Product Name:  
Power Port  
Product Description:  
Product Number:  
Document Version:  
Blow off valve (BOV)  
TS-0207-100X  
V1.00 Rev D  
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IMPORTANT NOTES ON YOUR POWER PORT BOV  
Do NOT block lower chamber ports unless used with a pressure source  
Use only silicone hose that is the correct size and pressure/vacuum rating for your application.  
Ensure that all plumbing is secured with suitable clamps or the correct fittings are used.  
Your Power Port should be mounted at least 100mm from any significant heat source.  
Check the vacuum level produced by your engine to ensure the correct spring/s combination for your Power Port for maximum response.  
RECOMMENDATIONS  
Turbosmart recommends that your Power Port is fitted by an appropriately qualified technician  
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HOW TO INSTALL YOUR POWER PORT BOV  
KIT CONTENTS  
Please check that the following items have been provided in your Power Port BOV kit.  
Quantity  
Description  
Turbosmart Power Port  
1/8” NPT Blank  
Use  
1
1
1
1
1
1
1
1
Main BOV unit  
Used to seal spare inlet port on lower chamber of BOV  
Used to supply signal to lower chamber of BOV  
Used to mount BOV onto piping  
1/8” NPT Nipple  
Inlet Weld-On Flange (Alloy)  
V-Band  
Used to secure weld-on flange to BOV main unit  
Used for sealing inlet flange  
60x2.6mm O-Ring  
Collar Tool  
Used for removal of BOV collar  
Turbosmart Sticker  
Turbosmart sticker  
Figure 1 - Kit Contents  
POWER PORT BOV OVERVIEW  
Primary Signal Port from  
Intake Manifold  
Lockwire Holes  
Removeable Collar  
Lower Chamber Signal Port  
(usage optional)  
Lower Chamber Signal  
Port (usage optional)  
V-band for Fitment  
1
FITTING YOUR POWER PORT BOV  
Locate charge pipe for Power Port installation  
and prepare for welding  
Fit Lower Chamber Port Fittings (OPTIONAL)  
1
3
This pipe is located between the pressure source outlet and the This step is optional. Prior to mounting the Power Port, install  
throttle body. Take time to determine where you wish to mount 1/8” NPT blank with 3/16” hex key and signal nipple into lower  
the Power Port along this pipe and prepare the pipe for welding. chamber ports. Port order or orientation is not important,  
Weld alloy inlet flange onto pipe in your desired location. select which suits your packaging requirements. Apply thread  
(Stainless Steel Weld Flange Optional TS-0207-2001)  
lubricant and screw in clockwise until finger tight, then tighten  
further 1-2 turns for seal.  
CAUTION!  
Allow engine to cool down before installing your Power  
Port.  
Prepare Power Port for installation  
2
Prior to mounting the Power Port, 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 Power Port to be installed. (Replacement  
V-Band Optional TS-0207-3004)  
CAUTION!  
Do NOT insert fittings and blank unless lower chamber is  
to be used as this can affect the performance of the  
product.  
Mounting your Power Port  
4
With all fittings installed onto the Power Port, the Power Port  
can now be mounted. Place the O-ring provided onto the  
mounting flange. Align the Power Port onto the flange and  
squeeze the v-band in a syringe action to expand the v-band  
and slide over the flange and Power Port to clamp together.  
Tighten v-band bolt to 6 Nm or finger tight + 2.5 turns.  
Proceed to connect your signal lines.  
CAUTION!  
Ensure O-Ring is located between Power Port and  
mounting flange.  
Ensure signal source for BOV is located from inlet  
manifold post throttle body.  
2
Start engine and check for leaks  
POWER PORT SPRINGS  
5
*Power Port as supplied  
Congratulations, your Power Port is installed and  
Part Number TS-0207-3002  
Installed Installed  
ready for use. Double check all fittings, lines and mountings  
then proceed to start engine and check for leaks. No  
adjustment is required.  
Location  
Pressure  
Inner  
4inHg  
Middle  
8inHg  
Outer  
8inHg  
0
-4inHg  
-8inHg  
See over for troubleshooting steps if required.  
4
*
8-16inHg  
1
6-20inHg  
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HOW TO CHANGE YOUR POWER PORT BOV SPRING  
The Power Port has a variety of springs to suit different vacuum levels. Different tuning levels produce different levels of idle  
vacuum. The Power Port is fitted with a standard spring which will remain closed until the engine produces more than 16 inHg.  
Turbosmart has a range of springs to suit different vacuum levels to ensure high levels of response from the Power Port.  
Remove Power Port off charge pipe  
Remove Power Port top cap (cont.)  
1
2
This pipe is located between the pressure source outlet  
and the throttle body. Remove all signal lines to Power Port.  
Unscrew v-band bolt anti-clockwise until bottomed out and  
squeeze v-band against the bolt head in a syringe like motion to  
expand the v-band clamp. Lift off Power Port while expanding v-  
band to allow for it to slide out.  
CAUTION!  
Allow engine to cool down before removing your Power  
Port.  
Remove Power Port top cap  
2
Prior to removing the Power Port cap, remove the top cap signal  
nipple by unscrewing it anti-clockwise. Hold the cap down in a  
press or a vice. Unscrew locking collar in an anti-clockwise  
direction until completely disengaged and slowly remove tension  
from vice or press allowing the spring to expand, finally remove  
cap when cap has stopped expanding.  
Configure Power Port with your preferred spring combination  
of inner, middle or outer springs.  
CAUTION!  
Ensure diaphragm is contained within the groove prior to  
cap re-assembly.  
3
Familiarise yourself with the cap and body  
notches  
Press cap onto body (cont.)  
3
4
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!  
Maintain downward pressure on cap while tightening  
collar or non repairable thread damage will occur.  
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.  
Press cap onto body  
4
Reinstall Power Port onto charge pipe  
5
Using a vice or press, 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.  
Reinstall Power Port back onto piping by expanding v-band  
clamp in a syringe type motion and sliding Port Power port  
onto flange, clamp flange and Power Port together with v-band  
and tighten to 6 Nm or hand tight + 2.5 turns.  
4
Safety Wire (Lock Wire)  
6
Using safety wire pliers, install safety wire onto the collar using  
the small holes provided in the collar and using a suitable fixed  
location for the opposite end. Twist the safety wire to provide  
adequate tension to prevent the collar from coming loose. A  
typical installation, but not limited to, utilises nipples fitted to one  
of the lower chamber ports. The safety wire should be made as  
short as possible and in the direction that does not allow any  
loosening of the collar.  
CAUTION!  
Do Not overtension the Safety Wire as this could cause  
damage to the BOV  
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HOW TO CHANGE YOUR POWER PORT BOV DIAPHRAGM  
BOV Power Port Diaphragm Replacement: TS-0207-3005  
Remove Power Port off charge pipe  
Remove Power Port top cap (cont.)  
1
2
This pipe is located between the pressure source outlet  
and the throttle body. Remove all signal lines to Power Port.  
Unscrew v-band bolt anti-clockwise until bottomed out and  
squeeze v-band against the bolt head in a syringe like motion to  
expand the v-band clamp. Lift off Power Port while expanding v-  
band to allow for it to slide out  
.
CAUTION!  
Allow engine to cool down before removing your Power  
Port.  
Remove Power Port top cap and springs  
2
Prior to removing the Power Port cap, remove the top cap signal  
nipple by unscrewing it anti-clockwise. Hold the cap down in a  
press or a vice. Unscrew locking collar in an anti-clockwise  
direction until completely disengaged and slowly remove tension  
from vice or press allowing the spring to expand, finally remove  
cap when cap has stopped expanding.  
5
Diaphragm Replacement (cont.)  
3
Diaphragm Replacement  
3
Hold the two flats on the bottom of the valve using a 17mm  
spanner or similar, this may be easier if the valve is lifted  
allowing full side access to the valve  
Using a 4mm allen key, undo the bolt at the centre of the  
diaphragm holding it to the valve stem. Wipe off any  
residue left behind on the valve stem.  
Place your new diaphragm over the valve stem, apply  
thread locker to the bolt and tighten to 6 Nm or hand tight  
+
2.5 turns.  
Reassemble Power Port  
4
Refer to “HOW TO CHANGE YOUR POWER  
PORT BOV SPRING” parts 3 thru 5 for  
reassembly of your Power Port BOV  
CAUTION!  
Ensure diaphragm is contained within the groove prior to  
cap re-assembly.  
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6
HOW TO INSTALL YOUR POWER PORT SENSOR CAP  
BOV Power Port Sensor Cap Replacement: TS-0207-3006/7 (Black/Blue)  
Remove Power Port off charge pipe  
Install Sensor Cap onto BOV  
1
3
This pipe is located between the pressure source outlet  
and the throttle body. Remove all signal lines to Power Port.  
Unscrew v-band bolt anti-clockwise until bottomed out and  
squeeze v-band against the bolt head in a syringe like motion to  
expand the v-band clamp. Lift off Power Port while expanding v-  
band to allow for it to slide out.  
CAUTION!  
Allow engine to cool down before removing your Power  
Port.  
Remove Power Port top cap and springs  
2
Prior to removing the Power Port cap, remove the top cap signal  
nipple by unscrewing it anti-clockwise. Hold the cap down in a  
press or a vice. Unscrew locking collar in an anti-clockwise  
direction until completely disengaged and slowly remove tension  
from vice or press allowing the spring to expand, finally remove  
cap w
Ensure when assembling sensor cap onto BOV body that  
the wiring loom is not damaged or crushed. Please refer  
to “HOW TO CHANGE YOUR POWER PORT BOV  
SPRING” parts 3 thru 5 for reassembly of your Power  
Port BOV for accurate cap installation steps.  
Wiring your Sensor  
4
Note  
Wire  
Red  
Rating  
Sensor Supply  
Sensor Ground  
Sensor Output  
+5V  
Black  
White  
0V  
Non-Linear Analog  
The sensor calibration has been performed using 5V as  
most datalogging equipment has dedicated 0V and 5V  
rails, if your datalogger supply voltage varies from 5V  
please check calibration to ensure accurate results.  
Position (mm)  
Voltage (V)  
1.16  
Position (mm)  
Voltage (V)  
1.46  
0
2
4
6
8
12  
14  
16  
18  
20  
22  
1.19  
1.55  
1.25  
1.64  
1.3  
1.71  
1.36  
1.79  
10  
1.4  
1.88  
CAUTION!  
Ensure wiring polarity is not reversed as permanent  
damage will occur.  
7
TROUBLE SHOOTING  
-
Erratic Idle Check fittings are tight and O-rings are present or not damaged. Check signal hoses for splits, cracks, loose connection,  
kinking or any obstruction old or fatigued hose may collapse under vacuum causing an obstruction.  
-
BOV not actuating With engine running, remove the signal hose to the BOV, there should be a loud hissing sound, confirmation of  
vacuum can be felt by momentarily blocking this hose with a finger. Check the hose and replace if necessary.  
-
-
-
Poor BOV actuation Ensure that the signal hose is not shared and that the signal source is directly from the inlet manifold.  
Poor BOV actuation Ensure that the lower chamber ports of the BOV are not blocked when lower chamber is not being used.  
Poor BOV actuation Check the seal between the adapter and the BOV ensure that there is no gap between the BOV base and the  
flange.  
-
-
Poor BOV actuation Ensure that the spring installed is representative of your engines vacuum level.  
Failing the above, submit a technical request to [email protected] with information of your engine configuration and photos of  
installation  
TURBOSMART  
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.  
Turbosmart 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, after receipt  
of the product from our authorized 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 is not responsible for voiding any original manufactures warranty.  
All warranty claims must be returned to the nearest Turbosmart Office, you must return the product and sales receipt, at your own expense, accompanied by the  
Customer Warranty Form stating the reason for the claim. Proof of purchase must be provided with any warranty claim and will be verified with the authorized 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 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, labor 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 and to hold Turbosmart harmless for any claim related to the item of the equipment purchased. Under no  
circumstances will Turbosmart 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 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.  
Head Office: Turbosmart Pty Limited, PO Box 264 Croydon, NSW, 2132 Australia  
Ph: +61(2) 9798 2866  
Fax: +61 (2) 9798 2826  
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