastegate 8 Tuning 9 ADVANCED FEATURES ON THE STRAIGHT WASTEGATE 10 TROUBLESHOOTING 12 ...

Page 3: ... valve manually set to about the middle of its stroke This will allow for an easier installation The Straight Gate can be used in both directions Please see below for a more detailed and helpful way of installing the Turbosmart Electronic Straight Wastegate MAINTENANCE Turbosmart Electronic Straight Wastegate will require periodic reapplication of spray grease such as Inox MX8 spray grease this is...

Page 4: ...e is Turbosmart s addition to its electronic wastegate line up A new level of control is now available with the butterfly valve and offers the option for customers who require another packaging or new level of control Control With the introduction of the electronic motor to drive the Electronic Straight Gate a new level of control is now available to boost control there is a wide range of tuning s...

Page 5: ...te Overview Outlet Weld flange Outlet V Band Inlet V Band Water Cooling port 1 8 NPT Wiring Loom Inlet Weld Flange Water cooling symbol Figure 2 Electronic Straight Gate Water Cooling Figure 3 Electronic Straight Gate Exploded Manual Override cap 3 x Housing locating screws ...

Page 6: ... place the Butterfly Valve pins exhaust side up Figure 4 Best flow Symmetric mounting Symmetric mounting allows an excellent flow of exhaust to the Straight Gate Figure 5 Good Flow Angle mounting Angle mounting allows a good flow of exhaust flow to the Straight Gate Figure 6 90 Degree mounting 90 Degree mounting gives poor exhaust flow to the Straight Gate and in some circumstances may contribute ...

Page 7: ...ition slide the v band over the flange to allow for the wastegate to be installed Figure 8 Butterfly Valve Pins 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 torquing the nut to not have a false torque as this will likely contribute to exhaust leaks It is important that the butterfly valve sits slightly open for insta...

Page 8: ...is at least 20A for seamless operation Connect the small Red Wire to a 5V power source from your ECU as well as the Black wire to Sensor ground Connect the white wire to a 0 5V analogue input on your ecu as well as the orange temperature sensor signal The blue wire Revision B only is an unfiltered position output signal for development purposes This can be left unterminated CAUTION Whilst the temp...

Page 9: ...egate Turbosmart recommends that the butterfly valve is only ever driven electronically to the maximum butterfly position of 90 Driving the butterfly valve to 100 will cause increased wear on components such as the electronic motor as it tries to force the butterfly valve to completely open Adjust the calibration to allow plenty of overshoot to the end stops of the butterfly valve recalibrate as a...

Page 10: ...tion In high demand unusually environments it is advisable to increase the service interval Turbosmart recommends that the internal gearbox is regreased with a spray type grease such as Inox MX8 spray grease this should be conducted half yearly or more depending on environment With the top plate removed grease can be sprayed into the small inspection holes located near the magnet Motor Replacement...

Page 11: ...y 30 deg to the body and the current configuration 90 deg to the body The actuator locking pins are 3mm Allen keys that lock the body to the actuator It is important that the butterfly remains in the same position the recommended position is to be just off the valve seat It is also advisable to not to move the manual override during this process CAUTION Moving body and actuator while separated wil...

Page 12: ...rbosmart if this occurs Wastegate fluctuates and fails to find targeted position motor wires may be the incorrect way Swap and test to see Ensure to use sensible current limits to prevent over currenting Wastegate seized Remove cap and manually move butterfly feeling for resistance Wastegate moves but sensor not reading Check connections Boost creeping at high rpm Wastegate flow path is poor waste...

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