Product Name:  
Mazda/Subaru Dual Port  
Product Description:  
Product Number:  
Model-Specific Dual Port BOV  
TS-0205-1009/TS-0205-1010  
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Suitable for: Mazda MPS (Mazdaspeed) 3, 6, CX7, Subaru WRX’08+, Legacy/Liberty GT’03 - current.  
IMPORTANT NOTES:  
This Blow-Off Valve does NOT fit the 2008 WRX STi. Please refer to www.turbosmartonline.com for product updates.  
Please thoroughly read and understand these instructions before commencing this installation.  
The thread on the cap for the vacuum source is AN#3. The standard swivel nipple can be changed to a AN#3 fitting if desired.  
RECOMMENDATIONS  
Turbosmart recommends that your Blow off valve (BOV) is fitted and adjusted by an appropriately qualified technician  
Turbosmart recommends that a boost gauge be permanently fitted to the vehicle  
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SETTING THE FLANGE TO SUIT DIFFERENT VEHICLES  
The BOV flange can be rotated to suit different vehicles. There are currently 2 setting notches; setting notch 1 for the Mazda range and  
setting notch 2 for the Subaru Range. The BOV comes preset to setting notch 1. The flange can be rotated by loosening the securing  
screws at the bottom with a 3mm allen key. Do not remove the screws, only loosen them. Rotate the flange until it lines up with the  
desired indicator groove. Re-tighten the screws.  
Setting notches  
Mazda = ο  
Subaru = οο  
Indicator Grooves  
HOW TO INSTALL YOUR BOV  
Please check that the following items have been provided in your Mazda/Subaru Dual port kit.  
Quantity  
Description  
Mazda/Subaru Dual port BOV  
Blanking plug  
Use  
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1
1
1
Model Specific blow off valve  
To blank off a port to convert the BOV to full atmospheric or plumb back  
To change configuration of flange to suit different vehicles  
To seal the BOV to the intercooler pipe  
3mm allen key  
Gasket  
1) Installation on a Mazda (Diagrams are from a Mazda 3 MPS) – Setting notch 1  
1)  
Remove the engine cover by removing the two securing screws/plugs.  
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2)  
Locate the intake standard BOV. Remove the vacuum/pressure source.  
3)  
Remove the bolts securing the standard BOV and then remove the plumb back hose by removing the spring clamp.  
4)  
Push the plumb back hose onto the plumb back fitting on the new BOV. Use the factory bolts to fit the new BOV onto the  
intercooler pipe. Remember to install the supplied gasket in between the BOV flange and the intercooler flange. Reinstall the  
vacuum/pressure source to the nipple.  
5)  
Replace the engine cover. Start the engine and check for leaks.  
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2) Installation on a WRX (MY08 Onwards) – Setting notch 2  
1.  
Set the BOV flange to setting notch 2 as per instructions. Locate the standard BOV and remove the vacuum/pressure source  
tube and the plumb back hose.  
Setting notch 2  
2.  
Remove the securing bolts and remove the standard BOV  
3.  
Use the factory bolts to fit the new BOV onto the intercooler pipe. Remember to install the supplied gasket in between the  
BOV flange and the intercooler flange. Reinstall the vacuum/pressure source to the nipple.  
4.  
Replace the standard plumb back hose and vacuum/pressure source tube, start engine and check for leaks.  
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3) Installation on a Liberty GT – Setting notch 2  
1)  
Remove engine cover by removing the 4 securing screws.  
2)  
Locate standard BOV and remove the plumb back hose and the vacuum/pressure source line.  
3)  
Remove standard BOV.  
4)  
Cut the raised circle area on the engine cover using appropriate cutting tools  
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5.  
Use the factory bolts to fit the new BOV onto the intercooler pipe. Remember to install the supplied gasket in between the  
BOV flange and the intercooler flange. Reinstall the vacuum/pressure source to the nipple and the plumb back hose. Re-  
install the engine cover. Start the engine and check for leaks.  
ADJUSTING YOUR BOV  
Each BOV needs to be adjusted to suit the vehicle it is being mounted on. The aim of the adjustment on Vee Port’s, Supersonic’s and  
Dual ports is to make sure that the piston is hard closed at idle and that the piston closes fast enough to minimise backfiring and not  
stall the engine. Plumb back BOV’s are equipped with a spring which are designed to keep the piston open at engine idle and hence the  
cap can be left in the middle position.  
Adjustment to the BOV is made by rotating the cap. To increase the spring force on the piston, rotate the cap clockwise in the direction  
of hard as marked on the top of the cap. To decrease the spring force on the piston, rotate the cap anticlockwise in the direction of soft  
as marked on the top of the cap - CAUTION - Do not rotate the cap beyond the first O-Ring indicator groove.  
Start with the BOV cap at the maximum soft position (The indicator O-Ring should be completely covered by the edge of the cap)  
With the engine at idle the exhaust port should be closed off by the piston – the piston should be hard against the seat and not  
floating or moving  
Free rev the engine and back off quickly, the engine should return to normal idle speed if the engine drops below idle or stalls  
increase the spring tension by one turn  
Repeat this process until the engine free revs and returns to normal idle speed  
Test drive the car and ensure that when decelerating or changing gears that the engine has minimal backfiring and no stalling. If  
backfiring is excessive or stalling is noticed then check all connections made during the installation, otherwise increase the spring  
tension  
MAINTENANCE  
Turbosmart recommends that the following maintenance procedure is carried out at six monthly intervals or at higher intervals if the  
environment is very dusty or wet. Regular maintenance will ensure that your BOV is operating at its peak performance and will extend  
the working life of the product.  
Remove the cap of the BOV by rotating in an anti-clockwise direction CAUTION, the cap is under spring force, remove with  
care!  
Carefully remove the piston and thoroughly clean the piston and the bore of the BOV  
Inspect the surface of the piston and the bore of the BOV for scoring or excessive wear, silver coloured marks on the bore are  
an indication of excessive wear  
Check the Base O-ring and the Cap O-ring for any damage – replace if necessary  
Lubricate the bore and the piston with Uni-Glide™, hydraulic oil or sewing machine oil – DO NOT use grease or viscous oils  
Re-assemble the BOV in the reverse order  
TROUBLE SHOOTING  
The following points should be checked if you find that your engine is dipping below normal idle, stalling or if the BOV is functioning  
poorly. Please note, the following checks will cure 99% of problems experienced with a BOV.  
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Check the vacuum hose for splits, cracks, loose connection, kinking or any obstruction – old or fatigued hose may collapse  
under vacuum causing an obstruction.  
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With the engine running remove the vacuum / boost hose from the nipple in the cap of the BOV, there should a loud hissing  
sound. The engine should idle poorly, double check by covering the end of the hose with your finger otherwise the hose is  
blocked.  
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Check to see if the BOV is blocked or contaminated with dirt or debris.  
Ensure that the vacuum / boost source is not shared and that the vacuum source is directly from the inlet manifold.  
Check the seal between the intercooler flange and the BOV. Make sure the supplied gasket is installed and the BOV Flange  
is secured on the intercooler flange with the two factory bolts.  
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Ensure the spring clamps are secured on silicon hoses and fittings.  
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TURBOSMART  
ONE YEAR LIMITED WARRANTY  
Turbosmart is a company built on Customer Satisfaction and Service. That is why all of our products go through regimented test procedures before they are packaged and shipped. Turbosmart stands  
behind its products for one full year after purchase. Terms of Warranty, Service and Returns are as follows:  
Limited Warranty: Turbosmart warrants its products to be free from defects in material and workmanship under normal use and if properly installed for a period of one year from date of purchase. If found  
to be defective, it will be replaced or repaired if returned prepaid along with proof of date of purchase. This shall constitute the sole remedy of the purchaser and the sole liability of Turbosmart to the extent  
permitted by law, the foregoing is exclusive and in lieu of all other warranties or representations whether expressed or implied, including any implied warranty of merchantability or fitness. In no event shall  
Turbosmart be liable for special or consequential damages. This warranty is only valid on products purchased from Turbosmart Authorized Dealers.  
Service: After the warranty period has expired, repair service is charged based on a minimum and maximum charge rate. (Contact Customer Service for current rate).  
Returns: When returning a Turbosmart product for repair, it must be accompanied by a completed Customer Warranty Form and RMA number. To access this form please go to our website  
www.turbosmartonline.com and you will find it on the Downloads page.  
THE TURBOSMART PLEDGE  
DO NOT USE ANY TURBOSMART PRODUCT UNTIL YOU HAVE CAREFULLY READ AND UNDERSTOOD THE FOLLOWING AGREEMENT.  
Please call if you have any questions or do not understand this agreement. Refer to our brochure, website or catalogue for terms and conditions and further information regarding your product. Turbosmart  
appreciates your business and pride ourselves on our customer service. We are always happy to offer you advice and will provide you with help in any way we can. The purpose of this agreement is to  
avoid any problems or hard feelings.  
We sometimes make mistakes, as do our dealers, distributors and suppliers. Even customers can sometimes order the wrong parts. Do not use, modify, install, trial assemble, nick, drop, scratch or adjust  
any part until you first check for any damage. Damage must be reported immediately. NO EXCEPTIONS. If there are any components missing please contact your authorized reseller immediately upon  
receipt of your shipment. Missing components must be reported within five (5) business days of receipt. Parts returned for any reason MUST BE IN RESALABLE CONDITION. It is YOUR responsibility,  
“THE CUSTOMER” to carefully package any returns to avoid shipping damage. Insurance is highly recommended. Credit cannot be issued for damaged goods.  
Turbosmart warranties the quality of the products it designs and manufactures to be free of defects in material and workmanship. This limited warranty is extended only to the original purchaser and may not  
be transferred or assigned. This limited warranty applies to any product, which after careful inspection by Turbosmart, after receipt of the product from our authorized reseller, is found to have a defect in  
either material or workmanship. Any modifications to the product will void any and all warranties and will not be exchanged. Before installation, check new car warranty. Turbosmart is not responsible for  
voiding any original manufactures warranty.  
All warranty claims must be returned to the nearest Turbosmart Office, you must return the product and sales receipt, at your own expense, accompanied by the Customer Warranty Form stating the reason  
for the claim. Proof of purchase must be provided with any warranty claim and will be verified with the authorized reseller from which the product was purchased.  
If all the above procedures are followed, and the product is found to be defective in either workmanship or material, Turbosmart shall either repair or replace the product, at its sole discretion, and sole cost.  
This limited warranty does not cover or apply to any personal injury, labor charges or any other incidental costs or damages caused by the defective product. The individual purchaser acknowledges and  
agrees that the disclaimer of any liability for personal injury is a material term for this agreement and the individual purchaser agrees to indemnify Turbosmart and to hold Turbosmart harmless for any claim  
related to the item of the equipment purchased. Under no circumstances will Turbosmart be liable for any damages or expenses by reason of use or sale of any such equipment.  
THIS LIMITED WARRANTY IS THE ONLY EXPRESS WARRANTY, WHICH APPLIES TO TURBOSMART PRODUCT AS EXPRESSLY GIVEN IN LIEU OF ANY OTHER WARRANTY EXPRESSED OR  
IMPLIED, INCLUDING THAT OF MERCHANTABILITY. ANY IMPLIED WARRANTY INCLUDING THAT OF MERCHANTABILITY AND/OR FITNESS FOR A PARTICCULAR PURPOSE IS HEREBY  
LIMITED BY THE SAME TERMS AND TIME LIMITATIONS SET FORTH IN THIS LIMITED EXPRESS WARRANTY AND OTHERWISE EXCLUDED. EXCEPT FOR THOSE OBLIGATIONS ASSUMED  
HEREIN, TURBOSMART ASSUMES NO OTHER OBLIGATIONS IN CONNECTION WITH THE SALE OF ITS PRODUCTS.  
IN THE EVENT THAT THE INDIVIUDAL PURCHASER DOES NOT AGREE WITH THIS AGREEMENT THE BUYER MAY PROMPTLY RETURN THIS PRODUCT, IN  
A NEW AND UN-USED  
CONDITION, WITH A DATED PROOF OF PURCHASE, TO THE PLACE OF PURCHASE WITHIN SEVEN (7) DAYS FROM THE DATE OF PURCHASE FOR A FULL REFUND. THE INSTALLATION OF  
THIS PRODUCT INDICATES THAT THE INDIVIDUAL PURCHASER HAS READ AND UNDERSTOOD THIS AGREEMENT AND ACCEPTS ITS TERMS AND CONDITIONS.  
Happy motoring!  
The Turbosmart Team.  
Head Office: Turbosmart Pty Limited, PO Box 264 Croydon, NSW, 2132 Australia  
USA Office: Turbosmart USA, 1185 Park Center Drive, Suite Q, Vista CA 92081 USA  
Ph: +61(2) 9798 2866  
Ph: (760) 727 7610  
Fax: +61 (2) 9798 2826  
Fax: (760) 727 7963  
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