Product Name:  
BOV SP Dual Port 2.0L VAG Golf R  
(MK6)/ Audi S3 (8P)  
Product Description:  
Blow off valve for 2.0L K04  
VAG engines  
Product Number:  
TS-0215-1041  
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IMPORTANT NOTES:  
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 an AN#3 fitting if desired.  
Make sure that the engine is cool before installing this product  
RECOMMENDATIONS  
Turbosmart recommends that your Blow off valve (BOV) is fitted by an appropriately qualified technician  
Turbosmart recommends that a boost gauge be permanently fitted to the vehicle  
Turbosmart recommends that this product is install on the car hoist/lift  
Please check that the following items have been provided in your kit  
Quantity  
Description  
Use  
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0cm  
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Model specific BOV  
Electronic plug  
5mmthBlack vacuum hose  
1/16 NPT Blank  
Replaces standard electronic bypass valve  
Blanking off OEM electronic by pass valve wiring loom  
Connects BOV to intake manifold  
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Port blank for boost reference adapter  
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6.3mm hose tail fitting  
5mm hose tail fitting  
Boost reference adapter  
Boost reference adapter collar  
M4 X 4 Grub screws  
6mm spring clamps  
Screwed into the boost reference adapter, provides boost reference for BOV  
Provides other devices such as boost gauges with vacuum/pressure source  
Adapter between intake manifold and oil air separator feed  
Connects boost reference adapter to intake manifold  
Clamps the boost reference adapter to collar  
Secures pressure lines  
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250mm cable ties  
Fixing pressure lines in position  
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HOW TO INSTALL YOUR BOV  
MK6 Volkswagen Golf R (2010-2013)  
Remove engine cover/airfilter box assembly by the following steps:  
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1)  
2)  
Unclip intake cover by pulling the cover up  
Using a torx driver, remove the torx screws which secure the intake snorkel to the front intake mount and lift the snorkel  
above the intake mount  
(3)  
(4)  
(5)  
(6)  
Unclip the airflow meter plug and unhook the wiring from the engine cover, move the harness out of the way  
Unclip turbo intake pipe by prying open the 2 metal straps. Pull the intake pipe out of the airflow meter  
Unclip the recirculation pipe from the straps by lifting the tabs on the straps  
To remove engine cover, pull the engine cover up at (6) and (7) to pull the cover off the rubber mounts. Take care when  
popping the cover off the mounts  
(7)  
Pull the engine cover towards you to pop the cover off the rear mounts  
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(8) Unclip wiring harness off the OEM diverter valve  
(9) Remove torx screw from the bracket holding the diverter valve assembly  
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(10) Remove hose clamps from the recirculation pipe and the inlet to the diverter valve adapter. Remove diverter valve assembly.  
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11) Install the Turbosmart BOV in the reverse order of removing the OEM valve. Use the OEM torx screw to hold the body bracket  
on the BOV to the bracket on the engine as per the OEM diverter valve adapter. Secure all clamps.  
12) Install the electronic plug and cable tie the plug to plastic tubing  
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13) Unclip the recirculation hose by squeezing on the clip while pulling the hose  
14) Push the supplied plastic collar over the barb  
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15) The boost reference adapter has 2 ports and is supplied with a 6.3mm nipple, a 5mm nipple and a blanking plug. The 6.3mm  
nipple needs to be used for the BOV vacuum/boost reference. The 5mm nipple can be used if you want to hook up a boost  
gauge or boost controller. If you are only installing the BOV, then use the blanking plug to block off the unused hole. When  
installing the boost reference adapter, push the adapter onto the barb until it bottom out. The adapter might need to be rotated  
back and forth while pushing it onto the barb. Once it is home, with your fingers push the plastic collar back into the boost  
reference adapter so that the outer edge sits flush with the back end of the adapter. The plastic ring forms the surface for  
which the grub screws on the boost reference adapter screw into so that the barb is not damaged. Apply medium strength  
thread locker onto the grub screws and screw them into the plastic collar evenly. Make sure not to over tighten them as they  
will damage the intake manifold barb.  
(16) Reinstall the air recirculation pipe. Cut a piece of silicone tube from the supplied length and connect the BOV to the boost  
reference adapter. Secure all hose ends with the supplied spring clamps  
(17) Reinstall the engine cover in the reverse order. Start the car and check for leaks or idling issues.  
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ADJUSTING YOUR BOV  
Traditionally every BOV needs to be adjusted to suit the vehicle it is being mounted on. The new SP Dual Port BOV technology  
eliminates the need to adjust the BOV after installation.  
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.  
Ensure the spring clamps are secured on silicon hoses and fittings.  
Make sure that the trumpet valve is closed at idle. Pull on the trumpet valve to see if it freely opens and it’s not jammed.  
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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.  
Warranty as to Defects Australian Consumer Law  
1.1  
We warrant for a period of twelve (12) months from the date of supply of the Goods and/or Services that if due to the fault of Turbosmart the Goods  
and/or Services (as the case may be) provided by Us are defective then We will, as determined by Us do one or more of the following:  
1.  
In the case of Goods; the replacement of the Goods, the supply of equivalent Goods, the repair of the Goods, the payment of the cost of  
replacing the Goods or of acquiring equivalent Goods, or the payment of having the Goods repaired; or  
2.  
In the case of Services; the supplying of the Services again, or the payment of the cost of having the Services supplied again.  
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You will only be entitled to the benefit of the warranty set out in this pledge, if You have not wholly or partially caused or contributed to the defect  
to the Goods by the misuse of the Goods or the failure to use the Goods in accordance with any specifications or instructions applicable to the Goods.  
The warranty contained in this pledge is provided by Turbosmart Pty Limited of 32 Milton Street North, Ashfield NSW 2131, Australia, Telephone:  
+
(61) 1300 735 506, Email: [email protected].  
In order for a You to make a claim on the warranty You must within twelve (12) months of delivery of the Goods or Services give written notice to Us  
at the address specified in clause 1.3 above of the details of any defects in respect thereof. Any Goods referred to in a notice given pursuant to this  
clause should be left in the state and condition in which they were delivered until such time as We or Our duly authorised agent have inspected the  
Goods with such inspection to be carried out within a reasonable time after service of such notice. If the Goods are not so left in the state and condition  
in which they were delivered then the You shall be deemed to have accepted the Goods and the warranty contained in this pledge shall not apply.  
You shall be responsible for all expenses associated with making a warranty claim under this pledge however if the Goods and/or Services are found to  
be defective due to Our fault then We shall reimburse You for any expenses incurred by You in making a warranty claim upon receiving evidence  
satisfactory to Turbosmart to support such expenditure.  
The benefits to You given by the warranty contained in this pledge are in addition to other rights and remedies of You have under a law in relation to  
the Goods or Services to which the warranty relates. In accordance with the Australian Consumer Law We makes the following statement: “Our goods  
come with guarantees that cannot be excluded under the Australian Consumer Law. You are entitled to a replacement or refund for a major failure and  
compensation for any other reasonably foreseeable loss or damage. You are also entitled to have the goods repaired or replaced if the goods fail to be  
of acceptable quality and the failure does not amount to a major failure.”  
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EXCEPT AS PROVIDED BY LAW, 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  
Turbosmart Pty Limited P.O. Box 264 Croydon, NSW 2132 Australia ABN: 69 081 069 794  
Ph: +61 1300 735 506 Fax: +61 1300 735 509 Email: ins[email protected]  
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