Product Name:  
Gen V Wastegate (STD/Msport/HP  
Config)  
Product Description:  
Product Number:  
Gen V Wastegate  
TS-055X-101X & TS-055X-11XX  
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IMPORTANT NOTES ON YOUR EXTERNAL WASTEGATE  
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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 external wastegate is designed for use with a turbocharger that does not have an internal wastegate.  
Consult your local specialist before setting your desired boost pressure, setting boost beyond your engines capability may result in engine  
damage.  
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Use only high-quality fittings ensuring maximum sealing reliability. Optional Turbosmart fitting kit available.  
RECOMMENDATIONS  
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Allow for adequate cool airflow around the top diaphragm housing.  
DO NOT Mount the wastegate so that the top diaphragm housing is less than 100mm from a heat source.  
DO NOT wrap the body of the wastegate with exhaust wrap.  
Fitting your Gen V wastegate may require fabrication or modification to your exhaust manifold. Turbosmart recommends that your  
wastegate is fitted by an appropriately qualified technician.  
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Turbosmart recommends that the engines Air/Fuel ratio is checked while setting the desired boost pressure, as any increase in  
boost pressure can cause the engine to run “LEAN”, resulting in possible engine damage.  
Turbosmart recommends that boost pressure is set using a dynamometer and not on public roads.  
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 Wastegate kit.  
Part  
1
Description  
Turbosmart Gen V Wastegate  
Valve Seat  
Use  
Main unit  
2
Valve seat  
3
Inlet V-Band clamp  
Inlet Weld flange  
Outlet V-Band clamp  
Outlet weld flange  
Collar tool  
Inlet V-band clamp  
Inlet V-band weld flange  
Outlet V-band clamp  
Outlet V-band weld flange  
4
5
6
7
Adjusting actuator and changing springs  
8
Spring kit  
3x springs: 2x inner, 1x middle, 1x outer **(1x spring pre-installed) **  
2x 1/8” NPT nipple, 4x 1/8” NPT blanking plugs **(1x pre-installed) **  
Turbosmart sticker  
9
Fitting kit  
1
0
Turbosmart Sticker  
1
Figure 1 - Kit Contents  
CONTENTS  
KIT CONTENTS.................................................................................................................................................1  
TOOLS REQUIRED...........................................................................................................................................3  
SUGGESTED SEALANTS................................................................................................................................3  
WHAT IS AN EXTERNAL WASTEGATE.........................................................................................................4  
WHAT’S NEW....................................................................................................................................................4  
GEN V WASTEGATE OVERVIEW ...................................................................................................................5  
FITTING YOUR GEN V WASTEGATE.............................................................................................................6  
Basic Wastegate Hook-up...........................................................................................................................7  
HOW TO CHANGE YOUR GEN V WASTEGATE SPRING ............................................................................8  
ACHIEVING YOUR TARGET BOOST PRESSURE ........................................................................................9  
HOW TO CHANGE YOUR GEN V WASTEGATE DIAPHRAGM..................................................................10  
BOOST CONTROL HOOKUP ON THE GEN V WASTEGATE.....................................................................13  
Boost Tee Setup.........................................................................................................................................13  
e-Boost 2 Connection Methods................................................................................................................13  
Single Port Connection .........................................................................................................................14  
Two Port Connection method (1).........................................................................................................14  
Two Port Connection method (2).........................................................................................................15  
Two Port Connection method (3).........................................................................................................15  
HOW TO CHANGE YOUR GEN V HIGH PRESSURE WASTEGATE SPRING...........................................16  
ADVANCED FEATURES ON THE GEN V WASTEGATE ............................................................................17  
Re-Orientation of the Actuator.................................................................................................................17  
Water Cooling.............................................................................................................................................18  
HOW TO INSTALL A SENSOR CAP TO YOUR GEN V WASTEGATE.......................................................19  
2
Graph 1 – Calibration Graph.........................................................................................................................23  
TROUBLESHOOTING ....................................................................................................................................23  
TOOLS REQUIRED  
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3/8” square drive deep socket  
Square drive ratchet wrench  
Torque wrench (3/8” drive)  
Non-marking spanners to tighten fittings  
3/16” hex key  
Supplied collar tool  
14mm 12-point (double hex) socket  
Flat blade screwdriver  
Small hammer  
SUGGESTED SEALANTS  
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Loctite 243 Thread locker  
Loctite 567 Thread Sealant  
Resbond 907TS Red  
Penetrating oil  
3
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WHAT IS AN EXTERNAL WASTEGATE  
What is a wastegate  
Internal or external, a wastegate is a boost-controlling device that operates by limiting exhaust gases going through the turbocharger,  
controlling the maximum boost pressure produced by the turbocharger itself. A wastegate consists of an inlet and outlet port, a valve  
and a pressure actuator.  
How a wastegate works  
A pressure actuator, controlled by boost pressure determines whether the wastegate is open or shut. In its resting position, a  
wastegate is shut, and as the boost pressure builds, force is applied to the actuator. When the boost pressure exceeds the spring  
value, the actuator will progressively open the wastegate, bypassing some of the exhaust gases therefore maintaining the boost  
pressure at the set level. To put it simply – a wastegate prevents the boost pressure from climbing indefinitely and consequently  
blowing the engine.  
When is an external wastegate required?  
Most of the factory turbo systems feature an internal wastegate made to handle stock boost levels. The most common reason for  
investing in an external wastegate is fitting an after-market turbo or better control of the boost and consequently the power output of  
your engine. Additionally, most large frame turbochargers are not equipped with internal wastegate systems.  
Most tuners will recommend an external wastegate for any engine producing 400hp or more, as running high boost through a factory  
internal wastegate can overpower the actuator spring, limiting maximum boost level. Aftermarket external wastegates feature bigger  
inlet and outlet ports, higher pressure springs and bigger actuator diaphragms to effectively control high boost pressure.  
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WHAT’S NEW  
Our new wastegates are a direct fit upgrade to all 4th-generation Turbosmart wastegates and feature our unique collar-locking system,  
variable actuator cap and base, strap-type V-band clamps, liquid-cooling, 1/8″ NPT ports, and are provided with a range of springs.  
They are also available in Motorsport and compressed gas-only versions for those requiring specific applications.  
Modular  
The 5th series wastegate range has been designed for maximum user-adjustability, without compromising performance. We designed  
our new unit to allow actuators to be interchangeable across the range. So, if you need a large wastegate in a tight space you can  
run a smaller actuator on the larger body. Additionally, if you decide to upgrade your new wastegate to a motorsport or compressed  
gas-only actuator you can with an upgrade kit.  
Adjustability  
The unique variable adjustment design allows the wastegate actuator base to be oriented independently from the weld flanges. The  
cap is also completely independent and indexable in 12 different positions compared to the actuator base and body. This allows the  
wastegate to be fitted in confined positions without compromising packaging for fittings or aligning the cap.  
Upgrades and Servicing  
Due to the modular construction, the new range is also upgradeable and completely serviceable, as all components can be removed  
or upgraded. Components have been tested for over one million cycles so reliability will be rock-solid.  
Flow and Thermal Performance  
Our new range of wastegates out-flow all competitors thanks to our world-leading engineering and simulation abilities. Thermal  
performance has been improved drastically compared to our nearest rival, and all wastegates feature liquid cooling ports for further  
thermal performance if required  
Control  
For fine-tuning, boost performance, a selection of springs will be supplied with each wastegate. All wastegates feature 1/8″ NPT ports  
for maximum response and flow while maintaining a high level of compatibility for fittings.  
4
GEN V WASTEGATE OVERVIEW  
Compressed Gas  
Figure 2 -Gen V Wastegate Variants  
“
Top” Air Port  
1
/8” NPT  
Master Collar  
“
1
Bottom” Air Port  
/8” NPT  
Outlet V-Band  
“
Water Cooling” port  
1
/8” NPT  
Inlet V-Band  
Inlet Weld Flange  
Outlet Weld flange  
Figure 3 – Gen V Wastegate Overview  
Locking tabs  
2
water port  
holes on  
Water cooling  
symbol  
Slave Collar  
Figure 4 – Gen V Wastegate Cooling Ports  
Figure 5 – Gen V Wastegate Locking Tabs  
5
FITTING YOUR GEN
Wastegate  
Mounting your New Turbosmart Gen V  
Wastegate  
1
Exhaust flow  
to wastegate  
The Gen V series of wastegate is a direct fit replacement for the  
th  
4
gen wastegate range and no modification is necessary  
provided packaging space is sufficient.  
Turbine  
The weld flanges should be welded to your exhaust system. The  
weld flanges are compatible with Stainless Steel and Mild steel  
welding rod material.  
For best results an attempt should be made, if space allows, to  
mount the Gen V Wastegate at an angle to the exhaust flow to  
allow for better flow than a 90 degree mounting. See the  
schematic diagrams below for examples of mounting positions.  
Exhaust flow  
from engine  
CAUTION!  
Do not place the actuator cap near a significant heat source  
as this could shorten the life of the diaphragm.  
Figure 8 - 90 Degree mounting  
9
and in some circumstances may contribute to over boosting.  
0 Degree mounting gives poor exhaust flow to the wastegate  
Wastegate  
Wastegate  
Exhaust flow  
to wastegate  
Turbine  
Exhaust flow  
to wastegate  
Turbine  
Exhaust flow  
from engine  
Figure 6 - Best flow - Symmetric mounting  
Exhaust flow  
from engine  
Symmetric mounting allows an excellent flow of exhaust to the  
wastegate.  
Wastegate  
Figure 9 - Not Recommended - Less than 90 Degree Mounting  
Exhaust flow  
to wastegate  
An angle mounting as shown in not recommended and gives  
extremely poor exhaust flow to the wastegate which can  
contribute to poor boost control and over boosting.  
Turbine  
Fitting the Gen V Wastegate  
2
Prior to mounting the Gen V Wastegate, place v-band over weld  
on flange by unscrewing the nut 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 wastegate to be installed.  
Exhaust flow  
from engine  
Figure 7 - Good Flow - Angle mounting  
Do not forget to put the valve seat into the body before mounting  
the unit on the exhaust manifold. Using the 3/8” deep socket and  
a torque wrench Tighten the V-Band to 7N.m (5 ft/lbs). Ensure  
the wastegate is home correctly while torqueing the nut to not  
have a false torque as this will likely contribute to exhaust leaks.  
Angle mounting allows a good flow of exhaust flow to the  
wastegate.  
6
Basic Wastegate Hook-up  
4
Basic setup  
If no boost controller is being used connect the boost pressure  
source to the “bottom” port as shown. The boost only pressure  
source should be sourced from as close to the compressor side  
of the turbo as possible. The “top” ports of the wastegate should  
be left open, It is possible in harsh environments to blank one  
port and connect a hose to the other port that can be ran to a  
area less likely to allow contamination into the actuator.  
CAUTION!  
Do NOT source signal from the intake manifold as this is subject  
to vacuum and pressure losses across the system and could  
over-speed the turbocharger.  
Breather  
(
hose optional)  
Pressure  
only source  
to “Bottom”  
port  
Wastegate  
Turbocharger  
Figure 12 – Common External Wastegate Hook up  
Figure 11 – Exploded Drawing  
Start Engine and Check for Leaks  
5
Fit Actuator Port Fittings  
3
Congratulations, your Gen V wastegate is installed and ready for  
use. Double check all fittings, lines and mountings then proceed  
to start engine and check for leaks.  
Fit lower chamber port fittings prior to mounting the wastegate,  
install 1/8” NPT blank with 3/16” hex key and signal nipple into  
lower chamber ports. 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.  
NOTE!  
If you are unsure which port to install fittings into, please  
refer to ‘Boost Control Hookup’ section, refer to table of  
contents for page number.  
CAUTION!  
Do NOT insert fittings and blank into Top Ports unless  
advanced boost control methods are to be used as this can  
affect the performance of the product. See ‘Boost Control  
Hookup’  
7
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HOW TO CHANGE YOUR GEN V WASTEGATE SPRING  
The Gen V wastegate has a variety of springs to suit different boost levels. Turbosmart provides the Gen V wastegate pre-installed  
with your choice of either 7psi or 14psi springs depending on the part number. With your wastegate four springs will be provided, 3psi  
inner, 5psi inner, 7psi middle and 14psi outer. Different spring combinations may be required to suit different boost requirements and  
tuning.  
Remove Wastegate From Manifold  
Remove Top Cap (cont.)  
1
2
Remove boost pressure source hose from the wastegate 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  
wastegate being careful not to drop or lose the valve seat.  
CAUTION!  
Allow engine to cool down before removing your Gen V  
wastegate  
Remove Top Cap  
2
Prior to removing the Gen V wastegate 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 the large  
end of the provided collar tool in an anti-clockwise direction until  
completely disengaged and slowly remove tension from the  
press or vice allowing the spring to expand, finally remove cap  
when the spring has stopped expanding.  
Figure 14 – Releasing spring pressure  
CAUTION!  
Use soft jaws to prevent cosmetic damage  
Figure 15 – Spring location  
Configure wastegate with preferred spring combination of inner,  
middle and outer springs  
Figure 13 – Locking Collar removal  
8
Familiarise Yourself with Cap and Body  
Notches  
clockwise direction. While still in the press or vice, Tighten the  
collar further with the collar tool until the collar will not turn.  
3
CAUTION!  
Maintain downward pressure on cap while tightening collar  
or non-repairable thread damage will occur.  
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.  
Figure 17 – Locking Collar Tool  
Reinstall fittings to the cap of the wastegate using fresh Loctite  
567 thread sealant.  
Reinstall Gen V Wastegate  
5
Pace V-band over weld on flange by unscrewing the nut 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 wastegate to be installed.  
Figure 1
Press Cap ont
4
Do not forget to put the valve seat into the body before mounting  
the unit on the exhaust manifold. Using the 3/8” deep socket and  
a torque wrench tighten the V-Band to 7N.m (5 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  
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ACHIEVING YOUR TARGET BOOST PRESSURE  
There are various factors involved in achieving your target boost pressure including.  
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The size of the spring fitted in your wastegate i.e. the boost pressure achieved by the wastegate spring only.  
The desired level of boost pressure and the difference between this and your wastegate spring pressure.  
The size of your turbocharger and wastegate and the resulting exhaust manifold backpressure in your system.  
Turbosmart recommends the ideal setup for achieving your target boost pressure is to use the Gen V Wastegate in conjunction with  
a Turbosmart e-Boost controller.  
IMPORTANT NOTES ON SETTING THE WASTEGATE  
SPRING PRESSURE  
coded. Please see the following detailed instructions on setting  
your Gen V Wastegate’s spring pressure. The springs chosen  
should be rated to the lowest boost level desired.  
A stiffer spring should only be used when necessary. The Gen V  
Wastegate allows for different combinations of spring pressures.  
All springs that are adaptable with the Gen V Wastegate are  
shown in the table below. The tuner can use combinations of up  
to 3 springs to achieve the following base boost pressures. To  
aid in the identification of these springs they are supplied colour  
9
Spring Pressure  
High Pressure Spring Information  
Product  
Family  
3
psi  
5psi  
7psi  
Pink  
14psi  
Red  
Actuator  
Size  
Spring Pressure  
WG38/40  
WG45/50  
WG60  
Black  
Orange  
Raw  
Grey  
40psi  
50psi  
Yellow Green Sky Blue  
5
4mm  
63mm  
6mm  
Purple  
White  
Brown  
Table 1: Spring Identifier Chart  
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7
Location  
Pressure  
Inner  
3psi  
●
Inner  
5psi  
Middle  
7psi  
Outer  
14psi  
Table 3: Spring Chart  
3psi  
5psi  
7psi  
●
●
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●
Location Outer  
Outer  
50psi  
●
●
●
Pressure  
40psi  
40psi  
●
10psi  
12psi  
14psi  
17psi  
19psi  
21psi  
24psi  
26psi  
●
●
●
50psi  
●
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Table 3: Spring Chart  
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Table 2: Spring Chart  
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HOW TO CHANGE YOUR GEN V WASTEGATE DIAPHRAGM  
Gen V wastegate replacement diaphragm kit:  
(
(
WG38, WG40): TS-0550-3004  
WG45, WG50): TS-0550-3005  
(
WG60): TS-0550-3006  
CAUTION!  
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Ensure diaphragm is contained within the groove prior to cap re-assembly.  
Pay attention not to rotate diaphragm.  
Remove Wastegate from Manifold  
spring to expand, finally remove cap when the spring has  
stopped expanding.  
1
Remove boost pressure source hose from the wastegate as well CAUTION!  
as the breather hose is fitted. Unscrew outlet V-Band nut in a  
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  
wastegate being careful not to lose the valve seat. Mark the  
orientation of the valve to the body with tape or a paint pen.  
Use soft jaws to prevent damage  
CAUTION!  
Allow engine to cool down before removing your Gen V  
wastegate  
Remove Top Cap  
2
Prior to removing the Gen V wastegate cap, remove all fittings  
from the 1/8”NPT ports. Press down on the cap in a press or vice.  
Unscrew locking collar with the large end of the provided collar  
tool in an anti-clockwise direction until completely disengaged  
and slowly remove tension from the press or vice allowing the  
1
0
Figure 18 - Locking Collar removal  
Loctite  
243  
Valve retaining  
cap  
Spring washer  
Pry circlip up  
over the valve  
Figure 19 - Releasing spring pressure  
Diaphragm Replacement  
2
Figure 20 – Valve Cap removal  
Use the supplied tool in the diaphragm replacement kit, engage  
the diaphragm aligning the splines and grooves. Use a 25mm  
spanner on the tool to prevent the diaphragm from spinning. Use  
a 12point 14mm socket through the centre of this tool onto the  
valve retaining cap. Undo the valve retaining cap by rotating in  
Sit the new valve circlip on top of the valve ensuring it is  
concentric, Use the valve retaining cap on top of the circlip to  
lightly press the new circlip over the valve into place, Confirm the  
circlip is located correctly in the circlip groove of the valve, adjust  
if necessary. Let the valve drop down into the diaphragm, sit the  
new spring washer onto the nipple of the valve with the outside  
of the cone away from the valve. Apply a dab of blue 243 Loctite  
to the lower threads of the valve retaining cap and screw into the  
diaphragm. Support the diaphragm with the supplied tool and  
tighten the valve retaining cap to 20N.m (15ft/lbs)  
1
2point 14mm  
socket  
Diaphragm tool  
(
25mm hex)  
TS-0550-3007  
Spring washer  
(
Outside UP)  
Valve Circlip  
Figure 20 - Releasing Spring Pressure  
Remove the valve retaining cap and spring washer, Sit the  
wastegate on down so that the valve is elevated and supported.  
Using a small flat blade screwdriver to pry one edge of the split  
in the valve circlip out and up, work your way around the circlip  
until it is removed. Take note of the orientation of the diaphragm,  
lift the old diaphragm over the valve and discard. Use this  
opportunity to thoroughly clean the wastegate removing any dirt  
from the actuator, ensure the diaphragm groove is free of debris  
and fit your replacement diaphragm over the valve.  
Valve Stem  
Figure 21 – Valve Cap Sectioned View  
1
1
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.  
Clockwise to tighten  
Anti-clockwise to loosen  
**As viewed from above**  
Press cap onto body  
4
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.  
Hold still  
CAUTION!  
Maintain downward pressure on cap while tightening collar  
or
Figure 22 – Torquing Retaining Cap  
Align the valve orientation marks and confirm the diaphragm  
bead is seated in the groove of the actuator. Install desired spring  
combination.  
Configure Wastegate with preferred spring combination of  
inner, middle and outer springs  
Familiarise Yourself with Cap and Body  
Notches  
Figure 24 – Locking Collar Tool  
3
Reinstall fittings to the cap of the wastegate using fresh sealant.  
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  
Reinstall Gen V wastegate  
5
Place v-band over weld on flange by unscrewing the nut 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 wastegate to be  
installed.  
Do not forget to put the valve seat into the body before mounting  
the unit on the exhaust manifold. Using the 3/8” deep socket and  
a torque wrench Tighten the V-Band to 7N.m (5 ft/lbs),  
Figure 23 – Ca
1
2
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BOOST CONTROL HOOKUP ON THE GEN V WASTEGATE  
WARNING!  
Changing your connection method can cause a higher than expected increase in boost pressure. Turbosmart recommends  
adjusting your boost controller back to its minimum setting and measuring the new minimum boost pressure achieved by  
the new setup before increasing your boost again.  
IMPORTANT!  
Refer to your boost controller instructions for most suitable connection method to an external wastegate  
Boost Tee Setup  
1
When using your Gen V wastegate in conjunction with a Turbosmart Boost Tee, fit the controller between the boost pressure source  
and “bottom” port as shown. Ensure the arrow on the Boost Tee is pointing towards the wastegate. The “top” ports of the wastegate  
should be left open, It is possible in harsh environments to blank one port and connect a hose to the other port that can be run into a  
area less likely to allow contamination into the actuator. Refer to the instructions supplied with your Boost Tee for further detail if  
necessary.  
Breather  
(
hose optional)  
Boost Tee  
Gen V  
Pressure only  
source to Boost  
Tee  
Bottom port of wastegate  
to Boost Tee  
Turbocharger  
Wastegate  
Figure 25 – Conventional Setup  
e-Boost 2 Connection Methods  
2
Turbosmart recommends using the Gen V Wastegate in conjunction with the Turbosmart e-Boost. The first method of installation is  
a one port connection. If the desired boost level is not achieved i.e. boost level is too low, or not controllable, it is recommended that  
the wastegate spring be changed to a spring which is closer to the desired boost pressure or to trial a 2 port connection method.  
There are 3 different 2 port connection methods that can be trialled to achieve different results. The 2 port method (1) can be used if  
there is high exhaust manifold back pressure forcing the valve open. The 2 port method (2) allows the user to achieve the maximum  
boost pressure their turbo system is capable of. If a wide range of boost pressures is desired i.e. 5 – 40 PSI, a 2 port connection with  
a 4 port solenoid (sold separately – TS-0301-2003) might be needed. All unused ports and vents must have the pressure nipple  
installed and a piece of silicon connected and routed to an area which is shielded from dust and water.  
1
3
Single Port Connection  
2.1  
•
•
•
Port 1 of solenoid vent to atmosphere  
Port 2 of solenoid to bottom port of wastegate  
Port 3 of solenoid to Pressure only source  
Breather  
(hose optional)  
Solenoid  
Port 1 of solenoid,  
vent to atmosphere  
Gen V Wastegate  
Pressure only source  
to Port 3 of solenoid  
Bottom port of  
wastegate to Port 2  
of solenoid  
Turbocharger  
Figure 26 – Single Port Setup  
Two Port Connection method (1)  
2.2  
(
For controlling boost on a turbo system with high back pressure)  
•
•
•
Connect the bottom port of the wastegate and Port 1 of the solenoid to a Pressure only source  
Port 2 of the solenoid to the top port of the wastegate  
Port 3 of solenoid vent to atmosphere  
Solenoid  
Port 1 of solenoid,  
Port 2 of solenoid to  
Top Port of wastegate  
Pressure only source  
Port 3 of solenoid,  
Vent to atmosphere  
Gen V Wastegate  
Tee piece  
Pressure only source  
Bottom port of wastegate  
to pressure only source  
Turbocharger  
Figure 27 – Two Port Setup 1  
1
4
Two Port Connection method (2)  
2.3  
(
For obtaining maximum boost pressure on your turbo system)  
•
•
•
Port 1 of solenoid to Top port of wastegate  
Port 2 of solenoid to Pressure only source  
Port 3 of solenoid to Bottom port of wastegate  
Port 1 of solenoid to  
Top Port of wastegate  
Solenoid  
Pressure only source  
to Port 2 of solenoid  
Gen V Wastegate  
Port 3 of solenoid to  
Bottom Port of wastegate  
Turbocharger  
Figure 28 – Two Port Setup 2  
Two Port Connection method (3)  
2.4  
(
For obtaining a wide range of boost pressures e.g. 5 – 40 PSI, note that this method of boost control may not  
provide a smooth boost curve)  
•
•
•
•
Port A of solenoid to Top port of wastegate  
Port B of solenoid to Bottom port of wastegate  
EX port of solenoid vent to atmosphere  
IN port of solenoid to Pressure only source  
4
Solenoid  
port  
EX Port of solenoid  
vent to atmosphere  
Port A of solenoid to  
Top port of wastegate  
IN Port of solenoid to  
pressure only source  
Gen V Wastegate  
Pressure only source  
Port B of solenoid to  
Bottom port of wastegate  
Turbocharger  
Figure 29 – Two Port Setup 3  
1
5
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HOW TO CHANGE YOUR GEN V HIGH PRESSURE WASTEGATE SPRING  
The Gen V wastegate has a variety of springs to suit different boost levels. Turbosmart provides the Gen V HP wastegate pre-installed  
with 40psi springs. A 50psi spring is available as a spare part to further increase the base pressure of the wastegate.  
Remove Wastegate From Manifold  
Remove Top Cap (cont.)  
1
2
Remove boost pressure source hose from the wastegate 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  
wastegate being careful not to drop or lose the valve seat.  
CAUTION!  
Allow engine to cool down before removing your Gen V  
wastegate  
Remove Top Cap  
2
IMPORTANT!  
Use sufficient clamping load to relieve any axial load on the  
locking collar.  
Prior to removing the Gen V wastegate 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 the large  
end of the provided collar tool in an anti-clockwise direction until  
completely disengaged and slowly remove tension from the  
press or vice allowing the spring to expand, finally remove cap  
when the spring has stopped expanding.  
Figure 31 – Locking Collar Removal  
CAUTION!  
Use soft jaws to prevent cosmetic damage  
Figure 32 – Spring Location  
Configure wastegate with preferred spring combination of inner,  
middle and outer springs  
Figure 30 – Locking Collar Removal  
1
6
Familiarise Yourself with Cap and Body  
Notches  
clockwise direction. While still in the press or vice, Tighten the  
collar further with the collar tool until the collar will not turn.  
3
CAUTION!  
Maintain downward pressure on cap while tightening collar  
or non-repairable thread damage will occur.  
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.  
Figure 34 – Locking Collar Tool  
Reinstall fittings to the cap of the wastegate using fresh Loctite  
567 thread sealant.  
Reinstall Gen V Wastegate  
5
Pace V-band over weld on flange by unscrewing the nut 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 wastegate to be installed.  
Figure 33
Press Cap ont
4
Do not forget to put the valve seat into the body before mounting  
the unit on the exhaust manifold. Using the 3/8” deep socket and  
a torque wrench tighten the V-Band to 7N.m (5 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  
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ADVANCED FEATURES ON THE GEN V WASTEGATE  
is folded up to locate on the actuator. The actuator will need to  
Re-Orientation of the Actuator  
1
be freed from its body, a small soft mallet may be required to  
break the seal of the actuator from the valve guide. Once free  
rotate the actuator to desired location ensuring the folded tab  
aligns with a groove in the bottom of the actuator. It is possible  
to fold down this tab and use another if the actuator cannot be  
positioned correctly on the original tab.  
Turbosmart provide the Gen V wastegate with the actuator ports  
symmetrical to the centreline of the body, in some applications it  
may be advantages to clock the actuator to allow clearance for  
fittings and hoses.  
Locate the slave collar between the actuator and the body  
underneath the heatshield, A tab on the heatshield will be folded  
down into a groove on this collar. Using a flat blade screwdriver,  
pry this tab out of the groove allowing the collar to be loosened.  
CAUTION!  
Turbosmart does NOT recommend altering to position of the  
actuator once the wastegate has been used.  
It is recommended that the actuator be clocked without a  
valve seat installed to prevent twisting the diaphragm.  
Using the small end of the supplied collar tool undo the slave  
collar 1 complete revolution (anti-clockwise as viewed from the  
bottom). One tab on the heatshield at the back of the wastegate  
1
7
Pre-folded  
tab  
Water Cooling  
2
Turbosmart’s Gen V wastegate is equipped with water cooling  
ports to keep the wastegate cool in the most extreme conditions  
and keep consistent actuator temperature.  
Identify the water cooling ports on the bottom of the actuator  
adjacent to the water cooling symbol engraved in the actuator.  
Water cooling  
symbol  
Figure 35 – Slave Collar  
Tighten the collar using a torque wrench on the 3/8” square drive  
provided in the collar tool perpendicular to the length of the tool  
to 25N.m (18ft/lbs). Fold down a tab onto the slave collar to  
prevent the collar from coming loose during use.  
Water cooling  
Port (2 holes)  
Bottom Air Port  
(
1 hole)  
Figure 39 – Water Cooling Ports and Air Ports  
Fit water cooling port fittings Prior to mounting the wastegate,  
install 1/8” NPT fittings into the water ports, apply thread lubricant  
and screw in clockwise until finger tight, then tighten further 1-2  
turns for seal. Choose feed and drain source for the water and  
connect to the wastegate. Turbosmart recommends -4SAE  
fittings and hose compatible with coolant.  
Locating  
grooves  
Locking  
tabs  
Water  
feed/return  
Water  
feed/return  
Figure 36 – Slave Collar Locating Grooves  
3
/8” square  
drive  
Figure 40 – Water Cooling Hook-up  
CAUTION!  
Confirm water is only used on the water ports of the  
wastegate, damage to your engine may result in failure to  
correctly connect water cooling  
Figure  
3
7 – Slave Collar Tool  
Figure 38 – Slave Collar Torque Wrench  
1
8
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HOW TO INSTALL A SENSOR CAP TO YOUR GEN V WASTEGATE  
CAUTION!  
-
-
-
Ensure diaphragm is contained within the groove prior to cap re-assembly.  
Pay attention not to rotate diaphragm.  
Cool air flow is required around the actuator to keep the sensor in its operating window.  
Remove Wastegate from Manifold  
1
Remove boost pressure source hose from the wastegate as  
well as the breather hose is fitted. Unscrew outlet V-Band nut  
in a 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 wastegate being careful not to lose the valve  
seat. Mark the orientation of the valve to the body with tape or  
a paint pen.  
CAUTION!  
Allow engine to cool down before removing your Gen V  
wastegate  
Remove Top Cap  
2
Figure 42 – Releasing Spring Tension  
Prior to removing the Gen V wastegate cap, remove all fittings  
from the 1/8”NPT ports. Press down on the cap in a press or  
vice. Unscrew locking collar with the large end of the provided  
collar tool in an anti-clockwise direction until completely  
disengaged and slowly remove tension from the press or vice  
allowing the spring to expand, finally remove cap when the  
spring has stopped expanding.  
Diaphragm Replacement  
3
Use the supplied tool in the diaphragm replacement kit,  
engage the diaphragm aligning the splines and grooves. Use  
a 25mm spanner on the tool to prevent the diaphragm from  
spinning. Use a 12point 14mm socket through the centre of  
this tool onto the valve retaining cap. Undo the valve retaining  
.  
CAUTION!  
Use soft jaws to prevent damage  
1
2point 14mm  
socket  
Diaphragm tool  
(
25mm hex)  
TS-0550-3007  
Figure 41 – Cap Removal  
Figure 43 – Diaphragm Removal Tool  
Clear any Loctite and debris from the thread in the diaphragm  
support, Note careful not to get chemicals onto the diaphragm  
as this may damage the diaphragm.  
1
9
Configure Wastegate with preferred spring combination of  
inner, middle and outer springs  
Familiarise Yourself with Cap and Body  
Notches  
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  
Loctite 243  
Spring washer  
(Outside UP)  
CAUTION!  
Ensure notches are aligned and seated home correctly  
prior to exerting force to tighten collar, permanent  
e not aligned correctly.  
Valve Circlip  
Valve Stem  
Figure 44 – Sensor Valve Retaining Cap Sectioned View  
Sit the new spring washer into the valve retaining cap with the  
centre of the washer pointing out of the cap. Apply a dab of  
blue 243 Loctite to the lower threads of the valve retaining cap  
and screw into the diaphragm. Support the diaphragm with the  
supplied tool and tighten the valve retaining cap to 20N.m  
(
15ft/lbs)  
Clockwise to tighten  
Anti-clockwise to loosen  
Figure 46 – Cap L
**As viewed from above**  
Press cap onto bo
5
Using a press or vice, compress the cap onto the body  
ensuring the notches are remaining aligned, use spacers to  
ensure the wire from the sensor it not crimped or damaged  
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.  
CAUTION!  
Maintain downward pressure on cap while tightening  
collar or non-repairable thread damage will occur.  
Take care not to damage the wire during assembly.  
Figure 45 – Torqueing Valve Retaining Cap  
Align the valve orientation marks and confirm the diaphragm  
bead is seated in the groove of the actuator. Install desired  
spring combination.  
2
0
Figure 49 – Sensor Cap  
Figure 47 – Locking Collar Tool  
Reinstall fittings to the cap of the wastegate using fresh  
sealant.  
Wire  
Red  
Note  
Sensor Supply (Vsup  
Rating  
)
4.5-5.5 Vdc  
0V  
Black Sensor Ground (V )  
0
Reinstall Gen V wastegate  
6
White Sensor Output (Vout  
)
0-Vsupply  
Table 5 – Wiring Diagram  
Place v-band over weld on flange by unscrewing the nut 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  
wastegate to be installed.  
Connect the wires to your data logger accordingly. Use a high-  
quality connection to reduce noise and calibration fluctuation.  
Ensure that the wiring is properly shielded from external heat  
sources.  
CAUTION!  
To ensure longevity from the sensor, ensure adequate  
airflow is supplied directly to the sensor to avoid  
overheating or sensor failure.  
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.  
Figure 48– Vee Band  
CAUTION!  
Do not forget to place valve seat into the body before  
mounting the wastegate on the exhaust manifold. Use a  
3/8” deep socket and torque the V-Band to 7N.m (5 ft/lbs)  
Wiring  
7
Your new Turbosmart sensor cap comes with sensor pre-  
installed into the cap with unterminated wires for you to fit the  
connector of your choice.  
2
1
9
1
1
1
.25  
0.5  
1.75  
3
1.692  
1.454  
1.126  
0.683  
0.118  
0.003  
Calibration*  
8
Insert the relevant calibration curve into your data logger for  
the product family you have  
14.25  
15  
WG38/40 (all configurations)  
Table 6 – Wiring Diagram WG60  
Valve Lift (mm)  
0.75  
V
OUT  
NOTE! For best results, each wastegate should be calibrated  
to your setup.  
-
2.221  
2.138  
2.03  
0
1
3
4
5
6
8
9
1
.5  
.75  
1.88  
.25  
.5  
1.692  
1.454  
1.126  
0.683  
0.118  
0.003  
.75  
.25  
0
Table 6 – Wiring Diagram WG38/40  
WG45/50 (all configurations)  
Valve Lift (mm)  
0.25  
V
OUT  
-
2.344  
2.288  
2.221  
2.138  
2.03  
1
2
3
4
6
7
8
9
1
1
1
.25  
.5  
.75  
1.88  
.25  
.5  
1.692  
1.454  
1.126  
0.683  
0.118  
0.003  
.75  
1
2.25  
3
Table 7 – Wiring Diagram WG45/50  
WG60  
Valve Lift (mm)  
0.75  
V
OUT  
-
2.423  
2.387  
2.344  
2.288  
2.221  
2.138  
2.03  
0
1
3
4
5
6
8
.5  
.75  
.25  
.5  
.75  
1.88  
2
2
Graph 1 – Calibration Graph  
Calibration Table  
3
.5  
2
2
1
0
.5  
1
.5  
0
-2  
0
2
4
6
8
10  
12  
14  
16  
Valve Lift (mm)  
WG38/40  
WG45/50  
WG60  
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TROUBLESHOOTING  
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Wastegate not actuating - Confirm signal hose is plumbed to a pressure only source, confirm preload on valve seat during  
installation  
Poor wastegate actuation - Ensure signal hose is not shared and is sourced as close to the compressor as possible, check seal  
on fittings  
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-
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Poor wastegate actuation - Confirm Top ports are not blocked and free from debris  
Boost creeping at high rpm - Wastegate flow path is poor, wastegate is too small for the application  
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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2
3