Product Name:  
Product Description:  
Product Number:  
RACE PORT  
Blow off valve  
TS-0204-11XX  
-
-----------------------------------------------------------------------------------------------------------------------  
IMPORTANT NOTES ON YOUR RACE PORT  
Use only silicone hose that is the correct size and pressure/vacuum rating for your application when fitting your Race Port  
Ensure that all plumbing is secured with suitable clamps or the correct fittings are used  
Your Race Port should be mounted at least 100mm from any high heat source or adequately shielded  
Check the vacuum level produced by your engine to ensure the right spring is installed in your Race Port for maximum response  
RECOMMENDATIONS  
Turbosmart recommends that your Race Port is fitted and adjusted by an appropriately qualified technician  
------------------------------------------------------------------------------------------------------------------------  
HOW TO INSTALL YOUR RACE PORT  
Allow the engine to cool down before installing your Race Port  
Identify a suitable location along the intercooler/intake piping for the Race Port this will need to be between the outlet of the turbo  
and the throttle body ideally between the throttle body and the intercooler  
Remove the Race port from the weld on adapter by removing the V-Band clamp. The V-band clamp is removed by opening the  
screw until it has reached the end stop, then pushing the head of the screw in a “syringe” like motion and lifting the Race Port off  
the weld flange.  
Step 1:  
Step 2:  
Step 3:  
Pull down  
Lift off  
Bolt head  
Squeeze  
Weld the adapter onto the intake pipe in your ideal position, then allow the adapter to cool down  
Put the V-Band clamp over the adapter before re-installing the O-Ring seal and the Race Port  
Open the V-Band clamp and place in position. Tighten the V-Band clamp screw until it is finger tight then turn an additional 2.5  
turns or 4 Nm (3 ft/lbs) with an allen key. Be sure not to over tighten the screw as this will cause damage to the V-Band clamp  
Install the provided vacuum nipple into one of the ports in the top cap and install the blanking plug into the other.  
Identify a standalone vacuum / pressure source from a port after the throttle body and connect with correctly sized hose to the  
vacuum/boost port nipple on the cap of the Race Port. Ensure this line is as short as possible  
Secure all silicone hose ends with correct clamps  
Start the engine and check for air leaks in the system  
RACE PORT DIAGRAM  
1
ACCESSORIES AND SPARE PARTS  
th  
TS-0204-2001  
TS-0204-2104  
TS-0204-2006  
TS-0204-3001  
TS-0204-3102  
TS-0204-3103  
TS-0204-3004  
TS-0204-3005  
BOV Race Port S/S Weld flange  
BOV Race Port Spring Kit  
TS-0505-2007  
TS-0505-2008  
TS-0505-2009  
TS-0505-3007  
TS-0505-3008  
TS-0505-3009  
1/16 NPT Male 1/8 NPT Female fittings  
th  
1/16 NPT Male -3AN Flare fittings  
th  
BOV Race Port Flange blank  
BOV Race Port Alloy Weld flange  
BOV Race Port 18 inHg spring  
BOV Race Port Piston Assembly  
BOV Race Port V-Band clamp  
BOV Race Port Flange O-Ring  
1/16 NPT Male -4AN Flare fittings  
74mm Locking Collar  
74mm Collar tool  
th  
1/16 NPT 6mm hose tail fittings  
SPRING REPLACEMENT  
The Race Port has a variety of springs to suit different vacuum levels. Different tuning levels produce different levels of idle vacuum.  
The Race Port is fitted with a standard spring which will remain closed until the engine produces more than 18 in/Hg. Turbosmart has a  
range of springs to suit different vacuum levels to ensure high levels of response from the Race Port.  
1
)
)
Remove the Race Port off the intercooler piping  
2
Remove any pressure nipples in the top cap. Hold the cap down in a press or vice. Unscrew the locking collar. Slowly, back  
off the vice or press and remove the cap.  
3
)
)
Select and install the required spring or combination of inner and outer springs into the piston assembly.  
Ensure that the diaphragm is inside the diaphragm groove.  
4
5)  
Slowly push the top cap down on the lower diaphragm housing in a vice or press. As the cap reaches the diaphragm, line up  
the notches in the cap (Figure 1) with the cut outs (Figure 2) in the lower diaphragm housing. Carefully push the cap down till  
the cap is home on the lower diaphragm housing. Reinstall the locking collar and tighten with the provided locking tool. Make  
sure that the cap is clamped down while tightening the collar.  
2
VALVE POSITION SENSOR CAP  
The Race Port can be upgraded to change the top cap to allow for a new piece which has provision for a valve position sensor. The  
sensor is an analog 0-5V contact type.  
-
-
The cap is designed to be a straight replacement to the original blow off valve cap. No modifications are required for fitment.  
The “top port” is incorporated in the valve position sensor cap design. Pressure is still supplied to the top port as per normal  
race port operation.  
-
The valve position sensor (TS-0502-2008) and valve position sensor plug (TS-0502-2009) are sold separately.  
Remove the Race Port off the intercooler piping  
1
)
)
2
Remove any pressure nipples in the top cap. Hold the cap down in a press or vice. Unscrew the locking collar. Slowly, back  
off the vice or press and remove the cap.  
3
)
)
Ensure that the diaphragm is inside the diaphragm groove.  
4
Slowly push the sensor cap down on the lower diaphragm housing in a vice or press. As the cap reaches the diaphragm, line  
up the notches in the cap with the cut outs in the lower diaphragm housing. Carefully push the cap down till the cap is home  
on the lower diaphragm housing. Reinstall the locking collar and tighten with the locking tool. Make sure that the cap is  
clamped down while tightening the collar.  
Wiring the sensor plug  
WARNING! Use caution when soldering the wires.  
Ground Pin 1 (0VDC)  
Power Pin 2 (+5VDC)  
Signal Pin 3 (0-5)VDC  
-
The valve position sensor plug has three wire ends. The first terminal is for positive voltage supply (+5VDC, black and green  
wire), the second terminal is for ground supply (0VDC, black and white wire) and the third terminal is the positive variable  
voltage return (0-5 VDC).  
-
-
Connect the wires to your data logger accordingly. Use a solder iron and heat shrink insulation when joining the wire ends.  
Gently inset the plug into the sensor. The plug can only be inserted in one way. Check for plug and sensor orientation. Do not  
force the plug into the sensor.  
-
-
Test the wiring. Gently push the sensor pin up and down and ensure that the voltage input on the data logger is changing  
between 0-5 VDC. The data logger should approximately read 0 VDC when the sensor pin is in free form and approximately  
+
5VDC when the sensor pin is pushed all the way in.  
Ensure that the wiring is properly shielded from external heat sources.  
3
Installing the valve position sensor  
WARNING! Use caution when installing the valve position sensor.  
-
-
Insert sensor into cap. Rotate left and right as you are pushing the sensor in. Ensure that the screw holes in the sensor body  
are aligned with the tapped screw holes on the sensor cap in your desired position.  
Use supplied screws to screw the sensor to the cap. Torque screws to 2 N-m (1.5 lb-ft). Be careful not to over tighten the  
screws as it will damage the sensor.  
----------------------------------------------------------------------------------------------------------------------  
TROUBLE SHOOTING  
The following points should be checked if you find that your engine is dipping below normal idle, stalling or if the Race Port is functioning  
poorly. Please note, the following checks will cure 99% of problems experienced with a Race Port.  
Check the vacuum hose for splits, cracks, loose connection, kinking or any obstructionold or fatigued hose may collapse under  
vacuum causing an obstruction  
With the engine running remove the vacuum / pressure hose from the nipple in the cap of the Race Port, there should a loud  
hissing sound. The engine should idle poorly, double check by covering the end of the hose with your finger. If this does not occur,  
the hose could be blocked or crimped. Check the hose and replace if necessary.  
Ensure that the vacuum / pressure source is not shared and that the vacuum source is directly from the inlet manifold  
Check the seal between the adapter and the Race Port ensure that there is no gap between the Race Port base and the weld  
flange  
Check the join between the adapter and the intercooler pipe for leaking  
Ensure that the right spring is installed in the Race Port for your engine’s vacuum level  
4
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  
authorised 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 Pty Ltd 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 Pty Ltd, after receipt of the product from  
our authorised 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 Pty Ltd is not  
responsible for voiding any original manufactures warranty.  
All warranty claims must be returned to the authorised reseller, you must return the product and sales receipt, at your own  
expense, accompanied by a letter stating the reason for the claim. Proof of purchase must be provided with any warranty claim  
and will be verified with the authorised 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  
Pty Ltd 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, labour 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 Pty Ltd and to hold Turbosmart Pty Ltd harmless for  
any claim related to the item of the equipment purchased. Under no circumstances will Turbosmart Pty Ltd 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 PTY LTD  
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 PTY LTD 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 SIXTY (60) 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  
Tel: +(612) 9798 2866 Fax: +(612) 9798 2826 Email: [email protected]  
www.turbosmart.com.au www.turbosmartusa.com www.turbosmart.co.nz  
5