Kompact EM Instructions Fiat Abath

Product Name:

BOV Kompact EM VR8 (Fiat/Abarth)

TS-0223-1X89

Product Description:

Product Number:

Document Version:

V1.00 Rev A

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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 as long as 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

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KIT CONTENTS

Please check that the following items have been provided in your EM Series BOV packaging

Part

1

Description

Turbosmart EM Series BOV

2x Hose clamps

Use

Main unit

2

Mount BOV to inlet and outlet hoses

3

1x Blanking plug*

1x Mount

Block off second outlet port *(Dual Port Variants only) *

Fiat 500 Kompact BOV Mount

4

5

2x Allen Bolts

Allen bolts for mounting Kompact to mount

Turbosmart sticker

6

Turbosmart Sticker

Figure 1 - Kit Contents

1

TOOLS REQUIRED

-

Hose clamp screwdriver

Flat bladed screw driver

Allen Key Set Metric

Basic Socket set

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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.

Control Signal Plug

Connect to BOV Control

circuit

Electronic Actuator

Controls when the valve opens,

and closes based on OEM

signal

Vent to Atmosphere Port

(Only on “Dual Port” Models)

Vents excess air to

atmosphere

Plumb Back Port

Recirculates excess air to

turbocharger inlet

Inlet Port

Boost pressure from the charge pipe

enters BOV from this port.

Flange Mounting Holes (Underneath)

Mounts BOV in a secure location

Figure 2 - EM Series BOV Overview

2

FITTING YOUR EM SERIES BOV

OEM Diverter Valve

Usually black plastic

construction

Identify diverter valve location

1

Recirculation hose

Plumbs back into the

turbo inlet pipe

The diverter valve will be located on the charge pipe between

turbo and throttle body, some applications have a hose to mount

the diverter valve away from the charge pipe linking the plumb

back hose into the turbocharger inlet pipe.

Boost Pressure hose

Connects to the charge

pipe between turbo and

throttle body

On the model designation Type 312 (Above) Abarth 500 the

Diverter valve is located below the battery. Next to the washer jet

fill up point. It has been located using the white circle below.

Removing the OEM diverter valve

2

Remove the electronic plug from the OEM diverter valve and

unscrew any hose clamps and disconnect any hoses, Remove

the BOV from any brackets, ensure you do not drop the OEM

valve as permanent damage may occur to the plastic.

The Yellow Tab must be pulled backwards to unlock the

mechanism that unlatches the electrical connector from the

Diverter valve. This yellow tab will be in the unlocked position till

the Turbosmart valve has been plugged in.

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

Mounting your EM Series BOV to it’s Mount

5

Removing the OEM hose clamps and hoses

3

Using the bracket and associated fasteners the BOV bracket

must be fastened to the bottom of the BOV. This is done with two

Allen key fasteners that have been included in the packaging.

Next to remove is the hose clamps from the diverter valve. This

is done using a screwdriver or appropriately sized socket. If the

car is fitted with an ear clamp. They can be removed by using a

flat bladed screwdriver to flick up the locked ear that is located

on the inner raised ear.

The hoses can now be persuaded off the diverter valve. Some

force may be required to dislodge the hoses.

Mounting your EM Series BOV to the Vehicle

6

The BOV can now be mounted to the car using the supplied

fasteners, making sure to keep the originals in a safe place. As

seen above. It is important to hold the supplied bolts from below

to ensure they are not dropped into the engine bay.

Removing the OEM mounting bolts

4

With the hose clamps loose and electrical connector removed.

The two mounting bolts that hold the OEM diverter in place must

now be removed ensuring not to drop the bolts.

Once removed can remove the OEM diverter valve from the

engine bay and store in a safe place.

Mounting your EM series BOV to it’s Hoses

7

The hoses must now be attached as seen by picture above and

below, making sure that the hose clamps are on before putting

the hoses back on! Once on they must be tightened to ensure

no leaks are present.

NOTE!

These bolts are not captive and will fall into the engine bay

if not supported from underneath.

Congratulations the OEM Diverter valve has been removed.

4

Finialising your EM series BOV installation

8

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 push the yellow tab towards the

connectors to ensure they are locked in

Congratulations, your EM Series BOV is installed and ready for

use. Double check all electrical connections and fasteners.

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

in the grooves before installation

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

the metallic portion of the flats and not on the plastic cover.

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.

5

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.

TROUBLE SHOOTING

-

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.

-

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

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