Product Name:  
BOV Kompact EM VR17  
BOV Kompact EM VR17 (4th Gen Yaris GR)  
TS-0223-1X77  
Product Description:  
Product Number:  
Document Version:  
V1.00 Rev A  
------------------------------------------------------------------------------------------------------------------------  
IMPORTANT NOTES ON YOUR BOV  
-
-
-
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 EM series BOV 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 BOV.  
Ensure the engine is cold prior to installation.  
RECOMMENDATIONS  
- Turbosmart recommends that your Blow off valve (BOV) is fitted by an appropriately qualified technician.  
------------------------------------------------------------------------------------------------------------------------  
KIT CONTENTS  
Please check that the following items have been provided in your EM Series BOV packaging  
Part  
1
Description  
Turbosmart EM Series BOV  
3 x Allen Bolts  
Use  
Main unit  
2
Allen bolts for mounting Kompact to mount  
Figure 1 - Kit Contents  
1
TOOLS REQUIRED  
-
-
-
Allen Key Set Metric  
Basic Socket set  
Torx Bits  
------------------------------------------------------------------------------------------------------------------------  
ABOUT YOUR EM SERIES BOV  
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.  
The EM series BOV is available in two configurations, Dual Port and Plumb Back. The functionality of the BOV is still the same, there  
is no performance difference between the two units, it is a personal preference if the user wishes to utilise a classic vent to atmosphere  
sound or revert all bypass gasses back into the inlet tract of the turbocharger.  
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 BOV to be considered “very active” as it is protecting your turbocharger from surge events or  
bypassing air for torque management purposes.  
Figure 2 - EM Series BOV Overview  
2
FITTING YOUR EM SERIES BOV  
Identify diverter valve location.  
1
On the model designation 4th Generation Yaris GR (XP210) the  
Diverter valve is located on the compressor cover housing. It is  
hidden behind the chassis rail in the right-hand front wheel well.  
It is located on the other side of the chassis leg. You will need to  
remove the wheel to gain access as well as the splash guard.  
Removing the OEM Engine Splash Guard.  
2
The Engine undertray and wheel guard panel will need to be  
removed. These interior fasteners are required to be flicked up  
which unlocks them and then pulled out. There is also 8 x 10mm  
fasteners running along the front of the engine undertray.  
NOTE!  
Allow for the engine to cool down.  
NOTE!  
The complete floor is removed for ease of access.  
It may not be necessary to remove the engine undertray  
panel. It is required on the bottom of the wheel well splash  
guard as this connects to the undertray.  
If the diverter valve cannot be located, seek assistance from your  
local specialist.  
NOTE!  
It may be required to remove auxiliary components to  
access the diverter valve, ensure you consult your local  
specialist or a service manual for correct disassembly  
procedures.  
3
Removing the OEM Turbo Inlet Pipe  
4
Remove the Turbo Inlet Charge Pipe, this is fastened to the  
turbocharger with one 12 mm bolt and a 12mm nut. The stud  
will also have to be removed, it is removed with a E7 female  
Torx or 6mm socket.  
The opposite end is fastened to another charge pipe, this is  
held on with a 10mm hose clamp. This is difficult to remove as  
there is no line of sight, a small ¼ inch ratchet works well in this  
area.  
The charge pipe can now be removed.  
Removing the OEM Charge Pipe  
3
The Charge pipe is held on with 2 x 10mm bolts on a bracket and  
x 10mm hose clamps. One on the turbo snout and one near the  
2
front of the car near the bracket.  
This can now be removed from out under the car and put in a  
safe place till reassembly.  
Removing the OEM Diverter Valve  
5
Next, remove the OEM Diverter Valve There are 3 x T30 Torx  
bits holding the valve on. Be careful not to drop these near the  
turbo inlet. With the bolts removed, remove the valve once  
slightly removed it becomes a lot easier to separate the electrical  
connector. It must be pushed down and pulled apart.  
Once removed store the diverter valve and hardware in a safe  
place.  
Pictured above is the hose clamp that will need to be removed. It  
is located on the turbo snout.  
4
Mounting your EM series BOV  
Connecting the Turbosmart Electrical  
connectors  
6
7
Install the Turbosmart Valve , remembering that the install is the  
opposite of the removal. Firstly, install the new valve in place.  
Making sure that both O rings are present and in place, making  
sure they remain in place tightening them up. The original T30  
bolts will be replaced by an Allen cap head bolt that uses a 5mm  
Allen key. Please consult your service manual for the correct  
torque specifications.  
Once the valve has been mounted, connect the electrical plug  
into the OEM factory plug and secure the wiring safely away from  
a heat source. Ensuring to hear a click of the connector locking  
together.  
Connecting the OEM Charge Pipe  
The orientation of the standard valve and flange give an  
indication of how they fit in the car. The arrow signifies the top of  
the engine. The body of the blow off valve can be orientated any  
direction due to the flange. It is important to note that it will want  
to foul with the turbo inlet and turbo charge pipe, as well as get  
in the way of the lower Allen bolt. Some care should be taken in  
planning clearance between those parts.  
8
Place the OEM Turbo inlet can now go back in, the pipe will  
need to be wiggled onto the turbo charge pipe located behind  
the chassis rail. With that in place it can be checked with the 3  
tabs around the circumference of the pipe ensuring that it has  
seated firmly and correctly.  
Then the stud and 12mm bolt and nuts can go back on at the  
correct torque.  
Top of Engine  
Installing Turbo Charge pipe  
9
The charge pipe can now be installed, the pipe will need to be  
moved up from the bottom of the engine bay and into position,  
the two hose clamps and 2 x 10mm bolts will need to be tighten  
up once all-in position.  
5
Fitting Engine Splash Guards  
10  
With everything back together the BOV can now be tested, with  
conformation that everything is working correctly. Fitting of the  
engine trays will be required to complete the install.  
Testing your install  
10  
It is important to check for leaks and correct operation as well as  
listening for compressor surge. This noise is the sound of the  
boost pressure air running back into the turbo causing cavitation.  
Now the car can be taken for a test drive in a safe environment  
and listen for the correct operation and that no turbo charger  
surge occurs.  
6
CHANGING THE ELECTRONIC ACTUATOR  
Remove Your EM series BOV.  
1
Install New Electronic Actuator into your  
EM series BOV.  
3
Remove the electronic plug from the EM series BOV and  
loosen the hose clamps on the inlet and recirculation hoses.  
Remove the BOV from the vehicles  
Ensure the O-rings on your new actuator are correctly seated  
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.  
O-Rings  
Remove Electronic Actuator from your EM  
series BOV.  
2
Using a 11mm open end wrench in the flat sides of the  
solenoid, undo the actuator in an anti-clockwise direction  
when viewed from the end. Ensure the wrench is placed on  
CAUTION!  
Failure to ensure O-rings are seated correctly may lead to  
cutting of an O-Ring and unexpected results from the EM  
series BOV.  
Slowly insert the new actuator while turning in a clockwise  
direction to avoid tearing the O-rings.  
Ensure the cavity is free from debris using avoiding shifting dirt  
into the passages.  
Tighten the new solenoid into the EM series BOV ensuring the  
wrench is on the metallic portion of the solenoid.  
NOTE!  
Tightening the solenoid on the plastic cover may result in  
unrepairable damage to the solenoid.  
7
TROUBLE SHOOTING  
-
-
It is important that any issues are resolved before heavy driving.  
BOV not actuating - Confirm electrical signal plug is connected appropriately, as the plugs are new, some force may be  
required to click the plug into place. The car will experience heavy surge if not actuating.  
Valve is staying open – Confirm the valve has O-rings as they may have been dropped or lost during installation.  
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.  
------------------------------------------------------------------------------------------------------------------------  
8