Product Name:  
Gen V Raceport  
Gen V Raceport  
TS-0204-113X  
V1.00 Rev D  
Product Description:  
Product Number:  
Document Version:  
2
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IMPORTANT NOTES ON YOUR GENV RACEPORT  
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Turbosmart accepts no responsibility whatsoever for incorrect installation of this product which is potentially hazardous and can cause serious  
engine damage or personal injury.  
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The Gen V Raceport is designed for use with a turbocharger that do not have inbuilt BOV’s or when a larger flow rate is required.  
Use only high-quality fittings ensuring maximum sealing reliability.  
RECOMMENDATIONS  
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Allow for adequate cool airflow around the top diaphragm housing.  
DO NOT Mount the Raceport so that the top diaphragm housing is less than 100mm from a heat source.  
Fitting your Gen V Raceport may require fabrication or modification to your turbocharger piping. Turbosmart recommends that your  
Raceport is fitted by an appropriately qualified technician.  
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Turbosmart recommends that a boost gauge be permanently fitted to the vehicle.  
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KIT CONTENTS  
Please check that the following items have been provided in your Gen V Raceport kit.  
Part  
1
Description  
Turbosmart Gen V Raceport  
V-Band Clamp  
Use  
Main unit  
2
V-Band Clamp  
3
Weld Flange  
Aluminium Weld Flange  
Inlet Flange O-Ring seal  
4
O-Ring  
5
Fitting Kit  
1x 1/8” NPT nipple, 1x 1/8” NPT blanking plugs **(1x pre-installed) **  
6
Turbosmart Sticker  
Turbosmart sticker  
5
1
2
4
3
Figure 1 - Kit Contents  
1
CONTENTS  
KIT CONTENTS..........................................................................................................................................................1  
TOOLS REQUIRED....................................................................................................................................................2  
SUGGESTED SEALANTS..........................................................................................................................................2  
GEN V RACEPORT OVERVIEW ................................................................................................................................3  
FITTING YOUR GEN V RACEPORT...........................................................................................................................4  
HOW TO CHANGE YOUR GEN V RACEPORT SPRING ...........................................................................................5  
TUNING YOUR VACUUM LEVEL...............................................................................................................................6  
HOW TO CHANGE YOUR GEN V RACEPORT DIAPHRAGM ...................................................................................7  
TROUBLESHOOTING..............................................................................................................................................12  
TOOLS REQUIRED  
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Non-marking spanners to tighten fittings  
4mm hex key  
3/16” hex key  
Collar tool (TS-0505-3008)  
Flat Blade screwdriver  
SUGGESTED SEALANTS  
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Loctite 243 Thread locker  
Loctite 271 Thread locker  
Loctite 567 Thread Sealant  
2
GEN V RACEPORT OVERVIEW  
“Top” Port  
1/8” NPT  
Master Collar  
Inlet V-Band  
Inlet Weld Flange  
Figure 2 – Gen V Raceport Overview  
3
FITTING YOUR GEN V RACEPORT  
Mounting your New Turbosmart Gen V  
Raceport  
1
The Gen V series of Raceport is a direct fit replacement for the  
Raceport and no modification is necessary provided packaging  
space is sufficient.  
The weld flanges should be welded to your charge pipe in a  
suitable location. The weld flanges are compatible with  
aluminium welding rod material. Purge bungs should be used to  
maintain the straightness of the flange during the welding  
process. TS-0204-3003  
For best results, an attempt should be made, if space allows, to  
mount the Gen V Raceport as close to the throttle as possible.  
The Raceport should be mounted such that it is not on the inside  
radius of any bend.  
CAUTION!  
Do not place the actuator cap near a significant heat source  
as this could shorten the life of the diaphragm.  
Fitting the Gen V Raceport  
2
Prior to mounting the Gen V Raceport, place v-band over weld  
on flange by unscrewing the bolt on the v-band as far out as  
possible and then squeezing the bolt in a syringe motion to  
expand the v-band (squeeze the dots together below). Once the  
v-band is in its fully expanded position, slide the v-band over the  
flange to allow for the Raceport to be installed.  
Fit Actuator Port Fittings  
3
Fit top chamber port fittings prior to mounting the Raceport, install  
/8” NPT blank with 3/16” hex key and signal nipple into ports in  
the cap. Port order or orientation is not important, select which  
suits your packaging requirements. Apply thread lubricant and  
screw in clockwise until finger tight, then tighten further 1-2 turns  
for seal.  
1
Do not forget to put the O-Ring seal into the flange before  
mounting the unit on the charge pipe. Using the 4mm hex bit  
socket and a torque wrench, Tighten the V-Band to 4N.m (3  
ft/lbs). Ensure the Raceport is home correctly while torquing the  
Select a suitable manifold pressure source, use the shortest  
possible hose length to the Raceport.  
CAUTION!  
Do not share manifold pressure source with fuel pressure  
regulator or any other critical instrument.  
Start Engine and Check for Leaks  
5
Congratulations, your Gen V Raceport is installed and ready for  
use. Double check all fittings, lines and mountings then proceed  
to start engine and check for leaks.  
4
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HOW TO CHANGE YOUR GEN V RACEPORT SPRING  
The Gen V Raceport has a variety of springs to suit different Vacuum levels and applications. Turbosmart provides the Gen V Raceport  
pre-installed with 18InHg spring. Different spring combinations may be required to suit different application requirements and tuning.  
Remove Raceport BOV From Charge Pipe  
1
Remove Top Cap (cont.)  
2
Remove manifold pressure source hose from the BOV. Unscrew  
V-band bolt in an anti-clockwise direction to the very end of the  
thread, squeeze the bolt against the V-band in a syringe like  
motion to expand the V-band over the flange. Remove Gen V  
Raceport being careful not to drop or lose the sealing O-Ring.  
CAUTION!  
Allow engine to cool down before removing your Gen V  
Raceport  
Remove Top Cap  
2
Prior to removing the Gen V Raceport cap, remove all fittings  
from the 1/8”NPT ports. Press down with light to medium load on  
the cap in a press or vice. Unscrew locking collar with a collar  
tool (TS-0505-3008) in an anti-clockwise direction until  
completely disengaged and gently remove tension from the  
press or vice allowing the spring to expand, finally remove cap  
when the spring has stopped expanding.  
CAUTION!  
Use soft jaws to prevent cosmetic damage.  
Configure Raceport with preferred spring combination.  
Familiarise Yourself with Cap and Body  
Notches  
3
Locate cap and body notches and grooves which dictate the  
alignment of the cap. These notches are used to locate the cap  
onto the body and must be aligned prior to compression of the  
cap onto the body.  
CAUTION!  
Ensure notches are aligned and seated home correctly prior  
to exerting force to tighten collar, permanent damage will  
occur if these are not aligned correctly.  
5
CAUTION!  
Maintain downward pressure on cap while tightening collar  
or non-repairable thread damage will occur.  
Reinstall fittings to the cap of the Raceport using fresh Loctite  
567 thread sealant.  
Reinstall Gen V Raceport  
5
Place V-band over weld on flange by unscrewing the bolt on the  
V-band as far out as possible and then squeezing the bolt in a  
syringe motion to expand the V-band. Once the V-band is in its  
fully expanded position, slide the v-band over the flange to allow  
for the Raceport to be installed.  
4
Do not forget to put the O-ring into the flange before mounting  
the unit on the Charge pipe. Using the 4mm hex bit socket and a  
torque wrench tighten the V-Band to 4N.m (3 ft/lbs).  
Using a press or vice, compress the cap onto the body ensuring  
the notches are remaining aligned. Once the cap has seated  
home onto the body, screw the collar down by hand in a  
clockwise direction. While still in the press or vice, Tighten the  
collar further with the collar tool until the collar will not turn.  
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TUNING YOUR VACUUM LEVEL  
The Race Port has a variety of springs to suit different vacuum levels. Different tuning levels and engine configurations 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.  
IMPORTANT NOTES ON SETTING THE RACEPORT SPRING  
PRESSURE  
See over for Spring Chart.  
A stiffer spring should only be used when necessary. The Gen V  
Raceport allows for different combinations of spring pressures.  
All springs that are adaptable with the Gen V Raceport are shown  
in the table below. The tuner can use combinations of up to 3  
springs to achieve the following Manifold vacuum pressures. To  
aid in the identification of these springs they are supplied colour  
coded. Please see the following detailed instructions on setting  
your Gen V Raceport’s spring pressure. The springs chosen  
should be rated to the lowest boost level desired.  
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Location  
Colour  
Inner  
Pink  
Inner  
Orange  
Middle  
Purple  
Middle  
Green  
Outer  
Blue  
Part # TS-0203-3002  
TS-0204-2105  
7 InHg  
TS-0204-2104**  
9 InHg  
TS-0204-3105  
15 InHg  
TS-0204-3102  
18 InHg  
Vacuum  
4 InHg  
0
-4 InHg  
-8 InHg  
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4
●
6
-10 InHg  
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●
1
1
1
1
1
1
2
0-14 InHg  
1-15 InHg  
4-18 InHg  
5-19 InHg  
8-22 InHg  
9-23 InHg  
2-26 InHg  
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●
●
●
●
●
●
●
●
●
*
* Purple TS-0204-2104 only available in the spring kit  
Table 1: Spring Chart  
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HOW TO CHANGE YOUR GEN V RACEPORT DIAPHRAGM  
Gen V Raceport replacement diaphragm kit:  
Piston Assembly: TS-0204-3103  
Collar Tool: TS-0505-3008  
CAUTION!  
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Ensure diaphragm is contained within the groove prior to cap re-assembly.  
Pay attention not to rotate diaphragm.  
CAUTION!  
Allow engine to cool down before removing your Gen V  
Raceport  
Remove Raceport BOV From Charge Pipe  
1
Remove manifold pressure source hose from the BOV. Unscrew  
V-band bolt in an anti-clockwise direction to the very end of the  
thread, squeeze the bolt against the V-band in a syringe like  
motion to expand the V-band over the flange. Remove Gen V  
Raceport being careful not to drop or lose the sealing O-Ring.  
CAUTION!  
Allow engine to cool down before removing your Gen V  
Raceport  
Remove Top Cap  
2
Prior to removing the Gen V Raceport cap, remove all fittings  
from the 1/8”NPT ports. Press down with light to medium load on  
the cap in a press or vice. Unscrew locking collar with a collar  
tool (TS-05005-3008) in an anti-clockwise direction until  
completely disengaged and gently remove tension from the  
press or vice allowing the spring to expand, finally remove cap  
when the spring has stopped expanding.  
CAUTION!  
Use soft jaws to prevent cosmetic damage.  
7
Remove Top Cap (cont.)  
Change Piston Guide  
2
4
The Raceport Piston replacement kit includes a new guide that  
is to be fitted to the cap, this guide is mandatory on early models  
of the GenV Raceport that use a smaller diameter stem on the  
piston.  
This guide is held into the cap with Loctite and will require some  
effort to remove, Hold the cap in a way that does not distort or  
damage the cap in any way, use a friction wrench to undo the  
guide from the cap in and anticlockwise direction (standard Right-  
Hand thread). Clean any debris from the cap and replace with  
the new guide applying a small amount of red 271 thread locker  
Change Piston Assembly  
3
Lift the piston assembly out of the body of the Raceport, use a  
O-Ring pick to lift the bead of the diaphragm out of the groove if  
necessary. Clean all components removing all dirt and dust from  
the assembly.  
Inspect for Damage before inserting new piston assembly into  
Raceport Body. Ensure Diaphragm bead is seated correctly in  
the groove on the body.  
CAUTION!  
Do NOT allow any thread locker to dry on the inside of the  
guide, this will result in the piston seizing.  
Familiarise Yourself with Cap and Body  
Notches  
5
Locate cap and body notches and grooves which dictate the  
alignment of the cap. These notches are used to locate the cap  
onto the body and must be aligned prior to compression of the  
cap onto the body.  
CAUTION!  
Ensure notches are aligned and seated home correctly prior  
to exerting force to tighten collar, permanent damage will  
occur if these are not aligned correctly.  
8
Press Cap onto Body  
6
Using a press or vice, compress the cap onto the body ensuring  
he notches are remaining aligned. Once the cap has seated  
home onto the body, screw the collar down by hand in a  
lockwise direction. While still in the press or vice, Tighten the  
ollar further with the collar tool until the collar will not turn.  
Remove boost pressure source hose from the Raceport as well  
as the breather hose is fitted. Unscrew outlet V-Band nut in an  
anti-clockwise direction to the very end of the thread, Squeeze  
he nut against the V-Band in a syringe like motion to expand the  
V-band over the flange. Repeat for inlet V-Band. Remove Gen V  
Raceport being careful not to lose the valve seat. Mark the  
orientation of the valve to the body with tape or a paint pen.  
TO CONFIGURE SENSOR CAP VERSION  
CAUTION!  
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Applicable to Sensor Cap versions of GenV Race Port only.  
Cool air flow is required around the actuator to keep the sensor in its operating window.  
CAUTION!  
Allow engine to cool down before removing your Gen V  
Raceport  
CAUTION!  
Use soft jaws to prevent cosmetic damage.  
Remove Raceport BOV From Charge Pipe  
1
Remove manifold pressure source hose from the BOV. Unscrew  
V-band bolt in an anti-clockwise direction to the very end of the  
thread, squeeze the bolt against the V-band in a syringe like  
motion to expand the V-band over the flange. Remove Gen V  
Raceport being careful not to drop or lose the sealing O-Ring.  
CAUTION!  
Allow engine to cool down before removing your Gen V  
Raceport  
Remove Top Cap  
2
Prior to removing the Gen V Raceport cap, remove all fittings  
from the 1/8”NPT ports. Press down with light to medium load on  
the cap in a press or vice. Unscrew locking collar with a collar  
tool (TS-05005-3008) in an anti-clockwise direction until  
completely disengaged and gently remove tension from the  
press or vice allowing the spring to expand, finally remove cap  
when the spring has stopped expanding.  
9
Remove Top Cap (cont.)  
2
Install Magnet  
3
Clean the top of the stem ensuring nothing will impede the  
installation of the magnet. Fit the magnet into the top of the stem  
with the marking facing out of the stem ensuring the magnet is  
placed all the way in.  
Apply 243 thread locker to the locking screw provided and screw  
down with a flat blade screwdriver until firm against the magnet.  
Familiarise Yourself with Cap and Body  
Notches  
4
CAUTION!  
Excessive force may damage the magnet or threads.  
Locate cap and body notches and grooves which dictate the  
alignment of the cap. These notches are used to locate the cap  
onto the body and must be aligned prior to compression of the  
cap onto the body.  
Locking screw  
CAUTION!  
Ensure notches are aligned and seated home correctly prior  
to exerting force to tighten collar, permanent damage will  
occur if these are not aligned correctly.  
Inspect for Damage before inserting piston assembly i
Raceport Body. Ensure Diaphragm bead is seated correctly
the groove on the body.  
CAUTION!  
Press Cap onto Body  
To ensure longevity from the sensor, ensure adequate  
airflow is supplied directly to the sensor to avoid  
overheating or sensor failure.  
5
Using a press or vice, compress the cap onto the body ensuring  
the notches are remaining aligned. Once the cap has seated  
home onto the body, screw the collar down by hand in a  
clockwise direction. While still in the press or vice, Tighten the  
collar further with the collar tool until the collar will not turn.  
Turbosmart HE sensor has an operation temperature  
window of -40C up to 170ºC (340ºF) junction temperature, for  
temperatures outside of this window the VOUT will revert to  
less than 2.5V  
Temperature exposure above 260ºC (500ºF) can cause  
permanent damage to the sensor.  
Remove boost pressure source hose from the Raceport as well  
as the breather hose is fitted. Unscrew outlet V-Band nut in an  
anti-clockwise direction to the very end of the thread, Squeeze  
the nut against the V-Band in a syringe like motion to expand the  
V-band over the flange. Repeat for inlet V-Band. Remove Gen V  
Raceport being careful not to lose the valve seat. Mark the  
orientation of the valve to the body with tape or a paint pen.  
Calibration*  
7
Insert the relevant calibration curve into your data logger for the  
product family you have.  
WG38/40 (all configurations)  
Wiring  
Your new Turbosmart sensor cap required installation of  
6
the sensor into the cap, apply a small amount of 243  
Loctite to the threads of the sensor housing and screw into the  
cap of the Raceport by hand. If and grabbing is felt stop and try  
again ensuring the sensor is properly seated within the housing.  
The Sensor is supplied with unterminated wires for you to fit the  
Valve Lift (mm)  
-0.75  
V
OUT  
2.35  
0
2
4
6
8
2.313  
2.236  
2.174  
2.075  
1.946  
1.731  
1.444  
0.977  
0.712  
10  
12  
14  
16  
CAUTION!  
Ensure magnet is installed in the correct direction if Vout is  
more than 2.5V  
NOTE! For best results, each raceport should be calibrated to  
your setup.  
Wire  
Red  
Note  
Rating  
4.5-5.5 Vdc  
0V  
2.500  
2.000  
1.500  
Sensor Supply (Vsup  
)
Black Sensor Ground (V )  
0
White Sensor Output (Vout  
)
0-Vsupply  
1.000  
0.500  
0.000  
Connect the wires to your data logger accordingly. Use a high-  
quality connection to reduce noise and calibration fluctuation.  
0
5
10  
15  
20  
Ensure that the wiring is properly shielded from external heat  
sources.  
Standardised lift (mm)  
1
1
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TROUBLESHOOTING  
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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.  
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.  
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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.  
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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