Kompact Instructions Kia Stinger

Product Name:

BOV Kompact Kia Stinger

TS-0203-1025

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 Kompact series BOV is designed for use as a factory replacement

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 Kompact Series BOV packaging

Part

1

Description

Turbosmart Kompact Series BOV

Vacuum Hose

Use

Main unit x2

2

Fix plumb back hose to BOV

Mount BOV to mounting flange x8

3.1

3.2

3.3

3.4

3.5

M6 Flange Bolts

Blanking plug

Black off VTA trumpet to convert to pure plumb back. X2

250mm cable tie x2

Cable Tie

Tee

Hose Tee piece

Hose clamp

Spring action hose clamps x6

Turbosmart sticker

4

Turbosmart Sticker

1

3

1

2

Figure 1 - Kit Contents

1

TOOLS REQUIRED

-

5mm hex key

Screw drivers

Pliers

Socket Set

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ABOUT YOUR KOMPACT SERIES BOV

A direct fit high performance replacement for the factory all plastic unit, the Turbosmart Kompact BOV suits the Kia Stinger. The

Turbosmart unit is made of billet aerospace grade aluminium with high temperature seals that allows for minimal leakage and a

complete seal across the bypass aperture providing as much performance as possible.

Benefits include:

•

Direct fit upgrade for the factory BOV on Kia Stinger

Packaged with a blanking plug to switch the unit into pure vent to atmosphere or plumb-back modes

All billet CNC construction and attractive anodized finish

Manufactured, assembled and validated in-house at Turbosmart HQ

Nipple

Tee into factory control

solenoid to both BOV units

Plumb Back Port

Recirculates excess air to

turbocharger inlet

Flange Mounting Holes

Bolt to charge pipe through

adapter plate

Vent to Atmosphere Port

(Only on “Dual Port” Models)

Vents excess air to

atmosphere

Sealing O-Rings (Underneath)

Ensures the valve does not leak

compressed air

Figure 2 – Stinger Kompact BOV Overview

2

FITTING YOUR KOMPACT SERIES BOV

Identify Diverter valve location

1

Identify the location of the factory diverter valve assembly, The

Kia Stinger factory bypass valves are located at the front of the

engine and have easy access

Recirculation hose

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.

Remove the four bolts holding the diverter valve to the charge

pipe and remove from the engine bay.

Diverter Valves

Located at front of

engine.

Remove the OEM diverter valve

2

Remove the signal hoses from the factory control solenoid and

the bypass valves by clamping the tabs on the spring action hose

clamps and moving away from the end of the hose. Twist the

hoses to break the initial seal of the hose from the nipple and pull

away.

Mount your new Turbosmart Kompact BOV

3

Align your new Turbosmart Kompact BOV with the flange on the

charge pipe, align the plumb back port outwards to lign up with

the recirculation hoses, place all bolts in the flange of the BOV

before sitting in place. Ensure the sealing O-rings are correctly

seated in their grooves and tighten down the bolts.

Re attached the recirculation hose onto the BOV and tighten the

hose clamp. Align the swivel nipple on the cap of the BOV and

attach the signal hose.

Congratulations, your Turbosmart Kompact Series BOV is

installed and ready for use. Double check all connections and

mounting screws. Start your engine and check for leaks.

Remove the recirculation hose from the valve by loosening the

hose clamp,

3

Connecting the Signal hose

4

Using the supplied vacuum hose and Tee piece, connect the

vacuum hose to the OEM control solenoid using hose clamps to

secure it in place.

Use the Tee piece to split the hose to join to both BOV’s.

Repeat the process for both BOV units.

Slide the factory recirculation hoses over the plumb back fitting

of the BOV and secure the hose clamps.

Congratulations, your Turbosmart Kompact Series BOV is

installed and ready for use. Double check all connections and

mounting screws. Start your engine and check for leaks.

ADJUSTING YOUR BOV (DUAL PORT ONLY)

The aim of the adjustment on the Dual port is to make sure that the piston is hard closed at idle and that the piston closes fast enough

to minimise backfiring and not stall the engine. In most cases, the cap is in the correct position from factory.

INSTALL THE BOV WITH THE FACTORY SETTING FIRST BEFORE PERFORMING ANY ADJUSTMENT.

Adjustment to the BOV is made by rotating the cap. To increase the spring force on the piston, rotate the cap clockwise in the direction

of hard as marked on the top of the cap. To decrease the spring force on the piston, rotate the cap anticlockwise in the direction of

soft as marked on the top of the cap - CAUTION - Do not rotate the cap beyond the O-Ring groove.

•

Start with the BOV cap at the maximum soft position (The indicator O-Ring should be completely covered by the edge of the cap)

With the engine at idle the exhaust port should be closed off by the piston – the piston should be hard against the seat and not

floating or moving

•

Free rev the engine and back off quickly, the engine should return to normal idle speed – if the engine drops below idle or stalls

increase the spring tension by one turn

•

Repeat this process until the engine free revs and returns to normal idle speed

Test drive the car and ensure that when decelerating or changing gears that the engine has minimal backfiring and no stalling. If

backfiring is excessive or stalling is noticed then check all connections made during the installation, otherwise increase the spring

tension

4

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.

-

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 / 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.

-

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.

Check the seal between the charge pipe flange and the BOV. Make sure the supplied O-Rings are installed properly and

the BOV Flange is secured on the compressor cover flange with the 3 supplied screws.

Ensure the spring clamps are secured on silicon hoses and fittings.

If the valve does not open properly or is slow to react, it could be due to the mapping of the drive by wire system from such

things as aftermarket chips and engine tunes. Check with the tuner that the mapping of the throttle is the same as OEM.

The valve may not open if the engine is just free reved. Check that the valve operates by driving the vehicle.

-

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