Product Name:  
Product Description:  
Product Number:  
HP Wastegate Range  
High pressure wastegate  
TS-05XX-12XX  
------------------------------------------------------------------------------------------------------------------------  
IMPORTANT NOTES ON YOUR EXTERNAL WASTEGATE  
-
Fitting your HP Wastegate may require fabrication or modification to your exhaust manifold. Turbosmart recommends that your  
wastegate is fitted by an appropriately qualified technician.  
-
-
The HP 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.  
-
-
-
DO NOT wrap the body of the wastegate with exhaust wrap  
DO NOT Mount the wastegate so that the top diaphragm housing is less than 100mm from a heat source  
Allow for adequate cool airflow around the top diaphragm housing  
RECOMMENDATIONS  
-
-
-
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.  
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.  
------------------------------------------------------------------------------------------------------------------------  
BASIC COMPONENTS OF YOUR HP EXTERNAL WASTEGATE  
Use the diagram to help identify the “top” and “bottom” ports, and inlet/outlet ports of your wastegate.  
Top” Port  
Upper diaphragm housing  
Lower diaphragm housing  
Outlet  
“Bottom” Port  
Inlet  
-
-
-
-
When pressure is applied to the “bottom” port of a wastegate, i.e. underneath the  
wastegate diaphragm, it acts against the wastegate spring and the wastegate valve opens.  
When pressure is applied to the “top” port of a wastegate, i.e. above the wastegate diaphragm, its acts with the wastegate  
spring and helps to close the wastegate valve.  
The Inlet is connected to the exhaust manifold before the turbine housing of your  
turbocharger. See recommendations following for HP Wastegate mounting position.  
Outlet returns exhaust gas back into the exhaust system after the turbocharger. (NOTE if mounted on a dedicated race car  
the outlet can be vented directly to atmosphere towards the ground)  
CONTENTS  
Please make sure that the following parts have been included in the box  
Part  
Quantity  
1
Description  
HP Wastegate  
High pressure wastegate with pre-fitted spring (check the label  
on the box for rating)  
Inlet weld flange  
1
Stainless steel inlet weld flange (Comp-Gate40 HP /Hyper-  
Gate45 HP only)  
Valve seat  
1
1
Stainless steel valve seat  
Outlet weld flange  
Stainless steel outlet weld flange (Comp-Gate40 HP /Hyper-  
Gate45 HP only)  
Inlet V-Band clamp assembly  
Outlet V-band clamp assembly  
Stainless steel gasket  
1
1
2
Inlet V-Band clamp assembly (Comp-Gate40 HP /Hyper-Gate45  
HP only)  
Outlet V-Band clamp assembly (Comp-Gate40 HP /Hyper-  
Gate45 HP only)  
Gaskets to seal inlet and outlet flanges to wastegate (Ultra-  
Gate38 HP only)  
1
www.TURBOSMARTONLINE.com  
Valve seat  
1
2
2
2
Stainless steel valve seat  
M8X25 Socket head screw  
M8X35 Socket head screw  
M8 Nut  
Securing wastegate to outlet flange (Ultra-Gate38 HP only)  
Securing wastegate to inlet flange (Ultra-Gate38 HP only)  
Securing wastegate to inlet flange (Ultra-Gate38 HP only)  
Tightening collar  
Collar tightening tool  
1
1
/16 NPT Blanking plugs  
2
2
Blanking off unused pressure ports  
5mm 1/16 NPT Vacuum Nipples  
Connecting pressure to the actuator  
RECOMMENDATIONS FOR MOUNTING YOUR HP WASTEGATE  
The mounting position of your HP Wastegate will be largely determined by your turbo and manifold setup and may be constrained by  
space restrictions in your engine bay. The following points should be considered when mounting your HP Wastegate.  
The weld flanges should be welded to your exhaust system. The weld flanges are compatible with Stainless Steel and Mild steel welding  
rod material.  
Weld flange  
(
sold separately)  
Outlet Weld  
flange  
M8X25 Screw  
Outlet V-Band  
M8X35 Screw  
Valve seat  
Remember to install)  
Valve seat  
Remember to install)  
(
(
Outlet V-Band  
Weld flange  
(
sold separately)  
Stainless steel  
gaskets  
Inlet Weld flange  
M8 Nut  
Ultra-Gate38 HP  
Comp-Gate40/Hyper-Gate45 HP  
PORT BLANKING PLUGS AND PRESSURE NIPPLES  
The HP Wastegate is supplied with 2 X 1/16NPT nipples and 2 X 1/16 NPT plugs. These are installed in the lower and upper diaphragm  
housings depending on the boost control hook up to create an air tight volume above or below the diaphragm so that air pressure can  
control valve movement. Single port hook ups require a nipple and plug to be installed only on the lower diaphragm housing while two  
port hook ups require a nipple and a plug to be installed in both lower and upper diaphragm housings. Use thread sealant on the  
threads of the nipples and plugs to prevent leaks.  
Upper diaphragm housing  
Upper diaphragm housing  
with plugs installed  
with nipples installed  
Lower diaphragm housing  
with plugs installed  
Lower diaphragm housing  
with nipples installed  
2
www.TURBOSMARTONLINE.com  
VALVE SEAT  
The valve seat must be installed in the wastegate before mounting it onto the exhaust manifold. Failure to install the valve seat will  
result in very limited boost produced by the turbocharger as the exhaust gases flow between the void where the valve seat normally sits  
and the valve instead of flowing through the turbine.  
MOUNTING  
For the best results, an attempt should be made, if space allows, to mount the HP Wastegate at an angle to the exhaust flow to allow for  
better flow. See the schematic diagrams below for examples of mounting positions. (Comp-Gate40 used for illustration only)  
Turbine  
Wastegate  
Turbine  
Wastegate  
Exhaust gas flow  
from engine  
Exhaust gas flow  
from engine  
Exhaust gas flow  
to wastegate  
Exhaust gas flow  
to wastegate  
Best flow shallow  
Good flow slight  
mount angle  
mount angle  
Turbine  
Turbine  
Exhaust gas flow  
to wastegate  
Exhaust gas flow  
to wastegate  
Exhaust gas flow  
from engine  
Exhaust gas flow  
from engine  
Poor flow 90  
degree mounting  
Not recommended less  
than 90 degree mounting  
SPARE PARTS AND ACCESSORIES LIST  
TS-0505-3006: WG38/40/45 Diaphragm assembly  
TS-0505-3007: 74mm Locking collar  
TS-0505-3008: 74mm Collar tool  
TS-0505-3009: 1/16TH NPT - 6mm barb vacuum fittings  
TS-0505-2007: 1/16TH NPT - 1/8 NPT Female fittings  
TS-0505-2008: 1/16TH NPT - -3AN Flare fittings  
TS-0505-2009: 1/16TH NPT - -4AN Flare fittings  
ACHIEVING YOUR TARGET BOOST PRESSURE  
There are various factors involved in achieving your target boost pressure including.  
-
-
-
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 HP Wastegate in conjunction  
with a Turbosmart e-Boost controller.  
3
www.TURBOSMARTONLINE.com  
IMPORTANT NOTES ON SETTING THE WASTEGATE SPRING PRESSURE  
A stiffer spring should only be used when necessary. The HP Wastegate allows for different combinations of spring pressures. All  
springs that are adaptable with the HP Wastegate are shown in the table below. The HP Wastegate utilises 2 springs to achieve the 35  
PSI base pressure: a 10 PSI inner spring and a 25 PSI outer spring. You can remove a spring to reduce the base pressure. HP springs  
will only work in the HP Wastegate.  
Changing the springs  
WARNING! Fitting a heavier wastegate spring may 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 spring, before increasing your boost pressure again.  
IMPORTANT: A press or clamping device MUST BE USED when removing or installing the collar as clamping the cap down removes  
the load off the collar from the compression of the diaphragm and allows it to be removed. The following are examples of different  
clamping devices that can be used to remove or install the collar (Pictures of Comp-Gate40 used for illustration purposes only):  
Vice  
Vice  
Hydraulic Press  
Hydraulic Press  
Drill Press  
Drill Press  
Arbor press  
Arbor press  
1
)
)
Remove the wastegate from the exhaust manifold. Use CAUTION! The wastegate may still be HOT!  
2
Remove any pressure nipples in the top cap. Hold the cap down in a press or vice. Using the provided locking collar tool,  
unscrew the locking collar. Slowly, back off the vice or press and remove the cap.  
3)  
Select and locate the required wastegate spring or combination of inner and outer springs on the upper diaphragm spring  
support. See spring information above for detail on wastegate spring identification and selection.  
4
)
)
Ensure that the diaphragm is inside the diaphragm groove.  
5
Slowly push the top cap down on the lower diaphragm housing in a vice or press. As the cap reaches the diaphragm, line up  
the notches in the cap (Figure 1) with the cut outs (Figure 2) in the lower diaphragm housing. Carefully push the cap down till  
the cap is home on the lower diaphragm housing. Reinstall the locking collar and tighten with the provided locking tool. Make  
sure that the cap is clamped down while tightening the collar.  
4
www.TURBOSMARTONLINE.com  
NOTES ON BOOST CONTROL HOOKUP  
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. Comp-Gate40  
pictures used for illustration purposes only.  
Basic setup  
If no boost controller is being used connect the boost pressure source to the “bottom” port as shown. Connect the HP Wastegate “top”  
port to the intake side of the turbo, between the air cleaner and the inlet on the front of the turbocharger. Otherwise connect a short  
piece of the silicon hose and face the vent downwards to stop water or debris entering the top port.  
Top port of wastegate  
vent to atmosphere  
Wastegate  
Bottom port of wastegate  
vent to pressure only  
source  
Turbocharger  
Boost Tee setup  
When using your HP 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 in the direction illustrated. Connect the HP Wastegate “top” port  
to the intake side of the turbo, between the air cleaner and the inlet on the front of the turbocharger. Otherwise connect a short piece of  
the silicon hose and face the vent downwards to stop water or debris entering the top port.  
Refer to the instructions supplied with your Boost Tee for further detail if necessary.  
Top port of wastegate  
vent to atmosphere  
Pressure only source to  
Boost Tee  
Wastegate  
Bottom port of wastegate  
e-Boost 2 connection methods  
to Boost Tee  
Turbocharger  
Turbosmart recommends using the HP 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.  
Single port connection Method  
Port 1 of solenoid vent to atmosphere  
Port 2 of solenoid to bottom port of wastegate  
Port 3 of solenoid to Pressure only source  
Top port vent to  
atmosphere  
Port 1 of solenoid  
vent to atmosphere  
External wastegate  
Pressure only to Port  
3 of solenoid  
Turbocharger  
Bottom port of  
wastegate to port 2  
of solenoid  
*NOTE: An increase in your minimum boost pressure is expected when using any of the 2 port connection methods. Ensure all boost  
set point values and gate pressure values are set to Zero and measure the new minimum boost pressure achieved by this method  
before increasing your Boost Set Point values.  
Two port connection Method (1) (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  
Solenoid  
Port 3 of solenoid vent to atmosphere  
Port 1 of solenoid to pressure  
only source  
Port 2 of solenoid to top  
port of wastegate  
Tee Piece  
Pressure only source  
Wastegate  
Turbocharger  
Bottom port of wastegate  
To pressure only source  
Port 3 of solenoid vent  
To atmosphere  
6
www.TURBOSMARTONLINE.com  
Two port connection Method (2) (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  
Solenoid  
Port 1 of solenoid to  
Top port of wastegate  
Port 2 of solenoid to  
pressure only source  
Turbocharger  
Wastegate  
Port 3 of solenoid to  
bottom port of wastegate  
Two port connection Method (3) (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 Port solenoid  
Port A of solenoid to top port of  
wastegate  
EX Port of solenoid vent  
to atmosphere  
Wastegate  
IN Port of solenoid to  
pressure only source  
Port B of solenoid to  
Turbocharger  
bottom port of wastegate  
7
www.TURBOSMARTONLINE.com  
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.  
8
www.TURBOSMARTONLINE.com