Product Name:  
BPV Kompact EM Series  
BPV Kompact EM Series  
TS-0223-1282  
Product Description:  
Product Number:  
Document Version:  
V1.00 Rev A (Bronco Sport / Maverick)  
IMPORTANT NOTES ON YOUR BPV  
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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.  
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The EM series BPV is designed for use as a factory replacement for a turbocharger that utilises an electronic diverter valve, this valve can be  
used on other applications if there is a control signal to actuate the BPV.  
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Ensure the engine is cold prior to installation.  
For Standalone ECU configuration, ensure valve is not energised for indefinite periods of time as this can cause significant life detriment to the  
actuation solenoid.  
RECOMMENDATIONS  
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Turbosmart recommends that your Bypass Valve (BPV) is fitted by an appropriately qualified technician  
KIT CONTENTS  
Please check that the following items have been provided in your EM Series BPV packaging  
Part  
1
Description  
Use  
Turbosmart EM Series BPV with collar Main unit  
Turbosmart Sticker  
2
Figure 1 - Kit Contents  
TOOLS REQUIRED (REQUIRED)  
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E5 (FEMALE) TORX SOCKET  
Extension  
Ratchet  
Flathead screwdriver  
Pliers  
5mm Allen Wrench  
1
ABOUT YOUR EM SERIES BPV  
Turbosmart has developed a unique “plug and play” diverter valve (or bypass valve) upgrade for your vehicle that is currently equipped  
with an electronic diverter valve. While we have developed this unit to be as simple as possible for you to install, we have not  
compromised on performance. This unit will not leak under elevated boost pressures and will still provide you with rapid response  
ensuring that all the OEM calibration strategies are not interfered with, providing you with maximum boost performance while the  
advanced strategies of the OEM’s are retained.  
As the valve is completely controlled by the factory engine control unit, the factory diverter valve is almost silent, due to our  
construction, it is possible that your EM series will be much more audible. By being able to hear the unit actuate, occasionally the  
valve may be opening for a few seconds under the following events such as traction control, cruise control management, rapid  
gearchanges and varying throttle position changes, these are all coded as part of the torque management software in the OEM engine  
control unit, there is no adjustment available over these functions via our product. By hearing these events, it is not abnormal, it is  
completely normal for the EM series BPV to be considered “very active” as it is protecting your turbocharger from surge events or  
bypassing air for torque management purposes.  
Electronic Actuator  
Controls when the valve opens,  
Control Signal Plug  
and closes based on OEM  
Connect to OEM harness  
signal  
Flange Mounting Holes  
Bolt to turbo compressor  
cover  
Sealing O-Rings (Underneath)  
Ensures the valve does not leak  
compressed air  
Plumb Back Port (Underneath)  
Recirculates excess air to  
turbocharger inlet  
Plumb Back Orientation Indicator  
A flat on the flange, acts as a visual  
cue to install the BPV in the correct  
position relative to the plumb back  
pathway  
Figure 2 - EM Series BPV Overview  
(Figure for illustration purposes only, actual product may vary slightly)  
2
FITTING YOUR EM SERIES BPV  
Identify OEM diverter valve location  
Additionally, remove the clamp and recirculation tube for  
additional clearance (pictured below).  
1
The factory diverter valve is mounted UNDER the intake tube (see  
photo below). The diverter valve is mounted with 3 E5 Torx studs.  
BEFORE you begin remove the factory engine cover using a  
10mm socket and ratchet (circled in red).  
CAUTION! Always exercise caution when working  
in engine compartment. Some components may be hot  
or operate intermittently. Always refer to your  
manufacturers owner manual to ensure your safety is not  
compromised.  
OEM Diverter Valve  
Located behind intake  
3
Removing the factory valve  
Remove the electronic plug (Red arrow) from the OEM diverter  
valve and unscrew the three screws in a counter clockwise  
direction (circled below). The valve will likely want to fall off the  
mounting flange as you unscrew the last screw, ensure you do not  
drop the OEM valve as permanent damage may occur to  
the plastic.  
OE BPV (RED ARROW) AND ENGINE COVER NUT (RED CIRCLE)  
NOTE: The factory Torx screws can be reused or the INLCUDED  
3
x M6 Fasteners. Take special care not to lose them. It is also  
strongly recommended you retain your OEM diverter valve should  
you ever need to return the vehicle to stock.  
Diverter Valve  
Black plastic construction  
2
Partially remove intake tube  
In order to make room to remove the OEM BPV, the primary  
intake tube must be partially removed. Remove the clamp from  
the air box to make room (pictured below) using a flathead  
screw driver.  
(Instructions continued on next page)  
3
FITTING YOUR EM SERIES BPV  
Install Kompact EM valve  
4
Install the included clockable flange onto the EM valve. Ensure the  
bolt holes align in the correct orientation, matching up with the  
factory flange hole pattern (image below). Slide the EM series BPV  
onto the mounting flange ensuring that the sealing O-rings are still  
in place on their respective grooves. Once the unit is inserted into  
the mounting flange, the valve can be rotated accordingly.  
Finally, screw the OE mounting screws into place securing the  
BPV. Once the valve has been mounted and the screws tightened,  
connect the electrical plug into the OEM factory plug and secure  
the wiring safely away from a heat source.  
IMPORTANT! Be sure to mount your new valve with the  
solenoid & wiring facing in a direction where it does not  
interfere, rub, or pull on the wiring. Failure to do so could  
result in damage.  
Turbosmart Kompact EM Valve correct orientation (installed)  
Ensure secure connection  
Congratulations, your EM Series BPV is installed and ready for  
use. Double check all electrical connections and mounting screws  
4
CHANGING THE ELECTRONIC ACTUATOR  
CAUTION!  
Failure to ensure O-rings are seated correctly may lead to  
cutting of an O-Ring and unexpected results from the EM  
1
Remove Your EM series BPV  
Remove the electronic plug from the EM series BPV and  
unscrew the flange screws in an anti-clockwise direction,  
completely remove and safely store the mounting screws. The  
valve will likely want to fall off the mounting flange as you  
unscrew the last screw, ensure you do not drop the valve as  
permanent damage may occur. Ensure O-Rings are kept with  
the valve for reinstallation.  
series BPV  
Slowly insert the new actuator while turning in a clockwise  
direction to avoid tearing the O-rings  
NOTE!  
Cosmetic engine covers may be required to be removed  
prior to the assembly being visible.  
CAUTION!  
The turbocharger assembly may require the vehicle to be  
raised on a hoist or jacked up and secured using vehicle  
jack stands, ensure your safety is not compromised.  
Tighten the new solenoid into the EM series BPV ensuring the  
wrench is on the metallic portion of the solenoid.  
Remove Electronic Actuator from your EM  
series BPV  
NOTE!  
Tightening the solenoid on the plastic cover may result in  
unrepairable damage to the solenoid.  
2
Using a 11mm open end wrench in the flat sides of the  
solenoid, undo the actuator in an anti-clockwise directionwhen  
viewed from the end. Ensure the wrench is placed on the  
metallic portion of the flats and not on the plastic cover.  
4
CAUTION!  
Ensure the plumb back port is located correctly if there is  
a flat on your mounting flange facing the plumb back port  
on the turbocharger or diverter valve mounting assembly,  
this is to allow for effective flow from the plumb back port  
back into the recirculation path, failing to do this can  
cause compressor surge due to insufficient flow.  
Once the valve has been mounted and the screws tightened,  
connect the electrical plug into the OEM factory plug and  
secure the wiring safely away from a heat source.  
Congratulations, your EM Series BPV is installed and ready  
for use. Double check all electrical connections and mounting  
screws.  
Ensure the cavity is free from debris using avoiding shifting dirt  
into the passages.  
Install New Electronic Actuator into your EM  
Series BPV  
3
Ensure the O-rings on your new actuator are correctly seated in  
the grooves before installation  
TR
- O-Rings  
required to click the plug into place.  
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BPV not actuating - Confirm electrical signal plug is connected appropriately, as the plugs are new, some force may be  
Valve is staying open – Confirm the valve has O-rings as they may have been dropped or lost during installation  
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Boost pressure loss or lower than before - Confirm the valve has O-rings as they may have been dropped or lost during installation  
Failing the above, submit a technical request to tech@turbosmart.com.au with information of your engine configuration and photos of  
installation