Product Name:  
PSG50 Pneumatic Straight Gate 6psi Black  
PSG50 Pneumatic Straight Gate 6psi Black  
TS-0565-1762  
Product Description:  
Product Number:  
Document Version:  
V1.00 Rev A  
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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 Straight 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.  
Correctly setting up a sensible boost control strategy to ensure engine safety is highly recommended.  
RECOMMENDATIONS  
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Allow for adequate cool airflow around actuator.  
DO NOT Mount the wastegate so that the actuator is less than 100mm from a heat source.  
DO NOT wrap the body of the wastegate with exhaust wrap.  
Fitting your Straight 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 Straight Wastegate kit.  
Part  
1
Description  
Turbosmart Straight Wastegate  
Inlet V-Band clamp  
Use  
QTY  
Main unit  
1
1
1
1
1
1
2
Inlet V-band clamp  
Inlet V-band weld flange  
Outlet V-band clamp  
Outlet V-band weld flange  
Turbosmart sticker  
3
Inlet Weld flange  
4
Outlet V-Band clamp  
Outlet weld flange  
5
6
Turbosmart Sticker  
2
1
3
4
5
Figure 1 - Kit Contents  
1
CONTENTS  
KIT CONTENTS................................................................................................................................................................ 1  
TOOLS REQUIRED .......................................................................................................................................................... 2  
PART NUMBERS.............................................................................................................................................................. 2  
STRAIGHT PNEUMATIC WASTEGATE OVERVIEW..................................................................................................... 2  
INSTALLING YOUR PNEUMATIC STRAIGHT GATE .................................................................................................... 3  
Mounting your new Pneumatic Straight Wastegate ..........................................................................................................3  
Clocking Actuator .....................................................................................................................................................................4  
Sensor Characteristics ................................................................................................................................................... 5  
HOW TO CHANGE YOUR GEN V WASTEGATE SPRING ............................................................................................ 6  
Checking/Adjusting Preload....................................................................................................................................................7  
TROUBLESHOOTING...................................................................................................................................................... 8  
TOOLS REQUIRED  
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3/8” square drive deep socket  
Square drive ratchet wrench  
Torque wrench (3/8” drive)  
Metric Allen Key set  
PART NUMBERS  
TS-0565-1212 – PSG50v Vacuum Pneumatic Straight Gate 6psi Black  
TS-0565-1762 – PSG50 Pneumatic Straight Gate 6psi Black  
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STRAIGHT PNEUMATIC WASTEGATE OVERVIEW  
Air Feed IN  
3
x Housing locating  
screws  
Inlet Weld Flange  
Outlet V-Band  
Inlet V-Band  
Outlet Weld flange  
Figure 1 - Pneumatic Straight Gate Overview  
2
INSTALLING YOUR PNEUMATIC STRAIGHT GATE  
Mounting your new Pneumatic Straight  
Wastegate  
1
The weld flanges should be welded to your exhaust system. The  
weld flanges are compatible with Stainless Steel and Mild steel  
welding rod material.  
The Straight Gate utilises WG60 Outlet Flanges to connect the  
Pneumatic straight gate to exhaust manifolds.  
For best results, an attempt should be made, if space allows, to  
mount the Straight Gate 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.  
NOTE!  
The Straight Gate can be used in both directions. Both  
directions will regulate the same. It is advisable however to  
place the Butterfly Valve pins exhaust side up.  
Figure 6 - 90 Degree mounting  
0 Degree mounting gives poor exhaust flow to the Straight Gate  
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and in some circumstances may contribute to over boosting.  
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 Straight Gate 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  
Straight Gate.  
CAUTION!  
Do not place the Straight Gate near a significant heat source  
as this could shorten the life of the internal actuator.  
Exhaust flow  
from engine  
Figure 5 - Good Flow - Angle mounting  
Angle mounting allows a good flow of exhaust flow to the Straight  
Gate.  
3
Fitting the Pneumatic Straight Gate  
2
Clocking Actuator  
3
Even though possible to mount the Straight gate in both  
directions, it is suggested that the Butterfly valve pins (Figure 8)  
are facing towards the exhaust exit.  
The actuator can be removed and rotated through 3 different  
orientations; these are every 120 degrees. The actuator 3 x M5  
Allen bolts that lock the body to the actuator. It may be required  
to remove the snap ring ensuring not to lose it.. Once these are  
removed the actuator can be rotated to two other positions of the  
three.  
Valve Pins  
Figure 8 – Butterfly Valve Pins  
Prior to mounting the Straight Gate, place v-band (Figure 10)  
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.  
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 torquing the nut to not have a false torque as this will likely  
contribute to exhaust leaks.  
Connecting Your Wastegate  
4
The Pneumatic wastegate is plumbed up as any IWG would be  
plumbed up. The Two top ports are utilised in this instance. One  
is blanked off and the other the 1/8 NPT Nipple. The hook up  
method required for a standard style boost control again is no  
different.  
Single Port  
•
•
Port 1 - Vent  
Port 2 - Boost Pressure In  
Figure 10 – V Band Clamp  
Note!  
Figure 11 – Exploded drawing of assembly of Pneumatic Straight  
In a single port configuration the bottom ports should  
be vent to atmosphere  
Gate.  
4
Dual Port Method  
1
20%  
00%  
•
•
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Port 1 - Boost Pressure In  
Port 2 - Vent  
Port 3 -Twin Port Chamber  
1
8
6
4
2
0%  
0%  
0%  
0%  
o
Blank or Sensor In remaining Port  
CAUTION!  
Please note that base boost pressure will increase when  
using this method. Reset your Turbosmart electronic boost  
controller to factory settings prior to further configuration.  
0%  
0%  
50%  
100%  
Butterfly Position  
Butterfly Position  
Flow Percentage  
3.3%  
3.7%  
0
3
6
%
%
%
4.7%  
1
2
30%  
4
5
6
7
8
9
0%  
0%  
6.7%  
14.9%  
26.7%  
40.8%  
55.7%  
70.4%  
83.4%  
93.5%  
99.4%  
100.0%  
Ensure all connections are high quality and away from any  
heat source.  
0%  
0%  
0%  
0%  
0%  
0%  
Sensor Characteristics  
Flow Characteristics  
1
Due to the nature of the butterfly 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 butterfly valve position  
1
00%  
rd  
with valve flow. A 3 order polynomial is provided to relate valve  
position to flow.  
y = -2.1519x3 + 3.0586x2 + 0.0582x + 0.0326  
2
R = 0.999  
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HOW TO CHANGE YOUR GEN V WASTEGATE SPRING  
The Gen V Pneumatic Straight wastegate has a variety of springs to suit different boost levels. Turbosmart provides the Gen V  
Pneumatic Straight wastegate pre-installed with a 6 psi spring. With your wastegate 3 other springs will be provided, 9psi inner, 12psi  
middle and 21psi outer. Different spring combinations may be required to suit different boost requirements and tuning.  
Remove Wastegate Actuator From  
Turbocharger  
1
Remove Top Cap (cont.)  
2
To remove the Wastegate actuator we can simply remove the  
actuator. This is outlined below.  
•
Circlips must be removed with a small flat bladed  
screwdriver ensuring to catch them as they spring off.  
Linkage is removed. (Air pressure may be required  
to allow for preload to be removed)  
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Actuator Mounting nuts 2 x 10mm  
Remove Boost pressure source hose  
Remove wastegate actuator from bracket  
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 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.  
CAUTION!  
Use soft jaws to prevent cosmetic damage  
Configure wastegate with preferred spring combination of  
inner, middle, and outer springs  
6
Familiarise Yourself with Cap and Body  
Notches  
closed as possible, wind the eyelet in to ensure that the correct  
amount of preload has been applied.  
3
To apply 1mm/0.039” preload, simply turn the adjuster eyelet  
1
full turn in the clockwise direction.  
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  
To lock the actuator in this position, turn the locking nut by  
hand until finger tight, then proceed to tighten nut firmly to  
secure actuator in place. (6.5Nm / 4.8 ft lb)  
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.  
If a regulated air source is available on-hand, apply the air  
pressure of the spring installed to the actuator and observe the  
linkage, the linkage should begin to move slowly and freely  
over the range of travel as air pressure increases. If the rod  
does not move at all with increasing air pressure, proceed to  
troubleshooting.  
Press Cap onto Bod
4
Using a press or vice, comp
ensuring the notches are remain
seated home onto the body, scr
a clockwise direction. While stil
the collar further with the collar tool until the collar will not turn.  
Reinstall Gen V Wastegate  
5
Install wastegate actuator assembly to bracket  
Install rod to straight gate  
Apply wastegate preload  
Lock adjuster nuts  
Connect wastegate signal lines and check for leaks  
CAUTION!  
Maintain downward pressure on cap while tightening  
collar or non-repairable thread damage will occur.  
If an adjustable air source is available, connect to signal ports  
and check for smooth free operation of wastegate, if  
wastegate does not move with increasing air pressure,  
proceed to troubleshooting.  
Reinstall fittings to the cap of the wastegate using fresh  
Loctite 567 thread sealant.  
Checking/Adjusting Preload  
5
NOTE!  
Turbosmart sets preload from factory and should only  
need to be set after changing springs.  
To correctly preload the wastegate, ensure wastegate valve is  
in the full closed position by holding the actuator valve as far  
7
ACHIEVING YOUR TARGET BOOST  
PRESSURE  
Table 1: Spring Chart  
Location  
Pressure  
Colour  
6psi  
Inner  
6psi  
Inner  
9psi  
Middle  
12psi  
Pink  
Outer  
21psi  
Red  
There are various factors involved in achieving your target  
boost pressure including.  
Black  
Grey  
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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  
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9
psi  
12psi  
8psi  
21psi  
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resulting exhaust manifold backpressure in your system.  
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1
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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  
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 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.  
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TROUBLESHOOTING  
Wastegate not actuating - Confirm signal hose is plumbed to a pressure only source, confirm preload 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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Poor wastegate actuation – Confirm no obstructions in actuator rod path  
Boost creeping at high rpm - Wastegate flow path is poor, wastegate is too small for the application, ensure linkage joints are  
not seized  
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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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