Product Name:  
Gen V eWastegate (Electronic Config)  
Gen V eWastegate  
Product Description:  
Product Number:  
TS-055X-15XX  
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V1.00 Rev A  
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Document Version:  
IMPORTANT NOTES ON YOUR EXTERNAL EWASTEGATE  
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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 eWastegate 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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Always disconnect motor wires before removing the top cap of the actuator  
Allow for adequate cool airflow around electronic actuator.  
DO NOT Mount the wastegate so that the electronic actuator 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 eWastegate kit.  
Part  
1
Description  
Turbosmart Gen V eWastegate  
Valve Seat  
Use  
Main unit  
2
Valve seat  
3
Inlet V-Band clamp  
Inlet Weld flange  
Inlet V-band clamp  
Inlet V-band weld flange  
Outlet V-band clamp  
Outlet V-band weld flange  
Adjusting actuator location  
Turbosmart sticker  
4
5
Outlet V-Band clamp  
Outlet weld flange  
Collar tool  
6
7
8
Turbosmart Sticker  
1
3
4
5
6
7
2
Figure 1 - Kit Contents  
1
CONTENTS  
KIT CONTENTS..........................................................................................................................................................1  
TOOLS REQUIRED....................................................................................................................................................3  
SUGGESTED LUBRICANTS AND SEALANTS..........................................................................................................3  
PART NUMBERS .......................................................................................................................................................3  
QUICK START GUIDE................................................................................................................................................3  
HOW TO USE.............................................................................................................................................................3  
MAINTENANCE..........................................................................................................................................................3  
TEMPERATURE.........................................................................................................................................................3  
BASIC TUNING PARAMETERS.................................................................................................................................4  
WHAT’S NEW ............................................................................................................................................................4  
GEN V EWASTEGATE OVERVIEW ...........................................................................................................................5  
FITTING YOUR GEN V WASTEGATE........................................................................................................................6  
Mounting your New Turbosmart Gen V eWastegate ....................................................................................................6  
Fitting the Gen V eWastegate...........................................................................................................................................6  
Connecting Your Wastegate.............................................................................................................................................7  
Calibration............................................................................................................................................................................8  
Tuning...................................................................................................................................................................................8  
Sensor Linearisation..........................................................................................................................................................9  
ADVANCED FEATURES ON THE GEN V WASTEGATE...........................................................................................9  
Re-Orientation of the Actuator .........................................................................................................................................9  
Water Cooling....................................................................................................................................................................10  
TROUBLESHOOTING..............................................................................................................................................11  
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TOOLS REQUIRED  
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¼” drive socket 5mm  
¼” drive extension  
¼” drive ratchet  
3/8” square drive deep socket  
Square drive ratchet wrench  
Torque wrench (3/8” drive)  
Non-marking spanners to tighten fittings  
Supplied collar tool  
SUGGESTED LUBRICANTS AND SEALANTS  
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Loctite 243 Thread locker  
Loctite 567 Thread Sealant  
Resbond 907TS Red  
Penetrating oil  
Inox MX8 spray grease  
PART NUMBERS  
TS-0553-1502 Gen-V WG45 Hyper-Gate45 Electronic Black  
TS-0555-1502 Gen-V WG60 Powergate 60 Electronic Black  
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QUICK START GUIDE  
HOW TO USE  
The Turbosmart eWastegate is a brand-new way to drive aftermarket wastegate valves, it involves using an electric motor  
to drive the position of the valve, this allows far greater control over the valve during its actuation on the car, this paired  
with an aftermarket ECU controlling it, allows for plenty of new and safer ways to control boost on your car.  
The Body will need to be fitted to the vehicle. Please see the exploded drawing (figure 10). This involves the two V  
Bands clamps, the Inlet (fitted on the exhaust manifold), and the outlet which is where the regulated exhaust gases are  
bypassed. A Valve seat is fitted inside the inlet V Band allowing the valve to seal upon closing. It is important to have the  
valve manually set to about the middle of its stroke as well as the valve seat installed. This will allow for an easier  
installation.  
Please see below for a more detailed and helpful way of installing the Turbosmart Gen V eWastegate.  
MAINTENANCE  
Turbosmart’s Gen V eWastegate will require periodic reapplication of spray grease such as Inox MX8 spray grease, this is  
important that the manual override is used to move the valve up and down allowing the grease to be applied throughout  
the entire valve gearbox. Turbosmart recommends that this is done regularly at least half yearly or in demanding  
temperature environments.  
It is also important to check V Band tightness after the wastegate has run through a couple of heat cycles. To ensure that  
the wastegate is seated and sealing correctly.  
TEMPERATURE  
The Turbosmart Gen V eWastegate has a maximum thermal stress of 1250oC for 24hr if thermally cooled through the  
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water-cooling ports, it is important that the actuator internal housing doesn’t go above a temperature of 150 C as this may  
cause damage to the internal electronics. Turbosmart recommends that the eWastegate is water cooled and paired with  
good airflow over the body to help regulate temperature. Turbosmart also recommends data logging the temperature that  
is seen inside the actuator using the temperature sensor included onboard.  
It is recommended that water cooling is in line with the turbo this will increase the longevity of the eWastegate and allow it  
to operate seamlessly. This does depend on the certain application and the rate and period at which the eWastegate is  
exposed to the high temperatures.  
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BASIC TUNING PARAMETERS  
It is important that the basic tuning parameters are discussed with a trained professional, please consult your ECU  
manufacture. There are a few basic parameters that are worth noting.  
Motor polarity is important, Due to the nature of PID controllers (Proportional-integral-derivative controller) the  
eWastegate will be targeting a set position, this will move further away if the motor polarity is wrong as it’s trying to reach  
it’s setpoint.  
Current limitations, it is important that the Current that is driven through the motor is limited to no more than 20amps for  
more than 1 second and 5 amps for more than 5 seconds. It is important that the current values such as the dead band are  
correctly set in the ECU to allow for the motor to only be active if needed.  
Sensor Diagnostic limits should be monitored for values that are lower than 0.1V and higher and 2.15V with respect to  
the Temperature sensor and 0.1V-4.9V with the position sensor. It is also recommended that safety tuning strategies are in  
place to lower temperatures if the eWastegate internally reaches a temperature of 150degC (302degF).  
Valve Position limits should be set to target 0% for valve closed and 90% for completely open, Since the design of the  
end stops is biased to operate better with the valve in the closed position it is recommended to avoid opening the valve to  
full lift.  
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WHAT’S NEW  
Our new eWastegates are a direct fit upgrade to all 4th-generation Turbosmart wastegates and feature our unique collar-locking  
system, variable motor cap and base, strap-type V-band clamps, liquid-cooling, 1/8″ NPT ports.  
Control  
With the introduction of the electronic motor to drive the eWastegate, a new level of control is now available to boost control, there is  
a wide range of tuning strategies that can be implemented to better control boost as well as engine protection. This allows the Engine  
to maintain much better control with the turbo boost strategies.  
Adjustability  
The 5th generation eWastegate range has been designed with maximum user-adjustability, without comprising performance. We  
designed this unit with almost infinite possibilities of directions in which the motor assembly can be mounted with the engine bay. So,  
if you need the eWastegate mounted in the opposite orientation to stop fouling with parts within the engine bay, there is an orientation  
that is suitable for the eWastegate to operate in. This mixed without the need of having to remove and reassemble due to changes in  
base wastegate spring pressure the eWastegate has next level control adjustability of the position of the wastegate valve.  
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.  
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GEN V EWASTEGATE OVERVIEW  
Wiring Loom  
“Water Cooling” port  
1/8” NPT  
Inlet V-Band  
Outlet Weld flange  
Outlet V-Band  
Inlet Weld Flange  
Figure 1 -Gen V eWastegate Overview  
Locking tabs  
Water cooling  
symbol  
Slave Collar  
Figure 2 Gen V eWastegate Water Cooling  
Figure 3 Gen V eWastegate Locking  
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FITTING YOUR GEN V WASTEGATE  
Mounting your New Turbosmart Gen V eWastegate  
1
Water cooling is highly recommended for sustained heat  
exposure.  
The Gen V series of Wastegate including Electronic is a direct fit  
replacement for the 4 gen wastegate range and no modification  
is necessary provided packaging space is sufficient within the  
engine bay.  
th  
Exhaust flow  
to eWastegate  
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.  
Exhaust flow  
from engine  
For best results, an attempt should be made, if space allows, to  
mount the Gen V eWastegate 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.  
Figure 6 - 90 Degree mounting  
90 Degree mounting gives poor exhaust flow to the wastegate  
and in some circumstances may contribute to over boosting.  
CAUTION!  
eWastegate  
Do not place the eWastegate near a significant heat source  
as this could shorten the life of the internal electronics.  
eWastegate  
Exhaust flow  
to eWastegate  
Turbine  
Exhaust flow  
to eWastegate  
Turbine  
Exhaust flow  
from engine  
Exhaust flow  
from engine  
Figure 7 - Not Recommended - Less than 90 Degree Mounting  
An angle mounting as shown in not recommended and gives  
extremely poor exhaust flow to the eWastegate which can  
contribute to poor boost control and over boosting.  
Figure 4 - Best flow - Symmetric mounting  
Symmetric mounting allows an excellent flow of exhaust to the  
wastegate.  
Wastegate  
Fitting the Gen V eWastegate  
Exhaust flow  
to wastegate  
2
Prior to mounting the Gen V eWastegate, place v-band (figure 9)  
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). Ensure  
the wastegate is home correctly while torqueing the nut to not  
have a false torque as this will likely contribute to exhaust leaks.  
Turbine  
Exhaust flow  
from engine  
It is important that the valve sits slightly open for installation. This  
allows for no interference during the installation process. This  
can be adjusted via the manual override. (Figure 8)  
Figure 5 - Good Flow - Angle mounting  
Angle mounting allows a good flow of exhaust flow to the  
wastegate.  
eWastegate  
6
Connecting Your Wastegate  
3
Manual  
override  
The Turbosmart Electronic wastegate come unterminated with 7  
wires. A revision has been made to include the ability for a PWM  
signal. This is the Revision B (current). It can be identified by the  
colour of the wires and number of wires in the core (5 smaller  
gauge wires).  
Revision B (current) Wiring  
Colour  
Description  
Large Gauge Red Motor A tending towards  
0%  
1
single core  
wire each  
Large Gauge  
Black  
Motor B tending towards  
100%  
Red  
5V  
Black  
White  
Blue  
Sensor ground 0V  
Position Signal 0-5V  
Pulse Width Modulation  
Signal  
Figure 8 Manual Override  
Multi Core  
Wire  
(
Rev B Only)  
Yellow (Orange  
Temperature Signal 0-5V  
Rev A)  
Sensor Voltage Limits  
Deg C (Deg F) Temperature Sensor Temperature Sensor  
Output (mV) Rev A  
Output (mV) Rev B  
0
1
(32)  
50 (302)  
500  
2000  
2630  
538  
Position Sensor  
Target Voltage (V) Duty Cycle (Rev B  
only)  
1
0
00%  
%
0.20-0.60V  
4.40-4.80V  
~16%  
~84%  
CAUTION!  
Turbosmart recommends calibrating the position sensor  
before connecting the motor wires to your motor drive.  
Figure 9 V Band Clamp  
The two large wires are directly connected to the motor of the  
wastegate and need to be connected to high power drives in a  
Full bridge configuration like that of an electronic throttle drive  
circuit, see your ECU supplier documents for suitable  
connections. Turbosmart recommends the eWastegate should  
be driven by an External dual H-Bridge, that is at least 20A for  
seamless operation.  
Connect the small Red Wire to a 5V power source from your ECU  
as well as the Black wire to Sensor ground. Connect the white  
wire to a 0-5V analogue input on your ecu as well as the orange  
temperature sensor signal.  
CAUTION!  
Whilst the temperature sensor is not required for operation  
it is recommended for activating failsafe protocols.  
CAUTION!  
Ensure all connections are high quality and away from any  
heat source.  
Figure 10 Exploded drawing of assembly of eWastegate.  
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CAUTION!  
Do not apply excessive force to the manual override, doing  
so will damage the product and effect the performance.  
Calibration  
4
CvAUTION!  
Disconnect the motor wires to prevent accidental spin up.  
Valve Down  
To calibrate the electronic wastegate the cap must be removed  
to allow access to the manual override screw. Please note that  
the valve seat must be in place before calibration.  
Valve UP  
Cap retaining  
bolts  
Figure 13 ¼ Drive extension with 5mm socket manually  
adjusting.  
Using your ECU manager software, read the voltage from the  
sensor and set this as your closed position.  
Wind the manual adjustment in an anticlockwise direction until it  
stops. From this position rotate the adjustment 2 full turns in a  
clockwise direction. Read the sensor value and set this as 100%  
valve travel.  
Using an Allen key remove the 2 top bolts allowing the cap to be  
removed, and a spacer or shift the cap off to one side and reinsert  
at least one of the bolts. This prevents the preload in the  
mechanism separating the housing potentially effecting the  
calibration accuracy.  
Monitor sensor signal voltage to ensure no wrap around occurs  
throughout the stroke of the valve that could affect operation.  
CAUTION!  
Figure 11 Top Cap removed for calibration  
It is critical not to set the 100% position at the end of the  
travel as this may lead to seizing of the wastegate and  
overloading the system.  
Carefully move the motor wired allowing access to the manual  
override below (Figure 12)  
NOTE!  
Manual  
Turbosmart recommends allowing additional clearance  
from the end stops until the wastegate control is tuned to  
minimise risk of overshoot into end stops at high speeds.  
Override  
Tuning  
5
The eWastegate will come calibrated from Turbosmart,  
the targeted values have been set with regards to the position  
sensor are 0.5V (completely open) and 4.5V as (completely  
closed), It’s important to note that as the wastegate valve moves  
through its range of motion that the valves are monitored to move  
from 4.5V decreasing to 0.5V, 0% open to 100% open. This  
should be done manually with the ECU package monitoring  
Voltage Values. The electronic motor should be disconnected at  
this point.  
Voltage wraps around will cause errors with the eWastegate, this  
is when the Voltage increases from 4.8V up to 5V and jumps  
through to 0V.  
Position Sensor  
Target Voltage (V) Duty Cycle (Rev B  
only)  
Figure 12 Manual Override  
1
0
00%  
%
0.20-0.60V  
4.40-4.80V  
~16%  
~84%  
Using a ¼” drive extension with a 5mm socket, turn the manual  
override in a clockwise direction with your fingers until the  
mechanism stops rotating. In this position the valve should be  
home against the valve seat and will be your 0% position.  
Remember to have the valve seat inserted.  
It is important to set up the correct limits manually with  
eWastegate. Turbosmart recommends that the valve is only  
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ever driven electronically to the maximum valve position of  
0%.  
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Sensor Linearisation  
6
Driving the valve to 100% will cause increased wear on  
components such as the electronic motor as it tries to  
force the valve to completely open.  
Due to the nature of the poppet valve design, the flow  
characteristics are nonlinear. In some cases, it may be  
advantages to correlate the linear sensor output to match the flow  
of the valve. The following plot compares valve position with  
rd  
Adjust the calibration to allow plenty of overshoot to the end stops  
of the valve, recalibrate as above once you have good control of  
valve position.  
valve flow. A 3 order polynomial is provided to relate sensor  
position to flow. Note due to the design of the wastegate, the  
valve is on a preloaded mechanism to minimise binding at the  
end stops, this results in the sensor reading past the home  
positions and for this reason the calibration sequence with low  
force is essential.  
PLEASE NOTE that temperatures over 180 degC (356degF)  
will create an error in the temperature sensor readings.  
Therefore, the internal temperature is rated to a temperature of  
1
sufficient alarms to monitor this.  
50degC (302degF) it is recommended to log and place  
Sensor Linearisation  
1
20%  
00%  
80%  
120%  
100%  
80%  
PLEASE NOTE When driving the electronic actuator, the current  
should be limit to no more than 20 amps at a period of 1 second  
and 5 amps for more than 5 seconds.  
1
60%  
40%  
20%  
60%  
Follow your ECU manufacturers guidelines for tuning wastegate  
servo control. Ensure dead band is set to a reasonable level to  
not have the output active when not needed.  
40%  
20%  
0%  
0%  
-20% 0%  
50% 100%  
Valve lift  
150%-20%  
y = 0.5596x3 1.8306x2+ 2.2847x 0.0189  
2
R = 0.9989  
ADVANCED FEATURES ON THE GEN V WASTEGATE  
screwdriver, pry this tab out of the groove allowing the collar to  
be loosened.  
Re-Orientation of the Actuator  
1
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  
is folded up to locate on the actuator, 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.  
CAUTION!  
Turbosmart does NOT recommend altering to position of the  
actuator once the wastegate has been used.  
It is recommended that the electronic actuator be clocked  
without a valve seat installed to prevent damage to the valve.  
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drive  
/8” square  
Turbosmart provide the Gen V eWastegate in a set orientation,  
in some applications it may be advantages to clock the actuator  
to allow clearance for fittings and wiring.  
Locate the slave collar between the electronic 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  
9
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. It is not important  
which way the water flows through housing.  
Locking  
groove  
Locking  
collar  
Locking  
tabs  
Pre-folded  
tab  
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 30N.m (22ft/lbs). Fold down a tab onto the slave collar to  
prevent the collar from coming loose during use.  
Water  
feed/return  
CAUTION!  
Check for leak, ensure the water-cooling circuit is free from  
leaks.  
Water Cooling  
2
Turbosmart’s Gen V eWastegate 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  
Port (2 holes)  
Water  
cooling  
symbol  
1
0
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TROUBLESHOOTING  
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Wastegate not actuating - Confirm continuity of wiring, manually adjust valve position and feel for binding.  
Poor wastegate actuation Ensure wiring is correct, check for dirt and smooth operation by manual over-ride, ECU that is  
driving the valve may not be set up correctly.  
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Wraparound of signal on position sensor – Turbosmart Pre “time” every sensor, contact Turbosmart if this occurs.  
Wastegate seized Remove cap and manually move valve feeling for resistance.  
Wastegate moves but sensor not reading Check connections.  
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 [email protected] with information of your engine configuration and  
photos of installation.  
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